Professional Documents
Culture Documents
1. What Is an FA Sensor?
FA stands for Factory Automation and refers to the automation of and reduction of the amount of workers at factories.
By using a large number of industrial robots in place of workers in the operations that were conventionally performed by
people, FA aims to improve productivity (reducing production costs and improving takt time) and quality (increasing yields
and making performance uniform) and to shift the human workers to more productive work.
FA sensors refer to the sensors that perform a variety of operations in the place of human workers.
Some concrete examples are given below.
2
Sensors That Use Magnetism
As shown above, sensors use a variety of principles. Every sensor has things that it can do and things that it cannot do,
things that it excels at and things that it is poor at. This guide will introduce “displacement sensors,” which can not only detect
the presence of targets but are also capable of measuring a variety of items such as the position and dimensions of targets.
3
2. What Is a Displacement Sensor?
As shown in the following figures, displacement sensors can not only detect the presence of targets but can also detect
the amount of displacement such as for small/large targets and for near/far targets.
Reflective Type
Photoelectric/proximity switches Displacement sensors
Far
Present Not present Small Large
Near
Thrubeam Type
Photoelectric/proximity switches Optical micrometers
The typical types of displacement sensors are the 6 types listed below.
4
Principles of Typical Displacement Sensors
HDE lens
Linear collimator lens
Delta cut technology
Cylindrical lens Target
Optical Micrometer
Monitor CMOS
ø8 mm ø0.31"
The absolute value scale, with different slit patterns High-resolution
CMOS
engraved according to position, is captured at high Absolute value
glass scale
speed with a high-resolution CMOS sensor.
This world’s first detection principle delivers the highest
accuracy in its class with no tracking errors during
high-speed movement.
HL-LED
CMOS sensor detects
the position of the
absolute value scale.
Transmitted wave
Received wave
5
3. What Can Be Done with a Displacement Sensor?
Displacement sensors can be used to perform a variety of measurements.
This chapter will introduce concrete examples grouped into the six major types of measurements.
Positioning/
tionning/ Runout/
nouut/
Height/Level
ht/L
Level Outer
ute
er Position
sitioon Stroke
rokke Vibration/
ation/ Wave/Curve 3D
Thickness erence
difference me
eter
diameter ureement
measurement tan
nce
Distance entrricity
Eccentricity Flatness Shape
Sh
hap
pe measurement
3D
Thickness
Substrate thickness measurement of Measurements of glass sheet thickness, Thickness measurement of a wafer
solar cells curvature, and parallelism
HDD arm assembly position Height and width measurement of rubber overlap Height control of dispenser
Drill bit outer diameter measurement Roller outer diameter measurement Film width measurement
6
Eccentricity and Vibration
Disk rotor warpage measurement Tire runout measurement Ultrasonic welder monitoring
Position Measurement
Precision stage positioning Feedback control of a welder Position tracking of high temperature steel pipe
Warpage measurement of a circuit board Ampoule shape inspection Thermal expansion of a lithium-ion battery
7
4. Displacement Sensor Applications
Displacement sensors are used in a variety of applications and for a variety of purposes.
This chapter explains how to use displacement sensors in inspections and when checking machine operations.
Inspection means two things: inspection of individual parts and inspection of assembled parts.
To create a product, a great number of parts are necessary.
In order to assemble all these parts to create the correct product, each and every part also has to be
correct. Also, inspections must be performed when the parts are assembled to check that they have been
assembled correctly.
Example: A process in which a gray part is set within a gray part, and then a transparent glass lid is set on top.
Displacement sensors are also used to check the machine operations performed during the assembly of
parts. It is possible to prevent defective products from being released
by checking whether the machine is operating normally.
8
So, what can be done to prevent failures from occurring?
Method 1
Check whether the dimensions of each part
are correct.
This prevents the failure shown in 2 .
Method 2
When the gray part is attached, check the status of the attachment.
This prevents the failure shown in 3 .
Method 3
Finally, check whether the lid has been set on top correctly.
9
5. Displacement Sensor Selection
When selecting a displacement sensor, it is necessary to consider accuracy.
This chapter will discuss accuracy.
Tolerance refers to the difference between the maximum and minimum values that is permitted for the reference.
Tolerance: ± 0.1 mm
±0.004"
The following table shows the ratio to the tolerance of ±0.1 mm ±0.004" and the target size that can be judged to be OK
for accuracies of (1) ±0.001 mm ±0.00004", (2) ±0.01 mm ±0.0004", and (3) ±0.03 mm ±0.0012".
