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Sensors

A sensor is a device that converts energy from some other form (e.g. heat, light, sound, pressure, motion, flow), into electrical energy for the purposes of measurement or control

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Block diagram of control circuit

Noise Frequently measured values are: Input data Process Ouput data

Temperature Pressure/Force Flow Humidity ph-value Revolutions per minute (speed) Position

Actuator

Sensor Actual value Process computer Display

Control input

Basic Function of Sensors

Presence of object Type of material Appearance of material Dimension of material Measurement of distance, force, pressure, temperature, speed and acceleration

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Inductive
I

Capacitive
C

Magnetic
B

Photoelectric
?

Ultrasonic
U

Inductive Sensors

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Block Diagram
Plastic cover Coil Epoxy resin LED Cover paste O-ring seal

Ferrite core Support IC Printed board Housing Support ring

Oscillator

Comparator

Outputamp.

Types of Connection 1
Two-wire Sensors (Type Z)
"Positive logic" NO (Z0)
+ 24 VDC BN/3 1 2 3 4 Load Load

NO/NC (Z2)
+ 24 VDC

"Negativ logic", NO
- 24 VDC BU/4

BU/4

BN/3

Load

NC (Z1)
+ 24 VDC BN/1

NO/NC (Z2)
+ 24 VDC 1 2 3 4 Load Load

"Negativ Logic", NC
- 24 VDC BU/2

BU/2

BN/1

Load

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Types of Connection 2
Three-wire Sensors (Type E)
E2
L+ (+24 VDC) BN/1 BK/4 BU/3 Load BN/1 BK/2 BU/3 Load Output Load

E3
L+ (+24 VDC)

pnp-type

L- (Ground)

L- (Ground)

E/E0
L+ (Ground) BN/1 BK/4 BU/3 Load L- (-24 VDC)

E1
L+ (Ground) BN/1 BK/2 BU/3 Load L- (-24 VDC)

npn-type

Load Output

Types of Connection 3
Four-wire Sensors (Type A)
A2 (pnp)
1 2 4 3

A (npn)
1 2 4 3

L+ (+24 VDC) Load L- (Ground)

L+ (Ground) Load L- (-24 VDC)

Advantage: Two types of output in one housing Disadvantage: Higher price

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Reduction Factor
Steel Fe360 (1)

Reduction factor records the reduction of operating distance from the standard target because of the deviating object characteristics Reduction factor is a function of
conductivity permeability

Stainless steel (0.65 ... 0.85) Brass (0.25 ... 0.55) Aluminium (0.2 ... 0.5) Copper (0.15 ... 0.45)

Influence of the target characteristics

The area a*b is smaller than the area of the standard target
operating distance decreases

The area a*b is larger than the area of the standard target
no influence

The target is thicker than the standard target

influence is a function of penetration depth low penetration depth (small proximity b switches) ==> no influence high penetration depth (big proximity switches) ==> operating distance decreases

The target is thinner than the standard target

operating distance increases (only for NE metals)

a d

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Differential travel H
Distance between the operating point when the target approaches the proximity switch and the release point when the target moves away less than 20% of the effective operating distance sr test conditions:
temperature range power supply actuating standard target : 23 ( +/- 5 C C) rated voltage as already defined
Direction of movement

switch off switch on

Embeddable/Non-embeddable Mounting
> 3*d > 3*sn > 3*sn > 2*sn

d >d

> 3*d

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Position Detection of Doors

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Position Detection in a Conveyor System

Speed Control in a Conveyor System

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Capacitive Sensors

Capacitive Sensor
Sensor electrode Printing board

Housing

Shielding

Potentiometer

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Physical Basics
Sensor electrode Target Shield

C = f(0, r, A, s-1)

Reduction Factor
Reduction factor

Ice PVC Ceramics

Alcohol

Oil

Water

Glas

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Detection of Empty Box

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Magnetic Sensors

Principle Magnetic Sensor

Ferrit core Housing Coil Cable

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Application
Sensor for the detection of position of pistons in hydraulic cylinders

Integration the magnets

Piston Magnet Sealing Cylinder wall

Magnet mounting ring

Bore hole

Piston rod

Cylinder wall
made of steel, e. g. Fe360

Magnet mounting ring

NFE material, e. g. brass

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Photoelectric Sensors

Block Diagramm Photoelectric Sensor

Transmitter

Signal converter receiver

Amplifier

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Wavelenght
Visible red light
easy adjustment depending on visible red light point

Infrared light
higher measurement range at same power consumption than red light sensor

Laser (red- or Infrared)

smaller divergence ==> smaller light point detection of smaller objects possible higher measurement ranges (up to 100 m) the measurement area must be indicated

Modes of Operation
Direct detection Sensor
Trans./Receiv. Object

Throug-Beam Sensor

Transm.

Receiver

Object

Retro-Reflective Sensor

Trans./Receiv.

Retro reflector

Object

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Modes of Operation
Direct detection Sensor
Trans./Receiv.

Object

Through-Beam Sensor

Transm.

Receiver

Object

Retro-Reflective Sensor

Trans./Receiv.

Retro reflector

Object

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Modes of Operation
Direct detection Sensor
Trans./Receiv. Object

Through-Beam Sensor

Transm.

Receiver

Object

Retro-Reflective Sensor

Trans./Receiv.

Retro reflector

Object

Polarization Filter

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Ultrasonic Sensors

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Block Diagram
Transducer Decoupling layer

Integral foam Ultrasonic transducer

Piezo ceramic Signalprocessing

Output

Physical Basics
Infra Audible Ultra Hypersonic

Velocity of sound c (m/s) Pressure [hPa]

Temperature [ C)

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Ultrasonic sensors in a conveyor system

Level Control of a crusher

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Level Control of a crusher

Level Control of Plastic Granulat

A sensor with two independent switching outputs controls the minimum and the maximum level.

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