Kempston Controls in the community: The Ferrers School

On the 1st of July we attended a careers fair at The Ferrers School in Higham. It was a fantastic opportunity to converse with their year 12 students, we spoke about their career aspirations and informed the students about our apprenticeship schemes and the many job opportunities we have to offer. We later returned to The Ferrers School on the 5th of July to meet their year 10 students and educate them on Industrial and Automation industry via a hands-on experience day. This gave the students a chance to wire up a contactor holding circuit. The year 10’s were also taught how to wire up ultrasonic, photoelectric, magnetic and inductive sensors, all of which were kindly donated to us by Sick UK.Kempston Controls at The Ferrers School

Attending the careers fair gave us great experience working alongside many local businesses and we were successful in gaining an insight into the year 12 students future prospects. Whether that be staying in education post sixth form or going straight into work we were able to discuss and advise on the opportunities that Kempston Controls have to offer. This sparked interest with many of the students and teachers at The Ferrers School and will help us to push and develop many new and existing job/apprenticeships opportunities that we at Kempston Controls have to offer.

After our successes at the careers fair our team were very excited to go back and put on the hands-on experience day with the year 10 students. Interacting with a vast range of products really helped the students to grasp and understand the differences between the four types of sensors that we brought along. We were very impressed with how quickly the students got involved with the many tasks and challenges set. One of the tasks was to wire up a contactor holding circuit, this was a great conversation starter with the students as we were able to demonstrate how a circuit breaker works and why they are used, this led to very insightful questions being asked which our technical team members were very happy to answer. Along with these products we also brought a vast amount of limit switches and microswitches. As we had such a wide range of products and items, we were able to demonstrate how engineering doesn’t always have to be considered as a typical industrial hands-on role.

Our team at Kempston Controls are constantly looking into new ways of interacting with the local community and our suppliers, if you would like to collaborate with us please feel free to get in touch!

Kempston Controls at The Ferrers School

Kempston Controls and the SICK SPEETEC Sensor Help Solve a Real Steel Processing Problem

Recently, Kempston Controls eagerly answered the call when TATA Steel Tubes, who are based in Corby, Northants, called asking for a demonstration of the versatile non-contact SICK SPEETEC sensor to help them solve a processing issue.

TATA Steel Tubes manufactures a wide range of steel products and they were looking for a way of using the SPEETEC sensor system to monitor the speed of tubing travelling through a process, and another SPEETEC sensor to verify the length of the material being cut.

After an initial discussion with the engineering manager at TATA Steel a demonstration was arranged. A member of Kempston Controls technical sales team, along with a sensor specialist from SICK would be onsite. The production line would be stopped so they could set-up and test the advanced SICK SPEETEC sensor within the actual process itself.

The operating environment in a steel processing plant is, as you can imagine, very demanding, and during the demonstration the sensor was sprayed with industrial machine coolant and exposed to swarf from the cutting process which had no effect on the performance of the robust non-contact SPEETEC sensor.

During the Demonstration the Following Issues were Found:

  • The existing process demanded that an encoder be mechanically coupled to the tube, resulting in a potential for damage to valuable equipment and material
  • The speed reference provided to the flying saw was incorrect, resulting in angled cuts in the tubing with unwanted axial forces being placed on the cutting blade. Ultimately leading to damage to the processing equipment and unwanted down time
  • The typical speed of operation was 20m/min – 180m/min
  • For the second cut-to-length application the goal was to reduce material tolerances and waste

The Actual  SICK SPEETEC sensor within the Processing Machine

The Savings

The invoice cost of steel tube at the time of installation was approximately – £1000/ton. The Kempston Controls technical sales engineer based the calculation around using a typical mild steel tube of 50mm diameter and a 3mm wall thickness weighing 3.5 kilograms per metre. The steel processing line was running at approximately 90 metres per minute.

