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Need Help - Change sensor to accurately detect box jams
MaintDude posted a topic in Allen Bradley / Rockwell Automation
Hi guys....first post here. It's been about 6 years since I worked heavily with PLC's and automation, but I'm getting back into it. I was hoping you might be able to help me with an issue I've noticed at work. Problem: The sensor we use just reads if there's something there, or not. A make or break if you will. When boxes are pushed together and there is no gap between them it thinks there's a jam (after 6 seconds) even when the boxes are moving past (as they should). A jam stops the conveyor belt requiring someone to physically move the boxes to clear the sensor and restart the equipment. I'm trying to find a sensor that will see the distance changes from box to box (mounted on the side of the conveyor). Only when there is a true jam and the distance isn't changing will it send a jam signal. I've tried researching sensors and have been overwhelmed by the endless possibilities and combinations (not all of which I understand). We are currently using an Allen-Bradley 42EF-P2RJB-A2H It would be ideal to have a similar style plug, but it isn't a deal breaker. Here's an idea of what I'm dealing with. (The actual conveyor the jams are occurring on is a decline belt, not a roller accumulator.) There are varying box sixes, but they are all packed together. Creating a gap between boxes or using metering belt is not an option here. Thank you for any help/guidance you can offer! -Steve