OMRON ZX-GT Smart Sensor: High-Accuracy 10-µm Laser Measurement
Brand: OMRON
Product Type: Industrial Measurement Sensor
Introduction
The OMRON ZX-GT Smart Sensor is a Wide Laser Beam Measurement Sensor utilizing a Line Imaging Device Type. It offers exceptional precision with 10-µm accuracy over a substantial 500-mm range, setting new standards for dimension measurement in industrial applications.
Visual Description: The document cover displays the OMRON logo, abstract grey circles, and an image of two sensor heads emitting a red laser beam, illustrating the measurement principle. It highlights "10-µm Accuracy by 500-mm Range".
New Standards for Dimension Measurement
The ZX-GT overcomes traditional limitations of laser measuring sensors, such as confined measurement areas and positioning errors. It enables consistent measurements within a 500 mm area, regardless of work orientation or stage of production, without interference from work feed or size limitations.
Visual Description: A diagram illustrates the 500mm measurement area. Another graphic compares the "10-micron by 500-mm" accuracy to measuring a tiny gap between a long airplane and a runway, emphasizing its precision. A diagram explains the concept of measuring an airplane's gap to the runway, highlighting the small 1mm gap over 50 meters.
Key Features
10-µm Accuracy by Non-Contact Method
The ZX-GT is unique in its ability to measure and locate position with 10-µm accuracy without physical contact. Its advanced algorithm supports various applications, including precise measurement of glass and mirror surfaces.
Visual Description: A diagram shows the sensor head emitting a laser and detecting an object. Text explains that the sensor achieves 10-micrometer level accuracy through sub-pixel processing of the detected shadow.
High Speed Measurement
Featuring OMRON's unique TRIO (Triple parallel processing) algorithm, the ZX-GT can take up to 2000 high-speed samples per second, achieving speeds 7 times faster than conventional products, significantly reducing tact time.
Visual Description: A timeline graphic compares the measurement speed: ZX-GT at 0.5ms versus a previous product at 3.3ms, indicating "1/7 of the previous speed". A diagram illustrates the "New concept TRIO structure" with CPU, FPGA, and CPU components.
Compact Design
The controller is the smallest in its class, continuing the ZX series design. Combined with its compact sensor head, it is ideal for integration into various equipment and tight spaces.
Visual Description: Images show the compact sensor head and the controller, highlighting their small size and suitability for integration.
Strong Temperature Compensation
To ensure measurement accuracy, the ZX-GT significantly reduces the influence of temperature changes. This leads to a low error rate of just 0.01% (2.8 micro-meters) under varying environmental conditions.
Visual Description: A graph illustrates how the "Imaging Device method" provides consistent measurement across temperature fluctuations (Hot to Cold), unlike the "PD method (legacy method)".
Dedicated Glass-Detection Function
Leveraging OMRON's unique MRC filter (Mirror Reflection Cut Filter) and Imaging Device methodology, the ZX-GT accurately detects edges of transparent objects like glass (including coated glass) and reflective surfaces like mirrors, which are challenging for traditional sensors.
Visual Description: A diagram shows the sensor detecting the edge of a glass object. Another illustration demonstrates its effectiveness on mirror-finished surfaces.
Collimate Optical Technology
OMRON's proprietary collimate optical technology creates an ideal parallel laser beam, minimizing errors within the measurement area for the longest and most accurate measurements.
Visual Description: A diagram illustrates how laser light is collimated using mirrors and lenses to form a parallel beam.
Applications by Industry
- Automotive & Automotive-components: Outer diameter measurement of metal objects, large-scale pipes, and crankshafts.
- LCD & PDP: Glass-edge measurement for FPD industry applications.
- Semiconductor: Insertion-amount measurement, notch position detection of glass wafers.
- Electronic components: Lead-pitch and diameter measurement, width and spacing inspection of leadframes.
Visual Description: Multiple images depict the ZX-GT sensor in action across various industries: measuring metal objects, pipes, crankshafts, glass edges, glass wafers, and electronic component leads.
Easy to Use and Strong Support
The ZX-GT is designed for ease of use and robust data management.
