I.

Introduction
1. Basic information of sensor used in this report
Diffuse-reflective photoelectric sensors are a type of optical sensor that are
commonly used in industrial automation applications. They have a built-in
light emitter and a receiver. These sensors detect the emitted light bouncing
off of an object, and thereby determines if an object is present.
The sensor used in this report is the photoelectric sensor E3FA-DP21.

The photoelectric sensor E3FA-DP21 is used for obstacle detection.

Therefore, the sensor is often used in automation lines.

2. Purpose of the report

Understand the general operation principle of the photoelectric sensor
applied on the automation lines and the principle of the photoelectric sensor.
The sensor is taken as an example of the photoelectric sensor E3FA-DP21.
Understand the sensor calibration steps, measurement accuracy and
environment factor that affect sensor performance.
Understand the common applications of photoelectronic sensor in industry
and consumer.
3. Summary of the content of the report
Informal 6 main issues:
1. Explanation of the sensor’s operating principle
2. Sensor specifications
3. Calibration produces
4. Measurement accuracy
5. Environmental factors that affect sensor performance
6. Industry and consumer applications

II. Sensor Technology

1. Explanation of the photoelectric sensor operating principle
What is the photoelectric sensor?
A photoelectric sensor consists primarily of an emitter for emitting light and
a receiver for receiving light. When emitted light is interrupted or reflected
by the sensing object, it changes the amount of light that arrives at the
receiver. The receiver detects this change and converts it to an electrical
output. The light source for the majority of photoelectric sensor is infrared or
visible light.

Classification of photoelectric sensors:

- Through-beam sensors
- Retro-reflective sensors
- Diffuse reflective sensors
In this report, we focus on the diffuse reflective sensor to detect objects.

What is a diffuse reflective sensors?

 A diffuse photoelectric sensor, also known as diffuse-reflective sensor is an
optical proximity sensor. It uses the principle of reflection to detect objects in
its sensing range.

The object itself acts as a reflector, eliminating the need for a separate
reflector unit. The intensity of the reflected light is used to detect the
presence of the object.
Working principle of through-beam sensor
Diffuse photoelectric sensors, like every other photoelectric sensor, have built-in
circuitry to modulate, emit, receive and demodulate the light beam and control
the output. They have both the emitter and receiver elements built into the same
housing.

A photoelectric sensor, in general has a few circuits inside:

1. Modulator and Amplifier

2. Transmitter and Receiver
3. Detector Amplifier and Demodulator
4. Output

1. Modulator and Amplifier stage

 This stage generates a signal to rapidly turn the LED on and off. The
signal typically has a shape of a square wave.

The amplifier stage uses the signal from the modulator stage and drives
the LED. Some sensors do not have a modulator stage and outputs a direct
beam. These tend to have a higher range, but are more prone to
interferences caused by external light sources.
2. Transmitter and Receiver Stage
The transmitter is often an LED due to its lower power consumption and
switching speed. The emitted light is in the visible light and the infrared
wavelength range. Red LEDs are the most common among the visible
light types.

To receive the signal, a photodiode/phototransistor is used. For pulsating

emitter type, this phototransistor is spectrally coupled with the emitter
LED’s wavelength. This ensures that the phototransistor allows more
current to flow when it receives the light that falls in the emitter LED’s
wavelength.

3. Detector Amplifier and Demodulator

The received signal is amplified and further conditioned by filtering and

smoothing. The receiver circuit also works in sync with the transmitter,
reducing further chances of external interruptions.

This helps the sensor to reject any unwanted light beams emitting at
different frequencies that are directed towards the sensor.

4. Output Stage

The output stage receives the conditioned signal from the demodulator
and switches the output. This can be sourcing or draining for a PNP/NPN
type sensor, or simply activating a normally open or normally closed
contact for a relay output type sensor.
III. Sensor performance
1. Sensor specifications
The Emitter and Receiver are installed in the same housing and light
normally does not return to the Receiver. When light from the Emitter
strikes the sensing object, the object reflects the light and it enters the
Receiver where the intensity of light is increased. This increase in light
intensity is used to detect the object.

Features:

 Sensing distance ranging from several centimeters to several

meters.
 Easy mounting adjustment.
 The intensity of reflected light, operating stability, and sensing
distance vary with the conditions (e.g., color and smoothness) on
the surface of the sensing object.