Assuming the tolerance could be reduced by 0.1% this would result in an additional invoice value of material of:

  • 90 x 3.5 x 0.1 / 100 = 0.315 Kg per minute
  • If the process was to be run continuously for 8 hours this would equate to 0.315 x 8 x 60 = 151.2 Kg
  • At £1000/ton that effectively means £151.20 per 8-hour shift

On this basis alone TATA Steel would see the return on investment of a SICK SPEETEC sensor system in only a matter of weeks!  Over a longer period-of-time the process savings will quickly add-up, not just by reducing the manufacturing cost of the product itself, but also by improving the reliability of the process, through-put, reducing wear on process machinery, and helping to keep downtimes to a minimum.

The SPEETEC Sensor

The rugged and maintenance-free non-contact SICK SPEETEC laser surface motion sensor has been designed to detect movement via the surface of a product. Measuring the speed, length, movement direction and the position of objects of almost any surface type. The ideal solution for use in encoder-based applications that feature fast and dynamic processes.

SPEETEC Sensor Features

  • Non-contact measurement speed, length, and position of objects
  • Compatible with multiple materials, colours, and surfaces
  • Very high measurement accuracy and repeatability, speeds up to 10 m/s
  • Laser class 1, rugged design, compact dimensions, low weight
  • Standardised communication interface
  • Maximum resolution 10 m/s
  • Wear free

View the Range

Read More about the SICK SPEETEC Sensor Here

SICK PBS plus Pressure Sensor – Added Versatility for Pressure Monitoring Installations

The PBS plus Pressure Sensors from SICK, expands upon their existing PBS Sensor range, they have been purposely designed for demanding industrial applications, providing an electronic pressure switch, pressure transmitter and display all-in-one, available with up to two switching outputs, analogue output and IO-Link communication.

PBS plus Pressure Sensor in actionSimple to set-up, the PBS plus features three large pushbuttons and an easy-to-read display and they can be set-up using IO-Link, which also provides diagnostic functions and simplifies predictive maintenance, external parameterisation also makes handling easier and ensures lower maintenance costs.

 

Easily adapted for countless installation possibilities

The PBS plus range of Pressure Sensors are easily adapted to suit numerous installations, for example, the housing can be rotated twice, once at the process connection and then at the display cap, meaning the electrical connection can be rotated in the desired direction at any time.

Versatile, thanks to the large number of available process connections, including a flush-mounted membrane for sticky, crystallising and viscous media, helps to widen the integration possibilities of the PBS plus Pressure Sensor series. With measuring ranges of 0.4 bar to 1,000 bar (gauge pressure), the PBS plus can be used in many different applications. It also has absolute pressure and vacuum measuring ranges.

PBS plus Pressure Sensor Applications

  • Measurement of system pressure in hydraulic systems
  • Control of the clamping pressure in CNC machines
  • Monitoring of the cylinder pressure in hydraulic presses
  • Control of the pressure in cooling and lubricant systems
  • Hydrostatic level measurement
  • Measurement of system pressure in PET bottle production

 

 

The best in challenging conditions

Whether in aggressive environments, with measuring ranges of 0.4 bar to 1,000 bar, or when used with viscous liquids, the PBS plus takes challenging environments in its stride. Due to the integrated electrochemical cell with fully welded stainless steel membrane, it can withstand even aggressive media, as no sealing medium is required between the electrochemical cell and the membrane. Temperatures between –20 °C and +85 °C are no problem for the PBS plus.

 

PBS plus Pressure Sensor in action

 

This series of robust pressure switches have been designed for optimum functionality and range of use, resulting in a wide range of setting options reducing the number of sensor variants required within a production process ultimately reducing costs for customers.

 

SICK PBS plus Sensor Benefits

  • Switchable switching outputs (PNP/NPN) and analogue output (current/voltage)
  • Scalable analogue output (5:1 turn down)
  • High measurement accuracy: ± 0.5%
  • IO-Link for transmitting process data to the control system, measured values in bar
  • Housing can be twisted in two places (process connection/display), display can be rotated 180°
  • Common process connections, also with flush-mounted membrane
  • Rugged design: stainless steel measuring cell
  • Extensive diagnosis options via IO-Link
  • Economic solution for hydrostatic level measurement
  • Reduced installation time

