The Application of Inductive Proximity Switches with Analog Output

General application advice and an equal number of normal switches. phase 1

rest position
Evaluation in the case of a PLC application
In general, the same application rules as is carried out via a PLC input module with
for the well-known inductive switching analog inputs (e.g. Siemens S5, type 6ES5
devices apply. However, there are, in 464-8MC11). For current PLCs, these
addition, a number of extra features, which modules are available at reasonable prices.
are discussed in the application report “New Alternatively, appropriate signal evaluation
Inductive Proximity Switch with Analog Out- devices, available from various suppliers,
put”. can be used.
phase 2
2. Conversion of a linear movement
into an electrical signal
phase 3
In the simplest case, a linear movement
can be directly converted, as shown in Fig. 2. Fig. 1
In this case, it only has to be ensured that the
device is not physically touched. In practice however, the sensing range of the devices is
often not enough for such a direct detection. However, using a wedge-shaped intermediate
piece, it can be modified at will (Fig. 3). Moreover, interesting possibilities arise when this
piece is non-planar. For instance in this way, linearization of the transfer function can be
achieved (Fig. 4).

wedge

direction of
movement
direction of
movement

Fig. 3

The following application examples have

all been taken from practice. Due to space non-planar
availability, only a selected few are described wedge
here, the possibilities being virtually
unlimited.
direction of
movement

Application examples Fig. 2

1. Several switching points with a sin-

gle proximity switch
One often comes across the case that,
Fig. 4
during the movement of the target to be
detected, a particular action should not be
triggered at just one position. More often, 3. Conversion of a rotational movement into an electrical signal
relevant specific actions should take place
Delivery of a rotational movement or an angle to the analog device can be made by using
at various positions. Thus, in a program
an eccentric disk (Fig. 5). As in example no. 2, by a suitable choice of the disk form, the angle
switching station, the task can be resolved
range can be modified within wide limits, and / or a linearization of the transfer function can
using a single disk and a single analog
be effected in this case too.
device (Fig. 1), instead of several disk cams

1
 eccentric disk 5. Elevator start-up adjustment
An interesting case of start-up adjustment is found in the field of elevators. A conventional
elevator generally switches to crawling shortly before reaching its destination, and then
stops abruptly without overshooting to any great extent. This is certainly very simple from the
technical viewpoint, but there are two drawbacks. Firstly, the crawling phase prolongs the
total traveling time, and secondly, despite crawling, the accuracy of the end position is both
limited as well as load dependent. By using an analog inductive proximity switch as a
transmitter for detecting the cabin position, combined with a start-up adjustment (analogous
to Fig. 6), these disadvantages are elegantly resolved, with no appreciable increase in the
sensor cost. The requirement for an adjustable drive creates an additional expense, but
today, these no longer cost the earth.
6. Detecting the pedal position in vehicles
The pedal positions in modern vehicles are required as information sources for
numerous processes. Their detection requires sensing devices that convert a path or angle
into an electrical quantity, which can then be fed to the control system. In the simplest case,
these converters consist of a potentiometer; in addition, magnetic field semiconductors are
used. Moreover, the use of displacement sensors, which work according to the differential
Fig. 5 transformer principle, is conceivable.
However, there are applications where
4. Start-up adjustment previously no satisfactory solution had been
The classical procedure of motion control found, i.e. construction equipment. Here, a
consists of simply switching off the drive after high level of vibration is combined with the
passing over an end point (detected for worst possible environmental conditions,
instance by means of a binary proximity such as dirt, extreme operating temperatures
switch). The mechanical end-point position and humidity. Moreover, permanent
is however quite vague as a result of magnets are not well viewed, since they
uncontrolled runout. By using a proximity collect metal parts and shavings. Unac-
“switch” with analog output, together with a ceptable reliability problems are the
Fig. 7
PLC for instance, it is possible to carry out inevitable result.
high-precision start-up adjustment at Analog inductive proximity switches
negligible cost (Fig. 6). meet all the above requirements to a great extent, and moreover, at a favorable cost.
Constructional realization is very simple, as Fig. 7 shows.
7. Non-contact potentiometer
What has been said above concerning
vehicle pedal position is of course also valid
for other applications where mechanical
PLC /control
unit
values have to be converted into electrical
ones. The use of a proximity switch as a
potentiometer is not obvious at first sight, but
however it permits a constructively simple
solution to the problem, e.g. following Fig. 5.
Multiturn potentiometers can also be simply
realized (with spindles).
drive
8. Parts control
slide
Monitoring of the correct position of parts
UA output signal on conveyor belts is a classic application for
photoelectric proximity switches, above all
in combination with optical fibers. In the case
path of metallic parts, analog inductive proximity
switches offer an interesting alternative,
Fig. 6

