Sensor Definitions
Used in Industrial Automation:
Electrical device capable of identifying
change within an automated process.
Sometimes…
Sensor = Switch
Sensors used in general are
◦ Automatic opening doors.
◦ Conveyer start stop.
◦ Safety sensors on garage doors.
◦ Glowing of lamp when car door is opened.
Sensors used in Manufacturing
◦ Part position verification of Tools.
◦ Counting products.
◦ Liquid level control.
◦ Sensing of dielectric
materials,insulators.
◦ Personal safety systems.
The three major components:
The sensing side The electrical side
Back-end
Front-end
Housing
Back-end – Electrical
Options:
Electrical voltage
AC/DC
DC
Output type
Discrete (on-off, like a switch)
Analog
Selection base on: Control System
The Sensors Housings
◦ Material Options:
Metal (nickel-plated brass)
Stainless steel
Aluminum
Plastic
◦ Shape (mounting style):
Tubular
Block
Selection base on: Environment
Sensor Definitions
Front-end - Sensing
Five technology choices:
Inductive
Optical
Capacitive
Magnetic
Mechanical
Selection base on: Application
Housing
Environment
Electrical Interface
Electronics
Sensing Side
Front-end
Electronics
Switch
Power Wires
Sensing Technologies
When voltage is applied, an electromagnetic field is generated and
extends out the face of the sensor.
When metal enters the sensing zone, an eddy current is induced in
the metal.
The change in eddy current is detected and the sensor’s output is
energized.
Electro magnetic
field
Active surface
Inductive coil
Oscillator circuit
Triggering circuit
Output switching
circuit
Sensing Technologies
Two basic Sensing types
◦ Flush mount
Shorter range
Sensor can be buried in metal
Non-flush mount
Longer range
Sensor can NOT be buried in metal
different metals have different values of resistivity
(which limits the eddy currents) and permeability (which
channels the magnetic field through the target), the type
of metal being sensed will affect the sensing range.
Inductive proximity sensor manufacturers derate their
sensors based on different metals, with steel being the
reference
METAL DERATING FACTOR
Steel 1.0
Stainless steel 0.85
Aluminium 0.40
Brass 0.40
Copper 0.30
REQUIRED DISTANCE
SENSOR RANGE
DERATING FACTOR
EX: If we want to sense a copper metal from 5mm
distance so what should be the sensor range we
required(Derating factor of copper=0.30)
ANS:
SENSOR RANGE /
5mm 0.30=16.7mm
Electrical Interface
Sensors with relay output
Unlike a switch,
Electronics sensors require power
to operate
-
It utilize the electrical property of and the
change of based on a change in the electrical
field around the active face of the
It is of 2types : i)Dielectric type
ii)Conductive type
i)Dielectric type :
In the dielectric type of capacitive sensor, there
are two side-by-side capacitor plates in the sensor
face. For this type of sensor, the external target
acts as the dielectric. As the target is moved closer
to the sensor face, the change in dielectric
increases the capacitance of the internal capacitor,
making the oscillator amplitude increase, which in
turn causes the sensor to output an “on” signal.
Dielectric type capacitive proximity sensors will
sense both metallic and non-metallic objects.
The conductive type of sensor operates similarly; however,
there is only one capacitor plate in the sensor face. The target
becomes the other plate. Therefore, for this type of sensor, it
is best if the target is an electrically conductive material
(usually metal or water-based).
Conductive type capacitive proximity sensors require that the
material being sensed be an electrical conductor. These are
ideally suited for sensing metals and conductive liquids.
they are ideal for liquid level sensors.
CONDUCTIVE TYPE CAPACITIVE SENSOR
An optical proximity sensor includes a light
source. it is capable of sensing any objects that are
opaque, regardless of the color or reflectivity of the
surface.
These are generally available in one of three types
of light source - incandescent light, red LED and
infrared LED. The red LED and IR LED types of
sensors generally have a light output that is pulsed
at a high frequency
optical proximity sensor is preffered for
long range sensing application.
It is of 3types :
i) Through-Beam (Dark on)
ii) Diffuse Reflective (Dark off)
iii) Retro-reflective
OUTPUT OFF
EMITTER RECEIVER
OUTPUT ON
EMITTER OBJECT RECEIVER
EMITTER
OUTPUT OFF
RECEIVER
EMITTER OUTPUT ON
RECEIVER OBJECT
EMITTER OUTPUT OFF
RECEIVER REFLECTOR PLATE
EMITTER
OUTPUT ON
OBJECT REFLECTOR PLATE
RECEIVER
Magnetic proximity sensors are non contact
proximity devices that are used to detect
magnetic objects (e.g. permanent magnets).
SENSOR TYPE RED/BROWN BLUE BLACK WHITE GRAY
3 Wire +VE -VE O/P(NO) N/A N/A
4 Wire +VE -VE O/P(NO) O/P(NC) N/A
5 wire +VE -VE O/P(NO) O/P(NC) O/P
(ANALOG)
4 WIRE
3 WIRE
5 WIRE
Electrical Interface
Standard diagram form
The Sensor
1 +
4 Load PNP Output
3 -
The Load
Connector
Pins
Electrical Interface
Watching the current flow
Sensors Power
Output Signal
1 +
4 Load PNP Output
3 -
Electrical Interface
Watching the current flow
Sensors Power
Output Signal
1 +
4 Load NPN Output
3 -
Non- Contact Contact
◦ No physical contact ◦ Contact with target
with target ◦ Simplest method
◦ Preferred method for available
sensing end products
On/off operation
only
Two general modes
◦ Normally Open (NO)
◦ Normally Closed (NC)
For a wide range of
uses
Sensing Technologies
Mechanical switch
◦ Contact with plunger
opens electrical contacts
Where physical contact is possible
Where definitive position is required