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Technology of Fiber-Optic Sensors

Fiber-​optic sen­sors de­tect ob­jects and con­di­ti­ons by di­rec­ting light to a test ob­ject and eva­lua­ting the in­ten­si­ty chan­ge of the re­tur­ning light. They can de­tect very small ob­jects, are par­ti­cu­lar­ly fle­xi­ble to mount and are ex­tre­me­ly re­sistant in harsh en­vi­ron­ments – even in high tem­pe­ra­tu­res, hu­mi­di­ty or wet media. 
Definition
Technology Comparison
Fiber-Optic Amplifiers
Fiber-Optic Cables
Functional Principles
Fiber-Optic Heads
Installation
Industries

What Are Fiber-​Optic Sen­sors?

Fiber-​optic sen­sors use the phy­si­cal pro­per­ties of light when trans­mit­ting it via fiber-​optic cable with glass or plastic fi­bers to de­tect ob­jects. They con­sist of a fiber-​optic am­pli­fier and fiber-​optic ca­bles with or wit­hout op­tics. The fiber-​optic am­pli­fier con­tains the light source and the re­cei­ving ele­ment as well as the proces­sing unit of the sen­sor. The fiber-​optic ca­bles are only in­ten­ded to trans­mit and re­cei­ve light. Since fiber-​optic ca­bles do not con­tain elec­tro­nic com­po­n­ents, fiber-​optic sen­sors are par­ti­cu­lar­ly sui­ta­ble for ap­pli­ca­ti­ons in con­fi­ned spaces, harsh en­vi­ron­ments or where other sen­sors can­not be used.

   

How Do Fiber-​Optic Sen­sors Work?

Fiber-​optic sen­sors mea­su­re dif­fe­rent light sizes such as wa­velength and in­ten­si­ty in order to de­ri­ve other mea­su­red va­lu­es from them. In in­dus­tri­al au­to­ma­ti­on, the en­er­ge­tic prin­ciple is often used. The emit­ter, usual­ly an LED light source, cou­ples light into a fiber-​optic cable. The light exits at the end of the fiber-​optic cable and eit­her hits an ob­ject which re­flects it back (sen­sing/re­flec­tion prin­ciple) or it is de­tec­ted di­rect­ly by a re­cei­ver (through-​beam prin­ciple). The re­tur­ned light is then di­rec­ted to the ana­ly­sis mo­du­le, where a pho­to­di­ode mea­su­res the amount of light re­cei­ved. The elec­tro­nics con­stant­ly com­pa­re this amount of light with a de­fi­ned th­res­hold value and switch the out­put of the sen­sor ac­cor­din­gly.

What Are the Ad­van­ta­ges of Fiber-​Optic Sen­sors?

Fle­xi­ble In­stal­la­ti­on

Fiber-​optic sen­sors are ex­tre­me­ly com­pact and ideal for in­stal­la­ti­on in con­fi­ned in­dus­tri­al en­vi­ron­ments. In ad­di­ti­on, the high fle­xi­bi­li­ty and low at­tenua­ti­on of the fiber-​optic ca­bles also make lar­ger trans­mis­si­on di­s­tances pos­si­ble.

High Re­lia­bi­li­ty

Fiber-​optic sen­sors are ex­tre­me­ly dura­ble and en­su­re re­lia­ble per­for­mance even under harsh am­bi­ent con­di­ti­ons such as high tem­pe­ra­tu­res, hu­mi­di­ty and ag­gres­si­ve media such as coo­ling lu­b­ri­cants or clea­ning agents. 

Elec­tro­ma­gne­tic Com­pa­ti­bi­li­ty

In fiber-​optic ca­bles, si­gnal trans­mis­si­on is pu­re­ly op­ti­cal, which eli­mi­na­tes the chal­lenges as­so­cia­ted with EMC for fiber-​optic sen­sors. They are also ex­tre­me­ly in­sen­si­ti­ve to elec­tro­ma­gne­tic in­ter­fe­rence.

