Task for the sensor:

• For aligning welded metal tubes it’s welding seam must be detected safely at varying metal colors.

Used products:

• 2-channel color sensor PCS-III in differential operating mode, 2 reflex mode fiber optical cables

Solution:

• The application was solved with the PCS-III in differential operating mode. The reflex mode fiber cables were positioned in parallel and close together in the same distance to the surface. After balancing the sensor channels the zero difference was taught into the sensor. The tolerance was adjusted according to the color difference. If no welding seam is present the sensor output switches to high. If beneath one channel the welding seam is present the sensor output switches to low. Because similar changes beneath both channels cause no signal difference the application is eveb robust at varying metal colors.

Task for the sensor:

• At the assembling of distance sensors with car bumpers the matching of the color must be checked. The number of possible colors amounts to hundreds. The colors are changing frequently. The object position varies slightly in the mm range. The working distance must be in the region of 7-15cm.

Used products:

• 2-channel color sensor PCS-III in differential operating mode, 2 Through-beam mode fiber optical cables, 2 focus lenses of type FOD-A2.0-100 with 95mm working distance an 12mm spot

Solution:

• The application was solved with the PCS-III in differential operating mode. The focus lenses were arranged shiftily according to the mounting position of the distance sensor and the bumper and angled approx. 30° in a distance of approx. 95mm to the surface. After balancing the sensor channels the color difference of zero was taught into the sensor. The tolerance was adjusted according to the color distances. If the color of the bumper and the color of the distance sensor match the sensor output switches to high. If the colors do not match the output goes to low.

Task for the sensor:

• For protection purposes manufacturer of bearings cover the housings with metal caps. The presents of the cap must be detected by use of color sensors. Due to the metallic gloss and a point-shaped scanning color values of the cap overlap with the color values of the bearing housing.

Used products:

• Standard color sensor PCS-II, Reflex mode color sensor with profile conversion (6x1)mm

Solution:

• The application was solved with the standard color sensor PCS-II and a reflex mode fiber cable with profile conversion. Due to the line-like scanning profile of the fiber an average of approx. 6mm of the bearing housing is taken. By this the detection becomes definite.

Task for the sensor:

• The plastic insets of retainer in airbag systems are coded by color. The type can be determined by it’s color. A definite and reliable detection of the color is required for the safety. 11 different colors must be detected. At the plastic inset there is a small area of approx. 2mm for the color detection.

Used products:

• Standard color sensor PCS-II, Reflex mode fiber optical cable, Focus lens KL-3

Solution:

• The application was solved with the standard color sensor PCS-II and a reflex mode fiber cable with KL-3 focus optic. The signal level drive has been done on the white plastic. Subsequently all 11 color were taught into the sensor the tolerances were adjusted according to the color differences between the different colors.

Task for the sensor:

• Pharmacy tubes are sealed with differently colored plastic caps and sorted in a sorting machine by color. The colors of the caps differ distinctively. The detection must be reduced to 6 basic colors. There is a small area of approx. 2mm on the caps for the color detection. The machine operates with 6 sorting lines in parallel. The detection of the cap’s color must take place synchronously.

Used products:

• 6 x Standard color sensor PCS-II, 6 x Reflex mode fiber optical cable, 6 x Focus lens Type KL-3

Solution:

• The application was solved with 6 color sensors of type PCS-II installed in parallel and 6 reflex mode fiber cables with focus lenses. Each color sensor was taught with the 6 basic colors and the color tolerance was adjusted according to the deviation of the basic colors. For synchronization the trigger signals were used.

Task for the sensor:

• Single-sided PTFE coated silicone sealing plates are passing an oscillating conveyor. Before further processing the position of the plates must be checked. The coating causes a slight color difference between top and bottom side.

Used products:

• Standard color sensor PCS-II, Reflex mode fiber optical cable with M6 sleeve

Solution:

• The application was solved with the PCS-II and a reflex mode fiber optical cable. The sensing head of the fiber cable was mounted in approx. 2mm distance and was angled in approx. 45° to the surface. The color difference of the top and the bottom side of the plate amounts to approx. 10 units. After teaching in the top side of the plate the application was safely solved with a tolerance of 6 units.

Task for the sensor:

• A manufacturer of PCB processing equipment must detect red films long term stable. Sensors were installed in quantities. The sensors must exactly detect the color right after mounting without any adjustment effort. That is why the possibility of a data transfer of the sensor parameter from one sensor to the other without individual adjustment on the machine is required.