"Smart Recipe" Setup
Using the PC software 'Smart-monitor GT', setup is simplified through intuitive icon clicking, embodying OMRON's Smart Recipe methodology.
Visual Description: A screenshot of the 'Smart Monitor GT' software interface is shown, displaying measurement results and various setting options. A diagram illustrates the Interface Unit connecting the controller to a PC for RS-232C communication and binary output.
Easy Setup and Data Logging
Features are organized by tabs in the software, allowing users to easily understand and change settings. Measurement conditions can be saved on PCs. The measurement data is gathered in real-time, enabling easy analysis of current conditions and trends.
Visual Description: A time-dependent graph shows measurement trends, helping users identify sudden changes. Text indicates that logged data can be exported to Excel for traceability and quality assurance reports.
3-Way Optical Axis Adjustment
Integrated functions allow for optimal sensor head adjustment on-site, viewable via the sensor head's LED indicator, the controller's display, or graphically on a PC.
Visual Description: Images show the adjustment indicators on the sensor head (LED), controller (display), and PC (graphical waveform). A diagram illustrates the 30-meter cable extension capability for large-scale production lines.
Ordering Information
The ZX-GT series offers various sensor types, controllers, and accessories to suit different application needs.
Sensors
| Appearance | Optical System | Measuring Width | Sensing Distance | Resolution | Output Type | Model |
|---|---|---|---|---|---|---|
| [Separate type sensor image] | Through-beam | 28mm | 0 to 500mm | 10µm | NPN | ZX-GT28S11 |
| [Separate type sensor image] | Through-beam | 28mm | PNP | ZX-GT28S41 | ||
| [Integrated type sensor image] | Through-beam | 40mm | 0 to 500mm | NPN | ZX-GT2840S11 | |
| [Integrated type sensor image] | Through-beam | 40mm | PNP | ZX-GT2840S41 |
Controllers
| Appearance | Power Supply | Output Type | Model |
|---|---|---|---|
| [Controller image] | DC | NPN | ZX-GTC11 |
| [Controller image] | DC | PNP | ZX-GTC41 |
Accessories (Order Separately)
Set of Interface Unit and Setup software PCs
| Output Type | Model |
|---|---|
| NPN | ZX-GIF11A |
| PNP | ZX-GIF41A |
Interface Unit (RS-232C/Binary output)
| Appearance | Power Supply | Output Type | Model |
|---|---|---|---|
| [Interface Unit image] | DC | NPN | ZX-GIF11 |
| [Interface Unit image] | DC | PNP | ZX-GIF41 |
Setup Software PCs
| Name | Model |
|---|---|
| Smart Monitor GT | ZX-GSW11 |
Calculating Units
| Appearance | Model |
|---|---|
| [Calculating Unit image] | ZX-CAL2 |
Receiver-Controller Extension Cable
| Cable length | Model (Standard cable) | Model (Flexible cable) | Quantity |
|---|---|---|---|
| 1m | ZX-XGC1A | ZX-XGC1R | 1 |
| 2m | ZX-XGC2A | ZX-XGC2R | |
| 5m | ZX-XGC5A | ZX-XGC5R | |
| 8m | ZX-XGC8A | ZX-XGC8R | |
| 20m | ZX-XGC20A | ZX-XGC20R |
Note: Up to two extension cables can be connected. Total extension cable length between receiver and controller must be limited to 30 meters (including the receiver cable).
