KEYENCE IL Series: High-Performance CMOS Laser Displacement Sensors
The KEYENCE IL Series offers advanced CMOS laser displacement sensors designed for high-precision measurement and stable detection in demanding industrial environments.
Introduction
The IL Series represents the pinnacle of stable detection, delivering top-tier performance within its class. These intelligent sensors provide high-resolution measurement at an affordable price, making advanced sensing capabilities accessible.
Key Specifications:
- ? Measurement Range: 20 mm to 1 m
- ? Repeatability: As low as 1 µm
- ? Advanced Features: Super-resolution Algorithm, SCAN function, Sharp-line Beam
The system typically consists of a sensor head and a multifunction amplifier (display unit) that processes the measurement data and communicates with control systems.
Measurement Principle
The IL Series utilizes a triangulation-based measurement principle. When the position of a target object changes, the light received by the CMOS sensor shifts. By detecting this shift in the received light position, the sensor accurately measures the object's displacement.
Diagram Description: A diagram shows a laser emitting from the sensor head, reflecting off a target object, and returning to the sensor's receiver. The receiver has a CMOS sensor that detects the position of the reflected light spot. Changes in the target's distance cause the spot's position on the CMOS to move.
Key Features & Technologies
1. Super-resolution Algorithm
This industry-first algorithm analyzes variations in the CMOS received light waveform caused by differences in target surface conditions (e.g., metal, plastic, rubber). It automatically applies optimal waveform processing, enabling stable detection of previously difficult-to-measure workpieces like fine metal wires or rubber.
Diagram Description: Waveforms are shown for different materials (ideal, metal, ceramic, resin, diffuse reflection), illustrating how the algorithm adapts to varying reflection patterns.
2. SCAN Function (=Sensitive-laser Control Analyzer)
To ensure stable and reliable measurement of various targets, the SCAN function dynamically adjusts laser power, shutter speed, and amplifier gain. A newly developed digital circuit provides a dynamic range of up to 1.5 million times (2.5 times that of previous models), enabling real-time control of target and surface conditions for consistent measurement.
Diagram Description: A graph shows how laser power is adjusted based on target color (lighter targets reduce laser power, darker targets increase it). Another diagram illustrates the adjustment of shutter speed, power, and gain over time.
3. Sharp-line Beam
KEYENCE's proprietary optical system narrows the beam diameter to an extreme 25 µm. This allows for highly stable measurements that were previously unattainable. By optimizing the light spot shape and optical system, it stabilizes measurements that were prone to unevenness.
Diagram Description: A diagram shows the laser beam being focused to a very small spot (25 µm) on the target, with a simplified representation of the light path to the CMOS sensor.
4. Waveform Filtering
This function ignores changes below a specific cutoff frequency, allowing for the display of only significant variations. It is particularly effective when needing to ignore slow drifts and capture rapid changes.
Diagram Description: Two graphs show a measurement value over time. The first shows an input waveform with gradual changes. The second shows the filtered waveform, where only sharp changes are visible.
5. Anti-Interference Function
When the sampling cycle is set to 2 ms or 5 ms, the IL Series' anti-interference function effectively minimizes the impact of external light sources, ensuring stable measurements even in environments with ambient light.
Diagram Description: A diagram illustrates how the sensor captures light during specific sampling periods, differentiating between the laser emission and ambient light to cancel out interference.
Sensor Head Models
The IL Series offers a variety of sensor heads to suit diverse applications, from short-range to long-range measurements up to 1 meter.
| Model | Reference Distance | Measurement Range | Repeatability | Linearity (F.S.) | Weight |
|---|---|---|---|---|---|
| IL-S025 | 25 mm | 20 - 30 mm (10 mm range) | 1 µm | ±0.075% | Approx. 60 g |
| IL-S065 | 65 mm | 55 - 75 mm (20 mm range) | 2 µm | ±0.05% | Approx. 75 g |
| IL-030 | 30 mm | 20 - 45 mm (25 mm range) | 1 µm | ±0.1% | Approx. 60 g |
| IL-065 | 65 mm | 55 - 105 mm (50 mm range) | 2 µm | ±0.1% | Approx. 75 g |
| IL-100 | 100 mm | 75 - 130 mm (55 mm range) | 4 µm | ±0.15% | Approx. 75 g |
| IL-300 | 300 mm | 160 - 450 mm (290 mm range) | 30 µm | ±0.25% | Approx. 135 g |
| IL-600 | 600 mm | 200 - 1000 mm (800 mm range) | 50 µm | ±0.25% | Approx. 135 g |
Diagram Description: Multiple diagrams illustrate the measurement distance and range for each sensor head model (IL-S025, IL-S065, IL-030, IL-065, IL-100, IL-300, IL-600), showing the laser beam path and measurement area.
Multifunction Amplifier (Display Unit)
The amplifier unit processes measurement data and offers versatile connectivity options, including Analog, RS-232C, and BCD. It also supports communication protocols like DeviceNet™ and EtherNet/IP™.
Calculation Functions
Supports internal calculations such as addition and subtraction, simplifying programming for PLCs and reducing integration time.
- Addition Mode: Used for thickness measurement (e.g., measuring the thickness of two stacked parts) or width measurement.
- Subtraction Mode: Used for step difference measurement or flatness measurement.
Thickness Correction Function
A simple 3-step process allows for easy thickness calibration using dedicated sensor heads, streamlining setup compared to older models.
Diagram Description: A 3-step illustration shows how to position two sensor heads, input data, and complete the thickness calibration.
