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OGD precision distance sensor

Simplify error-proofing to reduce product scrap

  • Reduce risks associated with product recalls by error-proofing in assembly steps.
  • Reduce scrap rate by early identification of manufacturing process drift.
  • Eliminate false triggers linked to reflectivity and position of target.
  • Error-proofing solution is easier to implement versus complex vision cameras.
  • Increase number of error-proofing points on machine because of the price / performance ratio.

The OGD laser sensor measures distance to any target. Powered by ifm's pmd time-of-flight technology, the OGD provides accuracy and flexibility in many applications regardless of target material or angle. The OGD makes machines reliable by producing high quality parts.

Traditional error-proofing solutions such as vision systems or 2D devices are accurate, but integration is complex and price points are high.

ifm's OGD Precision Sensor is designed with a powerful laser light source that detects deviations in the positon of tiny parts via distance measurement to the nearest millimeter, making it ideal for quality control.

Challenges Experience ifm!
Production defects often go undetected till the end of a manufacturing process, wasting time and money The OGD precision sensor catches errors immediately during a process, allowing for corrections to be made on the fly to reduce loses.
Traditional error-proofing solutions, such as vision systems or 2D devices are accurate, but integration is complex and price points are high. "Time of flight" core principle ensures consistent measurement in quality control tasks. Setup takes less than five minutes. Also, precision sensors offer the right balance of performance and price for error-proofing, so the OGD can be used throughout the entire process run!

Applications

Assembly automation error proofing

What if your optical sensor could see whether a small part was missing, upside down or misaligned before it moved to the next assembly step?

The OGD Precision sensor is ideal for error proofing. The 1 mm diameter laser light spot easily detects the slightest change in part orientation.

Accurate position monitoring

What happens when the quality of your part does not meet specification? What if you could also collect the data from your machines to prove correct quality?

The OGD Precision sensor locates a miniature plastic lug to verify it is correctly positioned on the carrier before the workpiece is transferred to the next assembly station. If the lug is not positioned correctly, the distance will be off by a few millimeters. The sensor detects and signals this deviation.

 

What if you could detect a tapped hole with a single laser sensor?

If your part is missing threads at final assembly, your manufacturing process is not as efficient as it can be. The cost to repair the nonconformance increases the further down the process it is detected. If it reaches your customer, in addition to the cost to repair/replace the part, you also may have damaged your customer relationship. Measuring small thread sizes by distance is very expensive.

The OGD sensor detects the reflectivity of a part. A tapped hole has a very different reflectivity than an untapped hole. This value is avialable from all OGD sensors via IO-Link, but you can set the OGD582 to display and send a switching signal based upon reflectivity.

Technology overview

ifm’s laser distance sensors leverage the advantages of pmd time-of-flight technology for accurate and long range distance measurement.

Light waves propagate from the laser light source. When the light bounces off the target, the phase pattern shifts and the shift is directly proportional to the distance.

Diagram of sensor using time of flight technology

This proprietary technology provides:

  • Robust detection of small reflective targets
  • Quick installation due to color and angle independence
  • Measured distance information via IO-Link

Unlock sensor potential with IO-Link

Via IO-Link, the OGD family can provide:

  • Current distance to target
  • Target reflectivity
  • Device status
  • Remote parameterization

FAQs

Q. Why is error proofing important in manufacturing?

A. Error proofing ensures the quality of products leaving a manufacturing plant. The sooner defects are found, the less expensive it is to fix. The image below is a representation of the escalating cost of defects the further they go into the assembly process.

Q. How is error proofing accomplished?

A. There are three general methods for error proofing:

  1. Single point solutions – high accuracy lasers, background suppression sensors, distance measurement
  2. 2D vision systems – most expensive and highest cost
  3. Manual checks – least effective due to labor costs and inconsistency

Manual checks are decreasing over time and the single point solutions increasing over time.

Q. How does PMD time-of-flight technology compare to other single point solutions for distance measurement?

A. Standard background suppression sensors are lower-cost alternatives, but they can rapidly lose accuracy as sensing distance increases. Ultrasonic sensors are also lower-cost, but they can be negatively affected by background noise, ambient temperature and target size. Traditional time-of-flight sensors can be more accurate, but that accuracy comes at a higher cost and typically in a larger housing.

Q. Why can I only set the set point in the programming menu and not the reset point?

A. The difference between the set and reset points is known as hysteresis. It keeps the output stable if the measured value varies around the set point. The OGD sensors have a fixed hysteresis that depends on the reflectivity of the background and it is shown on the datasheet. For black backgrounds, the hysteresis is approximately 5 mm and for white backgrounds, it is approximately 3 mm.

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