Department of Electrical Engineering

Faculty Member: Dr.Mustafa Tehseen Dated: 22-11-2024

Semester: 5th Section: A

EE-383-Instrumentation and Measurements

Experiment # 9

Inductive Proximity Switches

PLO4/ PLO4/ PLO8/ PLO9/

CLO3 CLO4 CLO5 CLO6

Analysis
of data in Modern Ethics and Individual
Viva / Quiz / Lab Tool Safety and
Name Reg. No Lab Report Usage Teamwork
Performance
5 Marks 5 Marks 5 Marks 5 Marks 5 Marks
Ayesha Nahman 424154

Hamza Irshad Bhatti 415468

Ahraf Fatima 414862

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 Lab no. 9

Inductive Proximity Switches

OBJECTIVE
• In this exercise, you will be introduced to inductive proximity switches;
• You will learn how and when they are used;
• You will also learn their advantages and disadvantages;
• You will experiment with their operation using the Reflective Block.

DISCUSSION

Inductive proximity switches are designed to detect the presence of metallic objects. They
detect their presence by generating an electromagnetic field and detecting changes in this
field caused by an approaching metallic object. Inductive proximity switches consist of a
wire coil, oscillator, rectifier (detector circuit), and transistor (output circuit) as shown in
Figure 4-1.

Figure 4-1. Inductive proximity sensor.

The oscillator produces a high frequency voltage applied to the wire coil to produce an
electromagnetic field. As Figure 4-2 shows, when a metallic object enters the magnetic
field, eddy currents are induced in the object. This causes a loss in energy and a reduction in
the magnitude of the oscillations. When the energy loss becomes important enough, the
oscillator stops functioning.

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 Figure 4-2. Operation of an inductive proximity switch.

The rectifier converts the AC output signal from the oscillator to a DC voltage. When the DC
voltage drops below the "operate level", the sensor switches the output transistor to the
activated mode. When the DC voltage raises to the "release level", the sensor switches the
output transistor to the deactivated mode. Because the magnetic field associated with the
induced eddy currents is quite small, the maximum sensing distance of an inductive proximity
switch is also quite small. Typical sensing distances are from 1 to 15 mm (0.04 to 0.6 in).
These distances are standardized against a mild steel target, typically measuring 50 × 50 ×
1 mm (2 × 2 × 0.04 in), the same as for capacitive proximity switches. Objects smaller than
the standard target will lessen the maximum sensing distance, and objects larger than the
standard target may increase the sensing distance.

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 Sensing distance, for capacitive proximity sensors, depends on the size of the probe and the
target. With inductive proximity sensors, the sensing distance depends on the size of the coil
and the composition of the target object. The chart in Table 4-1 shows the effect of target
composition on the sensing distance.

TYPE OF METAL CORRECTION FACTOR

Mild steel 1

Stainless Steel 0.9

Brass 0.5

Aluminum 0.45

Copper 0.4

Table 4-1. Sensing Distance.

For example, an inductive proximity switch detects copper at 40% the standard sensing
distance, and stainless steel at 90%. Non-metallic objects are very poor conductors and will
not be detected at all. Because nearby metallic objects affect the operation of inductive proximity
switches, they must be spaced from surrounding metallic objects and/or other sensors as
shown in Figure 4-3. Proximity Switch of your training system.

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Inductive proximity sensors can be shielded or unshielded. Shielded sensors are constructed
with a metallic band surrounding the coil. This helps to direct the electromagnetic field to the
front of the sensor and results in a more concentrated field.
Figure 4-4 (a) shows an inductive proximity switch checking bottles for bottle caps. Bottles
without caps are rejected. Inductive proximity switches work better than other proximity
switches in this application because they are not affected by high humidity. In Figure 4-4 (b)
an inductive proximity switch inspects and counts the rivets on a finished work pie

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The Inductive Proximity Switch of your training system is shown in Figure 4-5.
As Figure 4-5 shows, the sensor has an output indicator (red LED) that lights when the output
is activated. There is no sensitivity adjustment. Other characteristics of the Inductive Proximity
Switch are shown in Table 4-2.

