Prime Controls Double Sheet Detectors

Overview

Prime Controls double sheet detectors catch two sheets or blanks fed at once, before the extra thickness damages tools and dies or makes a double-stamped part. Prime offers contact and non-contact systems with one or two probes for steel, tinplate, stainless steel, copper and aluminum, from thin foil to thick steel blanks.

Key Features

• Single- and dual-probe systems
  • Single-probe detectors sense the sheet from one side; dual-probe systems measure metal passing between two opposing sensors.
• Contact and non-contact sensing
  • Magnetic single probes read ferrous metal touching the sensor face, while inductive and eddy current dual probes never touch the sheet.
• Ferrous and non-ferrous metals
  • Probes are tuned for steel and tinplate or for aluminum, copper and stainless steel, so there is a system for each metal group.
• Automatic signal selection
  • At power-up, Prime dual-probe detectors test ten signal options and pick the best one for the metal, probe type and probe gap.
• Calibration memory
  • Higher-end controls such as the DS1522 and DS600-PC store up to 64 calibrations for different materials.
• Plant network connection
  • The DS210 and DS600 connect to EtherNet/IP through Prime's ET210 and ET600 gateways.

Product Line / Models

Prime Controls double sheet detector families:

• DS60 Series – Low-cost single-probe contact system, just 18 mm in diameter, for thin steel and other ferrous metals. Sensors cover .002" to .06" (.050–1.524 mm).
• DS100 Series – Single-probe contact systems for thin steel and ferrous metals.
• DS150 Series – Dual-probe, non-contact systems for all metal types, from the basic DS150 to the DS1522 with over/under thickness detection and 64-slot memory. Sensors cover .002" to .300" (.050–7.5 mm).
• DS160 Series and DS3410 System – Non-contact detectors for thin stainless steel and aluminum (DS160 single-probe, DS3410 dual-probe).
• DS210 System – Single-probe contact detector for steel and tinplate. Pulse-and-release sensing suits pick-and-place and end-of-arm robot transfer. Sensors cover .01" to .25" (.25–6.35 mm).
• DS600 Series – Single-probe, non-contact, non-marring detector for aluminum auto body parts. Range .001" to .15" (.025–3.81 mm).
• DS-FLEX Series – Configurable single- and multi-channel double sheet detection for metal forming.

Applications & Benefits

• Die protection: Catching a double blank before the stroke prevents damage to tools and dies and the downtime that follows.
• Part quality: Keeps double-stamped defective parts from being made and shipped.
• Feeders, destackers and robots: Detectors are used on sheet feeders, destackers, robot loaders and stamping presses.
• Aluminum body panels: The DS600 detects doubles on aluminum from one side without touching the sheet.
• Canmaking and appliances: Prime serves canmaking, automotive, appliance and other metal forming plants.

How to Choose the Right Prime Controls Double Sheet Detector

1. Metal type: ferrous (steel, tinplate) or non-ferrous (aluminum, copper, stainless steel).
2. Thickness range of a single sheet.
3. Whether the sheet can pass between two opposing probes (dual probe) or can only be sensed from one side (single probe).
4. Whether the sensor may touch the sheet, or the surface must not be marked.
5. Where it mounts: press, sheet feeder, destacker or robot end-of-arm tooling.
6. How many materials you run, and whether you need stored calibrations or EtherNet/IP.

Why Prime Controls Double Sheet Detectors Are Trusted

• Automotive track record: Prime Controls double sheet detectors are used by top automakers around the world.
• 25+ years of experience: Prime has focused on double sheet detection for canmaking, automotive, appliance and metal forming for more than 25 years.
• A method for every metal: Inductive, eddy current and magnetic sensing cover ferrous and non-ferrous sheet from foil to heavy blanks.

Contact & Ordering

Need help picking the right model or getting a quote? Provide these details:

• Metal type and grade
• Single-sheet thickness range
• Machine: press, sheet feeder, destacker or robot
• Can the sheet pass between two probes, or only be sensed from one side
• Whether the sensor may contact the sheet
• Output or network needs (discrete I/O, EtherNet/IP)
• Contact PRI to discuss specs, lead times, and installation support.