Sensor Speed: Exploring Multiple Applications and Solutions

Speed Matters More Than Ever

With demand for various products continuing to increase, manufacturers need automated sensor solutions that can keep up — while continuing to deliver the performance needed to maintain quality and accuracy. Whether you’re looking to verify the presence of certain materials or components or need to validate that aspects of your products meet key thresholds, EMX Industrial Automation offers a complete portfolio of solutions with the sensor speed you need to meet your goals.

1. Luminescence

Luminescence sensors detect materials that fluoresce (i.e. glow) when struck with a beam of ultraviolet light. The sensor identifies that reaction, but because it’s extremely quick, the sensor speed needs to be lightning-fast.

• Application: Glue on cotton swabs. The stick features a dab of glue to which the cotton is applied later. Manufacturers need to be able to verify that the glue is present. Due to the small size of the product, product line speed is extremely fast.
• Recommended Sensor: The UVX-300 (10 kHz), or the UVX-50-T (40 kHz) or UVX-30-TP (40 kHz) for even faster sensor speed as needed.

2. Contrast

At EMX, our CNTX contrast sensors are already our fastest solutions. But depending on your application, you can take greater advantage of its rapid 40 kHz switching speed by focusing on a smaller object or mark.

• Application: A common use for the CNTX is identifying the presence of registration marks on labels and packaging. Faster sensor speed means you can verify smaller marks, providing you with greater flexibility in packaging design.
• Recommended Sensor: Any of the CNTX series, but for extremely small marks, consider using the CNTX-05-0 for spot sizes as small as 0.5 mm.

3. Color

Color sensors are ideal for applications where a product or surface must be within a color range threshold, such as within a specific RGB range. 

• Application: Small part color verification for automotive components. Parts must be extremely accurate in their color threshold. Deviations could mean there’s a problem with an upstream manufacturing process.
• Recommended Sensor: The ColorMax-1000 series; note that if speed matters above other requirements such as detecting RGB or luminosity, the CNTX contrast sensor may be the ideal choice. It converts colors to a grayscale within a 0-50 range, making identification and verification much faster and simpler. 
  • External Triggering: If greater speed is needed with the ColorMax, you can use a method called external triggering, in which two sensors are set up but conduct readings at alternate times, allowing you to effectively double the rate of detection. Our team can advise if your line would require this.

4. Label Detection

Label detection sensors are specific to the label industry in that they are used to count labels on a sheet by verifying their presence as the backer sheet passes through. Their 12.5 kHz speed is unique among our products but is still incredibly fast for this purpose.

• Application: Identifying the number of labels on a sheet. The LabelX sensor deactivates when it registers the webbing between labels on the sheet.
• Recommended Sensor: Either of the two LabelX sensor options, but if your label is transparent or otherwise hard to read, the LabelX-100 may be the way to go.

5. Particulate Monitoring and Opacity

Particulate monitoring sensors and opacity sensors are slower in terms of switching speed, but their uses justify the reduced switching speed. Particulate monitoring sensors identify reduced light transmission in air, thus revealing a higher level of particulate matter (PM). An example includes measuring PM in commercial kitchens and chemicals in greenhouses. EMX Industrial Automation offers the PMX particulate monitor for these needs.

Opacity sensors provide an opacity measurement on a 0-99 scale, allowing you to set a threshold and rapidly evaluate materials such as packaging, paper, films, and other translucent materials. An application example includes ensuring certain bottles have the right amount of opacity to protect the product(s) inside from the harmful effects of light. EMX offers the OPAX-1000 line of sensors to support manufacturers with high-speed verification of opacity in their production lines.

Find a Solution with the Right Sensor Speed

Calculating the ideal sensor speed can be challenging, especially if you have multiple products or don’t currently have a sensor solution in place. At EMX Industrial Automation, our engineering team can work with you to find the right sensor based on your line speed and the material or product that you need to detect.

Often, we’re able to identify this through our complimentary sample testing. Simply tell us a bit about your production environment and what you need to detect, then send in a sample of that material. We’ll conduct a free test, and you’ll receive a detailed report outlining which sensor is best, what you should know about the sensor speed, and more — along with any photos as applicable to show proper integration or installation and setup.

Reach out today to get started!