Giảng viên: Th.S Phạm Bạch Dương

Ging vin: Th.
S Phm Bch Dng
CAC PHN T CUA H THNG C IN T
21/08/2012
http://www.hcmute.edu.vn
Bi 2:
DIGITAL SENSORS
21/08/2012
SENSORS
In this lesson you will learn
About advantages, disadvantages, and applications of limit switches, photoelectric sensors, inductive sensors, capacitive sensors, and ultrasonic sensors. About principles of mechanical limit switches, inductive, capacitive, ultrasonic, and photoelectric sensors and describe differences and similarities. To select the type of sensor best suited for a particular application based on material, sensing distance, and sensor load requirements.
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Block Diagram of Control Unit

Frequently measured values are:
Temperature Pressure/Force Flow Humidity pH-value Revolutions per minute (speed) Position
Noise Input data Process Output data
Actuator
Sensor Actual value Process computer
Control input
5
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Advantages of Sensors
No physical contact and therefore no stress. No wear and tear, hence long life. Contact less and therefore maintenance free. Electronic high precision. Protected and safe switching in harsh environments. High switching rate. Bounce-free contact, thus not prone to false pulses.
21/08/2012 http://www.hcmute.edu.vn 6
Physical Principles
Inductive
I
Capacitive
C
Magnetic
B
Photoelectric
?
Ultrasonic
U
Microwave
M
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Inductive sensors
detects only conductive materials.
Inductive
operation distance up to 100 mm. switching frequency up to 5 kHz. max. ambient temperature 250 C.
max. protection class IP 68.

high noise immunity.
Inductive sensors
Block Diagram
Plastic cover
Inductive
Epoxy resin LED Cover paste O-ring seal
Coil
Ferrite core Support IC Printed board Housing Support ring
Oscillator
Comparator
Output amp.
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Inductive sensors
Applications
Inductive
Position Detection of Doors

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Valve Position
Cylinders Position Detection

10
Inductive sensors
Physical Basics
R1 R2
Inductive
I
Primary circuit: sensor coil
Secondary circuit: target
the alternating electromagnetic field created by the coil induces eddy currents in the target if the target is made of non-ferromagnetic (NFE) material. the alternating electromagnetic field created by the coil induces eddy currents and generates magnetic losses in the target if the target is made of ferromagnetic (FE) material. the magnetic losses are higher than the losses generated by the eddy currents. operating distances vary depending on the target material and are normally shorter than the usable operating distance.
Inductive sensors
Operation Distances

sn = Rated operation distance sr = Effective operating distance
Target
Su max. Sr max. Sn Sr min. Su min. Sa Su max. + Differential travel Sr max. + Differential travel Sn + Differential travel Sr min. + Differential travel Su min. + Differential travel
single proximity switch voltage within the operating voltage range ambient temperature 23 C + 5 C
0.9* sn < sr < 1.1*sn su = usable operating distance

single proximity switch voltage between 85% and 110% of rated operating voltage temperature range -25 C ... +70 C
0.9* sr < su < 1.1*sr 0.81*sn < sa < 1.12*sn sa = assured operating distance
Inductive
I
Inductive sensors
Reduction Factor
Reduction factor records the reduction of operating distance from the standard target because of the deviating object characteristics. Reduction factor is a function of:

Steel Fe360 (1)
Stainless steel (0.65 ... 0.85) Brass (0.25 ... 0.55)
conductivity permeability
Aluminium (0.2 ... 0.5)

Copper (0.15 ... 0.45)
Inductive
I
Inductive sensors
Operating Frequency (f )
number of operating cycles performed by a proximity switch during a specified period of time. This value is a function of the oscillator frequency of the given proximity switch:
Target / no target ratio = 1:2
high oscillator frequency (small operating distance) high frequency of operating cycles low oscillator frequency (large operating distance) low frequency of operating cycles
Inductive
I
Inductive sensors
Electrical Values
DC Sensors
Inductive
Voltage range:
10 VDC ... 30 VDC 10 VDC ... 60 VDC 5 VDC ... 60 VDC
AC Sensors