Fiber-Optics vs. Small Photoelectrics: Technology Overview

 
Fiber-​optic cable Small pho­to­elec­trics
Mea­su­re­ment range
 
Am­bi­ent tem­pe­ra­tu­re
 
Moun­ting ef­fort
De­tec­tion of trans­pa­rent ob­jects
 
Small parts de­tec­tion
Fle­xi­bi­li­ty and custo­miza­ti­on
 

What Are Fiber-​Optic Am­pli­fiers?

Fiber-​optic am­pli­fiers, also known as op­ti­cal am­pli­fiers, are com­po­n­ents that am­plify si­gnals in op­ti­cal com­mu­ni­ca­ti­on sys­tems and play a key role in fiber-​optic com­mu­ni­ca­ti­on. Here, they in­cre­a­se the trans­mis­si­on range.

In the con­text of in­dus­tri­al au­to­ma­ti­on, fiber-​optic am­pli­fiers are sen­sors that use fiber-​optics such as glass fi­bers or plastic fiber-​optics to mea­su­re va­rious phy­si­cal va­ria­bles such as pres­su­re, tem­pe­ra­tu­re, ex­pan­si­on and the pre­sence or po­si­ti­on of ob­jects. They uti­li­ze the abi­li­ty of fiber-​optics to trans­mit light, de­tec­ting chan­ges in the spec­trum or amount of light.


What Does Multi Unit Mean?

A sen­sor net­work, also known as a multi unit, con­sists of se­ve­r­al sen­sors that can com­mu­ni­ca­te di­rect­ly with each other. The sen­sors do not in­ter­fe­re with each other, even if they are close to each other or op­po­si­te each other and in­spec­ting the same ob­ject. This en­ables ef­fi­ci­ent coor­di­na­ti­on and col­la­bo­ra­ti­on bet­ween the sen­sors. In ad­di­ti­on, the sen­sor net­work mi­ni­mi­zes the need for cab­ling, as only one cable is re­qui­red for the con­nec­tion to the IO-​Link mas­ter. The si­gnal le­vels and swit­ching chan­nels of all con­nec­ted sen­sors are trans­mit­ted via the IO-​Link process data, a con­nec­tion cable and a port on the IO-​Link mas­ter. This op­ti­mi­zes data trans­fer and si­gni­fi­cant­ly re­du­ces cab­ling and in­stal­la­ti­on ef­fort.

What Is the Ali­gnment Mode?

Fiber-​optic ca­bles must be ali­gned pre­cise­ly to the tar­get for re­lia­ble ob­ject de­tec­tion. Es­pe­cial­ly when using the through-​beam prin­ciple, the emit­ter and re­cei­ver should be po­si­tio­ned axi­al­ly as clo­se­ly as pos­si­ble to each other. Since the am­pli­fier or ana­ly­sis mo­du­le is often in­stal­led in the con­trol ca­bi­net or out­si­de the field of vi­si­on, the setup is often based on the ope­ra­tor’s view and as­sess­ment. The ali­gnment mode vi­sua­li­zes the si­gnal strength by pul­sing the trans­mit­ting light. Si­mi­lar to par­king sen­sors in the car, the pulse fre­quen­cy in­cre­a­ses the stron­ger the si­gnal re­cei­ved. The sen­sor head is ad­jus­ted in its angle and axis until the op­ti­mal ali­gnment with the ma­xi­mum si­gnal is achie­ved. This en­ables ef­fi­ci­ent and pre­cise setup even with grea­ter di­s­tances bet­ween the emit­ter and re­cei­ver.

What do you need a DIN rail ad­ap­ter for?

The am­pli­fier unit is usual­ly moun­ted on stan­dar­di­zed DIN rails. In­stal­la­ti­on is tool-​free by sim­ply and quick­ly snap­ping the am­pli­fiers onto the rail. When using the multi-​unit mode, se­ve­r­al fiber-​optic am­pli­fiers can be ar­ran­ged next to each other in the con­trol ca­bi­net in a space-​saving and non-​slip man­ner.

