Sugiyama Electric System Products

Products

Sugiyama Electric System makes the press peripherals that stop, count and lubricate: slug detectors, misfeed detectors, sensors, digital cam switches, lubrication units and counters that protect dies and products.

Digital cam switches(4)

Lubrication units(5)

Automatic box changers(1)

Miss-grip detectors(1)

Counters(3)

Slug detectors

Eddy-current sensors on the die measure bottom-dead-center displacement to detect slugs and double blanks, then stop the press.

PS-474P/478PSlug Detector

The Slug Detector "PS-474P/478P" combines advanced detection capabilities with excellent usability, solving challenges that were previously considered unsolvable. Furthermore, by adding up to 8 channels, a revamped waveform display, and IoT connectivity, it makes "detection" more powerful and smarter.

Key specifications

Channels: 4CH (PS-474P) / 8CH (PS-478P)
Resolution: 1μm or 0.1μm (Export Specification:0.5μm(standard value fixed))
Max. limit value: 200μm or 20.0μm
Detect mode: Internal timing , External timing
Max. SPM: 4000SPM
Sensor Installation distance (at B.D.C.): 0.7 to 1.5mm
Length of sensor cable: 1 to 10m(Standard 3m)
Temperature: 0 to 55°C
Number of record labels: 8000 data
Number of record strokes (Approx.): 30 million data

PS-482/484/488Slug Detector

The Slug Detectors PS-482/484/488 are designed for detecting slugs, double piles driving, and so on, during automatic press working and for outputting stop signal to the press in case of abnormalities. It reads a signal from Eddy current proximity sensor installed on the mold for the press and calculate the displacement by a microcomputer. If the displacement exceeds the limit, it outputs the stop signal to the press. Since Ethernet is supported, the PS-482/484/488 can be connected to personal computer (PC) and PLC.

Key specifications

Channels: 2CH (PS-482) / 4CH (PS-484) / 8CH (PS-488)
Resolution: 1μm or 0.1μm
Max. limit value: 200μm or 20.0μm
Detect mode: Internal timing, External timing
Max. SPM: 4000SPM
Sensor Installation distance (at B.D.C.): 0.7 to 1.5 mm
Length of sensor cable: 1 to 10m (Standard 3m)
Temperature: 0 to 55°C
Power supply voltage: 100 to 240 VAC ±10%,50/60Hz (Max. 40VA)
Relay output: EMG Stop, TDC Stop, READY,ALARM (Max. 250VAC / 30VDC 3.0A)

PS-474AMSTAD

High-resolution slug detector called AMSTAD(PS-474) can show not only bar graphs but also waveform graphs and plot graphs because we added liquid crystal display to the slug detector with the resolution of 0.1μm developed by the experience of many years. Therefore, it is easy to adjust detection timing which was difficult to adjust up until now by checking waveform and to check a variation of displacement in the graph. In addition, it is not only showing graphs but also recording a waveform data for 8 strokes immediately before the press stops and recording a displacement data constantly.

Key specifications

Number of channels: 4CH
Resolution: 1μm or 0.1μm
Max. limit value: 200μm or 20.0μm
Sensing distance of sensor head: 0.7 - 1.5nm
Ambient temperature of sensor head: 0 - 55°C
Type of timing: Internal timing , External timing
Length of sensor cable: Standard 3m
Max. SPM: 4000SPM
Number of record strokes (Approx.): 60 million data
USB flash drive: Formatted USB flash drive with FAT32 in USB2.0 or less

PS-464/462Bottom dead center detector

The PS-464/462 bottom-dead-center detector reaches sub-micron resolution. With 0.1 μm resolution and a unique internal angle timing it catches slugs even on bottoming dies.

Key specifications

Detection channels: 4(PS-464), 2(PS-462)
Resolution: 1 μm or 0.1 μm
Maximum setting value: 200 μm or 20.0 μm
The closest gap between sensor head and target (BDC): 0.7 ~ 1.5 mm
Sensor Ambient operating temperature: 0 to 55 degree C
Detection timing: External, internal, internal angle timing,and timer timing
The length of sensor cable: 3 m (standard)
SPM: 4000 SPM (max.)
Relay output: 250 VAC / 30 VDC 3.0 A (max.)
Input specification: Connect the contact of no-voltage or the semiconductor switch. Internal voltage (DC12 V) type

Sensor heads

Sensor heads for the slug detectors. Same electrical characteristics, different shapes to fit the die.

