MSN:Steve.ye@carlogavazzi.cn; Email:Steveyts@126.

com Voice of 叶铁锁

The Self-Contained
Throughbeam Sensor
Among the dizzying array of specialized photoelectrics, fork sensors (self-contained throughbeams) are proving surprisingly
useful in many applications.

When they first arrived on the scene, photoelectric sensors debuted as throughbeam
devices using lights and reflectors. Over the years, they 抳 e blossomed into full lines of
specialized designs, each excelling at a certain job. Today 抯 sensors typically consist of
a relatively complex system of separate emitters, receivers, and/or

reflectors, sometimes with associated fiber-optic cabling and

separate amplification modules. Now, a new type of sensor, the
self-contained throughbeam 梥 ometimes called a fork sensor 梞 ay
be the wave of the future. When working with production-oriented
customers, we 抳 e found the self-contained throughbeam to be
much more than just an addition to our photoelectric arsenal. It
抯 quickly emerging as a jack-of-all-trades, and master of a
variety of applications.

The Basics
This sensor style, typically configured in a block letter
揅?shape (see Figure 1), sends a beam of visible red or laser
light across from one arm of the sensor to the other.
Configurations vary from narrow-gap versions to sensors with
5
gaps ~8 /8 in. wide. Originally developed for translucent or
transparent contrast mark applications, the slot-style sensor
has evolved to handle a range of applications because of the
versatility of its basic configuration. These sensors offer high
accuracy, e.g., laser versions are capable of resolutions down
Figure 1. Self-contained throughbeam sensors can
to 0.03 mm, and are often a better choice than conventional be used for a host of applications on the production
line. In this example, the sensor is being used to
multi-component throughbeam designs with their two cables, check that all caps have been correctly sealed as
the bottles proceed along a small conveyor.
associated fiber-optic amplifier, and additional special
mounting brackets.

The Advantages of Throughbeam Sensing

When it comes to reliability and accuracy, there is no optical sensing mode that
outperforms throughbeam. Its reliability is a result of the high levels of excess gain
inherent in the design. Excess gain is the ability to sense light energy above the level
required for normal sensing (see Figure 2).
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Figure 2. As shown in this chart, self-contained laser throughbeam sensors have superior excess gain
characteristics over such sensing modes as retroreflective and diffuse. Not only are laser throughbeams very
accurate, their high excess gain enables them to maintain their accuracy in the type of harsh environments that
would degrade that of most conventional sensors.

The more excess gain, the more tolerant the sensor is of dirt, moisture, and debris.
Throughbeams also have a tightly controlled, small sensing area called the effective beam,
which is defined by the size of the emitter and receiver lenses. The smaller the lens, the

smaller the effective beam. Because the beam has such a

small diameter, very small targets and variations of
targets can break it. This combination of excess gain and
small effective beam increases the utility and accuracy of
throughbeam sensors. Moreover, these sensors are immune to
variations in target color, reflectivity, or surface
condition.

The Advantages of Fork Sensors Figure 3. An example of traditional throughbeam sensors

There are two significant drawbacks to traditional using fiber optics involves comparatively complex setup,
including tricky calibration, multiple cables, and multiple
throughbeam sensors: their two-piece architecture and their components. This makes for longer setup time and a less
robust overall configuration during heavy, vibration-prone
need for accurate, stable alignment. Today 抯 conventional production cycles.

throughbeam system requires a separate emitter and receiver; these may be difficult to
install because of space or configuration requirements and the need for additional
comparatively complex wiring (compare Figure 3 to Figure 4). Beyond that, to achieve excess
gain, the system must be properly aligned and stay in alignment over time regardless of
vibration, incidental operator interaction, and random contact with the sensor.