Specifications
Sensor Specifications
| Item | ZX-GT28S11 | ZX-GT28S41 | ZX-GT2840S11 | ZX-GT2840S41 |
|---|---|---|---|---|
| Output type | NPN | PNP | NPN | PNP |
| Light source | Visible semiconductor laser diode (wavelength 650 nm, CLASS 1) | |||
| Measuring width | 28mm | 28mm | 40mm | 40mm |
| Sensing distance | 0 to 500mm | 0 to 500mm | 0 to 500mm | 0 to 500mm |
| Minimum sensing object | 0.5mm dia. (*1) | 0.2mm dia. | 0.5mm dia. (*1) | 0.2mm dia. |
| Linearity | ±0.1%F.S. (*2) | |||
| Resolution | 10µm (number of process values to average: 16) (*3) | |||
| Temperature characteristic | 0.01%F.S./°C (*4) | |||
| Indicators (emitter) | Laser ON indicator (green), laser alarm indicator (red) | |||
| Indicator (receiver) | Optical axis setting indicator (green) | |||
| Laser OFF input/sync input | ON: Short-circuited with 0 V or 1.5 V max. OFF:Open (leakage current: 0.1 mA max.) | ON: Short-circuited with power supply voltage or power supply voltage -1.5 V max. OFF:Open (leakage current: 0.1 mA max.) | ON: Short-circuited with 0 V or 1.5 V max. OFF:Open (leakage current: 0.1 mA max.) | ON: Short-circuited with power supply voltage or power supply voltage -1.5 V max. OFF:Open (leakage current: 0.1 mA max.) |
| Laser deterioration alarm output | NPN open-collector output 30 VDC 20 mA max. Residual voltage 1.2 V max. | PNP open-collector output 30 VDC 20 mA max. Residual voltage 2 V max. | NPN open-collector output 30 VDC 20 mA max. Residual voltage 1.2 V max. | PNP open-collector output 30 VDC 20 mA max. Residual voltage 2 V max. |
| Power consumption (emitter) | 30 mA max. | |||
| Power supply voltage (emitter) | 24 VDC ±10%, -15% ripple (p-p) 10% max. | |||
| Dielectric strength | 1,000 VAC, 50/60 Hz for 1 min | |||
| Insulation resistance | 20 MΩ (at 500 VDC megger) | |||
| Operating ambient illumination (emitter) | 3000 lx (incandescent light) | |||
| Operating ambient illumination (receiver) | 1000 lx (incandescent light) (*5) | |||
| Ambient temperature | Operating: 0 to +40°C Storage: -15 to +50°C (with no icing or condensation) | |||
| Ambient humidity | Operating and storage: 35 to 85% (with no condensation) | |||
| Vibration resistance (durability) | 10 to 150 Hz Single-amplitude: 0.75 mm for 80 min each in X, Y and Z directions | |||
| Shock resistance (durability) | 300 m/s² 3 times each in six directions (up/down, left/right, forward/backward) | |||
| Degree of protection | IEC60529 IP40 | |||
| Cable length | 2m | |||
| Material | Case: aluminum die-cast, Lens: glass | |||
| Weight (packed state) | Approx.550g | Approx.570g | Approx.550g | Approx.570g |
| Accessories | Laser warning labels, Instruction Sheet | |||
Notes: *1: Distance between emitter and receiver: 500 mm, measurement object at 250 mm from receiver. Glass ends of chamfer 0.1 mm or more can be detected in glass edge measurement mode. (at binary level 70%) *2: Linearity is given to be a typical error with respect to an ideal straight line when the distance between the emitter and receiver is 100 mm and light is blocked at a distance of 50 mm from the receiver. (On the ZX-GT2840__, the measurement object is measured at a distance of 20 mm from the receiver.) *3: The amount of fluctuation (±3) in the analog output when the distance between the emitter and receiver is 100 mm and a ZX-GTC__ is connected. *4: Change in the light cutoff value on one side when the distance between the emitter and receiver is 100 mm and the light is half-cutoff at a distance of 50 mm from the receiver. (On the ZX-GT2840__, the measurement object is measured at a distance of 20 mm from the receiver.) *5: Standard mode(NORM) used.
