Alex Ferrell Leuze electronic Sensor Concepts – Technology and Application Alex Ferrell Product Marketing Manager
Alex FerrellLeuze electronic
Sensor Concepts – Technology and Application
Alex FerrellProduct Marketing Manager
RK/PRK
RT/HRT
120m
12m
26m
LSThroughbeam principle
Reflection principle
Scanning principle
Function Principles
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Transmitter LSS… Receiver LSE…
A light beam sent from the transmitter is detected by the receiver.
Throughbeam Overview
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Advantages of Throughbeam Sensors
• Very large operation range
• Very high performance reserve (in usage of short distances)
• Detection of very small objects using blinds (diaphragms) or laser source
• Reliable detection of shiny objects
• High price (high material and installation effort due to separate transmitter and
receiver)
• Double mounting, adjustment and cabling effort
Disadvantages of Throughbeam Sensors
Throughbeam – Advantages/Disadvantages
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Large distances Outdoor Dirty environment Difficult / shiny objects
Throughbeam – Features/Applications
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Sensor Reflector
RK: Reflecting head
Transmitter and receiver are located in the same housing. The light beam leaving the transmitter is reflected back by a reflector positioned opposite and detected by the receiver. The light must travel twice the distance, which results in lower operating ranges than the throughbeam principle.
Retroreflective – Operating Principle (RK/PRK)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Advantages of reflecting sensors• Reduced mounting effort (1x cabling, installation, adjustment)
• Reduced space ( flat reflector)
• Good reflector selection (for various situations)
• Cheaper than throughbeam sensor systems
• Reduced operating range compared to throughbeam systems
• Unwanted signals from reflecting objects possible
Disadvantages of reflecting sensors
Retroreflective – Advantages/Disadvantages
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Reflecting PrincipleExample
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
RT: Reflection ScannerRTF: Reflection Scanner with fadingHRT: Reflection Scanner with background suppressionVRT: Reflection Scanner with Foreground suppression
Diffuse Reflection
Like retro-reflective photoelectric sensors, the transmitter and receiver are contained in a single device. However the transmitter light is not reflected by a reflector but by the object to be detected. In this case relatively little light gets back to the receiver which means shorter operating ranges - in the scanner this is referred to as scanning ranges - can be realized than with the reflection principle.
Transmitter and receiver unit Object
Scanning – Operating Principle
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Scanning PrincipleIn which situations?
Function: Detection if something is in the light beam,but without access to the opposite side!
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
- distance of the object
- color of the object
- object size
- surface structure of the object
- pitch of the object surface
Scanning – Range Factors
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
A key parameter in scanners is the black/whitebehavior.
This refers to the relationship of the scanning ranges to black and white objects (b:a).
Scanning range (mm)
White 90%
Grey 18%
Black 6%Reduction of the scanning range (mm)
Scanning – Black/White Factor
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Light coming from the transmitter hits the object, a part of it is reflected. A certain amount of this reflected light is collected by the receiver and causes a signal. If this signal is higher than the threshold set by teach button or potentiometer, the sensor switches.
Transmitter
Receiver
transmitter
receivertransmitter
receiver
Energetic Scanning – Operating Principle (ET/RT)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Diffuse Energetic Scanners RTTypical Applications
• Detection of objects of the same color and surface structure on conveyor tracks
• Simple collision protection on overhead conveyors
• Differentiation of strong contrasts• Plate glass detection (with no background
present)
Product examples:
RT 318
RT 46B
1000 mm scanning range limit
700 mm scanning range limit
http://www.youtube.com/watch?v=Wu86DWw2Bg0&list=PLF9B1DC91A373AD13 Uhlmann Blister
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Case study: What happens if a dark object is to be detected against a light background?
Solution:... Option 1: Scanner with fading RTF, if the background is in a defined distance to the object... Option 2: Scanner with background suppression HRT
Diffuse Energetic Scanning – Background Effects
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
The field of view of the fading scanner is limited as the receiver unit is tilted. This scanner is “shortsighted”, the detecting range is smaller than the range of an energetic scanner. Objects which are outside the field of view are not detected, so signal from the background is faded out.
This object can bedetected.
