Reasons for false detection: 1. The installation distance is inappropriate
Different from the identification of the reflective intensity of ordinary photoelectric switches, because the color mark sensor recognizes the grayscale contrast, if the measured material is not placed within the detection distance, its sensitivity (grayscale recognition ability) is significantly reduced, or even cannot be detected.
solution
In general, there will be a graph of the sensitivity and sensing distance in the sample data of the color mark sensor, which can be referred to to confirm whether the current installation distance is appropriate. As an example, the optimal distance between the color code and the measured object is about 12mm, and the operator needs to fully measure to ensure the correct installation position when installing the color code.
Sick KTS/X series color code sensor has installation feedback display, so that the operator can confirm whether the position of the sensor is correct at any time, avoid false detection caused by the installation distance, and also make the installation of the sensor convenient.
False detection cause 2: Similar color interference
There may not be only one color on the color mark detection path, as shown in the figure below, you need to detect the dark blue logo at the end of the material, but there are black, green, pink and other interfering colors on the detection path. However, the two-point teaching method of the traditional color mark sensor generally only sets the output threshold between the logo color and the background color, and other similar color interference cannot be ruled out.
solution
1. Change the detection path so that as few colors appear in the path as possible. In the image above, for example, if you change to inspect along the narrow edge of the material, the interfering color is greatly reduced.
Disadvantages: In actual industrial production, some stations cannot adjust the detection path at will.
2. If the color mark sensor has a measured value display, the output threshold can be adjusted according to the measured value of the measured mark.
Disadvantages: The color mark sensor is required to display the measured value and have a high color resolution.
Sick KTS/X series color scale sensor with built-in color mode:
With just a little teach-in of the color scale to be measured, the color can be accurately detected without interference from other similar colors.
The user can see the current measured values via the digital display and adjust the thresholds manually
False Detection Cause 3: The sensor response time cannot keep up with the running speed of the production line
The response time can reflect the detection accuracy of the sensor, that is, whether the switch quantity of the detected identification can be transmitted to the host computer in time.
Take a sensor with a 50 μs response time in a 100 m/s production line as an example: 50 μs× 0.1 mm/ μs = 5 mm,
That is, under ideal circumstances, false detection will occur when the width or separation distance of the measured color scale is less than 5mm!
Based on the width of the marking block and the separation distance, the appropriate response time/switching frequency is calculated, which is confirmed when selecting the color mark sensor.
Sick KTS/X series color scale sensors with fast response times of up to 3 μs and high switching frequencies of up to 70 kHz!
False detection cause 4: The surface of the tested material is uneven
The traditional color mark sensor uses a single photosensitive device, and the green light path at the level shown below has a great impact on the detection of the uneven or bent surface of the measured object.
solution
When selecting a color mark sensor, choose a model with a wide sensing distance tolerance range, such as +/- 5mm, as much as possible
Disadvantages: The tolerance range of the sensing distance does not necessarily directly reflect the depth of field of the color scale sensor, so the selection requires actual field testing to determine whether it is feasible.
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