Solutions by Process

We offer a wide range of application-specific products, e.g. Displacement/ Vision Sensors, Photoelectric/ Proximity Sensors, 2D Code Readers, RFID Systems, Safety Products, Temperature Controllers, Digital Panel Meters, Power Supplies, PLCs, Monitoring Relays, Ionizers, Clean Sensing Systems, etc. Find out how each product works in your selected application here!

Text Verification Sensor for the Pharmaceutical Industry
Inspections for correct dates is possible while inspecting for light, chipped, or disarrayed characters.
Text Verification Sensor for the Food Industry
Flexibly handles changes in text that occur on production sites. Increases production efficiency by eliminating false negatives.
Inspection of Exhaust Pressures for Cleaning Liquid Tanks
One Controller connects to four compact Pressure Sensors. Increase wafer throughput with little installation space.
Measures Motor Shaft Eccentricity
The laser enables eccentricity to be precisely measured from a distance.
Measures Pulley Eccentricity and Flatness
The Smart Monitor allows measurement data to be collected and stored on a personal computer.
Inspects the Evenness of a Spindle Motor after Assembly
Four measurement points can be calculated at high speed with a Multi-Controller to enable inline, non-contact inspection of all units on the line.
Measures and Calculates Two Points on a Driver IC Surface
By measuring the height differences between two points, warped products that may cause contact defects in the mounting process can be eliminated.
Detects PCB Warping with a Single Measurement
2D Profile Measuring Smart Sensor detects PCB warping with a single measurement. Three-point height differences can be measured within the line beam, for PCB warping detection with a single measurement.
Measures the Displacement Amount of Roller Brackets
Enables optimal roll pitch correction by precisely measuring the displacement amount of roller brackets.
Measures Height and Width of Chip Electrode Foaming
Height and width errors in foaming rise are measured together within the line beam.
Detects Slight Inclination of Minute Chips
This application uses a Fiber Sensor with a homogenous area beam. You can detect lifting and inclination of chips placed on trays. A change in the amount of interrupted light caused by the inclination of components enables detection. This system uses special optical components to detect the same size of workpieces anywhere in the 11-mm-wide detection area.
Inline Inspection of the Thickness of Coated Plywood Boards
The thickness can be stably inspected because movement in the sensing object is absorbed by installing Laser Displacement Sensors above and below and using a Calculating Unit.
Measures the Thickness of Automotive Components
The thin head also makes it possible to measure narrow spaces.
Measures Bearing Thickness with 0.5-µm Accuracy
The thickness can be easily and accurately measured by using a Calculating Unit and installing Sensors on both sides.
Detects Right/Left Uniformity of Paper Thickness
The paper thickness is measured for the left and right edges, and the data is sent to a PLC for processing.
Detects the Edge of Non-woven Fabrics
Distance-settable Sensor detects the edge of non-woven fabrics without being affected by the background or color. Sharp, clear beam with 2-mm diameter simplifies positioning.
Detects Sheet Edge to Prevent Sheet Snaking
This Fiber Sensor with differentiation controls the edges of transparent sheets that are wound with a roller.
Accurately Measures Sealing Dispenser Height
Laser-type 2D CMOS Smart Sensor for nozzle gap accurately measures sealing dispenser height to help improve production yield. A Sensor Head that separates the emitter and receiver while maintaining an integrated structure matches the measurement point with the nozzle drip point to enable highly accurate measurement.
Stably Detects the Presence of Coating Liquids
Smart Sensor with Ultra-high-speed Color CCD Camera can detect the presence of coating liquids that are not detectable by a Photoelectric Sensor. Smart Sensor distinguishes surfaces rather than points, therefore it is able to determine whether the amount of coating is excessive or insufficient.
Precisely Detects Adhesive Presence and Consumption
The amount of adhesive applied is monitored by the amount of incident light that is blocked by the adhesive extracted from the nozzle.
Precisely Detects Pin Pitches
A single sensor can easily inspect the intervals of up to 14 pins and edges can be specified.
Detects Height Differences Even at Long Distance
Laser-type 2D CMOS Smart Sensor provides simple detection of height differences even from a distance. The long-distance Displacement Sensor can detect height differences even in large sensing objects.
Detect Presence of Button Cells after Packaging
Smart Sensor with Ultra-High-Speed Color CCD Camera detects the presence of button cells after packaging.Pattern matching of the button cell and the background is used to eliminate the effects of the film's surface gloss and enable stable detection.
LCD Monitor Inspects for the Presence of Two Dates
High-speed detection of more than one text string is possible with one Amplifier.
Detects Vinyl Cushioning Material from Top of Medicine Bottles
The automatic sensitivity adjustment function makes it possible to detect transparent objects with high stability. Detection stability can be further enhanced by combined use with a Line-beam Sensor.
Detects Wrapping Foil on Chocolates after Packaging
The Proximity Sensor externally detects wrapping foil errors after packaging.
Detects Chipping and Crack Defects for Minute Chip Capacitors
Even chipping and crack defects of minute chip capacitor that shows only a small difference in contrast can be detected via Real Color Vision Sensor with high stability.
Detects the Presence of Printing on Chips
The real-time search function enables high-speed processing for use on high-speed lines.
Inspects the Profile of Cast Components
Scanning with the wide laser enables measurement of the cross-sectional shape without having to move the workpiece.
Distinguishes Car Models by Scanning Body Shape
Workpieces passing through the sensing area are scanned using the signal of each beam to distinguish shape and size.
Wire Stripping Inspection
Through-beam Laser-type Smart Sensor precisely inspects wire stripping process. The high-resolution, through-beam Sensor detects unstripped wire from the difference of wire diameter.
Detects Soiling and Foreign Matter on Non-woven Textiles
Real color sensing technology enables stable detection of subtle soiling and foreign matter of any color.
Measures Color Area to Detect Mixing of Different Bottle Caps
Caps are distinguished by color area, so differentiation is not affected even if the caps are turned or somewhat out of position.
Detects Coating Defects and Double Coating on Molded Products
Vision Sensor with real color sensing simultaneously detects coating defects and double coating on molded products. Real color sensing technology enables subtle hue inspection with good stability similar to that of the human eye.
Counts Pins with a Pin Pitch of 0.5 mm
This application uses a Thin-beam Fiber Sensor. ?You can achieve a stable pin detection with this Thin-beam Fiber Sensor. The small built-in lens generates a thin beam.
2-Dimensional Form Measurement Smart Sensor Measures Apex Height of the Minute Rivet with High Accuracy
The line beam is able to measure stably multi-points of the apex height of the rivet from the datum level.
Detect the Number of Connector Pins
Vision Sensor that integrates a smart sensor and LCD display detects the number of connector pins. The camera with built-in illumination greatly reduces installation work.
Measures Both Sides of Embossing Tape to Detect Snaking
Stable detection is achieved with edge measurements of transparent embossing tape moving at high speed.
Checks Battery Voltage
K8AB-VS voltage relay is used to check battery voltage and its charge level.
Detects Eccentricity and Vibration of Processing Machines
High-precision detection of eccentricity and vibration in processing machines is possible at a sampling speed as high as 150 µs.
Detects Surface Wobbling of Mirror-finish Workpieces
The 2D CMOS Laser precisely detects mirror-finish workpieces, such as the aluminum vapor-deposited side of hard discs.
Detects the Surface Precision of Steel Plates
Highly precise detection of the surface precision of steel plates is possible with a linear proximity sensor located at each of the four corners of the steel plates.
Ensures Precise, Multi-point Co-planarity Detection
The 2D CMOS laser achieves stable, multi-point co-planarity detection of black resins and glossy metals.
Precisely Detect Warping in Hard Drive Chassis
Smart Sensor (High-precision Contact Model) precisely detects warping in hard drive chassis. The multi-point operation function reduces measurement time.
High-precision Detection of Packing Machine Engagement
Achieves stringent inspection of the displacement of the watchdog when the packing machine engages.
Detects Presence and Position of Sealing Tape on Individual Packaging Boxes
The detection area is treated as a plane to simplify tape position detection.
Detects Food Trays of Various Heights or Types
The Area Sensor for workpiece detection precisely detects food trays of a wide variety of heights or types within the sensing area.
Detects Absence of Sales Campaign Stickers on Beverage Cans
The patterned parts of the sticker are registered, and the sticker is determined to be present or not by detecting whether the registered patterns are in the field of view of the 2D Sensor.
Detect Raised or Misaligned Shrink-wrap Film
This application uses a Line-beam Laser Photoelectric Sensor. ?This Line-beam Photoelectric Sensor detects raised or misaligned shrink-wrap film.
Detects Instruction Sheets in Paper Boxes
The distance between the aluminum foil package of medicines and the sensor varies depending on whether the instruction sheet is included or not. The Proximity Sensor precisely detects the instruction sheet, which is not visible from the outside.
Detects Press-fit Conditions of Components in Analog Values
The linear proximity model allows monitoring inspections of the displacement of a metal watchdog mounted to a pusher.
Inspects a Mark or a Gap of Printing Sheets
This application uses a Line-beam Laser Photoelectric Sensor to inspect mark or gap on various sheets. ?This Line-beam Laser Photoelectric Sensor is ideal for printed areas.
Detects the Presence of Flavor Packets
Because the Sensor measures the area of predetermined colors, detection is possible even if the position of the flavor packet changes.
Detects the Presence of Screw Threads
By installing the Sensor Head at a slight angle, the threads shine white. This allows detection by comparing the area of the white part.
Detects the Double Feeding of Metallic Plates
When there is not enough space to install sensors above and below, an Ultra-High-Speed Color CCD Camera can be installed at the side to detect misalignment with high precision.
Detects Clear Pouches Inserted Together
Two clear pouches with a thickness of approximately 100 µm each are detected by mounting the sensor head to a resin plate to measure the clearance between the cylinder tip and the metal presser plate.
Detect Double PCBs
In order to minimize changes in the surface conditions and holes of PCBs, the line beam averages the changes to detect double PCBs inserted together.
Detects Double Presser Plates of Crystal Oscillators
"Through-beam Smart Sensor detects double presser plates of crystal oscillators inserted together. Precisely detects the difference between one and two 80 µm thick aluminum plates by the amount of passing light."
Detect Double Pallets of Canned Beer
This Fiber Sensor with a Long-distance Lens enables detecting changes in the height caused by double pallets for canned beers being inserted together.
Inspect Liquid Level
Smart Sensor with High-Speed Color CCD Camera inspects liquid level edges. Because it is capable of detecting the liquid surface as an area, stable detection is possible in spite of workpiece movement or slight movements in the surface of the liquid.
Achieves High-precision Overhead Detection
High-precision inspection of colored liquids can be conducted with area beam linear output, provided that detection from the upper side of the tank is possible.
Inspects Overlapped Ceramic Base Plate
A parallel-beam laser displacement sensor ZX-L-N can detect single or overlapped plates easily. With this solution, inspection of several plates on each tray can be done and higher yield can be realized.
Detects Quantity of Copper Foil on Base Plate
If the inspection is done by using two sensors, one on the top and the other below the object, the effect of vibration is eliminated and stable detection can be actualized.
Detects Meandering with Coated Cardboard Sheets
Control of meandering can be attained with this 30mm measurement width laser-beam sensor.
Detects the Width of Rubber Sheets
Changes in the amount of light received brought about by the meandering of the sheet enables precise checks on the width of rubber sheets.
Inspects Mixed Bearing (Material and Height Sensing)
Material and height screening using E2C-EDA High-Resolution Digital Proximity Sensor (Separate Amplifier Type).
Measure Glass Thickness
Since high-speed and stable detection of transparent glass is possible, total inline inspections can be actualized. Furthermore automation of data acquisition is also possible with smart monitor ZERO.
Identify Front or Reverse Side of Auto Parts
Easy identification via color extraction without the impact of background or base.
Identifies Metal Part Orientation
Check for the registered shape in the measurement area by teaching a part of the component.
Identify Front or Back Side of Washer
Identification of the front or back side as the reflected light at the edge with shear drop is smaller.
Inspects Metal Chip and Shaving Buildup for Presses
Inspect the gap between presses with E2C-EDA High-Resolution Digital Proximity Sensor (Separate Amplifier Type).
Inspects Screw Assembly
Inspect the screw assembly by measuring the height of the screw.
Measures Glass Surface
New ZS Laser Displacement Sensor is using CMOS technology with glass mode function. Hence measuring glass height, thickness or gap is possible with high accuracy.
Detects Rail Distortion
Wide-line-beam of 30mm width detects any distortion in rails with the use of multi-point measurement with calculation functions.
Checks the Outer Diameter of Metal Pipes
Outer diameter of metal pipes can be precisely checked by using calculation functions.
Inspects Drive Belt Thickness
Continuous monitoring of drive belt thickness by parallel beam laser displacement sensor. Compact sensor can be installed in limited space.
Measure Surface Evenness of Brake Pads
Surface evenness inspection of brake pads is possible by measuring its height at a few points.
Inspects Robot Arms for Flatness
Multi-point precision height measurement on robot arms that transport wafers in load ports, can be done with ease using smart sensor.
Sheet Meandering
Position of sheet can be controlled using digital amplifier with analog output of 1-5V. With analog offset value function, any reference can be set.
Detects Amount of Grease Applied
The area beam detects the amount of grease applied to sliding components.
Checks Disc Motor Tables for Surface Movement
High-speed inspection of height and wobble is possible, even though on object with shiny surface.
Detects CDs
With a maximum spot diameter of 4mm, minute height differences can be differentiated and CDs can be precisely detected.
Measure Outline of Painted Objects
The outline form and type of a painted object can be inspected by locating four F3ZN Area Scanners around the workpiece and measuring its height and width according to the number of optical beams blocked.
Identifies Package Inserts
Identification of different inserts or differences in orientation by registering some of the characters/patterns on the package insert.
Detect Printing Character
Detection of printing characters on the product by recognizing the shape.
Detect Missing Labels
Check for missing or misaligned labels by connecting to the amplifier extracting color of the seal and detecting the position.
Detects Chipped Broken Syringe Caps of Small Breakages
Stable detection is possible with laser point beam.
Detects Protruding Straws
A black/white error as low as 5% makes detection and operation more stable.
Counts Bottles
The spot diameter for Through-beam and Retro-reflective Models is 5 mm (a typical example at 3 m), making it possible to detect small workpieces at long distances. The sensing distance for Retro-reflective Models is 15 m (when an E39-R1 Reflector is used). This is the longest leeway in the industry. The maximum ambient operating temperature is 55° with an IP67 degree of protection, allowing the Sensor to be used in severe operating environments.
