智能制造网APP
智能制造网手机站
智能制造网小程序
智能制造网官微
智能制造网服务号
智能控制
机器人
仪器仪表
物联网
3D打印
工业软件
预告
回放
品牌
费希尔/Fisher
来自资深用户的实用见解
光电传感器理论上具有优异的性能，但实际生产现场往往会面临许多产品目录中未提及的挑战，例如不同材料导致的检测性能差异以及环境因素造成的故障。
以下将结合实际应用与运行经验，详细阐述相关的实践知识。
Practical Insights from Experienced Users
While photoelectric sensors have excellent characteristics in theory, real manufacturing sites often face many challenges not reflected in catalogs—such as differences in detection performance by material and failures driven by environmental factors.
Below is a detailed explanation of practical knowledge based on real implementation and operational experience.
加工现场按材料/形状划分的检测结果及问题解决方法
Detection Results by Material/Shape in Machining Sites and How to Address Issues
车床上的金属加工
Metal Machining on a Lathe
对于铝合金的检测，根据材料是处于原始状态还是经过机械加工，需要采取完全不同的检测方法。对于未经加工的铝材，由于其表面存在氧化层，使用漫反射式传感器通常能够实现稳定检测；但经过机械加工的铝材表面往往呈镜面状，会产生镜面反射，导致传感器无法正常检测。
例如，在检测经过机械加工的铝制零件时，可采用30°倾斜安装的方式，以避开镜面反射，从而解决该问题。
不锈钢的情况也因材质而异，例如SUS304与SUS430之间就存在显著差异。由于SUS304不具磁性，无法使用电感式传感器，因此必须选用光电式传感器；但受表面光洁度的影响，其检测距离可能会有近三倍的差异。在实际应用中，对于#400表面光洁度的工件，检测距离可达约50 mm；而对于镜面光洁度的工件，检测距离可能仅为15 mm左右。
在检测塑料零件时，常会因静电导致传感器误动作。POM(聚甲醛)和PE(聚乙烯)等材料极易产生静电，在靠近传感器时可能会发生放电，从而产生干扰信号。有效的应对措施包括安装离子发生器(除静电器)，或选用带有金属外壳的传感器。
黑色橡胶零件属于最难检测的目标之一。由于填充了碳黑，黑色橡胶会吸收绝大部分光线，若使用漫反射式传感器，检测距离通常需控制在3–5 mm以内。在这种情况下，选用具备背景抑制功能的传感器，并设计能够限定工件运行路径的夹具，至关重要。
For aluminum alloy detection, completely different approaches are required depending on whether the material is in its raw state or after machining. Wrought materials can often be detected stably even with diffuse sensors due to the surface oxide layer, but mirror-like machined surfaces reflect light specularly and can become undetectable.
For example, you can standardize a 30° angled installation for detecting machined aluminum parts, avoiding specular reflection and resolving the issue.
Stainless steel also varies greatly between SUS304 and SUS430. Because SUS304 is non-magnetic, inductive sensors cannot be used, making photoelectric sensors essential; however, sensing distance can vary by nearly a factor of three depending on surface finish. In practice, about 50 mm may be usable for a #400 finish, while a mirror finish may be limited to roughly 15 mm.
With plastic parts, sensor malfunctions caused by static electricity occur frequently. POM (polyacetal) and PE (polyethylene) are particularly prone to charging and may discharge near the sensor, generating noise. Effective countermeasures include installing an ionizer or using sensors with metal housings.
Black rubber parts are among the most difficult targets to detect. Carbon-filled black rubber absorbs most light, so with diffuse sensors you may need to position the sensor within about 3–5 mm. In such cases, selecting a sensor with background suppression and designing fixtures that constrain the workpiece path are critical.
如何利用光电传感器简化换产流程
How to Use Photoelectric Sensors to Streamline Changeovers
转换概念
Changeover Concept
在多品种、小批量的生产环境中，光电传感器可用于在换产过程中核对夹具的更换情况。其原理是为每种夹具设置独特的遮光模式，并通过传感器自动识别夹具类型。例如，在夹具上组合安装 3 mm、5 mm 和 8 mm 的遮光板，并配合三个对射式传感器进行二进制识别，即可区分出八种不同的夹具类型。
此方案可以避免操作人员选用错误夹具的情况，从而减少因换产失误而导致的缺陷。此外，PLC(可编程逻辑控制器)在接收到夹具识别信号后，可自动调用相应的加工程序，进而缩短换产时间。
光电传感器还可用于补偿工件装载位置的偏差。在卡盘夹紧工件之前，利用双轴传感器测量工件端点位置，以检测其在 XY 平面上的偏差。根据这些信息对搬运机器人的动作进行修正，可将定位精度控制在一定范围内(例如 ±0.5 mm 以内)。
In high-mix, low-volume production, photoelectric sensors can be used to verify fixture changes during changeovers. The idea is to create a unique light-blocking pattern on each fixture and automatically identify the fixture type using sensors. For example, by combining 3 mm, 5 mm, and 8 mm light-blocking plates on a fixture and using three through-beam sensors for binary identification, you can distinguish eight fixture types.
This can completely prevent operators from selecting the wrong fixture and reduce defects caused by changeover mistakes. In addition, the PLC can receive the fixture identification signals and automatically select the machining program, shortening changeover time.
Photoelectric sensors can also be used to compensate for variation in workpiece loading position. Before chuck clamping, two-axis sensors measure the workpiece tip position to detect XY misalignment. Using this information to correct the transfer robot’s motion can achieve positioning accuracy within, for example, ±0.5 mm.