What Are the Ad­van­ta­ges of Dif­fe­rent Light Sources?

De­pen­ding on the spe­ci­fic re­qui­re­ments of the ap­pli­ca­ti­on, wenglor fiber-​optic sen­sors use red, blue, pink or in­fra­red light.

  • Red LEDs (633 nm) offer high process sta­bi­li­ty, even with very bright or white test ob­jects.

  • Blue LEDs (455 nm) are par­ti­cu­lar­ly sui­ta­ble for pre­cise mea­su­re­ments on glo­wing, glos­sy or dark sur­faces, as they pe­ne­tra­te less deeply into the test ob­ject.

  • In pink light mode, red and blue LEDs are ac­ti­va­ted si­mul­ta­neous­ly to in­cre­a­se light out­put and im­pro­ve the range of the sen­sors.

  • In­fra­red light (over 750 nm) is in­vi­si­ble to the human eye, pre­venting vi­su­al dis­trac­tions and ma­ni­pu­la­ti­on – ideal for mo­ving sen­sors on robot grip­pers or au­to­no­mous ve­hicles. It also en­ables a grea­ter range due to its hig­her power.

What Are Fiber-​Optic Ca­bles?

Fiber-​optic ca­bles are optic fi­bers con­sis­ting of a light-​conducting core and a ja­cket, each ha­ving a dif­fe­rent re­frac­ti­ve index. In this process, the light is trans­por­ted through the core with vir­tual­ly no los­ses due to total re­flec­tion on the ja­cket. When exi­ting the fiber-​optic cable, the light is scat­te­red at an aper­tu­re angle of ap­pro­xi­ma­te­ly 60 de­grees.
 

What Is the Re­frac­ti­ve Index?

The re­frac­ti­ve index de­scri­bes how much light rays chan­ge di­rec­tion when they enter from one me­di­um to ano­ther. It is de­fi­ned by the ratio of the light ve­lo­ci­ty in the va­cu­um c to the light ve­lo­ci­ty in the con­side­red me­di­um v. The re­frac­ti­ve index n is di­men­sion­less and va­ries de­pen­ding on fac­tors such as the tem­pe­ra­tu­re and wa­velength of the light.

The fol­lo­wing phy­si­cal for­mu­la is used to de­ter­mi­ne the re­frac­ti­ve index:
 
n = v/c

What Is an Aper­tu­re Angle?

The aper­tu­re angle re­fers to the angle at which light exits the op­ti­cal fiber. A large aper­tu­re angle of­fers the ad­van­ta­ge that it en­ables re­lia­ble de­tec­tion of even he­te­ro­ge­neous ob­jects at a short di­s­tance. It is also easy to hand­le, as the ori­en­ta­ti­on of the de­vice is not im­portant. Howe­ver, the light out­put quick­ly spreads over a large area, re­du­cing the range as the light does not stay fo­cu­sed.

To con­trol this wide aper­tu­re angle, len­ses are used that focus or col­li­ma­te the light as re­qui­red. This en­ables the de­tec­tion of very small ob­jects or si­gni­fi­cant­ly in­cre­a­ses the range of the fiber-​optic ca­bles.

Op­ti­cal Fi­bers in Com­pa­ri­son

Plastic fiber-​optic ca­bles are ideal for ob­ject de­tec­tion in ap­pli­ca­ti­ons re­qui­ring litt­le space. Glass fiber-​optic ca­bles, on the other hand, prove them­sel­ves in de­man­ding am­bi­ent con­di­ti­ons with high tem­pe­ra­tu­res and offer che­mi­cal re­sis­tance. These and other ad­van­ta­ges of these ma­te­ri­als open up numerous ap­pli­ca­ti­on pos­si­bi­li­ties to meet a wide range of re­qui­re­ments.