Inspects Overlapped Pouch Sack
Using through-beam fiber unit, the object can be detected stably, reducing the number of overlapped sheets.
Inspects Color Caps
With analog output, subtle differences in color can be recognized.
Detect Marks in Dusty Environment
Mark detection in dusty environment is possible using E3X-DA[]AT-S threshold compensating digital amplifier sensor, which counteracts dusty environment with the use of a reflective fiber head.
Detect and Count Translucent Capsules
Retro-reflective fiber unit detects and counts the number of translucent capsules. With the use of external input amplifier model, counting can be done.
Excellent Environment Resistance Ensures Precise Air Flow Control
The Pressure-difference Flowmeter of compact mono-block construction with a digital indicator monitors the air flow rate in real-time.
Detects Various Sheet Markings or Sheet Shifting (2)
Sheet markings or sheet shifting is detected with a variety of beam shapes.
Stringent Inspection of Black Liquid
The Vision Sensor achieves stringent inspection of black liquid, which is difficult to optically inspect, provided that inspection from the side is possible.
Detects the Positions of Holes Arranged in a Row
Even subtle differences in images are stably detected with a Sensitive Search.
Detects Level in Cleaning Solution
Detection of the fluid level by teaching the fluid surface as the edge position.
Detects the Number of IC Pins
Edge measurements enable stable counting. More than one area can be counted simultaneously.
Detects TAB Tape
Detection using the average brightness valve by teaching using the OK area.
Orientation of Electronic Components and Detects Incorrect Models
Measuring part of an electronic component's shape or patterns enables determining the orientation of electronic components and detecting incorrect models.
Count Pins
Identification of OK/NG by registering the OK article and using it as a basis (number of pins).
Lead Wire Inspection
Identification of OK/NG by checking lead wire width, using the OK lead width during teaching as a basis.
Detects Solder
Detection of solder by teaching the conforming soldering state (solder area).
Inspects Capacitor Sleeve Mounting
Inspects capacitor sleeve mounting with E2C-EDA High-Resolution Digital Proximity Sensor (Separate Amplifier Type).
Detects Presence of Gap between Electronic Parts
With thin fiber head, small gap of 25µm can be detected when light passes through. Use together with amplifier E3X-DA-S, sensing distance of 50 mm can be attained.
Detects Knots in a Thread
Using differential operation mode, any knots in wire/threads can be detected reliably.
Counts Connector Pins
With an ultra-small spot beam of 50µm diameter, detection of small items like connector pins can be done precisely irregardless of color and influence from background.
Measure Surface Flatness of Battery Caps
Surface flatness inspection of battery cap is possible by measuring heights at few points.
Detects Connection Pins
Detection of thin connector pins are possible with long sensing distance.
Alignment Inspection
This ultra-compact, thin-sleeve fiber unit enables reliable alignment inspection of small objects, such as electronic components.
Inspect and Measure Orientation Flats of Semiconductor Ingots
The parallelism at the orientation flat position is inspected by locating two Laser Smart Sensor Units with the Operation Unit so that the distance difference between the Sensor Units on the left- and right-hand sides will be zero.
Detects Bad Marks
The extra-narrow beam precisely detects minute bad marks.
Detects Glass Substrates
The reflective model stably detects a variety of glass substrates including wobbling substrates and those with various edge-processing conditions.
Easily Detects Liquid through Pipes (without Pipe Dimensional Restriction)
No pipe dimensional restrictions. Incorporates a Fluororesin-coated sensor that is not strongly influenced by foam or water drops.
Checks Wafer Notch
Detection of the notch shape by teaching using the notch.
Temperature Management for Heating Process
Non-contact temperature control for heating ovens. Measure the actual temperature of the process item without contact by using an ES1 Non-contact Temperature Sensor with an E5CN Temperature Controller. Non-contact measurement enables sanitary and accurate quality control.
Detects Exhaust Dust
Changes in the amount of passing dust are detected with a photoelectric sensor at 4 to 20 mA to monitor the release of dust into the atmosphere. An alarm is given if the set value is exceeded.
Monitors Interior Tank Pressure
Centralized monitoring is performed by converting and displaying the output of a pressure sensor as a pressure value on the K3HB-X, and transmitting the linear output data of the K3HB-X to the CPU.
Counts Workpieces
This application controls production of workpieces on conveyors.A Photoelectric Sensor detects workpieces on a conveyor. This application uses the pulse counting mode of a K3HB-C Up/Down Counting Pulse Indicator to display values. A BCD output that is sent to the PLC or large display unit enables production management.
Measures the Rotational (rpm) / Circumferential Speed Error (Absolute Error) between Two Conveyors
The rotational speed of conveyors is detected with a rotary encoder to measure and control the rotational (rpm) / circumferential speed error between two conveyors. In error ratio mode, the K3HB-R Rotary Pulse Indicator converts and displays the values for monitoring.
Detects Workpiece Warp
Workpiece warp of products, such as molded goods, is monitored with an attachment that transfers the action of a metal piece for detection by a linear proximity sensor and discriminated by the K3HB-X.
Measures the Thickness of a Decorative Laminate Sheet
The thickness of a decorative laminate sheet is detected with a displacement sensor. The result is judged and displayed on the Linear Sensor Indicator, and data is also sent to the PLC by BCD output for control.
Displays the Flow Rate of a Liquid
The flow rate of a liquid, such as oil or water, is displayed in a unit such as l/min or l/h for monitoring and control. A Liquid Level Sensor measures the outflow rate of water, oil, or other liquids from a pump. The K3HB-R Rotary Pulse Indicator converts and displays the momentary flow rate in l/min., l/h, or other units proportional to the input frequency.
Uses a Display Device for Inspection and Testing Devices
Downsizing is achieved when the K3GN is used as the display device for measurement, inspection, and testing devices.
Measures Temperature Changes in the Roller of a Copy Machine
Temperature changes are monitored by detecting the surface temperature of the roller with an infrared temperature sensor. This process can be used to inspect the characteristics of the roller.
Displays the Speed of Reflow Soldering and Washers
The speed of a reflow washing machine is detected with a proximity sensor, and converted and displayed by a Rotary Pulse Meter as m/min to control the speed of the reflow washing machine.
Displays the Speed of a Mixer or Agitator
The speed of a mixer or agitator is detected with a proximity sensor, and converted and displayed by the Rotary Pulse Meter. It converts and displays the rotation speed proportional to the input frequency.
Detects the Amount of Dust Expelled
The amount of expelled dust is detected, displayed, and monitored by detecting the amount of dust expelled with a photoelectric sensor, scaling the linear output, converting and displaying the result as digital data, and transmitting the data to the PLC as BCD data.
Detects Malfunctions in a Packaging Machine
The distance between the sealing portion of a bag fill and seal machine is detected with a linear proximity sensor, and measured with the Process Indicator. The machine can be stopped or an alarm output if a malfunction is detected.
Measures the Amount of Residual Liquid Gas
The amount of gas remaining is measured and displayed by detecting the amount of residual gas with a load cell.
Detects Notches and Eccentricity of Wafers
This application uses a Side-view Fiber Sensor with a homogenous area beam. ?This Sensor uses a change in the amount of interrupted lights caused by notches and eccentricity to enable detecting the position of notches and eccentricity of wafers. The amount of interrupted light by wafers is proportional in the 11-mm-wide detection area. The special optical components enable homogenous area beams in the detection area.
Detects and Measures the Curvature of Transparent Substrates
The 2D CMOS laser adopted precisely measures curvature / warping of transparent plastic substrates.
Detects the Peaks of Minute Rivets
Multiple measurements can be made within the line beam, so the peaks of rivets can be measured from a reference surface with good stability.
Detects Milk in Paper Cartons
The Capacitive Proximity Sensor detects the milk in opaque paper cartons.
Measures Co-planarity of Connector Pins
The 2D CMOS Laser stably detects angled connector pins.
Detection and Displacement of Minute Watch Components
The small spot achieves stringent inspection of very small gears used for watches
High-precision Chip Alignment Inspection
Inspection of the floating and inclination of chips on trays is possible. Each tray is measured once, which reduces inspection time.
Detect Fast-moving Registration Marks through Color Sensing
This Color-sensing Digital Fiber Sensor is used to detect registration marks. It achieves more-stable detection than a conventional sensor, which judges with the amount of reflected light against positional fluctuations in the workpieces in the production process.
Detects Double Glossy Metal Plates
Double glossy metal plates (e.g. lead frames) inserted together are detected by the signals of two sensors that are installed above and below the workpieces.
High Accuracy Non-contact Inspection of Thickness
High-accuracy measurement of sudden change of work is possible.
Inspects Missing Pages
These sensors compare the object being inspected with a registered pattern, enabling detection of solid-color (plain) objects.
Inspects the Length of Paper Tubes
By using an end plate and detecting from the side of the tube, detection is possible without being affected by paper splinters.
Counts Clear Plastic Cups in High Speed
The extra-narrow beam detects, and counts, the cup edges.
Distinguishes Ceramic Types
Using two Sensors, the changes in thickness can be measured with high stability, without being affected by fluctuations in the conveyor belt.
Inspects the Gap between the Dial Plate and Indicator Needle in Pressure Meter
The gap between the dial plate and indicator needle of the pressure meter can be measured through the transparent glass cover.
Counts Sheets of Paper
The number of sheets in a stack can be counted by detecting the level difference resulting from a single sheet.
Counts Cards
Bundles of cards, such as prepaid telephone cards, can be counted by detecting the card edges.
Inspects the Height of Corrugations in Cardboard Boxes
Crumpling can be detected by measuring the distance to the top of the corrugations in the inner layer of cardboard sheets as they move on a belt.
Sorts Packed Fruit Boxes by Grade
The boxes are sorted by distinguishing printed grade markings.
Detect Chips or Burrs in Components
Chips, burrs or light-colored dirt can be detected on curved or tapered components.
Inspects Component Shapes
The edges of measured objects captured by camera are detected to inspect the shape.
Detects the Level of Heat-medium Oils
The 200°C heat resistance of these Sensors enables use with extremely high-temperature liquids.
Detects Rubber Material Arrival
The arrival of the rubber material is confirmed so that it can be cut to fixed dimensions.
Inspects Spraying Coverage by Detecting the Spray Angle
The spray angle of a substance can be measured by detecting the amount of light that it blocks and the total time of the blocking.
Measures the Distance between Rollers
These Sensors enable the distance between metal rollers to be measured.
Distinguish the Front and Back Side of Nuts
The process of determining the front and back side of nuts as they leave a parts feeder can be automated. The regular reflections of the glossy front surface are deflected away, while the diffuse reflections of the back surface are detected.
Detects Screw Threads
The E32-D33 Thin Head Fiber Unit is able to determine whether threads have been cut into aluminum die cast workpieces. Because the light strikes at an angle, even extremely small threads can be accurately detected.
Detects Frayed Edges on Safety Belts
The ZX-L-N can detect the strands of frayed edges during the weaving process in safety belt production.
Inspects End-polished Components
The diffuse reflections of poorly polished surfaces make it possible to detect the difference between them and properly polished surfaces.
Manages Liquid Level for Lubricating Oils
The use of Fluororesin makes these Sensors ideal for the applications with a wide variety of oils.
Inspects High-speed Table Movement
A response frequency of 1kHz makes the E2S well suited to high-speed machine and device applications.
Inspects Tape Remaining in Tape Take-up Application
E32-T16W Area-detecting Fiber Unit inspects tape remaining in tape take-up application.
Counts Copy Machine Staples
The ultra-small spot of the ZX Series enables counting by precisely detecting the grooves between the staples.
Confirms Insertion of Shadow Masks into CRTs
Stable detection of even mesh-type shadow masks is achieved by using a line beam.
Passage Detection using Area Sensing Method
This application uses an Area-sensing Fiber Sensor. ? This Area-sensing Fiber Sensor eliminates the effect of the detected position of workpieces.
Counts Desiccant Packets
The perforations between desiccant packets are detected by the E32-T22S Narrow-view Fiber Unit.
Detect Individually Wrapped Candy
Stable detection of individually wrapped candy is possible without being affected by the color, tilt, or glossiness of the candy.
Detects Liquid Color
The E3MC RGB Color Sensors distinguish colors by detecting differences between them and registered reference colors. Stability can be further enhanced by placing a white panel in the background.
Checks Sealing Tape on Boxes of Pharmaceuticals
The difference in glossiness is used to detect sealing tape without being affected by the colors of patterns on the box.
Counts Glass Ampoules
The difference in glossiness is used to differentiate between the ampoules and the dividers between them, to ensure that only the ampoules are counted.
Accurately Inspects for Blurred Characters and Inspects Dates
Accurately inspect printed character conditions by checking the readout and expiry date shown on packaging.
Detects Noodles in Trays
Being able to differentiate between the tray separators and the tray bottoms enables stable detection of noodles without chattering. Water resistance of IP67 is provided to application in water rinse process in the food industry.
Inspects Food Packages
Wrinkles in package materials can be detected. As shown below, light diffused by wrinkles in the package is received if the emitter and receiver are installed at an angle to each other.
Detects Candies and Biscuits on Conveyor Belt
Detection of food such as candies or biscuits is even possible from overhead. Sensitivity adjustment is not required even if the color of the product changes.
Detect Inner Linings in Bottle Cap
The judgment output of the amplifier can be used to determine the number of cap inner linings.
Detects Cap Height
A check can be made for caps that are not straight by comparing the height of a cap left-to-right. The height and inclination of a cap can be determined by measuring and comparing two points.
Detects Lids on Milk Bottles
Stable detection is possible without being affected by the color of the lid, using ZX-L-N Smart Laser Sensor.
Detects Aluminum Caps
A special sensor for aluminum is used to detect any missing caps.
Detects Character Defects on Caps
Character defects and other defects such as dirts can also be detected with Machine Vision Sensor.
Detect Pinholes on Sealed Containers
Differences in the depression of the film on the top of the container can be used to detect pinholes.
Detect Black Shade on Sheets
Differences in mark density can be used to enable detection using an infrared light source and through-beam sensor.
Detect Loose Sheets
Small surface variations can be averaged out to enable stable detection via ZX-L-N Smart Laser Sensor.
Detects Coating on Paper or Metal
Differences in gloss can be used to detect coatings.
