Swiftpack infrared sensor bar system (PSR35 / PSR25)

The XIAC infrared sensor bar system replaces OEM PSR35 and PSR25 sensor assemblies used in IMA Swiftpack detection units. Instead of individual channel sensors that require precise manual alignment, XIAC implements fixed channel geometry directly in two precision PCBs — one emitter bar and one detector bar.

Channel pitch is defined mechanically by the PCB layout: 35 mm for PSR35 and 27 mm for PSR25. This guarantees consistent optical alignment across all channels.

The result is improved channel symmetry, reduced installation effort, and stable long-term performance.

8 → 12 channel expansion

Many Swiftpack machines mechanically support 12 channels but are configured as 8-channel systems. The XIAC sensor bar provides a clean expansion path where the machine configuration allows it.

• Direct detector-board connection for expansion projects
• OEM harness plug-board option for fast drop-in replacement
• Clean wiring topology and reversible integration

OEM harness plug-board option allows fast installation while maintaining original machine wiring configuration.

Direct terminal connection: individual channel wires connect directly to the detector PCB terminal block. This method provides a clean and structured installation and is recommended for new builds or 8 → 12 channel expansion projects.

Self-calibrating LED drive

The sensor firmware automatically adjusts LED drive to maintain stable signal margin as operating conditions change.

• Compensates for gradual optical attenuation (e.g. dust)
• Maintains consistent detection threshold
• LED drive percentage available via optional QA terminal

Optional QA monitoring terminal

A compact terminal can be connected via RS‑232 (Modbus RTU) for live diagnostics. The terminal is hot-pluggable and does not interrupt production.

• Date / time and unique board ID
• Channel health percentage (relative to reference channel)
• LED drive percentage
• Sensitivity and trailing edge timer adjustment

Example QA display showing channel health and LED drive percentage.

Video demonstration

The video below demonstrates the QA terminal connected to a Swiftpack detection head that has been running in production for several years. It shows how channel health and LED drive indicators can be used during real-world diagnostics.

Engineering architecture

Beyond fixed mechanical pitch, the XIAC sensor platform introduces several architectural improvements over legacy discrete-channel designs.

• Synchronised multi-channel detection: detector channels are synchronised in firmware to prevent cross-channel optical interference ("ghost counts").
• Minimum 20 dB optical margin compensation: the self-calibrating LED drive maintains signal integrity even under significant dust accumulation.
• Reduced current consumption: significantly lower power draw compared to legacy boards, reducing thermal load inside the head box.
• Per-channel status LEDs: immediate visual confirmation of channel activity during commissioning and service.
• Ambient light immunity: designed to operate independently of surrounding lighting conditions.
• Self-matching boards: emitter and detector assemblies automatically align and calibrate themselves — no field matching required.

Validation philosophy

All XIAC sensor platforms are validated using in-house simulation equipment that reproduces realistic tablet modulation patterns across all channels at controlled speeds.

Each channel is subjected to multi-million event simulations at varying product lengths and speeds before deployment. This ensures consistent detection behaviour across a wide range of tablet and capsule types.

This validation methodology evolved from earlier Swiftpack detection developments, documented in the XIAC museum archive. The current platform represents the structured continuation of that lineage.

View the historical Swiftpack sensor development →

Compatibility

• SPC Swiftpack, Kalish Swiftpack, DT Swiftpack, IMA Swiftpack
• ELSEN35PSR – 35 mm channel pitch
• ELSEN25PSR – 27 mm channel pitch
• 8 or 12 channel configurations (machine dependent)
• Standalone operation without QA terminal

What this upgrade delivers

• Elimination of individual sensor alignment effort
• Consistent optical geometry across all channels
• Clean expansion path from 8 to 12 channels
• Measurable optical condition via optional QA interface