Allen-Bradley Color Registration Mark Sensors

Allen-Bradley Color Registration Mark Sensors

Allen-Bradley Color Registration Mark Sensors are high-performance photoelectric devices designed for accurate detection of registration marks, color marks, or contrast bars on packaging, films, labels, and other moving materials. These sensors play a critical role in applications requiring precise positioning and alignment, such as printing, packaging, converting, labeling, and high-speed automated production systems. By detecting marks with high accuracy, these sensors help maintain product quality, minimize waste, and ensure synchronization of downstream operations.

Purpose of Color Registration Mark Sensors

Color registration mark sensors are used to:

• Detect printed registration or timing marks on moving webs, sheets, or films.
• Ensure correct alignment of labels, packaging, and printed materials during production.
• Trigger machine functions such as cutting, indexing, or labeling at the correct position.
• Provide feedback to PLCs or motion controllers for precise positioning in automated systems.
• Reduce material waste and production errors caused by misaligned or missing marks.

These sensors are essential in high-speed production environments where millimeter-level accuracy is critical.

Key Features

High-Precision Detection

• Detects small color or contrast marks, often less than 1 mm in size, even on fast-moving materials.

Adjustable Sensitivity and Threshold

• Enables fine-tuning to detect marks of varying colors, contrasts, and backgrounds.

Multiple Sensing Modes

• Reflective, through-beam, or diffuse sensing configurations.
• Some models incorporate background suppression to avoid false triggers from the material surface.

Fast Response Time

• Ideal for high-speed printing, labeling, or converting operations.

LED Indicators

• Visual indicators for power, detection status, and margin alignment for easy setup and troubleshooting.

Flexible Mounting Options

• Threaded or through-hole mounts, adjustable brackets for optimal sensor alignment.

Robust Industrial Housing

• IP67-rated construction for dust, moisture, and washdown environments.
• Resistant to industrial vibrations and contaminants.

Output Options

• PNP, NPN, or complementary outputs for PLC or motion controller integration.
• IO-Link-enabled models provide color and contrast data directly to the automation system.

Gating / Inhibit Input

• Synchronizes detection with moving materials or machine cycles, reducing false triggers.

Common Allen-Bradley Color Registration Mark Sensor Part Numbers

• 42GRC-9200-QD — DC, 10–40 V, coaxial optical design, detects transparent or opaque registration marks, M12 connector.
• 42GRC-9200-QD1 — Cable variant of 42GRC-9200 with 2 m fixed cable.
• 42GTC-9202-QD — AC/DC timing version with SPDT relay output, suitable for precise mark-based machine triggering.
• 45CLR-5JPC1-D8 — Diffuse color/contrast detection, 3 PNP outputs, suitable for opaque registration marks.
• 46CLR-D5LAC1-D5 — True color detection, IO-Link enabled, suitable for multi-color registration marks.

How Color Registration Mark Sensors Work

• Illumination: The sensor emits a focused LED light beam onto the material.
• Detection: The reflected light from the registration mark or contrast bar is captured by the photodiode.
• Signal Processing: Internal circuitry compares the signal against taught or preset thresholds to confirm mark presence.
• Output Triggering: The sensor activates the output to the PLC or motion controller, synchronizing cutting, labeling, or indexing operations.

Advanced models provide IO-Link connectivity for transmitting detailed RGB and intensity data, enabling multi-color mark detection and adaptive process control.

Applications

• Printing: Detect registration marks for accurate web alignment and cutting.
• Packaging & Labeling: Ensure labels are applied correctly relative to the product.
• Film Converting: Detect timing marks on plastic films, laminates, or foils for cutting or indexing.
• Food & Beverage: Verify printed marks on cartons, bottles, or packaging.
• Pharmaceuticals: Detect color-coded marks, lot numbers, or expiration dates for precise tracking.

Benefits

• High Accuracy: Millimeter-level detection ensures precise synchronization.
• Reduced Waste: Minimizes errors due to misaligned cuts, labels, or print defects.
• High-Speed Operation: Reliable detection in fast-moving production lines.
• Flexible Integration: Compatible with PLCs, motion controllers, and IO-Link systems.
• Durable & Robust: Industrial-grade housing withstands harsh conditions and washdown environments.
• Easy Maintenance: LED indicators simplify alignment, teaching, and troubleshooting.

Design & Deployment Considerations

• Spot Size and Range: Choose a sensor appropriate for the size of the registration mark and distance from the material.
• Contrast & Lighting: Ensure adequate mark-to-background contrast; consider models with glare suppression for reflective surfaces.
• Synchronization: Use gating inputs or timing versions in high-speed operations to prevent misreads.
• Color vs Contrast Detection: For multi-color marks, use true-color models (46CLR series) with IO-Link for advanced detection.

Conclusion

Allen-Bradley Color Registration Mark Sensors are critical for modern automation processes that require precise detection of printed or colored marks. These sensors ensure accurate material alignment, high-speed processing, and consistent product quality. With robust construction, flexible outputs, and advanced features like IO-Link and true-color detection, they are ideal for printing, labeling, packaging, and converting industries, improving productivity, reducing waste, and maintaining operational reliability.