Industrial Automation System

Sensors and Actuators

Prepared by:
Dr. Tee Kian Sek
Date: 10 March 2014

TABLE OF CONTENTS
1

EXAMPLES OF SENSOR APPLICATIONS .......................................................................................... 1

1.1

SLOT SENSORS (PHOTO SENSOR)................................................................................................................ 1

1.2

PROXIMITY SENSOR .................................................................................................................................. 2

1.3

PHOTO SENSOR VARIOUS TYPES (DIFFUSED, RETRO-REFLECTIVE, THRU BEAM) ...................................... 5

1.4

FIBRE SENSORS ......................................................................................................................................... 7

1.5

VISION SYSTEM......................................................................................................................................... 8

1.6

SINGLE AXIS POSITIONING ........................................................................................................................ 9

EXERCISES .............................................................................................................................................. 10
2.1

AN AUTO GATE ........................................................................................................................................ 10

2.2

SCISSOR LIFT .......................................................................................................................................... 10

2.3

CARGO LIFT ............................................................................................................................................ 11

2.4

HYDRAULIC PRESS .................................................................................................................................. 12

2.5

PLASTIC INJECTION MOULDING MACHINE .............................................................................................. 12

2.6

BOTTLE FILLING MACHINE ...................................................................................................................... 13

2.7

HORIZONTAL PACKING MACHINE ............................................................................................................. 13

2.8

WATER LEVEL CONTROL ......................................................................................................................... 14

2.9

LOCK AND DAM ....................................................................................................................................... 15

2.10

CAROUSEL STORAGE SYSTEM ............................................................................................................ 15

2.11

AUTOMATIC PALLET WRAPPER .......................................................................................................... 16

2.12

AUTOMATED VACUUM SUCTION AND LIFTER .................................................................................... 16

2.13

CRANE AND HOIST .............................................................................................................................. 17

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This document introduces the usage of industrial sensors via a collective of graphical
illustrations. For further detail information, the readers are encouraged to click on the links
attached or refer to any college textbooks relevant to industrial automations. The second half
of the document is drafted as the exercises for the students. The exercises require the students
to propose logically and reasonably the sensors with respect to the application. The learning
will be much fruitful if these exercises are discussed.

1 EXAMPLES OF SENSOR APPLICATIONS

1.1 Slot sensors (photo sensor)

1.2 Proximity Sensor

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Detects Aluminum Components
https://www.ia.omron.com/products/applications/case/378.html

Detects Bottle Caps

https://www.ia.omron.com/products/applications/case/381.html

Positioning at the Welding Site

https://www.ia.omron.com/products/applications/case/380.html

Liquid Level Control of Various Pipes and Liquid

https://www.ia.omron.com/products/applications/case/98.html

Detects Lead Frames (Aluminum/Copper)

https://www.ia.omron.com/products/applications/case/376.html

1.3 Photo sensor various types (diffused, retro-reflective, thru beam)

Picking Sensor Implements and Inspects Component Extraction Confirmation

https://www.ia.omron.com/products/applications/case/56.html

Accurately Detects Automobiles in Parking Lots

https://www.ia.omron.com/products/applications/case/35.html

Detects Black Tires at Long Distance

https://www.ia.omron.com/products/applications/case/388.html

1.4 Fibre Sensors

Detects Knots in a Thread

Source: https://www.ia.omron.com/products/applications/case/397.html

Detect Black Shade on Sheets

https://www.ia.omron.com/products/applications/case/395.html

1.5 Vision System

1.6 Single Axis Positioning

Positioning for Wafer Cutting Machines

https://www.ia.omron.com/products/applications/case/375.html

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2 EXERCISES

An automated system is illustrated. The students are asked to:

1. identify the locations of the sensors
2. determine the types of sensors of the pre-determined locations
3. Suggest the actuator (or actuators) and its (their) location.

2.1 An auto gate

Note: imagine the gate of your house.

2.2 Scissor Lift

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Videos: http://www.youtube.com/watch?v=6g60eUcbGZA

2.3 Cargo Lift

Source: http://www.indotara.co.id/cargo-lift

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2.4 Hydraulic Press

Source: http://www.youtube.com/watch?v=LiRnt_qbwgU

2.5 Plastic Injection Moulding Machine

Source: Introduction to Manufacturing Processes by Mikell P. Groover, 2011, Wiley

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2.6 Bottle Filling machine

Volumetric Bottle Filling Machine

http://tsac.tradeindia.com/volumetric-bottle-filling-machine--1098236.html

2.7 horizontal packing machine

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(1) Packaging film (2)Photocell (3)Former (4)Pusher (5)Product

(6)Fin sealing wheel (7)End sealing jaw (8)Discharging conveyor
Horizontal Packing Machine
Source: http://www.ccs.com.tw/automatic-form-fill-seal-machine/flow-wrapping.html#p2
Video: http://www.youtube.com/watch?v=zpN_jy4ABW8

2.8 Water level control

River Gate Control System

Source: http://www.obermeyerhydro.com/SpillwayGates

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2.9 Lock and dam

Lock and dam

Source:
http://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cu
b_dams_lesson03.xml

2.10 Carousel Storage System

Horizontal Carousel Storage System

http://www.drsystems.com/html/vertical_storage.html#HorizontalStorage

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2.11 Automatic Pallet Wrapper

Source: http://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000overview.php
See the videos for further detail on its operations!

2.12 Automated Vacuum Suction and Lifter

Vaccum Suction and Lift

Source: http://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheetmetal-69726-553305.html
Videos: http://www.youtube.com/watch?v=8KQWEf3haS4

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2.13 Crane and hoist

Overhead Crane and Hoist System

Source: http://www.saturnoe.com/products/crane_kits.asp
Videos: http://www.youtube.com/watch?v=eebN63D0eF8