This object cannot be detected.
transmitter
receiver
Fading Scanner – Operating Principle (FT)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Diffuse Energetic Scanners with Fading Typical Applications
• Object detection on conveyor tracks with- defined background- short scanning range
• Price-sensitive applications
RTF 25B
RTF 3B5 - 350 mm scanning range limit
10 - 550 mm scanning range limit
Product example:
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Receivertransmitter
Near field receiver
Far field receiver
Background suppression scanners have two receiving elements arranged next to each other. Light reflected from the object near to the scanner hits the near field receiver, light from the background hits the far field receiver. By moving the double receiver element one can define the areas for near field and far field. The scanner will switch if the signal on the near field receiver is bigger than the signal on the far field receiver. This means a dark object in front of a light background is still detected if the sensor is set correctly.
Scanner w/ Background Suppression –Operating Principle
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Scanner with Background Suppression Typical Applications
• Positioning tasksUniversally deployable in tight installation spaces where suppression is required for surrounding machine contours (e.g. special machine, construction, mounting/manipulation technology,...)
• Detection of- small objects- colored structured objects against a background
Product examples:
HRT 318
HRTR 46B-Teach2500 mm scanning range limit
110 mm scanning range limit
HRTL 3B500 mm scanning range limit
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Advantages of scanning sensors• Reduced mounting effort (1x cabling, installation, adjustment)
• No reflector required
• Cheaper than throughbeam sensor systems
• Reduced operating range compared to throughbeam and reflector systems
• Unwanted signals from reflecting objects possible
• More expensive than reflective sensors
Disadvantages of scanning sensors
Scanner – Advantages/Disadvantages
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Forked SensorsGK 14 GS 04GSU 14DGSU 06GS 61
SR 53
Cubical Series SR 3B SR 25BSR 55 SR 8SR 18B SR 96SR 46B
SR 412 SR 318 SR 618
CylindricsM12, M18
FiberAmplifier LV463
SR 2
GS 63B
SR 318B
SR 28SR 5 SR 46CVarOS
Binary Switching Optical Sensor Lineup
SR 49C
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Ultrasonic SensorsPhysical Basics
Ultrasonic sensors emit short, high-frequency sound pulses at regular intervals. These propagate in the air at the speed of sound. If they strike an object, they are reflected back to the sensor as an echo. The ultrasonic sensor internally computes the distance to the object based on the time which lapses between the emission of the sound signal and the reception of the echo. (Measures travelling time)
Applications: At edge of using optical sensors(glass detection, transparent objects, filling level, at optically difficult labels
LSSU (Transmitter)
LSEU (Receiver)
RKU (Reflex)
HRTU (Scanner)
VRTU (Scanner)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Wood
Bulk goods Glass
Packaging-materials
Highly polished surfaces
Metal
Liquids
Ultrasonic SensorsTypical objects and materials
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Ultrasonic SensorsTypical Applications
Bottling Industry:bottle detection
(LSU 18)
Stretched Object Detection:
foil detection(HRTU 418)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Inductive SwitchesSensor Principal
Inductive proximity sensors detect the reduction of magnitude in the internal oscillating circuit.When an electrically conductible material enters the electromagnetic field, parasite Foucault currents are generated in this target object.These currents are consuming energy out of the sensor's oscillating circuit, whose amplitude will drop under the predefined trigger level.
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Inductive SwitchesReduction Factors
Reduction factors are material dependent factors, which reduce the switching distance Srfrom the „norm“ distance
Sr = factor * Sn
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Inductive SwitchesTypical Applications
End position detection
Switching cam
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Contrast / Color / Luminescence Scanners Examples
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Contrast / Color / Luminescence Scanners Difference
Color
One marking (color, grey level) on a (colored) constant reference
KRT
colorOne color or one markingon a multicolor reference
CRT
Luminescence
Luminescent marking
LRT
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Contrast Scanner KRT
To detect One marking (color) on a single color or transparent reference
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Color Scanner
One single color mark on an multicolor reference
Detection / control of the right color
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Color Scanner CRTPrinciple
Multicolor
Transmitter (RGB)sequential emitting of colored light pulses
Receiverdiscrete sampling color selective (RGB) intensity / energy measurement
uP • Analysis of each measurement and translate into spectral values color
• Switching decision
t
t
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Luminescence Scanner LRTPrinciple
UV
Transmitter
Receiverenergetic
uP • Teach values( Switching)
• Selection of light source with M-version
Black-Light effect
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring SensorsWhat are they used for?