PBS plus Pressure Sensor Technical Features

  • Gauge pressure – 0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 1,000 bar (0 psi …14,504 psi)
  • Absolute pressure -0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 25 bar (0 psi … 363 psi)
  • Compound pressure  -1 bar … 0 bar (-14.5 psi … 0 psi) to –1 bar … +24 bar (-14.5 psi … +348 psi)
  • Pressure unit – bar (can be switched to psi, MPa, kPa, kg/cm2)
  • Accuracy  ≤ ± 0.5 % of the span
  • Setting accuracy of switching outputs  ≤ ± 0.5 % of span
  • Output signal – Output 1: PNP/IO-Link, Output 2 (optional): PNP/NPN switchable, Analog output (optional): 4…20 mA / 0…10 V switchable
  • Electrical connection M12x1 round connector
  • Approvals CE, cULus
Get in Touch

 

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Free Space Radar Lever Detection

SicWave – 80 GHz Free-space Radar Level Detection for all Liquids and Solids

The storage of products such as grains, sugar, ore and liquids can take up a lot of space, typically utilising silo systems which can reach considerable heights. Measuring the level of product within these storage facilities can be difficult at the best of times where both the height and the media within can cause various issues with accurate level sensing. Similarly, production processes that involve stirrers and preparation tanks can create internal environments where accurately measuring the level of the contents within is challenging.

Dust and Foam Frustrations

Dust, moisture, foams, the build-up of residues and other obstructions within a storage or processing vessel can frustrate your average sensor, leading to down time, additional costs and frustration. What you need is a sensing solution that can deliver reliable level sensing results no matter how tall the silo or how demanding the process and the media involved prove to be.

To address these challenges and more, SICK, world renowned for their sensor solutions, have created the high-specification SicWave LFR and LBR ranges of level sensors, these sensors utilise an 80 GHz free-space radar technology delivered via a highly-precise narrow beam that is a thousand times more sensitive than previous generations 26 GHz radar technology.

SicWave LBR – For Solid Media Level Detection

SicWave LBR sensors

Demanding situations require dedicated solutions, the SicWave LBR free-space radar provides continuous non-contact level measurements, is highly resistant to external interference, dust and deposits and works with all solids. A high-contrast built-in LCD display option is available, aiding set-up and installation and providing the user with essential sensor feedback data. Utilising a unique non-contact 80 GHz radar technology and a highly-focused narrow beam, the LBR range is simple to install and is maintenance-free. With a wide range of options such as antenna design, process connectivity and housing material types ensures these sensors are ready for any application.

Avoiding Those False Signals

The narrow field of view also avoids the potential for false signals caused by dusts and deposits on walls or by other obstructions inside the storage vessel the LBR Level Sensor helps prevent unexpected downtime.

SicWave is accessible using bluetooth

 

Remote set-up and interrogation of the sensors is straightforward, either using the on-board WPAN interface to a smartphone or tablet via Bluetooth or through standard HART communication which also enables easy integration with control and diagnostic systems. These sensors feature a 4 – 20 mA output, allowing signals to be monitored and displayed on a cloud-based dashboard environment using IIoT gateways such as SICK’s Telematic Data Collector.

 

 

 

SicWave LBR Solid Media Level Sensor Range Features

  • Non-contact detection principle, continuous measurement
  • 80 GHz free-space radar with various antennas
  • Highly-focused narrow beam microwave radar pulse
  • Built-in high-contrast display option
  • Measuring range: up to 120 m
  • WPAN, HART and Bluetooth communication
  • 4-20 mA output
  • Process temperature: −40 °C to +200 °C
  • Process pressure: −1 bar to 20 bar
  • Sensor element accuracy ≤ 5 mm
  • Process connection options: thread, flange, special brackets
  • Housing: plastic (IP66 / IP67) or aluminium (IP66 / IP68)
  • Certificates: Ex d, Ex ia, Ex ta

View the Range

 

Typical SicWave LBR Sensor Applications

  • Crushers, belt transfer, raw meal, clinker and cement silos as well as silos for solid fuels
  • Breakers, storage silos for ore, silos in the metal and steel industry
  • Bulk material stockpiles, belt transfer, buffer and production silos in the mining industry
  • Storage and small silos in the food and beverage industry
Enquire Now

 

SicWave LFR for Liquid Level Detection

SicWave LFR Sensors

The 80 GHz SicWave LFR non-contact free-space radar sensor, with its highly-focused narrow beam, provides continuous level measurements, works with all liquids and is highly resistant to external interference, false signals, foam and deposits. Insensitive to material build-up, the LFR range of level sensors helps prevent unexpected downtime.

