Optical sensors

The light spot makes all the difference: small, bright and precise

The diffuse sensors and photoelectric sensors with Power PinPoint LED use innovative light source technology. Thanks to the newly developed light-emitting diode, the sensors’ optical system generates a light spot that retains its size, shape and homogeneity throughout the sensor’s entire working range.

Compartment fine positioning with diffuse sensors

Diffuse reflection sensors ensure the load receptacle is positioned correctly. A wide range of profile types as well as color or glossy surfaces are reliably detected. Diffuse sensors with background suppression have an optimal response behavior and a high level of precision when sensing the edge of a column thanks to the defined and homogeneous Power PinPoint light spot. 

Detection of boxes in conveyor systems with retro-reflective photoelectric sensors

Requirement:

In packaging processes, products are transported between different process steps in standardized containers. To protect unpackaged food, systems and their components must withstand regular, intensive cleaning processes. 

Solution: 

With Power PinPoint LEDs, retro-reflective photoelectric sensors achieve a higher function reserve, especially with small reflectors. This is particularly advantageous for space-critical applications. Furthermore, commissioning and alignment with the reflector is completed in no time at all. 

Presence control of battery cells with throughbeam photoelectric sensors

When carrying out presence control in automated processes, the job of the sensor system is to safely detect the various objects. Handling of the sensor, including mounting, alignment and adjustment, must also be quick and simple, especially as a large number of sensors often need to be installed. This is why a) standardization and b) adaptation of the sensor to the individual needs of the customer are extremely important for the cost-effective commissioning of a system.

We have developed an optimized sensor generation for precisely these requirements:
The new 5B series. Highly economical. Perfect handling.

Directly to the 5B series article selection

Advantages for you

• Flexible implementation: Complete series with all operating principles, each in identical and installation-compatible housings. Depending on the respective application, it is possible to choose between throughbeam photoelectric sensors, retro-reflective photoelectric sensors and diffuse sensors
• Housing: New, compact housing (dimensions W x H x L: 11 mm x 32.4 mm x 20 mm) – installation-compatible with previous series – ideal for tight installation spaces. Certified with degree of protection IP 67 and ECOLAB
• Attachment and mounting: Fast attachment and easy mounting thanks to metal inserts with M3 thread
• Commissioning: All-around visible 360° indicator LEDs for easy installation and status display. Fast alignment thanks to homogeneous and easily visible light spot
• Optimal configuration: Easy alignment and adjustment to the application thanks to a user-friendly potentiometer
• Safe detection of depolarizing objects: Optimized performance for the detection of reflective, shrink-wrapped, and shiny objects
• Electrical connection: Adaptation to individual customer requirements thanks to different connection options (e.g., cable, M8 connector, pigtail,...)
• Switching frequency: Improved switching frequency for throughbeam photoelectric sensors with up to 900 Hz and for diffuse sensors up to 1000 Hz for high performance and function reserve
• Tamper protection: Light/dark switching takes place in a tamperproof manner through polarity reversal of the (cable) wiring

Presence control in intralogistics using retro-reflective photoelectric sensors

Requirement:
In a logistics center, various containers and cardboard boxes are to be transported on roller conveyors that are positioned closely to each another. In addition, some cardboard boxes are shrink-wrapped in film. All objects must be reliably detected. During commissioning, the sensor must be fast and simple to install, align, and adjust. The light spot must be easy to see.

Solution:
With their compact, space-saving housing, the new 5B series sensors can be mounted directly on roller conveyors that are positioned closely to each other. The sensors are installed and securely mounted using convenient metal inserts with M3 thread. They are aligned quickly and easily using a homogeneous and clearly visible light spot as well as 360° indicator LEDs. Adjustment is user-friendly by means of a potentiometer. Performance optimized for the detection of shrink-wrapped and glossy objects ensures that they can be reliably detected.