光电传感器在质量保证中的应用法
Using Photoelectric Sensors in Quality Assurance
加工工件的尺寸检测
Dimensional Check of Machined Workpieces
对于加工零件的尺寸检测，使用光电传感器进行简化测量是一种有效的方法。在测量直径时，可使用两个相对放置的激光光电传感器来测量工件的阴影宽度，从而实现精度达 ±0.1 mm 的分拣。
在钻孔作业中，若需确认通孔情况，可在工件背面放置一个对射式传感器，以检测钻头尖端是否穿透工件。通过这种方式，可以可靠地检测出沉孔深度不足，或是因钻头折断而导致的未完全钻穿等问题。
For dimensional checks of machined parts, simplified measurement using photoelectric sensors can be effective. For diameter measurement, two opposing laser photoelectric sensors can measure the workpiece’s shadow width, enabling sorting with ±0.1 mm accuracy.
To verify through-holes in drilling operations, a through-beam sensor can be placed on the back side of the workpiece to detect drill tip breakthrough. This enables reliable detection of insufficient counterbore depth or incomplete penetration due to drill breakage.
在自动化系统中的应用
Use in Automated Systems
工厂输送带
Factory Conveyor
在无人化作业系统中，利用光电传感器进行异常检测至关重要。在切屑排出监测方面，安装于输送带上方的对射式传感器可实时监控切屑的流动情况。若10秒内信号未发生变化，系统便会判定为发生切屑堵塞并自动停机，从而避免在夜间无人值守运行时造成设备损坏。
在机器人夹具作业中，传感器可嵌入夹爪内部，用于检测工件是否存在及其具体位置。与真空吸盘吸附不同，机械夹持仅凭夹持力无法准确确认工件状态，因此必须借助光电传感器进行确认。
在输送带上的产品分拣环节，可通过组合使用多个传感器来识别产品形状。通过测量产品的长度、高度和宽度，并在PLC(可编程逻辑控制器)中进行尺寸模式匹配，即可实现多种产品类型的高速分拣。
In unmanned operation systems, anomaly detection using photoelectric sensors plays a critical role. For chip discharge verification, a through-beam sensor installed over a conveyor continuously monitors chip flow. If there is no signal change for 10 seconds, the system determines a chip clog and stops automatically, preventing equipment damage during unattended night operation.
For robot gripper confirmation, sensors can be embedded inside the hand to detect both the presence and position of the workpiece. Unlike suction with vacuum pads, mechanical gripping cannot be validated by gripping force alone, making photoelectric confirmation essential.
For product sorting on conveyors, product shapes can be identified by combining multiple sensors. By measuring length, height, and width and performing dimensional pattern matching in the PLC, multiple product types can be sorted at high speed.
海外工厂部署中的合规性与实际挑战
Compliance and Practical Challenges When Deploying to Overseas Plants
在海外工厂部署光电传感器时，确保符合安全标准是重中之重。除了必须选择带有CE认证标志的设备外，还必须确认当地的电气标准(电压、频率)以及环境要求(IP防护等级、工作温度范围)。
特别是在亚洲部分地区，高温高湿的环境常因冷凝现象导致传感器频繁故障。在湿度超过90%的环境下，可能会出现镜头内部起雾以及电子电路腐蚀的问题。对此，应统一选用高密封性能(IP67及以上等级)的产品，并安装除湿设备。
在备件采购方面，务必选择在当地供应能力强的制造商。即便某个品牌在本国很常见，若其在海外缺乏当地经销商，可能会导致维修或更换的周期过长。在进行海外扩张前，请务必确认目标国家的服务支持覆盖情况，并准备一份可在当地采购的替代产品清单。
When deploying photoelectric sensors in overseas plants, compliance with safety standards is the top priority. Selecting CE-marked equipment is a given, but you must also confirm local electrical standards (voltage, frequency) and environmental requirements (IP rating, operating temperature range).
In particular, hot and humid environments in parts of Asia often cause frequent sensor failures due to condensation. In environments with humidity above 90%—rarely experienced in Japan—fogging on the inside of lenses and corrosion of electronic circuits can occur. As countermeasures, standardize the selection of products with high sealing performance (IP67 or higher) and the installation of dehumidification equipment.
For spare parts procurement, it is important to select manufacturers with strong local availability. Even if a brand is common in Japan, it may have no local distributor overseas, leading to long lead times for repair or replacement. Before expanding overseas, be sure to confirm support coverage in the target country and prepare a list of locally procurable alternatives.
Telco Sensors 是 1975 年创立于丹麦的光电与安全传感制造商，专注为工业与通行领域提供光电检测及安全光幕传感解决方案。品牌以光学检测、安全防护技术应用为核心，产品涵盖光电传感器、安全光幕、U 型叉形传感器、框式传感器、远程光电系统及配套电源配件，并提供 OEM 定制开发与工程选型支持。产品广泛应用于工业门闸、造纸制浆、物料搬运、电梯、包装、锯木林业、洗车、农业、公共交通等领域。
作为高端工业产品一站式服务平台，爱泽工业专注为工业自动化、设备安全、通行防护等领域提供相对全面的光电检测与安全传感产品及解决方案。
我们整合欧美优质资源，汇聚丹麦 Telco Sensors、德国 SICK、德国 Leuze、德国 Pilz、美国 Banner、意大利 ReeR 等品牌，产品线覆盖光电传感器、安全光幕、叉形传感器、框式传感器、测量检测光电系统及配套组件，从流水线检测、设备安全防护、工业门安全防护，到电梯、洗车、林业、包装检测，提供全系产品与工程选型支持。
原标题：为什么样本上性能拉满的光电传感器，到车间就翻车？(中英文)
浙公网安备 33010602000006号
智能制造网APP
智能制造网小程序
微信公众号