Up and Running in No Time!

Easy to commission, the LFR range can be put into operation quickly and easily and is maintenance-free. A wide range of options for antenna design, housing materials and a range of process connections ensure these sensors are ready for any application. A durable stainless-steel housing option is available for use in hygienic environments such as those required in the food, beverage and drug industries. A high-contrast built-in LCD display option is available, aiding set-up and installation and providing the user with essential sensor feedback data. Remote set-up and interrogation is carried out in the exactly the same way as the LBR range.

SicWave LFR Liquid Media Level Sensor Range Features

  • Non-contact detection principle, continuous measurement
  • 80 GHz free-space radar with various antennas
  • Highly-focused narrow beam microwave radar pulse
  • Built-in high-contrast display option
  • WPAN, HART and Bluetooth communication
  • 4-20 mA output
  • Measuring range: up to 30 m
  • Process temperature: −196 °C to +200 °C
  • Process pressure: −1 bar t0 25 bar
  • Accuracy of sensor element ≤ 1 mm
  • Process connection options: thread, flange, clamp
  • Housing: plastic (IP66 / IP67), aluminium (IP66 / IP68) or stainless steel (IP69)
  • Certificates: Ex d and Ex ia, WHG, shipbuilding

View the Range

SicWave LFR sensor in action

Typical SicWave LFR Sensor Applications

  • Chemical industry: large tank storage, storage and buffer tanks, reaction and transport containers
  • Oil and gas industry: mud pits, trip tanks, shakers and wastewater containers
  • Food and beverage industry: large, stirring and preparation tanks, thickener and filling tanks
  • Water industry: storage tanks for flocculants, coarse and fine screens
Enquire Now

 

Kempston Controls is the place to come to find the perfect SicWave Level Sensor for your next retrofit or installation project. Call us today on +44 (0) 1933 411 441, use the enquiry form below, or contact us via email at – sales@kempstoncontrols.co.uk.

 

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Motion Capture

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SPEETEC Sensors -Motion Capture without Contact

The rugged and maintenance-free SPEETEC laser surface motion sensor detects the movement of the surface of a target object without any physical contact. The laser Doppler effect-based technology of this contact-free sensor allows it to measure the speed, length, movement direction and the position of objects of almost any surface type.

Delicate Materials? No problem…

Dependable and gentle, the non-contact measurement method used by the sensor makes it particularly suitable for applications with soft or sensitive surfaces that would be damaged by conventional wheel measurement processes. The SPEETEC is also the ideal solution for use in encoder-based applications that feature fast and dynamic processes that are physically unsuitable for encoders to be used effectively.

  • Non-contact measurement speed, length and position of objects without measuring elements
  • Compatible with multiple materials, colours and surfaces
  • Very high measurement accuracy and repeatability
  • Laser class 1
  • Rugged design, compact dimensions, low weight
  • Standardised communication interface
  • Speed – up to 10 m/s
Enquire Now

 

Contact Free and Easy to Integrate

As the SPEETEC Sensor measures without making physical contact, it enables new applications in automation where direct measurements on sensitive and soft surfaces needs to be avoided due to damage that could be caused by full contact methods.

Thanks to the compact dimensions and the standardised communication interfaces it’s easy to integrate the SPEETEC into new or existing plant and they are simple to set-up and install, requiring no specialist support equipment.

Utilising an infrared class 1 laser, these dependable non-contact sensors require no additional protective or specialist devices during operation, such as safety glasses or protective housings, and no special safety training for staff is required.

The capable infrared class 1 laser utilised in this sensor delivers exact speed values of up to 10 m/s with very high repeatability. Whether endless materials or individual production pieces, the high-resolution laser enables a maximum resolution of 4 µm and, on a one metre path, the sensor measures material lengths down to the final millimetre. Superbly reliable, these contact free sensors are perfect for a wealth of applications in countless industrial applications.

