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More and more users today are turning to fiber optic sensors to address sensing
applications that have minimal space, adverse environment or electromagnetic
interference and radio frequency interference problems. Why? The answer to this
question lies in knowing what a fiber optic sensor is.
Figure B
Cladding
Core
etc. This, however, is not the case. As a matter of fact, users who use glass
fibers in applications that require repeated flexing or sharp bending tend to
experience breakage. The reason for this is the fact that individual glass fibers
can easily receive excessive stress and fracture. Breakage of a few strands of
glass fibers in a bundle is generally not noticeable. As more and more fiber
strands break, however, the signal strength loss will increase proportionately.
In order to achieve a high degree of light coupling efficiency, fiber manufacturers
optically polish the sensing surface of the sensing face; the polishing process
ensures that the end of each fiber is perfectly flat. Since glass fibers require
polishing to ensure high degree of light coupling efficiency, it is recommended
that customers not cut the fiber.
Non-standard cable lengths need to be special-ordered.
Plastic Fibers
Whereas glass fiber optic cable is made of multiple glass fiber bundles, plastic
fiber optic cable is usually a single strand (typically .254 mm to 1.52 mm in
diameter). Unlike glass fibers, plastic fibers are flexible, and are excellent
solution for applications that require repeated flexing. Its flexibility enables it to be
used in extremely tight areas. In recent years, companies such as Omron,
among others, have released plastic fibers that they call multi-core high-flex
plastic fiber. Unlike conventional plastic fibers, which use a single core of
material, multi-core fibers use multiple independent cores. This configuration
allows a bending radius as small as 1mm, and as result gives it a flexibility similar
to electric wire. These Omron fibers can be bent at 90 with no reduction of light
transmission. The 1 mm bending radius enables these fibers to conform to
machine contours without experiencing any problems normally associated with
extreme vibrations or pulling. Various vendors also offer coiled versions of plastic
fibers for applications that require articulated or reciprocating motions.
Applications that are exposed to chemicals or solvents, and have high operating
temperatures are generally more conducive for glass fibers. Plastic fibers are
less tolerant to these types of conditions. There are instances, however, where
sheathing materials such as Teflon, nylon, and polypropylene are used to shield
plastic fibers; these sheathing materials enable plastic fibers to withstand these
extreme conditions.
The level of attenuation of light energy as it travels through fiber optics is
influenced by three factors. These factors are the fiber material, the distance
traveled in the fiber, and the wavelength of the light. The performance of glass
fibers is fairly consistent at all wavelengths. However, in the case of plastic fibers,
the attenuation of infrared light emitting diodes (LEDs) is greater than the
attenuation of visible LEDs, such as red. Plastic fibers tend to absorb infrared
LEDs. As a result, red LEDs are generally used to ensure effective sensing.
When ordered, plastic fibers typically come with a cutting device. The cutting
device enables customers to cut fibers to their desired length.
The critical angle is less than the angle of incidence for the particular
combination of materials (see Figure C). The materials in this case are
the core and the clad of the optical fiber; the materials that make up an
optical fiber.
Figure C
Cladding
Critical Angle
Core
The light is in the denser medium and approaching the less dense
medium. The cladding material is less dense than the core material,
and as a result has a lower index of refraction.
As long as the two conditions are met, the principle of total internal reflection
applies whether the fiber optic cable is bent or straight (within a defined minimum
bend radius).
Figure D
Emitter
Sensing Head
Receiver
Latest Developments
As industrial automation applications continue to get more complex, and as real
estate becomes more of an issue, the need to develop a more sophisticated
sensing device in a smaller package continues to increase. Companies such as
Omron, Keyence, Banner, SUNX, to name a few, have started addressing this
need by introducing new waves of fiber optic sensors.
These companies now offer fiber optic amplifiers (remote sensors) that have
easy-to-read digital LED. The numerical values and percentages that are
displayed enable customers to monitor and precisely set up their sensing
application. The digital display provides users real time feedback, which allows
users to know the slightest misalignment or when dust accumulation on the fiber
optic cable tip is beginning to degrade sensor performance.
Some of these new fiber optic sensors have also significantly reduced sensor
wiring. Models that allow 16 sensors to be connected together are now available.
Only one power line is required for all 16 sensors. How? A master connector
(from the master sensor) distributes power to the slave sensors, thereby
eliminating the power lines that each slave sensor would normally require (see
Figure E). Only output wiring is needed for the slave fiber optic sensors. In
addition to reducing wiring, some of these connector designs have also simplified
installation and maintenance. Some have unique connector design that allows
users to easily detach the sensor without disturbing the fiber cable installation or
output wiring.
Figure E
Fiber optic sensors with dual outputs are now also available. This configuration
offers the performance of two sensors in one package. Certain models offer
either two independent digital outputs or a combination of analog and digital
output. Other models now also offer lockout feature; a feature that prevents
unwanted adjustments or tampering of the sensors settings. This feature allows
the customers to give their employees on the shop floor a level of autonomy
without compromising their performance goals.
Most of these sensors now incorporate either a 12-bit or 16-bit CPU as well as
12-bit AD converter, which enable these new sensors to have higher resolution
and faster response time. Some of these sensors have a response time as fast
as 20 microseconds.
Customers can also appreciate the various built-in auto-teach functions that
enable quick sensor setup. Most of the available models now offer as many as
four different self-teaching functions. This enables customers to select the
method that best meets each sensor application.
Certain models also allow customers to perform remote settings. This is
especially important in potentially hazardous environments. A fiber optic sensor
that has a remote control programmer (see Figure F) that comes with a standard
5-foot cable (16 foot cable is also available) is now available. With this remote
control programmer, customers with sensors in potentially hazardous
environments can now monitor and program them from a safe distance. The
remote programmer has a digital display that shows the incident and the
threshold levels simultaneously so that customers can fine-tune the threshold
point while monitoring the incident level. The programmer also saves customers
sensor setup time. With the remote control programmer, customers can quickly
copy the configuration settings from one sensor and pasting them to as many
additional sensors as necessary. The programmer also gives users the ability to
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copy the settings for an entire group of sensors and paste the settings to a new
group of sensors on another machine. This is a real time saver for OEMs and
users with many similar machines.
With all the flexibility and benefits that the fiber optic sensor system provides
users, it is no wonder that it is becoming more widely used. As industrial
automation applications continue to become more sophisticated, expect sensor
experts to continue developing innovative fiber optic sensors.
Figure F