Application Case of Atonm Color Mark Sensor CL4 in Tape Machine Equipment

Ⅰ. Project Background

A tape machine equipment manufacturer undertook an industrial production project. The main body of the tape machine used in this project is black, and it is required to apply white color marks on the tape at certain intervals. When the tape machine operates at a high speed of 4m/s, it is necessary to accurately identify the white color marks and output signals in a timely manner after recognizing the white color marks to trigger subsequent industrial production processes, such as packaging and sorting. To meet this demand, the manufacturer finally selected the Atonm Color Mark Sensor CL4 to realize the color mark recognition function after multiple investigations and comparisons.

Ⅱ. Project Demand Analysis

(Ⅰ) Accurate Recognition Under High-Speed Operation

The tape machine operates at a high speed of 4m/s, which means the color mark sensor needs to quickly capture the white color marks in an extremely short time and ensure the accuracy of recognition to avoid missing detection or false detection. A slight deviation may cause confusion in subsequent production processes, affecting production efficiency and product quality.

(Ⅱ) High-Contrast Color Mark Recognition

The tape has a black background, and the white color marks form a sharp contrast with it. However, this still puts forward requirements for the recognition sensitivity and anti-interference ability of the color mark sensor. The sensor needs to stably distinguish between black and white without being interfered by factors such as changes in ambient light and reflections on the tape surface.

(Ⅲ) Timeliness of Signal Output

After the color mark sensor recognizes the white color marks, it must output signals quickly to ensure that subsequent equipment can respond in a timely manner and complete the corresponding production actions. The delay in signal output may lead to action misalignment, resulting in material waste or equipment failure.

Ⅲ. Solution Design

(Ⅰ) Sensor Selection

The Atonm Color Mark Sensor CL4 meets the project requirements with its excellent performance. It has an extremely short response time of only 200 microseconds, which enables it to quickly capture white color marks during the high-speed operation of the tape. It also has high sensitivity and accurate color recognition ability, which can effectively distinguish between black backgrounds and white color marks. At the same time, it has strong anti-ambient light interference ability and can adapt to different working environment light conditions.

(Ⅱ) Installation Scheme

Installation Position: Based on the structure and operation characteristics of the tape machine, the Atonm Color Mark Sensor CL4 is installed above the tape machine, 150mm away from the tape surface. This height not only ensures the sensor can accurately identify color marks but also avoids the impact of vibration during tape operation caused by being too close.

Angle Adjustment: Adjust the installation angle of the sensor so that its emitted light is perpendicular to the tape surface. This ensures the light irradiates the color marks vertically, improving recognition accuracy. At the same time, fine-tune the angle to make the sensor’s detection range fully cover the width of the tape, avoiding detection blind spots.

(Ⅲ) System Integration

Connect the signal output port of the Atonm Color Mark Sensor CL4 to the tape machine’s control system. According to the interface requirements of the tape machine’s control system, select appropriate connecting cables and communication protocols to ensure the signal output by the sensor after recognizing white color marks is accurately transmitted to the control system. This triggers corresponding control commands to achieve precise control of subsequent equipment.

Ⅳ. Implementation Process

(Ⅰ) Equipment Installation and Commissioning

Install the Atonm Color Mark Sensor CL4 at the designated position of the tape machine according to the design plan, then adjust the angle and fix it.

Set the initial parameters of the sensor, including sensitivity, detection distance, and output mode. Simulate white color marks on the tape to test the sensor’s recognition effect, and continuously adjust parameters until the sensor can stably and accurately recognize white color marks and output signals in a timely manner.

(Ⅱ) Joint Commissioning Test

After completing the sensor installation and commissioning, conduct joint debugging of the tape machine and subsequent production equipment. Start the tape machine and make it run at a speed of 4m/s, then observe the sensor’s recognition of white color marks and the timeliness of signal output. At the same time, check whether the subsequent production equipment can accurately perform corresponding actions (such as starting/stopping of packaging equipment, sorting actions of sorting equipment) according to the signals output by the sensor. Through multiple joint commissioning tests, troubleshoot and solve the problems found one by one to ensure the entire system operates stably and reliably.

Ⅴ. Project Effect Evaluation

(Ⅰ) Recognition Accuracy

After a long-term operation test, the Atonm Color Mark Sensor CL4 meets the project’s requirements for color mark recognition accuracy when the tape machine runs at 4m/s.

(Ⅱ) Stability and Reliability

Under different ambient light conditions and long-term continuous operation, the Atonm Color Mark Sensor CL4 always maintains a stable working state. No performance degradation or malfunctions caused by environmental factors or equipment fatigue occurred, demonstrating good stability and reliability.

Ⅵ. Project Summary

In this project, the application of the Atonm Color Mark Sensor CL4 in tape machine equipment was a complete success. Its excellent performance effectively solved the problem of white color mark recognition during the high-speed operation of the tape machine, meeting the project’s strict requirements for color mark recognition accuracy, signal output timeliness, and equipment stability. Through this application case, the reliability and practicality of the Atonm Color Mark Sensor CL4 in the field of industrial automation have been verified, providing valuable experience and reference for similar color mark recognition projects of tape machine equipment.