The laser-based technology also prevents contamination on the material surface to be measured and in addition, the laser is wear-free, this helps maintain process reliability with minimal maintenance downtime and associated costs.

 

Packaging

 

 

Perfect for Speed and length measurement in a packaging process with simple electrical and mechanical integration, without damaging and abrading material with a measuring wheel.

 

 

Tyre Manufacturing

 

 

Non-contact and precise speed and length measurement directly on the rubber or other soft and slippery materials, eliminates slipping.

 

 

 

Building Materials

 

 

The production of plasterboard requires a very high level of quality and the fast production processes involved depend upon on a reliable measurement to ensure the standard dimensions of the plasterboard is maintained.

 

 

Digital Printing

 

 

Speed measurement directly on the object being printed upon without damaging its sensitive surface and with a high signal quality and resolution, the SPEETEC sensor helps delivers optimal print results.

 

 

Extrusion

 

 

Quality control for cutting processes through automated 100 % length measurement directly on the material with enhanced process control and analysis.

 

 

Textile Industry

 

 

The non-contact motion sensor measures the speed and length of fabric sheets optically. Inaccuracies caused by slippage or impairment of the product are no longer a problem.

 

 

Enquire Now

View the SPEETEC Range

 

PowerProx Sensors – Powerful Photoelectric Sensing in Miniature

Photoelectric Sensors are utilised in a vast array of industrial applications, from monitoring products on a production line in a food and beverage processing plant to controlling automatic doors for safety and security. Whatever the installation, there is a photoelectric sensor out there to suit your particular application, but when the installation is limited in space, you need a quality photoelectric sensor from one of the worlds renowned leaders in the design and manufacture of dependable sensor technology, SICK.

Powerprox Sensor in situ

SICK has taken its ultra-reliable, high-performance, PowerProx sensor and shrank all that technology into a space-saving miniature housing that is capable of some of the longest detection range distances ever achieved for a sensor of this scale.

Size Does Matter

The diminutive SICK WTT4SL PowerProx Mini photoelectric sensor measures in at just 12.2 x 41.8 x 17.3 mm but packs a big punch, delivering outstanding performance that you would expect from a sensor 4 times its size. Capable of detecting objects up to 1300 mm away. The knock out performance of the WTT4SL makes it ideal for high-speed production and logistics applications.

This capable photoelectric sensor can be integrated into tight machine spaces such as the grippers of picking robots or for material handling duties in AGVs, as well as for empty bay and clearance detection in high-bay warehouses.

Packed with innovation, SICK has crammed its renowned autocollimation time-of-flight sensing technology into the tiny housing. Autocollimation ensures reliable high-speed detection and outstanding repeatability even in challenging ambient conditions, without cross-talk interference from other sensors.

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Finding the Edge

Even at high process line speeds the ultra responsive PowerProx Mini will register the leading edges of products with precision, even through small holes, such as those found during the quality control inspection of automotive parts and assemblies. Its red-light Class 1 laser, small-light spot size and wide angle of incidence with switching frequencies up to 1 kHz ensure highly-competitive performance across a broad range of applications.

David Hannaby, SICK’s UK Product Manager for Presence Detection stated :
“The SICK PowerProx Mini can replace through beam, background suppression or reflex sensors, so machine builders and production teams can streamline their inventories while still guaranteeing high-performance sensing. The PowerProx Minis can be set up in an instant using the on-board teach-in function, or via IO-Link. It’s all the reliability, repeatability and versatility you expect from SICK, packed into a sensor no larger than a packet of sugar cubes.”

Powerprox Sensor in situ

Easy to Configure

The PowerProx Miniature Photoelectric Sensor can easily be configured for multi-task applications, packed with features including the option of IO Link communication and up to 8 variable switching outputs. Detection is guaranteed with 100% background suppression ensuring that only the desired target is detected, ignoring any interference from shiny objects and materials behind the detected subject. Available in speed or distance variants for optimum performance and with superb repeatability ensuring reliable component counting, sorting and quality control applications in high-speed fast moving consumer good processes, even with products that feature varying surfaces.

Enquire Now

Kempston Controls