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Sensor Basics
Understanding fundamental principles and features
03 Contact Sensors
Introduction
“detection principles.”
Utilize and share this textbook as a resource for all those involved
with sensors.
2
Table of Contents
Photoelectric Sensors
Detection based Fiberoptic sensors P08
01 on “light”
“Received light”
recognition type P12
Laser sensors
“Position”
recognition type P14
Contact Sensors
Detection based Contact-type displacement sensors P21
03 on “contact”
Ultrasonic Sensors
Detection based Ultrasonic sensors P25
04 on “ultrasonic”
Vision sensors
Detection based Vision sensors P27
05 on “images”
3
01 Photoelectric Sensors
❚ Outline
A photoelectric sensor emits a light beam (visible or infrared) from its light-emitting element.
A reflective-type photoelectric sensor is used to detect the light beam reflected from the target.
A thrubeam type sensor is used to measure the change in light quantity caused by the target crossing
the optical axis.
A beam of light is emitted from the light emitting element and is received by the light
receiving element.
4
01 Photoelectric Sensors
❚ Features
¨ Non-contact detection
Since detection is possible without contact, there will
be no damage to targets. The sensor itself will not
be damaged either, ensuring long service life and
maintenance-free operation.
Notification
KEYENCE’s PZ-G Series has built-in with light
“Alignment indicators” that are obvious,
Tip even from long distances.
When the optical axes are aligned, the
Alignment indicator illuminates on the
receiver. The light can be seen clearly even
from a long distance so a single operator can
align the sensors easily and quickly.
5
01 Photoelectric Sensors
❚ Classification
Detection occurs when the target crosses the optical axis between
Target transmitter and receiver.
• Long-detecting distance
Thrubeam • Stable detecting position
Transmitter Receiver
• Opaque objects detectable regardless of shape, color or material
• Powerful beam
Detection occurs when the target crosses the optical axis between sensor
Target head and reflector.
• Reflector allows installation in a limited space
Retro-
• Simple wiring
reflective • Longer detecting distance than the diffuse-reflective sensor type
Transmitter/receiver Reflector • Easily-adjustable optical axis
• Opaque objects detectable regardless of shape, color, or material
Target Detection occurs when the light beam, emitted to the target, is reflected by
the target and received.
Diffuse- • Space-saving (requires installation of sensor unit only)
reflective • Adjustment of optical axis not required
Transmitter/receiver • Reflective transparent objects detectable
• Color differentiation possible
Target Detection occurs when the beam spot, emitted to the target, is reflected by
Focused- the target and received.
• Minute objects detectable
beam • Target markings detectable
reflective Transmitter/receiver • Detection possible through narrow openings between machines
• Visible beam spot
Transmitter/receiver Target Detects the target at a specific distance according to the angle of the
reflected light beam.
Fixed- • Unaffected by highly reflective targets or backgrounds
distance • Stable detection of materials with varying reflectance and color
• Highly accurate detection of minute objects
• Visible beam spot
Transmitter/ When the light beam hits a target, the beam reflects differently according
receiver Target
to the luster of the target. The sensor detects the difference in luster based
Luster on how the beam reflects (specular or diffusive).
recognition • On-line detection is possible.
• Detection is not affected by target color.
• Transparent targets can be detected.
6
01 Photoelectric Sensors
❚ Other variations
There are various types of photoelectric sensors depending on environment or installation location. The following
are typical classifications which allow you to select photoelectric sensors more suitable for your environment.
Classification
based on
whether
the amplifier is Separate-amplifier type An amplifier is separate from
the sensor head to allow for
separated or not remote setting and feedback.
This allows the sensor head to
be smaller and more flexible to
mount.
Classification
based on
housing material Metal housing type The housing is made of metal
such as stainless steel. This type
is robust and has long service
life compared to the plastic
housing type.
7
01 Photoelectric Sensors
❚ Outline
The fiberoptic sensor has an optical fiber connected to a light source to allow for detection in tight
spaces or where a small profile is beneficial.
The optical fiber consists of the core and the cladding, Optical fiber configuration
Core (high refractive index)
which have different refractive indexes. The light beam LED
Plastic type
The core of the plastic-fiber consists of one or more acrylic-resin fibers 0.25 to 1 mm 0.01" to 0.04" in diameter,
encased in a polyethylene sheath. Plastic fibers are light, cost-effective, and flexible which is why they are the most
common type of fiber sensor.