Presence control in packaging systems using throughbeam photoelectric sensors

Requirement:
At a food manufacturer's plant, potato chips are packed in primary packaging. The packages are then transported further on a conveyor line where they are to be reliably detected. The light spot must be visible. The sensor state should also be visible from a distance of 2 m.

Solution:
The new sensor of the 5B series can also be mounted horizontally on the conveyor line, and the light spot is easy to see. Thanks to the bright 360° indicator LEDs, the sensor state is visible at all times, even at some distance away from the conveyor line. The advantage of the throughbeam photoelectric sensor is the very high function reserve. This ensures reliable detection even in very demanding environmental conditions, and it reduces the risk of system downtimes. Furthermore, the new 5B series has an optimized switching frequency of 900 Hz.

Presence control in intralogistics using a diffuse sensor

Requirement:
Packages are transported on a conveyor belt in a distribution system. A sensor is to check whether the packages are filled properly. Underfilled or overfilled cartons are to be removed.

Solution:
The HT 5B diffuse sensor looks down onto the conveyor belt and detects the cartons and their contents with rapid switching behavior of up to 1000 Hz. Alignment and fine adjustment are user-friendly by means of a potentiometer. Background suppression of the sensors ensures that only the object is detected and the conveyor belt is blanked out.

Detection of foil tears in battery cell production using a diffuse sensor

Requirement:
During the production of lithium-ion battery cells, rolls of copper or aluminum foil are compressed in a complex process (calendering). High and irregular speeds can cause tears in the foil sheet. If a tear occurs, sensors are to stop the process immediately in order to prevent damage to the machine.

Solution:
The HT 5B diffuse sensor with background suppression monitors the presence of the foil continuously and detects a film tear immediately. The sensor also detects very glossy or dark surfaces reliably and, thanks to its compact design, is suitable for installation in extremely confined spaces.

For the processing, filling or packaging of foods and pharmaceutical products, there are very strict specifications regarding hygiene and cleaning of the systems.

Not only the production systems but also electronic components such as sensors must withstand regular, intensive cleaning and disinfection cycles with, in some cases, aggressive cleaning agents. Especially in applications with direct contact with foods or for detection tasks above unpackaged products, the use of sensors with a hygienic design acc. to standard DIN EN 1672-2 ("Food processing machinery - Basic concepts") is recommended. These sensor solutions are characterized by a special design as well as a high leak tightness and resistance to cleaning agents.

Our new stainless steel sensor platform with the 53C series in hygienic design and 55C in wash-down design was especially developed for applications with increased hygiene requirements. To be able to withstand the demanding requirements, the housings of both sensor series are made of high-quality V4A stainless steel (AISI 316L). The smooth stainless steel surfaces (typical value ≤ 0.8 Ra) ensure that cleaning agents drip off directly and bacterial carry-overs in production systems are prevented. During the design process, great value was placed on shaping both the glass-free optics cover and the operational controls so as to be absolutely leak and gap free. All housing materials are FDA compliant and approved for direct contact with foods. This provides additional safety in food processing and packaging.

Advantages for you

• Two complete series with all operating principles: throughbeam photoelectric sensors, retro-reflective photoelectric sensors and sensors for specific application areas and tasks
• Two housing designs for use in wet applications (Wash-Down) and hygiene applications (Hygienic Design)
• High-quality V4A (AISI 316L) stainless steel housing with smooth surface and the glass-free optics cover made of PMMA+ with special scratch-resistant coating prevent bacterial carry-overs
• Degree of protection IP69K for reliable functional capability and absolute leak tightness of the housing
• Thermal and chemical resistance (inspected and certified in accordance with ECOLAB, CleanProof+, JohnsonDiversey)
• FDA-compliant housing materials allow the sensor to be used in applications that come into direct contact with food
• Simple configuration and condition monitoring through IO-Link interface and variants with electronic range adjustment and measurement value output via IO-Link

Directly to the 53C series article selection

Directly to the 55C series article selection

Loading check of a sausage cutting machine

Requirement:
In the food industry, sausage is delivered in large bars and cut into thin slices in a cutting machine. The product must be reliably detected in the infeed of the machine so that the gripper can uniformly push the material towards the knife and so that all cut slices have the required thickness.