Detect Misalignment of Candy Wrapper Tapes
E3MC Color Sensor (LED Type) detects misaligned candy wrapper tapes.
Measures Dimensions of Electronic Components
The ZX-T has the ability to measure many small or thin components simultaneously.
Inspects Board Mold Height
The peak height of a board can be measured by using the Self Peak Mode.
Detects PCBs
Stable PCB detection is possible because the large spot is not affected by the color, or holes and notches on the board.
Detects the End of Chip Components Cases
The EE-SX77/87 features a compact size with a thickness of only 4.6 mm. They can be mounted densely in very limited spaces.
Classifies Capacitors
The diameter of each capacitor is used to determine its type.
Detects Parts Inside Metal Cases
The E32-DC200F detects reflected light from internal threads to check for missing components inside.
Inspects Connector Leads
The number and bending condition of leads are inspected.
Detects Connector Pins
When inspecting two levels of connector pins with an ordinary fiber unit, the lower set of connector pins caused an ON signal even when the upper level is missing. The E32-L25L Convergent Reflective Fiber Unit, however, is able to detect upper and lower sets separately.
Detect Lead Wire Defects in Components
The length of lead wires of electronic components can be confirmed.
Detects Full IC Sticks
E3T Miniature Photoelectric Sensor with Built-in Amplifier detects full IC sticks.
Detects Rises in Lead Frames
Easy detection, even in tight spaces, is possible with no sleeve bending.
Verifies IC Models, Lot Numbers, and Printed Characters
IC model numbers, lot numbers, and other information can be read and checked.
Detects Bent or Missing IC Pins
Three sensors are used to simultaneously detect defects (bent, missing etc.) of IC pins.
Discriminate Tablet Length
The resin tablets for different IC types with different length can be distinguished by the amplifier's monitor output.
Detect Lead Frames (Ferrous)
Teaching function of E2C-EDA Digital Proximity Sensor enables ferrous metal detection at the optimal distance.
Detect Lead Frames in Tight Space
IDE-view configuration of E32 Side-view Fiber Sensor allows use in spaces that are too small to mount ordinary through-beam sensors. Highly effective for space-saving installation.
Nitrogen Pressure Control
Minute pressure differences are used to monitor nitrogen gas flow.
Detect Levels of Corrosive Liquids
Sensitivity adjustment can prevent detection errors previously caused by foam in cleaning tanks containing soap. Application in corrosive liquids is also possible by using a Fluororesin-coated Sensor.
Detects Level in Heated Chemicals
The Fiber Unit uses Fluororesin so that chemical levels can be precisely and directly detected in cleaning tanks or chemical processing tanks.
Detects Chemical Level with Pipe Mounting
A minimum level difference of 4 mm can be detected in stages to control resist liquid levels.
Orientation Flat Alignment Inspection with a Fiber Unit
High-precision detection is possible using a narrow-view beam.
Detect Aluminum / Iron Objects in Environments with Aluminum Chips
This application uses a Proximity Sensor with a Built-in Amplifier with resistance to aluminum chips. ?If you mount this Sensor facing upward, it can detect presence of drills without being affected by aluminum chips.
Detects Cap Indentation to Determine Label Position
The measurement is unaffected by color or gloss, so eccentricity can also be absorbed.
Measures the Position of a Lowered Nozzle Tip
The tip is detected without making contact, so positioning is done without scratching or damaging the nozzle.
Measures the Distance to the Workpiece on Both X and Y Axes
Laser-type Smart Sensor measures the distance to the workpiece on both X and Y axes to detect position shifting. The compact Sensor Head and small beam spot make it possible to inspect thin workpieces.
Detect Notches of Transparent Glass Wafers
Laser-type CCD Smart Sensor accurately detects the notch positions of transparent glass wafers when used in transparent object detection mode.
Detects Positioning of Infusion Bag Caps
This application uses a Spot-type Laser Photoelectric Sensor. ?This Spot-type Laser Sensor detects minute positioning of infusion bag caps.
Inspects the Offset Positioning of Pressed Workpieces
With a long sensing distance of 100 mm, small position gap of the press work can be precisely detected.
Performs Position Inspection on Robot Hands
When precision positioning of robot hand is necessary, small beam spot laser displacement smart sensor is recommended.
Check Cutting Position on External Wall Material
This laser spot beam sensor accurately detects cutting spot so that precise cutting position of external wall material can be attained.
Check Misaligned Packaging Wrap Label
Check for misalignment of packaging wrap label in the vertical position by checking the edge position.
Detects Inner Aluminum Foil Locations
The linear proximity model stringently detects inner aluminum foil locations that are not visible from the surface of the capacitors.
Displays the Position of Pressure Rollers and Detecting Position Errors
The position of the rollers is displayed and position errors are detected during operation using a device for moving the position of the rollers according to the panel pressure of the panel. A forced zero input can be used to easily return to the reference setting. (The forced zero control can be keyed in using the keys on the front panel of the Process Indicator.)
Detects Aluminum Evaporation in a Vacuum Deposition Process
The amount of aluminum evaporation is detected using the reflectance amount detected by a photoelectric sensor. The value is converted and displayed as a percentage by scaling the linear output.
Positioning at the Welding Site
These Sensors are designed for use in places subject to spattering.
Detects Weld Locations on Metal Pipes
Because teaching without a workpiece is possible for the E3X-DA-S, the sensitivity for detecting weld locations can be set without having to stop the workpiece.
Positioning of the Welding Point on Ring Gears
The compact size makes it possible for these Sensors to be mounted on welding machines in small spaces.
Rotational Positioning of Batteries
Target patterns can be quickly and easily registered to inspect marks and positioning, or to prevent the inclusion of incorrect product types.
Proper Object Angle Alignment during Packing
The angle of objects can be aligned properly during packing by detecting minute color differences and marks.
Detects Position of Glass Bottle Hollows
The 2- to 3-mm hollow on the bottom of bottles can be used for positioning and other operations.
Measures Liquid Crystal Position
The positions of liquid crystal reference marks can be measured using two cameras to determine the overall position. Stable measurement is achieved at low cost for moving objects.
High-precision Positioning of Transparent LCD Substrates
The Ultrasonic Displacement Sensor achieves stable positioning of transparent LCD substrates from a considerable distance.
Terminal Picking
The position and orientation of workpieces can be confirmed to enable accurate grasping with a robot arm and packing into cases.
Detects Wafer Cassette Racks
Mounting a Slit and Adjustment Unit enable restricting the light for stable detection even when there is inconsistency in the cassette resin or individual units.
Confirms Wafer Carrier Mounting
The mounting of wafer carriers can be confirmed.
Confirms Wafer Cassette Mounting
This slim sensor is only 3.5mm thick so that it can be mounted in small gaps and spaces.
Wafer Positioning and High-speed Detection
Wafer positioning and high-speed detection using E6L Easy Scale Linear Encoder.
Positioning for Wafer Cutting Machines
This sturdy rotary encoder enables positioning at a consistent cutting pitch when cutting silicon wafers.
Pulse Response for Long-distance Detection of Cylinder Blocks
This application uses a Pulse-response Proximity Sensor with a Built-in Amplifier, which enables a long distance detection for aluminum workpieces.
Ensures Precise Detection of the Retaining Bottles on the Line
The Ultrasonic Dispalcement Sensor can detect the workpiece in a wide view from the above, without being affected by one or two bottles but detect all the bottles that the sensor covers.
Detect Glass in Wet Cleaning Process
This application uses a Fiber Sensor that resists cleaning liquids and a Fiber Amplifier that eliminates the effects of drops of water. ?This Fiber Sensor detects passage of glass substrates in the cleaning process of glass substrates. This Sensor resists cleaning liquids and does not need mechanical adjustments to enable easy positioning adjustments with glass in a wide detection area. A special Fiber Sensor that mounts the new 'Tough Mode' eliminating interference from water droplets enables stable detection that resists the spray of liquids.
Detect Hot-melt Adhesive Coating with Area Sensing Fiber Unit
This Area-sensing Fiber Sensor detects hot-melt adhesive coatings
Stably Detect Blurred Printed Character on Cardboard
Smart Sensor with Ultra-High-Speed Color CCD Camera stably detects blurred printed character on cardboard. Adopting automatic color filter, it provides stable detection by allowing the Sensor to process images, even for the mark with low contrast.
Detects the Height of a Liquid in a Pipe
This application uses a pipe-mounting Capacitive Liquid-level Sensor that is not affected by the color of the pipe, the color of the liquid, or foams on the liquid surface. ?This Sensor allows you to detect chemical liquid levels without being affected by the color of the pipe, the color of the liquid or foams on the liquid surface. Two models are available, one for pipes with a diameter from 8 to 11 mm and one for pipes with a diameter from 12 to 26 mm.
Stably Detects Falling Products
Amplifier with a differentiation function and wide-area detection area head detects falling products stably.Differential operation makes it possible to detect workpieces by ignoring changes in light intensity over time.
Detect Non-woven Textiles in Dusty Environment
This Digital Photoelectric Sensor with ATC detects non-woven textiles in an area filled with airborne paper dust. ATC automatically corrects the threshold of the Sensor to match changes in the light intensity caused by dirt.
Detect Broken Drill Bit
This application uses a Laser Sensor with a Built-in Amplifier and a long detection distance. ?This Laser Photoelectric Sensor has a long detection distance and is ideal for drills in environments with sprayed oil mist.
Detects Broken Drills in Places where Chemicals are Sprayed
The Fluororesin Photoelectric Sensor with a compact built-in amplifier ensures detection in places where oil or chemicals are sprayed.
Detect Metal Cassettes in Medical Fluid Tank
Metal cassette detection in medical fluid tank is possible using E2FQ Fluororesin Proximity Sensor. The E2FQ with an all fluororesin casing enables detection in places where medical fluid is sprayed.
Detects Cans Under High-temperature Environment or Chemical Cleaning Line
The SUS316L body withstands cleaning agents at temperatures up to 120°C and features high resistance to corrosion, allowing direct installation onto lines that require cleaning.
Precisely Detects and Counts PET Bottles
The stainless-steel housing is ideal for use in the food processing industry, because it has excellent corrosion resistance to detergents and disinfectants. With IP69K degree of protection, it is able to withstand high-temperature, high-pressure water. Optimum for Food Industry that requires high level of hygiene.
Precisely Detect Mold Mating
Mold mating detection using heat-resistant Digital Proximity Sensor. Inspection of mating of models in molding machines is possible at temperature as high as 200°C.
Precisely Detects Wafers
The E32-T61 features a temperature-resistant fiber for stable wafer detection at high temperature of 300°C or higher.
Detects Protrusion of Large Cargo with a 60-m Sensing Distance
This application uses a Laser-type Photoelectric Sensor with a Built-in Amplifier. ?The E3Z Laser Photoelectric Sensor with a 60-m sensing distance detects protrusion of large cargo.
Detects Electronic Components with Rising Position
Electronic component in standing position, which can cause misfeeds and downtime of production line, can be detected by measuring height differences.
Detect Small Amount of Silver Paste
This application uses a Spot-type Photoelectric Sensor with Separate Amplifier. ?You can remotely detect the presence of minute amounts of silver paste on lead frames.
Overhead Detection of Liquid in Tank
The Ultrasonic Displacement Sensor stably detects all types of liquid to meet stringent inspection requirements, provided that inspection from the upper side of the tank is possible.
Detects Transparent Bottles of Any Color without Adjustment
Using ultrasound enables stable detection that is not affected by the color of the bottles.
Sensing Distance of 6 m Accurately Detects Liquid Surfaces
Accurate detection of liquid surfaces at long distances is enabled by using the E4PA-N Reflective Ultrasonic Displacement Sensor with a sensing distance of 6 m.
Detects Even Slight Difference in Liquid Level Through Pipe
This application uses a pipe-mounting Capacitive Liquid-level Sensor that is not affected by the color of the pipe, the color of the liquid, or foams on the liquid surface. ?This Sensor allows you to detect chemical liquid levels without being affected by the color of the pipe, the color of the liquid or foams on the liquid surface. Two models are available, one for pipes with a diameter from 8 to 11 mm and one for pipes with a diameter from 12 to 26 mm.
Detect Liquid Level of a Tank
This application uses a Fiber Sensor. Install this Diffuse-reflective Fiber Sensor at the glass window on the side of a tank to detect the presence of liquid.
Precisely Detects the Presence of Hot-melt Adhesive on Individual Packaging Boxes
The condition in which hot-melt adhesive is present is registered in the Vision Sensor to enable accurately detecting the presence or absence of hot-melt adhesive.
Detect Adhesive Application with Small Spot Fiber
This Small Spot Fiber Sensor detects shortage of adhesives during adhesive application.
Detects Wafers in Chemical Washing Tubs
The capacitive model ensures detection of not only silicon wafers but also glass wafers.
Detects Liquid Level of Solder Baths
The Smart Sensor (Linear Proximity Model), which is highly environment resistant (up to 200°C), carefully detects liquid levels in high-temperature solder baths, provided that close-range inspection from the upper side of the tank is possible.
Detects Cars in Parking Lots
The E3G-R13 (retroreflective model), with a rated sensing distance of 10 m, enables long-distance detection of cars in multi-storey parking lots.
Precisely Detects Glass with Sensing Distance of 7 m
This application uses a Retroreflective Sensor with long detection distance. ?This Sensor remotely detects the presence of glass substrates with a sensing distance of 7 m. Mounting a Beam Unit enables the use of line and area beams.
Detect Position of Transparent LCD Substrates
This application uses a thin Convergent-reflective Fiber Sensor with a long-distance detection. The two fiber heads embedded into the robot hand and a single amplifier achieve stable detection of the position of transparent LCD substrates.
Detect Small-diameter Pins
This application uses a Spot-type Laser Photoelectric Sensor to detect minute objects. The minute spot laser beam with maximum diameter of 1 mm accurately detects small-diameter pins, at a sensing distance as long as 1 m.
Detect Passage of Minute Chips
This application uses an area-detecting Fiber Unit to detect passage of minute chips that may drop in various different positions. The passing of chip components is detected even if the passage location varies within a width of 11 mm, regardless of whether they are metallic or non-metallic.
Measure the Main Pressure of Air Presses
This application uses a Digital Pressure Sensor with LED display that controls the main pressure of air presses.
Detects Up to Four Types of Tray Colors
A single E3MC unit with four outputs detects the differences of up to four colors.
Differentiate Types of Candy or Cookies
This application uses a Twin-output Fiber Sensor. This Reflective Fiber Sensor detects the color difference of two types of candies or cookies.