Glass type
The glass-fiber consists of 10 to 100 μm 0.39 to 3.94 Mil diameter glass fibers encased in stainless steel tubing.
This allows it to be used at high operating temperatures (350°C 662°F max.).
The optical fiber sensors are divided into two categories: Type Description
thrubeam and reflective. The thrubeam type comprises
Parallel Generally used for plastic fibers.
a transmitter and a receiver. The reflective type, which is
a single unit, is available in 3 types: parallel, coaxial, and High-precision type, consisting of a core (transmitter) and surrounding
Coaxial area (receiver). The operating position can remain the same regardless
separate. The 3 are based on the shape of the cross- of the direction from which the target enters the detecting area.
section of the optical fiber. This type, containing several 10 μm 0.39 Mil glass fibers
Separate in diameter, has separate areas for the transmitter and
receiver.
8
01 Photoelectric Sensors
❚ Features
¨ Versatile installation
A flexible optical fiber enables easy installation in limited
spaces such as a space between machines.
9
01 Photoelectric Sensors
❚ Classification
Fiber units have many variations. Because the fiber does not house any of the electronic components, there are
very few limitations on size and shape. The following is a classification example of KEYENCE’s fiber units
(FU Series).
Great for small object detection. Use of a lens reduces the field of view
Beam
Spot size and focal distance are based on the aperture angle.
adjustable, so there is no need to This narrow beam helps
change the distance between avoid deflection and is suitable for
the sensor and the target. detecting objects at longer distances.
Retro-reflective Definite-reflective
Transparent object
This thin profile sensor comes The thin sleeve design eliminates
with mounting holes for problems caused by limited mounting space
installation where space and allows the sensor to be placed closer to the
is limited. target. Lineup includes side‑view and
bendable sleeve types.
The fluorocarbon resin Provides higher flexibility Ideal for use in high
coating allows these fibers than an electric wire. temperature applications.
to be used in almost any Resistant to 30 million Withstands temperatures up
environment, including oil or bends! to 350°C 662°F.
chemical‑splash conditions.
The wide‑area beam is ideal for Accurate liquid level detection Can be used in vacuum
applications where there is sensors are available in and high temperature
variance in target position transparent tube-mount or environment.
and for detecting multiple immersion type models.
shapes or moving targets.
10
01 Photoelectric Sensors
The following is the key terms for selecting a fiber unit and their meaning.
Fiber unit length The length of a fiber unit. A longer fiber unit can be installed at a location
farther from the fiberoptic amplifier.
Ambient temperature The range of temperature in which the fiber unit can be used. To use
a fiber unit at high ambient temperature, it is recommended to select
a heat-resistant type.
Bend radius The index indicating the maximum radius in which the fiber unit can be bent
and still operate without problems. Fiber units with smaller bend radius are
beneficial in locations where routing is difficult.
Detecting distance The distance from which the sensor can detect targets.
Optical axis diameter This index is mainly used for thrubeam model fiber units. For thrubeam fiber
units, this is the size of object that will obstruct the optical axis entirely.
Minimum detectable The size of the smallest target which the fiber unit can detect.
object
11
01 Photoelectric Sensors
Detection based on “light”
Laser sensors: “Received light” recognition type
❚ Outline
A laser sensor uses a “laser” to emit light in a straight line. Its visible beam spot makes alignment and
positioning very easy. Since the light beam is focused, the sensor can be installed without worries
about stray light.
A light beam is emitted from the light emitting element (laser) in the transmitter
and is received with the light receiving element in the receiver.
Transmitter/Receiver
Target
Reflective Light emitting element
model
Reflected light
Light receiving
element
Transmitter/Receiver Reflector
Retro-
Light emitting element Target
reflective
model
Signal light is
Light receiving interrupted.
element
12
01 Photoelectric Sensors
Detection based on “light”
Laser sensors: “Received light” recognition type
❚ Features
13
01 Photoelectric Sensors
Detection based on “light”
Laser sensors: “Position” recognition type
❚ Outline
This type of sensor detects the position of a target. This is achieved by using a triangulation system or
a time measurement system.
The change in the distance to the [At reference distance] [Shorter distance] [Longer distance]
Light receiving element
target affects the position of the Semiconductor
laser
light concentrated on the CMOS
Transmitter lens
detecting element. This information
Receiver
is used for detecting the target lens
position.
