Sensors PDF

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Sensors
Introduction to PLC
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What is a sensor?
A sensor is a technical converter of a physical
quantity
temperature
distance
Pressure
Etc.
to an electrical signal such as voltage, current,

resistance or frequency of oscillation.
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Physical Quantity
(Distance
Pressure
Weight
)
Physical Quantity
(Temperature,
Pressure,
Distance, etc)
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Sensor
Electrical quantity
(Voltage:
0..10V
Current:
4..20mA
Resistance: 0..600)
Transducer
Another Physical
Quantity
(Display,
Length, etc)
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What is a sensor?
In electro pneumatic controllers, sensors
are primarily used for the following
purposes:
To detect the advanced and retracted end
position of the piston rod in cylinder drives.
To detect the presence and position of work
pieces.
To measure and monitor pressure.
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Classification of Sensors
Classified on the basis of the
Physical quantity to be detected.
Sensor signal
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Sensor signals
Sensors convert a physical value, usually
into an electrical signal.
Sensors can be divided, according to the
type of output signal.
binary sensors (switches)
analogue sensors
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Sensor signals
In automation, analogue sensors are used,
if a gradual change of the value is of
significance.
Binary sensors are however often used as
limit monitors or alarm switches.
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Analogue/ Binary sensors

Displacement/ Distance
Linear Potentiometer
Proximity switch
Analogue sensor signal
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Switching signal
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Sensor Switching Distance
Sensor
Object
Sn
Sn = Switching Distance
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Sensor Hysteresis
Object
Object
Sensor
h
Sn
Sn = Switching Distance
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h = Hysteresis
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Connection and Circuit

Technology
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Two-Wire Technology
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Technology
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Three-Wire Technology
BN(1)
BK(4)
+24V DC
PNP normally closed
L
BU(3)
0V
BN(1)
BK(4)
BU(3)
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PNP normally open
+24V DC
PNP normally closed
L
0V
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Technology
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BN(1)
BK(4)
+24V DC
NPN normally open
L
BU(3)
0V
BN(1)
+24V DC
BK(4)
NPN normally closed

L
BU(3)
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0V
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Parallel and Series Connection

Usually logic operations of the proximity sensors
are carried out by the controller.
By means of series or parallel connections it is
possible to achieve the logic operation of several
sensors.
With parallel connection, it is possible to effect a
logic or connection and with series connection
a logic and connection.
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Advantages
Logic operations can be achieved without using
an electrical controller.
With the use of electrical controllers, logic
operations can be carried out immediately on
the spot so that only the logic operation result is
signaled to the controller using a minimum
amount of cabling.
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Disadvantages
The design and construction of logic operations
requires experience, as the mutual influences of
proximity sensors, increases response and drop-off
times and a limit in the number of proximity sensors
connected must be taken into account.
Maintenance becomes difficult.
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Parallel Connection
Two-Wire Technology
+24V DC
BN(1)
BN(1)
BU(3)
BU(3)
UV
L
0V
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Parallel Connection
+24V DC
BN(1)
BK(4)
BU(3)
BN(1)
BK(4)
BU(3)
L
0V
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Series connection
Two-Wire Technology
+24V DC
BN(1)
BU(3)
V1
BN(1)
BU(3)
V2
L
0V
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Series connection
+24V DC
BN(1)
BK(4)
BU(3)
BN(1)
BK(4)
BU(3)
V1
V2
L
0V
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Proximity sensors
Proximity sensors is the more commonly used
sensor.
Proximity Sensors are classified as:
Contact type
Non-contact type
Non contact type proximity sensors have:

Long service life
High switching reliability.
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Limit Switches
Contact type sensor
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Reed Switches (Magnetic)

a)
Most Widely Known and

Used as Cylinder
Switches
b)
1
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Reed switches are magnetically actuated proximity switches.

They consist of two contact reeds in a glass tube filled with
inert gas.
The field of a magnet causes the two reeds to close, allowing
current to flow.
Reed switches have a long service life and a very short
switching time (approx. 0.2 ms).
They are maintenance-free.
Should not used in environments subject to strong magnetic
fields.
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Glass Tube filled
with nitrogen
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Reed contacts
LED
indicator
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24v
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24v
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Reed Switches
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Inductive Proximity Sensors
LED
Cable or
plug-in connection
Active surface
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High Frequency magnetic field (300
to 800 kHz) Active Surface
Resonant circuit coil
LED indicator
Connection cable
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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Target
Sensor
Oscillation
Amplitude
Sensor
output
signal
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ON
OFF
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The bigger the coil, the greater the active
switching gap.
Inductive sensors can only detect metals.
Different switching distances for
different metals
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Material
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Reduction Factor
Mild Steel
1.0
Chrome Nickel
0.70 ~ 0.90
Brass
0.35 ~ 0.50
Aluminum
0.35 ~ 0.50
Copper
0.25 ~ 0.40
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Inductive sensors detect metals and operate
quickly, reliably and tirelessly. They are used to:
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Count
Identify
Detect
Switch
Control
Check
Distinguish
Sort
Position
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Sensing a Cam Controller
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Measurement of Speed and Direction of Rotation
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Checking the End Positions of a Semi-Rotary Drive
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Inductive
proximity
sensor
Detecting the End Position of a Press Ram
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Capacitive Proximity Sensors

