Sensors that integrate intelligent functions and can communicate offer enormous potential.
Continuously improve efficiency
The increasingly effective IO-Link technology is not only being implemented in more and more applications—this manufacturer-independent communication technology is also seen as a catalyst for innovative sensor solutions and supports the global availability of data and information needed for Industry 4.0. “Smart” sensors utilize the IO-Link communication channel to reliably acquire data, communicate, and self-diagnose. Combined with intelligent functions integrated into the sensor (a SICK exclusive), they offer significant potential for machine productivity, especially when performing certain automated tasks in a decentralized manner.
Ready to use immediately: During the initial integration and commissioning of smart sensors, various parameters can be visualized, tested, and optimized. Furthermore, multiple different parameters can be stored in the automation system and loaded into the sensors during operation, eliminating the need for additional commissioning time. This feature is particularly suitable for machinery and equipment that requires frequent changes in workpiece or product types, enabling rapid retrofitting while ensuring process safety.
(Sensors with eyes: By visualizing the detection process—for example, on an HMI or, in the future, on mobile devices such as phones or tablets—all relevant functional details of the sensor can be presented. This transparency allows us to more easily optimize the sensor for specific application conditions and aids in troubleshooting.)
Self-diagnostics enables prediction of maintenance needs.
In production environments, machine and equipment components are constantly exposed to environmental influences such as dust, cardboard scraps, moisture, and vibration. SICK sensors are not only mechanically, electrically, and optically designed to withstand the harshest operating conditions, but they also improve performance and availability under high-load and high-throughput production through self-monitoring capabilities. Machine-oriented (or cloud-based) analytics tools utilize diagnostic data to promptly identify potential faults and prevent them through predictive maintenance. Furthermore, SICK's smart sensors can visualize their operating data and settings for machine operators. Operators can see at a glance at their HMI terminal how the sensors are currently operating, which switching thresholds are configured, and how far the sensors are from critical values.
Establishing IO-LINK Coherence: Proximity Switch Example
IO-Link is the communication channel for smart proximity switches. Smart proximity switches include the IMC and IQC product families. Both integrate up to four programmable/teachable switching points into a single sensor, enabling more precise, space-saving, and cost-effective solutions for multi-level or stepless fixture position detection applications—since different switching points can be achieved with just one sensor. Furthermore, IO-Link allows us to verify whether the sensor is within a safe sensing distance and to perform basic diagnostic functions through status monitoring visualization, i.e., obtaining corresponding information based on the sensor's output status.
From smart sensors to smart application solutions
Smart sensors offer numerous advantages over conventional sensors—they aim to progressively improve the efficiency of existing operations, such as rapid installation and replacement, remote monitoring and commissioning, self-diagnosis, and rapid parameter downloading. SICK goes a step further: integrated additional intelligent functions—enabling the transfer of data processing from automation systems (e.g., PLCs) to field devices (e.g., sensors)—provide a future-oriented approach to designing more efficient and powerful automation networks. Unlike traditional target detection, intelligent functions can generate new, higher-value information (which can be generated in conjunction with other sensors when necessary) as required by the application and transmit it to higher-level systems (PLCs, ERP systems, cloud platforms), thereby enabling various intelligent application solutions.
Examples of Smart Tasks
Object and Gap Monitoring
By using diffuse reflection photoelectric sensors that integrate the intelligent function of "Object and Gap Monitoring," it is possible to automatically screen out defective products before the next production step. For example, broken or stuck chocolate bars need to be identified as "too short" or "too long" and screened out before the packaging process. If the minimum distance between individual chocolate bars on the conveyor belt does not meet the requirements, the corresponding chocolate bars also need to be screened out. These parameters (the length of the chocolate bar itself, the gap length between bars) can be set directly in the sensor and judged during operation. When the above situations are encountered, the sensor will directly provide an execution signal to the screening equipment (such as a cylinder).
Result: While ensuring efficient and accurate process operation, the PLC controller was also relieved of the data processing task.
QL = Switch signal corresponding to intelligent task
C = IO-Link communication
t = time
to = length of the object (in units of time)
tg = gap length (in time)
Carrier Load Analysis
By integrating the intelligent sensor with the "Carrier Load Analysis" function and working in conjunction with other sensors, it is possible to determine which positions on the carrier passing by the sensor are occupied by loaded items and which positions are vacant. The sensor transmits this information directly to subsequent process units (such as robotic grippers) or PLCs.
Advantages: Using smart sensors instead of complex image processing systems to monitor whether items are correctly loaded on the workpiece rack.
More transparency, more monitoring
The realization of a smart factory—characterized by self-monitoring sensors, workstations where sensors and actuators coordinate their respective programs and functions, and production structures containing autonomously organizing and optimizing units—means significant improvements are needed in implementing production and internal logistics processes. These improvements require the support of intelligent and communication capabilities at the field level. Transparency of sensor status, settings, and the processed information within sensors also imply better monitoring of the entire process. (tm)
Speed and Length Monitoring
Leveraging the intelligent "Speed and Length Monitoring" function, the absolute length or speed of passing objects is directly assessed within the sensor. Therefore, the intelligent sensor can directly handle classification or monitoring tasks and transmit the assessment results to the controller. In addition to speed monitoring, this solution also offers two object length measurement modes:
Mode 1: Using a smart diffuse reflective photoelectric sensor and a standard diffuse reflective photoelectric sensor directly connected to it. Condition: The conveying speed cannot be slowed down or increased during length measurement.
Mode 2: Uses a smart diffuse-reflective photoelectric sensor and an incremental encoder directly connected to it. In this mode, the measurement is not limited by the conveyor speed, meaning that deceleration or acceleration is allowed during length measurement.
Print Mark Counter and Speed Monitoring
The intelligent color mark sensor, integrating the smart functions of "Print Mark Counter" and "Speed Monitoring," can detect and count printed marks (e.g., on film rollers). If the number of printed marks on each film is known, the sensor can transmit information about how much film remains on the roller at the desired time, thus promptly identifying and notifying the roller to be replaced. The speed monitoring function provides the simplest way to collect, control, or monitor the conveying speed of packaging materials.
Learn about four aspects of smart sensing technology through the following video :
Founded in 1946, SICK has become a highly influential supplier of intelligent sensor solutions after years of development and accumulation. Its products are widely used in various industries, including packaging, food and beverage, machine tools, automotive, logistics, transportation, steel, airports, electronics, and textiles. SICK China currently has branches in Guangzhou, Shanghai, Beijing, Qingdao, and Hong Kong, forming an organizational structure and business network covering all major regions of China.
For more details, please visit www.sickcn.com or call our national customer service hotline at 4000 121 000.