2. Calibration procedures
Method for calibrating a through beam sensor
In the process of calibrating, laser displacement sensor moves along Z-
axis and Y-axis of machine, CCD camera takes the image of the spot
projected by laser beam on the calibration plate, then calculate the laser
beam’s direction based on the movement distance of laser displacement
sensor and the spot’s position on calibration plate.
3. Measurement accuracy

Sensing distance White paper 300 x 300 mm; 100mm

 Spot size 40 x 45 mm

Differential distance 20% max

Light source Red LED (624nm)

Power supply voltage 10 to 30 VDC±10% ripple (p-p) 10%

included

Current consumption 25 mA max

Control output PNP open collector

30 VDC max.
100 mA max.
Residual voltage: 3 V max.

Light-ON/Dark-ON selectable

Protective circuit Output short-circuit protection, Output

reverse polarity protection, Power
supply reverse polarity protection

Response time Operate or reset: 0.5 ms max.

Sensitivity setting Single-turn adjustment

Ambient illuminance Incandescent lamp: 3,000 lx max.

Sunlight: 10,000 lx max.

Ambient temperature range -25 to 55 ℃ (with no freezing or

(Operating) condensation)

Ambient humidity range 35 to 85% (with no condensation)

(Operating)

Degree of protection IEC: IP67

DIN40050-9: IP69K

Indicator Operation indicator (orange), Stability

 indicator (green)

Connection method M12 connector models

Material Case: ABS

Lens: Methacrylate resin (PMMA)
Display: Methacrylate resin (PMMA)
Adjustment: POM
Nut: POM

4. Environmental factors that affect sensor performance

Sensors often have plastic housings, so they should not be exposed to direct
sunlight, especially in the measuring area of the sensor. Due to the strong
infrared radiation of the sun, the sensor will be interfered with. Do not install
the sensor signal wire together with the power cord. Because the power cord
is subject to a large load, it will generate heat, and the temperature will affect
the results of the measuring device.

IV. Photoelectric Sensor Applications

1. Industrial photoelectric sensors
Many industries around the world are using photoelectric switches to gain
benefits, such as:
- Food and Beverage Industry:
 Photoelectric sensors are also used in assembly and strapping lines
in the food and beverage industry. For example, you can install a
plant to cap bottles by precisely adjusting and arranging each cap.
In the case of errors, photoelectric switches can provide great help.
It helps the company identify errors and correct them to ensure the
smooth operation of the plant.
- Automotive Industry:

 When a company builds a car body, every component needs to

move along the creative line with solid consistency. Every part
needs to stop before a well-planned important station. Therefore, it
can be welded well, or, in any case, it can be handled without error.
The photoelectric switch wiring can distinguish when the
applicable station is close to the target. Then, the line can be
stopped and the parts can be prepared.
 The automatic light switch used in the automotive industry has high
accuracy. This makes it possible to provide precise results even
when working on different items with shiny surfaces.

- Mechanical Engineering:
 The photoelectric sensor can provide quite high reliability, working
with the huge machine in a beautiful synchronization. In this case,
there is no place for it. Machine parts can be arranged and emptied
using photoelectric sensors.

- Material Handling:
 In storage facilities that have complete or semi-automation,
photoelectric sensors make it possible to efficiently track objects in
storage, help with automating the storing and stacking of goods,
and helps maintain inventories.

- Pharmaceutical Industry:
 Pharmaceutical industry applications such as packaging of
medicines also use photoelectric sensors. During packaging,
sensors can be used to avoid discrepancies such as empty
packaging due to medicine tablets not being present on the line, etc.
  Photoelectric sensors are evolving with the rise in demand and
accurate, efficient sensors are available that can be used for various
purposes. With a sensing range of up to 100mm, the photoelectric
sensor provides efficient sensing. They have a high IP rating
making it ideal for them to be used in harsh conditions.

2. Photoelectric sensors in daily life

- Doors and gates:
 Automatic doors and gates, for example on buses, trains, elevators,
garages, etc. need to have reliable sensing technology so that they
open and close at correct times. The entire area in front of the door
needs to be under the sensing area for the automated doors to work
properly. Photoelectric sensors coupled with infrared scanners can
detect approaching people or vehicles.

V. Conclusion

1. Summary of the report’s findings

Understand the general operation principle of the photoelectric sensor
applied on the automation line and the principle of operation of the
photoelectric sensor.
The sensor is taken as an example of the ultrasonic sensor E3FA-DP21.
Understand the sensor calibration steps, measurement accuracy, and
environmental factors that affect sensor performance.
Understand the common applications of photoelectric sensors in industry
and consumer.

2. Recommendations for future research and development.

- Upgrade the sensor production line to be more optimized, use the right
materials to increase accuracy in automation, and improve to achieve
higher working efficiency.