PS-40XXシリーズPS-40XX Series Sensor head

In order to accept various dies, we get a lot of sensor heads lined up. All electric property is the same but outside dimension of them are different.

Misfeed detectors

Monitors material end, misfeed and product ejection, and sends a stop signal to the press when something goes wrong.

PS-682Malfunction detector

The Malfunction Detector “PS-682” detects the status of automatic pressing, such as material shortage, material feeding, discharge of processed goods, and outputs a stop signal to the press in case of trouble. Several functions using timing signal, such as counting, calculation of work rate, error recording, will assist you in production control. PS-682 supports Ethernet to connect with a personal computer or PLC. It employs DIN connector and remotely operable light sensor can be used. Since a voltage of 12V or 24V is outputted, a 24 V sensor can be used as well as conventional light sensor.

Key specifications

Channels: 6Channels
Detect mode: Touch, Synchronization, Passage, Feed, Extraction, Timer, Counting feed
Power source for sensors (by the total): 12VDC (Max. 500mA) 24VDC (Max. 200mA)
Output response time: Max. 10 ms
Digits: Total Counter:6 Preset Counter:6
Output response time: Max. 10ms
Power supply voltage: 100-240VAC ± 10%、50/60Hz(Max. 40VA）
Relay output: EMG Stop, TDC Stop, READY, ALARM (Max. 250 VAC / 30 VAC 3.0A)
External input: ON/OFF, RESET, LOCK,TIMING (T1, T2, T3)
Sensor input: No-voltage contact 3-wire NPN open collector

PS-661/662Malfunction detector

PS-662/661 is a high-reliability malfunction detector with redesigned detection functions and circuits. Detection modes matched to real dies reduce minor stops and prevent die damage and defects.

Key specifications

Detection channels: 6
Detection timings: 3 input
Power source for sensor: 12 V , 600 mA (max.)
Detection style: 6 types (Touch, Synchronization, Extraction, Timer, Passage, Miss-feed)
SPM: 1500 SPM (max.)
Relay output: Emergency, T.D.C., alarm, continuous inhibition 250 VAC / 30 VDC , 2A (max.)
Input Specification: Internal volt system (12 VDC)
H level: 9.0V or over, 1mA or below
L level: 3.0V or below, 8mA or over (12mA MAX)
Digits: 6

PS-101TMalfunction detector

PS-101T is a safety device of one channel used for the exhaust confirmation of the miss feed detection or the product.

Key specifications

Detection channels: 1
Detection mode: Passage (modes1,2)
Voltage of detection circuit: DC12V
Timing mode: Timer timing (25 ms ~ 2.5 s)
Voltage of timing circuit: DC12V
Stop output circuit: Relay output AC200 V 2 A (max.)
Stop output delay time: Approx. 25 ms
Power supply voltage: AC100 V ~ 200 V
Temperature: 0 to 50 degree C
Dimensions(WHD): 170 * 49 * 146 mm (An umbo is not included.)

PS-104FMalfunction detector

PS-104F is a malfunction detection device with four channels of the contact detection method for the press machine. The jack method is used for detection-input terminals of all channels in front of the panel.

Key specifications

Detection channels: 4
Detection mode: Detect the touch or break (The rotation and the synchronization of the press can be taken in CH1. )
Stop output circuit: Relay output AC200 V 2 A (max.)
Stop output delay time: Approx. 5 ms
Power supply voltage: AC100 ~ 200 V
Temperature: 0 to 50 degree C (No sudden temperature change during the use.)
Dimensions(WHD): 200 * 68.5 * 184 mm (An umbo is not included.)
Weight: 2.0 kg(inc. mounting brackets.)
Power consumption: Approx. 7 VA (max.)
Attachments: Output cable (Standard: 5 m) US-1 4(red,blue,yellow,orange) Instruction manual

Light sensors

Photoelectric sensors that detect workpiece passage and material feed, used together with the misfeed detectors.