Used products:

• Compact color sensor PCS-I, electronically balanced

Solution:

• The application was solved with the PCS-I. Therefore the sensor is exactly electronically balanced to the color of the customer to be detected before delivery. All parameters can now be transmitted from one sensor to the other at the customer without individual adjustment.

Task for the sensor:

• A manufacturer of plastic key pads for implementation in automobile instruments must detect 17 color variants. The colors are very close (DE approx. 1) and all in the color range of beige and gray. The colors must be detected in a distance of 2-4cm. The Application must be long term stable.

Used products:

• 2-channel color sensor PCS-III in reference operating mode
• 1 reflex mode fiber optical cable with A2.0 sleeve
• 1 Reflex mode focus lens type KL-M18 with 25mm working distance an 4mm spot

Solution:

• The application was solved with the PCS-III in reference operating mode. The focus lens was angled in approx. 30° and positioned in a distance of approx. 25mm above the surface. After adjusting the sensor signal level to the brightest object and subsequent reference value activation all 17 colors were taught into the sensor with a tolerance of 1.

Task for the sensor:

• A manufacturer of zips must check the color of the fabric on both sides of the zip in a distance of 2-4cm.

Used products:

• 2-channel color sensor PCS-III in 2-channel operating mode
• 2 through beam mode fiber optical cables with A2.0 sleevs
• 2 focus lenses of type FOD-A2.0-35 with 30mm working distance an 7mm spot

Solution:

• The application was solved with the PCS-III in 2-channel operating mode, two through beam mode fiber optical cables and focus lenses of type FOD-A2.0-35. The desired color values were taught into each color channel and parameterized with a small tolerance.

Task for the sensor:

• Glass has a distinct color at a higher thickness (e.g. greenish). The color is an indicator for the glass quality and it’s properties. The determination of the color is therefore important for the development and production of glasses. For the illumination a special tungsten lamp is used. The ambient light must be compensated during measurement.

Used products:

• 2-channel color sensor PCS-III in active and differential operating mode
• 1 Reflex mode fiber optical cable with profile conversion (45x0.3)mm
• 1 Reflex mode fiber optical cable for reference

Solution:

• The application was solved with the PCS-III in active and differential operating mode. The first channel is used as measuring channel. Therefore the fiber optical cable with the profile conversion is positioned in front of the glass bar. The glass bar is illuminated with the special tungsten lamp from the opposite. The second channel is used as reference channel. The fiber optical cable of that channel is directly positioned in front of the tungsten lamp. The sensor channels are balanced to a difference of zero with switched off illuminant. At switched on illuminant the color of the glass bar can be determined.

Task for the sensor:

• The spreading of thin films on parts is conventionally controlled by measuring the discharge on the lubricant spattering nozzle. If the spreaded films are very thin the sensitivity of measuring the discharge is not sufficient. The control if a lubricating film is there doesn't work. Particularly the spreading of silicone slip additives is difficult to control beacuse the slip additive is transparent.

Used products:

• Standard color sensor PCS-II
• reflex mode optical fiber optics

Solution:

• The color of the parts with and without lubricating film is teached to the sensor.
• The sensivity of the PCS-II is sufficient to detect the change by spreading thin films.
• The signals on the output ports provide secure information about the spreading of lubricating films.

Automatic check of the components if a lubricating film/silicone film is spread.

Task for the sensor:

• For the mounting of LEDs in assemblies an unchanging quality of color and brightness of the LEDs is important. A checking of the LEDs concerning right brightness and color is necessary.

Used products:

• Standard color sensor PCS-II in active mode
• optical fiber

Solution:

• The permissible tolerances are preselected by parametrizing the L-value (intensity) and the u’v’-values (color). Via the software of the PCS-II the classes can be displayed graphically.

Automatic check of the components by values of color and brightness. High safety that the components contain checked LEDs.

Task for the sensor:

• The joining position of polyethylene coated papercup blanks is covered with a 3mm wide transparent protection film. If the protection film is missing, wetness can penetrate the joining and finally loosen it. The presents of the film must be detected.

Used products:

• 2-channel color sensor PCS-III in differential operating mode
• 2 in parallel arranged reflex mode fiber optical cables with 1.5mm fiber bundle

Solution:

• The application was solved with the PCS-III in differential operating mode. The two reflex mode fiber optical cables were positioned in parallel, angled in approx. 45° and in approx. 1mm distance to the surface. The L*a*b* differential color value without protection film is stored as zero difference. If the difference of zero is achieved, the sensor output switches to high. If the film is present on the paperboard the color difference is unequal to zero and the sensor output switches to low. The tolerance was adjusted according to the difference of film present/absent (approx. 4 units).

