Ging vin: Th.

S Phm Bch Dng

CAC PHN T CUA H THNG C IN T

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Bi 2:

DIGITAL SENSORS

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SENSORS
In this lesson you will learn
About advantages, disadvantages, and applications of limit switches, photoelectric sensors, inductive sensors, capacitive sensors, and ultrasonic sensors. About principles of mechanical limit switches, inductive, capacitive, ultrasonic, and photoelectric sensors and describe differences and similarities. To select the type of sensor best suited for a particular application based on material, sensing distance, and sensor load requirements.

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Block Diagram of Control Unit

Frequently measured values are:
Temperature Pressure/Force Flow Humidity pH-value Revolutions per minute (speed) Position
Noise Input data Process Output data

Actuator

Sensor Actual value Process computer

Control input
5

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Advantages of Sensors
No physical contact and therefore no stress. No wear and tear, hence long life. Contact less and therefore maintenance free. Electronic high precision. Protected and safe switching in harsh environments. High switching rate. Bounce-free contact, thus not prone to false pulses.
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Physical Principles
Inductive
I

Capacitive
C

Magnetic
B

Photoelectric
?

Ultrasonic
U

Microwave
M

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Inductive sensors
detects only conductive materials.
Inductive

operation distance up to 100 mm. switching frequency up to 5 kHz. max. ambient temperature 250 C.

max. protection class IP 68.

high noise immunity.
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Inductive sensors
Block Diagram
Plastic cover

Inductive
Epoxy resin LED Cover paste O-ring seal

Coil

Ferrite core Support IC Printed board Housing Support ring

Oscillator

Comparator

Output amp.

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Inductive sensors
Applications
Inductive

Position Detection of Doors

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Valve Position
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Cylinders Position Detection

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Inductive sensors
Physical Basics
R1 R2

Inductive
I

Primary circuit: sensor coil

Secondary circuit: target

the alternating electromagnetic field created by the coil induces eddy currents in the target if the target is made of non-ferromagnetic (NFE) material. the alternating electromagnetic field created by the coil induces eddy currents and generates magnetic losses in the target if the target is made of ferromagnetic (FE) material. the magnetic losses are higher than the losses generated by the eddy currents. operating distances vary depending on the target material and are normally shorter than the usable operating distance.
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Inductive sensors
Operation Distances

sn = Rated operation distance sr = Effective operating distance

Target
Su max. Sr max. Sn Sr min. Su min. Sa Su max. + Differential travel Sr max. + Differential travel Sn + Differential travel Sr min. + Differential travel Su min. + Differential travel

single proximity switch voltage within the operating voltage range ambient temperature 23 C + 5 C

0.9* sn < sr < 1.1*sn su = usable operating distance

single proximity switch voltage between 85% and 110% of rated operating voltage temperature range -25 C ... +70 C

0.9* sr < su < 1.1*sr 0.81*sn < sa < 1.12*sn sa = assured operating distance

Inductive
I
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Inductive sensors
Reduction Factor
Reduction factor records the reduction of operating distance from the standard target because of the deviating object characteristics. Reduction factor is a function of:

Steel Fe360 (1)

Stainless steel (0.65 ... 0.85) Brass (0.25 ... 0.55)

conductivity permeability

Aluminium (0.2 ... 0.5)

Copper (0.15 ... 0.45)

Inductive
I
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Inductive sensors
Operating Frequency (f )
number of operating cycles performed by a proximity switch during a specified period of time. This value is a function of the oscillator frequency of the given proximity switch:

Target / no target ratio = 1:2

high oscillator frequency (small operating distance) high frequency of operating cycles low oscillator frequency (large operating distance) low frequency of operating cycles

Inductive
I
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Inductive sensors
Electrical Values
DC Sensors

Inductive

Voltage range:

10 VDC ... 30 VDC 10 VDC ... 60 VDC 5 VDC ... 60 VDC

AC Sensors

Voltage range: 98 VAC ... 253 VAC Frequency range: 48 Hz ... 62 Hz

AC/DC Sensors

Voltage range:

10 VDC . .. 30 VDC 24 VAC ... 240 VAC

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Inductive sensors
Types of Connection 1
"Positive logic"
NO (Z0)
+ 24 VDC BN/3 1 2 3 4

Inductive

NO/NC (Z2)
+ 24 VDC

"Negative logic", NO
- 24 VDC BU/4

BU/4

Load

Load

BN/3

Load

NC (Z1)
+ 24 VDC BN/1

NO/NC (Z2)
+ 24 VDC 1 2 3 4 Load Load

"Negative Logic", NC
- 24 VDC
BU/2

BU/2

BN/1

Load

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Inductive sensors
Types of Connection 2
Three-wire Sensors (Type E)
E2
L+ (+24 VDC)
BN/1 BK/4 BU/3 Load BN/1 BK/2 BU/3 Load Output Load

Inductive

E3
L+ (+24 VDC)

pnp-type

L- (Ground)

L- (Ground)

E/E0
L+ (Ground) BN/1 BK/4 BU/3 Load

E1
L+ (Ground) BN/1 BK/2 BU/3 Load L- (-24 VDC)

npn-type

Load

L- (-24 VDC)

Output

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Inductive sensors
Types of Connection 3
Four-wire Sensors (Type A)
A2 (pnp)
1 2 4 3

Inductive

A (npn)
1 2 4 3

L+ (+24 VDC) Load L- (Ground)

L+ (Ground) Load L- (-24 VDC)

Advantage: Two types of output in one housing.

