Notre Dame University

Faculty of Engineering
ECCE Department




EEN 365
Programmable Logic Controller Laboratory





Experiment 1
Introduction to industrial sensors




Eng. Yves Mansour














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1. Objective: the object of this experiment is to describe the construction and
characteristics of the different types of industrial sensors and their application, such
as mechanical switches, magnetic, inductive, capacitive, optical and fiber optic
sensors.


2. Background information:


2.1 Push button and control switches

Switches are installed in circuits to apply a current to a load or to interrupt the circuit. These
switches are divided into pushbuttons and control switches.

1. Control switches are mechanically detented in the selected position. The switch position remains
unchanged until a new switch position is selected. Example: Light switches in the home.

2. Push button switches only maintain the selected position as long as the switch is actuated
(pressed). Example: Bell push.

In the case of a normally open contact, the circuit is open if the switch is Normally open contact in
its initial position (not actuated). The circuit is closed by pressing the (make) push button current
flows to the load. When the plunger is released, the spring returns the switch to its initial position,
interrupting the circuit.



In the case of a normally closed contact, the circuit is closed when the switch is in its initial position.
Pressing the pushbutton interrupts the circuit.
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In the case of a changeover contact, the changeover contact combines the functions of the
normally open and normally closed contacts in one device. Changeover contacts are used to close
one circuit and open another in one switching operation. The circuits are momentarily interrupted
during changeover.









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2.2 Displacement and Pressure Sensors

Sensors have the task of measuring information and passing this on to the signal processing part in
a form that can easily be processed.
In electro pneumatic controllers, sensors are primarily used for the following purposes:


1. To detect the advanced and retracted end position of the piston rod in cylinder drives

2. To detect the presence and position of work pieces

3. To measure and monitor pressure

A limit switch is actuated when a machine part or work piece is in a certain position. Normally, a
cam effects actuation. Limit switches are normally changeover contacts. They can then be
connected as required
As a normally open contact, normally closed contact or changeover contact.






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2.3 Proximity switches


In contrast to limit switches, proximity switches operated contactlessly (non-contact switching) and
without an external mechanical actuating force. As a result, proximity switches have a long service
life and high switching reliability.
The following types of proximity switch are differentiated:

1. Reed switch (magnetic sensors)
2. Inductive proximity switch
3. Capacitive proximity switch
4. Optical proximity switch

2.3.1 Reed switch (magnetic sensor)

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. In reed switches that act as normally closed contacts, small
magnets close the contact reeds. This magnetic field is overcome by the considerably stronger
magnetic field of the switching magnets.
Reed switches have a long service life and a very short switching time (approx. 0.2 ms). They are
maintenance-free, but must not be used in environments subject to strong magnetic fields (for
example in the vicinity of resistance welders).


Inductive, optical and capacitive proximity switches are electronic sensors. They normally have
three electrical contacts.
1. Contact for supply voltage
2. Contact for ground
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3. Contact for output signal

In these sensors, no movable contact is switched. Instead, the output is either electrically
connected to the supply voltage or to ground (= output voltage 0 V).
There are two types of electronic sensor with regard to the polarity of the output voltage.

1. In positive switching sensors, the output voltage is zero if no part is sensors detected in the
proximity. The approach of a work piece or machine part leads to switchover of the output,
applying the supply voltage.
2. In negative switching sensors, the supply voltage is applied to the output if no part is
detected in the proximity. The approach of a work piece or machine part leads to switchover
of the output, switching the output voltage to 0 V.


2.3.2 Inductive proximity sensors

An inductive proximity sensor consists of an electrical oscillator (1), a flip-flop (2) and an amplifier
(3). When a voltage is applied, the oscillator generates a high-frequency alternating magnetic field
that is emitted from the front of the sensor. If an electrical circuit is introduced into this field, the
oscillator is attenuated. The downstream circuitry, consisting of a flip-flop and an amplifier,
evaluates the behavior of the oscillator and actuates the output. Inductive proximity sensors can be
used for the detection of all good electrical conductors (materials). In addition to metals, these
include, for example, graphite.