Solution:
Our HT53C.S diffuse sensor in Hygienic Design reliably monitors the product infeed at the sausage cutting machine. If enough material is present for operating the machine, the system starts up automatically. The especially small light spot is characterized by very good performance, particularly with objects with colored structure; the background suppression of the sensor ensures reliable, color-independent detection of products.

Detection of the the leading edges of cut-good products

Requirement:
In an industrial cutting machine, cut goods are cut into small stacks and pre-portioned for the subsequent packaging in trays. The challenge for the sensor system is that the front edge of the cut goods must be reliably detected at the same switching point – regardless of whether they are located on the conveyor belt with a slight lateral offset. The sensors are mounted directly above the conveyor belt. In this application, it must be ensured that no cleaning agent residues drip onto the cheese or cut goods.

Solution:
The HT53CL1.X diffuse sensor with background suppression is specially optimized for the detection of the front edge of products thanks to a long laser light spot. With the linear light spot, cut goods are also reliably detected at the same switching point even with lateral offset on the conveyor belt. This guarantees clean positioning of the cut goods when loading into the tray packaging and ensures that the edge of the tray is not touched by the food, thereby preventing traces of fat from affecting the subsequent, hygienically perfect sealing of the trays. The housing construction of the 53C series was designed in Hygienic Design without drilled holes and is suitable for areas of application with direct contact with food.

Level detection when filling liquids

Requirement:
In the beverage industry, water is filled in 3 liter bottles in a filler. The fill level must be exactly the same in all bottles – underfilling of bottles should be prevented. Reliably detecting the fill level of aqueous liquids in all types of containers is one of the most challenging detection tasks for sensor systems and requires extremely powerful sensor solutions.

Solution:
The LS55C.H2O and LE55C.H2O throughbeam photoelectric sensors were developed for the detection of aqueous liquids as well as for fill-level monitoring and reliably stop the filling process. The transmitter and receiver system of the 55C stainless-steel series in Wash-Down design has a high radiation capacity and can also be used with colored containers and containers with plastic labels.
This solution can replace an expensive fill-level monitoring system, such as a scale or a flow measurement, and is easy to set up: aside from the precise alignment of the optical axis, no other settings via an operational control are necessary.

Presence control in bottle filling applications in the transfer star

Requirement:
Bottle filling is characterized by very high speeds. For a smooth process, it must be ensured prior to filling that all positions of the transfer star are occupied with bottles.

Solution:
The HT55C diffuse sensor with background suppression reliably detects containers in bottle filling applications and does so without reflectors. The sensors are designed for wet areas and can also withstand intensive cleaning processes. An ECOLAB certification as well as our expanded CleanProof+ long-term cleaning agent test ensures the reliable functionality of the sensor even under harsh conditions.

Bottle detection during transport

Requirement:
In a filling system for milk bottles, the position of the bottles must be reliably and precisely detected on the conveyor belt for the subsequent packaging steps in the system.

Solution:
The PRK55C.TT3 retro-reflective photoelectric sensor also reliably detects transparent containers. The sensitivity adjustment can be actuated via the teach button. The integrated tracking function automatically compensates for soiling on the reflector or sensor. This extends the cleaning intervals and reduces system downtime. With the highest degree of protection IP69K, the stainless steel housing in Wash-Down design is very robust. Resistance to cleaning agents commonly used on the market is confirmed by the ECOLAB certification, the Leuze CleanProof+ test as well as tests in accordance with JohnsonDiversey.

Precise positioning of vials

Requirement:
For the filling of vaccines and other liquids, vials made of transparent glass must be precisely detected and positioned.

Solution:
In combination with a small stainless steel reflector, the PRK53CL1.T3 retro-reflective photoelectric sensor with a small laser light spot enables the highly precise detection and positioning of vials. The sensor with miniature housing can also easily be integrated in constrained spaces. Both the sensor and the reflector have a hygienic design.