Glass Fiber-​Optic Ca­bles

Trans­mis­si­on of vi­si­ble light and in­fra­red light
To­le­rant to ex­tre­me tem­pe­ra­tu­re ran­ges
Sui­ta­ble for cor­ro­si­ve or wet in­dus­tri­al en­vi­ron­ments
Par­ti­cu­lar­ly low at­tenua­ti­on in the area of the in­fra­red light
Risk of breaka­ge due to ex­ces­si­ve or re­pea­ted ben­ding

Plastic Fiber-​Optic Ca­bles

Trans­mis­si­on of vi­si­ble light
Less to­le­rant to ex­tre­me tem­pe­ra­tu­re ran­ges
Not sui­ta­ble for cor­ro­si­ve or wet in­dus­tri­al en­vi­ron­ments
Par­ti­cu­lar­ly low at­tenua­ti­on in the vi­si­ble light area
Re­pe­at bends pos­si­ble due to high fle­xi­bi­li­ty

Par­al­lel Fi­bers

With this type of re­flec­tion, the fi­bers run par­al­lel to each other to trans­mit light si­gnals. This fiber ar­ran­ge­ment is availa­ble as both plastic and glass fiber-​optics and is used in most stan­dard ap­pli­ca­ti­ons.


 

Co­axi­al Fi­bers

The co­axi­al re­flec­tion type is a high-​precision mea­su­re­ment me­thod con­sis­ting of a core (emit­ter) and a sur­roun­ding area (re­cei­ver). With this type, the di­rec­tion of entry of the test ob­ject into the mea­su­ring range is ir­rele­vant for the po­si­ti­on of the fiber-​optic sen­sor.

 

Mixed Fi­bers

The mixed re­flec­tion type re­fers to a fiber-​optic struc­tu­re in which many trans­mit­ting and re­cei­ving fi­bers are ar­ran­ged wit­hout se­pa­ra­ti­on. The po­si­ti­on and di­s­tance of the fiber-​optic cable to the ob­ject are less re­le­vant here. The image area is very small or not pre­sent.

Ef­fect of Fiber Dia­me­ter/Bund­le Dia­me­ter

The lar­ger the dia­me­ter of the light-​conducting core, the more light can be trans­por­ted through the cable. This leads to grea­ter ran­ges and im­pro­ved de­tec­tion of deep black ob­jects. For cer­tain fiber-​optic heads, such as fiber-​optic cable bands, more fi­bers and con­se­quent­ly a lar­ger dia­me­ter are the­re­fo­re re­qui­red.

What Does the Ben­ding Ra­di­us Say?

The ben­ding ra­di­us de­ter­mi­nes how much a cable can be bent wit­hout da­ma­ging it or af­fec­ting the si­gnal qua­li­ty. If a fiber-​optic cable is bent ex­ces­si­ve­ly, there is a risk that the fiber ja­cket in the cable breaks and light es­capes from the fiber core. This can lead not only to in­cre­a­sed dam­ping, but also to mi­crocracks in the fiber core, re­sul­ting in per­ma­nent da­ma­ge. The­re­fo­re, it is im­portant to ob­ser­ve the ben­ding ra­di­us, es­pe­cial­ly for glass fiber-​optic ca­bles.

What Is the Struc­tu­re of Fiber-​Optic Ca­bles?

Plastic Fiber-Optic Cables

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Glass Fiber-Optic Cables

What Types of Ja­ckets Are there for Glass Fiber-​Optic Ca­bles?

Plastic, PVC

The most cost-​effective va­ri­ant. Sui­ta­ble for stan­dard ap­pli­ca­ti­ons that do not re­qui­re spe­cial re­sis­tance to en­vi­ron­men­tal in­flu­en­ces.

Stain­less Steel

Pro­vi­des the hig­hest level of pro­tec­tion against me­cha­ni­cal stress. Less fle­xi­ble in­stal­la­ti­on as lar­ger ben­ding radii are re­qui­red. No pro­tec­tion against gas­ses or li­quids.

