Photoelectric proximity sensor 4022

rectangularwith relay outputAC

Overview
The NEEDLE SENSOR 4022 monitors, contact-free, needles on single, double, jacquard and interlock circular knitting machines. When a defective needle is detected, the system stops the machine immediately and indicates the exact position of the broken or bent needle. Typical configurations comprise one control unit and one or two optical heads, depending on machine type.

Main functions

• Immediate machine stop when a defective needle is recognized
• Detection of breakage and bending for cylinder and dial needles
• Hand-held terminal 8024 available as a setting aid

Key features

• Needle sequence detection range: 15/s - 5000/s
• Easy replacement of the optical lens
• 4-digit display for quick identification of the defective needle
• Colour-coded LED status display per optical head
• Suitable for high-speed circular knitting machines
• Safe red light illumination
• Maximum gauge support up to E50

Operation
The optical head projects a narrow light spot onto passing needles; reflected light pulses are transmitted to the control unit via fibre-optic cable. The control unit adapts automatically to the needle sequence according to machine speed and needle gauge. If a pulse is missing or out of position due to a defective needle, the unit triggers the machine stop and a needle counter indicates how many needles must pass until the optical head reaches the defective position. Missing needles (e.g. cutting lines or pattern zones) can be masked out. To avoid false stops, the number of revolutions before stopping is adjustable.

Product tour / Visual highlights

• 4-digit display for fast identification of the defective needle
• Control unit with colour-coded LED status for each optical head
• Hand-held terminal 8024 for settings and diagnostics
• Easy and safe optical lens replacement
• Compatibility with high-speed circular knitting machines

Technical specifications

• Sensor range: 15 mm ±1 mm
• Needle sequence: 15/s - 5000/s
• Gauge: Up to E50
• Supply voltage: 11 V - 28 V AC/DC
• Average power consumption: 5 VA
• Output: Relay output, switchable (max. 60 V)
• Typical configuration: 1 control unit and 1 or 2 optical heads depending on machine type
• Hand-held terminal: 8024 (setting aid)