With the continuous upgrading of high-end packaging and textile processes, traditional optical sensors often face technical bottlenecks of “direct light penetration” or “irregular refraction” when dealing with fully transparent films or highly breathable silk. To address this, ISSR has officially launched the all-new ISUDB5-F85-E4-V31 ultrasonic fork label sensor based on the single/double sheet thickness detection principle, utilizing acoustic technology to bring you a more stable and accurate new experience in label detection.
Breaking Through Optical Blind Spots, Reshaping Detection Standards
In modern automated production lines, applications such as “clear labels on clear films (Clear-on-Clear)” or “thin and breathable silk materials” have always been major challenges for label detection. These materials can easily cause photoelectric sensors to miss detections or make false judgments.
To completely overcome this problem, the ISUDB5-F85-E4-V31 abandons reliance on surface optical characteristics (color, transparency, reflectivity), and innovatively introduces ultrasonic penetration technology that is extremely sensitive to the physical thickness of materials, providing a perfect non-contact solution for complex working conditions.
Core Technology Deep Dive: Ultrasonic Single and Double Sheet Detection Principle
The core secret to why this sensor can achieve flawless accuracy lies in the clever utilization of the energy attenuation characteristics of ultrasonic waves when penetrating media of different thicknesses.
In the U-shaped fork structure, the upper emitter continuously emits high-frequency ultrasonic waves, vertically penetrating the running web:
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🟢 State 1: Base Material Only (Single-Layer State)
When only the silk or film base material without a label is present in the slot, the sound waves easily penetrate the single-layer medium, and the acoustic energy captured by the lower receiver is maintained at a relatively high and stable reference value. -
🔴 State 2: Label Passing (Double-Layer State)
When the label passes through the slot along with the base material, the local overall thickness increases instantly (base material + label). When ultrasonic waves penetrate this thicker “double-layer structure,” the proportion of absorption and refraction rises significantly. At this point, the acoustic energy captured by the receiving end experiences a distinct, cliff-like attenuation (significantly lower than the energy when only the base material is present).
The sensor’s built-in microprocessor accurately determines the presence of a label by rapidly capturing this “energy drop.” No matter how transparent the label is, the ultrasonic waves can keenly sense the physical changes brought by its thickness, completely eliminating missed and overlapping labels!
Innovative Highlights, Built for Automated Production Lines
In addition to its impeccable underlying algorithm, the ISUDB5-F85-E4-V31 also demonstrates outstanding engineering value in terms of electrical control and mechanical design:
- Intelligent Remote Teach-in: Say goodbye to the tedious mechanical knob adjustments of traditional sensors! To adapt to high-frequency flexible production changeovers, the ISUDB5 adopts a “wire teach-in” mode compatible with modern PLC control. When switching to a new material, simply place the pure base material without a label between the sensor’s emitter and receiver, and press and hold the teach-in button for 2-4 seconds. The sensor will automatically read and lock the current penetration energy as the absolute reference baseline in an instant. It perfectly supports one-key remote line changeovers from the host system, truly achieving “zero manual intervention.”
- Powerful Material Adaptability: Thanks to the physical characteristics of ultrasonic waves, whether it is fully transparent films, hot-stamped laser labels, or silk wash labels printed with complex color blocks on the surface, the ISUDB5 can identify them stably, unaffected by any surface visual characteristics.
Compact Yet Powerful Industrial Design
- Optimized Fork Space: Features a 68mm ultra-large fork depth and a 5mm fork width, calmly handling the running flutter of high-speed webs and avoiding physical scratches.
- Full-Polarity System Compatibility: Supports a 10-30VDC wide voltage input and simultaneously integrates both NPN and PNP bipolar switching outputs, allowing for easy integration into major brands of industrial control systems.
- Clear Status Feedback: The housing integrates high-brightness multi-color indicator lights, making the learning status and work output clear at a glance. The total weight is only 105g, perfectly adapting to lightweight labeling heads.
Widely Empowering Multi-Industry Applications
Relying on its excellent single and double sheet thickness identification capabilities, the ISUDB5-F85-E4-V31 has become the ideal choice for the following high-end automated scenarios:
- High-End Daily Chemicals and Pharmaceutical Packaging: Precise positioning of clear-on-clear labels on high-speed assembly lines.
- Advanced Textile and Garment Processing: Identification of thin wash labels and fabric splices on flexible fabrics such as silk and non-woven materials.
- Lithium Battery New Energy and Semiconductors: Prevention of missed detections for transparent separator films, special marking layers on pole pieces, and transparent tape splices.
- Precision Printing and Die-Cutting Systems: Single and double sheet anti-overlap monitoring of paper and film sheets during high-speed feeding.
Empowering intelligent manufacturing begins with precision. ISSR will always stand at the forefront of innovation in smart sensing technology, safeguarding the efficient operation of your equipment with the ISUDB5 series ultrasonic sensors.
For detailed product parameters, please click here to download the full version: [ISUDB5-F85-E4-V31 Ultrasonic Label Sensor Official Product Manual.pdf]