Si­li­co­ne

Ma­xi­mum re­sis­tance to ag­gres­si­ve media. Ab­so­lut­e­ly tight, so fluids and gas­ses can­not pe­ne­tra­te the ja­cket and da­ma­ge the op­ti­cal fi­bers. FDA com­pli­ant.

What Are the Ope­ra­tio­nal Prin­ci­ples of Fiber-​Optic Sen­sors?

Re­flex Mode

In the case of re­flex mode, the emit­ter and the re­cei­ver are en­clo­sed in a sin­gle housing. The light emit­ted by the emit­ter hits the test ob­ject and is re­tur­ned to the re­cei­ver. The ob­ject is de­tec­ted based on the amount of re­flec­ted light rea­ching the re­cei­ver of the fiber-​optic cable.

Through-​Beam Mode

The through-​beam model con­sists of an op­po­sing emit­ter and re­cei­ver. As soon as the test ob­ject pas­ses through the space bet­ween the emit­ter and re­cei­ver, the light of the fiber-​optic cable is in­ter­rup­ted. De­tec­tion is then per­for­med by re­du­cing the re­cei­ved light in­ten­si­ty.

Retro-​Reflex Sen­sor

With the retro-​reflex sen­sor prin­ciple, the emit­ter and re­cei­ver are lo­ca­ted in a housing, while on the op­po­si­te side a re­flec­tor is po­si­tio­ned. The test ob­ject is de­tec­ted when the light re­flec­ted back by the re­flec­tor is eit­her com­ple­te­ly in­ter­rup­ted or re­du­ced. 

Fiber-​Optic Cable Bands

Fiber-​optic cable bands are used to mo­ni­tor areas. In con­trast to spot-​shaped light spots, which only mo­ni­tor the pre­sence of ob­jects within one point, fiber-​optic cable bands de­tect se­ve­r­al cen­ti­me­ters. The sen­sor de­tects the ob­ject as soon as the si­gnal is we­a­ke­ned or com­ple­te­ly in­ter­rup­ted.

Com­pa­ri­son of Dy­na­mic Re­ad­just­ment and Jump De­tec­tion

Both dy­na­mic re­ad­just­ment and jump de­tec­tion are sui­ta­ble for re­lia­ble de­tec­tion of ob­jects under chan­ging en­vi­ron­men­tal con­di­ti­ons. In dy­na­mic re­ad­just­ment, a quasi-​fixed th­res­hold value is used, whe­re­as jump de­tec­tion does not re­qui­re a th­res­hold value and only eva­lua­tes si­gnal chan­ges in­s­tead.

Fixed Swit­ching Point

The most com­mon mode of ope­ra­ti­on of a sen­sor is based on a fixed swit­ching point. The sen­sor de­ter­mi­nes the th­res­hold value or the swit­ching point du­ring the teach-​in process in ac­cordance with a spe­ci­fied teach-​in logic. In nor­mal teach, this cor­re­sponds to 50% of the cur­rent si­gnal, for ex­ample. If the am­bi­ent con­di­ti­ons and the ob­jects to be de­tec­ted are very con­stant, the mode of ope­ra­ti­on with a fixed swit­ching point of­fers the hig­hest in­sen­si­ti­vi­ty to in­ter­fe­rence, as ex­ter­nal in­flu­en­ces can­not chan­ge the swit­ching point: If the si­gnal is above the de­fi­ned th­res­hold, the out­put is ac­ti­va­ted; if it is below, the out­put re­mains in­ac­ti­ve. Howe­ver, if the si­gnal is al­te­red due to con­ta­mi­na­ti­on, for ex­ample, this can lead to per­ma­nent mal­func­tions.