CHARACTERISTICS OF THE INDUCTIVE

PROXIMITY SWITCH

Type Inductive unshielded

Transistor output type Sourcing (PNP)

Maximum sensing distance 10 mm (0.4 in)

Response time (sensor only) 40 ms

Table 4-2. Characteristics of the Inductive Proximity Switch.

Procedure Summary

In the first part of the exercise, Characteristics, you will observe the ability of the Inductive
Proximity Switch to detect the presence of various objects.

In the second part of the exercise, Sensing Distance, you will determine the maximum sensing
distance of the Inductive Proximity Switch by using the Reflective Block.

EQUIPMENT REQUIRED

Refer to the Equipment Utilization Chart, in Appendix A of this manual, to obtain the list of
equipment required to perform this exercise.

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 PROCEDURE

Characteristics

1. Connect the circuit shown in Figure 4-6 and turn on the DC Power Supply.

2. Test the ability of the Inductive Proximity Switch to detect the surfaces of the Reflective Block.

Position the proximity switch and the Reflective Block as shown in Figure 4-6 and determine
which surfaces are detected by the sensor. Note your observations in Table 4-3.

Figure 4-6. Circuit using the Inductive Proximity Switch

 SURFACE DETECTED NOT DETECTED

Black Plastic Surface Yes

White Plastic Surface Yes
Matte Black Metallic Surface Yes
Shiny Metallic Surface Yes
Retroreflective Surface Yes
Table 4-3.

3. Does the Inductive Proximity Switch detect all surfaces of the Reflective Block whatever
the surfaces covering the plastic block?
No, plastic surfaces are not detected.

4. Which surfaces are detected by the proximity switch?

Metallic surfaces are detected.

5. Place some objects of different materials (metallic and non-metallic) against the sensor. Do your
observations confirm that only metallic surfaces are detected by the Inductive Proximity
Switch?
Yes, we placed our hands. And they were not detected. Only metallic materials are
detected.

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 Sensing Distance

6. Determine the maximum sensing distance of the Inductive Proximity Switch. To do so, place the
shiny metallic surface of the Reflective Block against the sensor. Raise the sensor slowly away
from the metallic surface until pilot lamp L1 turns off. Determine the distance.

Maximum sensing distance = 5mm

7. Turn off the Power DC Supply and remove all leads.

CONCLUSION

In this exercise, you were introduced to inductive proximity switches. You learned how and
when they are used, their advantages and disadvantages. You observed the ability of the
Inductive Proximity Switch to detect the presence of various objects. In the last part of the
exercise, you observed that the maximum sensing distance of this type of sensor is quite
short.

REVIEW QUESTIONS

1. What type of Materials do inductive switches detect?

Metallic materials, especially ferromagnetic ones like iron and steel.

2. What are the four main parts of an inductive proximity switch?

Oscillator, coil, demodulator, and output circuit.

3. What causes the maximum sensing distance of an inductive proximity switch to be relatively
short?
Rapid weakening of the electromagnetic field with distance.
4. Explain why inductive proximity switches must be spaced from surrounding metallic
surfaces and/or other sensors.
To prevent electromagnetic interference and false triggering.

5. Name two parameters that affect the sensing distance of an inductive proximity switch.
Target material type and size.

Conclusion
Inductive proximity switches are reliable sensors designed to detect metallic materials
through electromagnetic fields, with ferromagnetic metals being the most responsive.
Their functionality relies on key components like the oscillator, coil, demodulator, and
output circuit, ensuring precise detection within a limited range. Proper spacing from
metallic surfaces and other sensors is essential to avoid interference and maintain
accuracy. The sensing distance is influenced by factors such as the type and size of the
target material. Overall, these switches are efficient and widely used in industrial
automation for non-contact detection.

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