Concrete Advantages and Performance ‘Bar’ None from Contrinex High-Pressure-Resistant Inductives

High-rise buildings and large construction projects commonly use concrete pumps to deliver the concrete to where it is needed. It is common for concrete pumping trucks to rely upon Contrinex’s High-pressure-rated inductive sensors. 

The sensors which monitor the position of the piston hydraulic drive cylinder of the pump provide exceptional reliability despite the challenges of pressure cycles and high-pressure peaks. As part of Contrinex’s Extra Distance family of inductives, they combine long operating distances, with a pressure-resistant housing to increase longevity and efficiency to reduce the maintenance costs of the pump.

CUSTOMER APPLICATION

Concrete pumps use a double-piston pump and require two feed cylinders that pump concrete at a working pressure of up to 400 bar (5800 psi). These feed cylinders are driven by pairs of hydraulic cylinders which operate in push-pull opposition. To achieve the maximum possible efficiency, the timing of this push-pull operation must be precisely coordinated. It is therefore essential to monitor the cylinder limit position with sensors that are resistant to high pressure.

The dynamic stresses on all components built into the hydraulic system are very high, due to constantly changing pressure cycles during pump operation.

Concrete pump failures are extremely costly because they can cause construction problems and stoppages and risk compromising the building being constructed. If the breakdown is due to problems in the hydraulic system, all the hydraulic oil must be drained to correct the fault. Then, after refilling and before start-up, several time-consuming de-aeration cycles must take place before the pump is fully fit for service again. This prolongs the construction stoppage.

The customer’s requirements for longevity and resistance to high peak pressures are essential to guarantee the smooth operation of such systems.

CUSTOMER SOLUTION

Contrinex High-Pressure sensors (series 500P) withstand the necessary pressure levels (peak pressure up to 1000 bar – 14500 psi) due to a patented process whereby a solid ceramic disk is built into the stainless steel housing.

These sensors are fully resistant to dynamic stresses. A patented technology ensures that all electronics, including the ferrite core and coil, are located on the unpressurised side of the housing. This results in an unusually long life under pressure cycle stress.

Two sensors monitor cylinder limit positions in the concrete pump, reporting to the control system. Due to their longevity, which is ten times greater than the market standard, maintenance costs are reduced to a minimum.

PRODUCT ADVANTAGES

• 500 Bar operating pressure and 1000 Bar peak pressure (14500 PSI)
• -25°C to +100°C – Excellent temperature stability and enhanced range
• Robust & reliable in demanding conditions
• High-performance detection
• Long-distance sensing
• Affordable and long-operating life
• Ease of mounting
• Practically unlimited number of pressure cycles
• IO-Link – Ideal for Industry 4 and offering Plug and Play swap-out

Call PLUS Automation on 0121 58 222 58 or email Sales@PLUSAutomation.co.uk to discuss how they can help you #MakeSenseofSensors using Inductive, Machine Safety, Photoelectric, Pressure, Process, RFID & Ultrasonic sensors from Contrinex, ReeR & Satron.

With over 2,000 sensors in UK stock, supported by stock held in Europe and short manufacturing lead times, they’d welcome the opportunity to talk about improving automation and machine performance, or how to reduce costs.