Dy­na­mic Re­ad­just­ment

The dy­na­mic re­ad­just­ment is par­ti­cu­lar­ly sui­ta­ble for the re­flex mode with sta­tic back­grounds as well as for the through-​beam mode. The non-​switched state should pre­vail, as the th­res­hold value is only re­ad­jus­ted in this state. If there is con­ta­mi­na­ti­on on the fiber-​optic head or on the back­ground, this is com­pen­sa­ted by dy­na­mic ad­just­ment of the th­res­hold value.

Jump De­tec­tion

The ab­so­lu­te si­gnal va­lu­es are ir­rele­vant for jump de­tec­tion. In­s­tead, the di­rec­tion of the si­gnal chan­ge (ne­ga­ti­ve, po­si­ti­ve or both di­rec­tions), the ma­gni­tu­de of the chan­ge and the ob­ser­va­ti­on pe­ri­od can be in­clu­ded in the eva­lua­ti­on. This en­ables the de­tec­tion of high­ly va­ria­ble ob­jects (e.g. in color or sur­face fi­nish) on non-​static back­grounds (such as a slow­ly soi­ling con­veyor belt) as well as the de­tec­tion of ob­jects wit­hout prior tea­ching (e.g. with chan­ging bat­ches).

Over­view of Fiber-​Optic Heads

An­gled

An­gled sen­sor heads are ideal for tight spaces where the op­ti­cal axis and cable out­let must be ori­en­ted dif­fer­ent­ly. Thanks to the th­read, the sen­sor heads can be ea­si­ly scre­wed into pre­pa­red holes or fas­tened to an angle or plate with two nuts.

L Type

The L type al­lo­ws easy moun­ting with two screws and of­fers pre­de­fi­ned po­si­ti­ons of the op­ti­cal axes. Exact ali­gnment is not ne­cess­a­ry due to the large aper­tu­re angle of the fiber-​optic ca­bles.
 

Flat

Flat sen­sor heads can be ea­si­ly in­te­gra­ted into the base of the work­piece car­ri­er. The fle­xi­bi­li­ty of the cable out­let on the sen­sor head al­lo­ws easy cable rou­ting to the left, right or rear.

Fle­xi­ble

The thin, long metal sen­sor lance can be ad­ap­ted to the spe­ci­fic re­qui­re­ments of the re­spec­ti­ve ap­pli­ca­ti­on by simp­le ben­ding.

Fiber-​Optic Cable Bands

Fiber-​optic cable bands in through-​beam mode are ideal for mo­ni­to­ring large areas. Re­flex fiber-​optic cable bands, on the other hand, are par­ti­cu­lar­ly ef­fec­ti­ve for de­tec­ting he­te­ro­ge­neous ob­jects and can also be used for mea­su­ring ap­pli­ca­ti­ons through the eva­lua­ti­on of the re­flec­ted light.

Mi­nia­tu­re

Mi­nia­tu­re sen­sor heads are par­ti­cu­lar­ly sui­ta­ble for ap­pli­ca­ti­ons in the tigh­test of spaces.

Th­read

Th­rea­ded sen­sor heads allow for quick and easy in­stal­la­ti­on. They can eit­her be scre­wed di­rect­ly into pre-​drilled holes or fixed to bra­ckets or pla­tes using two nuts.

Smooth

Smooth sen­sor heads are ideal for use in con­fi­ned spaces and can be in­ser­ted or glued into pre­fa­bri­ca­ted moun­ting bra­ckets.

The Fol­lo­wing Must Be Ob­ser­ved when In­stal­ling Fiber-​Optic Sen­sors

To en­su­re re­lia­ble ob­ject de­tec­tion and ac­cu­ra­te mea­su­re­ment data, the fol­lo­wing in­struc­tions should be ob­ser­ved when in­stal­ling the sen­sor.

Length and Cut­ting

Fiber-​optic ca­bles are availa­ble in va­rious lengths. Plastic fiber-​optic ca­bles can be cut to size by the custo­mer, glass fiber-​optic ca­bles only in­dus­tri­al­ly, as they must be ground and po­lished after cut­ting. The length has litt­le ef­fect on the de­tec­tion range, but lon­ger fiber-​optic ca­bles let less light through.