OSシリーズOS series Light sensor

OS series is the retro-reflective photoelectric sensor for passage detection of a detection target in the automatic stamping. It outputs signal when a detection target pass between sensor unit and reflector. Install it to exit-side of die, chute or belt conveyer. The device is connected to our malfunction detector PS-682, PS-662, PS-661, PS-104, PS-101 and all. Arm-type brackets are now available as an option for the OS-83 and OS-123 (effective August 1, 2025). Using the Arm-type bracket allows for direct replacement of the LS-82 and LS-122. From May 21, 2023, the production of "Side type" for panel direction and "PNP output" for sensor output type has been end of life.

Key specifications

OS-153: OS-203
Detecting distance: 100mm - 1000mm
Approx. 150mm: Approx. 200mm
Minimum size of object to detect (In case of detecting distance 100mm and MAX sensitivity): Passage detection：sphere of 1mm in diameter (Opaque) Presence/Absence detection：rod of 1mm in diameter (Opaque)
Response time: 100μs
Light source: Infrared LED(850nm)
Signal output: NPN, MAX 100mA
Power supply voltage: DC12 - 24V ±5%
2.0VA typ.: 2.5VA typ.
Temperature: 0 - 55°C (No rapid change during operation allowed)

OS-33Light sensor

The grooved light sensor OS-33 is a transmissive photoelectric sensor intended for material feed detection in automatic press processing. This product is used by connecting to our mistake detection devices PS-682, PS-662, PS-661, etc.

Key specifications

Model: OS-33
Detection range: 25mm
Minimum size of object to detect: 0.5mm diameter bar(opaque, non-remote) （However, at sensitivity 9, a rod with a diameter of 0.1 mm）
Response time: 1ms
Light source: Red(640nm)
Signal output: NPN output, Max. 100mA
Power supply voltage: DC12-24V
Consumption current: Max. 50mA
Temperature: 0 to 55°C (no sudden change during use)
Humidity: 35 to 85% RH (non-condensing)

Loop sensors

Ring-type magnetic sensors that detect metal passing through the loop, typically for ejection confirmation.

MSシリーズMS series Magnetic sensor

MS series loop sensor is a loop-type magnetic sensor designed to detect the passage of metal objects. The sensor and control box are separated, the compact sensor allows detection in tight spaces where installation was previously impossible. The control box is attached to the side of our malfanction detector, making it easy to access the operation unit.

Key specifications

MS-156: MS-126W
□140×140: □110×90 x2
Φ8 Steel ball: Φ6 Steel ball

LSシリーズLS Series Loop sensor

Ring proximity sensors such as LS-50 output when metal passes through the ring (e.g. 50 mm), used for ejection confirmation. The MS series is the newer model.

Key specifications

product shape (for iron): 2 pieces
φ30～60: φ10～20
LS-150: LS-90W

Touch sensors

Spring contact sensors that close a circuit when the material touches the rod, for presence detection inside the die.

USシリーズUS Series Spring sensor

The spring sensor is contact type sensor. When a conductive workpiece contacts the sensor rod, the sensor circuit closes and an electric signal flows. Therefore, this sensor can detect touch of only conductive workpiece. The cable for spring type contact sensor of US-1 and USD-1 is 6 kinds of color. Blue, Red, White, Yellow, Pink and Orange are prepared. (US-2 - US-7 and USD-2 - USD-7 are nothing but Red cable and White cable. ) US series and USD series are the same in form except connector. USE-1 and USE-2 are possible to specify the spring diameter, the cable length, connector and others of US-1, US-2, USD-1 and USD-2 by your choice. USE-E series is extension cable for RCA pin-plug.USE-DE series is extension cable for DIN-plug.

Vibration sensors

Picks up die vibration (acoustic signal) to detect abnormal stamping.

AS-11Acoustic sensor

AS-11 is a vibration (acoustic) sensor mounted on the die. Combined with a malfunction detector, it catches abnormal stamping from changes in the sound.

