Tag Archives: sonic control

CS-5000-72xx

Our best selling product, the CS-5000-72xx is the industry standard in non-contacting loop controls. And it’s not hard to see why. With an outstanding list of features and unrivaled ability for customization, not to mention a full line of useful accessories and free lifetime over-the-phone customer support, the CS-5000 series of no-touch loop controls is the gold standard.

Each CS-5000 is a custom build, with customers first choosing their stand height (15″, 54″, 72″, or 84″), with our 72″ stands being the most popular (hence the 72 in the part number mentioned earlier in this post). Customers then choose a boom length, which replaces the xx in the part number. With a wide range of boom lengths between 11″ and 48″, customers can order exactly what they need.

The new CS-5000 series of non-contacting loop controls contains our state-of-the-art new CB-5501M main control board. This new board has all the features of the previous generation CB-5101M board, such as on-board storage for up to 8 preset programs and remote access to 3 presets, plus virtually instantaneous push-button calibration that lets you set your unit up in seconds, USB compatibility for remote set-up, and a program-locking jumper. Best of all, the new board is completely backwards compatible, making it easy and affordable to update your current system by simply buying a replacement board.

For more information on our products, including our full line of non-contacting loop control systems, please visit our main site. If you would like to ask us a question or request a quote, please contact us.

 

The CS-5100 Line of Ultrasonic Loop Controls

Here at Coiltek we sometimes joke that the CS-5100 line of loop controls are the Jan Brady of our loop control family. The tall, industry standard CS-5000 series is the Marsha, getting lots of attention for its adaptability and capable, reliable handling of lines big and small. The CS-6200 is the baby of the family, a small, affordable line that is perfect for many applications, such as plastic medical tubing, and representing a large step up for those looking to replace an existing Sonatrol unit.

Then there’s our CS-5100 series. It’s the proverbial middle child. It’s smaller than the CS-5000, because it lacks a stand, but it’s just as powerful, since it features the same new and updated CB-5501M control board. However, like the CS-6200 it is small, consisting of just an 11″ tubular housing (the nose or boom) containing the sensor, a 15′ long cable, and an electrical enclosure containing the powerful new CB-5501M control board.

The best of both worlds, the CS-5100 is as powerful as it is portable, and while you may not move it much within your shop, it’s small size is a boon when it comes to shipping costs. Likewise, all the accessories for our loop controls, from the Hammerhead, to the Cone of Silence, to the 3CPO are all compatible with these small but mighty units.

This series also has some very special add-ons for wide stock applications, which we will look at tomorrow. In the meantime, if you would like more information on our CS-5100 series of sonic loop controls, please visit our website, check out our brochures, and contact us.

The CTAC-2 “Cone of Silence” from Coiltek

At Coiltek we try to anticipate any issues that our customers may have and create a solution. One such issue when using an ultrasonic loop control system is off-axis ultrasonic interference. This interference can be caused by things such as nearby blow-off hoses and can cause a unit to behave in strange ways.

Luckily we have devised a simple solution to issues of ultrasonic interference: The CTAC-2, nicknamed the “Cone of Silence”, the CTAC-2 is a cast aluminum cone lined with acoustic foam, which slides easily over the boom of your existing unit and absorbs any off-axis interference.

If you have any questions or comments on the CTAC-2 or any of our high quality no-touch loop control systems or accessories, please don’t hesitate to contact us.

Sneak Peak of the All New CS-6202 Loop Control

The next step in the evolution of ultrasonic controls is here: The CS-6202 from Coiltek. This no-touch ultrasonic loop control system is small (about 4′ tall), but mighty. It is sensitive enough to “see” even the thinnest stocks and equipped with all the same standard features you’ve come to expect from Coiltek’s industry standard sonic loop controls: On-board storage for up to 8 distinct programs, 0-10 VDC  and 4-20 mA output, easy remote set-up via computer with on-board USB port, and instant push button manual calibration. The new CS-6202 also comes with a potentiometer on the exterior of the electrical enclosure, for easy sensitivity adjustments.

Ideal applications for this product are wire and plastic tubing, such as for medical and automotive applications. For more information on this or any other Coiltek product, please don’t hesitate to contact usCS-6202 edited 1.

Even more variety in the Coiltek lineup!

The Coiltek lineup is growing! We are pleased to announce that soon we will be unveiling a new no-touch sonic loop control system specifically geared towards working with the smallest stock, such as medical tubing. This ultra-sensitive unit will come with a stand, but be smaller and lighter weight than our CS-5000 series.

If you would like to learn more about our current lineup of products, please visit our products page. If you have questions, comments, or new applications for this or any other product, please feel free to contact us.

Non-Contact Loop Controls

Our Coiltek loop controls are non-contact loop controls. While most manufacturers of ultrasonic loop control systems have only one line of no-touch loop controls which use out-dated technology, we have two distinct lines of completely upgraded ultrasonic loop control systems.

The new Coiltek CS-5000 V2 and CS-6200 lines of non-contacting loop control systems are powerful and reliable. Our updated technology allows for on-board storage of preset programs, USB connected remote programming via computer, and instantaneous manual calibration.

At Coiltek we are always looking for new applications. With this in mind, we are creating a model of the low-cost, non-contacting CS-6200 line, the CS-6202, for use specifically within plastic tubing manufacturing.

If you have an application you believe could benefit from our ultrasonic distance sensing technology, please contact us. With great customer service and expert technical and engineering know-how, we can answer every question you may have and even tailor our products to suit your needs. Give us a call today.

Coiltek Loop Controls

Coiltek makes ultrasonic loop controls, which are sometimes known as sonic loop controls, sonar loop controls, and no-touch loop controls. Our founder invented the concept of using ultrasonic frequencies to sense and control the height of a loop during processes such as stamping, winding, rewinding, and extrusion and our loop controls have been the industry standard ever since.