Sensor is looking for a
change in capacitance in
the active field
Electrostatic field
Active surface
Active electrode
Earth electrode
LED indicator
Adjusting screw
Connection cable
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Target
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Almost similar to the inductive sensor.

Able to detect most materials.
Switching distance adjustable.
Able to detect fluid level through the wall
of a bottle.
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Sensor is adjusted so that it does

not see the wall of the vessel.
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As the level rises the fluid affects

the sensor field.
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Until the sensor switches.
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Detecting fluid level, wall thickness must
be limited.
Detection of matt, black objects.
Monitoring the winding of electrical
wires and cables.
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D e te c tio n o f B la c k R u b b e r S o le s
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Optical Proximity Sensors

There are three different types of optical
proximity sensors:
Through beam optical sensor
Retro-reflective optical sensor
Diffuse optical sensor
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Diffuse
Sensors
Through-beam
Sensors
Designs with
Fiber-optic cable
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Retro-Reflective
Sensors
Designs with
Fiber-optic cable
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Through Beam Sensor
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Through Beam Sensor
Transmitter
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Receiver
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Transmitter
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Receiver
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Target
Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Transmitter
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Receiver
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Through Beam Sensor

Advantages of through beam sensors
Enhanced reliability because of permanent
light during operation.
Wide range.
Small objects can be detected even at large
distances
Suitable for aggressive environment.
Good positional accuracy
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Through Beam Sensor

Disadvantages of through beam sensors
Two separate proximity sensor modules and
separate electrical connections are required.
Cannot be used for completely transparent
objects.
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Through Beam Sensor

Applications of through beam sensors
Used as safety devices.
Fast counting applications.
Monitoring for broken parts.
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Through Beam Sensor
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Retro-Reflective Sensor
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T
R
Transmitter
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Receiver
Reflector
(prismatic)
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T
R
Transmitter / Receiver
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Reflector (prismatic)
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T
R
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Target
T
R
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T
R
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T
R
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T
R
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T
R
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T
R
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T
R
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Advantages of retro-reflective sensors
Enhanced reliability because of permanent light
during operation.
Simple installation and adjustment.
Objects can be diffuse reflecting, mirroring or
transparent as long as enough light is absorbed.
A greater range as compared to diffuse sensors.
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Disadvantages of retro-reflective sensors
Transparent, very bright or shiny objects
may remain undetected.
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Counting of Objects
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Slack Control
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Diffuse Sensor
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Target
T
R
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T
R
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T
R
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T
R
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T
R
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T
R
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Diffuse Sensor
Advantages of diffuse sensors
Because the reflection on the object activates
the receiver, an additional receiver is not
required.
Diffuse sensors allows frontal detection.
Objects can be detected selectively in front
of a background.
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Diffuse Sensor
Disadvantages of diffuse sensors
They are not as suitable as through beam
sensors if accurate lateral response is crucial.
They do not react to objects with reduced
reflection eg. Black objects
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Diffuse Sensor
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Diffuse Sensor
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Fibre-Optic Cables
Advantages of using fibre optic cables
Detection of objects in areas of restricted
access.
Possibility of remote installation.
Accurate detection of small objects.
Sensing elements can be moved.
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Fibre-Optic Cables
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Fibre-Optic Cables
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Fibre-Optic Cables
Optoelectronic
proximity sensor
Fibre-optic
cable
Emitter
Receiver
LED display
and
adjusting screw
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Fibre-optic cable
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Fibre-Optic Cables
Optoelectric
proximity sensor
Emitter fibre-optic cable
Object
Receiver fibre-optic
cable
LED display
and
adjusting screw
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Fibre-Optic Cables
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Fibre-Optic Cables
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Fibre-Optic Cables
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Fibre-Optic Cables
Workpiece
Workpiece
carrier
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Ultrasonic Sensors
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Ultrasonic Sensors
Advantages of ultrasonic sensors
Relatively large range.
Object detection irrespective of colour and
material.
Safe detection of transparent objects.
Relatively dust and dirt insensitive.
Fading out of background possible.
Outdoor application possible.
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Ultrasonic Sensors
Disadvantages of ultrasonic sensors
Object surface should be at right angles.
They react slowly.
Generally more expensive than optical
sensors.
They cannot detect sound absorbing
materials.
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Ultrasonic Sensors
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Ultrasonic Sensors
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Ultrasonic Sensors
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Sensor Exercise
Red
Sorting
Station
Metal
Black
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Sensor Exercise
A Conveyor transports three different coloured
work pieces to a sorting station.The Red and
Black work pieces are Plastic. At the sorting
station, the work pieces will be sorted according
to their colour and directed to their respective
paths.
The work pieces are :
Red
Black
Metal
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How many sensors and which sensors are

