Area Detection Redefined
Introducing the KEYENCE AI Series, a revolutionary pattern matching sensor designed for advanced area detection. Experience redefined performance with simple operation and powerful capabilities.
Effortless Setup: Teach with One Button
Simply present the target, and teach the sensor using just one button. This intuitive process makes setup quick and easy, even for first-time users.
Process:
- STEP 1: TEACH - Present the target to the sensor.
The sensor offers models with built-in amplifiers and separate amplifier models, catering to various installation needs.
New Technology: AIA (Auto Intelligent Adjustment)
The proprietary AIA (Auto Intelligent Adjustment) technology quantifies the target's brightness, shape, and outline information automatically. This allows for immediate judgment of whether the target matches the master, enabling stable part inspection that is challenging for traditional light intensity or position measurement sensors.
Key Features:
- Quantifies brightness, shape, and outline.
- Automatic judgment against master.
- Stable inspection for difficult parts.
The sensor utilizes a CMOS image sensor for its detection capabilities.
Overcoming Conventional Sensor Limitations
Conventional sensors often require precise mounting angles and custom configurations for stable detection, yet can still face issues with:
- Position is not fixed
- Position of the target is random
- Targets with several NG cases
- Unstable reflection from surfaces
The AI Series sensor, with its automatic teaching and advanced pattern matching, solves these challenges, requiring nothing more than presenting the target.
Versatile Detection Modes
The AI Series offers two primary detection modes:
Presence Check in an Area
This mode searches the entire area to confirm the presence of a target. It's ideal for simple presence checks.
Difference Check by Pattern
This mode compares the entire pattern of the target, allowing for more detailed differentiation and defect detection.
Enhanced Usability and Configuration
Detection Result Shown as an Image
The sensor's display shows the current image and the current value (degree of similarity), facilitating easy configuration and understanding of detection results.
Text + Animation for Easy Configuration
An OLED display with text and animation support makes configuration intuitive, reducing the need to consult manuals. Users can easily zoom in/out and adjust target positions directly on the display.
Digital Zoom Function
Offers 17 steps of digital zoom for detailed inspection.
Zoom Position Adjustment
Allows adjustment of the zoom position (Up/Down & Left/Right).
As Easy to Use as General-Purpose Sensors
While employing advanced AI principles, the AI Series is designed for ease of use comparable to general-purpose sensors, featuring two core detection modes:
Presence Check Mode
Easily configured in two steps, similar to two-point calibration of general-purpose sensors. Example: Detecting the presence of a nut.
- STEP 1: Register target as present.
- STEP 2: Register target as absent.
Configuration is then complete. ✔️
Difference Check Mode
Configured in three steps, ideal for users needing simple target determinations without complex vision systems. Example: Identifying a defect in an O-ring assembly.
- STEP 1: Register OK product.
- STEP 2: Register NG product (failure).
- STEP 3: Register target as absent.
Configuration is then complete. ✔️
Advanced Functions
Synchronizes and Judges Without a Controller
The sensor can synchronize and judge targets using hold input from an external sensor. The failure hold function retains the degree of similarity and displays the image when an NG (failure) occurs.
Visualize Line Operation
Stat displays show maximum and minimum degrees of similarity, aiding in checking operation status and analysis at start-up.
Use on Lines with Multiple Product Types
The bank switching and external calibration functions allow one unit to handle multiple product types (up to four registered banks).
Specialized Modes and Options
Feeder Mode
Optimized for parts feeders, this mode detects objects and their orientation, automatically identifying and judging only the identified targets.
Language Selection for Easy Export
Supports English, Japanese, and Chinese, facilitating easy use overseas.
Multiple Output Options
Standard options include toggling between NPN, PNP, and IO-Link for flexible integration and warehouse consolidation.
Product Lineup
Separate Amplifier Models
Sensor Heads: Available in Short Range (AI-H010, AI-H020), Standard (AI-H050, AI-H100), and Long Range (AI-H160) with varying detecting distances and areas.
Amplifiers: Models include AI-1000 (Cable Type) and AI-1000C (M8 Connector Type), offering different input/output configurations.
Built-in Amplifier Models
Available in Standard (AI-B050, AI-B100) and Long Range (AI-B160) with integrated amplifiers, offering similar detecting distances and areas as their separate amplifier counterparts.
Detailed specifications for detecting distance, detecting area, and digital zoom are provided for each model.
Key Specifications Summary
Sensor Heads (Separate Amplifier Models)
| Model | Detecting Distance | Detecting Area (at 4X zoom) | Light Source |
|---|---|---|---|
| AI-H010 | 9 to 11 mm | 0.5 x 0.5 mm to 2 x 2 mm | Red LED (660 nm) |
| AI-H020 | 18 to 22 mm | 1.4 x 1.4 mm to 5.6 x 5.6 mm | Red LED (660 nm) |
| AI-H050 | 45 to 55 mm | 4 x 4 mm to 16 x 16 mm | Red LED (660 nm) |
| AI-H100 | 90 to 110 mm | 8 x 8 mm to 32 x 32 mm | Red LED (660 nm) |
| AI-H160 | 140 to 180 mm | 13 x 13 mm to 52 x 52 mm | Infrared LED (850 nm) |
Amplifiers
| Model | Response Time | Power Voltage | Output Type |
|---|---|---|---|
| AI-1000 / AI-1000C | 3 ms (minimum) | 20 to 30 VDC | NPN/PNP/IO-Link |
| AI-B050 / AI-B100 / AI-B160 (Built-in) | 3 ms (minimum) | 20 to 30 VDC | NPN/PNP/IO-Link |
Environmental resistance (IP67) and operating temperature (-10 to +50°C) are standard across many models.
Applications
The AI Series is suitable for a wide range of industries and applications:
Automobiles/Metals
- Check for arrival of product conveyor cages
- Check for passage of O rings in a parts feeder
- Detect presence of springs
- Differentiate processed product types
- Check O ring assemblies
- Detect incomplete processing of machined parts
Electrical
- Detect presence of minuscule chip parts
- Check attachment of chip parts
- Detect presence of lead wires
- Differentiate front/back of chip parts
- Check PCB parts mountings
- Check for fallen parts in parts feeders
Food/Medicine
- Check passage of transparent bottles
- Detect tape seams
- Detect presence of noodles
- Differentiate cap types
- Check sealing tape presence
- Check for presence of labeling
Attachments and Mounting
Various attachments, including polarized light filter attachments and dome attachments, are available to optimize performance in different environments. A range of mounting brackets (Vertical, Rear, Adjustable) are also offered for flexible installation.