2
 twisting the device in the thread. This certainly
involves supplementary labor, but at least it
does not give rise to problems with the origi-
false nal equipment. The situation is completely
correct different during field replacement. Here, the
manufacturer is at the mercy of the
qualifications and competence of his
customer’s maintenance personnel.
For this application, the analog inductive
proximity switch offers a relatively low-cost
Fig. 8 and interesting alternative. The reasoning
behind this is that during installation, the
proximity switch is adjusted only appro-
particularly as far as sensitivity to dirt and costs are concerned. An example is shown in Fig. ximately, e.g. by eye using a mark or label.
8. Next, an initialization cycle, which is anyway
in most cases already available in the
9. Monitoring of axle concentricity
software, is started. It merely has to be exten-
In the concept of preventive maintenance, the monitoring of axle concentricity plays an ded with a suitable, low-cost module. In the
important role. During the course of time, concentricity can deteriorate in an unpredictable course of initialization, the control system
fashion, e.g. due to bearing wear, leading to unexpected and often catastrophic breakdowns brings the machine part to be detected to the
with costly repairs and downtime. Continuous exact point where the corresponding
concentricity monitoring allows immediate Axe proximity switch must react. The signal at the
information concerning the state of the output of the analog inductive proximity
bearings. It is true that there have been switch is now read by the PLC, and digitally
efficient devices on the market for some time stored as switching point information in the
for this purpose but, however, their price has memory. This value will only be overwritten
hindered wide application. It is quite the during an eventual future initialization cycle.
opposite with analog inductive proximity swit- In such a cycle, any number of proximity
ches, their price being only a fraction of that switches can be installed accurately, speedily
of conventional systems, and their use and and independently of the skill and reliability
signal evaluation are child’s play (Fig. 9). of the maintenance personnel.
Their capacity, on the other hand, is
exceptionally high, and can measure up to UA Signal
systems many times more expensive. The
t
definition and short-term repeat accuracy
reach such high values (in the region of < 0.1
µm) that, as a rule, they cannot be measured
with normal workshop equipment. Attention t
must only be paid to ensure that the electronic
motor vibration
analyzer can keep pace! Fig. 9

10. Vibration monitoring

90o
Vibration can also be an indication of a machine’s condition. Monitoring of its amplitude
over a period of time makes preventive maintenance possible, and helps eliminate
unexpected and often catastrophic breakdowns with costly repairs and downtime. In this vibration

case also, a proximity “switch” with analog output, in combination with a PLC, frequently
already installed, offers a simple, cost-effective and, in many cases, adequate solution (Fig.
10). Monitoring can take place axially, biaxially or triaxially, one proximity switch being
necessary for each axle. In this application, attention must be paid to the device’s upper
frequency limit.
11. Automatic adjustment of the switching point (Teach-in) Fig. 10
In many cases, the switching point of proximity switches must be maintained with extreme
accuracy, and for this reason, it is mechanically adjusted during installation by means of

3
12. Automatic correction of specimen scatter Contrinex AG Industrial Electronics
Like all components, analog inductive proximity switches are inevitably subject to route André Piller 50 - CH 1762 Givisiez
specimen scatter, whose value given in the manufacturer’s data sheets is for the most part Switzerland
only rudimentary. CONTRINEX data sheets, however, indicate this value at three points on Tel: ++ 41 26 460 46 46
the curve, which nevertheless does not alter the fact that scatter can be too high for certain Fax: ++ 41 26 460 46 40
applications. This means that manual adjustment is necessary, which is a considerable Internet: www.contrinex.com
disadvantage when fitting exchange parts in the field. Here, the procedure described in the E-mail: [email protected]
previous paragraph can be used, and the problem thus elegantly resolved.
 Contrinex AG 2002
13. Electronic linearization of the response curve
Dipl. Ing. Peter Heimlicher studied
Inductive technology produces a rough curve (for instance as in Fig. 11), which is not electronics at the ETH in Zurich. In
particularly linear, especially at the ends of the range. Certainly, the proximity switch 1972, immediately after his studies,
he founded CONTRINEX AG, of
manufacturer could build an additional linearizing circuit into his device, but this would, which he has been managing
however, make it larger and more expensive. This need not be the case of electronically director ever since. His company is
controlled applications. On the contrary, the specialized in the manufacture of
curve should be digitally linearized. To high-performance inductive and
U A [V]
photoelectric proximity switches.
achieve this, a procedure that inserts the
I A [mA]
device’s transfer function into the PLC aluminum steel
memory during an initialization cycle is used. 5
Instead of a single switching point as in
example number 11, the whole response 4

curve of the device, with an application-

specific resolution, i.e. with sufficient numbers 3

and positions of measuring points, is

memorized during the initialization cycle. 2

After digitalization of the measured values,

1
the ratio between the measured and ideally
expected value is calculated for each
S [mm]
measuring point, and stored in the form of a 0 1 2 3 4 5 6
correction table in the PLC. During operation, Fig.11
this table is then interposed between the
values registered and the further signal
treatment.
14. Identification of direction of rotation with only one proximity switch
By a suitable arrangement of the toothed or perforated disk (see also the application
report “Inductive Proximity Switches as Encoders”), identification of the direction of rotation
is possible with only one, in this case analog, proximity switch. For this, there are a number
UA
of possibilities, of which one example is shown in Fig. 12. At the electronic analyzer, three
switching points are set, two of which must lie in the area of the teeth surfaces and one outside. clockwise direction
switching points

From the sequence in which they move past, the direction of rotation of the toothed or
perforated disk can be derived. It goes without saying that the rotational speed can thus be
measured at the same time.
t
Summary UA
anti-clockwise direction
switching points

With the series of analog inductive proximity switches with large sensing ranges
introduced by CONTRINEX, an abundance of technically interesting and economically
advantageous possibilities for converting mechanical quantities into electrical ones have
become available to constructors. The devices combine the well-known advantages of tried
and tested inductive proximity switches with those of mechanically susceptible potentiometers, t

magnetic field sensors with permanent magnets and far more complex length measuring Fig. 12
systems.