Sensor Concepts – Technology and Application Alex Ferrell Leuze electronic

Alex Ferrell Product Marketing Manager

Function Principles Throughbeam principle

LS 120m

Reflection principle

RK/PRK 26m

Scanning principle

RT/HRT 12m

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Throughbeam Overview

Transmitter LSS…

Receiver LSE…

A light beam sent from the transmitter is detected by the receiver.

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Throughbeam – Advantages/Disadvantages 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

Disadvantages of Throughbeam Sensors • High price (high material and installation effort due to separate transmitter and receiver) • Double mounting, adjustment and cabling effort

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Throughbeam – Features/Applications  Large distances  Outdoor  Dirty environment  Difficult / shiny objects

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Retroreflective – Operating Principle (RK/PRK) RK: Reflecting head

Sensor

Reflector

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.

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Retroreflective – Advantages/Disadvantages 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

Disadvantages of reflecting sensors • Reduced operating range compared to throughbeam systems • Unwanted signals from reflecting objects possible Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Reflecting Principle Example

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanning – Operating Principle RT: RTF: HRT: VRT:

Reflection Scanner Reflection Scanner with fading Reflection Scanner with background suppression Reflection Scanner with Foreground suppression

Diffuse Reflection

Transmitter and receiver unit

Object

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. Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanning Principle In 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

Scanning – Range Factors

- distance of the object

- color of the object

- object size

- surface structure of the object

- pitch of the object surface

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanning – Black/White Factor

A key parameter in scanners is the black/white behavior. This refers to the relationship of the scanning ranges to black and white objects (b:a).

Black 6% Reduction of the scanning range (mm)

Grey 18% White 90% Scanning range (mm)

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Energetic Scanning – Operating Principle (ET/RT) Transmitter transmitter receiver

Receiver transmitter receiver

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. Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Diffuse Energetic Scanners RT Typical 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:

1000 mm scanning range limit http://www.youtube.com/watch?v=Wu86DWw2Bg0&list=PLF 9B1DC91A373AD13 Uhlmann Blister

RT 46B

RT 318

700 mm scanning range limit

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Diffuse Energetic Scanning – Background Effects 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

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Fading Scanner – Operating Principle (FT)

receiver

This object can be detected.

This object can not be detected.

transmitter

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. 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

Product example:

5 - 350 mm scanning range limit RTF 3B

10 - 550 mm scanning range limit RTF 25B

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanner w/ Background Suppression – Operating Principle Near field receiver Far field receiver Receiver transmitter

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. Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanner with Background Suppression Typical Applications • Positioning tasks Universally 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: 2500 mm scanning range limit HRTR 46B-Teach

HRTL 3B

HRT 318

500 mm scanning range limit

110 mm scanning range limit

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Scanner – Advantages/Disadvantages Advantages of scanning sensors • Reduced mounting effort (1x cabling, installation, adjustment) • No reflector required • Cheaper than throughbeam sensor systems

Disadvantages of scanning sensors • Reduced operating range compared to throughbeam and reflector systems • Unwanted signals from reflecting objects possible • More expensive than reflective sensors Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Binary Switching Optical Sensor Lineup

Cubical Series SR 2

SR 3B SR 5

Cylindrics M12, M18 Fiber Amplifier

SR 53

SR 412

SR 55

SR 25B

SR 28

SR 318B

SR 318

SR 18B SR 8

SR 46B

SR 46C VarOS

SR 618

LV463

Forked Sensors GS 61

GS 63B

GSU 06

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

GK 14

GSU 14D

GS 04

SR 96

SR 49C

Ultrasonic Sensors Physical Basics LSSU (Transmitter) LSEU (Receiver) RKU (Reflex) HRTU (Scanner) VRTU (Scanner)

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

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Ultrasonic Sensors Typical objects and materials

Wood

Liquids Highly polished surfaces

Packagingmaterials Bulk goods Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Glass

Metal

Ultrasonic Sensors Typical Applications

Stretched Object Detection: foil detection (HRTU 418) Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Bottling Industry: bottle detection (LSU 18)

Inductive Switches Sensor 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 Switches Reduction Factors Reduction factors are material dependent factors, which reduce the switching distance Sr from the „norm“ distance Sr = factor * Sn

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Inductive Switches Typical Applications End position detection

Switching cam

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

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

Luminescence KRT Luminescent marking

One color or one marking on a multicolor reference

CRT Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

color LRT

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 Detection / control of the right color

One single color mark on an multicolor reference

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Color Scanner CRT Principle Transmitter (RGB)

sequential emitting of colored light pulses

Multicolor t

Receiver

discrete sampling t  color selective (RGB) intensity / energy measurement

uP

• Analysis of each measurement and translate into spectral values  color •  Switching decision

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Luminescence Scanner LRT Principle Black-Light effect Transmitter

UV Receiver energetic

uP

• Teach values ( Switching) • Selection of light source with M-version

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors What are they used for? How far? How high? How big?