Detects Remaining Sheets
By using ultrasonic wave, even though workpiece is transparent or with color pattern, detection with stability is not affected.
Inspect Bottom Dead Center on Presses
Bottom dead center of press machine with small-sized head in high accuracy inspection is possible.
Detects Casting Molds Using E32-T14 Fiber Sensor
Powerful beam reduces influence of dust and dirt. Long sensing distance enables use in large-scale installations.
Ensures Long-distance Detection of Adhesive and Sealing Material Application
A small spot with a sensing distance as long as 1 m stably detect adhesives or sealing materials.
Precisely Detects Height Difference of Miniature Watch Compon
Allows close mounting in narrow spaces, thus carefully detecting the height differences of miniature built-in watch components.
Detects the Sides of Large Tiles
Greatly enhanced beam visibility for easier optical axis adjustment of sensors. The optical design maximizes the linear propagation of laser beams. Red laser beams (class 1) can be precisely aligned on the targeted position. The through-beam sensing distance of 60 m provides sufficient allowance, enabling Through-beam Models to be used with reliability even in dusty environments. With Through-beam Models, an emission interruption function is also available by request. This function is ideal for preventive maintenance applications.
Detects the Presence of Strip Materials
With its super-sharp beam spot of 2 mm diameter, precise detection of strip material can be attained.
Precisely Detects Broken Drills
With a rated sensing distance as long as 30 m and an IP67G enclosure rating, the E3S-CT11 Metal Case Sensor enables long-distance detection of broken drills in places where oil is sprayed.
Ensures Precise Wide-area Detection of Scratches on Ceramic Application Sheets
By arranging four 30-mm-wide Area-detecting Fiber Units and using a differential function, scratches in a 120-mm-wide sheet can be precisely detected.
Detect Presence of Different Adhesive Labels
Check for different adhesive labels by teaching the mark and measuring the blank area.
Detects Transparent Bottles
By adopting the new optimum optical system mechanism, detection of transparent PET bottles can be realized. Long-distance type model can detect many bottles in a carton.
Detects Bottle Caps in Humid Environment
This resin case model photoelectric sensor ensures stable detection of bottle caps in humid environment.
Detects Presence of Sheet Materials
Precisely eliminate background influences. Differential travel of 2% maximum is the best in its class.
Detects Parts Inside (Translucent) Containers
The E32-T11L features a high-power, long-distance fiber for stable detection of parts inside (translucent) containers.
Detects Liquid in Tube from Side
If the pipe is transparent with comparatively a small diameter and inspection from the side is possible, the liquid in the pipe can be detected by light refraction. In that case, the E39-F1 Long-distance Lens Unit is mounted to the emitter only, and high power is obtained by stopping down the beam.
Detects Meandering of Clear Packing Film
The line beam of the through-beam laser sensor stably detects the edges and meandering of clear packing film.
Detects Various Types of Clear Film
Ultrasonic detection stably detects thin, clear film that is not detectable with photoelectric sensors.
Detects Displacement of IC Chips on Tray
With laser point beam, small displacement can be detected.
Maps LCD Glass
Stable detection is possible with no influence from a glossy background frame. The spot diameter for BGS models is 0.5 mm (typical example at 300 mm). Combined with an hysteresis of only 5%, even minute differences can be detected. Models with a response time of 0.5 ms (E3Z-LL[]3/[]8) are available as standard models for fast-moving objects.
Detects Chip Components on Tape
Long sensing distance of 300 mm (white paper) allows flexibility in positioning Sensors.
Inspects Overlapped Condenser
ZX-L-N sensor is small size, it can detect tiny condensers with high performance and stable.
Detects Workpieces in Cleaning Processes
Fluoroplastic-coated, long-distance fiber unit is ideal for applications requiring resistance to chemicals.
Detect Normal Nitrogen Injection Precisely
The Minute Pressure Sensor of mono-block construction with digital display is used to check the normal output of nitrogen gas.
Precisely Detects Transparent Glass Substrates
This space-saving sensor used under dry environments stably detects the bottoms of glass substrates while they are transferred on a conveyor.
Detects Glass Substrates in Vacuum Chamber
This application uses a Photoelectric Sensor to detect transparent objects, including glass wafers or transparent glasses. ?Through a view port, this Sensor can detect glass wafers that travel in a vacuum chamber. We used optical and circuit technology that detect minute signal differences of transparent glass.
Detect Wafers in Vacuum Conveyor System
This application uses a Vacuum Fiber Sensor that can be used under a high vacuum. ?This Sensor can be used under a 10-5Pa vacuum. The Sensor has 1-channel and 4-channel flange system that you can combine according to the number of Sensors.
Detects Wafers in Chemical Washing Process
This application uses a chemical-resistant Fiber Sensor that can be used in a chemical washing processes. This Fiber Sensor can detect passage of wafers in a chemical washing process. It uses fluororesin, which provides resistance to chemicals. And you can install it in a tight space because of the thin side-view design.
Detect LCD Substrates in Oven using Heat Resistant Fiber
This application uses a Through-beam Fiber Sensor that is heat-resistant to 200°C.Install heat-resistant Through-beam Fiber Sensor with a convergent-reflective arrangement. This setting is hardly affected by the background, which enables precisely detecting the presence of LCD substrates.
Detect IC Chips with 200°C Resistant Through-beam Fiber
This application uses a Flexible Through-beam Fiber Sensor. This Sensor enables detecting passage of IC chips at temperatures up to 200°C. The heat-resistant and flexible fluororesin case solves the weak points of conventional heat-resistant fibers, thus achieving a bending radius of 10 mm.
Precisely Detects Automobiles with Sensing Distance of 20 m
The E32-T17L, with a rated sensing distance of 20 m, enables precise long distance detection of automobiles during automotive coating process.
Detects Transparent LCD Substrate Mapping
This application uses a Line-beam Laser Photoelectric Sensor. This Line-beam Diffuse-reflective Laser Sensor is ideal for detecting the edges of transparent LCD substrates. You can install a Laser Photoelectric Sensor away from the workpieces.
Small-spot Fiber Precisely Detects Minute Chips
The fiber sensor with an added lens unit achieves a small spot beam with a variable diameter ranging from 0.1 to 0.6 mm.
Detect Presence of Minute Components
This application uses a space-saving Flat View Fiber Sensors to detect presence of minute components and precisely inspect their front and back surfaces. You can connect two Fiber Sensors with a two-channel Fiber Amplifier, thus saving both energy and space.
Low Cost Chemical Level Control Through Transparent Pipes
This application uses a Pipe-mounting Liquid Level Photomicrosensor with built-in amplifier that achieves detection through pipes. This Sensor uses difference in the refractive index between liquid and air in pipes to enable detecting the presence of liquid in the pipes.
Detects Thin Clear Film
This application uses a Retroreflective Photoelectric Sensor for clear films. Install a Sensor and a Reflector between which a clear film is placed. This Sensor enables stable detection of clear films with optical and circuit technology that detects slight signal differences caused by clear films.
Detect Gas Flow Meter Balls
The red transparent ball in a gas flow meters can be detected with high stability by the Blue LED Digital Fiber Amplifier.
Warning Alarms for Cranes
The direction of crane movement can be distinguished, and the crane's entry into danger zones can be detected.
Detects Cardboard Boxes
A diffuse reflective sensor can be used to detect cardboard boxes from a distance of up to 1 m. A retro reflective sensor enables detection from up to 4 m. The use of the Cover Bracket provides even greater durability.
Detects Casting Molds
Even in a dusty environment, 1-m² sand molds can be detected diagonally from a distance.
Detects Black Tires at Long Distance
These sensors are minimally affected by backgrounds, enabling them to accurately detect black objects, such as tires, at a distance.
Detects Distant Glossy Metal Objects through Narrow Spaces
This narrow beam enables detection as far as 200 mm away, through an opening as small as 1 mm.
Determines Proper Amount of Adhesive during Packing Box Assembly
The amount of adhesive being dispensed can be monitored by detecting the amount of light blocked by the adhesive as it leaves the nozzle.
Confirms Robot Arm Chucks
These Proximity Sensors can be mounted on moving objects, such as robot arms for chucking applications.
Confirms Close Die Contact
Dies in molding machines can be checked to ensure close contact even in temperature of 200°C.
Detects Oil Drops
The E32-D12F can detect light reflected from oil drops. The Fluororesin-coated fiber can also be safely used in an environment where oil is likely to be spattered.
Detects Aluminum Components
The slot-type head configuration of these Aluminum-detecting Proximity Sensors can be mounted in small spaces for use in confirming the seating of workpieces.
Inspects Engine Blocks
The E3Z-T61, with a rated sensing distance of 15m, enables precise long-distance detection of engine blocks.
Accurate Chip Component Pickup Inspection
Connect up to four miniature sensors to one 4-channel Controller to enable the pressure management capacity of four controllers at one location.
Confirms the Application of Adhesive/Grease onto Components
The small 2-mm-diameter spot can detect even minute amount of adhesive or grease applied to precision components.
Detects Adhesive Application on Bags of Chemicals
The application of adhesive is detected by using two sensors to measure the thickness of the bag.
Detects the Powdered Chemicals Passing through a Transparent Tube
Powdered chemicals passing within a specific area can be detected, and adjustment can be made by teaching. Teaching can be done without a workpiece.
Detect Missing Characters in Dates
The ZFV Smart Sensors are able to determine when characters are missing in printed dates.
Inspects the Size and Presence of Confectionery in Trays
The ZX-L-N Smart Sensor inspects the size of confectionery with a precision of ±1mm. Because the color of the objects being inspected is not consistent, a reflective photoelectric sensor cannot provide stable inspection.
Inspect the Content of Opaque Packaging Materials
The E3X-DA-S Long-distance Sensor enables inspection on content of opaque packaging materials.
Detects Liquid in Paper Boxes
A powerful light beam of E3Z Photoelectric Sensor can penetrate paper boxes to detect the contents.
Detect Transparent Bottles
A retroreflective sensor that saves both space and wiring can achieve stable detection of transparent PET bottles with gaps between the bottles as small as 5 mm.
Detects Clear Label on Support Paper
Even clear labels at close intervals on support paper can be positioned without contact.
Detects Labels
Detection is possible with a through-beam fiber sensor if the backing material is translucent. The light beam is interrupted when there is a label and received when there is no label.
Detects Shrink Tubes
Stable detection is possible even for clear shrink tubes.
Detects Missing Chips on Embossed Tape
Adding a Lens Unit to a fiber sensor enables detection of very small workpieces at a detection distance of 17 mm with a 0.2-mm-diameter spot.
Inspects for Defects on Chip Capacitors
Inspection is possible for mold defects, missing terminals and other chip capacitor defects.
Detects Chip Components on the Tapes of Taping Machines
The E3T is capable of detecting objects as small as 0.15 mm. Detection remains stable, with minimal effect from backgrounds or surrounding metals.
Detects Chips on TAB Films
Chips are detected in an area of 11 mm.
Detects Lead Frames (Aluminum/Copper)
Compact, flat sensor head can be mounted in small spaces for detecting non-ferrous metals, such as copper and aluminum.
Detects Silver Paste
The ultra-small spot with a 2-mm diameter detects even minute amounts of silver paste on lead frames.
Detects Workpieces by Robot Hand
An allowable bending radius of 4mm enables the E32-D11/D21 to withstand repeated bending, making it ideally applicable to moving parts subject to frequent bending.
Maps Wafers with a Through-beam Laser Sensor
The ZX-L-N even detects transparent objects and glossy wafers.
Maps Wafers with a Through-beam Side-view Sensor
The narrow beam enables detecting single wafers, even wafers with mirror surfaces.
Detect Glass Plate in a Baking Ovens
An L-shaped side-view sensor that requires little space and provides 200°C heat resistance is used. The detection distance of 1,300 mm (for E3X-DA-N Standard Mode) is more than sufficient to detect even large glass plates.
Ideal for Improving or Upgrading Facilities for Automotive Parts
The internal setting banks meet upgrading needs for increases in the number of molds. The E5CN-H at 48 x 48 mm is compact and yet provides up to eight banks to register settings. You can change the bank with event inputs, communications, or the simple program function. Use it to meet your device upgrade needs.
Ideal for Increasing the Control Performance of Industrial Hot Air Blowers
This Temperature Controller provides the performance that is needed for industrial hot air blowers and it also enables downsizing. Displays are possible below the decimal point even for temperatures above 1,000°C. You can switch between three colors to clearly show the current status.
Solves Problems in Electronic Component Assembly
This Temperature Controller helps improve the response to external disturbance that results from inconsistencies in the air from air heaters to increase control performance. High-speed sampling at 60 ms provides high-speed response and robust tuning. This improves the response to external disturbance, such as inconsistencies from air heaters.
Low-cost Position-proportional Control for Brewing Equipment
You can use the E5EN-H Temperature Controller with position-proportional control to achieve low-cost position-proportional control. Control of control valves is possible with the E5EN-H Temperature Controller with position-proportional control. This enables a low-cost position-proportional control system.
Improves Control Performance in Hydraulic Control of Metal Processing Machines and Other Equipment
The PID automatic selection function of the E5EN-H improves control performance to achieve high-precision control. High-speed response of 60 ms is possible. Robust tuning calculates the ideal PID control constants. The PID automatic selection function automatically switches PID control for temperature controls that are set in advance. This greatly improves temperature control performance.
Ideal for High-precision Testing Equipment for Automotive Parts
The E5CN-H provides a compact size of 48 x 48 mm and measurement/control to five digits and 1/100°C. A 24-bit AD converter improves measurement precision. An output resolution of 10,000 enables high-precision control. Displays to 1/100°C are also possible with thermocouples.
Low-cost Program Control of Industrial Furnaces
One E5EN-H/E5AN-H Temperature Controller can perform simple program control for 16 steps. You can start programs with event inputs. You can monitor the current bank number or remaining soak time on the three displays.
Easy Temperature Setting with Infrared Communications Port on Front Panel
You can easily set temperatures for the E5EN-H/E5AN-H with the CX-Thermo Support Software and the infrared communications port on the front of the E5EN-H/E5AN-H. You can connect a E58-CIFIR USB-Infrared Adapter Cable between the USB port on a computer and the infrared peripheral port on the front of the E5EN-H/E5AN-H. This allows you to easily set the temperature from the front panel without the loss of the dustproof, drip-proof structure.
