Friday 1st November 2024 Flow control problem solvers Maintaining the flow of a 2-piece canmaking production line requires precise coordination between machines and line controls to reduce backups and smooth out production flows. In a perfect world, every machine on a can line would operate at a constant speed, producing cans at the fastest possible rate. However, real-world production is full of variables that make it a challenge to maintain that ideal. A well designed control system is essential, and this is where Sencon's specialized sensors can make a significant difference by ensuring smooth flow control. To achieve peak efficiency, conveyors need to adjust their speed dynamically, running fast when empty but slowing down as they fill. Machines should match the can supply rate to maintain a constant 'head' of product at the infeed. Without proper flow control, you risk can damage, unnecessary downtime, and inconsistent machine performance. Fortunately, dedicated sensors like Sencon's Area Mass Sensor (AMS) and Linear Mass Sensor (LMS) are designed to tackle these challenges head-on. These sensors detect the flow and density of cans on the line and send an analog signal to variable speed drives, optimizing conveyor speed in real-time, reducing backups, and smoothing out production flow. CONTROL CAN DENSITY FOR MAXIMUM EFFICIENCY An added benefit of using Sencon's flow control sensors is the ability to modulate machine speeds, improving quality control. Stopping and starting the cupping press too frequently, for example, can lead to fluctuations in tooling temperature which negatively affects cup quality. By monitoring the density of cups on distribution conveyors, the cupping press can be modulated to match the usage rate, keeping it running smoothly for longer periods without compromising quality. THE SOLUTION TO COMPLEX FLOW CONTROL PROBLEMS Sencon Linear Mass and Area Mass sensors ensure smooth, continuous product flow, making two-piece can lines more efficient and productive. If you''re dealing with issues of flow control, Sencon's AMS and LMS sensors offer a reliable, easy-to-install solution that will keep your line running at its best. LINEAR MASS SENSORS × SMOOTH AND PRECISE CONVEYOR AND MACHINE CONTROL The Linear Mass Sensor is a game changer for conveyor systems. By providing a linear output signal (either voltage or current) that is directly proportional to the fill level on the conveyor, the LMS ensures precise control of machine and conveyor speeds. Whether it's a mass conveyor or a single-file system, the LMS adjusts speeds according to the number of cans in the queue, preventing damaging backups and unnecessary halts to production. Smooth speed adjustment also saves wear and tear on conveyor clutches and machine drive motors. Installation of the LMS is simple. It uses an isolated section of the conveyor's existing side guide, which means it can be seamlessly integrated into even the most complex conveyor shapes, like swan necks or curved tunnels. And with minimum and maximum settings available, you can set alarms to prevent conveyor motors from running at zero speed, making sure your machines are always operating at optimal capacity. AREA MASS SENSORS MODULATED SPEED SAVES TIME AND IMPROVES PRODUCT QUALITY The Area Mass Sensor takes control of mass conveyors to the next level. This sensor monitors can or cup density over a wider area of the conveyor, delivering an output that adjusts machine speeds in real-time. This is particularly useful for ensuring that cans fed into downstream machines are packed correctly and consistently, preventing jams or the risk of cans falling over when they are not closely packed enough. The AMS helps to maintain perfect packing density at critical points like washer infeeds, ensuring that cans are properly aligned under water jets to avoid issues downstream. Whether you're working with metering conveyors or cupping presses, the AMS can modulate speeds to meet production demands while maintaining quality.