Step Filtering Function
Automatically identifies step edges and outputs each step individually, simplifying applications like counting steps or detecting seams without complex programming.
Diagram Description: A 3-step illustration shows setting the low and high sides of a step, followed by automatic edge detection and output.
Communication Modules & Accessories
Various communication modules and accessories are available to integrate the IL Series into different control systems.
Communication Modules
- DL-EP1 (EtherNet/IP™ Module): Simplifies real-time data acquisition and message communication.
- DL-DN1 (DeviceNet™ Module): Facilitates status monitoring and configuration changes.
- DL-RB1A (BCD Output Module): Enables synchronized output of measurement values with trigger inputs.
- DL-RS1A (RS-232C Module): Provides compatibility with devices supporting ASCII communication.
Accessories
Includes mounting brackets, extension cables, and sensor head connection cables to suit various installation requirements.
| Accessory Type | Model | Description | Weight |
|---|---|---|---|
| Communication Modules | DL-EP1 | EtherNet/IP™ Module | Approx. 70 g |
| DL-DN1 | DeviceNet™ Module | Approx. 80 g | |
| DL-RB1A | BCD Output Module | Approx. 46 g | |
| DL-RS1A | RS-232C Module | Approx. 53 g | |
| Mounting Bracket | OP-60412 | For DIN rail mounting | Approx. 12 g |
| Extension Cable | OP-35361 (300 mm) | Extends sensor cable length | Approx. 10 g |
| Sensor Head Cable | OP-87056 (2 m) | Connects sensor head to amplifier | Approx. 80 g |
| OP-87057 (5 m) | Approx. 190 g | ||
| OP-87058 (10 m) | Approx. 360 g | ||
| OP-87059 (20 m) | Approx. 680 g |
Applications
The IL Series is suitable for a wide range of applications requiring precise measurement and inspection:
- Positioning: Robot arm positioning, camera height adjustment, workpiece positioning on cutting machines.
- Thickness Measurement: Material thickness inspection (e.g., steel plates, building materials, sheet metal), flatness measurement.
- Inspection: Detecting surface defects, measuring flatness of ceramic substrates, identifying different material types, checking for warpage in PCBs.
- Process Control: Controlling print height, managing coil diameter, monitoring welding gun height, controlling winding material height, managing press processes, monitoring conveyor tilt.
- Counting & Inspection: Seam detection (rubber belts, welds), stack height and count, air conditioner filter counting.
Diagram Description: Various application scenarios are depicted, such as a robot arm being measured, a camera inspecting a PCB, a sensor measuring the thickness of a steel plate, and a sensor monitoring a conveyor belt.
Specifications Summary
Detailed specifications for sensor heads and amplifier modules are provided below.
Sensor Head Specifications
| Model | Reference Distance | Measurement Range | Repeatability | Linearity (F.S.) | Weight | Ingress Protection | Operating Temperature |
|---|---|---|---|---|---|---|---|
| IL-S025 | 25 mm | 20 - 30 mm | 1 µm | ±0.075% | Approx. 60 g | IP67 | -10 to +50°C |
| IL-S065 | 65 mm | 55 - 75 mm | 2 µm | ±0.05% | Approx. 75 g | IP67 | -10 to +50°C |
| IL-030 | 30 mm | 20 - 45 mm | 1 µm | ±0.1% | Approx. 60 g | IP67 | -10 to +50°C |
| IL-065 | 65 mm | 55 - 105 mm | 2 µm | ±0.1% | Approx. 75 g | IP67 | -10 to +50°C |
| IL-100 | 100 mm | 75 - 130 mm | 4 µm | ±0.15% | Approx. 75 g | IP67 | -10 to +50°C |
| IL-300 | 300 mm | 160 - 450 mm | 30 µm | ±0.25% | Approx. 135 g | IP67 | -10 to +50°C |
| IL-600 | 600 mm | 200 - 1000 mm | 50 µm | ±0.25% | Approx. 135 g | IP67 | -10 to +50°C |
Amplifier Module Specifications
| Model | Type | Sensor Compatibility | Display Unit | Analog Voltage Output | Analog Current Output | Power Consumption | Weight |
|---|---|---|---|---|---|---|---|
| IL-1000 (DIN Rail) | Main Unit | IL-S025/IL-030: 1 µm, IL-S065/IL-065/IL-100: 2 µm, IL-300: 10 µm, IL-600: 50 µm | ±99.999 mm to ±99 mm (4 levels) | ±5V, 1-5V, 0-5V (100Ω load) | 4-20mA (350Ω max. load) | 2300 mW max. | Approx. 150 g |
| IL-1050 (DIN Rail) | Expansion Unit | (See Main Unit) | (See Main Unit) | (See Main Unit) | (See Main Unit) | 2000 mW max. | Approx. 140 g |
| IL-1500 (Panel Mount) | Main Unit | (See Main Unit) | ±99.999 mm to ±99 mm (4 levels) | ±5V, 1-5V, 0-5V (100Ω load) | 4-20mA (350Ω max. load) | 2500 mW max. | Approx. 170 g |
| IL-1550 (Panel Mount) | Expansion Unit | (See Main Unit) | (See Main Unit) | (See Main Unit) | (See Main Unit) | 2200 mW max. | Approx. 160 g |
Diagram Description: Dimensional drawings are provided for the sensor heads (IL-S025/IL-030, IL-S065/IL-065/IL-100, IL-300/IL-600) and amplifier modules (DIN rail and panel mount types), showing key dimensions and mounting hole details.
Wiring Diagram Description: A wiring diagram illustrates the connections for amplifier modules, showing input/output signals, power, and communication lines with color coding.
