Conveyor Monitoring
Presence/absence detection and height measurement to identify defects on conveyor belt systems.
Material Handling & Process Control
ToughSonic® ultrasonic sensors are utilized in hundreds of factories throughout the world. Senix sensors are vital in material handling, process control, and object positioning systems by providing non-contact detection and distance measurement.
ToughSonic sensors detect object presence, position, and level for various applications such as conveyor systems, robotic arms, and forklift machinery. They can be configured to react in as quickly as 5 milliseconds in the case of an incident or critical error.
Non-contact sensors measure without handling the material or object. Measurements are typically captured from above, but the sensors can be installed horizontally in open air for positioning applications.
Why Efficient Material Handling Matters
As industrial automation becomes commonplace in production environments, smart material handling systems are critical to meet industry demands, minimize waste and out-of-spec product, and maximize ROI.
Instead of continuous labor on the production line, sensors replace tedious tasks until human intervention is needed.
Fast-updating readings and non-contact measurements ensure Senix ultrasonic sensors' success in a versatile range of manufacturing industries, including sanitary processing and harsh indoor or outdoor conditions.
Real-time distance ranging and object detection facilitates precise process control where automation is required.
Senix sensor measurements can also be delivered directly to local displays, a control room, or remote monitoring software.
Positioning & Monitoring Applications
ToughSonic sensors handle material handling, object detection, and positioning tasks with accuracy and ease.
Roll Diameter Detection
Continuous roll monitoring to replace film, foil, or paper rolls before unexpected downtime occurs.
Dimensioning & Height Control
A height or level is defined in a ToughSonic's settings. It alerts when outliers enter the measurement window.
Automotive Positioning
Ultrasonic sensors detect obstacles—regardless of color or reflectivity—and alert vehicle operators.
Equipment Alignment
Sensors detect if machinery is in the correct position or orientation by monitoring proximity and presence.
Material Handling with Ultrasonic Sensors
Senix ToughSonic® ultrasonic sensors enhance material handling operations with accurate, non-contact distance measurement for positioning, detection, and automation.
Designed for industrial environments, ultrasonics deliver consistent performance regardless of color, reflectivity, or lighting conditions.
- Improve process efficiency with precise object detection, counting, and positioning
- Ensure accurate web handling and roll measurement in printing, converting, and packaging applications
- Enhance automation by integrating with PLCs, industrial equipment, and control systems for real-time feedback
- Maintain reliability in harsh environments with rugged, dust and moisture-impervious sensors
Here's How Ultrasonics Handle Automation
ToughSonic ultrasonic sensors can assist in several manufacturing processes, including material feed, robotics positioning, and object discrimination on conveyor belts.
Vehicle Positioning
Utilize ToughSonics to display, verify, and/or control positioning in real-time—including vehicles on automotive scales, in loading docks, or for car wash automation.
Smooth Manufacturing
Ultrasonic sensors alert operators when blockages, jams, or breaks are detected on conveyor lines, in material rolls, or in tubing and cable loops.
Roll Diameter Alerts
From metal to plastic to paper, Senix sensors detect diameter of a roll—regardless of its material, color, or reflectivity—to ensure reliable feed and timely web material replacement.
SensorView™ Configuration Software
SensorView™ setup software for Windows PC contains over 80 user-configurable settings that can be used to personalize the settings of Senix ultrasonic sensors.
Customers can alter individual sensor settings to meet their specific object positioning, material handling, and industrial process monitoring needs.
Settings are stored within each sensor's memory, making cloning or duplication a breeze. No recalibration needed!
Simple process control can be created with just a sensor and an external relay option.
Plus, scaling up operations is simple when employing and connecting multiple ToughSonic sensors.
Positioning Industrial Processes for Success
Film Slack Detection
Real-Time Diameter
Paper & Foil Printing
Automated Material Handling Articles
ToughSonics® Accurately Measure Distance in Cold Foil Printing
In printing applications, the right sensor is the difference between productivity or unexpected downtime. Senix ultrasonics are the correct choice.
ToughSonic Sensors Teach Dynamics at Duke
Senix ultrasonic sensors have found a niche in research, development, and lab testing environments—including in Duke University's Dynamics Laboratory!
Measure & Control Roll Diameter with Senix Non-Contact Sensors
ToughSonic® ultrasonics make material handling easy! From roll full and empty to slack monitoring and tension control, choose Senix for roll diameter.
Ultrasonic Sensors by Senix for Agricultural Automation
Automated tools are often invented to make tasks easier. ToughSonics® supported this concept in the development of Trebro Manufacturing's "AutoStack."
Ready to get Tough? Connect with a Senix sales expert today.