Sensors or sensing technologies are commonly used in manufacturing facilities to enable quick and accurate reading and storage of available data. In the food and beverage industry, sensing technologies are often used in packaging applications. There are different types of sensors available, and manufacturers can choose the most suitable system depending on the requirements.

Many application engineers would rather choose a vision system if an inspection application requires more sophisticated data acquisition than that provided by a traditional photoelectric sensor. Through a vision system, they can obtain image-based data and identify label orientation, part presence and arrangement and other product features. But for some of these applications, a full vision system may not be required. Instead, one can use a compact touch-screen image sensor that does not require a computer or any additional electronic devices.

iVu Series TG image sensors and their applications
One such development in the image sensors series is the iVu Series TG image sensors, which combine the simplicity of a photoelectric sensor with the intelligence of a vision sensor to deliver powerful and affordable inspection capabilities. The iVu features a touch-screen with an intuitive interface and easily configurable inspection parameters.

This allows even first-time users to quickly and conveniently apply and support inspections right on the factory floor, without the use of a computer. The iVu offers three advanced sensor types in one compact, rugged package, making it possible to solve a wide variety of complex applications with one sensor.

Typical applications of these sensors include the following.

• Label inspection

• Part presence and orientation

• Date/lot code inspection

• Vial cap inspection

• Injection molding verification

• Packaging verification

• Drilled-hole inspection

• Blister pack inspection

• Weld nut presence and orientation

• Feeder bowl inspection

• End-of-mail indication

• Electronic-marking verification

Label orientation
The touch-screen image sensor allows the setting of inspection parameters on the spot, and subsequent examination of a target object, such as a salad dressing bottle, to verify label placement and orientation. A touch-screen image sensor can combine the capabilities of three dedicated sensors into a single housing. The first type is a match sensor, which compares the target object to a stored reference point, identifying parts of irregular shape, alphanumeric characters, etchings and labels at rapid production speeds. The second is an area sensor that identifies target features within a region of interest, which is ideal for detecting drilled holes into a metallic component or inspecting blister packs. The sensor also verifies that all the features are correctly sized and located. The third sensor has a similar function of examining an area for specific features, but it also offers tools to adjust motion.

Drilled-hole inspection
The image sensor features integrated lighting to create a contrast between target features (drilled holes) and their background (metal plates), allowing any reject parts to be readily identified.

These tools enable the sensor to detect objects of varying positions and orientation along the production line. The image sensor also incorporates integrated lighting and adjustable lenses to optimise image contrast as well as to accommodate changes in the plant conditions.

Injection molding verification
Once the sensor is programmed, it compares the obtained image, a plastic container in this case, to a reference pattern in order to confirm that its size and shape matches the set parameters. If the target object fails inspection, it is rejected from the production line.

The sensor’s touch-screen LCD display is used for setting up inspection and modifying parameters. Once the sensor type is selected (match, area or area with motion), it captures a sample image which can be considered as the reference to configure the same by adjusting the region of interest, setting inspection parameters and designating the minimum and maximum pass count.

The final setup configuration and logged inspection results can be downloaded from the sensor to a USB drive through the sensor’s USB port. To minimise system downtime, one can set new application parameters offline through the sensor’s software emulator, and then upload these new configurations onto the sensor using the USB drive.

The World-Beam photoelectric sensor series
Apart from touch-screen image sensors, there are other types of sensors that are compact, robust and can withstand harsh environments and washdown conditions.

The World-Beam photoelectric sensor series is one such range that could be of interest to the food and beverage packaging domain. The series comprises numerous sensor models with a wide range of sensing modes. These sensors are available in an industry-standard design, which can be fit or retrofit in order to conform to the differing requirements of the various plant layouts.

World-Beam QS30 water sensor
In this sensor, cutting-edge sensors are integrated with the latest technology to optimise performance in challenging bottling applications.

Conventionally, when an optical sensor is used to detect water in a clear container, the low contrast causes the sensor to see the bottle and the water as the same item, resulting in inconsistent, faulty sensing. To detect liquid contained within dark plastics or colored bottles, optical sensors require high-excess gain to see through the containers and detect the enclosed liquid.

However, with this high excess gain, the sensing beam often cuts through the liquid as well. World-Beam’s QS30 Water Sensor combines high excess gain with a 1,450-nanometer infrared sensing beam, especially tuned to an absorption band of water, to provide a dual-purpose solution. When the bottle is clear, the energy absorption of the water creates a high-contrast between the water and the bottle. Additionally, the beam is paired with high excess gain to ‘burn’ or see through colored, decorated or frosted bottles to detect the liquid inside.

QS18 Universal Voltage Sensor
Further enhancing the flexibility of the World Beam sensing family, Banner Engineering has provided AC or DC voltage alternatives with several sensor models. One example is the QS18 Universal Voltage Sensor, which delivers solid-state output for reliable presence/absence detection in package and material handling. Pairing this capability with exceptional optical performance and user-selected AC or DC voltage operation, the QS18 Universal Voltage Sensor offers enhanced sensor life and faster switching and response time than mechanical relays.

This sensor also provides versatile mounting options to suit diverse plant environments. These sensors when combined with vision, safety, indication and wireless products ensure that food and beverage industry challenges are solved conveniently, effectively and cost-efficiently.

Courtesy: Banner Engineering India Pvt Ltd