required at the sorting station?
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Pneumatic Sensors
With pneumatic proximity sensors the
presence or absence of an object is detected
by means of contactless sensing with air
jets.
A signal pressure change occurs which is
further processed.
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Pneumatic Sensors
Advantages of pneumatic sensors
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Operational safety in dusty environments.

Operational safety with high ambient temperatures.
Can be used in areas of explosion hazard.
Insensitive to magnetic influences and sound waves.
Reliable even in extreme ambient brightness and for
sensing of light transparent objects.
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Pneumatic Sensors
Types of pneumatic sensors are:
Back pressure sensors
Reflex sensors
Air barriers
Detectable distances range from 0 to 100 mm.
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Back Pressure Sensors
A
P
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Back Pressure Sensors

0.1 to 0.3 bar
to the pump
Back pressure
nozzle
P
A
Immersion tube
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Reflex Sensors
Emitter nozzle
Receiver nozzle
A
P
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Reflex Sensors
X
1
X
2
X
2
X
1
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Reflex Sensors
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Air Barriers
A
Receiver nozzle
Emitter nozzle
P
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P
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Air Barriers
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Air Barriers
m
20
1m
38
Air barrier
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Air Barriers
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Pressure Switches
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Selection Criteria
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Object material
Conditions for the detection of objects
Installation conditions
Environmental conditions
Safety applications
Options/features of proximity sensors
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Selection Criteria
Sensors can be selected according to the
material which they are to detect.
Metals of any kind can be detected easily and
economically with inductive sensors if short
switching distances only are required (eg. 0.4
. 10 mm)
For greater distances, optical sensors of varying
designs are available. The greatest distances
can be spanned by means of through beam
sensors.
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Selection Criteria
Capacitive proximity sensors are suitable for
the detection of a wide range of materials, but
again only for relatively small distances,
similar to inductive proximity sensors.
Ultrasonic and optical diffuse reflective
proximity sensors are able to detect a wide
range of different materials over greater
distances. However, the detection of reflecting
objects with tilted surfaces may create
problems.
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Selection Criteria
Further criteria for the selection of
proximity sensors are the conditions under
which the object is to be detected, what the
installation requirements for the proximity
sensors are and the environment factors to
be taken into account
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Sensor Exercise
Red
Sorting
Station
Metal
Black
Introduction to PLC
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Sensor Exercise
A Conveyor transports three different coloured
work pieces to a sorting station.The Red and
Black work pieces are Plastic. At the sorting
station, the work pieces will be sorted according
to their colour and directed to their respective
paths.
The work pieces are :
Red
Black
Metal
Introduction to PLC
How many sensors and which sensors are

required at the sorting station?
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Nikini
Introduction to PLC
1/21/2011 11:19 AM

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to an electrical signal such as voltage, current,

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Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Analogue/ Binary sensors

Analogue sensor signal

Nikini Automation Systems (Pvt) Ltd

Sensor Switching Distance

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Connection and Circuit

Nikini Automation Systems (Pvt) Ltd

Connection and Circuit

PNP normally open

Nikini Automation Systems (Pvt) Ltd

Connection and Circuit

NPN normally closed

Nikini Automation Systems (Pvt) Ltd

Parallel and Series Connection

Nikini Automation Systems (Pvt) Ltd

Parallel and Series Connection

Nikini Automation Systems (Pvt) Ltd

Parallel and Series Connection

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Non contact type proximity sensors have:

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Reed Switches (Magnetic)

Most Widely Known and

Nikini Automation Systems (Pvt) Ltd

Reed switches are magnetically actuated proximity switches.

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Nikini Automation Systems (Pvt) Ltd

Inductive Proximity Sensors

Nikini Automation Systems (Pvt) Ltd

Inductive Proximity Sensors

Resonant circuit coil