If you would like to explore our products, please visit the Products and Brochures sections of our website. Any further questions? Contact us.

Advantages of Coiltek Ultrasonic Loop Controls

The advantages of Coiltek loop control systems are plentiful, but today we will focus on three major advantages: No-touch feeding control, durability, and programability.

Coiltek makes the industry standard ultrasonic loop control systems. Our CS-6200 series of low-cost loop controls and our popular CS-5000 series of ultrasonic loop controls provide a 0-10v output to control the feeding of a straightener or decoiler, allowing for consistent feeding without touching the stock. This is an advantage especially for stocks that move a lot during feeding, such as wide stocks, and for non-conductive stock, such as plastic tubing or extruded rubber.

Coiltek products stand the test of time and it is not unusual to see a unit in a plant that is more than a decade old. In fact, our shop regularly receives inquiries about updating working systems built over 15 years ago. We stand behind our product and offer free lifetime phone support for every product we make. We also repair our old boards to save our customers money. All of our new products are backwards compatible, meaning that any time you decide to update your system, you will be able to find parts that work.

Finally, our Coiltek units make switching between stocks and their respective programs easy with on-board storage of up to 7 preset programs. We even offer an option to make 3 of those presets remotely accessible, called the 3CPO.

If you have any questions about what the durability, flexibility, and adaptability of Coiltek loop controls can do for your business, please contact us.

The 3CPO Accessory for Coiltek Loop Control Systems

The 3CPO option allows for easy-access to multiple stored programs.

Coiltek’s CS-5000 ultrasonic sensor has always had the capability of storing multiple loop control parameters.  The 3CPO option makes it easy for press operators to quickly switch to the appropriate loop control algorithm to run the job.

Why would you need different loop control parameters?  Here a few examples of press jobs that beg special treatment.

  • Long Feed Progressions.  If each press cycle pulls most of the slack from the loop, your loop control algorithm should include offset.  With offset, the control signal from the CS-5000 jumps from zero volts to some percentage of full scale output.  Figure 1 shows a comparison of a standard analog output with a 30% offset output.  With offset, the feed equipment (decoiler or straightener/flattener) gets a substantial move signal before too much loop is depleted.  This head start overcomes the  inertia of the equipment giving it more of a chance to match the press throughput.   With offset set properly, the feed device will run more smoothly.  Here’s why: The loop will swing up and down dramatically with each stroke of the press.  This is an unavoidable. The loop control will sense the large fluctuation.  Note that with offset, the output signal over the control range presents a gentler slope than a pure 1:1 analog output.  Provided the loop stays within the desired control range, the drive that the CS-5000 controls will exhibit far less “wow” (variation in speed with each press stroke).  Offset works best with constant speed devices like straighteners or nip-pullers than with decoilers.   The dwindling radius of the coil represents a constantly changing system gain, which can make the offset characteristics difficult to dial in.
  • Thick stocks.  In a given looping area, thin stocks ‘drape’ better than thick stocks.  In fact, if there is insufficient looping distance, thick stocks cannot be pushed all the way to the floor without imposing set (curvature) in the material.  Where a straightener/flattener is used to remove coil-set, it’s hardly good practice to re-institute it in the loop.  It’s critical then, if you run different stock thicknesses through the same press, that you set different control ranges to adapt to material thickness.  A preset program associated with a particular stock thickness  lets you control the radius of curvature in the loop so that stock bending stress is kept below yield.
  • Short Feed Progressions.  When a straightener, designed to keep up with high press throughputs, is presented with a very short feed progression or slow press SPMs, a standard loop control algorithm  can cause problems.  The straightener will grind along at a small fraction of its rated speed. Without ventilation from its internal fan the motor overheats.  At best, the thermal cutouts snap, and the straightener’s down.  Usually, the motors just burn up.  The CS-5000’s control relay lets you program an ON-OFF system with hysteresis  Using the control relay, the straightener turns on when the loop rises to a predetermined height, then stops when the loop drops below a certain level (see figure below).  This way the straightener is ON at a reasonable speed for a while, then rests. In the figure below the diagonal arrows in the time graph indicate whether the loop is depleting (arrows point UP) or re-filling (arrows point DOWN).

This algorithm is a little more complicated to program and wire.  If your line requires this feature, refer to our white paper entitled Accessing ON-OFF Control Within the 3CPO Option.

Programming the CS-5000 series controls for multiple program presets can be performed manually with the on-board DIP switches.  Full functionality including programming OFFSET or the Control Relay must be performed using Coiltek’s CSWin32 software.  It’s a free download from this website.  The 3 CPO option is available pre-installed on our CS-5000, CS-5100 or even our CS-6100 series controls.  It is also sold as a simple-to-install kit.

To learn more about the 3CPO option, check out our full brochure, complete with pictures and diagrams. As always, feel free to contact us with any questions you may have about your application. Click here to find all our contact information.

Coiltek Hammerhead Accessory

At Coiltek we’re always trying to find innovative solutions to industrial problems involving loop controls. One such innovation is our Hammerhead accessory for the CS-5000 series of ultrasonic loop controls.

The only one of its kind, the Hammerhead features 3 ultrasonic elements which, when the kit is attached to the boom of the unit, are seated in a line parallel to the stock the unit is sensing. This innovative design triples the sensing area of the CS-5000 in order to sense stock continuously even when the bottom of the loop moves vertically throughout the process.

To learn more about the Hammerhead Accessory, as well as our other offerings, please visit our Products page. You can also learn more about our loop control systems by checking out the brochures in the Downloads section of our site. If you should have any questions or would like to request a quote, please don’t hesitate to call us or drop us a line using the widget on our Contact Us page.