Key specifications

Weight: 0.4 kg (Sensor head + Amplifier)

Digital cam switches

Digital cam switches that output at set angles from a rotary encoder signal, plus the encoder itself.

PS-781Digital Cam

The digital cam "PS-781" is a device that compares the signal from the incremental rotary encoder attached to the rotary shaft of the press machine with the set value and outputs the signal as well as the rotary cam. Since it has a built-in AC/DC dual-use SSR output, the connected power supply can be used with either AC or DC. It can be connected to a personal computer or PLC by Ethernet compatibility.

Key specifications

Resolution: 360 steps/resolution
Angle display: 000 - 359(1 step)
Maximum speed: 1500SPM
Detection method: magnetic
Output method: Incremental method (A phase, B phase, Z phase)
Channels: 12 Channels(Optional 36CH) ・SSR：8CH ・Open collector: 4CH (+24CH as an option)
SSR rating: SSR for AC/DC 75-240VAC, 5-24VDC 1.0A maximum (5.0A total for all channels)
Open collector rating: 5-24VDC 100mA
Power supply voltage: 100-240VAC ±10%,50/60Hz (Max.40VA)
relay output: MD output (Max.250VAC / 30VDC 3.0A)

PS-711Digital Cam with LCD

PS-711 digital cam with liquid crystal display is designed to compare signals from the rotary encoder installed to the rotating shaft of the press machine with the setting values and to output control signals conforming to the rotary cam. Similarly to our “PS-701,” the PS-711 has [advance angle function] that compensates delays in operation of the machine, [Timer function] that controls the ON time, [Motion detector function] that monitors rotation signals of the rotary encoder, and so on. In addition, operability and visibility are advanced with [liquid crystal display] and SSR of all 6CH is common use both AC and DC that achieves better cost-effectiveness.

Key specifications

Resolution: 360 steps/resolution
Angle display: 000 - 359(1 step)
Cam (Channels): 6 Channels
Cam output: Cam output is SSR or Open collector for each CH. SSR for AC/DC : 75-240VAC, 5-24VDC 1A Open collector 5-24VDC 100mA
MD output: Relay 100-240VAC, 5-24VDC 2A
Maximum speed: 1500SPM
Power source voltage: AC100-240V±10%, 50/60Hz
Environment: 0-55℃, 35-85RH
Dimensions of the body: 170(W)×120(H)×146(D) ＊excluding projections
Weight: 2.5kgW(including mounting bracket)

PS-731Digital cam

Digital cam PS-731 is designed to compare setting values on the panel with signals from the rotary encoder installed in the rotating shaft of the press machine and output control signals equal to the rotary cam. PS-731 has many features that have never been seen before. Due to the installation of high performance microcomputer and large capacity memory in PS-731, its operability has been improved; especially the enhanced display functions make it easier for you to check the settings and operations.

Key specifications

Channels: 12
Patterns: 100（00～99)
Resolution: 360 step/revolution
Angle display: 000 ~ 359 (1step)
Roulette display: 10°step
Maximum speed: 1500SPM
SPM display: 0 ~ 999 (above 1000 SPM, 000-500 )
CH1-CH8: Either AC or DC SSR 75～240VAC 1A 5～24VDC 0.5A
CH9-CH12: Open collector 5～24VDC 100mA
Motion detector: Relay 100～240VAC / 5～24VDC 2A

ECD-03ARotary encoder

This is an incremental rotary encoder that is attached to the rotary shaft of the press.

Key specifications

Resolution: 360 steps/resolution
Detection method: magnetic
Output method: Incremental method (A phase, B phase, Z phase)

Lubrication units

Mist-spray units that apply a thin, even film of stamping oil to the material, cutting oil use and protecting dies.

PS-228/226Lubrication Device

PS-228/226 is friendly introduction of mist spray system in plentysystem variation. Evenness spray condition lead you expect not only decreasing in the usage of stamping oil or reducing slug and clogged slug but also stabilization of processing accuracy. It is equipped with monitoring of flow rate abnormalities and remote switching of banks and nozzles. There are digital flow controllable PS-228 and easy operation of PS-226.