How far?
How high?
How big?
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring SensorsDistance Sensors
Measuring distance: to an object / reference
Parameter:Range max. distance to measureResolution smallest detectable differenceAbsolute / relative accuracy max. deviation to realityMeasuring time / reaction time period until a value / first value is sent out
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
dz
Measuring Sensors Triangulation (far field)
Transmitter
CCD-line
Triangulation
Calculation in sensor:
Distance d = f(x)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring Sensors Triangulation (near field)
dz
Transmitter
CCD-line
Best Accuracy in near range
Fast
Triangulation
Calculation in sensor:
Distance d = f(x)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Object
Measuring Sensors Time of Flight (TOF)
0:0000 ns:ps2:0855 ns:ps
Transmitter
Receiver
Distance d
t=0
Calculation in sensor:
Distance d = f(t)
Robust (i.e. ambient light) Accuracy in long range
TOF (Time of Flight)
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Object
ODSL 30
ϕ
Measuring Sensors Phase Measurement
Distance d
Best Accuracy (in far range)
Calculation in sensor:
Distance d = f(φ)
P h a s e
Transmitting signal
Receiving signal with shifted phase (ϕ )
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Triangulation: Depending on the absolute resolution of the CCD Accuracy linear to measurement distance in %
Phase / TOF: Depending on the time accuracy in the sensor constant accuracy in mm (independent on distance)
Measuring Sensors Sensor Selection
distance [z]
Resolution [dz]
1.5m
Phase shift ODSL 30
Triangulation1mm
3 mm
ODSL 96B TOFTime of flight
2m1m
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
ODS 96(B)ODSL 96
LED
Measuring Sensors 1D Measuring Sensors
ODSL 9ODSL 8 ODSL 30 AMS 300
Max. range 0,5 m 0,65 m 6 m 2,3 m 25 m 65 m 300 m
HRTU 418VRTU 430
Interface Analog U / A,
2x switch
Analog U / A, RS232, RS485,
2x switch,(MA 2xxi)
Analog U / A,
1x switch
Analog U / A, RS232, RS485,
2x switch,(MA 2xxi)
Analog U / A, RS232, RS485,
3x switch,(MA 2xxi)
RS232, RS422, RS485,field-busses!!!!
Accuracy ± 2mm ± 2 .. 5mm± 0,4 .. 20mm ± 0,25 .. 6,5mm ± 7,5 .. 90mm ± 1,5..69mm ± 30mm
Meas. time 30 .. 100ms 1,6ms2 .. 7ms 2ms 100 .. 400ms 1 .. 7ms 1,4 ..100ms
Triangulation P h a s eTOFTriang.Triangulation P h a s eTOF
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Function in details:
FIB : First interrupted beam
LIB : Last interrupted beam
FNIB : First not interrupted beam
LNIB : Last not interrupted beam
TIB : Total interrupted beam
TNIB : Total not interrupted beam
Measuring Sensors CML700i Measuring Light Curtains
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring Sensors CML700i Applications
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring light curtainsCML700i series – typical applications
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring light curtainsCML700i series – typical applications
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
The important features Operating range up to 6m
Solutions for a lot of industry applications Fastest cycle time
For detection in fast processes Display
Full parametrization und visualisation Connector at rearside
Minimal deazoneMeasuring field height until 3000mm
Measurement of large objects Excellent resolution
Detection of minimal change of dimension
Measuring light curtainsCML700i series
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
The characteristics:
Analog output (Current-or voltage range configurable)
IO-Link interface (the general interface for CML)
Integrated fieldbus connection (CANopen, Profibus in preparation)
Ethernet-fieldbus connection via IO-Link-master modul
Up to 4 in- / outputs (configurable)
Teach- and/or trigger input
Digital Area-Outputs, warn out (autoControl), trigger out
Display (alignment / configuration / statusinformation)
Connector axial or rear side (still everything under control)
Measuring light curtainsCML700i series
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring Sensors Application Diameter and Position
Detection of up to 3 objects with a diameter of > 0,5mm
Resolution 14µm (mode 7)
Measuring mode 7 (max. measuring frequency 50Hz): Serial output of every edge position (binary)
Measuring mode 1-5: Resolution of 0,1mm
Digital data output via RS232 or RS422