Task for the sensor:

• In many automated production processes color is used for control purposes. A manufacturer of bearing shells marked the parts according to the type with red, green or yellow. When packing or installing the bearing shells the color mark provides information if the right one is chosen. The difficult part in this application is, that the color marks differ in nuances (e.g. different shades of green) The color sensor needs to be able to clearly recognize the color marks as red, green or yellow.

Used products:

• Standard color sensor PCS-II
• reflex mode fiber optics

Solution:

• The different shades of yellow, green and red are teached to the sensor. Afterwards they are pooled to one yellow, one red and one green group.

The screenshot shows an example of color grouping with bearing shells. It can be seen that different shades of green are pooled to one group (group No. 2, rightmost column). In the color diagram the coressesponding chromaticity coordinate and tolerance circle are visible.

Task fot the sensor:

• Differently colored boxes have to be sorted by predefined ground colors (e.g. brown, red, blue, green, yellow). For that a correct classification is vital. A color processing of the sensors differing from human color perception leads to wrong classifications and therefore faulty sorting results.

Used products:

• Standard color sensor PCS-II
• reflex mode fiber optics

Solution:

• The sensor needs to be teached with prototypical ground colors that shall be recognized.
• The sensor is classifying all unknown color objects like humans would do.
• With this function boxes can be safely sorted by ground colors, like blue, yellow, red, brown or green.

The implemented perceptive i.e. true-to-perception color processor assures correct color classification.

Task for the sensor:

• A special 1.5cm wide white membrane material is designed as a short band. To extend the band it is joined with a red adhesive tape and wound onto a reel. The ending of the band is marked with a black adhesive tape. The white band is processed in a plastic injection molding machine with two tracks in parallel. For controlling the unwinding of the band the white, the red joins and the black ending mark must be detected.

Used products:

• 2-channel color sensor PCS-III in 2-channel operating mode
• 2 Reflex mode fiber optical cables with M6 sleeves and 2.5mm fiber bundle

Solution:

• The application was solved with the PCS-III and 2 reflex mode fiber optical cables with M6 sleeves. The sleeves were angled in approximately 45° and mounted in a distance of approximately 8mm to the band surface. The 3 colors were taught into each sensor channel. The sensor was run in the classification mode. By that the determination of tolerance values is not applicable.

Task for the sensor:

• In a bottling plant it has to be secured that only brown glass bottles are used. Hence all non-brown glass bottles have to be sorted out.

Used products:

• Standard color sensor PCS-II
• through beam mode fiber optics with M6 sleeves

Solution:

• A brown sample bottle is teached. A through-beam fiber optic is used.
• The color tolerance is adjusted for recognizing brown glass bottles, but not recognizing non-brown glass bottles.
• The outputs are connected to an SPS.

By the high resolution and the used sensor options the wrong glass bottles are sorted out safely.

Task for the sensor:

• Polyethylene Glycol, if in proper condition, is a clear liquid. Due to thermal stress or exposure a slightly yellow discoloration occurs that must be detected before processing. The detection must be done in a PG tube of 50mm diameter.
• The detection must be done in a PG tube of 50mm diameter.

Used products:

• Compact color sensor PCS-I-F
• Through beam mode fiber optical cables with M6 sleeves and 2.5mm fiber bundle

Solution:

• The application was solved with the PCS-I-F and a through beam mode fiber optical cable with M6 sleeves. The fiber optical cable is therefore arranged as light barrier. It is mounted directly into the PG tube with the M6 sleeves. The L*a*b* color value of the clear Polyethylene Glycol is stored as reference into the sensor. The tolerance threshold is adjusted to 1.

Task for the Sensor:

• Manufactured fiber optics need to be checked for translucence in conformity with the speed of robots. Depending on particles in the fiber optics different values are expected. Three ranges of dispersion (qualities) have to be distinguished: Normal range, A-range (to much brightness), B-range (to much darkness)

Used products:

• 2-channel color sensor PCS-III in reference mode
• through beam mode fiber optics with M6 sleeves

Solution:

• The possible color variations of the shining-through light are teached by samples of the three ranges of dispersion.
• The deviations of the three ranges of dispersion are parametrized by Delta E units in a way that no overlapping is possible.
• The outputs are connected to an SPS.

The fiber optics are safely assigned to the three ranges of dispersion by the high resolution of the sensor. Deviant parts are safely recognized and sorted out.