Department of Electrical Engineering

University of Moratuwa
EE 2044 - Electrical Measurements and
Instrumentation

- Sensors and Applications -

• [Link] -230287N
• [Link] – 230293E
• [Link] – 230294H
TASK 1 – Sensors Used in a Soft Drink Production Factory

Introduction

A soft drink production factory uses automated machines to perform tasks such as bottle
cleaning, filling, quality inspection, and packaging. These automated systems rely heavily on
sensors to detect physical changes such as position, level, weight, temperature, and presence of
objects. A sensor is a device that detects changes in the physical environment and converts
them into electrical signals that can be processed by control systems such as Programmable
Logic Controllers (PLCs). Industrial automation companies such as Siemens and Allen-Bradley
manufacture PLC systems that receive signals from sensors and control machinery accordingly.
The use of sensors improves production speed, ensures product quality, reduces human error,
and increases safety.

Stage 1 – Bottle Detection on Conveyor

Sensor Used: Photoelectric Sensor

Example manufacturers:

• Omron – Model E3Z-D61

• Keyence – Model PZ-G series

• SICK AG – Model W12 series

Working Principle:

A photoelectric sensor consists of:

• Light emitter (LED or laser)

• Light receiver

• Signal processor

When a bottle passes between emitter and receiver:

• Light beam is interrupted

• Sensor detects change

• Sends electrical signal to PLC

Types of Photoelectric Sensors:

1. Through-beam type (most accurate)

2. Retro-reflective type

3. Diffuse type

Advantages:

• Very fast response time (<1 ms)

• High accuracy

• Non-contact operation

• Long lifespan

Stage 2 – Bottle Position Detection

Sensor Used: Inductive Proximity Sensor

Manufacturers:

• Pepperl+Fuchs

• IFM Electronic

Working Principle:

• Generates electromagnetic field

• Detects metal objects

• When metal enters field → signal generated

Used to detect:

• Machine position

• Conveyor alignment

• Metal components

Advantages:

• Very reliable
 • No physical contact

• Resistant to dust, water, oil

Stage 3 – Bottle Filling Control

Sensor Used: Ultrasonic Sensor

Manufacturers:

• Banner Engineering

• Baumer

Working Principle:

• Emits ultrasonic sound waves (20–400 kHz)

• Sound reflects from liquid surface

• Sensor measures return time

• Distance calculated using:

Distance = Speed × Time / 2

Used to control filling level precisely.

Advantages:

• Works on transparent liquids

• High accuracy

• No physical contact

Stage 4 – Liquid Level Detection

Sensor Used: Capacitive Sensor

Manufacturers:

• Turck

• Balluff
Working Principle:

Capacitive sensor detects changes in capacitance:

Capacitance formula:

C = εA / d

Where:

• C = capacitance

• ε = permittivity

• A = plate area

• d = distance

When liquid enters sensing area → capacitance changes → detected.

Advantages:

• Detects liquids through plastic

• High sensitivity

• No contact needed

Stage 5 – Weight Measurement

Sensor Used: Load Cell

Manufacturers:

• HBM

• Vishay Precision Group

Working Principle:

Load cell contains strain gauges.

When weight applied:

• Material deforms slightly

• Electrical resistance changes

• Resistance converted to voltage signal

Strain = Change in length / Original length

Used to ensure:

• Correct amount of drink in bottle

• Detect underfilled or overfilled bottles

Accuracy: ±0.01%

Stage 6 – Cap Detection and Quality Inspection

Sensor Used: Vision Sensor

Manufacturers:

• Cognex

• Keyence

Working Principle:

Camera captures image → image processing → detects:

• Cap present or missing

• Label alignment

• Bottle defects

Uses digital image processing algorithms.

Stage 7 – Temperature Monitoring

Sensor Used: Temperature Sensor (RTD or Thermocouple)

Manufacturers:

• Omega Engineering

Used to monitor:

• Drink temperature

• Sterilization temperature
Working principle:

RTD resistance changes with temperature:

Rt = R0 (1 + αT)

Stage 8 – Packaging and Counting

Sensor Used: Optical Sensor

Manufacturers

• Keyence – Example model: PZ-G series

• Omron – Example model: E3Z series

• SICK AG – Example model: W12 series

• Banner Engineering – Example model: QS18 series

Working Principle

• Uses a photoelectric sensor consisting of a light emitter and receiver

• The emitter produces a light beam (infrared or visible light)

• The light beam travels across the conveyor belt

• When a bottle or box passes, it interrupts or reflects the light beam

• The receiver detects the change in light intensity

• The sensor converts this change into an electrical signal

• The signal is sent to the PLC (Programmable Logic Controller)

• The PLC counts the number of bottles or boxes

• When the required number is reached, the PLC sends a signal to the packaging machine

• The packaging machine then seals or moves the box automatically

History of the Computer Mouse

The computer mouse was created in 1964 by Douglas Engelbart at the Stanford Research
Institute. The computer mouse was created to make it easier for people to interact with
computers. In the past, computers only had keyboards, making it difficult for people to navigate.
The computer mouse made it easier for people to control the cursor on the computer screen.

The first computer mouse was a mechanical mouse that used a rubber ball. The rubber ball
turned when the mouse was moved, and rollers inside the mouse detected the movement.
Sensors in the mouse turned the movement into electrical signals that moved the cursor on the
screen. However, the mechanical mouse had several drawbacks, including dust buildup and loss
of accuracy over time.

