More precision at high production speeds…can you have both?
- Aug 6
- 3 min read
In fast production processes, it is not enough to simply determine whether a product is present. Color, opacity, and even minor deviations must be detected reliably – all within the available process time.
This is precisely where the PREMOSYS PR0120 and PR0128 sensor systems come into play. Both combine fast processing with precise color detection, but each focuses on different measurement requirements.
PR0120: High-Speed Color and Opacity Measurement
The PR0120 was developed for absolute color and opacity measurement. With a sampling rate of 2 kHz, it is particularly suitable for applications that require measurement results within very short process cycles.
Its three color channels are processed simultaneously and synchronously. A resolution of 16 bits per channel makes it possible to evaluate both very bright and very dark colors within the same application. Eleven gain levels provide additional flexibility when adapting the sensor to different products and measurement conditions.
The detected color values are output directly in the CIELab color space. This means that the sensor provides more than a simple pass/fail decision: it delivers specific and comparable color values. According to the product manual, its long-term stability in the CIELab color space is significantly better than 0.2 Delta E.
In addition to color measurement, the PR0120 supports two methods for determining opacity:
· The transmitted-light method determines optical density within a range of OD0 to OD5.
· The reflected-light method outputs opacity as a percentage between 0 and 100%.
A differential measurement method reduces the influence of ambient light. The external stabilized white light source also helps minimize the effects of aging and temperature drift on the measurement results.
This makes the PR0120 suitable for processes that require high speed, absolute color measurement, and opacity inspection to be combined in a single system.
PR0128: Precise Color Detection for Flexible Inspection Tasks
The PR0128 focuses on the precise detection and evaluation of colors. It operates across a spectral range of 380 to 780 nm and provides results as CIE 1976 L*a*b* values, X, Y, and Z tristimulus values, and Delta E.
Its specified performance features include:
· Color resolution below 0.10 Delta E
· Repeatability below 0.50 Delta E
· Eight gain levels with 12-bit resolution each
· Management of up to 63 products
· Digital outputs for directly communicating product detection results
· A fiber-optic connection for flexible optical coupling
For applications involving different brightness levels, the gain can be adjusted automatically. The averaging settings make it possible to balance lower signal noise against a shorter response time. This allows the sensor parameters to be adapted to both the available process time and the required level of accuracy.
For particularly fast detection tasks, the PR0128 also offers the “MARKS” operating mode. In this mode, the sensor settings are automatically optimized for the shortest possible measurement time and therefore the highest possible measurement frequency. The mode is specifically designed for detecting colored marks.
If required, an adjustable hold time ensures that rapid changes in the digital output states can be reliably detected by the higher-level control system.
Finding the Right Balance Between Precision and Speed
High production speeds and precise measurement results are not inherently contradictory. The key is to adapt the measurement system and its parameters to the specific application.
The PR0120 is particularly strong in fast, absolute color and opacity measurement. The PR0128 enables flexible color evaluation and provides targeted optimization for rapid color-mark detection through its MARKS mode.
In both cases, the best solution results from the interaction between the sensor, optics, lighting, available process time, and required accuracy. Increasing the level of averaging, for example, can reduce signal noise, but it also increases the time required to produce a stable output.
By considering these factors during the system design stage, even minor color deviations can be reliably detected within short process cycles, enabling stable and consistent inspection results.
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