Improvement in Control Performance for Heating and Cooling of Molding Machines
Independent PID constant settings for heating control and cooling control. The EJ1 Modular Temperature Controller performs control using independent PID constants for the heating and cooling control systems. It can also perform stable control for control systems that have different response characteristics for heating and cooling.
Monitoring Temperature of Continuous Firing of Electronic Components
Ideal for temperature monitoring of multi-point heaters. With an EJ1 Modular Temperature Controller, it is easy to perform integrated processing for temperature monitoring and high-precision control with multi-point heaters in simple, waste-free systems.
Stable Control of Water Supply and Drainage for Water Tanks
Stable reading of rapid input changes, such as surface waves in water tanks. ON/OFF control of water-supply and drainage pumps is performed by measuring the water level in the tank using an ultrasonic displacement sensor. Fluctuations in the present value caused by surface waves can be smoothed by using the input digital filter.
Oven Temperature Equalization for PCB Mounting Process
Uniform oven temperature by using linked Temperature Controllers. Use an external analog signal (4 to 20 mA) as the set point (SP). Uniform oven temperature with a total of three Temperature Controllers. Use the Temperature Controller's transfer output for zone control in electric ovens.
Automatic Fine-tuning of Heating Temperatures When Mounting PCB Components
Achieve high-precision temperature control in conveyor ovens by adding a temperature sensor near the PCB. Cascade control is performed with a High-speed, High-precision Digital Temperature Controller with multiple outputs.
Detects Surface Wobbling of Disk Motors
The mirror reflection model inspects surface wobbling in mirror-finish objects at a resolution as high as 0.25 µm at the edge of the table, where the change is greatest.
Detects Heater or Sensor Errors in Control Loops during Heating Process
Use a Power Controller to control the temperature of the electric furnace. Heater burnout could not be detected based on current output, but the loop break alarm function will detect it. The LBA (loop break alarm) turns the alarm signal ON by assuming the occurrence of a control loop failure if there is no input change with the control output set to the highest or lowest value. Therefore, this function can be used to detect control loop errors.
Time-sequence Temperature Management for Constant-temperature Tanks
Heating pattern control for constant-temperature tanks. Time-sequence temperature control for constant-temperature tanks is automatically controlled by the internal program.
Sand Coloring Ratio Control
Prevent waste by controlling sand and coloring liquid's ratio to maintain a constant sand-to-dye ratio.
Stable Temperature Data Collection during Automotive Coating Process
Using E5AR cascade control function to achieve stable internal temperature during automotive coating process.
Prevents Rapid Heating for Ceramic Firing Process
The SP (set point) ramp function of the E5CN Temperature Controller prevents rapid heating of the workpiece and enables smooth temperature increase.
Monitors Temperature Errors in Greenhouses
Visibility when an error occurs is improved by setting the parameters to change the color of the present value on the Temperature Controller.
Redundancy in Temperature Control and Temperature Monitoring
Low-cost safety measures using temperature control redundancy in the frying process. Low-cost redundant temperature control monitoring for fryers is performed by using two Temperature Controllers.
Higher Efficiency for Bread Baking Process
Easy switching of temperature settings by bread type. Temperature settings can be registered for up to eight banks by using the bank function of the E5EN-H Temperature Controller. Easily perform external temperature settings according to the type of bread.
Detects Cream Filling
An ES1 Infrared Thermosensor is used to measure the temperature because the cream filling is still warm following injection. The Infrared Thermosensor is used for hygiene.
Automated Temperature Adjustments for Furnace
Apply E5EK Digital Controllers for cascade control and apply object temperature sensing for heater temperature control. With two thermo sensors, fine temperature between furnace and actual object can be adjusted.
Vending Machine Control
Built-in controller for vending machines. ZEN Programmable Relay is also ideal to replace PLC to save space and cost.
Production Line Conveyor Shift Unit
Used as a conveyor shift unit. A sensor detects when a product has arrived, and inputs this to ZEN. ZEN then moves two stoppers and shifts the product to another conveyor.
Automatic Flow Meter Maintenance
Used with intermittent purge-type flow meters. Automates maintenance by periodically cleaning and applying reverse-pressure purging to prevent sensor blockage. • Replacement for relay + timer. • Relay + timer requires too much space. • ZEN is both low-priced and easy to program.
Automated Ventilation System for Restaurants
Detects kitchen smoke, and automatically controls the frequency and power of the ventilation fan in accordance with the temperature. Settings can be changed after wiring. For use in place of relay logic (to reduce maintenance by eliminating relays). It is also ideal for kitchen that works without PLC.
Water Treatment Device
ZEN is used as the controller for water treatment device.
Opens/Closes Swimming Pool Cover Automatically
Automatically opens and closes the swimming pool cover to prevent children from entering and leaves from falling into the pool, while also helping to keep the pool temperature constant.
Elevator and Escalator Operation Control
Problem: Dedicated controller (manufactured in-house) and controller for inverter interface. Replace with Programmable Logic Relay. One ZEN Programmable Relay can replace 10 relays, greatly simplify wiring.
ON/OFF Control of Street Lights
ZEN V2 Programmable Relay serves as an economical time switch, which turns ON the street lights along roads or in parks only at night.
Industrial Furnace Temperature Monitoring and Control
Using the multi-output capacity of the Temperature Indicator, the temperature of an industrial furnace is monitored and controlled according to the interior temperature of the furnace by detecting the interior temperature of the furnace with a thermocouple.
Monitors the Roller Bearing Temperature of a Power Generator or Motor
The temperature of the roller bearing is detected by a temperature sensor and displayed on the Temperature Indicator. The output is transmitted to a computer via a communications link to monitor overheating.
Monitors Motor Load Currents
Excessive loads on the motor are monitored by monitoring the current to the motor. Use the startup compensation timer to prevent output due to the inrush current created when starting the motor.
Monitors the Exhaust Temperature of a Marine Engine
The temperature of the exhaust dust of an engine is detected with a thermocouple to monitor the exhaust temperature with respect to the set temperature.
Monitors the Concentration of a Liquid Mixture
The concentration of a liquid mixture is monitored by detecting the flow rates of the two liquids, converting the mixture ratio for the two liquids in the Concentration Mode, and displaying the results for monitoring purpose. Also, a recorder records the data.
Determine Coating Position during Coating Process
The coating position for applying a resin coat to the handles of a knifes, which are held by a robot arm, is controlled in 32 steps. Four outputs and bank condition calculations are performed by the PLC.
Molding Machine Temperature Monitoring with Alarm Output
The temperature of a molding machine is displayed and monitored, and an alarm is output if a temperature error occurs.
Controls the Preset Cutter of a Butter Manufacturing Machine
This application cuts continuous Butter that moves on a conveyor into a specified size. ? A Rotary Encoder detects the feed rate on the conveyor. A K3HB-C Up/Down Counting Pulse Indicator converts and displays the Butter length proportional to the input frequency. The system controls an output with a preset value, and the contacts of the H3CR Timer cut the Butter to size.
Weighing Control / Mixing Control
The output of the load cell of the weighing hopper is measured and control outputs are transferred to the PLC for hopper control.
Dioxin Countermeasure for Incinerators
Problem: It has become necessary to keep the combustion temperature at 800ºC or higher to cope with the problem of dioxin from the incinerator. Use a Temperature Controller to keep the temperature constantly at 800ºC or above. When the temperature exceeds a preset level, turn OFF the burner.
Two-color Display
Problem: Red displays cannot be used on a film production line because the film is sensitive to red light. Change the Present Value (PV) display to green in the display color function of E5CN. Cover other unnecessary display area.
Turbine Power Generation Control
Use the E5AR to solve the problem with less expense in comparison with a PLC (with an AD function).
Control Switching for SP and Heating/Cooling
Do the SP switching for the Temperature Controller and the control switching by external input. Do the forward/reverse operation switching via a PLC.
Cooling Water Control for a Spindle Motor
Problem: The client is using a spindle motor, but unless the cooling water is linked to indoor temperature, condensation occurs, leading to motor damage and lost work time. Use the remote SP for heating and cooling control (linked to indoor temperature) and high-speed control to accurately synchronize with indoor temperature. Condensation will not occur, preventing damage to the motor.
Flow Control of Diaphragm Pump
Use the high-speed sampling and high-speed response features of the E5AR to prevent color spraying irregularities.
Discharge Control of Mono Pump at Constant Quantity
Connect a flow meter to the E5ER for high-speed sampling to stabilize the discharge quantity.
Tension Control
Problem: The client requires two inputs and two outputs. Using a standard E5AR unit with two inputs.
Uniform Control of Metallic Mold Temperature
Use the proportional control function of the E5AR to change the ratio of output for uniformed temperature control.
Multiple Set Points Using Bank Selection Function
Problem: Temperature need to be repeated between 200°C and 500ºC. Using bank selection function in E5AR to switch between two temperature.
Uses a Master Temperature Controller to Change Set Value of Other Temperature Controllers
Use E5AR with analog output range of 4 to 20 mA to assign values using remote SP. Settings on multiple Temperature Controllers to change when the Master Temperature Controller set values changes is possible.
Heater for an Exhaust Gas Analyzer
Problem: Using our existing 4 to 20mA transmission output to send signals about 40 to 50 meters to the measurement room without having to pay extremely high cable costs. Furthermore, a large number of Temperature Controllers per device (about 25, including 12 for control and 12 for alarms) are required, and space constraint in the heating device control panel. Change the present 4- to 20-mA transmission output to RS-485 for a major education in wiring and labor. Use E5ZN Modular Temperature Controllers to save space.
Shortens Temperature Stabilization Time
When the crucible temperature (sensor 1) is used for control, the crucible itself reaches the set temperature, but the liquid does not. By using cascade control, if sensor 2 and 3 are used for control, the response is slow and sufficient control is sufficient. Bottom line: The liquid temperature needs to reach the set temperature as quick as possible.
Production Control of Belt Fabrication using Bank Selection
Use the event input of the E5AR to change the SP according to the type of belt.
Air Conditioning Temperature Control
The outlet temperature is under cascade control.
Separates Temperature Controllers for Control and Warning
Problem: During the continuous heating process, failure will result in major damage to machine. Need a redundant system or other safety measure. Create a system with two Temperature Controllers: One for warnings, and the other for control. Damage is also minimized if an error occurs in one of the Temperature Controllers.
Coating Temperature Control
Problem: Unevenness in coating due to uneven temperature. Difficulty in measuring temperature of roller. Use three Non-contact Temperature Sensors to monitor temperature at each point. A warning will be output if the temperature is uneven, enabling maintenance and preventing output of defective products.
Positive Pressurization of Food Manufacturing Plant
Problem: In order to achieve HACCP (Hazard Analysis Critical Control Point) compliance, factories are investigating various measures for maintaining cleanliness in the food factory. Despite extensive cleaning, dust and other contaminants still enter the factory. Use positive pressurization indoors to prevent external air entering the space and also eliminate humidity, thereby keeping the indoor area clean. • Detect the differential pressure between the indoor space and external air, and use fan rotation (air flow) to control and stabilize the positive pressurization indoors. • Connect the E8Y Differential Pressure Sensor’s output (4 to 20 mA) to the E5AR, and connect the E5AR’s control output of 4 to 20mA to the Inverter. • Use high-speed control to control the high level of external interference (workers entering/exiting).
Chemical Flow Control
Use the proportional control function of the E5ER to mix the sulfuric acid at a constant ratio.
Multiple Temperature Control of Food Processing Equipment
A single E5AR Unit is available for both temperature control and pressure control. A precision of ± 0.1°C or less is ensured.
Tea Baking Equipment Temperature Control
Problem: The client has to use two units because no single temperature unit with two selectable input points is available. A single E5_R Unit enables two input points, thus solving the problem.
Food Factory's Hot-Water Valve Control
Problem: The temperature of water changes with the season and the mixing quantity is not constant. Use the event input of the E5AR to make PID changes between summer, mid season, and winter.
Hot Melt Application System
Register two SVs (one for idling, one for operation) in the Temperature Controller. Use buttons on the control panel to change all Temperature Controller settings during production.
Cascade Control Using PID Banks
Using cascade control and PID bank function to restrict the upper limit of the remote SP.
Cascade Temperature Control of CVD Equipment
Using E5AR cascade control function to stabilize internal temperature of CVD equipment.
Uniform Control of Wafer Temperature
Using the Remote SP (RSP) as the Set Value (SV) to equalize the temperature of the wafer.
Space-saving and Easy Connection of Semiconductor Manufacturing Equipment
Space saving is possible with the 4-point input of the E5AR. NS direct connections are possible. High-speed control at the sampling rate of 50 ms is possible.
Furnace Temperature Control
Use the E5AR for cascade control. Input noise is mitigated.
Displays Bread Baking Time
To control the baking condition of conveyor-transported bread by monitoring the time that it spends passing through the oven, the speed of the conveyor belt is detected by the Rotary Encoder, and the result is converted to passage time and displayed by the Frequency/Rate Meter.
Operation / Control Panel Downsizing
Equipment and panel downsizing by using DIN 48 x 24 mm components. Reduce panel usage from 1/2 to 1/4 by using the E5GN Temperature Controller, K3GN Digital Panel Meter, and H8GN Electronic Timer/Counter.
Safety Mat/Safety Mat Controller
Prevents Danger From Being Trapped Inside An Enclosure
D4JL Guard Lock Safety-Door Switch prevents danger from being trapped inside an enclosure.
Suitable for Maintenance Work
Safety Guard Switching Unit that is suitable for maintenance work.
Suitable for Semi-automatic Machines
Safety Guard Switching Unit that is suitable for semi-automatic machines.
Position Detection Muting is Achieved for Greater Work Efficiency
Position detection muting is achieved for greater work efficiency using F3SJ Ver.2 Safety Light Curtain.
Floating Blanking
This is convenient for moving items that would ordinarily interrupt the beams inside the detection area.
Fixed Blanking
This is convenient when an interrupting object is fixed in the detection area.
Safety Light Curtains Enable Horizontal Presence Detection
F3SJ Ver. 2 Safety Light Curtain (Type 4) enables horizontal presence detection.
Presence Detection in Areas with Complex Shapes
OS3101 Safety Laser Scanner detects presence in areas with complex shapes.
Non-contact Door Switches for Loose Doors Subject to Water Splashes
D40A Non-contact Compact Door Switch is ideal for loose doors subject to water splashes.
Presence Detection in the Vicinity of a Palletizing Robot
OS3101 Safety Laser Scanner detects presence in the vicinity of a palletizing robot.
