Solutions in the Field

Applications by industry

30 years of solved automation applications across Indian industries. Explore the sectors we serve.

PackagingSafety

Safety light curtain on case erector infeed

Case erector infeed required guarding that allowed fast jam clearance without triggering a full safety reset and production halt.

Solution: Cedes Grid scan/Mini SIL 2 safety light curtain installed across infeed aperture with muting during material feed cycle.

PackagingPositioning

Encoder for bag-make-seal cam synchronisation

Cam timing drift at 300 bags/min caused inconsistent seal width and 3% seal-failure reject rate on FMCG powder line.

Solution: Kubler 5020 hollow-shaft incremental encoder mounted directly on main cam shaft with shielded cable to servo drive.

PrintingPositioning

Print-register encoder for narrow-web label press

Colour register shifted by ±0.3 mm over a 4-hour run as heat expanded the drive shaft and slipped the friction coupling encoder.

Solution: Kubler 5873 hollow-shaft absolute encoder with zero-backlash clamp collar replaced friction-mount unit on nip roller shaft.

PrintingCable Management

Slip ring for rotating print cylinder

Flying-lead connections to rotating print cylinder snapped repeatedly under continuous 360° rotation, causing unplanned downtime.

Solution: LTN SC120 multi-channel slip ring with gold-on-gold contacts installed on cylinder stub shaft; Murrplastik MP52 conduit protects lead-in.

WoodworkingLinear Positioning

Linear encoder for CNC router in MDF dust

Optical linear scale on X-axis failed every 6–8 weeks due to MDF dust ingress, causing position errors and scrapped panels.

Solution: Siko SG10 magnetic linear encoder with IP67 read head and sealed Murrplastik MP cable conduit replaced optical scale.

WoodworkingSafety

Safety light curtain on panel saw table

Panel saw required guarding that did not obstruct large panel handling, making fixed guards impractical for the operator workflow.

Solution: Cedes Grid scan/Mini SIL 2 light curtain fitted across the blade aperture with manually-actuated muting during panel feed.

CNC MachinesPositioning

Sealed rotary encoder for lathe spindle

Standard encoder seals failed within weeks on a turning centre due to coolant mist ingress, causing intermittent spindle feedback errors.

Solution: Kubler 5020 IP67 hollow-shaft incremental encoder with V-ring seal installed on spindle nose; Murrplastik cable conduit used throughout.

CNC MachinesLinear Positioning

Absolute linear scale on cylindrical grinding slide

Incremental linear scale required re-homing after every power cycle, adding 8 minutes to each setup on an aerospace grinding cell.

Solution: Siko SGH25 absolute magnetic linear encoder installed on grinding slide; position retained through power cycles with battery back-up.

ElevatorsPositioning

Hollow-shaft encoder for traction machine floor levelling

Friction-drive encoder on traction sheave slipped under load changes, causing ±30 mm floor mis-levelling and lift-out-of-service calls.

Solution: Kubler KIH40 hollow-shaft incremental encoder clamped directly onto traction machine shaft; no friction coupling required.

ElevatorsSafety

Cedes Cegard/Mini SIL 2 door safety edge

Ageing electromechanical door edges on a 1990s lift bank no longer met EN 81-20 SIL 2 requirements, risking regulatory non-compliance.

Solution: Cedes Cegard/Mini optical safety edge with SIL 2 output fitted to all 8 car doors; existing wiring reused with adapter harness.

RenewablesCable Management

Slip ring for wind turbine pitch control hub

Conventional brush-type slip ring in the pitch-control hub required quarterly maintenance and failed prematurely in high-humidity coastal sites.

Solution: LTN SC050 maintenance-free slip ring with gold-on-gold contacts and hermetic sealing fitted to hub; Murrplastik UV-rated conduit used for lead-ins.

RenewablesPositioning

Dual-axis inclinometer for solar tracker PLC

Single-axis encoder feedback missed cross-axis tilt caused by ground settlement, reducing tracker efficiency by 4% on a 5 MW field.

Solution: Siko IK360 dual-axis inclinometer with CANopen output added to tracker frame; signal fed to Unitronics Unistream PLC for real-time correction.

AutomotiveSafety

Safety area scanner for robotic welding cell

Fixed guarding around welding cell made part loading slow and created blind spots that could not be monitored during robot operation.

Solution: Cedes IMS 100 pro 2D safety laser scanner installed at cell perimeter; two-zone configuration separates warning from stop zones.

AutomotiveVision & ID

Fixed-mount barcode reader for VIN traceability

Hand-held scanning of laser-etched VIN plates on body shells had a 1.5% miss rate, causing traceability gaps on the final-assembly audit trail.

Solution: Optex-FA CDX fixed-mount code reader with 30 mm field of view installed at shell-transfer point; output wired to MES via Unitronics gateway.

SPMsPositioning

Draw-wire sensor for hydraulic press stroke

Rack-and-pinion position transducer on a 200-tonne hydraulic press required frequent backlash adjustment, causing press-stroke repeatability of ±0.8 mm.

Solution: Siko SGP/1 draw-wire position sensor directly coupled to press ram; analog 4–20 mA output fed directly to Unitronics PLC.

PaperPositioning

Draw-wire sensor for winder spool diameter

Ultrasonic diameter measurement on the parent-roll winder gave ±15 mm accuracy at 2000 m/min, causing early reel changes and yield loss.

Solution: Siko SGH50 cable-extension transducer mounted on winder frame measures spool radius directly; 4–20 mA signal fed to winder PLC.