This shows how the better the accuracy of the displacement sensor,
the more accurately judgments can be made.
10
6. Support
We hope that you now understand just what FA sensors and displacement sensors are.
In addition to this guide, KEYENCE has a rich variety of contents related to measuring instruments for people who are
planning to select a displacement sensor in the near future. Feel free to download these materials from the KEYENCE website.
Applications
We have grouped together examples of improvements according to different processes, manufactured products, and
applications. These materials are packed with know-how for implementing improvements.
ENT MEASUREM
EN
Mobile
APPLICATI N AP UREM
Reduce Costs
Improve
Quality
Impro and Tech nes
Inspection
GUIDE
and Tech Methods
P
ve Qu
E
Increase
GUID LICATION NT
Costs Yield Rates ality nologies
Reduce Redu For PROFIL
ce Co NESS/ E
GUIDE
Com
EXPERT
For THICK Measuremen
Yield Rates sts t
Increase WIDTH ent
Veh plete
Increa
T
se Yie
Measurem
EXPER IONS E
ld Ra
icle d
SOLUTION EX
tes Insp
Bod
and ection
OUTER
SOLPERT
DIA ME /INNE
ie
S
Tech Met
SOLUT
nolo hods
gies
s Measu TER R
remen
RESI N PRO t
U TI
TRY CES SING /MO
US LDIN G
E IND
MO TIV
ON S
EL EC
AU TO TR O
N IC
S IN
DE
INDE Oute
X
3 X r
y Selec Diam eter
· P.2 to y Selection tion Meas
EX ············· Guide ················
IND ············· to 5
y Meas Guide urem
············· ···· P.4 y Measuremen ················ urem ······ ent
············· ············· t Principle ················ y Oute ent ······
Guide ············· y Profile Measuremen ················ ····· P.2 r Diam Princ ······
y Selection ············· to 7 ················ yX eter iple ······
ent Principle t Glass, ······ P.6 or Sensor t by Moving ··········· P.3
to 4
and
Meas Y Axes Meas ······ ······ ······ ······
y Measurem ent of Transparen
·············
·············
P.8
Head ················ a Workpiece
urem Sync urem ······ ······
Measurem ········· y Profile Measuremen ················ y Oute ent ent ······ ······ ······
y Thickness Membrane s ············· Side ············· ················ ······ hrono us ······ ·····
Films and One ·· P.8 y Profile Measuremen t Using a 2D Sensor ····· P.5 a Larger Diam ······ Oute
······
······ ······ P.2
ent from a Roll ············· ················ eter ······
t Using Diam Meas ······ ······ r Diam ······ · P.3
Measurem Sheet on Stage System
················ a Displacemen t Sensor
····· P.5 y Multi
······ eter ······
y Thickness ent of a Diffic -poin t
eter
Objec
urem
ent ······ ·····
Measurem a Workpiece ······ P.9 y Successful ················ + ult GeomSimu t ······ of ······ P.4
y Thickness ent by Passing ·············
·············
P.10
Applications
················
················
······· P.6 Inner ltane ······ ······
Measurem ous ······
y Thickness Two Sensors ············· Material)
··········· ················
··········· P.7 y Inner Diam eter etrie s ······ Meas ······
······ · P.5
Plate (Thick P.10 Meas ······ urem ······
between
ent of a ··········· y Meas Diam eter urem ······ ent of ······
Material) ······ ·····
y Width
Measurem Sheet (Thin ······· P.11 urem Meas ent Shap P.5
ent of a Point ·············
ent
Princ
urem ······
······ es with
Measurem ent ······
y Width Specified iple ······
ent at a ······ ······ ·····
P.6
Measurem ······ ······
y Width ······ ······
······ ······
······ ·····
······ P.7
······
· P.7
KEYENCE website
How to Select
Your Measurement Equipment
Displacement Meters and Measurement Systems
Selection Catalog
Free-of-Charge Tests
On-site tests Scale tests
■ Free lending of test machines ■ Demonstrations using actual machines
■ Lending of mounting jigs for testing and performed by salespeople
etc. etc.
11
http://www.keyence.com/measure
www.keyence.com/ www.keyence.com/inquiry/
landing/basic_guide.jsp askKeyence/
www.keyence.com/landing/
appli_guide.jsp
www.keyence.com
Copyright (c) 2015 KEYENCE CORPORATION. All rights reserved. SensorBeginnersG-KA-EN-US 1045-1 E 611A36