Safety Light Curtains with Water-resistant Cases (IP67)
F3SJ Ver. 2 Safety Light Curtain with water-resistant cases provides IP67 protection against water and dust.
Trapped Key Types are Also Available to Prevent Entrapment
Even if the operator is trapped inside, the device will not restart.
Easy Mounting with door-mounting Slide Key
Flexible design of switch-mount slide key allows eight switch mounting patterns to match the opening or closing direction of the door. With this switch-mount slide key, door switch can be mounted symmetrically left and right.
Detects Intrusions into Wide Entrances to Work Areas
Detects intrusions into wide entrances to work areas using F3SJ Ver.2 Safety Light Curtain.
Non-contact Open/Close Detection for Covers and Doors
Made possible by non-vertical application with D40A / G9SX-NS Compact Non-Contact Door Switch/Flexible Safety Unit.
Implements and Inspects Component Extraction Confirmation
The Picking Sensor ensures precise confirmation of component extraction with no mistakes.
Preventive Maintenance by Periodically Performing a Sensor Test
E3Z Sensor with light-intensity switching function achieves preventive maintenance by periodically performing a sensor test. If the Sensor fails to operate when the incident level is switched to 1/2, it is determined that the operating margin is too small and maintenance is required.
Maintains Cleanliness for Clean Suit Storage Shelves
Combined use of the Ionizer Unit ionizes the area within the booth and prevents the adhesion of particles to the Clean Suits.
Clean Monitoring for CCD/CMOS Mounting Process in Clean Room
The Air-cleaning Unit and Air Particle Sensor provide integrated cleaning of the work area and equipment inside Clean Rooms.
Constantly Monitors Particles Inside Clean Rooms
The use of a high-performance fan for pulling in outside air enables 40,000 hours of constant measurement.
Air Particle Monitoring during Manufacturing Process
The Air Particle Sensor monitors the existence of particles on operating equipment without the need for manual assistance.
Particle Monitoring of Lens Molding Machines to Ensure Clean Air Quality
Prevents the adhesion of particles by enclosing the lens molding machine in a clean booth.
Air Cleaning and Ionization in Cellular Manufacturing Processes
The ionizer unit inside the Air-cleaning Unit works to ionize the space inside cellular manufacturing booths.
Static Charges from Cardboard Boxes Just before Printing
The Ionizer can be installed between the guard and the printing stage.
Smart Static Sensor to Monitor Static Charges
Static can be removed while monitoring it with a Static Sensor during work procedures.
Prevents ESD Damage and Adhesive Dust
A Fan Ionizer removes static from PWBs just before mounting components to prevent electrostatic discharge (ESD) damage and adhesive dust. Variable DC mixing system maintains the optimal ion balance at all times.
Removes Electrostatic Charges Generated When Removing Films
Pipe mounting bracket provided for cell production system. Self-diagnostic function to prevent missing maintenance.
An Air-blow Ionizer Neutralizes Performs and Blows OFF Dust
A high-speed valve and regulator supply air to accurately remove dust with pulsed air.
Light Bulb Burnout Detection
The K8AB-AS can detect burned out light bulbs by detecting under current levels. The Relay's sensitivity can be adjusted to detect burned out light bulbs even in applications where multiple light bulbs are used.
Monitors the Control Power Supply at Communication Bases
Communications bases must be carefully monitored because the effects of a power outage or voltage drop would be highly detrimental to communications. This is why the K8AB-VW monitors the control panel power supply for over voltage and under voltage levels.
Protection against Idle Running of a Submersible Pump
A submersible pump must be turned OFF as soon as it begins to operate out of water, or it will immediately malfunction. Instantaneous detection of this kind of idle operation is essential.
Roller Chain Breakage Protection for Conveyors
When the motor locks up, its rotational torque may break the roller chain. To prevent that from happening, the relay must trip the instant it detects a motor lock error. A thermal relay cannot be used for chain protection because it takes too long to start operating.
Distinguishes between Workpieces and Workers
Workers are discriminated from workpieces by reading the operation timing of the muting sensors located in front of the Safety Light Curtain.
Four-axis Multi-beam Safety Sensor Precisely Detects Human Body
Safety measures for people are possible within a sensing radius of 10 m in areas where safety fences cannot be installed.
Ionizes Parts in Parts Feeders
Prevents adhesion of foreign matter and keeps parts from sticking together due to static electricity in the parts feeder.
Ionizes Injection Molding
Prevents adhesion of resin parts to the die (holdovers) because of static electricity.
Ionizes Bumpers
Prevents adherence of foreign matter to bumpers on car body production lines.
Detect Human Precisely with Safety Controller and Necessary I/O Connections
The integrated monitoring of a variety of safety devices is possible by simply connecting the Safety Controller to the safety devices of existing equipment.
Ionizes when Conveying DVDs
Prevents adhesion of foreign matter when conveying DVDs.
Ionizes Resin Parts
Prevents adhesion of foreign matter from static electricity on resin parts.
Ionizes Packaging Films
Prevents adhesion of foreign matter and keeps the film from sticking to itself. Both sides of the film are ionized by Straight Bar Nozzles.
Ionizes Containers
Prevents foreign matter from adhering to and contaminating containers before they are packed with food.
Ionizes PET Bottles on Conveyors
Prevents adhesion of foreign matter when conveying PET bottles
Ionizes PET Bottles on Conveyors
Prevents adhesion of dust and other foreign matter when labeling.
UV Sterilization in Food Production
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp. This Sensor detects the degradation and output conditions of UV lamps used for UV sterilization in food production lines. It keeps the amount of light of UV lamps constant to enable quality control of hardening conditions.
Drying Process in UV Printing
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp. The system detects the degradation and output of UV lamps used for drying and hardening of UV printing. It keeps the amount of light of UV lamps constant to enable quality control of hardening conditions.
Ionizes Elements
Prevents adhesion of foreign matter and damage to circuits from static electricity on elements. Ionization is localized by a Flexible Tube.
Ionizes PCBs
Prevents adhesion of foreign matter and damage to circuits from static electricity generated when conveying PCBs. Both sides of the PCB are ionized by a Straight Bar Nozzle.
Ionizes Chip Components
Prevents adhesion of foreign matter and damage to circuits from static electricity. The full width of the line is ionized by an Air Purge Ionizer.
A Fan Ionizer Prevents Adhesion of Dust
A Fan Ionizer discharges formed products, which easily collect dust due to static electricity.
UV Cleaning Process of LCD Glass
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp. This Sensor detects the degradation and output of UV lamps used for drying and cleaning of LCD glass. It keeps the amount of light of UV lamps constant to enable quality control of hardening conditions.
UV Adhesion and Hardening at the Dicing Stage
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp. This Sensor detects the degradation and output of UV lamps used for chip UV adhesion at the dicing stage. It keeps the amount of light of UV lamps constant to enable quality control of hardening conditions.
UV Hardening Process of High-precision Resin Components
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp. This Sensor accurately detects the degradation and output of UV lamps used for hardening high-precision resin components. It keeps the amount of light of UV lamps constant to enable quality control of hardening conditions.
Monitors Degradation of UV Lamps Used for Bonding LCD Substrates with UV Adhesion
This application uses a UV power monitor that allows you to monitor the amount of light from a UV lamp.? This Sensor not only detects the degradation of UV lamps used for bonding LCD substrates, but also detects LCD glass, which is usually difficult to detect. The system keeps the amount of light of UV lamps constant to enable quality control of the hardening conditions.
Monitors Temperature to Prevent Ignition
Fire prevention in pulverization process of Urethane foam. Temperature is monitored because of the possibility of fire due to heat in the foam debris in the foam pulverization process.
Energy-saving Measures for Solder Tank Idling
Registering two set values, one for idling and one for operation, in the E5EN Temperature Controller. Using the multi-SP function enables saving energy during idling by externally changing the settings of the Temperature Controller.
Centralized Control of Power Supply Maintenance Timing
Problems: Regularly replacing power supply to prevent the system going down due to a malfunction of the conventional power supply, resulting in huge administrative and regular replacement costs. Need for centralized control of maintenance information, if possible. Use the S8VS, which indicates when replacement is required. Central control enabled by sending advance replacement warning output to the PLC. External alarm indicates that replacement is required.
Chemical Solenoid Valve Control
Problems: Automatic chemical supply system stops due to unknown causes. System recovers automatically approximately 5 seconds after stopping. The PLC and other devices, however, need to be restarted. The line is operating for 24 hours, making it difficult to determine the specific cause. One factor is the Switching Power Supply’s output stopping (overcurrent protection function). Propose investigating the inrush current of the device’s load, and using a redundant power supply system and an S8TS for redundant operation. Implement redundant operation with a set of S8TS.
Measures against Momentary Power Interruptions
Problems: Momentary power line interruption damaged 10,000,000 units (wafer loss). Considering countermeasures, but still seeking the best method. Block-type S8TS Switching Power Supply and backup block used to cope with momentary power interruptions. Production able to continue despite any momentary power interruption that may occur.
Improves Machine Maintenance with the S8VS
Problems: The machine supplied to the user occasionally stops. Time and effort are spent in troubleshooting to enable recovery. Need to shorten recovery time to increase customer satisfaction. Change to a Power Supply with a display that will allow faster troubleshooting of machine problems. Customers can easily check Power Supply status on the display, letting them to know whether the Power Supply is the cause of the problem.
Using the S8TS to Improve Reliability of the Backup Operation Circuit
Problems: Currently using two Power Supplies for backup operations, but the circuit configuration is complex and recovery after a malfunction is time-consuming and complicated. Change to S8TS Switching Power Supply, which provides a simple backup operation to replace conventional power supply systems. Use a system that can be constructed without specialized knowledge.
Improves Power Supply Maintenance
Problems: One maintenance staff is usually in charge of a few production equipments. Major down time will incur if production equipment stops when factory maintenance personnel are absent. Use simple backup operation using the S8TS Switching Power Supply. A warning signal is sent if a malfunction occurs, allowing replacement when maintenance personnel are present or replacement during next maintenance.
Power Supply Standardization
Problems: Furnaces are located near power supply, so ambient operating temperature is 50°C, and a power supply with a greater capacity than normal is required (derating curve). The number of fans and capacity often changes. Use an S8TS Switching Power Supply that can be easily expanded in 660-W blocks. Respond quickly to sudden need for increased power supply capacity.
Safety Sensor to Protect People from Dangerous Machinery
The entry of people into the danger zones on and around high-speed machinery, such as chip inserters, can be detected.
Detect Human Entering the Work Area of Unmanned Robots
F3SN-A Safety Light Curtains help to provide a liability-protection measure by detecting the entry of human into dangerous area. (They cannot, however, be used as a safety device for press work in Japan.)
Production Control for LCDs and Color Filters
The necessary information is dispersed and managed by storing work instructions (quality information, processing instructions, process completion information, substrate information, inspection information, etc.) to an ID Tag attached to the cassette.
Process Instructions and History Management for Engine Processes
An ID Tag (Data Carrier) is attached to the pallet, and process instructions are written to the ID Tag. When processing is completed, the history information is written to the ID Tag. As the pallet moves to the next process (and is replaced with a new pallet), the information on the ID Tag is read and transferred to the ID Tag attached to the pallet for the next process.
Traceability Control for Important Automotive Safety Components
For quality control, important automotive components affecting safety are physically managed by inscribing them with 2-dimensional codes. For example, when assembling engines, the 2-dimensional code is read and linked to the engine number, and this data is stored in a database for history management.
Random Sampling of Electronic Components in a Clean Room
Two-dimensional codes containing product information, such as serial numbers and feature values, are printed onto components by direct marking. This data is read during inspections, and saved onto an SD card together with the inspection results. When the work is completed, the saved log is transferred to a database.
Reads 2-dimensional Codes on Metallic Parts
For quality control, important metallic parts affecting safety are physically managed by inscribing them with 2-dimensional codes. For example, when assembling engines, the 2-dimensional code is read and linked to the engine number, and this data is stored in a database for history management.
Reads 1-dimensional Codes on PCBs
Physical management is possible by attaching labels containing 1-dimensional or 2-dimensional codes (with model numbers, lot numbers, production history, inspection data, etc.) to PCBs.
Production History and Control Traceability of a Hard Drive
Production data (serial number, lot number, etc.) is attached to each part using labels that have 1-dimensional or 2-dimensional codes. By reading the code for each part during assembly, a link can be made that shows which part was used in which product, and this data can be stored in a database.
QR Codes for Automobile Parts
For quality control, important components affecting safety are physically managed by attaching 2-dimensional code labels to them. For example, when assembling engines, the 2-dimensional code of the part is read and linked to the engine number, and this data is stored in a database for history management.
Reads 2-dimensional Codes on Individual Boxes
Product information, serial numbers, lot data, etc., is written into 2-dimensional codes and printed onto labels that are attached to individual boxes. Because the data cannot be visually confirmed by using only the 2-dimensional codes, the necessary data is also printed in text form. The 2-dimensional codes are read when shipping the individual boxes, and when the individual boxes are received by the customer.
Sheet-feed Control of LCD Glass Substrates with Stringent Quality Controls
Two-dimensional codes containing product information, lot information, serial numbers, etc., are printed directly onto LCD substrates using a laser marker or exposure device, and the 2-dimensional codes are read at each process.
Reads 2-dimensional Codes on PCBs
Small, 4 mm x 4 mm 2-dimensional codes (with product number, lot number, production history, inspection history, etc.) are inscribed onto PCBs with direct marking for physical management.
High-accuracy Adhesion of Pickup Lenses
The use of a long-life LED in the UV Irradiator removes worries about burnout lamps and achieves lower running costs than lamp irradiators.
Micro spot Adhesion between Needles and Syringe Plastic Sections
Spot irradiation with a UV LED enables sure, low-cost adhesion of plastic parts.
Micro Adhesion of Magnetic Heads in HDDs
Spot-type UV Irradiator enables sure, high-accuracy adhesion
Multipoint UV Adhesive Hardening for Miniature Motors
This four-channel Irradiator provides separate irradiation patterns and installation in less space with a compact Amplifier.
High-precision Adhesion of Camera Modules for Mobile Phones
LED Irradiator provide long life and radiation only when required. It also reduces thermal damage to products.
High-quality Hardening of Ink Printed on Electronic Components
LED Irradiator reduces thermal damage to electronic components.