Controller Specifications
| Item | ZX-GTC11 | ZX-GTC41 |
|---|---|---|
| Output type | NPN | PNP |
| Measurement cycle(*1) | 1.5ms(standard mode(NORM)) 0.5ms(high-speed mode(FAST)) (*2) | |
| Samples to average | 1/2/4/8/16/32/64/128/256/512/1024/2048/4096 | |
| Analog output(*3) | For current output: 4 to 20mA/F.S., max. load resistance 300 Ω For voltage output: ±4V, (±5 V, 1 to 5 V (*4)), output impedance 100 Ω | |
| Timing input, bank switching input, zero reset input, reset input | ON: short-circuited with 0V or 1.5V max. OFF: Open (leakage current: 0.1 mA max.) | ON: short-circuited with power supply voltage or power supply voltage -1.5V max. OFF: Open (leakage current: 0.1 mA max.) |
| HIGH/PASS/LOW Judgment output (*5) | NPN open-collector output 30 VDC 50 mA max. Residual voltage 1.2 V max. | PNP open-collector output 30 VDC 50 mA max. Residual voltage 2V max. |
| Sync output(*6) | Judgment output indicator: HIGH (orange), PASS (green), LOW (orange) Main display (red) Sub-display (yellow) Bank 1/2 (orange), zero reset (green) | |
| Indicator | 2 banks | |
| Number of registered setups | Interrupted beam width measurement, incident beam width measurement, outer diameter measurement, center position measurement, IC lead pitch, IC lead width judgment, specified edge measurement, wire position measurement, glass edge position measurement | |
| Measurement Mode | Measured value, resolution, threshold, voltage output value, current output value (number of display digits can be changed) | |
| Display during measurement | Offset setting of zero reset value, zero reset value memory | |
| Zero reset functions | Sample hold, peak hold, bottom hold, peak-to-peak hold, average hold, delay hold | |
| Hold | ON delay, OFF delay, one-shot | |
| Timer functions | Optical Axis adjust mode/light intensityt writing mode, variable binary level, variable edge filter, analog output scaling | |
| Adjustment functions | 2Possible on up to two Controllers (Calculation Unit ZX-CAL2 is required for connecting Controllers to each other.) A-B, A+B, width | |
| Calculation | Measurement cycle setting, threshold setting, hysteresis setting, initialization, key lock | |
| Other | 0.005%F.S./°C | |
| Temperature characteristic | 150 mA max. with power supply voltage of 24 VDC (including receiver) (*7) | |
| Current consumption | 24 VDC +10%, -15% ripple (p-p) 10% max. | |
| Power supply voltage | 1,000 VAC, 50/60 Hz for 1 min | |
| Dielectric strength | 20 MΩ (at 500 VDC megger) | |
| Insulation resistance | Operating: 0 to +50°C Storage: -15 to +60°C (with no icing or condensation) | |
| Ambient temperature | Operating and storage: 35 to 85% (with no condensation) | |
| Ambient humidity | 10 to 150 Hz Single-amplitude: 0.35 mm for 80 min each in X, Y and Z directions | |
| Vibration resistance(durability) | 300 m/s² 3 times each in six directions (up/down, left/right, forward/backward) | |
| Shock resistance (durability) | IEC60529 IP20 | |
| Degree of protection | 2m | |
| Cable length | Case: PBT (polybutylene terephthalate), Cover: Polycarbonate | |
| Material | Approx.330g | |
| Weight (packed state) | Instruction Sheet | |
| Accessories | ||
Notes: *1: A simple average is used in IC lead pitch judgment mode or IC lead width judgment mode. The measurement cycle time can be calculated as follows: Specified measurement cycle time x (Number of samples to average + 1) +1 ms max. In other measurement modes, a moving average is used. The first measurement cycle time can be calculated as follows: Specified measurement cycle time x (Number of samples to average + 1) +1 ms max. The second and later measurement cycle times will be equal to the specified measurement cycle time. *2: The response time in the high-speed mode (FAST) for the IC lead pitch and IC lead width judgment modes is 1 ms. *3: Current/voltage can be switched using the switch provided on the rear of the Controller. *4: Can be set by the analog output scaling function. *5: The error (ERR) state is displayed when all HIGH/PASS/LOW outputs turn OFF. *6: Normally, wire the sync output wire directly to the emitter's sync input wire and run the Controller in the standard mode. On an NPN type Controller, use an NPN type emitter, and on a PNP type Controller, use a PNP type emitter.Wiring of the sync wires is not required when the Controller is run in the high-speed mode. (Note, however, that the Controller becomes more susceptible to the influence of ambient light in this case.) *7: The value is 175 mA max. (including receiver) when current output is set.
