Industrial Sensors-1

Industrial Control Systems

Fall 2006

Lecture Industrial Sensors 1 MME 486 Fall 2006 1 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 2 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 3 of 43

 The Need for Sensors
In the past, processes were control by Humans, with operators
monitoring and or adjusting the process based on analogue data
from gauges, etc.
In the need to create stable, repeatable, time effective processes,
to produce products with consistent quality, processes became
automated.

In a modern automated process, sensors can:

Initiate or terminate a process or process step by an operator.

Convert physical process parameters such as temperature,
pressure, liquid level or the presence / absence of an object into
discrete or continuous voltage or current values that may be
interpreted by a computer or PLC to control a process or process
sequence in a desired manner.

Lecture Industrial Sensors 1 MME 486 Fall 2006 4 of 43

 The Need for Sensors Contd
Sensors can also provide:
Feedback on task completion
Information on the status of the process
Inspection and measurement data
Collect product or process data for quality
monitoring

Lecture Industrial Sensors 1 MME 486 Fall 2006 5 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 6 of 43

 Sensor Types (1)
Contact versus Non-contact
Contact sensor :There is a physical contact
between the sensor an the parameter it
measures
Non-contact sensor: Also called proximity
sensors. Proximity indicates that the object is
near, but contact is not required

Lecture Industrial Sensors 1 MME 486 Fall 2006 7 of 43

 Sensor Types (1)
Contact Sensor Non-Contact Sensor

Limit Switch Proximity Switch

(Omron) (Omron)
Lecture Industrial Sensors 1 MME 486 Fall 2006 8 of 43
 Non-contact Sensor
Non-contact sensors do not operate
mechanically and are more reliable
Less likely to fail than mechanical ones
They are much faster than mechanical
devices

Lecture Industrial Sensors 1 MME 486 Fall 2006 9 of 43

 Sensor Types (2)
Digital (binary) versus Analog
Digital sensors
Have two states: on or off
Presence/absence of object
Counting such as used in a rotary encoder
Analog sensor:
It senses continuous variables (temp, pressure) and
provides a continuous (usually linear) voltage or current
according to an input /output transfer function.
More complex than digital and can provide more
information

Lecture Industrial Sensors 1 MME 486 Fall 2006 10 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 11 of 43

 Digital Sensors
Switches
Optical (photoelectric) sensors
Encoders
Ultrasonic sensors
Inductive sensors
Capacitive sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 12 of 43

 Switches
Pushbuttons and manual switches
(manual operators)
Limit switches

Lecture Industrial Sensors 1 MME 486 Fall 2006 13 of 43

 Pushbuttons and Manual
Switches

Start pushbutton
(normally open)

Stop pushbutton
(normally closed)

Selector switch
From Omron

Lecture Industrial Sensors 1 MME 486 Fall 2006 14 of 43

 Manual Operators
Push Buttons
Normally Open / Normally Closed
Spring return versus maintained
Selector Switches
Specify number of positions 2, 3, 4, etc.
Can be spring return or maintained
SRTC Spring return to center
SRFL Spring return from left
SRFR Spring return from right
Lecture Industrial Sensors 1 MME 486 Fall 2006 15 of 43
 Limit Switches

From Omron

Lecture Industrial Sensors 1 MME 486 Fall 2006 16 of 43

 Limit Switches Contd
Advantages:
Robust made for harsh environments
Can directly drive a load (contacts 15A+)
Disadvantages:
Mechanics wear out
Large size
May require contact with product
Operating force may be significant
Lecture Industrial Sensors 1 MME 486 Fall 2006 17 of 43
 Other Mechanical Switches
Level/Float Switch mechanical switch that is actuated by the level of a
fluid.

Pressure Switch mechanical switch that is actuated by the pressure in

fluid system

Flow Switch mechanical switch that is actuated by the flow rate of a fluid

Lecture Industrial Sensors 1 MME 486 Fall 2006 18 of 43

 Other Mechanical Switches
Temperature Switch Mechanical switch that is actuated above a set
temperature (usually incorporating a bimetallic element)

Speed Switch Switch that is actuated once a certain speed has been
reached. For example, a centrifugal switch in a capacitor start
/capacitor run motor

Lecture Industrial Sensors 1 MME 486 Fall 2006 19 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 20 of 43

 Optical (Photoelectric) Sensors
All optical sensors use light to sense objects
Operation method:
Lasers, Incandescent bulbs, or Light emitting
diodes (LEDs) are used as light source
The light source is turned off and on (modulation)
at a high frequency (could be as high as several
kHz).
A photodetector senses the pulsed light
The light emitter and receiver are tuned to the
modulation frequency

Lecture Industrial Sensors 1 MME 486 Fall 2006 21 of 43

 Optical (Photoelectric) Sensors
Example of sensor using LED as a light source

Lecture Industrial Sensors 1 MME 486 Fall 2006 22 of 43

 Optical (Photoelectric) Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 23 of 43

 Optical (Photoelectric) Sensors
All optical sensors function in the same
basic manner
The differences are in the way in which the
light source and receiver are packaged