Detection and positioning of transparent vials

Requirement:
In a pharmaceutical packaging system, vials are filled on multi-track packaging lines. The position of the transparent vials must be precisely detected prior to filling. One challenge is that the vials are very flat and the photoelectric sensors must be precisely directed at the reflector.

Solution:
Our PRK53C.T3 retro-reflective photoelectric sensors of the 53C series are used with the MTKS 14x23.P pharmaceutical micro-triad-type reflectors, specially developed for the pharmaceutical industry. The stainless steel sensors in Hygienic Design are precisely directed at the reflector and ensure reliable detection of the vials.

New sensor series for object detection

With perfect performance at the best price. The new 36 series.

The reliable detection of objects remains key for a high level of automation and for smooth processes in system technology. Particularly in intralogistics, packaging systems and the automotive industry, the objects to be detected pose huge challenges for sensor systems. Large detection distances, vibration, ambient light and soiling coupled with objects with very different optical properties require sensors with an extremely high detection performance.
At the same time, economic criteria are essential. In many applications, a higher level of automation is achieved by increasing the number of sensors, whereby the need for cost-optimized sensors moves to the fore.
The sensors of our new 36 series deliver perfect performance at the best price. Different operating principles in combination with superior signal processing result in outstanding reliability when detecting objects – even in challenging applications. The high function reserve allows objects to be detected at great distances or sources of interference or soiling to be compensated from shorter distances.

Advantages for you

• Extremely large operating ranges result in a large function reserve and therefore in a reliable detection rate, even in the case of critical applications
• Availability with your preferred operating principle:
  • Sensors with background suppression with max. 2500 mm operating range
  • Retro-reflective photoelectric sensors with max. 17 m operating range (optionally also for detecting objects with depolarizing properties)
  • Throughbeam photoelectric sensors with max. 80 m operating range
• Outstanding price/performance ratio
• All common switching logics supported: NPN and PNP switching, light and dark switching
• Diverse connection possibilities enable easy integration (cable, M12 connector or cable with M12 connector)
• Mounting compatibility with 46 series sensors

Detection of film-wrapped pallets.

Requirement:
To secure pallets for transport, they are often wrapped in film. Conventional retro-reflective photoelectric sensors are unable to detect these pallets reliably owing to the depolarizing properties of the tensioned film. As this method of transport safeguarding is widely used, the sensor must detect these special objects with absolute reliability. At the same time, a cost-effective solution needs to be found to enable scaling of this application.

Solution:
The new PRK36.D retro-reflective photoelectric sensor has special optics to enable depolarizing objects to be detected with absolute reliability. An improved design provides a cost benefit over sensors currently available on the market.

Detection of outer packaging in the food industry

Requirement:
In the food industry, identical products are generally bundled into larger packages in order to optimize and automate handling and logistical processes. A key requirement for a high level of automation are high-performance sensors which detect packages reliably – even in the case of changing products and outer packaging. To monitor these processes closely, a multitude of economically attractive sensors are required.

Solution:
With our new 36 series, we offer retro-reflective photoelectric sensors which, thanks to their very high function reserve, reliably detect different packaging units. An improved design provides a cost benefit over sensors currently available on the market.

Safeguarding material availability in production systems

Requirement:
On the one hand, highly automated production systems require high process reliability. On the other hand, the safeguarding of material availability and material tracking are essential. Sensor systems which reliably ensure that different assembly materials are present and therefore available are key components here. At the same time, sensors must be integrated flexibly in different installation situations.

Solution:
Thanks to the different operating principles, variance with respect to light color and the extremely high detection rate, our new range of 36 series sensors are ideal for detecting a wide variety of objects in production systems and therefore assessing the presence or absence of assembly materials. A broad range of mounting technology as well as diverse connection variants allow easy integration. The outstanding price/performance ratio allows scaling in large and complex production systems.