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Proximity sensors are the most basic data acquisition devices in automation. They measure /
detect physical input such as temperature, pressure, force, length, and proximity of an object.
Transducers are typically a sensorial system capable of signal processing, equipped with
electronic instrumentation. Position sensors give a yes or no response according to the place
of the object.
The aim of this experiment is to illustrate the aspects of different types of proximity sensors,
their properties, and to compare them. For this, a setup table containing Magnetic, Inductive,
Capacitive, and Optical sensors is used. A positioning slide coupled with a vernier caliper is
used to measure switching distances.
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GENERAL INFORMATION
Sensors are the first of the four milestones of Automation:
1. Sensing
2. Signal Processing
3. Planning and Response
4. Memory
They usually convert some physical data into a voltage difference for further processing by a
Computer, PLC or I/O Card. The advantages of proximity sensors are:
They determine the geometrical positions automatically and sensitively.
They do not need of a direct contact with the workpiece.
They do not have movable parts that can wear out.
They are usually equipped with electronic circuits for failure protection.
They have various types that can be used under different situations.
They provide the secure working of the process.
They are used for the system failure analysis.
CATEGORIES
According to I/O processing:
Binary: Convert a physical measurement value to a binary code (in the form of ON/OFF
signals in a selected voltage range)
Analog: Convert a physical measurement into an analog signal (e.g. temperature readings
to variable voltage differences)
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TYPICAL USAGE
Positioning of an object:
3
Determining the rotational speed:
4
TYPES
1. Mechanical switches:
Mechanical switches are simple GO/NoGO indicators. They have physical contact with the
object, usually coupled with relays and contactors to drive a circuit. Widely used in the industry
to mark the end-start points of cylinders, pistons, linear and rotary drives, to sense doors. They
are less sensitive and have lower maximum switching frequency compared to proximity
switches. Because of the physical contact with the object, they require maintenance and
replacement.
5
Light sensors (can be equipped with fiber-optic cabling for long distance transmission, may
use ambient light or the light produced in a coupled unit)
Reflected light sensors (can be equipped with fiber-optic cabling for long distance
transmission, uses the reflected light produced in the same unit from the part or a reflector
sheet)
Optical sensors have a relatively greater switching distance. Therefore they may be used in
detecting surface irregularities, failure detection, detection of transmissive surfaces, colors etc.
Fiber optic cabling for transmission also gives a flexibility to use small units at difficult
locations.