Efficient Management of Construction Equipment Rentals
Problems: Rental management of large equipment like construction equipment is often done by hand using a control ledger, but this results in considerable added work, such as entering the paper-based data into a personal computer for management. A more efficient and accurate system is desired. Because rental equipment is generally stored outdoors, it is necessary to use metal labels for bar code control, which raises costs. Use screws to mount an ID Tag directly to the construction equipment, and write the vehicle data and control number onto the ID Tag in advance. Each time the equipment is rented, add the customer data and rental period information to the ID Tag, and send this data to the control host. Install Antennas at the entrance/exit gates, then read the ID Tag data when a truck transporting the construction equipment passes through the gate, and send that information to the host for use in controlling all equipment that leaves the site. When the rental equipment is returned, read out the data from the ID Tag that is attached to the equipment as it passes through the gate, and simultaneously retrieve the rental information from the control host software. * The antenna conforms to IP62, and should be housed in a waterproof box. Consult your OMRON representative concerning the location for installing the Antenna when using a microwave-type RFID, because the signal sometimes reflects off of metal, or interferes with wireless LAN systems.
Motion Control for Raw Material Transportation Systems
Problems: Tracking control can be used to move AGVs around a factory to transport roll paper for printing. Using tracking control, however, means that the AGVs must be moved in order, and a large amount of time is lost waiting in line. With tracking control, the motion of the transportation vehicles is determined in advance and it is very difficult to make operation changes (e.g., interruptions). Write motion instructions (e.g., type, destination) to Data Carriers (ID Tags) mounted to the AGVs. Read the Data Carrier information at the stations and perform motion control of the AGVs as appropriate (e.g., instructions to move to material supply stations, standby stations, or production stations).
Fruit Sorting Systems
Problems: Selecting, sorting, or delivering fruit using mechanical flags (for variety discrimination) on special pallets gives rise to complicated mechanical parts with frequent malfunctions. Creating new mechanical flags to deal with new varieties uses up time and money. Water and dirt can cause reading errors in bar code systems. Store information obtained by a sorting machine, such as size, grade, and sugar content, in the Data Carriers (ID Tags) mounted to the pallets. Position Intelligent Flags at the sorting stations, read the information from the Data Carriers, and sort the fruit according to size, grade, or sugar content.
Management of Rental Machinery
Problems: Warehouse inventory control of rental machinery is complicated because it involves many different items. For example, it is necessary to keep track of which machinery has been rented out, which machinery has been returned, and what condition the machinery is in (e.g., how clean it is). Clerical errors can occur in management systems based on hand-written forms. Collating all the information into, for example, daily or monthly reports can be very difficult. Perform inventory control using ID Tags mounted to the machinery. Write information about the machinery, such as the machinery number and the status of the machinery (e.g., reserved/available, processed/not processed after return, clean/dirty), to the ID Tag.
Transport and Control of Construction Materials
Problems: The transport of construction materials, such as gravel and cement, used at construction sites is managed with a forms control system, which makes it extremely laborious to compile data and process the forms for each contractor. Efficiency is also poor because the driver has to leave the truck to fill in the forms. Install an Antenna and display at the entrance gate to read data (contractor's name, driver's name, truck number) from ID Tags held by the drivers. Weigh the loaded truck, and write that data to the ID Tag. When the weighing is completed, the unloading station is shown on the display. After the driver unloads the materials at the specified station, he proceeds to the exit gate. There, the data on the ID Tag is read and the empty truck is weighed. The difference in the two weights (loaded and empty) is used to determine the weight of the load and a form with that information is automatically issued to the driver.
Operational Control for Construction Tramcars
Problems: A company wants to automate the control of tramcars that are used to transport machinery and materials for tunnel construction and other works, in order to increase worker safety and improve the work environment. It is difficult to determine the present location and destination of the tramcars using a control system of only wireless devices and sensors. Mount an Antenna to the tramcar, and connect it to the equipment for controlling the tramcar operation (programmable controller, wireless device, etc.). Position an ID Tag at each point along the track where control is required. Write the basic position information into each ID Tag. The tramcar can then run automatically (stop, slow down, branch, etc.) according to instructions issued from above ground by wireless communications, while reading the data in the ID Tags.
Contractor Entry and Exit Management
Problems: Because the contractors entering and leaving through company gates tend to be concentrated in certain times of the day, the gates become crowded and distribution efficiency drops. This also causes traffic jams in the surrounding roads which inconveniences the local community. An entry/exit control system is necessary that will maintain high levels of security with regard to regular contractors while also increasing efficiency. Install an Antenna at the gates to read data (contractor's name, driver's name, truck number) from ID Tags held by the drivers, and write that data and the entry/exit time to a database. The driver does not need to leave the truck to do this. He can simply face the ID Tag in the direction of the Antenna to pass through the gate. By comparing the times read from the ID Tag when passing through the entry and exit gates, the peak traffic times inside the company grounds can be determined.
Branch Control for Automated Warehouse Delivery
Problems: Components from an injection molding machine are loaded onto pallets and transported by a conveyor belt, but the transport line has a large number of merging and branching locations so it is difficult to trace them at the host system. After setting up the line, several different components are produced by each injection molding machine. A simpler form of control is needed. The simplest, lowest-cost system is desired for sorting and controlling the branching of these components. Write the component classification data onto an ID Tag attached to the pallet following the injection process. Control the branching at a point immediately before the pallet enters the automated warehouse. Use the self-execution mode of the V670 to conduct branching control, thus simplifying control at the host system.
Forklift Management in Warehouses
Problems: Products on pallets are transported by forklift both inside and outside the warehouse, but it is necessary to have better control over forklifts entering and leaving the warehouse for product-liability reasons. Instructions to tell the forklift drivers which warehouse number to go to are generally given either in the form of job sheets or by wireless communications. Sometimes, however, drivers end up going to the wrong warehouse due to human error. A better system is needed. Place an ID Tag on the roof of the forklift (secure with a magnet if necessary). Then install one Antenna each at the entrance and exit of the warehouses. (For the most accurate control, these should ideally be designated as one-way routes. This point must be covered by control measures.) Store the number of the forklift and, if necessary, the name of the driver, in the ID Tag. The Antennas will then read the data from the ID Tag each time the forklift enters and leaves the warehouse, and send it to the host system. A system can also be built so that an alarm is sent to the forklift driver if he tries to enter the wrong warehouse. For additional control, the time that the forklift passes each Antenna can be written to the ID Tag. That data can later be uploaded to a database to show the operational flow of the forklifts.
Warehouse Pallet Control
Problems: Products and components in the warehouse are stacked on pallets (for example, T11 pallets) and managed, but retrieving the specified pallets with a forklift takes too much time because the operators have to visually confirm each pallet, and the operators sometimes make mistakes. A better method is desired. The method of attaching labels, for example, with bar codes, to the pallets has been considered, but the workflow would be much more efficient if the desired pallet could be identified without the operators having to get off of the forklift each time. Attach an ID Tag to each pallet, and write the pallet number onto the ID Tag. Then install an Antenna on the forklift and connect it to a PLC or other control unit on the forklift. The operator can then drive to the pallet storage area by following either a work instruction sheet or wireless communications, confirm that the pallet number read by the Antenna contains the desired cargo, and load it onto the forklift (basic application method). By also writing product information in addition to the pallet number onto the ID Tag, the information that is read by the Antenna when the pallet is loaded onto the forklift can by sent to the host system by wireless communications to help managing distribution control data inside the warehouse.
Cargo Container Management
Problems: Containers are used for transporting a wide variety of cargo, and each time the cargo changes, someone has to issue a paper or plastic plate, mount it to the holder on the container, and visually check the contents for accuracy. This system is not very efficient. When using plates labeled with bar codes for this purpose, the labels get dirty or wet since the containers are used outdoors where they are affected by the climate. The bar codes can then no longer be read accurately, and the overall management lacks stability. Mount an ID Tag to the container holding the cargo, and install an Antenna near the loading and/or unloading locations. Information can then be written to and read from the ID tag mounted to the container. In addition to the basic container number, the ID Tag can also store the necessary cargo data, destination data, station data, date, courier name, contractor name, security data, and more. To provide even more thorough control of the cargo destination, Antennas can be installed at each point to be confirmed along the route and every branching location. The data can then be read as the cargo passes by to make sure that it is following the specified route correctly.
Inventory Control for Automated Warehouses
Problems: Linking warehouse inventory systems based on bar codes to other systems for picking, sorting, or another kinds of operation necessitates the creation of a network. This makes the overall system very complicated. Dirt on bar code labels attached to pallets can cause reading errors. Mount Data Carriers (ID Tags) to the pallets and store the pallet number and information about the contents of the pallet (e.g., component numbers, model numbers, and quantities) in the Data Carriers. In response to a storage instruction, read (automatically) all the information in the Data Carrier, and, after checking the contents, store the pallet in the specified rack, and record the rack number of the stored pallet in the host computer. In response to a delivery instruction from the host computer, take the pallet from the applicable rack, and after checking the pallet information, send the pallet to the picking or sorting process.
Motion Control for High-speed Conveyor
Problems: Motion control for high-speed conveyors, such as OHTs and sorters, can be performed with mechanical flags that use photoelectric sensors and optical communications devices. With systems based on mechanical flags, however, position displacement caused by shocks and vibration can result in malfunctions. Wear-and-tear can lead to problems related to light-source deterioration, and malfunctions due to dirt can occur. In order to develop a faster system, a greater level of autonomy is needed. RFID technology would give the required level of autonomy but, generally speaking, the communications speed would be too slow. Mount ID Tags to the OHTs and install Antennas at stations and junctions as required. Store OHT unit numbers and other relevant information in the ID Tags. When an OHT reaches a station, read the unit number with the Antenna, and send the OHT to the specified location by switching points as necessary via the control system (e.g., PLC) connected to the Antenna.
Enhances Automatic Control of AGVs
Problems: There are AGVs (Automatic Guided Vehicles) and RGVs (Rail Guided Vehicles) that run while sensing magnetic tape attached to the floor. They must stop at stations to load or unload cargo, and control is required to ensure that they proceed in the correct direction at junctions. This kind of control can be performed with wireless devices and sensors but depending on the installation, positioning, and environmental conditions, the sensors used may not have sufficient detection accuracy. A way of allowing the system to be changed more simply is needed. Embed Data Carriers (ID Tags) in the stations and at junctions. Incorporate an Intelligent Flag in each vehicle and connect it to the PLC or (Control Board) already built into the vehicle to control vehicle motion. Write the station number or junction number in the Data Carriers as bit data (e.g., 00000001 for station 1 and 00000010 for station 2). Either program control information (e.g., stop, decelerate) for each station in the PLCs, or send control information to the PLCs when required using a wireless device. Motion control of the AGVs will be based on the data read by the Intelligent Flags.
Work Instructions for a Construction Equipment Assembly Line
Problem: Human error problems occur because operators are making line changes as they look at paper-based instructions. Store the work instructions (model information, welding instructions, programs, etc.) into the ID Tag, and mount it to the carriage. The work instruction data inside the ID Tag can be read by a non-contact reader to help automate the process.
Instructions for an Auto Body Welding Line
Problem: Human error problems occur because operators are making line changes as they look at paper-based instructions. Bar codes were previously used, but errors occurred in reading. Store the work instructions (model information, welding instructions, programs, etc.) into the ID Tag, and mount it to the carriage. The work instruction data inside the ID Tag can be read by a non-contact reader to help automate the process.
Instructions for a Finished Vehicle Inspection Line
Problem: The efficiency of the present, paper-based system of inspection instructions is extremely poor because the operator has to step out of the vehicle at each step to make the settings. Since the inspection results are entered by hand, human error is likely and the process requires considerable time. Automate the setting process with non-contact reading of the inspection instructions (such as vehicle model data and inspection data) stored in ID Tags. Eliminate manual entry by writing the inspection results directly into the ID Tag in the inspection process.
Tool Management for Machining Centers
Problem: Managing tools for machining centers, lathes, and hobbing machines on paper, by storage location, or by writing directly on the tools with a marker pen leads to delays and processing errors due to incorrect setting. Associating the information required for tool management (e.g., usage time and tool length) with the actual tools is difficult. Process the pull-stud or drive-key groove of each tool so that an ID Tag (dimensions: 8 dia. × 5 mm or 12 dia. × 5 mm) can be attached using adhesive, and store tool management information (e.g. tool number, name, usage time, and tool length) in the ID Tags. In addition, store information obtained by the tool presetter (e.g., initial tool length and compensation values) in the ID Tags.
Tire Types and Destination Discrimination
Problem: The manufacture and delivery of tires is carried out systematically based on a production plan. Urgent items, however, must be sorted by hand, giving rise to human error, such as destination direction, model discrimination, and quantity counting errors. The hangers vary with the size and type of tire and so conveyance efficiency is very low. Sorting is performed using bar codes on the tires but dirt on the label can lead to reading errors and it takes time to check the tires. When mounting a tire onto a hanger, write information regarding the tire type, the destination direction, and urgent-item flags to a Data Carrier (ID Tag) mounted to the hanger. Perform sorting (automatically) based on information regarding the tire type and destination direction read from the Data Carrier using a R/W Head (Antenna) mounted to the sorting point in the hanger conveyance system. Display information related to urgent-item flags on display devices.
Picking Instructions for Assembly Parts
Problem: Performing picking work using (paper) instruction sheets results in human error. Time wasted looking at instruction sheets results in low work efficiency. Store pallet numbers, picking station numbers, and picking instructions (e.g., picking component numbers and picking quantities) to Data Carriers (ID Tags) mounted to the pallets. At each picking station, read the information from the Data Carrier, turn ON the lamp for the rack corresponding to the picking component number and, at the same time, display the picking quantity. The operator puts the displayed quantity of the displayed component in the pallet.
Model Discrimination and Process Control for Engine Assembly Lines
Problem: In engine assembly lines that use mechanical flags and bar codes for model discrimination and process instructions, the production line sometimes has to be stopped because of mechanical failures or other factors, such as not being able to read the bar codes because of oil or coolant. Although mixed production lines can be handled, increasing diversification of client needs has led to further increases in the number of different models, and switching between different types of operation must be performed with more efficiency and stability than ever before. Mount Data Carriers (ID Tags) to the pallets or jigs. Write model information and process information to the Data Carriers, read the information at each process station, and, based on this information, switch the operation type (if necessary) and perform processing. After completing a process, enable the processing completion flag for that process."
