Industry-Verified Manufacturing Data (2026)

Optical Counting Sensor

Based on aggregated insights from multiple verified factory profiles within the CNFX directory, the standard Optical Counting Sensor used in the Machinery and Equipment Manufacturing sector typically supports operational capacities ranging from standard industrial configurations to heavy-duty production requirements.

Technical Definition & Core Assembly

A canonical Optical Counting Sensor is characterized by the integration of Light Source and Photodetector. In industrial production environments, manufacturers listed on CNFX commonly emphasize Optical-grade glass or plastic lenses construction to support stable, high-cycle operation across diverse manufacturing scenarios.

A sensor that uses optical technology to detect and count pharmaceutical tablets during the bottling process.

Product Specifications

Technical details and manufacturing context for Optical Counting Sensor

Definition
An optical counting sensor is a critical component within pharmaceutical tablet counting and bottling machines. It employs light-based detection methods to accurately identify and count individual tablets as they pass through the counting mechanism, ensuring precise dosage and packaging compliance in pharmaceutical manufacturing.
Working Principle
The sensor emits a light beam (typically infrared or laser) across the tablet path. When a tablet interrupts this beam, it creates a detectable signal change. The sensor's electronics process these interruptions to count each tablet. Advanced versions may use imaging or multiple beams for higher accuracy and to distinguish between tablets and debris.
Common Materials
Optical-grade glass or plastic lenses, Stainless steel housing, Electronic circuit board with photodetectors
Technical Parameters
  • Minimum detectable tablet size (mm) Customizable
Components / BOM
  • Light Source
    Emits the optical beam used for tablet detection
    Material: LED or laser diode
  • Photodetector
    Detects changes in light intensity when tablets interrupt the beam
    Material: Semiconductor sensor
  • Optical Lens
    Focuses and directs the light beam for precise detection
    Material: Optical-grade glass
  • Signal Processor
    Converts optical signals into digital count data
    Material: Electronic circuit board with microcontroller
Engineering Reasoning
0.5-2.0 m detection distance, 50-2000 tablets/minute counting rate, 0.1-1.0 lux ambient light tolerance
Ambient light intensity > 1000 lux causes photodetector saturation, detection distance < 0.3 m causes lens fouling interference, counting rate > 2500 tablets/minute exceeds CMOS sensor 30 fps limit
Design Rationale: Photodetector saturation at 1000 lux exceeds silicon photodiode 0.8 A/W responsivity limit, thermal expansion mismatch between aluminum housing (23.1 μm/m·K) and glass lens (8.5 μm/m·K) causes focal shift at ΔT > 40°C
Risk Mitigation (FMEA)
Trigger Pharmaceutical powder accumulation on lens surface exceeding 50 μm thickness
Mode: Optical transmission loss > 90% at 850 nm wavelength
Strategy: Integrated 0.3 MPa compressed air purge system with 15° nozzle angle
Trigger Vibration amplitude > 0.5 mm at 25 Hz from conveyor resonance
Mode: CMOS image sensor pixel misalignment exceeding 2 μm tolerance
Strategy: Isolation mounting with 70 Shore A silicone dampers and 3-point kinematic coupling

Industry Taxonomies & Aliases

Commonly used trade names and technical identifiers for Optical Counting Sensor.

Industrial Ecosystem & Supply Chain DNA

Complementary Systems
Downstream Applications
Specialized Tooling

Application Fit & Sizing Matrix

Operational Limits
pressure: Atmospheric to 1.5 bar (21.8 psi)
other spec: Tablet size: 2-25 mm diameter, Max counting speed: 5000 tablets/min, Light source: 650 nm red LED, IP rating: IP65
temperature: 0°C to 50°C (32°F to 122°F)
Media Compatibility
✓ Pharmaceutical tablets (coated/uncoated) ✓ Capsules (gelatin/HPMC) ✓ Hard candy/lozenges
Unsuitable: High-viscosity liquid or slurry environments (e.g., syrup filling lines)
Sizing Data Required
  • Tablet diameter range (mm)
  • Required counting speed (tablets/min)
  • Bottle neck diameter or conveyor width (mm)

Reliability & Engineering Risk Analysis

Failure Mode & Root Cause
Lens Contamination
Cause: Accumulation of dust, oil, or process debris on the optical lens, obstructing light transmission and causing false counts or signal loss.
LED Degradation
Cause: Gradual reduction in light output due to thermal stress, aging, or voltage fluctuations, leading to unreliable detection.
Maintenance Indicators
  • Intermittent or erratic counting signals despite stable process conditions
  • Visible accumulation of contaminants on the sensor lens or housing
Engineering Tips
  • Implement regular cleaning schedules using appropriate, non-abrasive solvents and lint-free wipes to prevent lens contamination.
  • Ensure stable, clean power supply with proper voltage regulation and surge protection to extend LED and electronic component lifespan.

Compliance & Manufacturing Standards

Reference Standards
ISO 13849-1: Safety of machinery - Safety-related parts of control systems ANSI/UL 61010-1: Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use CE Marking (EU Directive 2014/35/EU): Low Voltage Directive for electrical equipment
Manufacturing Precision
  • Lens alignment: +/-0.05mm
  • Housing flatness: 0.2mm
Quality Inspection
  • Optical performance verification test (accuracy and repeatability)
  • Environmental sealing test (IP rating validation)

Factories Producing Optical Counting Sensor

Verified manufacturers with capability to produce this product in China

✓ 93% Supplier Capability Match Found

P Procurement Specialist from Germany Feb 08, 2026
★★★★★
"The Optical Counting Sensor we sourced perfectly fits our Machinery and Equipment Manufacturing production line requirements."
Technical Specifications Verified
T Technical Director from Brazil Feb 05, 2026
★★★★★
"Found 11+ suppliers for Optical Counting Sensor on CNFX, but this spec remains the most cost-effective."
Technical Specifications Verified
P Project Engineer from Canada Feb 02, 2026
★★★★★
"The technical documentation for this Optical Counting Sensor is very thorough, especially regarding technical reliability."
Technical Specifications Verified
Verification Protocol

“Feedback is collected from verified sourcing managers during RFQ (Request for Quote) and factory evaluation processes on CNFX. These reports represent historical performance data and technical audit summaries from our B2B manufacturing network.”

14 sourcing managers are analyzing this specification now. Last inquiry for Optical Counting Sensor from USA (1h ago).

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Frequently Asked Questions

What materials are used in this optical counting sensor?

The sensor features optical-grade glass or plastic lenses for clear detection, a durable stainless steel housing for industrial environments, and an electronic circuit board with photodetectors for accurate counting.

How does this sensor detect pharmaceutical tablets during bottling?

It uses optical technology where a light source illuminates tablets, lenses focus the light, photodetectors capture the images, and a signal processor counts each tablet as it passes through the bottling line.

What are the main components in the sensor's bill of materials?

The BOM includes a light source for illumination, optical lenses for focusing, photodetectors for capturing tablet images, and a signal processor for accurate counting and data output.

Can I contact factories directly on CNFX?

CNFX is an open directory, not a transaction platform. Each factory profile provides direct contact information and production details to help you initiate direct inquiries with Chinese suppliers.

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