Special Sensors

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Special Sensors include a broad range of devices that must perform special detection tasks, or which were developed for specific applications. Here you will find contrast and luminescence sensors, color sensors, systems for monitoring double sheets and splices, as well as for overlap detection. You can use these sensors primarily for sorting, detection and inspection tasks.

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    Reliable products for ultimate detection

    Special sensors feature flexibility and diversity. You can benefit from them in the field of control and testing where they can handle even the fastest processes.
    From our extensive portfolio of special sensors, you will be able to choose the ones that perfectly fit the needs of your application. The top-quality sensors are manufactured by world’s leading companies:

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    Choose from a great variety of Special Sensors

    One of the key components in the high-speed production environment is the sensor, evaluating many of the features and characteristics of products at rates as fast as hundreds of items a second. With special sensors you can efficiently detect materials, objects, and positions in special industrial automation tasks.

    Different types of sensors are available for a great variety of purposes:

    Contrast sensors use white light or laser-generated red light or RGB light to precisely detect and compare contrasts. They can detect even the smallest contrast differences at the highest of process line speeds and they report the results with minimal signal jitter. They reliably detect various color or grey value combinations through the automatic selection of the right transmitter colors. You can primarily use them within the packaging and printing industries for the detection of contrast differences in printed or control markings.

    Luminiscence sensors respond to materials such as paints, greases, inks, and adhesives that have luminescent tracers, which emit light in the visible spectrum when stimulated by a UV light source. These sensors are useful in applications where the presence of these materials needs to be accurately verified. They send the result as switching output. The technique of applying a luminescent marking is often useful in applications where there is significant variation in the background that needs to be ignored, such as text and graphics printed on labels. You can therefore primarily use them for sorting and inspection tasks in areas in which other detection methods fail to supply reliable results or where the markings should not or must not be visible.

    Color sensors separate the reflected light from a target into its constituent red, green, and blue components, each of which is then evaluated to determine whether it is within the range of tolerances set for specific color recognition. The result is output as a switching signal depending on the configuration and specified tolerance values of the system. You can benefit from color sensors whenever the color of an object or marking can serve as a sorting or inspection criteria. They are effective in monitoring of color consistency in applications such as textile production, plastics, and other continuous output processes.

    Double sheet/splice inspection devices ensure system availability and the corresponding logistics in the graphics and other industries. The double sheet monitoring devices reliably prevent multi-layer sheets from being drawn in. As a result, scrap and damage are avoided in machines that process stacks of paper, cardboard, plastic sheets as well as metal foils. These devices operate on a variety of physical principles and thus cover a huge range of applications. The devices for splice inspection and for multiple track label inspection mainly detect splices in roll machines or labels in further processing. Their detection is independent of the surface color and material properties.

    Sensor Selection Considerations

    Special sensor - Infrared pyrometer Micro Epsilon

    Generally, selecting the proper sensor involves carefully assessing the target characteristic(s) and determining what constitutes the acceptance criteria. You need to consider:

    Certain sensor types lend themselves to use with various common materials.

    Except for the color sensor, all the other sensor types detect a single characteristic or condition. Multiple characteristics can often be differentiated using a color sensor or several contrast sensors.

    Glossy, highly reflective surfaces generally require the mounting of the sensor at an angle, e.g., 15° relative to the target surface. If you need to detect matte surfaces, the sensor should be mounted perpendicular to the target surface. Matte surfaces diffuse light in a relatively uniform manner, improving detection consistency.

    Reliable detection is a function of the sensor’s response time, sampling rate, size of the target, and the speed of the target as it moves through the sensor’s light spot. You can use sensors that have response times faster than 100 µs for all but the highest speed/small target applications.

    Greater distance operation requires the use of higher sensitivity sensors. Generally, it is best that you select a sensor that will provide reliable detection and place it at the optimum distance rather than to fix on a distance requirement and try to find a sensor that will work.

    Variation in sensor-to-target distance, typically referred to as “flutter,” is a factor in successful detection. The greater is the difference between presence and absence levels, the greater is the allowable distance variation.

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