By packaging the sensing elements and electronics into a

unique housing, both drawbacks are solved: Short of bending
the housing, sensor emitter and receiver are always aligned
correctly. As a result, self-contained throughbeam sensor
designs are an alternative to traditional throughbeam and
more complex fiber-optic multipiece units. Some of their
features include:
Figure 4. In contrast to Figure 3, the self-contained
• Highly visible red emission for easy setup throughbeam shown here is a snap to install. The sensor's
rigid construction means that its emitter and receiver are
• Rugged and rigid single-piece metal housings for always in alignment and it needs only one cable and no
auxiliary electronics. If it 抯 a laser version, it can see through
stable, accurate readings over long periods of dirty environments, and the one-piece housing conserves
space.
production time
• High-resolution capability that can sense very small parts or very small part
variation
• High switching frequency capability to handle rapid production rates
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This new class of sensor provides significant advantages to the production line.
Because the sensors are always in alignment, setup time is vastly reduced. If they 抮 e
dislodged during production, they can be quickly repositioned. Because they 抮 e self-
contained, they eliminate the need for additional wiring and fragile, fussy fiber-optic
cabling.

Expanding the Application Envelope

Rather than treating this style of sensor as an additional photoelectric sensor design, its
inherent advantages make it a good starting configuration when it comes to solving tough
production installation problems. Here are just some of the applications where

self-contained throughbeam sensors excel: Parts sensing on

feed lines and conveyor belts (down to 0.3 mm in size with
visible red; 0.03 mm using laser versions); parts dimension
verification (down to 0.2 mm repeatability with visible
red, 0.01 mm repeatability with laser versions); parts
counting on assembly lines; tool break monitoring; position
verification; feed verification on automatic assembly
equipment; part ejection verification; and double hit
elimination.

Although fork sensors are a good general-purpose choice,

they aren 抰 suitable for every application.

L-Shaped Throughbeams
Figure 5. This newer self-contained throughbeam
The latest example of this fast-expanding technology is our configuration was designed especially for hazardous duty
situations where the sensor was likely to be struck by product
new L-shaped self-contained throughbeam sensor (see Figure flow. Here, the sensor is mounted between the rollers of a
conveyor where it is protected, yet can still sense the edge of
5). We designed this product because customers needed a a steel slab. The L-shaped fork sensor retains the fork-style
throughbeam's advantages of robustness and ease of
sensor that could handle parts identification and quality installation.

verification duties while existing in an impact-rich

environment that would destroy conventional sensors and/or unacceptably degrade sensor
output. The result is our L-shaped design, which can be used in a variety of applications
where a fork style would be too large or inappropriately configured, or where the sensor
would be exposed to sensor-destroying contact or products moving in multiple directions
(see Figure 6). An angle design, this sensor can be tucked away out of danger and still get
the job done. Its robust stainless steel housing, which incorporates
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potted electronics, can withstand punishment that would destroy

or compromise the effectiveness of conventional sensors.

Laser Throughbeams
Another step forward is the self-contained laser throughbeam
sensor. Laser emission is required for applications that demand
higher resolution. Unlike throughbeams that use standard visible
red emission, this style substitutes laser for the more diffuse
visible red beam. (Visible red is the more economical version
for more applications.) With laser versions, the resolution is
consistent as the gap size increases. Not so with visible red. Figure 6. Here is an example of how two L-shaped
throughbeam sensors can be set up in concert to
As a result, the performance of laser self-contained throughbeam monitor a dual-feed conveyor. Their unique
configuration makes them perfect for tight and high-
designs remains constant regardless of the size of the sensor or contact production environments.

length of the beam 梐 major benefit in most production

environments.

The Evolution of Sensor Design

Until recently, sensor development has tended to concentrate on the electronic/ electrical
performance aspects of sensors. However, making sensors more accurate, more robust, and
more reliable in extreme environments is no longer enough. Today, state-of-the-art sensor
design is focusing on the mechanical side of the subject, considering issues such as
decreasing the amount of setup time, decreasing production downtime, and helping overloaded
production staff keep lines running at their peak. Rather than just improving the sensor,
we also have to focus on making the sensor easy to use and maintain. Helping customers in
the new production environment means looking at the whole picture and letting production
and mechanical environments drive electronic sensor design. Perhaps that 抯 how it should
be, since productivity is now squarely on the shoulders of those overworked mechanical
engineers trying to keep their lines at peak capacity.

FORK SENSORS AT A GLANCE

Pros
?Extremely tolerant of dirty environments
?Immune to target color, reflectivity, or surface
condition
?Most repeatable noncontact sensing mode available
?Able to detect small parts easily
Cons
?May see through translucent objects
?Will not work for color applications
?Requires an emitter and receiver
?Fork sensor has to wrap around the part