Outputs increase control for colour sensor

Combination of discrete and analogue outputs in one sensor provides more intelligent control over manufacturing processes requiring colour recognition.

EMX Industries has introduced the Colormax-1000 RGB colour sensor with four discrete outputs plus RGB analogue outputs.

The combination of discrete and analogue outputs in one sensor provides more intelligent control over manufacturing processes requiring colour recognition.

It outputs raw RGB readings as analogue signals representing the intensity of each colour component.

The raw RGB signals can be input to programmable logic controllers containing specific algorithms to evaluate the data.

Enabling operators to see the intensity of individual RGB readings allows them to adjust a process quickly to maintain colour consistency.

The colour sensor has individually programmable tolerances for each component (RGB) that makes up a specific colour.

The tolerances are adjustable on a channel-by-channel basis, which enables finer control of processes.

For example, an operator can determine that the critical reading for matching an exact colour in an operation is the level of red, in which case the acceptable range for red could be set more narrowly than the ranges for blue and green.

Analogue signals are better suited for communications because digital readings would exceed the throughput limitations of typical serial protocols.

Enabling operators to see the intensity of individual RGB readings allows them to adjust a process quickly to keep it running properly.

In addition to the analogue signals, the sensor has four discrete outputs that operate as a traditional colour sensor.

The discrete signals indicate a match or no-match condition for up to four colours programmed into memory.

The sensors can be used in applications that now require sophisticated colour-sensing equipment.

Colour variations detected by the sensor can be used as input by an automated system to take corrective action.

With this approach, the controller can make minor in-process adjustments without reprogramming or operator intervention.

In addition, instead of the sensor making the match decision, a controller can perform this function.

Process engineers have the option of developing their own algorithms for colour control.

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

Applications that can benefit from in-process monitoring of colour quality include manufacturing products with stringent colour specifications such as textile manufacturing, printing operations, plastic injection moulding and painting and coating systems.

Discrete applications include assembly, printing and packaging lines that have a need to detect components, verify steps in the manufacturing process and match different components by colour.

Like other sensors in the Colormax range, the Colormax-1000 RGB sensor is available in an M30 threaded enclosure, familiar to any engineer who has worked with proximity sensors.

This configuration simplifies installation.

Distance can be adjusted up to 7.6cm simply by turning the sensor.

The detection range is 30 to 100mm.

At recommended operating distance (50mm) the beam diameter is a 4 or 8mm spot, letting engineers pinpoint readings and reduce background colour interference.

By employing low-noise technology in the sensor, EMX reduced colour variation to 0.5%.

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

Sample speed is 5kHz, fast enough to keep up with high-speed manufacturing processes.

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

This prevents operators from changing sensor settings to avoid having to report manufacturing quality issues.

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

The sensors overcome this by using software algorithms that ignore lustre.

The sensors 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, the sensors automatically detect the PLC connection for PNP or NPN configuration during setup.

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

The range includes auto-teach and manual calibration.

This makes the sensors 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.

An IP67-rated nickel-plated brass housing is suitable for many manufacturing environments, plus they have short-circuit, overcurrent and reverse polarity protection.

Connections are made via a circular 12-pin connector.

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