Key specifications

PS-228: PS-226
●: ×
●: ●
MAX. 12: 6 *More than 7 is custom-build
Number of sensor input: 6
Number of regulator for spray: 2
Input: spray command, Float switch, Control, Bank selection(PS-228), Nozzle selection(PS-226) / Internal +24V
Output: Stop, Ready Contact output Max. 250VAC / 30VDC 3.0A

PS-255Mist spray system

PS255 is the mist spray system for metal stamping having electromagnetic pumps and spray nozzles. The electromagnetic pump mounted on each spray nozzle is possible to regulate the volume of oil spreading of each nozzle finely because of digital control. The nozzle sprays metalworking oil into workpiece materials uniformly by atomizing the oil at low pressure with compressed air. PS255 series that combines the controller, tanks, nozzles and others is for low kinetic viscosity oil (less than 10㎟/s) and suitable for wide range of requirements.

Key specifications

PS255: PS254
1-12: 4
20L : MAX 2 10L：Just 3: 1
AB switching, ABC switching, AA alternately switching: Impossible
Pump drive time, Pump drive frequency: Pump drive time
Liquid crystal display and Push switch: Rotary switch
100 banks: Impossible
64 banks: Impossible
Up to 3 units possible to apply: Only 1 unit possible to apply
Possible to select: Impossible

PS-225Lubrication Device

Lubrication device for stamping that enables fine flow adjustment without contact by featuring a low pressure atomization spray nozzle and a digitally controlled oil solenoid valve.

Key specifications

Available nozzle: ST8PL-1.0 / ST8PL-AUX
Number of oil solenoid valves: 3
Use of possible oils: Metalworking oil (that does not damage metals or resins; is not flammable or water-soluble.)
Viscosity: ～ 120cSt(mm/s)* * The diameter of the oil tube varies depending on the usage conditions.
Number of processing oil tanks: 1
Number of waste liquid tanks: 1
Flow sensor: 3
Number of air regulator for spray: 1
Filter regulator: Supply pressure/0.4-0.8 MPa, Set pressure/0.4-0.5 MPa
Air consumption: Maximum 40 L/min (ANR)

PS-218Mist spray system

The lubrication device PS-218 is designed to thinly spread the processing oil on the material in the press metalworking. PS-218 is composed of the controller, the oil distribution device, and the nozzle. The controller takes charge of controlling the solenoid valve for the nozzle air and adjusting the spraying amount of the oil. The oil distribution device is composed of the solenoid valve, the air regulator, and the pressurizing tank. The oil distribution device distributes the oil in the pressurizing tank to the nozzle by the controller's instruction. Adjust the amount of spraying by opening the installed solenoid valve of each nozzle for timing and the time decided in the oil control mode. Five nozzles or less can be connected with the oil distribution device. The number of nozzles that can be connected with the oil distribution device varies depending on the model of PS-218.

Key specifications

Number of nozzles: 5 (max)
Oil flow control: Valve open time control
Input specification: Internal voltage (DC12 V) type Connect the contact or the semiconductor switch of the no-voltage
High level: 9.0 ~ 50 V 0 ~ 1 mA
Low level: 0 ~ 3.0 V 8 ~ 10 mA
Output specification: Relay contact AC240 V , DC30 V / 3 A (max.)
Power supply voltage: AC100 ~ 240 V +/-10% 50/60Hz
Maximum current: 0.8 A / 100 V 0.4 A / 200 V
Weight: 2.3 kg
Dimensions(WHD): 200 * 83.5 * 184 mm (An umbo is not included.)

PS-216Mist spray system

Mist spray system PS-216 is designed to spray stamping oil on work-pieces. PS-216 is composed of the nozzle units, the controller, and the pressured oil tank. Nozzle unit sprays the oil on the work-piece by the use of compressed air before the process of die machining. The system can control three nozzle units; UPPER, LOWER, and AUXILIARY (AUX). (PS-216 can control two nozzle units of UPPER and LOWER.) The controller permits the compression air and the stamping oil in the tank to flow into the nozzle units, and control spraying by opening/shutting the solenoid valve inside the controller. Receiving signals from the press machine, it controls spraying. Spraying is interrupted when the press machine stops. The oil tank is a pressure feed type. Its total capacity is 2.4 litters (or 4 litters tank). When the remaining oil amount is 0.5 liters or less, a stop signal is output.

