If rejections, product changes and complex processes are slowing down your output in plastics processing, you need reliable inline control.
With well thought-out injection molding automation, you can ensure that parts are fed reliably, detected accurately and inspected directly in the process – before costly errors take place.
This is precisely where SensoPart, your dependable, experienced partner, comes in: Our sensors for plastics engineering reliably take on many different tasks – from object detection to determining exact position data for controlling robots.
- Benefits of plastics engineering automation with SensoPart
- Application examples in plastics engineering briefly explained
- Molding
- Intralogistics & material flow
- Jetzt die richtige Kamera für Ihren Roboter finden
- Are you interested in our products?
- Robotics & positioning
- Assembly & placement
- Quality control
- Surfaces & decoration
- Identification & traceability
- Packaging & end-of-line
- Products: the right solution for your application
- All application examples from the injection molding sector
- This could interest you as well
Automation in injection molding: Your advantages with SensoPart
When you use sensors for automation in the plastics industry, what ultimately counts most is stable quality with maximum process reliability. That is exactly what our optical sensors and vision sensors are made for – robust operation, precision inspections and easy integration.
- Fewer rejections and less rework: Detect injection molding defects, such as underfeeding, overfeeding and deformations, reliably at an early stage
- Inline quality checks: Check contours, spacings, radiuses, angles and drilled holes with process reliability
- Reliable detection: BlueLight technology for greater process reliability (even with dark black, transparent, shiny or highly angled parts)
- Fast commissioning: Setup in a few minutes with no special expertise
- Seamless integration: Support for common channels and protocols (Ethernet TCP/IP, EtherNet/IP and PROFINET)
- Tool protection: Reliably detect missing, misaligned, or doubled-up insertion parts and prevent costly tool damage
The right solutions along your entire process chain in plastics technology
In plastics engineering, it isn't just one step that determines the quality and output, but stability over the entire line. SensoPart assists you in this with vision solutions and optical sensors for plastic injection molding – so that your system runs efficiently and you have less scrap.
Molding: Precision in sync with the machine
In injection molding manufacturing, a stable manufacturing process is the decisive factor for the quality and cost-effectiveness of your products. Modern sensor technology provides the required support – from reliable detection of process-relevant conditions to safeguarding downstream steps in the automation. This allows you to reduce downtimes and avoid rejections early on.
Reliable detection is particularly important when it comes to picking and parts handling: Has a part been removed from the mold properly? Has the sprue been properly separated? Is there a part still in the tool or lying on the belt? Sensors such as the VISOR® Object AI provide the basis for process-reliable, automated downstream processing – including optional Visualization of the process data for your system.
Intralogistics & material flow: Transparency for conveyor sections
Whether roller conveyors, belts or transport routes between stations: Material flow stability requires reliable signals. Special challenges are faced with transparent or frequently changing materials, and traditional sensor technology reaches its limits here. This is where our BlueLight Technology delivers outstanding detection results. It synchronizes downstream processes correctly. This makes the material flow in your system not only faster, but also less prone to faults.
Are you interested in our products?
Our experts will be happy to advise you! You can reach us by phone at
+49 7673 8210 or use our contact form.
Robotics & positioning: flexible feeding, reliable removal
In modern plastics manufacturing, the position and orientation of parts often vary, for example on flexible feeding platforms. Vision sensor technology used in this context provides exact position data so that robots can grip, align and pass on parts reliably. This reduces the number of unintentional collisions and increases flexibility with changing products.
SensoPart facilitates applications in which the component position must be made “visible” and the coordinates need to be passed to the robot. This works well, for example, with our VISOR® Robotic, which is ideal for pick-and-place tasks with randomly arranged feeding. This also allows dynamic processes to be automated reliably.
Assembly & placement: Avoid defects using inline control
Every detail counts in assembly and placement processes: A missing component or misaligned part entail rework or customer complaints, which in turn lead to additional costs. With automated inspections in the running process, you have control over completeness and alignment at all times – and ensure that only components with proper placements continue onwards.
In addition to our VISOR® Vision Sensors, light barriers and photoelectric diffuse sensors are also suitable for applications such as inspections for completeness and positioning.
Quality control – detect defects before they become expensive
The demand for maximum control continues to grow – not only in the automobile industry or pharmaceutics industry. Image processing and AI-supported inspection make it possible to reliably detect and classify typical fail images before defective parts are passed along to downstream processes. This reduces your scrap, protects expensive tooling and stabilizes the overall delivery quality.
Typical inspection tasks include inspection of injection-molded parts for overfeeding and underfeeding or detecting process-critical features that are difficult to detect using rules-based sensor technology. With clear pass/fail decisions and optional visualization of results, photoelectric diffuse sensors with background suppression, for example, can control the quality directly on the line.
Surfaces & decoration: Objectively verify visual quality
Finishing processes such as printing and coating are crucial for visible parts – but they are also prone to variations. Automated inspection reliably checks the image quality, position and completeness and ensures that only flawless parts are passed on to assembly or packaging.
A typical example is the inspection of pad printing, during which defects such as incomplete print images, misalignment, and smudges are detected at an early stage. Consequently, when combined with the right accessories, a visual inspection based on a subjective impression can be replaced with a reproducible quality decision.