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring Sensors Edge Detection and Position Control
Detection of edges e.g. paper, metal, wood (no transparent objects)
Teaching to reference position (→ 5V / 10mA)
Analog edge output ( 0-10V / 4-12mA )
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Range: 0 – 65 mAngle: 190°Angular resolution: 0,36°Scan rate: 25 Hz
• Interface: Fast Ethernet, configuration interface
• Data block: x,y, distance (per scan)
• Integrated, online data analysis: (x,y coordinates, extreme value analysis)
Measuring Sensors –Optical Surface Distance Sensors
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring SensorsLine Profile Sensor
z
x
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
LRS 36 (Line Range Sensor):
Detection
LPS 36(Line Profile Sensor):
2D/3D Analysis
LES 36(Line Edge Sensor):
Edge analysis
Measuring SensorsLine Profile Sensor Overview
Switching deviceInterface: I/O, PROFIBUSInternal data processing
Measuring deviceInterface: analog, PROFIBUSInternal data processing
Measuring deviceInterface: Ethernet, Encoder External data processing 1564 bytes data per scan
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measuring SensorsLine Profile Sensor
Switching / measuring: “Look into the box”
Switching: Conveyor control
Measuring: Object profile
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Point to Point communication options
• Analog output (voltage, current)Advantages: Inexpensive, proven technology, universalDisadvantages: Input cards have varying number of bits resolution, have to scale the value, issues with scaling at both device level and input, susceptible to noise, only get data value
• Serial output (RS232, RS422, RS485)Advantages: Proven technology, universalDisadvantages: Have to set up input and device to match protocol, have to parse the data value into a useable format, susceptible to noise
• IO-LinkAdvantages: Digital data input, can get device status information, can access parametersDisadvantages: Need an IO-Link master
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measurement SensorsHow to get the data?
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
WHAT IS IO-LINK?IO-Link is a bi-directional point-to-point serial communication protocol used to
communicate with sensors and/or actuators
IEC 61131-9
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
5 THINGS TO KNOW ABOUT IO-LINK
1. Higher Level Flexibility:Easy to read, parameterize or configure smart devices without touching them.
2. Simple Device ReplacementSimple replacement of devices by being able to download parameters into the replacement right from the controller automatically. (Never redo work which you have already done!)
3. IO-Link is an Open Consortium of Manufacturers:New products are released on a regular basis and IO-Link is gaining ground in NorthAmerica as well as in Europe where it is already in widespread use.
4. Simple Serial Point to Point Communication:Uses a simple standardized cabling architecture.
5. Multiple Smart Devices per Address:A basic benefit of IO-Link is to allow for multiple smart network type devices tobe connected to one address and thus allowing for more devices to be connected inone network.
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
IO-LINK BENEFITSSimplified
installationAutomated
parameter settingExpanded
diagnostics
• Long-term cost reductions at all levels
• Standardized for easy operation
• Minimized downtimes through intelligent remote parameter management
• Comprehensive device diagnosis down to field level
• Enhanced flexibility in application
• Long-term investment security due to international standardization
Fieldbus communication optionsAdvantages: High speed, high bandwidth communications, can get data as well as status and parameter data, bi-directional communications
Disadvantages: Expensive, mainly PLC manufacturer dependent, more complicated to set up
• PROFIBUSNode-based industrial network primarily used with Siemens PLCs
• PROFINETIndustrial Ethernet network based on TCP/IP primarily used with Siemens PLCs
• Ethernet/IPIndustrial Ethernet network based on TCP/IP primarily used with Rockwell Automation (Allen-Bradley) PLCs
• Many Others such as DeviceNet, EtherCAT, Modbus, Modbus TCP…
Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015
Measurement SensorsHow to get the data?