Created Date: February 08,2017

Created by: jrstokka

I need to detect presence/absence of small rifle primers stacked in a vertical stainless tube.

Tube ID is approximately .185 ", OD is approximately .3125 "

Primers in the tube are .175 " in diameter and .12 " tall.

What would you recommend for sensor and how to mount on a round tube to detect when the tube is empty. Maximum flow is about 2 per second. Under normal conditions they will be "stacked " and flow will be continuous unless the machine runs out in which case a trigger is necessary to halt production.

Created Date: February 08,2017

Created by: jrstokka

1. Is it acceptable that detection of the top most primer as confirmation that the tube is filled? If so, then...

2. Is it acceptable to have a small hole .125 thru the tube at the height of the uppermost primer? If so, then...

3. Use a fiber optic photoeye, in a thru-beam setup, with a small diameter fiber, to look thru the tube hole.

Edit: hole could be smaller, it is all dependent on the fiber diameter.

Yes, that's exactly the type of thing I'm thinking, although I will probably place sensors both at the bottom and top of the tube. The top fiber switch can turn on the feed mechanism (absence) and the bottom sensor can stop the production line if the tube is near empty (absence). I assume the switch can have a built in time delay for instance the top sensor ignoring a falling primer so there is not an instant off/on caused by the falling primers past the top sensor before the tube is full.

I have seen thousands of fiber sensors, etc. yet having no experience in this I need some help with exactly what is necessary to purchase. Can you make recommendations on exact model/mfg and components necessary and perhaps how to mount. I have complete design latitude. A .125 hole seems quite large for the application, hopefully we can go with something smaller. Thanks for your input! I'm trying to decide if I want to go with PLC or solid state.

Created Date: February 08,2017

Created by: Ridgeline Mach

All Automation Direct components, meeting your described needs.

Sensor: https://www.automationdirect.com/adc/Shopping/Catalog/Sensors_-z-_Encoders/Fiber_Optic_Sensors/OPT_Fiber_Sensors/OPT_Amplifiers/OPT2040

Power cable: https://www.automationdirect.com/adc/Shopping/Catalog/Sensors_-z-_Encoders/Inductive_Proximity_Sensors_-z-_Proximity_Switches/Cables_-a-_Accessories/Pico_(M8)_Normal_Duty_Q-z-D_Cables/CD08-0G-050-A1

See-thru fibers: https://www.automationdirect.com/adc/Shopping/Catalog/Sensors_-z-_Encoders/Fiber_Optic_Sensors/OPT_Fiber_Sensors/OPT_Plastic_Fibers/OPT2065

You'll need some fixed mount outside either side of the hole through the tube the mount the fibers. The sensor can mount to DIN rail.

I'd use a PLC. With it you could program your time delays in the PLC code, rather than at the photo sensor, and use an output from the PLC to start/stop the filling process.

Go with a Click PLC: https://www.automationdirect.com/adc/Shopping/Catalog/Programmable_Controllers/CLICK_Series_PLCs_(Stackable_Micro_Brick)/PLC_Units/C0-00DR-D

You'll need the power supply for it: https://www.automationdirect.com/adc/Shopping/Catalog/Programmable_Controllers/CLICK_Series_PLCs_(Stackable_Micro_Brick)/Power_Supplies/C0-00AC

The programming software, which is free: http://support.automationdirect.com/products/clickplcs.html

And the programming cable: https://www.automationdirect.com/adc/Shopping/Catalog/HMI_(Human_Machine_Interface)/C-more_Micro_Panels/C-more_Micro_Panel_Programming_S-z-W_-a-_Cables/EA-MG-PGM-CBL

Created Date: February 08,2017

Created by: Ridgeline Mach

1. Is it acceptable that detection of the top most primer as confirmation that the tube is filled? If so, then...

2. Is it acceptable to have a small hole .125 thru the tube at the height of the uppermost primer? If so, then...

3. Use a fiber optic photoeye, in a thru-beam setup, with a small diameter fiber, to look thru the tube hole.

Edit: hole could be smaller, it is all dependent on the fiber diameter.