Automated Pouring in Casting Processes
Problem: When pouring is based on visual confirmation of a number plate mounted to the mold, the influence of dust, high temperatures, vibrations, or other conditions particular to the production site make work very difficult. The number plate is difficult to see because of dust, increasing the likelihood of human error. The versatility to switch between different types of operation and high work efficiency, essential for responding to a variety of needs, are difficult to attain. Store information about the mold number and pouring hole position in Data Carriers (ID Tags) mounted to the molds. Read the information from the Data Carriers on the molds with an Antenna mounted to the pouring machinery, and perform pouring work (automatically) based on this information.
Lot Control and Condition Control in Plating Processes
Problem: Components are inserted in a plating bath for metal plating. When multiple components are inserted, each of the individual components must be managed. Paper and labels are used for this purpose in other processes, but they cannot be used here because the components are inserted into the bath. Human errors and missing components can result because it is difficult to keep track of which components, from which lots, are in the plating process. In some cases, the plating conditions are determined prior to plating and written up into work instructions for manual input. Due to the short life cycles of products today, and the speed at which model revisions occur, this instruction system becomes quite rushed and subject to human error and other mistakes. An operating method with greater accuracy and efficiency is needed. Mount a Data Carrier (ID Tag) onto the plating basket (pallet) carrying the components. Write the component data, lot data, urgent-item flag data, and plating conditions onto the Data Carrier. Mount a R/W Head (Antenna) onto the controller of the plating device. Prior to placing the components into the bath, use the a R/W Head to read the lot data, product data, and plating conditions simultaneously, and automatically make the condition settings for the plating device. In order to achieve more advanced work process management, configure a system that writes the work start and end times for each plating job. This will enable process history and process progress control, making it easy to determine where components are in the process at any time.
Controls Carrier Boxes within Processes
Problem: The components, dies, etc., that are needed for the processing and assembly lines of home appliances are conveyed in carrier boxes or totes. A paper list is placed in the boxes, and the parts are sorted while checking the list at each process. This system is inefficient and lends itself to human error. Many companies would like to improve on it without having to make a large investment. Bar code labels are attached to carrier boxes, and a bar code reader is used to read the labels at each sorting stage. However, when labels become soiled, they cannot be read or they cause reading errors. Or, to lessen the parts control burden on the host computer, companies have switched to a system that issues parts-distinguishing labels for each component instead of carrier box-distinguishing labels, but the cost of issuing the labels and the extra work of replacing them is driving up operating costs. Companies are therefore seeking to improve on this system. Mount Data Carriers (ID Tags) onto the carrier boxes carrying the components. Use a special holder that allows the Data Carrier to be easily mounted and removed for this. Write bit data to the Carrier Data for distinguishing components (for example, 00000000 for component A, 00000001 for component B, 00000010 for component C, and 00000011 for component D; up to 258 components can be distinguished with eight bits). Install a system with Intelligent Flags and a PLC at each process to automatically read the component bits and sort the components accordingly.
Processes and Assembles CRTs and Displays
Problem: Bar code labels or photoelectric mechanical flag seals are attached to the pallets of hanger conveyors that are used to transport small lots of CRTs or monitors for TVs and PCs in the processing and assembly lines. Because the hangers sway, the reading depth changes and the labels or seals sometimes cannot be read, causing the line to stop. The number of models being produced has increased due to diverse user needs and the appearance of LCD and plasma TVs. This has created the need for frequent line changes, and the resulting complex processes make control by a host computer extremely difficult. Mount a Data Carrier (ID Tag) onto the hanger pallet carrying the product. Write the data to distinguish models in bits (for example, 0000 for product A, 0001 for product B, and 0010 for product C, allowing 16 models to be distinguished with four bits). Install a system with Intelligent Flags and a PLC at each process. When the work at each process ends, write the process end flag data onto the Data Carrier. Use a ""1"" flag for ending, and a ""0"" flag for not ending (for example, for four processes, use 0001 for the end of process 1, 0011 for the end of process 2, and 0111 for the end of process 3. These will enable process progress management).
Progress Control and History Notification within Processes
Problem: Since the production processing and assembly time, as well as the holding time, for each process in the production line cannot be accurately obtained, it is impossible to determine where to start in making process improvements aimed at raising productivity. Obtaining the progress status for each process in the production line is an important factor in achieving supply chain management (SCM), but it is extremely difficult to control this on a host computer because the processes are split into several branches and then merged. Mount a Data Carrier (ID Tag) onto the pallet carrying the product, or onto a workpiece. In addition to product information, write the work start and end times as they occur for each process onto the Data Carrier. Then, at the final process, read the time data that was written for each process and create a graph containing the process history and corresponding time data to analyze the processes. When the work at each process ends, write the process end flag data and instructions for the next process onto the Data Carrier.
Standardizes and Improves the Operating Rate of Production Lines
Problem: When multiple automated lines are used for production, there is no simple way of standardizing and maximizing the production volume of each line. It is also difficult to determine the operating condition of each automated machine. In a production system where the work results and inspection results from the preceding process are used to determine which automated line the product will be sent to for the next process, control by the host computer is difficult, and errors are extremely troublesome to handle. Mount a Data Carrier (ID Tag) to each pallet, write the work data for the automated machine (automated machine number used, lot number, tool used, work program number, etc.), and use this to send the product and components to an available line. The instructions are read by each automated machine, and the work is done. The work start time and end time are written to the Data Carrier. For inspection processes, the inspection results are written together with the automated line number that should be used next, and the subsequent work is done at that automated line.
Filling Inspection for Plastic Containers
Problems: Beverage production lines where plastic containers, for example, are filled with liquid, have a short tact time and require a high degree of accuracy. The foodstuff industry is subject to particularly stringent levels of product control (e.g., HACCP). Generally speaking, filling control is performed by measuring the weight of the plastic container once in the empty state and then again after the filling has been completed. The difference is calculated to confirm that the weight agrees with the specified value. Data must be exchanged, however, with the host at each measurement, necessitating a complicated system configuration. If, as a result of the inspection, the filling weight is found to disagree with the specified value, correction is necessary. A way of performing the necessary sorting control quickly, simply, without sacrificing reliability is required. Mount ID Tags to the jigs holding the products. If round jigs are used, mount the ID Tags to the bottom of the jigs and install the Antenna underneath to ensure access even if the jigs turn around. Measure the weight of each container in the empty state and write the result to the ID Tag. Write the filling machine number to the ID Tag to distinguish it from machines at subsequent processes. Measure the weight of the container again after the filling is completed and write the total to the ID Tag. In the weight inspection process, read the empty-state weight and total weight from the ID Tag and check the difference at the host system. At this point, if the difference disagrees with the specified value, send the item to the correction process. At the sametime, read the filling machine number stored in the ID Tag.
Quality Control for Food Products
Problems: Food products demand a high degree of safety. The importance of managing a wide variety of information, such as the date and place of production, the best-before date, and the destination direction is greater than ever and has made quality control of foodstuffs very difficult. Food products cartons are cleaned with alcohol, detergent, warm water, or steam and so machines that have a low resistance to chemicals or high temperatures, or that may allow bacteria to proliferate cannot be used. Mount Data Carriers (ID Tags) housed in a double layer of PFA (Fluororesin) to the cartons or pallets, and in addition to the product name, weight, and quantity, store information regarding the data and place of production, the best-before date, and the destination direction in the Data Carriers. Perform sorting and delivery work after confirming safety using the production date and best-before date information obtained from the Data Carriers and issue a form itemizing the relevant information.
Automated Raw Material Mixture and Measurement System
Problems: Using (paper) instruction sheets leads to incorrect combinations due to misplacement. When incorrect combinations occur, they are not discovered until the final inspection process. In each process, read combination information from the ID Tags mounted to the containers and add the specified weight of each raw material from the hoppers. Write the combination result (i.e., the weight) to the ID Tags.
Automated Inspection and Sorting of Blood Samples
Problems: In systems that perform batch control of sample racks and trays with bar codes, the inspection instructions and sorting information are handled at the host system. This gives rise to complicated programs and configurations, making it difficult to change the system when required. A new bar code label must be attached each time the sample racks and trays are cleaned. The labels have to be attached carefully without being creased. Read information from the bar codes on the test tubes with a bar code reader, and store that information along with inspection instructions and sorting information in the ID Tags embedded in the sample racks and trays. Write inspection history information and inspection results to the ID Tags and, in the final process, upload the information to the host system.
Organic EL Panel Control
Problem: In order to compile a production control history, data such as the lot number, serial number, and production date has to be documented for each panel. Using a paper-based system, though, makes it difficult to achieve complete production control starting at the initial stages of the process. It would be helpful if the panels could be controlled individually instead of in lots. Use an exposure device to directly mark each panel with a 2-dimensional code containing the production data for the glass substrate and the process history data. Read the 2-dimensional codes with a 2-dimensional Code Reader, and control the entire production process over a network.
Controls Parts for High-speed Mounters
Problem: Control is based on instruction sheets and so human error can occur when cassettes are mounted to the mounter. Also, in order to prevent errors, multiple reading is used. This means that work efficiency is low and personnel expenses are high. The remaining number of parts is ascertained, in cassette units, using paper and the human eye. This is insufficient for effective control and leads to large stock losses. In particular, stock inventory is not possible unless the line is stopped for several days. The parts mounted to the mounter are insufficient and there are frequent mounter stoppages due to missing parts. Read the part information (e.g. part number, part name, and quantity) written in the bar code on the part reel, and write the information to the Data Carrier (ID Tag) mounted to the cassette. After mounting the cassette to the mounter, automatically read the cassette information, check the part information and remaining quantity, and perform verification with the mounting program. Use an alarm to provide notification of cassette mounting errors and insufficiencies in remaining parts. After the mounting process is completed, write the latest information on the number of remaining parts, based on the mounter's data, to the Data Carrier.
Individual Wafer Control
Problem: Until now, in the production of DRAM, for example, wafers have usually been processed in lots of 25 (i.e., in wafer carrier units). The switch, however, towards high-diversity, low-volume production (e.g., custom LSI) has made individual wafer control necessary. In order to avoid reducing the number of IC chips produced per wafer, the markings used for individual wafer control must be as small as possible. Mark the back surface of each wafer with wafer ID (2-dimensional code) satisfying the specifications of the SEMI T7 standards using a laser marker. (The surface can be marked with a wafer ID consisting of 13 alphanumeric characters in an area of 4 × 1 mm.) When the wafers are introduced into the processing equipment, read the wafer ID (2-dimensional code) with a 2-Dimensional Code Reader and send the information to the equipment.
PCB Batch Control
Mount an ID Tag (Data Carrier) to the magazine rack, use it to store the PCB data (lot number, model number, board size, number of boards, etc.), then switch processes during mounting based on the ID Tag data. When mounting is finished, write completion data and mounted PCB data to the magazine rack ID Tag. Also write the result (OK/NG) of the inspection process to the ID Tag, and feed NG products back to the repair line.
Hard Disk Manufacturing Processes
Mount ID Tags (Data Carriers) to dedicated cassettes that contain (several dozen) disks. Write product information, lot information, work instructions for each process, process completion flags, and instructions for the next process to the ID Tags. In each process, read the information from the ID Tags using R/W Heads mounted to the machinery, and perform processing or inspection based on this information. For inspection processes, write the inspection results (i.e., OK or NG) to the ID Tags. At the end of each process, write instructions relating to process completion flags and the next process as appropriate. At the final process, read all the information in the ID Tags, and store it in the host for lot control.
Rechargeable Battery Management
Mount ID Tags to the pallets holding the rechargeable batteries for charge/discharge inspection. Write product information, lot information, and inspection conditions for each lot to the ID Tags. Change the inspection process according to this information. In addition, store process completion flags and instructions for the next process to enable process history management. When the charge/discharge inspection is finished, write classification information based on the inspection results to the ID Tags. ID Tag memory capacity is limited and so associate addresses in memory with the locations of the batteries in the pallets beforehand. To classify the batteries, read the classification information stored in the ID Tags, and perform sorting (automatically) with a robot.
Detailed Control of Parts for Mounters
When the cassette rack is mounted to the mounter, the information for all of the cassettes and placement information are read by the Antenna installed on the mounter, and a comparison is made to determine whether the correct cassettes have been loaded (that is, whether the mounting program is correct).
Automatic Recognition and History Management for Molds
RFID System stores information such as mold information, shot count, date of first use, and molding conditions to an ID Tag mounted to the mold. It reads the mold information and molding conditions from the ID Tag using an Antenna (R/W Head) mounted to the molding machine. At the same time, it also reads the shot count, and checks that the mold is within its service life specifications. After the molding process is completed, it writes information (e.g., shot count) from the molding machine to the ID Tag (Data Carrier).
LCD and Color Filter Manufacturing Control
Store work instructions and information (e.g., product information, process instructions and information, process completion information, substrate information, and inspection results) in the ID Tags mounted to the cassettes to enable distributed management of the necessary information.
Production Process for 300-mm Semiconductor Wafers
Mount an ID Tag (a FOUP Carrier ID) and store work instructions and information (e.g., model information, process instructions, process completion information, lot information, and inspection results) in the ID Tag. Dispersed control can then be applied to the necessary information.
Reticle Control
An ID Tag (Data Carrier) is mounted to the pod containing reticles, making it easy to check and manage the reticles inside.
Sheet-feed Control for LCD Substrates
Two-dimensional codes containing product information, lot information, serial numbers, etc., are printed directly onto LCD substrates using an exposure device or laser marker, and the 2-dimensional codes are read at each process. In locations where people are involved, a handheld reader is used.
Manages PCBs with 2-dimensional Codes
Two-dimensional codes containing product information, lot information, serial numbers, etc., are printed directly onto LCD substrates using an exposure device or laser marker, and the 2-dimensional codes are read at each process. In locations where people are involved, a handheld reader is used.
Molding Information Control and History/Lifetime Management for Molds
Store information such as mold information, shot count, date of first use, and molding conditions to an ID Tag mounted to the mold. Read the mold information and molding conditions from the ID Tag using an Antenna (R/W Head) mounted to the molding machine. At the same time, read the shot count, and check that the mold is within its service life specifications. After the molding process is completed, write information (e.g., shot count) from the molding machine to the ID Tag (Data Carrier).
Traceability Control for Home Appliance Production Processes
Product information, processing information, assembly information, and inspection information are written to an ID Tag attached to a pallet. At each process, the processing information, assembly information, and inspection information are separated according to the work instructions on the ID Tag. At each inspection step, the results of the inspection are written to the ID Tag, then uploaded to the host at the final process.