Key specifications

Flow control CH: AUX spray
2: 2
4: 2

Automatic box changers

Counts products and switches boxes automatically so the press keeps running during box changes.

CS-860-2Box changer

The CS-860-2 automatic box changer counts press products and switches boxes automatically, so the press keeps running instead of stopping at a preset count.

Key specifications

CS860-2SSH: 100 ~ 235mm

Miss-grip detectors

Detects grip errors on transfer presses and stops the press when a miss-grip occurs.

PS-581Transfer detector

The Transfer Detector “PS-581” detects grip errors in transfer pressing and outputs a stop signal to press machine in the event of error. It communicates with sensors installed on grips and detects errors by use of timing signal synchronized with advancing or returning operation. A preset counter is installed in it to provide counter function. It is ethernet compatible to connect to personal computer or PLC.

Key specifications

Channels: 30 Channels (Using 3 units:90CH)
Detect mode: Synchronization, Pass
Operation mode: Normal operation, Vacancy operation, Start-Stop operation

Counters

Electronic counters for press work: cycle step, total, preset and batch counting.

PS-381Cyclic Step Counter

The Cycle Step Counter PS-381 is a device for automatic press stamping, which controls output signals based on output setting with max. 1000 steps and counting of input signals. It can be used for control of cutting by controlling solenoid valves. Since it has built-in AC/DC SSR output terminals, it can be used at AC or DC. If it is connected to automatic switch for a cylinder, operation of the cylinder can be monitored (optional). It can be connected to a personal computer or PLC through Ethernet.

Key specifications

Max. step: 1000
Max. SPM: 2000SPM
Channels: 8 Channels
Rating: SSR for both AC load and DC load 75 to 240 VAC / 5 to 24 VDC Max. 1.0A (Total of all channels 5.0A)
Sensor detection: Forward end, Backward end
Sensor input: No-voltage contact DC 2-wire sensor
Power source for sensors: 24VDC (Max.200mA)
Power source voltage: 100 to 240 VAC ±10%, 50/60 Hz (Max. 40 VA)
Relay output: EMG Stop, READY, ALARM (Max. 250 VAC / 30 VDC 3.0 A)
External input(NPN): Count ON/OFF, Count RESET, LOCK, RESERVED TIMING (T1, T2, TD)

PS-330Digital counter

PS-330 is an electronic counter for the press working uses.It has the total, the pre-set, and the batch counter. This device has the input for counting and the device control.It has the relay contact and open collector outputs.The output is used to control the press machine stop and the alarm device. In addition, this device has the measuring function of WORK TIME, EFFICIENCY, and SPM. It is useful for the improvement of productivity.

Key specifications

IN A: 1 input Counting input
IN B: 1 input Count ON/OFF
KEY LOCK: 1 input Operation inhibit
ON level: 3.0 V or below 8 mA or over (10 mA max.)
OFF level: 9.0 V or over 1 mA or below
Output: 1 (Normally closed)
ALARM: 1 (Normally open)
Open collector: 2
READY: 1 (Normally open)
Output: DC30V/AC220V 3A

PS-321Cutting counter

Cutting counter PS-321 is designed to produce and output control signals from the Count input signal. The control signals are produced based on the Count cycle.

Key specifications

Count digit: 3 digit
Max Count speed: 200 CPS
Count channel number: 2 (Count mode 1) 1 (Count mode 2, 3)
Output form: 4 (Count mode 1) 15 (Count mode 2, 3)
DCSSR: DC30 V 500 mA max.
ACSSR: AC240 V 1 A max.
Open collector: DC30 V 100 mA max.
Power supply voltage: AC100 ~ 240V +/-10% 50/60Hz
Power supply Consumption: 15 VA max.
Weight: Body 2.2 Kg (inc. mounting brackets)

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