The laser emits a laser beam to the target as shown above. The light reflected off the target is concentrated by the
receiver lens and forms an image on the light receiving element. When the distance changes, the concentrated
light reflects at a different angle and the position of the image changes accordingly.
Time measurement system Example of a reflective model Time of Flight (TOF) sensor
Received light
Time before the reflected light is received: T
In the figure to the right, the sensor detects the time (T) that is the time until the reflected laser beam is received
to calculate the distance (Y). The calculation formula is: 2Y (go-and-return distance) = C (light speed) × T (time
before the reflected light is received)
14
01 Photoelectric Sensors
Detection based on “light”
Laser sensors: “Position” recognition type
❚ Features
15
02 Inductive Proximity Sensors
❚ Outline
A proximity sensor can detect metal targets approaching the sensor, without physical contact with
the target. Proximity sensors are roughly classified into the following three types according to the
operating principle: the high-frequency oscillation type using electromagnetic induction, the magnetic
type using a magnet, and the capacitance type using the change in capacitance.
A high-frequency magnetic field is generated by coil L in the oscillation circuit. When High-frequency magnetic field
General
a target approaches the magnetic field, an induction current (eddy current) flows in
sensor
the target due to electromagnetic induction. As the target approaches the sensor, the Target (Metal)
Internal circuit
induction current flow increases, which causes the load on the oscillation circuit to
increase. Then, oscillation attenuates or stops. The sensor detects this change in the
oscillation status with the amplitude detecting circuit, and outputs a detection signal. Sensing coil
[Metal object present]
[Metal object absent]
The nonferrous-metal type is included in the high-frequency oscillation type. The nonferrous-metal type incorporates an
Nonferrous-
oscillation circuit in which energy loss caused by the induction current flowing in the target affects the change of the oscillation
metal type
frequency. When a nonferrous-metal target such as aluminum or copper approaches the sensor, the oscillation frequency
increases. On the other hand, when a ferrous-metal target such as iron approaches the sensor, the oscillation frequency
decreases. When the oscillation frequency becomes higher than the reference frequency, the sensor outputs a detection signal.
[Aluminum object present]
[Aluminum object absent]
16
02 Inductive Proximity Sensors
❚ Features
17
02 Inductive Proximity Sensors
❚ Classification
General-purpose model
Type Self-contained Amplifier-in-cable Separate-amplifier
Model EV, EZ EM ES
Model ED
Classification 1
Self-contained type • The sensor can be used as soon as the
(EV, EZ, ED) power is turned on. (Simplified wiring)
Oscillation Detection Output
circuit circuit circuit • Sensitivity adjustment not possible
Sensing coil
Amplifier-in-cable Sensor head Amplifier unit • The sensor can be used as soon as the
power is turned on. (Simplified wiring)
type (EM)
Oscillation Detection Output • Small sensor head and amplifier
circuit circuit circuit
• Sensitivity adjustment not possible
18
02 Inductive Proximity Sensors
❚ Classification
Classification 2
Flush mounting
Shielded type
The side of the sensing coil is covered with
metal shielding. This type can be used by being
embedded in metal. (Excluding the EM Series)
Non-shielded type
Countersinking required
The side of the sensing coil is not covered
øA
with metal shielding. This type offers a longer
detecting distance compared with the shielded B
19
02 Inductive Proximity Sensors
Detection based on “eddy current”
Inductive displacement sensors
“Inductive displacement sensors” not only detect the presence of a target but also measure
the distance to a target.
Oscillation amplitude
Far
Near Rectified signal
Sensor head 0V
The rectified signal and distance have an approximate proportional relationship. The linearization circuit corrects
the linearity to obtain a linear output that is proportional to the distance.
Analog voltage output
100% 100%
Linearization
Output voltage
Output voltage
Final output
Reference waveform
The EX-500 Series detects both amplitude
and phase difference to enable detection
of nonferrous metals such as copper
and aluminum so that it can be an all
metal supporting sensor. When only the
magnitude of the amplitude is detected, it
Distance: Far Distance: Middle Distance: Near
is hard to determine whether it is changing
due to the change in the material or due to
the distance to the target. Therefore, the
sensor detects the change in the phase as
Amplitude: Large Amplitude: Middle Amplitude: Small
Phase difference: Small Phase difference: Middle Phase difference: Large well to verify the change in the material.
