Inductive Proximity Sensors

Brett Anderson
ECE 5230 Assignment #1

Outline
1. To Explore Further
2. Major Applications 3. Theory of Operation 4. Possible Measurements 5. Sensor Outputs

6. Applications
7. Conclusions

References
www.bently.com
www.allenbradley.com http://www.ndt-

ed.org/EducationResources/Community College/EddyCurrents/Physics/mutualin ductance.htm www.davidson.com/au

To Explore Further
An interesting paper on applications:

www.bently.com/articles/apnotes/an04 7.asp Here is a great presentation on monitoring industrial systems: www.vibration.org/Meeting/0903/ Gearbox%20Spectral%20Components %20Presentation%20V2.ppt

Major Applications
The Eddy Current probe has many

applications in industry These applications are varied, but all require reliable, accurate results These sensors are robust, and can typically handle extreme environments These applications are discussed in greater detail in later slides

Theory of Operation
These sensors use mutual inductance

between a known inductor and a conductive material Commonly referred to as eddy current probes Mutual inductance is a function of the distance between the inductor and the material

How Eddy Currents Work

An inductive coil is

placed near a conductive surface An AC voltage (typically around 2Mhz) is applied to the coil Mutual inductance begins to occur
Source: http://www.ndted.org/EducationResources/Com munityCollege/EddyCurrents/

How Eddy Currents Work

The coil generates a

magnetic field Circular or Eddy Currents begin to flow in the conductive material These currents resemble an eddy in a stream of water
http://www.ndted.org/EducationResources/Com munityCollege/EddyCurrents/

How Eddy Currents Work

The Eddy Currents

generate their own magnetic field These fields have interaction with the coil through mutual inductance This leads to a measurable result
http://www.ndted.org/EducationResources/Com munityCollege/EddyCurrents/

What can be measured?

Electrical conductivity and magnetic

permeability of the target material The amount of material cutting through the coils of the magnetic field The condition of the material(whether it contains cracks or defects Lift-Off

What is Lift-Off?
Lift-Off is a very important measurement

that can be made by Eddy Current Sensors It represents the distance from the coil to the test material This leads to a great number of industrial, manufacturing, and other important applications

Sensor Output in Proximity Applications

A demodulator demodulates the signal

from the sensor, and outputs a DC voltage which is proportional to the distance from the sensor to the conductive target This output voltage is linear over the specified range of the specific sensor

Typical Sensor Output

Provides very high

resolution output over ranges on the order of millimeters The range an be increased depending on the application, but typically not more that several inches

Calibration
From the factory, most proximity probes are

calibrated to measure 4140 steel Because different materials have different conductivity and permeability, special calibration is needed to ensure accurate measurement of each specific material This usually involves some alteration of the signal conditioning and demodulation process

Applications
Can be used as an

encoder that monitors rotation Can measure thing like speed and acceleration

Source: AllenBradly.com

Encoder Output
This is what the output

looks like when being used as an encoder The peaks represent the teeth on the sprocket Speed and acceleration can be determined from this output data

Source: AllenBradly.com

Applications(Cont)
Used in Automated

Assembly lines Sensor detects each part as it passes Provides Accurate, Real-Time information about quantity and quality in manufacturing processes
Source: AllenBradly.com

Another Application
Inductive sensors

monitor automated machinery They can detect anything out of the ordinary and serve as a fail safe shutoff, which can save millions of dollars in preventing damage to malfunctioning machinery.
Source: AllenBradly.com

Power Systems Applications

High Power turbines often operate in high

temperature, strenuous environments Inductive Sensors and be linked to a data system through a robust cable allowing for the monitoring of these systems Information gathered by these sensors can greatly add to the life and health of high power turbines and generators

Turbine Shaft Orbit Monitoring

Two inductive sensors can be used to

monitor the health of a turbine When placed 90 degrees apart, they can monitor the X and Y position of the shaft as it rotates When bearing start to go out, the movement in the X and Y direction begins to increase This is detected by the sensors, and the bearings can be replaced before serious damage occurs

Illustration of Orbit Monitoring

Vibration Monitoring
An inductive sensor can

monitor the vibration of a turbine shaft Typically, there is maximum limit that the shaft is allowed to vibrate, once that point is passed, the system is shut down to prevent serious damage

General Applications
Good for many short distance, high

resolution applications Can be used to detect the presence or absence of conductive material Good for long distance monitoring of machinery and industrial devices Usually works well in extreme environments

Other Applications
Quality Control
Autonomous

removal of bad parts on an assembly line Reliable and consistent results

Other Applications(Cont)
Real-Time

information on the position of railroad track switches Reliable due to resistance to changing conditions

Limitations
Very short range of measurement
Material being measured must be

conductive Target must be larger than the sensor tip Can only measure displacement in relation to the sensor

Conclusion
Inductive sensors operate on the

principle of mutual induction They are useful in a wide variety of applications They provide high-resolution, reliable outputs Can be used in varied conditions