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors Distance Sensors

Measuring distance: to an object / reference Parameter:

Range Resolution Absolute / relative accuracy Measuring time / reaction time

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

max. distance to measure smallest detectable difference max. deviation to reality period until a value / first value is sent out

Measuring Sensors Triangulation (far field) Transmitter

Triangulation

CCD-line

Calculation in sensor: Distance d = f(x) Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

dz

Measuring Sensors Triangulation (near field) Triangulation

Transmitter

CCD-line

dz Calculation in sensor: Distance d = f(x) Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

 Best Accuracy in near range  Fast

Measuring Sensors Time of Flight (TOF) t=0

TOF (Time of Flight)

Object

Transmitter

Receiver

Distance d

Calculation in sensor: Distance d = f(t) 0:0000ns:ps ns:ps 2:0855

 Robust (i.e. ambient light)  Accuracy in long range Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors Phase Measurement Phase

ϕ Transmitting signal

ODSL 30

Receiving signal with shifted phase (ϕ )

Distance d Calculation in sensor: Distance d = f(φ)

 Best Accuracy (in far range) Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Object

Measuring Sensors Sensor Selection 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)

Resolution [dz] 3 mm

ODSL 96B TOF Time of flight

1mm

Triangulation

Phase shift ODSL 30

1m 1.5m Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

2m

distance [z]

Measuring Sensors 1D Measuring Sensors LED

ODSL 8 Triangulation

ODSL 9

HRTU 418 VRTU 430

Triangulation

TOF

Triang.

TOF

2,3 m

25 m

Max. range Accuracy Meas. time

0,5 m

0,65 m

6m

± 0,4 .. 20mm

± 0,25 .. 6,5mm

± 7,5 .. 90mm

2 .. 7ms

2ms

100 .. 400ms

Interface

Analog U / A,

Analog U / A, RS232, RS485, 2x switch, (MA 2xxi)

Analog U / A,

2x switch

ODS 96(B) ODSL 96

1x switch

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

± 1,5..69mm ± 30mm 1 .. 7ms

1,4 ..100ms

Analog U / A, RS232, RS485, 2x switch, (MA 2xxi)

ODSL 30

AMS 300

Phase

Phase

65 m

300 m

± 2mm

± 2 .. 5mm

30 .. 100ms

1,6ms

Analog U / A, RS232, RS485, 3x switch, (MA 2xxi)

RS232, RS422, RS485, field-busses!!!!

Measuring Sensors CML700i Measuring Light Curtains 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

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors CML700i Applications

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring light curtains CML700i series – typical applications

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring light curtains CML700i series – typical applications

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring light curtains CML700i series The important features

 Operating range up to 6m  Solutions for a lot of industry applications

 Fastest cycle time  Display

 For detection in fast processes  Full parametrization und visualisation

 Connector at rearside

 Minimal deazone

 Measuring field height until 3000mm  Measurement of large objects

 Excellent resolution

 Detection of minimal change of dimension

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring light curtains CML700i series 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)

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

Measuring Sensors – Optical Surface Distance Sensors Range: Angle: Angular resolution: Scan rate:

0 – 65 m 190° 0,36° 25 Hz

•

Interface: Fast Ethernet, configuration interface

•

Data block: x,y, distance (per scan)

•

Integrated, online data analysis: (x,y coordinates, extreme value analysis)

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors Line Profile Sensor

z

x Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measuring Sensors Line Profile Sensor Overview

LRS 36 (Line Range Sensor): Detection

Switching device Interface: I/O, PROFIBUS Internal data processing

LES 36 (Line Edge Sensor): Edge analysis

Measuring device Interface: analog, PROFIBUS Internal data processing

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

LPS 36 (Line Profile Sensor): 2D/3D Analysis

Measuring device Interface: Ethernet, Encoder External data processing 1564 bytes data per scan

Measuring Sensors Line Profile Sensor

Measuring: Object profile

Switching: Conveyor control

Switching / measuring: “Look into the box” Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measurement Sensors How to get the data? Point to Point communication options • Analog output (voltage, current) Advantages: Inexpensive, proven technology, universal Disadvantages: 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, universal Disadvantages: Have to set up input and device to match protocol, have to parse the data value into a useable format, susceptible to noise

• IO-Link Advantages: Digital data input, can get device status information, can access parameters Disadvantages: Need an IO-Link master

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

WHAT IS IO-LINK?

IEC 61131-9

IO-Link is a bi-directional point-to-point serial communication protocol used to communicate with sensors and/or actuators

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

5 THINGS TO KNOW ABOUT IO-LINK 1.

Higher Level Flexibility:

2.

Simple Device Replacement

Easy to read, parameterize or configure smart devices without touching them. Simple 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:

4.

Simple Serial Point to Point Communication:

5.

Multiple Smart Devices per Address:

New products are released on a regular basis and IO-Link is gaining ground in North America as well as in Europe where it is already in widespread use. Uses a simple standardized cabling architecture.

A basic benefit of IO-Link is to allow for multiple smart network type devices to be connected to one address and thus allowing for more devices to be connected in one network.

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

IO-LINK BENEFITS Simplified installation

Automated parameter setting

Expanded 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

Leuze electronic | Sensor Technology | Alex Ferrell | 10/2015

Measurement Sensors How to get the data? Fieldbus communication options Advantages: 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

•

PROFIBUS Node-based industrial network primarily used with Siemens PLCs

•

PROFINET Industrial Ethernet network based on TCP/IP primarily used with Siemens PLCs

•

Ethernet/IP Industrial 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