Insensitivity to ambient light, detection of objects with ultra-black and glossy surfaces as well as transparent objects and the constant high measuring speed in as compact as possible machine designs: these are the challenges faced by the manufacturers of optical sensors. Baumer offers with the new Miniature sensors there Series O200 a solution that works reliably and quickly, even in demanding circumstances. Thus, the efficiency potential of today's manufacturing processes can be fully exploited.
In view of the tight timing of today's highly efficient production processes, even a short failure of the production machine can have expensive consequences. In addition to the software, the sensor system is also a potential source of error. If a sensor does not recognize an object or a position reliably and at the intended speed, this can disturb the entire process.
Due to their versatility, the long range, and a visible and focused light beam, optical miniature sensors offer the perfect conditions for use in modern production. However, in modern production environments, photoelectric sensors are faced with various challenges.
Energy-efficient LED lamps as a challenge
The first challenge is the increasing use of high-efficiency and high-luminosity LED luminaires, such as ceiling lighting or camera exposure systems. LED luminaires offer a high energy saving of up to 90% as well as a significantly longer service life than conventional lamps such as incandescent lamps or fluorescent lamps. However, LED bulbs are typically modulated at much higher frequencies in the range of 50 to 150 kHz and have different characteristics (ripple, center frequency, frequency change, waveform) depending on the ballast.
This makes them a potential source of interference for photocells and light sensors. These emit light pulses in the microsecond range with repetition rates from 10 to 30 kHz. Sub-sampling of the interfering signal by the sensor can thus lead to low-frequency interfering signals and faulty circuits are caused since these interfering signals can not be compensated within the measuring cycle time.
In addition to lighting, other sensors or indirect reflections - such as shiny machine parts - cause interference. These slow down the measuring cycles of many optoelectronic sensors. In addition, limited space increases the likelihood of interference, as the sensors are installed at short distances from each other.
Another challenge lies in the detection of "difficult" objects. For optoelectronic sensors, these are, for example, those with a deep black or glossy surface but also transparent objects. The physical properties, such as remission, absorption, and transmission of these objects, make sensors difficult to convert light beams to electrical signals because too little light is returned to the sensor for reliable signal evaluation.The O200 series miniature optical sensors provide a compelling solution to all these challenges.
One-time immunity to light
The O200 sensors offer the highest level of detection reliability regardless of the lighting situation thanks to their extraneous light algorithm. At the beginning of each measuring cycle, the sensors detect sources of disturbing light by rapidly pulsed light-dark measurements. The sources of interference identified by the extraneous light algorithm are suppressed and the optimum frequency spectrum is selected. Thanks to a continuous evaluation of the spectrum, the sensor automatically adapts to changes in the ambient lighting. Together with a high-precision optics and high-performance electronics, this guarantees a consistently high measuring speed with a short response time of 0,5 ms. This combination of speed and immunity is unique on the market.
Extremely versatile sensorsThe O200 reflective photoelectric sensors with background suppression are the best in their class according to the manufacturer and offer immunity to light without loss of speed. Thanks to increased functional reserves, they reach a range of 120 mm on ultra-black objects such as mobile phone cases. For additional range, the O200 high-power mode can be activated via IO-Link.
O200 variants with V-optics feature a focused light beam with only 0,2 mm diameter. Thus, glossy or transparent objects such as ampoules in laboratory automation can be easily detected at close range. For extremely compact machine designs such as For example, in very expensive clean room environments, the O200 "Smartreflect" photoelectric sensors are the optimal solution. They offer the reliability of a photoelectric sensor without the disadvantages of a reflector - and with a range of up to 180 mm. For even greater ranges, the portfolio offers retro-reflective photoelectric sensors up to 4 m and one-way photoelectric sensors with up to 6 m range. These are just a few examples of the performance spectrum of the O200 series.
Smart, intuitive to use, digitally connectedAll O200 sensors have an IO-Link interface, which in addition to the convenient automated parameterization through bidirectional communication opens up smart options. For example, the sensors can send meta-information such as operating hours, switch-on cycles or information on operational and process optimization - the best prerequisites for predictive maintenance.
The O200 offers two options for setting directly at the sensor: The sensors can be optimally adjusted to the application via a line teach or via the wear-free "Qteach" method from Baumer without any mechanical changes to the optics. Variants with fixed detection ranges do not have to be taught-in and are ready for immediate use. For designers, the O200 sensors offer a special highlight: They are the first optoelectronic sensors to offer 3D CAD data with integrated beam path. This saves precious time, which previously had to be spent to painstakingly trace the beam path from data sheets.
The O200 sensors are well suited for reliable use in industrial 4.0 applications due to their immunity to light, secure object detection, intuitive operation and smart connectivity in a compact form.