Tip: Sel­ect a sui­ta­ble glass fiber-​optic cable.

De­tec­tion Range

Due to the large aper­tu­re angle, fiber-​optic ca­bles have only a small de­tec­tion range. Hig­her de­tec­tion ran­ges can be achie­ved with lar­ger fiber bund­le/core dia­me­ters or with len­ses that focus the light.


Tip: Use fiber-​optic ca­bles pri­ma­ri­ly for short ran­ges and de­tec­tion of small parts.

Ben­ding Ra­di­us

Fiber-​optic ca­bles are fle­xi­ble, but mi­ni­mum ben­ding radii must be main­tai­ned to avoid da­ma­ge and light loss. High-​flex plastic fiber-​optic ca­bles are sui­ta­ble for tight ben­ding radii or mo­ving in­stal­la­ti­ons. The fol­lo­wing ap­plies in ge­ne­ral: Smal­ler dia­me­ters allow smal­ler ben­ding radii.

Tip: In­stal­la­ti­on of high-​flex fiber-​optic ca­bles.

Tem­pe­ra­tu­re

Plastic and glass fiber-​optic ca­bles dif­fer in terms of tem­pe­ra­tu­re re­sis­tance. Above 85 °C, stain­less steel or si­li­co­ne coated glass fiber-​optic ca­bles should be used.

Tip: Thanks to in­di­vi­du­al lengths, the ana­ly­sis mo­du­le can also be pla­ced in the con­trol ca­bi­net.

Sen­sor Ori­en­ta­ti­on

In re­flex mode, the emit­ter and re­cei­ver should be in­stal­led at a 90° angle to the test ob­ject when ap­proa­ching from the side to en­su­re smooth swit­ching on and off.

Tip: A pla­nar ori­en­ta­ti­on to the ob­ject leads to an off­set with de­layed on and off swit­ching.

Cable with De­di­ca­ted Emit­ter

For fiber-​optic heads with co­axi­al light emis­si­on and for cer­tain fiber optic cable bands, it is es­sen­ti­al to en­su­re the cor­rect as­sign­ment of emit­ter on the fiber-​optic head to emit­ter on the am­pli­fier.

Tip: The am­pli­fiers are mark­ed with ar­rows for this pur­po­se.

Sectors and Industries which Use Fiber-Optic Sensors

In the pro­duc­tion of metal pro­files, the pre­sence and di­men­si­ons of the ob­jects must be de­tec­ted be­fo­re a clam­ping de­vice se­cu­res them in place. Pro­files can be black, white, chro­me, glos­sy or matt. Glass fiber-​optic light curtains based on the transmitter-​receiver prin­ciple are used in con­fi­ned spaces, toge­ther with a uni­ver­sal re­flex sen­sor. The op­ti­cal fi­bers are ar­ran­ged in a sin­gle line to crea­te a light band. The width is mea­su­red, the li­ne­ar si­gnal is out­put pro­por­tio­nal to the glass fiber cover and the cor­rect po­si­ti­on is de­ter­mi­ned.

Which Ob­jects Can­not Be Op­ti­mal­ly De­tec­ted by Fiber-​Optic Sen­sors?

  • Water and other clear li­quids that ab­sorb light stron­gly or chan­ge its path through re­frac­tion can lead to in­ac­cu­ra­te mea­su­re­ments.
  • High­ly trans­pa­rent ob­jects such as clear glass, which allow light to pass through com­ple­te­ly wit­hout re­flec­ting it, make de­tec­tion more dif­fi­cult.
  • Deep black ob­jects that ab­sorb the in­co­ming light hea­vi­ly and hard­ly or not re­flect at all hin­der the si­gnal re­turn to the sen­sor.
  • Ex­tre­me­ly shiny ob­jects that re­flect light in un­pre­dic­ta­ble di­rec­tions pre­vent ac­cu­ra­te ob­ject de­tec­tion.
     
 

 
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