Lecture Industrial Sensors 1 MME 486 Fall 2006 24 of 43

 Optical Sensors Packaging

Lecture Industrial Sensors 1 MME 486 Fall 2006 25 of 43

 Light/Dark Sensing
Light/Dark sensing refers to the normal
state of the sensor and what its output is
(On or Off)
Optical sensors are either:
Light sensing (light-on)
Dark sensing (dark-on)

Lecture Industrial Sensors 1 MME 486 Fall 2006 26 of 43

 Light/Dark Sensing Contd
Light sensing: the output is energized (on)
when the sensor receives modulated
beam

Dark sensing: the output is energized (on)

when the sensor does not receive
modulated beam

Lecture Industrial Sensors 1 MME 486 Fall 2006 27 of 43

 Outline
The Need for Sensors
Sensor Types
Digital Sensors
Optical (Photoelectric) Sensors
Types of Optical Sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 28 of 43

 Types of Optical Sensors
Reflective Sensors
Polarizing Photo Sensors
Retroreflective Sensors
Thru-Beam Sensors
Convergent Photo Sensors
Fiber-Optic Sensors
Color Mark Sensors
Laser Sensors
Lecture Industrial Sensors 1 MME 486 Fall 2006 29 of 43
 Reflective (Diffuse) Sensors
Transmitter and receiver
are combined into one
unit
Relies on the reflective
surface of the target to
bounce the light from the
transmitter to the receiver

Lecture Industrial Sensors 1 MME 486 Fall 2006 30 of 43

 Reflective (Diffuse) Sensors
Contd
Target must be
somewhat perpendicular
to the sensor axis
Used when it is not
feasible to mount a
reflector
Less sensing range (rely
on reflected light).

Omron

Lecture Industrial Sensors 1 MME 486 Fall 2006 31 of 43

 Polarizing Photo-Sensors
They sense only shiny objects using special
reflector
The reflector vertically polarizes the light from
the sensor
Reflector with
small prisms

Lecture Industrial Sensors 1 MME 486 Fall 2006 32 of 43

 Polarizing Photo-Sensors
Contd
Reflections from shiny objects will be ignored
Only reflections from the polarizing reflector will
trigger this sensor
Reflector with
small prisms

Lecture Industrial Sensors 1 MME 486 Fall 2006 33 of 43

 Retroreflective Sensors
Transmitter and receiver are combined into one
unit
Makes use of a reflector to bounce the light from
the transmitter to the receiver

Lecture Industrial Sensors 1 MME 486 Fall 2006 34 of 43

 Retroreflective Sensors
Contd
Have more sensing distance than do
reflective sensors
Have less sensing distance than that of
thru-beam sensors

Lecture Industrial Sensors 1 MME 486 Fall 2006 35 of 43

 Thru-beam Sensors
Has a separate transmitter and receiver
Capable of sensing very small object by
narrowing the light beam

Light Emitter
Receiver

Parts Counting

Lecture Industrial Sensors 1 MME 486 Fall 2006 36 of 43

 Thru-beam Sensors Contd
Fiber optics can be
used to position the
beam transmitter and
receivers
Targets can be opaque
but not transparent
Omron

Lecture Industrial Sensors 1 MME 486 Fall 2006 37 of 43

 Convergent Photo Sensors
Also called focal length sensor
The sensor emits the light to a specific focal point
The light must be reflected from the focal point to be
sensed
Only objects near the focal point are detected

Lecture Industrial Sensors 1 MME 486 Fall 2006 38 of 43

 Fiber Optic Sensors
Same as the other types of photo sensors
except fiber is used to transmit and
receive the light
Allows the sensor to be used in very small
tight areas

Lecture Industrial Sensors 1 MME 486 Fall 2006 39 of 43

 Color Mark Sensors
These sensors can
differentiate between
different colors
Used to check labels
and to sort packages
by color mark
Charts are used for
proper selection
Omron

Lecture Industrial Sensors 1 MME 486 Fall 2006 40 of 43

 Laser sensors
Optical sensors can use laser as their light
source
Laser sensors can be used for precise
measurements (as small as few microns).
Examples is a bar code reader.
Outputs can be analog or digital

Lecture Industrial Sensors 1 MME 486 Fall 2006 41 of 43

 Optical Sensors
Advantages:
Long maximum sensing range (100 m)
High speed switching
Can detect extremely small objects
Disadvantages:
Cant use on light sensitive products
Alignment problems occur especially with
longer range sensing

Lecture Industrial Sensors 1 MME 486 Fall 2006 42 of 43

 Choosing Optical Sensors
Which is most costly?
Thru beam because it needs mounting and
power to separate transmitter and receiver
Most reliable/dependable?
Thru beam because when beam breaks the
sensor switches
Retro-reflective can be fooled by shiny objects
and miss small objects
Diffuse-reflective relies on the object to reflect
the light, color can also fool this device
Lecture Industrial Sensors 1 MME 486 Fall 2006 43 of 43