1. Project Background
A midsize logistics and packaging center implemented automated conveyors for sorting, packing, and labeling operations. The system required reliable detection of material presence at key conveyor zones to:
- Verify material arrival before packaging
- Detect conveyor blockage
- Count items being transferred
- Ensure correct timing for labeling and sorting
Because of tight space and high dust/particle conditions, optical and contact sensors experienced false signals and wear. A noncontact ultrasonic solution was selected to overcome these limitations without adding a PLC.
2. Measurement Challenges
The application needed to address:
- Dust and debris on conveyor surfaces reducing optical sensor reliability
- Need for robust detection unaffected by material color or reflectivity
- Rapid moving material requiring fast detection response
- Blockage conditions where items accumulate and stall
- Requirement to trigger alarms, counters, and indicators without PLC
These requirements led to choosing non contact ultrasonic sensing with tangible local outputs.
3. Solution Overview
The KUS3000 ultrasonic proximity sensor was installed at multiple conveyor zones, using its detection signal to trigger indicators, counters, and alarms locally. No PLC was used; instead, sensor outputs were integrated directly with:
- Local relay alarms
- Counters
- Visual indicators (lights)
- Packaging and labeling triggers
Ultrasonic waves detect material distance to determine presence, absence, or obstruction.
3.1 Equipment Configuration
The system consisted of:
- KUS3000 ultrasonic proximity sensors at key positions (infeed, midbelt, discharge)
- Adjustable mounting brackets to aim sensors at conveyor surface
- Signal output connected to counters and alarm modules
- Visual indicator lights
- Local power supply
3.2 Key Technical Specifications
| Parameter | Specification |
| Sensing Method | Ultrasonic non contact proximity |
| Sensing Range | 30 mm – 500 mm (typical configuration) |
| Output Type | Relay / Digital switch |
| Response Time | < 50 ms |
| Protection | IP65 |
| Operating Temp | -10°C ~ 50°C |
| Installation | Fixed above conveyor path |
3.3 Implementation Process
Installation
KUS3000 sensors were mounted above conveyor sections:
- Inbound zone — detect material arrival
- Clog detection zone — detect stalled items
- Pre packaging zone — trigger count/processing
- Labeling zone — confirm material present
Wiring
Each sensor’s digital/relay output was connected to local alarm units, counters, or indicator lights. No PLC integration was used.
Commissioning
Detection thresholds were adjusted on the sensor based on conveyor speed and product types. Test runs validated detection reliability and false trigger resilience.
4. Project Results & Performance
| Performance Indicator | Result |
| Detection Reliability | >99% accurate detection |
| False Alarm Rate | Low (minimal under dust conditions) |
| Response Time | < 50 ms |
| Maintenance | Reduced compared to optical sensors |
| Operating Stability | Stable under varying material types |
Ultrasonic proximity sensing maintained consistent detection unaffected by material color, texture, or dust accumulation.
5. Conclusion
Deploying KUS3000 ultrasonic proximity sensors enabled reliable logistics conveyor monitoring without a PLC. The non contact method improved detection stability for material presence, blockage, counting, and triggered packaging/labeling actions.
For more technical details, wiring diagrams, or model selection guidance, please click here to learn more or contact our technical team.