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2.3.3 Capacitive proximity sensor

A capacitive proximity sensor consists of a capacitor and an electrical resistance that together
forms an RC oscillator, and a circuit for evaluation of the frequency. An electrostatic field is
generated between the anode and the cathode of the capacitor. A stray field forms at the front of
the sensor. If an object is introduced into this stray field, the capacitance of the capacitor changes.
The oscillator is attenuated. The circuitry switches the output. Capacitive proximity sensors not only
react to highly conductive materials (such as metals) but also to insulators of high dielectric
strength (such as plastics, glass, ceramics, fluids and wood).





2.3.4 Optical proximity sensor

Optical proximity sensors use optical and electronic means for object detection. Red or infrared
light is used. Semiconductor light-emitting diodes (LEDs) are particularly reliable sources of red or
infrared light. They are small and rugged, have a long service life and can be simply modulated.
Photodiodes or phototransistors are used as a receiver. Red light has the advantage that the light
beam can be seen during adjustment
of the optical axes of the proximity switch. Polymer optical fibers can also be used because of their
low attenuation of light of this wavelength.
Three different types of optical proximity switch are differentiated:
1. One-way light barrier
2. Reflective light barrier
3. Diffuse reflective optical sensor

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The one-way light barrier has spatially separate transmitter and receiver units. The parts are
mounted in such a way that the transmitter beam is directed at the receiver. The output is switched
if the beam is interrupted.




In the reflective light barrier, the transmitter and receiver are mounted together in one housing. The
reflector is mounted in such a way that the light beam transmitted by the transmitter is practically
completely reflected to the receiver. The output is switched if the beam is interrupted.



In the diffuse reflective optical sensor, the transmitter and receiver are mounted together in one
unit. If the light hits a reflective object, it is redirected to the receiver and causes the output of the
sensor to switch. Because of the functional principle, the diffuse reflective optical sensor can only
be used if the material or machine part to be detected is highly reflective (for example polished
metal surfaces, bright paint).

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2.4 Relays

A relay is an electromagnetically actuated switch. When a voltage is applied to the solenoid coil, an
electromagnet field results. This causes the armature to be attracted to the coil core. The armature
actuates the relay contacts, either closing or opening them, depending on the design. A return
spring returns the armature to its initial position when the current to the coil is interrupted










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Rotary encoder

Whenever mechanical rotary motions have to be monitored, the encoder is the most
important interface between the mechanics and the control unit. Encoders transform rotary
movement into a sequence of electrical pulses. A number of bright/dark segments on a
disc are photo electrically scanned. The number of segments determine the resolution of
the movement and hence the accuracy of the position. Because only increments of rotation
are detected with a single channel, an additional signal, phase shifted by 90 degrees, is
generated by inserting a grid diaphragm. This 90 degrees out of phase signal enables,
together with the initial signal, the direction of rotation to be determined. Once per
revolution a reference signal may also be generated.


Pulse disc:

















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3. Equipment and Components

1- Power Supply
2- Sequence Indicator Module (SIM)
3- Sequence Switch Module (SSM)
4- Wires
5- Magnetic Sensor
6- Inductive Sensor
7- Capacitive Sensor
8- Photo Sensor
9- Fiber Optic Sensor

4. Procedure

In this experiment the students will be introduced to a number of sensor applications controlled by
Programmable Logic Controller (PLC), and commonly used in the industries. The sensors used in
this experiment are extremely important in machines automation.

Exercise 1: switches

Equipments used:

1. Power supply
2. Sequence Indicator Module (SIM)
3. Sequence Switch Module (SSM)

Connections
Connect VSW of the Sequence Switch Module to 24VDC of the power supply, 0V of the Sequence
Indicator Module to 0V of the power supply, connectors 0 to 6 of the SIM to connectors 0 to 6 of the
SSM

Application
By sliding the SSM switches up and down the corresponding LED in the SIM will light on and off.

