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Key Point Range Environment Accessibility Wiring Size Consistency Requirements Output signal Logic functions Integration
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Consideration How far is the object to be detected How dirty or dark is the environment What accessibility is there to both sides of the object to be detected Is wiring possible to one or both sides of the object What size is the object Is object consistent in size, shape, and reflectivity What are the mechanical and electrical requirements What kind of output is needed Are logic functions needed at the sensing point Is the system required to be integrated
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TABLE 2.3 Key Characteristics of Sensors
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can be used will establish a strong foundation. This understanding also will allow the user to obtain a descriptive picture of the condition of each manufacturing process in the production environment. Table 2.3 highlights key questions the user must consider.
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Detection Methods
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The three modes of detection used by photoelectric sensors are: Through-beam detection Reflex detection Proximity detection
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2.4.1 The Through-Beam Detection Method
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The through-beam method requires that the source and detector are positioned opposite each other and that the light beam is sent directly from source to detector (Fig. 2.29). When an object passes between the source and detector, the beam is broken, signaling detection of the object. Through-beam detection generally provides the longest range of the three operating modes and provides high power at shorter range to penetrate steam, dirt, or other contaminants between the source and detector. Alignment of the source and detector must be accurate.
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2.4.2 The Reflex Detection Method
The reflex method requires that the source and detector be installed on the same side of the object to be detected (Fig. 2.30). The light beam is transmitted from the source to a retroreflector that returns
C l a s s i f i c a t i o n a n d Ty p e s o f S e n s o r s
Detector
Field of View
e Eff
B ve cti
Field of View
Source
FIGURE 2.29
Through-beam detection.
Retroreflector
e Eff
B ve cti
Field of View
Source/ Detector
FIGURE 2.30
Re ex detection.
the light to the detector. When an object breaks a reflected beam, the object is detected. The reflex method is widely used because it is flexible and easy to install and provides the best cost-performance ratio of the three methods. The object to be detected must be less reflective than the retroreflector.
2.4.3 The Proximity Detection Method
The proximity method requires that the source and detector are installed on the same side of the object to be detected and aimed at a point in front of the sensor (Fig. 2.31). When an object passes in front of the source and detector, light from the source is reflected from the object s surface back to the detector, and the object is detected. Each sensor type has a specific operating range. In general, through-beam sensors offer the greatest range, followed by reflex sensors, then proximity sensors. The maximum range for through-beam sensors is of primary importance. At any distance less than the maximum range, the sensor has more than enough power to detect an object.
Two
Light Reflected by Object Field of View
Source/ Detector
FIGURE 2.31 Proximity detection.
The optimum range for the proximity and reflex sensors is more significant than the maximum range. The optimum range is the range at which the sensor has the most power available to detect objects. The optimum range is best shown by an excess gain chart (Fig. 2.32). Excess gain is a measure of sensing power available in excess of that required to detect an object. An excess gain of 1 means there is just enough power to detect an object under the best conditions without obstacles placed in the light beam. The distance at which the excess gain equals 1 is the maximum range. An excess gain of 100 means there is 100 times the power required to detect an object. Generally, the more excess gain available at the required range, the more consistently the control will operate. For each distance within the range of the sensor, there is a specific excess gain. Through-beam controls generally provide the most excess gain, followed by reflex and then proximity sensors.
RANGE (mm) 0.03 1000 0.3 3.0 30.5
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