Detect over height and alignment of a box with SIG100

Dear all,

Today I will show you a nice application.
The task is detecting the over height in a box. The problem is that the switching point is 20mm under the box top edge. In addition, we should detect the alignment of the box.

If the boxes are aligned the same way, you can put them into another and if the boxes are aligned the opposite way, you can stack them on each other. To stack on each other, the over height detection is necessary.

To solve the application we use this:
1x SIG100-0A0111100 #1089792 for the logic

2x GTB10-P4211 #1064694 for presence detection of the box and blank some areas.

1x GTB10-P4211 #1064694 for the detection of the alignment

4x UM30-212112 #6037665 for over height detection
3x SBO-02C12-SF #6041320 to connect more den 6 sensors to the SIG100

Note: The output current of the SIG100 is max 50mA, so you have to connect the UM30 directly to the power supply, only the switching output is connected to the SIG100. The pin 5 of all UM30 has to be connected together for synchronization.

The diagram:

The configuration looks like this.

Input: 

Box front, Box End & Alignment = 3 x 1064694 GTB10-P4211

Um30 /1/2/3/4 (over height) = 4 X 6037665 UM30-212112

Output: 

Direction is “1” (high) if box is correctly aligned.

Over height is “1” (high) if material in the box is over the adjusted height.

Presence is “1” if the box is present.


The logic looks like this.

The timer setting: 

The formation of the sensors look like this.

Notes: The distances are just reference values. But more important is 

-       If the “box front” sensor comes => Ultra sonic should not look on the corners of the box

-       If the “box end” sensor leaves => ultrasonic should not look on the corners of the box

-       “Box front” Sensor & “Alignment” should be adjusted so that it makes sense, in order to detect the correct alignment of the box AND they should come nearly at the same time. So there is a small distance between “Box Front” & Alignment Sensor

If you have any questions or other solutions, please do not hesitate to leave a comment.