Moving rapidly from pattern detection to precise position identification

14. November 2016

Greater flexibility with the pattern sensor

The PS30 pattern sensor, with its enormous flexibility, responds to trends in the packaging industry toward ever more complex and unusual labels. Offering unrestricted design freedom, the PS30 impresses not only when used on endless tracks – it also delivers outstanding results when detecting patterns on individual objects. The sensor detects and positions labels and any objects with a distinctive pattern reliably without print marks. Even without this unwanted design factor, the PS30 knows when an endless track needs to be cut into the roll-fed labeling or whether a package or tube is in the right position for sealing.



Exact positioning of endless tracks or individual objects – all without a mark, using the image.

Exact positioning of endless tracks or individual objects – all without a mark, using the image.


The innovative PS30 uses contrast to determine positions. And the best thing about it? In this way, it can also detect two-dimensional patterns. To begin with, the system learns an image using distinctive reference areas with a good recognition factor. The sensor reliably recognizes the patterns by analyzing these significant and distinct areas of the image – analysis of the entire image is not necessary.

The PS30 also accurately positions challenging objects or labels with low contrasts or interference from glare – it always decides on the reference area with the best possible contrast. This saves on material and time. It mainly saves time because image determination using pre-defined reference areas reduces the amount of processing power required. The conveyor speed rises as the time needed to retrofit the machines falls – all thanks to the option to store several image profiles.

Furthermore, less material is needed for labels when using the PS30, because significant material overlap is no longer necessary to cover the print mark. The PS30 therefore already offers some features of a vision sensor, which is similar to a contrast sensor when the speed of the material is high at the same time.

Full flexibility also for batch size 1

The device can be commissioned quickly, flexibly, and in a user-friendly way via the control panel or the integrated web server using the convenient human-machine interface (HMI). Various jobs can be stored and managed along with their image and teach-in data. This allows the format to be changed quickly and easily by selecting from the job file. The job data is selected using the job designation or a preview image.

There is also a great deal of flexibility when it comes to defining the switching point. This can be defined visually and directly using the image. The switching point can be defined by the machine operator via the HMI. The sensor operates according to the principle of “what you see is what you get”.




Defining the switching point (green line) directly on the image.

Defining the switching point (green line) directly on the image.


A pattern for success in Industry 4.0

The sensor is also already prepared to meet the requirements of Industry 4.0. With its Ethernet interface and integrated web server, it enables direct access to the sensor and its configuration via PC, tablet, or HMI with a standard browser outside of the PLC and without the need to install software as usual.

In addition, the sensor provides a great deal of analysis data, such as the detected object or format length, the current teach-in and process configuration, as well as the teach-in and process quality. The integrated web server enables easy access to sensor data and easy integration into a current visualization via OPC DA or JSON API.


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