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CALOPLEX sensors are measurement feedback devices that operate based on the optical principle of gratings. Grating scales are frequently used in the closed-loop servo systems of CNC machine tools for detecting linear or angular displacement. The measurement output signal is a digital pulse, characterized by a large detection range, high detection accuracy, and fast response speed. For example, in CNC machine tools, they are commonly used to detect the coordinates of tools and workpieces to observe and track tool path errors, thereby compensating for tool motion errors. Depending on the manufacturing method and optical principle, grating scales are divided into transmissive gratings and reflective gratings.

CALOPLEX sensor principles

Photoelectric sensors achieve control by converting changes in light intensity into changes in electrical signals. Generally, a photoelectric sensor consists of three parts: a transmitter, a receiver, and a detection circuit. The transmitter emits a light beam toward the target. The emitted light beam usually comes from a semiconductor source, such as a light-emitting diode (LED), a laser diode, or an infrared emitting diode. The light beam is emitted continuously or with modulated pulse width. The receiver consists of photodiodes, phototransistors, and photocells. Optical components such as lenses and apertures are installed in front of the receiver. Behind it is the detection circuit, which filters valid signals and processes them. In addition, the structural components of photoelectric switches include emitter plates and optical fibers.

CALOPLEX sensor classification

1) Slot-type photoelectric sensor: A slot-type photoelectric sensor is formed by mounting a light emitter and a receiver facing each other on opposite sides of a slot. The emitter emits infrared or visible light, which the receiver detects when unobstructed. When an object passes through the slot and blocks the light, the photoelectric switch activates, outputting a switching control signal to cut off or connect the load current, thereby completing a control action. Due to structural limitations, the detection distance of slot switches is generally only a few centimeters. 2) Through-beam photoelectric sensor: Separating the emitter and receiver increases the detection distance. A through-beam photoelectric switch consists of one emitter and one receiver, also known as a through-beam photoelectric switch. The detection distance of through-beam photoelectric switches can reach several meters or even tens of meters. When using a through-beam photoelectric switch, the emitter and receiver are installed on opposite sides of the object's path. When the object passes through and blocks the light path, the receiver activates and outputs a switching control signal. 3) Retro-reflective photoelectric switch: The emitter and receiver are housed in the same unit, with a reflector plate installed in front. It uses the reflection principle to achieve photoelectric control, known as a retro-reflective (or mirror-reflective) photoelectric switch. Under normal conditions, the light emitted by the emitter is reflected back by the reflector plate and received by the receiver. Once an object blocks the light path and the receiver no longer receives light, the photoelectric switch activates and outputs a switching control signal. 4) Diffuse-reflective photoelectric switch: The detection head of a diffuse-reflective photoelectric switch also contains an emitter and a receiver, but there is no reflector plate in front. Under normal conditions, the receiver does not detect the light emitted by the emitter. During detection, when an object passes through, it blocks the light and reflects part of it back. The receiver then detects the light signal and outputs a switching signal.

CALOPLEX sensor application cases

1) Photoelectric sensors in laser weapons: Since photoelectric sensors are highly sensitive to infrared radiation, visible light, or both, they are more likely to become targets of laser attacks. Furthermore, electronic systems and the sensors themselves are highly susceptible to interference from thermal noise and electromagnetic noise generated by lasers, preventing normal operation. Laser weapon attacks on photoelectric sensors on the battlefield mainly occur in the following ways: Using a laser beam of appropriate energy to "blind" the sensor, rendering it unable to detect or continue tracking already detected targets. Or, if the sensor is guiding a weapon toward a target, blinding it causes loss of the target. In summary, since sensors play an increasingly important role on the battlefield and are vulnerable to laser attacks, they have become the primary targets of low-energy laser weapons. 2) Photoelectric sensors in automatic meter reading systems: With the development of microelectronics, sensor technology, computer technology, and modern communications, photoelectric sensors can be used to develop automatic meter reading systems. The aluminum disk of an electricity meter rotates driven by torque generated under the influence of eddy currents and magnetic fields. Using a photoelectric sensor converts the number of rotations of the aluminum disk into pulse counts. For example, by partially blackening a section of the rotating shiny aluminum disk and pairing it with a reflective photoelectric emitter-receiver pair, pulses are generated at the blackened section as the disk rotates. The number of rotations is sampled and converted into corresponding pulse counts, then sent via an optocoupler isolation circuit to the T0 port of the CPU for counting processing. Using optocoupler isolators effectively prevents interference signals from entering the microcomputer. Combined with other transmission methods, this forms an automatic meter reading system. 3) Photoelectric sensors for monitoring smoke and dust pollution: A photoelectric sensor is a small electronic device that detects changes in received light intensity, achieving control functions by converting changes in light intensity into changes in electrical signals. Due to characteristics such as non-contact operation, fast response, and reliable performance, photoelectric sensors are widely used in industrial automation devices and robotics. We can utilize the characteristics of photoelectric sensors to detect smoke and dust conditions; thus, the strength of the output signal from the photoelectric sensor reflects changes in flue gas turbidity. 4) Hygienic washdown-resistant photoelectric sensors: Washdown-resistant sensors provide extremely high reliability and ease of use while minimizing operating costs. Equipped with IO-Link interfaces and the proTect+ sealing concept, which significantly extends service life, these two new sensors are suitable for demanding applications and are an ideal solution for the food and beverage industry.

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