APPLICATIONS

Our approach is simple.  We listen to our customers.  Because we know our products work well for various applications, we work closely with our customers to determine the system that will fit their needs.  Although we specialize in Double Sheet Detection, our sensors and controls can do more than just that.  From metal thickness detection to metal position detection, the following are just a few of the applications where you might find our products. 
 
Curious if one of our products will work for your specific application? Tell us about it.  We will do what we can to help.  That's our promise to you. 
 
DOUBLE END & MISSING TAB DETECTION
FOR HIGH SPEED CONVERSION SYSTEMS
High speed conversion of metal can ends to easy open tabs is a unique operation.  During this progressive operation, a rivet is formed, a tab inserted over the rivet, and the rivet closed in several progressive stations.  Press speeds approach 700 strokes per minute.  For this application, we engineered two detectors in one single package, a double end detector and a missing tab detector.  First, we make sure that only one can end is loaded in each station at the machine infeed and second, that a easy open tab is attached upon discharge.  The detector can also identify single ends, as well as missing ends.  Through this application, we saw the need for more detectors with different capabilities.  We also provide Double End Detectors for End Presses, Curlers and Conveyors. 
 
DOUBLE SHEET DETECTION
FOR AUTOMATIC SHEET & BLANK FEEDERS
Machines that automatically lift steel sheets from a stack and position them to the infeed conveyor of a processing machine or production line is considered an automatic sheet or blank feeder.  Depending on the industry, this can be called many different things, from a sheet feeder or an infeed de-stacker, to a vacuum plate lifter or a vacuum sheet feeder.  Regardless of the term used, it is important to use a double sheet detector during the process to ensure that two sheets of metal aren't stuck together when they are fed into the machine.  Failing to detect a double sheet of metal can damage the machine and halt operations indefinitely.  Prime specializes in Double Sheet Detection.  There are many characteristics of the application to consider before determining the correct double sheet detector and probe system solution.  These characteristics include, sheet thickness, metal type and whether the probe is able to come in contact with the metal or not.  Over the years, Prime has developed many products that cover a range of automatic sheet and blank feeder applications. 
 
THIN METAL DETECTION
FOR ENGINE HEAD GASKETS
Engine head gaskets are made of laminated metal. This application is difficult because the cross sectional size of the target is small and is made up of different metals. The metals are steel, magnetic and nonmagnetic stainless steel.  For this application, our system was responsible for determining if one or more of the metal laminations was missing from the stack. We were able to offer several detectors; however, the Model DS3410 was the best solution for this application because it Is able to detect very thin metals. 
 
THIN METAL DETECTION
FOR PHARMACEUTICAL PACKAGING
Pharmaceutical packaging companies often need to monitor the number of aluminum foil laminated packages that are stuffed into various cartons.  For this application, Prime needed to ensure that one package was stuffed with eight packs and the other was stuffed with twelve packs.  Originally, Prime recommended the DS3400; however, because additional capability was needed, Prime worked with the customer and a brand new detector was engineered to meet the customer's need.  This application demonstrates two things: the versatility of our detectors, being that they don't just detect double sheets, and our willingness to work with the customer and create a solution that solves the problem. 
 
METAL THICKNESS DETECTION
FOR STEEL STITCH IDENTIFICATION 
There are steel suppliers that provide low cost steel coils to plants by recovering out-of-spec or damaged prime metal. This provides substantial savings to steel users who are able to overcome the flaws of the recycled steel. This is where our products come into play.  When several small coils are run back through a roller mill or coiler to stitch them into one large coil, the quality of these splices vary and may contain welds that when entered into a press may cause serious damage to tooling, bearings and shafts.  They can also cause defectively formed products and are often aesthetically displeasing.  To our detectors, a weld looks like thicker metal.  Our DS1510 detects the stitch directly, preventing the metal from entering the press. 
 
METAL POSITIONING DETECTION
FOR LIGHT BULB PACKAGING
Light bulb packaging is designed to protect the sensitive bulbs from damage during its journey through the supply chain and to the ultimate consumer.  During packaging, if the orientation of the bulk base within the paper sleeve shifts or the bulb base is positioned to the wrong side, there is potential for damage. When the second bulb is loaded on the opposite side, it will try to occupy the same space and break one or both of the bulbs.  Prime was able to use a double metal sheet detector to detect the position of the metal, to ensure the bulb was positioned correctly.