SPMsSensing

Miniature photoelectric for part ejection confirmation

Missing-part ejection on a transfer SPM went undetected in 0.3% of cycles, causing downstream assembly errors and costly warranty claims.

Solution: Optex-FA BGS-Z miniature background-suppression sensor fitted in ejection chute; output wired as cycle-complete interlock to SPM controller.

DefencePositioning

Military-grade encoder for radar pedestal azimuth

COTS encoder on radar pedestal failed after 3 months due to shock and vibration levels exceeding commercial IP54 ratings.

Solution: Kubler 5020 heavy-duty IP67 incremental encoder with stainless-steel shaft and reinforced bearing fitted; Murrplastik EMI-shielded conduit protects signal cable.

DefenceCable Management

Multi-channel slip ring for rotating antenna

Flying-lead connections to a 360°-rotating antenna array failed within weeks due to cable fatigue, grounding the system for unplanned repair.

Solution: LTN SC2X0 multi-circuit slip ring with 8 power + 4 signal channels installed on antenna elevation axis; Murrplastik shielded conduit on stator side.

RailwaysPositioning

Magnetic encoder on traction motor bogie

Optical encoder on metro traction motor failed repeatedly due to vibration and wheel-spray contamination, causing unplanned bogie withdrawals.

Solution: Kubler F5868 IP67 magnetic incremental encoder with M12 connector and sealed housing replaced optical unit on all bogies.

RailwaysSafety

SIL 2 safety edge for platform screen doors

Electromechanical safety edges on platform screen doors did not meet EN 50155 SIL 2 requirements demanded by new operating authority audit.

Solution: Cedes Cegard/Mini SIL 2 optical safety edge with EN 50155 railway-grade certification fitted to all 48 door leaves on the station.

Entrance AutomationPositioning

Draw-wire sensor for door-leaf absolute position

Loss of door-leaf absolute position after a power cut forced a full recalibration run that blocked the entrance for 5–10 minutes on restart.

Solution: Siko SG20 absolute magnetic draw-wire sensor fitted to sliding door drive mechanism; position retained through power cycles via battery back-up.

Entrance AutomationSafety

Cedes Easygard presence sensor for sliding door

Standard infrared motion detectors missed low-reflectance clothing and caused 4 door-contact incidents per month in a busy retail entrance.

Solution: Cedes Easygard near-field presence sensor with 3D detection zone installed in door header; sensitivity tuned for dark and reflective surfaces.

Food ProcessingSensing

Stainless-steel photoelectric for bottle presence

Standard plastic-housed sensors corroded within 3 months on a beverage bottling line due to daily caustic wash-down at 80°C.

Solution: Telco MPA81 stainless-steel IP69K photoelectric sensors installed at all detection points; Murrplastik stainless-steel cable glands used throughout.

Food ProcessingCable Management

IP67 slip ring on rotary filling carousel

Continuous rotation of a 24-head rotary filler destroyed flying-lead wiring every 6–8 weeks, causing 4-hour downtime and product waste.

Solution: LTN SC080 IP67 food-grade slip ring with 316L stainless housing and EHEDG-compliant seals installed on carousel centre shaft.

PharmaPositioning

Absolute encoder for tablet press turret

Incremental encoder on a 61-station tablet press required homing on every batch start, adding 12 minutes of unvalidated setup time.

Solution: Kubler 5020 absolute multi-turn encoder with GQMP traceability certificate installed on turret drive shaft; position valid on power-up.

PharmaVision & ID

Cognex vision system for blister pack inspection

Manual AQL sampling on a 300 blister/min OSD line allowed defective (empty pocket, wrong tablet) packs to reach batch release with 0.08% defect rate.

Solution: Cognex vision system with backlit conveyor inspects every blister for pocket fill, seal integrity, and print-code presence at full line speed.

MiningSensing

Through-beam sensor for conveyor belt misalignment

Belt misalignment on a 1.2 km overland conveyor caused edge damage and spillage, with misalignment going undetected until a belt tracking emergency stop.

Solution: Telco SM 8000 through-beam sensors installed at 50 m intervals on return-strand rollers; output wired to PLC alarm with GPS location tag.

MiningPositioning

Magnetic encoder on cone crusher primary shaft

Optical encoder on crusher primary shaft failed within days due to dust ingress and high-frequency vibration from rock impact loading.

Solution: Kubler F5868 magnetic IP67 encoder with non-contact read head installed on primary shaft via taper-lock collar; vibration-damping mount used.

PaperCable Management

High-temperature slip ring on Yankee dryer

Standard slip ring on a 5.5 m Yankee dryer failed every 8 weeks due to bearing housing temperatures of 140°C, causing unplanned tissue machine stops.

Solution: LTN SC120 high-temperature slip ring rated to 200°C installed on dryer stub shaft; Murrplastik high-temp cable conduit used for lead-in wiring.

Harsh EnvironmentsSensing

ATEX Zone 2 photoelectric in paint-spray booth

Standard sensors in a solvent-based paint-spray booth created ignition risk; ATEX Zone 2 classification required Ex-rated equipment throughout.

Solution: Optex-FA Z4 Series ATEX Zone 2 certified photoelectric sensors installed at all part-detection points; Murrplastik Ex-rated cable conduit used.

Harsh EnvironmentsCable Management

Marine-grade slip ring for offshore knuckle-boom crane

Standard slip ring on the slewing ring of an offshore supply vessel knuckle-boom crane corroded within 4 months in salt-spray conditions.

Solution: LTN SC040 marine-grade slip ring with 316L stainless housing and IP67 sealing installed; Murrplastik armoured conduit protects stator wiring from mechanical damage.