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4 - Industrial Sensors

The document provides an overview of various types of sensors used in industrial automation, including mechanical, optical, inductive, and capacitive sensors. It discusses the importance of sensors in automating processes, their definitions, and key characteristics such as accuracy, resolution, and sensitivity. Additionally, it covers specific applications and principles of different sensors, including limit switches, proximity sensors, and encoders.

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12 views36 pages

4 - Industrial Sensors

The document provides an overview of various types of sensors used in industrial automation, including mechanical, optical, inductive, and capacitive sensors. It discusses the importance of sensors in automating processes, their definitions, and key characteristics such as accuracy, resolution, and sensitivity. Additionally, it covers specific applications and principles of different sensors, including limit switches, proximity sensors, and encoders.

Uploaded by

duytan170104
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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1

Proximity
- Mechanical
- Optical
Industrial Sensors - Inductive
- Capacitive

Position/Velocity
- Potentiometer
- LVDT
- Encoders
- Tachogenerator

Force/Pressure
Vibration/acceleration
Introduction to Sensors 2

l In manual, processes are controlled by human.


Ex: If water tank fulls then push Stop button to stop the pump
If motor overloads then push Error button to stop the system
l Automatic processes need to use sensors.
l Sensor is device that converts physical signal into discrete or
continuous voltage or current values.
l Physical signals: an object appears, the door open, temperature,
weight, pressure, liquid level, …
l Discrete values: 0V, 24V
l Continuous values: 0 .. 5V, 0 .. 10V, 0 .. 20mA, 4 .. 20mA
Need for Sensors 3

l Sensors are omnipresent (popular).


l They embedded in our bodies, automobiles, airplanes, cellular
telephones, radios, chemical plants, industrial plants and
countless other applications.
l Without the use of sensors, there would be no automation !!!
Definitions 4

Accuracy: The agreement between the actual value and the measured
value
Resolution: The change in measured variable to which the sensor will
respond
Repeatability: Variation of sensor measurements when the same quantity
is measured several times
Range: Upper and lower limits of the variable that can be measured
Sensitivity and Linearity
Choosing a Sensor 5
Mechanical Limit Switches 6

l Essentially a mechanical switch


l On/Off operation only
l Two general modes
- Normally Open (NO)
- Normally Closed (NC)
l Come in a wide variety of
mechanical forms
l For awide range of use
Example Mechanical Limit Switches 7
Use Limit Switch 8

l Use:
l Where physical contact is possible
l Where definitive position is required
l In operation-critical or safety-critical situations
l Where environment conditions preclude the use of optical or inductive sensors
l Applications:
l Easy to integrate into machinery of all types
l Requires contact (thus wear)
l Range of voltages: DC 0-1000V, AC, etc.
l Very robust (explosion proof if required)
l Usually used as:
- Limit switch
- Presence/absence indicator
- Door closed/open
Proximity Sensors 9

l Widely used in general industrial automation


- Conveyor lines (counting, jam detection, etc)
- Machine tools (safety interlock, sequencing)
l Usually digital (On/Off) sensors detecting the presence or absence of
an object
l Consist of:
- Sensor head: optical, inductive, capacitive
- Detector circuit
- Amplifier
- Output circuit: TTL, solid state relay
Optical Sensor 10

l Use light to sense objects


l Including a light Transmitter and Receiver
l All sensors function in the same basic manner
l Differences are in the way which the light transmitter and receiver are
packaged
l Light sensing - Light ON:
- The output is energized (ON) when received light
l Dark sensing - Dark ON:
- The output is energized (ON) when not received light
l NPN or PNP output
Basic Manner 11
Types of Reflection 12
Proximity Sensors 13

l Inductive Proximity Sensor: use change in local magnetic field to


detect presence of metal target
l Capacitive Proximity Sensor: use change in local capacitance caused
by metallic or non-metallic objects
l No physical contact required
l Sensing distance: < 20mm
l NPN or PNP output
Inductive Sensor Principles 14

Coil inductance increases


as metal object gets closer
Capacitive sensor Principles 15

Capacitance increases as metal or non-metal


object gets closer
Because capacitance path C2 and C3 added C1
is always present
Output Circuits of Digital Sensors 16

NPN Output

PNP Output
Applications of Sensors 17
Applications of Sensors 18
Analog Sensors 19

l LVDT Technique
l Wheaston Bridge
l Temperature sensor
l Pressure sensor
l Loadcell
l Ultrasonic sensor
l Encoder
LVDT Technique 20

● Linear Variable Differential Transformer


● Measure linear displacement over a limited range
● The magnitude of signal out voltage indicates the position of the core
● Electromechanical sensor used to convert mechanical motion or vibrations
LVDT Technique 21

● LVDT operating based on transformer theory


● Vac in LVDT, create Vac out that is proportional to position of the core
● Adding diodes, capacitors and resistor to create Vdc out
Wheaston Bridge 22

l Use resistors to make a resistor bridge


l Voltage bridge or current bridge
l V or I values between B and D will depend on Rx
l Strain Gauge: variable resistor is up to its strain
Loadcell 23

l Weighting sensor
l Resistor bridge concept, using Strain Gauge resistor
l Strain Gauge: variable resistor depend on force impact on it
Loadcell Datasheet 24
Flow Control 25
Pressure Transducer 26
Pressure Sensor Datasheet 27
Temperature Transducer 28
Pt100 Datasheet 29
Rotary Encoder 30

l Electro-Mechanical device that converts angular position or motion of a


shaft to digital code (Pulses)
l Absolute encoder: indicates current position of the shaft
l Incremental encoder: provides information about motion
With Optical Encoder 31
Type of Encoders 32

l Absolute and Incremental Encoder.


l Absolute and Incremental motion refer to the type of motion done by the motor either
by relating it to the absolute home position or the last known position.
Absolute Encoder 33
Incremental Encoder 34
Encoder Application 35
Actuators 36

l Pneumatic Actuators
l DC motors
l AC motors
l Step motors
l Servo motors
l Inverters

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