Later, optical mice were invented by companies such as Microsoft and Logitech. The optical
mouse uses an LED light and image sensors, unlike the ball mouse. The LED light shines light on
the surface, and a small camera takes pictures of the surface. The processor compares the
pictures to determine movement and move the cursor on the screen. The optical mouse is more
accurate, reliable, and durable than the mechanical mouse.

Modern mice use laser technology, which provides even greater accuracy and works on a wider
range of surfaces. These advancements have greatly improved computer usability and
performance.
History of Optical Sensors

The evolution of optical sensors is also linked to the development of light detection and
photoelectric technology. The basis for the development of optical sensors was laid in the early
20th century with the discovery of the photoelectric effect, which indicated that light energy
could be converted into electrical energy. This led to the development of devices that could
detect light and convert it into electrical signals. The early optical detection devices were based
on simple phototubes and photodiodes that could detect the presence or absence of light.
These early optical sensors were primarily used in scientific instruments and laboratory
equipment.

The 1950s and 1960s saw the development of optical sensing technology with the development
of semiconductor materials like silicon. This led to the development of more efficient and
reliable photodiodes and phototransistors. These devices are the basis for modern optical
sensors. This period saw the use of optical sensors in industrial applications like object detection
and counting systems in manufacturing processes. The increased development of industrial
automation led to an increased demand for fast, reliable, and non-contact sensing technologies.

In the 1970s and 1980s, optical sensors were adopted on a large scale in industrial automation
systems. Large automation firms like Omron, SICK AG, and Siemens developed sophisticated
photoelectric sensors that could function effectively in industrial settings. The photoelectric
sensors were employed in conveyor systems, packaging machines, and robotic systems for
object detection. The use of infrared LEDs and laser diodes enhanced the efficiency, accuracy,
and range of optical sensors.

In the 1990s, optical sensors became smaller, more efficient, and cost-effective because of
advances in semiconductor technology and electronic circuits. During this period, optical
sensors were incorporated into various consumer electronic products like printers, barcode
scanners, and computer mice. The development and popularity of optical computer mice
proved the success of optical sensing technology in accurately detecting motion.

In the 2000s and later, optical sensors have continued to develop with the advent of new
technologies such as laser sensors, fiber optic sensors, and CMOS image sensors. Modern
optical sensors have high accuracy, high speed, and the capability to detect small objects. They
are used in robotics, medical devices, smartphones, automotive systems, and industrial
automation. For instance, optical sensors are used in smartphones to detect proximity, adjust
screen brightness, and camera systems.

Modern optical sensors are crucial components in modern technology. They are used in
industries for automation, in the medical field for medical analysis, in transportation for safety,
and in consumer electronics for interaction. There are ongoing improvements in electronics and
photonics that are making optical sensors more accurate, efficient, and reliable, ensuring their
importance in future technological developments.

Working Principle of Optical Sensor

An optical sensor works by employing light to detect the presence, absence, position, or
distance of an object. An optical sensor has three primary parts: a light emitter, a light receiver,
and a signal processing unit. The light emitter produces light from a source, such as an LED or a
laser diode. The light is projected towards the sensing region. When an object is introduced into
the sensing region, the light behaves differently depending on the type of optical sensor
employed. The light can be blocked, reflected, or scattered. The light receiver, typically a
photodiode or phototransistor, senses the amount of reflected or received light. When the
intensity of the received light changes, the optical sensor detects the presence or movement of
an object.

The signal processing unit is responsible for translating the detected light into an electrical
output signal. The electrical signal is transmitted to a control system, such as a Programmable
Logic Controller (PLC), which responds accordingly, for example, by halting the movement of a
conveyor belt or by counting objects.

Optical sensors have different modes of operation, such as through-beam, retro-reflective, and
diffuse modes. In through-beam sensors, the emitter and receiver are fixed opposite to each
other, and the object is detected by interrupting the light beam. In retro-reflective sensors, the
light beam is reflected back to the receiver using a reflector. In diffuse sensors, the light beam is
reflected directly from the object itself to the receiver.

Optical sensors are preferred due to their fast response time, high accuracy, and non-contact
object detection. The absence of contact between the sensor and the object reduces wear and
tear on the sensor, thus increasing its life. Omron, SICK AG, and Keyence are some of the
companies that produce optical sensors for industrial automation, robotics, and safety
applications. Optical sensors are a crucial component in the quick and accurate detection of
objects in an automated production setup.

Working Principle of Optical Mouse

An optical mouse is a computer mouse that uses light and image processing technology to
detect movements. The basic components of an optical mouse consist of a light source (LED or
laser), a CMOS image sensor, and a digital signal processor (DSP). The LED or laser emits light
onto the surface below the mouse. The light emitted from the LED or laser reflects back to the
CMOS image sensor. The image sensor is like a small camera that takes thousands of pictures of
the surface every second, ranging from 1,000 to 6,000 images per second.

The digital signal processor continuously analyzes the images and compares them to the
previous image. The processor detects the changes in the images of the surface and determines
the direction and speed of the movement. The movement information is then converted into
electrical signals and sent to the computer. The computer interprets the information and moves
the cursor on the screen in the same direction as the mouse movement.
Optical mice are highly accurate because they rely on detailed image analysis rather than
mechanical parts. Unlike mechanical mice, optical mice do not use a moving ball, which reduces
mechanical wear and maintenance. Modern optical mice, developed by companies such as
Microsoft and Logitech, use advanced laser technology to achieve even higher precision. Optical
mice are widely used today because they are reliable, durable, and capable of providing smooth
and precise cursor control, making them essential input devices for modern computers.