20
03 Contact Sensors
Detection based on “contact”
Contact displacement sensors
❚ Outline
Since measurement is possible with the sensor Standard model GT2 Air push type
head being fixed, no mechanism is required to No jigs
required
move the sensor head. This saves installation Since the sensor
can be fixed at the
space and greatly reduces man-hours during same position, no
Linear guide complicated jig is
installation. required. There is
Slotted jig also no errors due
Stopper to the influence of
a jig on accuracy.
❚ Features
The following table shows typical characteristics that vary depending on the detection system.
Detectable target Metal Almost all materials Almost all materials Almost all materials Solid
21
03 Contact Sensors
Detection based on “contact”
Contact displacement sensors
Contact-type displacement sensors are generally divided into the following two groups depending on
the detection method:
• “Differential transformer” method -> Method using a magnetic coil
• “Scale” method -> Method using an internal scale (ruler).
In addition, there is another method originally developed by KEYENCE:
• “Scale Shot System”
-> World’s first method in which a CMOS sensor records a unique pattern on an absolute value glass scale.
❚ Structure of Coil ❚ When the cylinder extends ❚ When the cylinder retracts
the GT Series
Spring
Core Correction coil
Sensing coil
Core
Signal level
Dust boot
Contact
• The “absolute position” can be obtained based on the signal level that changes in
Advantage accordance with the spindle position.
(No zero point adjustment necessary, no tracking errors)
• The accuracy decreases at the end of the spindle. Since the system is coil-based, the
Dis magnetic field is applied evenly around the center but is not consistent near the end.
advantage
22
03 Contact Sensors
Detection based on “contact”
Contact displacement sensors
¨ Scale method
• High accuracy (The accuracy basically depends on the resolution of the scale
Advantage markings.)
• No need to consider the linearity because the scale markings are consistent along
the entire scale.
• The temperature characteristics are good because the scale markings do not change
with varying temperature.
• When the spindle moves abruptly due to vibration or other reason, the response of
Dis the photoelectric sensor may delay, resulting in tracking errors.
advantage
23
03 Contact Sensors
Detection based on “contact”
Contact displacement sensors
(1) When the spindle moves, the absolute value scale moves accordingly.
(2) The CMOS sensor reads the complex pattern in the scale at high speed.
(3) The spindle position information is sent to the amplifier.
Approx. 6 µs CMOS
shutter speed sensor
Advantages of the conventional differential transformer method CMOS sensor
No tracking errors * Shutter speed: Approx. 6 µs, Shooting interval: 1 ms
Absolute position detection
• Nothing in particular
Dis
advantage
24
04 Ultrasonic Sensors
As the name indicates, ultrasonic sensors measure distance by using ultrasonic waves.
The sensor head emits an ultrasonic wave and receives the wave reflected back from the target. Ultrasonic
sensors measure the distance to the target by measuring the time between the emission and reception.
Distance: L
An optical sensor has a transmitter and receiver, whereas an ultrasonic sensor uses a single ultrasonic element
for both emission and reception. In a reflective model ultrasonic sensor, a single oscillator emits and receives
ultrasonic waves alternately. This enables miniaturization of the sensor head.
[Distance calculation]
❚ Features
The following list shows typical characteristics enabled by the detection system.
25
04 Ultrasonic Sensors
Detectable target Detection is affected by target materials/colors Detection is unaffected by target materials/colors
What is ultrasonic?
Note “Ultrasonic” generally refers to a “high pitch sound that is inaudible to humans.”
Sound is expressed by a unit called frequency (Hz). The greater the frequency,
the higher the pitch of sound becomes. The unit Hz (hertz) means the number of
oscillations per second. For example, a wave that oscillates 100 times in a second is
expressed as 100 Hz. The audible range for humans is said to be between about
20 Hz and 20 kHz. In other words, ultrasonic waves have a frequency of 20 kHz or
greater.
26
05 Vision Sensors
❚ Outline
Vision sensors use images captured by a camera to determine presence, orientation, and accuracy of parts. These
sensors differ from image inspection “systems” in that the camera, light, and controller are contained in a single unit,
which makes the unit’s construction and operation simple. There are differences between these sensors and other
general-purpose sensors. For example, many things—such as multi-point inspections—can be done with a single sensor.
In addition, thanks to the wide field of view images, detection is possible even when the target position is not consistent.
❚ Features
27
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