Disadvantage: Higher price.

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Capacitive sensors
detects every materials (conductive, non-conductive, solids, fluids, ...). operation distance up to 50 mm. switching frequency max. 100 Hz. max. ambient temperature 70 C. max. protection class IP 67.

Capacitive
C

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Capacitive sensors
Block Diagram
Sensor electrode Printing board

Capacitive
C

Housing

Shielding

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Capacitive sensors
Physical Basics
Sensor electrode Target Shield

Capacitive
C

C = f(e0, er, A, s-1)

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Capacitive sensors
Applications
Capacitive
C

Stamping

Fire Works Production

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Position Detection

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Magnetic sensors
detects only magnetic objects. operation distance up to 60 mm. Magnetic
B

switching frequency up to 1 kHz.

max. ambient temperature 70 C.

max. protection class IP 67.

high noise immunity.

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Magnetic sensors
Block Diagram
Ferrite core Coil Cable

Magnetic
B

Application: Detection of magnets thru NFE-metals

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Magnetic sensors
Detection Area
Magnetic
B Detection area has two minor lobes ==> 3 switching points, if the magnet is too close to the sensor.

If the magnet is turned of 90 this happens 2 switching points.

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Magnetic sensors
Applications
Sensor for the detection of position of pistons in hydraulic cylinders (thru NFE-metals).

Magnetic
B

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Photoelectric sensors
three different operation principles: Photoelectric thru beam (receiver and transmitter in two housings). ? reflective (receiver/transmitter in one housing, retro reflector is necessary). diffuse reflective. detects, depending on the operation principle, light reflecting or non transparent materials. possibility to connect fibre optic. operation distance up to 100 m. switching frequency up to 1.5 kHz. max. ambient temperature 300 C (with fibre optic only). max. protection class IP 67. detects smallest objects (depending on the diameter of the fibre optic).
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Photoelectric sensors
Block Diagram
Photoelectric

?
Transmitter

Signal converter receiver

Amplifier

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Photoelectric sensors
Modes of Operation
Direct detection Sensor Detection of all materials.
Photoelectric

Through-Beam Sensor Problems with materials like glass.

Retro-Reflective Sensor Problems with mirror objects and objects like glass.
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Retro-Reflector

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Photoelectric sensors
Advantages/Disadvantages
Advantages

Photoelectric

not sensitive against changes in temperature and pressure. small housing (compared to ultrasonic sensors). small objects detectable (especially Laser version and fibre optic version). high measurement range.

Disadvantages /Problems

sensitive against dirt. Background reflections / Light from foreign sources. Reduction factors.
Dirt at the optic. other photoelectric sensors (mutual influence). Light from natural sources (ex: Sun). Light from fluorescent sources (Ex: Neon lamps).

Interferences

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Photoelectric sensors
Applications
Photoelectric

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Photoelectric sensors
Photoelectric

Applications

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Photoelectric sensors
Photoelectric

Applications
?

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Ultrasonic sensors
detects objects which reflect or absorb sound. Ultrasonic operation distance up to 12 m.
U

reaction time > 35 ms. max ambient temperature 70 C. max. protection class IP 67. lower noise immunity. not sensitive to dirt.
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Ultrasonic sensors
Block Diagram
Transducer

Ultrasonic
U

Decoupling layer

Integral foam Ultrasonic transducer

Piezo ceramic Signalprocessing

Output

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Ultrasonic sensors
Physical Basics
Ultrasonic
U
Infra Audible Ultra Hypersonic

Velocity of Sound c (m/s)

Pressure [hPa]

Temperature [C)

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Ultrasonic sensors
Advantages/Disadvantages
Advantages

Ultrasonic
U

detects solids, fluids, granulates. insensitive against dust. no reduction factor ==> switching distance is no function of material (except foam, foamed material). possibility to change the direction of the signal.

Disadvantages /Problems

sensitive against environmental conditions (temperature, pressure, ...) blind range. switching distance is a function of the form of the target.

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Ultrasonic sensors
Detection characteristic
Ultrasonic
U

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Ultrasonic sensors
Adjustment
blind range
sensing range

Ultrasonic
U

target opening angle

A1
minimum switching distance

A2
measuring window maximum switching distance

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Ultrasonic sensors
Operation
Ultrasonic
U

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Ultrasonic sensors
Applications
Ultrasonic
U

Glass detection
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Level Control
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Pattern sensors

Label arragement

Reverse Label Check

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Label check
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Image recognition

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Summary
What you have learned
There are six common types of proximity switches and their uses. Type of connections. Basic principles of many kinds of proximity switches/sensors. Typical applications of sensors.

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