Double sheet detection sensors

Double sheet control sensors are special sensors that are mainly used in the printing industry. They are used to detect and prevent double sheets or multiple sheets in printing presses.

Double sheets occur when several sheets of paper or other materials get caught or stuck together during the printing process. This can lead to misprints, interrupt the printing process or even damage the printing press.

The double sheet control sensors are usually placed near the feed or transfer unit of the printing press. They measure the thickness of the paper or material running through the machine and continuously monitor the printing process. If a double sheet is detected, the sensor sends a signal to the machine to stop the printing process or notify the operator.

Double sheet control sensors are important to ensure the quality and efficiency of the printing process and to prevent damage to the printing press. They are used in various types of printing machines such as sheet-fed offset printing machines, digital printing machines or web offset printing machines.

Double sheet control sensors are devices that are used in printing and processing machines to detect double sheets. A double sheet occurs when two or more sheets of paper or material are fed into the machine at the same time, which can lead to jams, damage or errors.

The operation of a double sheet control sensor can vary depending on the manufacturer and model, but in general they work on the principle of optical detection. The sensor consists of a light source and a receiver, which are located on opposite sides of the area to be monitored.

When a sheet of paper or material is fed into the machine, it interrupts the light signal between the light source and the receiver. The sensor detects this point of interruption and sends a signal to the machine control system, which can then take appropriate action to prevent the double sheet.

With a double sheet, two or more sheets of paper or material are fed in at the same time, causing the light signal between the light source and the receiver to be interrupted not just once, but at least twice. The double sheet control sensor detects this repeated interruption and sends a signal to the machine control system to stop operation or take other appropriate measures.

Some double sheet control sensors can also measure the thickness or weight of the material to ensure that only individual sheets are fed into the machine. They can also be combined with other sensors or monitoring systems to ensure comprehensive control and monitoring of the printing or processing process.

Double sheet control sensors offer various advantages in industrial production:

1. Detection of errors: Double sheet control sensors can detect faulty products where two or more sheets overlap or intersect. This enables faults to be detected and rectified at an early stage, resulting in improved product quality.

2. Prevention of blockages: By detecting double bends, blockages or blockages in the production line can be avoided. This is particularly important in areas such as print shops or packaging systems where continuous production must be guaranteed.

3. Increase in efficiency: Double sheet control sensors can help to make the production process more efficient. By detecting double sheets at an early stage, unnecessary production interruptions can be avoided, thereby increasing the overall performance of the system.

4. Cost savings: By avoiding faulty products and production interruptions, companies can save costs. The use of double sheet control sensors can help to reduce waste and maximize production capacity.

5. Improving safety: Double sheet control sensors can also help to improve occupational safety. By avoiding blockages and obstructions, potentially dangerous situations that could lead to injuries or accidents can be avoided.

Overall, double sheet control sensors offer a number of advantages in industrial production that can lead to improved product quality, efficiency and cost savings.

Double sheet control sensors are used in various areas where the control of double stacks of paper or double sheets is required. Some of the areas of application are

1. printing industry: In the printing industry, double sheet control sensors are used to ensure that only one sheet of paper is fed into the press at a time. This prevents duplicate sheets from being printed or errors from occurring in the printing process.

2. packaging industry: In the packaging industry, double sheet control sensors are used to ensure that only one sheet or film is fed into the packaging machine. This prevents duplicate packaging from being created and the packaging machine from being damaged.

3. Postal and shipping services: Double sheet control sensors are used in postal and shipping services to ensure that only one letter or parcel is inserted into the sorting machine. This prevents duplicate consignments from being created or the sorting machine from being damaged.

4. Banks and financial services: Double sheet control sensors are used in banks and financial services to ensure that only one sheet of paper is inserted into the ATM or scanner. This prevents duplicate transactions from taking place or errors occurring in the payment process.

5. Automotive industry: In the automotive industry, double sheet control sensors are used to ensure that only one sheet of metal is fed into the punching machine. This prevents duplicate parts from being produced or the machine from being damaged.

These applications are just a few examples, and there are many more industries where double sheet testing sensors can be used to improve the efficiency and quality of production processes.

Double sheet control sensors use various technologies to detect the position and movement of the sheet. The two most common technologies are capacitive sensors and optical sensors.

Capacitive sensors use electric fields to measure the distance between the sensor and the sheet. You recognize changes in the capacity of the field when the arc moves. Capacitive sensors are contactless and can work reliably even in high humidity or dirty conditions. However, they have a limited range and can be disturbed by other electrical devices in the vicinity.

Optical sensors use light to detect the arc. For example, you can work with a light barrier that interrupts a light beam when the sheet moves. Optical sensors can also work with cameras to capture and track the sheet. They have a greater range than capacitive sensors and can detect even the smallest movements. However, they are sensitive to soiling or changes in lighting.

The choice of technology depends on the specific requirements of the application. Capacitive sensors are well suited for applications with limited space or in environments with high humidity or contamination. Optical sensors offer greater flexibility in detecting and tracking the sheet, but are more sensitive to external influences.

Various challenges can arise when using double sheet control sensors, which can be solved as follows:

1. False alarms: Double sheet control sensors can react sensitively to dust, dirt or other interference and trigger false alarms. This can be minimized by regular cleaning and maintenance of the sensors. It is also important to adjust the sensors correctly to ensure optimum function.

2. Insufficient detection: Sometimes double sheet control sensors cannot reliably distinguish between a true double sheet and other faults such as a normal sheet or a single sheet of paper. This can be improved by using sensors with higher resolution or special algorithms for pattern recognition.

3. Ambient conditions: The environment in which the sensors are used can also pose a challenge. For example, strong light or electromagnetic interference can impair the performance of the sensors. Suitable protective devices such as shields or filters can be used here to protect the sensors from external influences.

4. Integration into existing systems: The integration of double sheet testing sensors into existing production or processing lines can pose technical challenges. It is important to check the compatibility of the sensors with the existing systems and make any necessary adjustments. Close cooperation between sensor manufacturers and users can be helpful here.

5. Costs: Double sheet control sensors can require a higher level of investment than conventional sensors. However, the costs can be justified by careful selection of the right sensors and by reducing false alarms and production downtime due to double bends.

It is important to note that the exact challenges and solutions may vary depending on the specific application and individual conditions. A thorough analysis of the requirements and close cooperation with the sensor manufacturers can help to find the optimum solutions.

Some leading companies in the development and manufacture of double sheet control sensors are:

1. Erhardt+Leimer: The German company Erhardt+Leimer is one of the world's leading suppliers of double sheet control sensors for the printing and paper industry.

2. BST eltromat International: BST eltromat International, headquartered in Germany, is a leading global manufacturer of sensors and systems for web guiding and double sheet control.

3. Fife Corporation: Fife Corporation, based in the USA, is a leading supplier of web guiding and double sheet control sensors for the packaging industry.

4. E+L China: E+L China is a subsidiary of Erhardt+Leimer and specializes in the development and manufacture of double sheet testing sensors for the Chinese market.

5. ISRA VISION AG: ISRA VISION AG, based in Germany, is a leading supplier of image processing systems and sensor solutions for industrial automation, including double sheet control sensors.

Please note that the list may change as new companies enter the market or existing companies change their position.