What are the benefits of using a fiber optic sensor?

In sectors such as manufacturing, logistics, and electronics assembly, you understand the value of having dependable detection and sensing technologies. It could be verifying that a tiny part is in position, controlling the speed of a production line, or checking that products are within the acceptable quality limit. Having the correct sensor is crucial in determining the efficiency of the processes. Recently, a growing number of companies are adopting fiber optic sensors, and the reasons are clear. These tools offer a number of benefits that meet the needs of diverse and modern industries, such as the ability to withstand harsh working conditions and the ability to provide accurate results. Here are some of the advantages of using fiber optic sensors.

Outstanding Flexibility When It Comes to Challenging Job Situations

One reason why people choose fiber optic sensors is because of the way they withstand unfriendly conditions. It is a fact that some industrial environments are hostile to sensitive technologies. Take any car assembly plant. Temperatures soar during welding. Food processing facilities are also tough environments. They spoil a sensor with abundant moisture and occasional splashes of water. Dense and fast moving conveyor belt systems, like those found in packaging lines, create heavy vibrations that cause ordinary sensors to fail. Not fiber optic sensors, though.

It is the absence of complex circuitry and mechanical components that makes fiber optic sensors different. They won't be forced to fail within extreme conditions. They use light for detection and are insensitive to temperature and humidity extremes. They also resist interference caused by other machines. In metalworking, for example, fiber optic sensors are immune to false readings caused strong electrical currents and cutting tools that would render a traditional photoelectric sensor useless. The sensor lets production run uninterrupted while other sensor types are forced to be repaired or replaced.

Suppliers such as Chenwei Automation have learned this in practice. Their fiber optic sensors can withstand the conditions found in automotive paint shops (high temperature and potentially hazardous chemicals) and beverage bottling plants (large volumes of water). The ability to withstand different environments saves businesses money from not having to replace broken sensors and minimizes downtime. In production environments, this is critical.

High Precision for Tiny or Detailed Detection Tasks

Another advantage of fiber optic sensors is the ability to focus and detect minute detail. This is very useful in the detection of small and very small objects. In the electronics industry, for example, some sensors have to work on components that are smaller than fingernails (microchips or small connectors for mobile phones). Using regular sensors in this field is a sure way to waste resources. They may miss the component altogether or indicate that a component is present when in fact it is not, resulting in defective products.

Fiber Optic Sensors use thin and flexible fiber optic cables, enabling them to tightly surround the object being identified even in cramped quarters. The light signal is so sensitive that it can capture details as small as a few microns, smaller than a human hair. Picture assembling a smartwatch and determining if a tiny battery is properly positioned in its slot. Off-center placement is something a traditional sensor might miss, but a fiber optic sensor can spot this.

Quality Control Chenwei Automation's fiber optic sensors are built to this level of precision in the production of medical devices, like syringes. Ensuring there are no small, detectable surface cracks, imperfections or flaws is critical in the product's safety. The electronic and medical device manufacturers trust that their products will meet the industry standards as a result of the quality and special processing of the Chenwei Automation's fiber optic devices. Working with small components and parts will always require that sort of accuracy.

Slim and Small

Every square foot in a factory is valuable. So is your time. When was the last time you installed a massive and heavy sensor in a cramped space like a small robotic arm or a narrow conveyor belt? It should not take a lot of planning to get sensors in place. Traditional sensors take a lot of space due to their wiring and plastic casings. So, you are rebuilt if not redesign a part of your equipment. That is not the case with fiber optic sensors. Their small size make installations painless.

The fiber cable is the most essential component of a fiber optic sensor. It is thin, flexible, and typically a few millimeters wide. The control unit, which processes the light signal, and is also compact, can be placed inconspicuously on a nearby wall or inside a control panel. This way, you don't have to rearrange your entire production line to fit the sensor. In logistics centers, for example, conveyor belts used for sorting small packages tend to be narrow and have very little free space beside them. A fiber optic sensor can be attached to the very edge of the conveyor belt without interfering with the movement of the packages or belt.

This compact design promotes sensor relocation. If you have to reconfigure your production line to make a different product, the fiber optic sensor can be moved. Flexibility is built into the design of the sensors from Chenwei Automation. This allows businesses to install the sensor in multiple locations without being stuck in one. In a work environment where you are trying to make the most of your space, having a sensor that is small and uncomplicated to install is a distinct perk.

Low Energy Consumption and Long Service Life

Finally, when it comes to saving on costs, fiber optic sensors truly shine. This is due to their low energy consumption and lengthy service life. Speaking to the energy-saving potential, many industrial facilities operate equipment on a 24/7 basis. Consequently, savings on electricity, no matter how small, become substantial. Compared to traditional sensors which are equipped with powerful LED and designed with complex circuitry, fiber optic sensors are much less power hungry. While savings in power consumption may go unnoticed on a day-to-day basis, they become pronounced over a year and positively impact the energy bill.

Finally, let's talk about the lifespan of fiber optic sensors. Nothing is more frustrating than having to stop production to replace a sensor that broke after just a few months. Traditional sensors often have parts that wear out quickly, such as moving switches, and so they are replaced frequently. But fiber optic sensors have no moving parts. The fiber optic cables are made out of strong materials that resist breaking and degrading, allowing them to withstand constant use over several years, which greatly reduces the frequency of sensor replacement.

Let's take the products from Chenwei Automation as an example–many clients provide testimonials that some of their products, a fiber optic sensor, have been used for 3 to 5 years without issues. This saves lots of time on maintenance, reduces the need for replacements, and cut downtime for your production line. During your business operations, every dollar and every minute is valuable, hence, an energy efficient and long lasting sensor is a great investment.