Identification & traceability Codes that control the process
End-to-end traceability is essential in many industry sectors, as well as for a functional automation. When components have been identified unambiguously, processes parameters can be configured automatically, variants can be distinguished reliably and data can be allocated accurately. Of decisive importance here is a high reading rate even under difficult conditions.
This is where our VISOR® Code Reader comes into play: The application options for this sensor range from capturing data matrix codes (DMC) for track-and-trace to reading and comparing plain writing (OCR) and DMC contents. This results in end-to-end documentation and a reliable basis for data-driven quality.
Packaging & end-of-line: Reliable outgoing deliveries, thorough documentation
The end of the line is where decisions are made about what gets delivered to the customer. With automated end-of-line inspections, you can ensure that packaging is complete, properly filled and clearly labeled. This reduces cost drivers, like customer complaints, rework and sorting effort. For instance, the FT 10-BHD masters tasks such as reliably detecting even highly light-absorbent or shiny objects effortlessly. Counting and timer functions are also already integrated in these sensors as "Smart Functions".
Choose the right solution for your requirements
In plastics engineering, process-reliable detection and end-to-end quality control are what matter most. Whether challenging surfaces (dark black, shiny, transparent), injection molding defects or traceability: With our sensor solutions, you can automate your manufacturing and quality assurance efficiently and reduce both rejections and rework in the field of injection molding.
All application examples from the injection molding sector
The following application examples show you the deployment possibilities for our products in practice.
Filter application examples
15 Application examples match your search criteria
Comparing Plain Text and DMC-Codes
In modern production facilities, where traceability and quality control are essential, reading OCR and DMC codes on components plays a key role. These codes are used not only for identification, but also to ensure complete traceability of products and components throughout complex manufacturing processes. A reliable vision system must not only recognize OCR and DMC codes, but also compare them against each other.
Detecting Adhesive Tape on Products
In wire harness production, new cables are attached to existing ones using adhesive tape. These connection points must be consistently detected by sensors throughout the cable manufacturing process.
Detection of foil coils during transport
In the production process for films, the films are transported from one station to the next using roller conveyor belts. Optical sensors are used to verify the presence of the films in order to initiate the next production step.
Detection of transparent bags
In many manufacturing processes in different sectors, such as in the packaging industry, transparent pouches or bags must be reliably detected with the help of a sensor.
Detection of trays
The detection of trays on conveyor belts is an important task in many industrial processes. It is important that the trays are recognized quickly and reliably with the help of a sensor in order to control further processing. The trays can be different colors and transparent
Effortless Traceability: Displaying code contents, texts,
In modern manufacturing, the need for seamless component traceability (Track-and-Trace) continues to grow. Data Matrix Codes (DMCs) have emerged as one of the most reliable methods for identification and traceability. The goal is to scan the Data Matrix Code on each component, guaranteeing precise product processing and flawless serial number management.
Full count of balls in a ball bearing housing
When manufacturing ball bearings, it is vital to know that the bearing has the full number of balls. The aim of the application is to inspect a ball bearing after assembly to ensure it is complete.
Handling Door Seals in Automotive Manufacturing
In car door seal production seals of various lengths must be handled with precision. To ensure correct placement, each seal is guided along a conveyor belt. During transport, the end of the seal must be detected so the conveyor can stop at the exact position for the next step. An optical sensor is required to identify the end of the seal in continuous operation and send a signal to the conveyor belt to stop at the correct position. Once the seal is correctly positioned, it can move on to the next production step.
Pad Printing Inspection
Pad printing is considered one of the main methods for printing on parts. However, during this printing process, various defects can occur...
Quality Control on Injection Molded Parts
The importance of quality assurance in plastic processing is continually increasing. Industries such as medical technology and the automotive sector require 100% product inspection. Defects including over/underfills or burrs not only affect the aesthetics and functionality of the end products but can also lead to increased costs due to waste/scrap or rework. Inspecting parts using a vision sensor allows for the early and reliable detection of these defects, ensuring product quality.
Reliable Completeness Check for Earplugs on the Conveyor Belt
In packaging inspection, every detail counts—even small deviations can lead to customer complaints or unnecessary waste. This is especially true in earplug packaging, where it’s essential to verify that every box contains the correct number of items before sealing. A sensor performs this check, ensuring each box reaches the customer fully complete and accurate, preventing faulty packaging from the start.
Reliable Position Control of Rollers in Vibratory Conveyors
For correct downstream assembly, rollers—such as those from roller or storage boxes—must enter the vibratory conveyor in the proper orientation. If a roller is misaligned, a sensor must reliably detect it and trigger an automatic return to the bunker via reverse air blast.
VISOR® Makes Component Positions Visible
A robot is tasked with picking components from a flexible feeding platform. The position of the objects may vary. A vision sensor can identify and relay the exact position of the part to the robot.
VISOR®: Precision Injection Molding Control with Inspection Results in Real Time
The necessity of quality control in plastics processing is increasing. Defects like overmolding/underfilling or burrs not only impact the appearance and performance of end products but can also escalate costs due to waste or rework. Utilizing a vision sensor for part inspection enables early and dependable detection of such flaws, ensuring product quality.
Displaying inspection results, defect classifications, and part numbers in real time optimizes production.
Visualisation of entire process with SensoWeb
Throughout the production process, a large quantity of data is generated that has to be monitored and checked. The operator must be able to consult, manage and evaluate this data easily in order to identify and implement any necessary modifications to the process.