Interface Unit Specifications
| Item | ZX-GIF11/-GIF11A | ZX-GIF41/-GIF41A |
|---|---|---|
| Compatible Controller | ZX-GTC11 | ZX-GTC41 |
| Indicator | Power ON (green), Controller communications (orange), Controller communications error (red), RS-232C communications (orange), RS-232C communications error (red), binary output (orange) | |
| Communications port | RS-232C (9-pin D-sub connector) | |
| 12-bit binary output (D11 toD0, GATE) | NPN open-collector output 30 VDC 20mA max. Residual voltage 1.2 V max. | PNP open-collector output 30 VDC 20 mA max. Residual voltage 2 V max. |
| Power supply voltage | Supplied from Controller (power consumption: 60 mA max.) | |
| Dielectric strength | 1,000 VAC, 50/60 Hz for 1 min | |
| Insulation resistance | 20 MΩ (at 500 VDC megger) | |
| Ambient temperature | Operating: 0 to +50°C Storage: -15 to +60°C(with no icing or condensation) | |
| Ambient humidity | Operating and storage: 35 to 85% (with no condensation) | |
| Vibration resistance(durability) | 10 to 150 Hz Single-amplitude: 0.35 mm for 80 min each in X, Y and Z directions | |
| Shock resistance (durability) | 300 m/s² 3 times each in six directions (up/down, left/right, forward/backward) | |
| Degree of protection | IEC60529 IP20 | |
| Cable length | RS-232C 0.5 m, binary output 2 m | |
| Material | Case: PBT (polybutylene terephthalate), Cover: Polycarbonate | |
| Weight (packed state) | ZX-GIF_1A:Approx.550g ZX-GIF_1:Approx.330g | ZX-GIF_1A:Approx.550g ZX-GIF_1:Approx.330g |
| Accessories | ZX-GIF_1A:Setup Software (CD-ROM), 2 clamps, Instruction Sheet | ZX-GIF_1:2 clamps, Instruction Sheet |
External Dimensions
Detailed physical dimensions are provided for all components.
Visual Description: Line drawings illustrate the external dimensions in millimeters for the Sensor (Separate and Integrated types), Controller, Interface Unit, Calculating Unit, and Receiver-Controller Extension Cable. Key features like mounting holes, connectors, and cable lengths are indicated.
Safety Precautions for Laser Equipment
⚠️CAUTION: Do not expose eyes to laser radiation directly or from reflected surfaces. Emitted laser beams have high power density and direct exposure may result in loss of eyesight.
The warning and explanatory label on the Sensor Head is in Japanese; an English label is provided with the product.
Visual Description: A "CAUTION" symbol and a "CLASS1 LASER PRODUCT" label are shown.
Contact Information
This document provides information mainly for selecting suitable models. Please read the User's Manual carefully for information that the user must understand and accept before purchase, including information on warranty, limitations of liability, and precautions.
OMRON Corporation
Industrial Automation Company
Kyoto, JAPAN
Contact: www.ia.omron.com
Regional Headquarters
- OMRON EUROPE B.V.
Wegalaan 67-69, 2132 JD Hoofddorp
The Netherlands
Tel: (31)2356-81-300/Fax: (31)2356-81-388 - OMRON ELECTRONICS LLC
2895 Greenspoint Parkway, Suite 200
Hoffman Estates, IL 60169 U.S.A.
Tel: (1) 847-843-7900/Fax: (1) 847-843-7787 - OMRON ASIA PACIFIC PTE. LTD.
No. 438A Alexandra Road # 05-05/08 (Lobby 2), Alexandra Technopark,
Singapore 119967
Tel: (65) 6835-3011/Fax: (65) 6835-2711 - OMRON (CHINA) CO., LTD.
Room 2211, Bank of China Tower, 200 Yin Cheng Zhong Road,
PuDong New Area, Shanghai, 200120, China
Tel: (86) 21-5037-2222/Fax: (86) 21-5037-2200
© OMRON Corporation 2009-2021 All Rights Reserved. In the interest of product improvement, specifications are subject to change without notice.
CSM_3_2
Cat. No. Q154-E1
