Reliable detection of material jams plays a key role in automated production processes. Especially in metal processing, where small parts are collected, conveyed or separated in narrow hoppers, blockages can quickly occur. Oil residue, gloss or irregular surfaces make detection even more difficult. If the material flow stops, there is a risk of downtime, inefficient reworking and, in the worst case, damage to machines or tools.
To avoid these risks, sensors must be able to precisely detect the material level – even under difficult conditions. This is exactly where the LevelTech FXPL004 fill-level sensors from wenglor come in.
Installation situations in metal processing plants are often complex: hoppers, pipes and attachments leave hardly any space for the installation of additional components. The sensor therefore often has to be installed at the side, as there is no space above the hopper.
In addition, the parts to be detected are themselves problematic. They reflect light strongly, are often irregularly shaped and wet with oil film or lubricants. Classic optical systems such as light barriers or retro-reflex sensors react sensitively to such conditions – the light is reflected or absorbed irregularly, resulting in incorrect switching. In practice, this means that the sensor does not reliably detect the traffic jam or switches too late. Optical models are also susceptible to contamination or misalignment. Even a small change in the sensor position can result in the light beam no longer hitting the measuring point correctly.
The LevelTech FXPL004 was specially developed for such scenarios. It works capacitively and measures changes in the electrical field that are triggered by the presence of a material. This means that detection works regardless of color, material, shape or gloss. Even highly reflective or oily metal parts are detected precisely – a decisive advantage over optical systems.
The sensor is typically mounted on the side of the hopper wall and reliably detects as soon as the fill level reaches a defined point. This punctual detection is sufficient to reliably report a jam or automatically interrupt the process. As the FXPL004 is calibrated at the factory, there is no need for time-consuming teach-in or readjustment. It reliably distinguishes between “material present” and “air” right from the start.
The compact design allows it to be used even in small hoppers with a diameter of around 100 millimetres. Users can read out the sensor data in real time or integrate it into the control system via IO-Link. This makes the solution not only robust, but also future-proof.
Another advantage of the FXPL004 is its high resistance to environmental influences. Oil, dust or metallic abrasion do not impair its function. The smooth, closed surface reliably protects the sensors from deposits and makes cleaning easier. Especially in production environments where employees regularly interact with the system, tamper resistance also plays a role. Unlike optical sensors, the FXPL004 has no visible adjustment knobs or potentiometers that could be accidentally adjusted. Configuration is carried out digitally via IO-Link – safe, reproducible and documentable. The sensor is equipped with a 360° LED indicator for a quick visual check. This clearly indicates the switching status from any direction – a practical detail in cramped installation situations where the sensor is not always freely accessible.
With the LevelTech FXPL004, wenglor offers a powerful and maintenance-free solution for level and accumulation detection in metal hoppers. Its capacitive technology enables precise results, even with oily, shiny or contaminated surfaces. Side mounting, easy initial start-up and high tamper resistance make it the ideal choice for production environments with demanding conditions. Thanks to its robustness, its IO-Link interface and its low-maintenance design, the FXPL004 ensures stable processes in the long term – without the need for readjustment or cleaning. This makes it not only an alternative to optical systems, but also a permanent solution for reliable congestion control in modern industrial plants.