Exercise 2: magnetic proximity sensors

Equipments used:

1. Power supply
2. Sequence Indicator Module (SIM)
3. Magnetic proximity sensor

Connections
Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the magnetic sensor the wiring connections is as follow:
Brown (bn): to 24VDC
Blue (bl): to 0VDC
Black (bk): to the SIM

Application
By placing a magnetic object in front of the magnetic sensor the corresponding LED in the SIM will
light on and off
Test this sensor on metallic, non-metallic objects, such as wood, plastic, paper. Note the result
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Exercise 2: Inductive proximity sensors

Equipments used:

1. Power supply
2. Sequence Indicator Module (SIM)
3. Inductive proximity sensor

Connections
Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the inductive sensor the wiring connections is as follow:
Brown (bn): to 24VDC
Blue (bl): to 0VDC
Black (bk): to the SIM

Application
By placing a metallic object in front of the magnetic sensor the corresponding LED in the SIM will
light on and off
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results

Exercise 3: Capacitive proximity sensor

Equipments used:

1. Power supply
2. SIM
3. Capacitive proximity sensor

Connections

Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the capacitive sensor the wiring connections is as follow:
Brown (bn): to 24VDC
Blue (bl): to 0VDC
Black (bk): to the SIM

Application
By placing a metallic object in front of the magnetic sensor the corresponding LED in the SIM will
light on and off
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results

Exercise 4: Optical proximity sensor

Equipments used:

1. Power supply
2. SIM
3. One-way light barrier
4. Reflective light barrier
5. Diffuse reflective optical sensor
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Connections

Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the optical proximity sensor the wiring connections is as follow:
Brown (bn): to 24VDC
Blue (bl): to 0VDC, for the reflective light barrier the white wire should be connected
Black (bk): to the SIM, for the reflective light barrier the black wire should not be connected
Note that (except for the reflective light barrier) the white color wire if connected to 0VDC the
output of the sensor is normally open (NO), if connected to 24VDC the output of the sensor is
normally closed (NC)

Application
1. In the one-way light barrier place a metallic object between the transmitter and the receiver, and
note the result.
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results

2. In the reflective light barrier place a metallic object between the sensor and the reflector, and
note the result.
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results

3. In the diffuse reflective optical sensor place a metallic object in front of the sensor, and note the
result.
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results

Exercise 5: Fiber optic sensor

Equipments used:
1. Power supply
2. SIM
3. Fiber optic sensor
4. Fiber optic cable

Connections
Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the the wiring connections is as follow:
Place the fifer optic cable in its position in the fiber optic sensor
Brown (bn): to 24VDC
Blue (bl): to 0VDC
Black (bk): to the SIM
Note that the white color wire if connected to 0VDC the output of the sensor is normally open (NO),
if connected to 24VDC the output of the sensor is normally closed (NC)

Application
In the fiber optic sensor application place a metallic object between the transmitter and the receiver,
and note the result.
Test this sensor on non-metallic objects, such as wood, plastic, paper. Note the results
Make a black mark on a white paper fix the fiber optic sensor at a fixed distance than move the
paper up and down, comment on the result.





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Exercise 6: Rotary Encoder

Equipments used:
2. Power supply
2. SIM
3. Rotary Encoder

Connections
Connect 0V of the Sequence Indicator Module to 0V of the power supply,
For the Rotary Encoder the wiring connections are as follow:
Brown (bn): to 24VDC
Blue (bl): to 0VDC
Black (bk): to the SIM (output channel A)
White (wt): to the SIM (output channel B)

Application
For the rotary encoder, turn on the power, turn the rotary encoder axe by using your fingers and
draw the timing diagram for channel A and channel B.


4. Conclusion

5. Briefly record your observations and comments and outline the major lessons learnt in this
experiment.