Intense claims for colour sensor

The ColorMax-1000 is billed as the industry's first colour sensor that outputs colour intensity.

New from EMX Industries, the ColorMax-1000 is billed as the industry's first colour sensor that outputs colour intensity.

Now machine operators and PLCs can know not just which colour, but how much colour - enabling automation processes to be finely tuned and to tighten control over colour in manufactured goods.

In addition, patented technology and an innovative design qualify the ColorMax-1000 for several industry firsts: sample speed that is two to five times faster than competing sensors, an M30 threaded enclosure that simplifies adjustment and installation, and the industry's highest resolution and repeatability specifications.

What's more, and it stores 15 colours in memory for matching - nearly twice as many colours as any competing sensor.

The ColorMax-1000 colour sensor has a high-intensity white LED that projects modulated light on a target.

The sensor analyses the reflected light for its constituent RGB values and intensities.

High accuracy, stability, and sophisticated software algorithms enable the ColorMax-1000 to meet the resolution and speed requirements of advanced manufacturing processes.

colour sensors are used on assembly lines to detect components, verify steps in the manufacturing process, and match different components by colour.

For example, in automotive assembly, colour sensors are used to match bumpers and mirrors to the body paint colour, and to match carpet colours with plastic and textile trims.

Other application examples include detecting colour marks on parts and product packaging, monitoring the colour of adhesive tape as it is manufactured, and confirming that the correct colour rubber seals are applied.

With this introduction, EMX has removed a longstanding limitation of colour sensors.

Traditional colour sensors output only a "match/no match" condition to the machine controller.

In contrast, the ColorMax-1000 sensor also outputs the analogue values for each RGB reading.

Now the PLC or operator can see how much colour, not just which colour.

Operators can analyse the RBG data to spot trends and diagnose the causes of colour variation.

In addition, instead of the sensor making the match decision, now the match decision can be made in a PLC or other controller.

For the first time, users have the option of developing their own algorithms for colour control.

Unlike other colour sensors that can be programmed to match only one to eight colours, the ColorMax-1000 has 15 hexadecimal unique colour channels that are stored in nonvolatile memory and compared against the reading of the target colour.

This reduces the number of sensors required for some applications, because now one sensor can be used where several were needed before.

In addition, it gives users more flexibility in changing manufacturing setups without the need to reprogram the sensor.

This is increasingly important as North American factories move to high-mix low-volume manufacturing which often requires frequent colour changes.

Although the ColorMax-1000 can match for 15 user-programmed colours - more than any other sensor - there may be applications where a greater number of colours is desired.

Using the colour intensity data, a PLC can store and make matching decisions on a virtually unlimited number of colours.

The ColorMax-1000 is the only colour sensor available in an M30 threaded enclosure, familiar to any engineer who has worked with proximity sensors.

Normally, colour sensors are square shaped to accommodate a beam-splitting mirror or light source and receiver combination.

To achieve a cylindrical design, EMX engineers had to develop an innovative optics arrangement and a special lens.

The 110mm-long sensor fits a standard 30mm diameter hole.

Installation is fast and easy: the technician screws in the sensor and tightens the jamb nuts.

The distance can be adjusted up to three inches simply by turning the sensor.

In contrast, all other colour sensors require users to install a special mounting bracket.

Should the operating distance of other sensors need adjustment, the bracket has to be moved and new holes may need to be drilled.

The detection range for the ColorMax-1000 sensor is 30 to 100mm.

At recommended operating distance (50mm) the beam diameter is a tiny 4 or 8mm spot - enabling engineers to pinpoint readings and minimise background colour interference.

Electrical noise affects sensing resolution and sensitivity.

If a colour variation is smaller than the noise, the sensor will not be able to detect the variation, meaning that a subtle difference in colour will go undetected.

Likewise, when presented with the same colour twice, a sensor with electrical noise may report a colour variation erroneously.

By employing low-noise technology in the ColorMax-1000 sensor, EMX reduced colour variation to 0.5% - the best specification in the industry.

High resolution is especially important for detecting colour variations at high speeds.

In applications where the target is in front of the sensor for a very short period of time, a sensor with a slow sampling speed can limit the speed of manufacturing.

The 5 kHz sample speed of ColorMax-1000 is two to five times faster than the speed of other colour sensors - fast enough to keep up with demanding high-speed manufacturing processes.

Because colour sensing is based on a measurement of reflected light, colour sensors can be "fooled" by the lustre of shiny surfaces.

This is particularly true of metallic paint used in automobile parts.

EMX's new colour sensor overcomes this challenge by using sophisticated software algorithms that ignore luster.

Few colour sensors offer this capability.

The ColorMax-1000 is reckoned to be the only colour sensor that can be programmed via a PC, simplifying sensor installation.

If additional sensors are added or if a sensor is replaced, the technician can copy and paste the colour profiles stored in the PC software.

colour profiles will not be lost if a sensor stops working.

In addition, EMX's new sensor is the only colour sensor that automatically detects the PLC connection for PNP or NPN configuration during setup.

This feature simplifies ordering and reduces stocking requirements by 75%, because users and distributors no longer need to stock different versions of the sensor.

Unlike some competing sensors, the ColorMax-1000 includes both auto-teach and manual calibration.

This makes the sensor easy for low-skill operators to calibrate, yet it provides the ability to be finely tuned.

LED indicators for power, programming, and detection functions aid in setup and troubleshooting.

The ColorMax-1000 sensor features an IP67-rated nickel-plated brass housing suitable for a wide range of manufacturing environments, plus short-circuit, overcurrent and reverse polarity protection.

Connections are made via a circular 12-pin connector.

For operational security, a supervisor may lock the unit's settings, either remotely or directly on the unit.

This feature prevents operators from changing the sensor settings in order to avoid reporting manufacturing quality issues.

Most colour sensors do not offer this level of assurance.

The ColorMax-1000 colour sensor from EMX is available three weeks ARO.

List price for one sensor is $595, with discounts available for quantity orders.

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