Voltage range: 98 VAC ... 253 VAC Frequency range: 48 Hz ... 62 Hz
AC/DC Sensors
Voltage range:
10 VDC . .. 30 VDC 24 VAC ... 240 VAC
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Inductive sensors
Types of Connection 1
"Positive logic"
NO (Z0)
+ 24 VDC BN/3 1 2 3 4
Inductive
NO/NC (Z2)
+ 24 VDC
"Negative logic", NO
- 24 VDC BU/4
BU/4
Load
Load
BN/3
Load
NC (Z1)
+ 24 VDC BN/1
NO/NC (Z2)
+ 24 VDC 1 2 3 4 Load Load
"Negative Logic", NC
- 24 VDC
BU/2
BU/2
BN/1
Load
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Inductive sensors
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
Inductive
E3
L+ (+24 VDC)
pnp-type
L- (Ground)
L- (Ground)
E/E0
L+ (Ground) BN/1 BK/4 BU/3 Load
E1
L+ (Ground) BN/1 BK/2 BU/3 Load L- (-24 VDC)
npn-type
Load
L- (-24 VDC)
Output
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Inductive sensors
Four-wire Sensors (Type A)
A2 (pnp)
1 2 4 3
Inductive
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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Capacitive sensors
detects every materials (conductive, non-conductive, solids, fluids, ...). operation distance up to 50 mm. switching frequency max. 100 Hz. max. ambient temperature 70 C. max. protection class IP 67.
Capacitive
C
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Capacitive sensors
Block Diagram
Sensor electrode Printing board
Capacitive
C
Housing
Shielding
Potentiometer 21/08/2012 http://www.hcmute.edu.vn 20
Capacitive sensors
Physical Basics
Sensor electrode Target Shield
Capacitive
C
C = f(e0, er, A, s-1)

Capacitive sensors
Applications
Capacitive
C
Stamping
Fire Works Production

21/08/2012 http://www.hcmute.edu.vn
Position Detection
22
Magnetic sensors
detects only magnetic objects. operation distance up to 60 mm. Magnetic
B
switching frequency up to 1 kHz.

max. ambient temperature 70 C.
max. protection class IP 67.

high noise immunity.
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23
Magnetic sensors
Block Diagram
Ferrite core Coil Cable
Magnetic
B
Application: Detection of magnets thru NFE-metals

Magnetic sensors
Detection Area
Magnetic
B Detection area has two minor lobes ==> 3 switching points, if the magnet is too close to the sensor.
If the magnet is turned of 90 this happens 2 switching points.
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Magnetic sensors
Applications
Sensor for the detection of position of pistons in hydraulic cylinders (thru NFE-metals).
Magnetic
B
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Photoelectric sensors
three different operation principles: Photoelectric thru beam (receiver and transmitter in two housings). ? reflective (receiver/transmitter in one housing, retro reflector is necessary). diffuse reflective. detects, depending on the operation principle, light reflecting or non transparent materials. possibility to connect fibre optic. operation distance up to 100 m. switching frequency up to 1.5 kHz. max. ambient temperature 300 C (with fibre optic only). max. protection class IP 67. detects smallest objects (depending on the diameter of the fibre optic).
Block Diagram
Photoelectric
?
Transmitter
Signal converter receiver
Amplifier
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Modes of Operation
Direct detection Sensor Detection of all materials.
Photoelectric
Through-Beam Sensor Problems with materials like glass.
Retro-Reflective Sensor Problems with mirror objects and objects like glass.
Retro-Reflector
29
Advantages/Disadvantages
Advantages

Photoelectric
not sensitive against changes in temperature and pressure. small housing (compared to ultrasonic sensors). small objects detectable (especially Laser version and fibre optic version). high measurement range.
Disadvantages /Problems

sensitive against dirt. Background reflections / Light from foreign sources. Reduction factors.
Dirt at the optic. other photoelectric sensors (mutual influence). Light from natural sources (ex: Sun). Light from fluorescent sources (Ex: Neon lamps).
Interferences

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Applications
Photoelectric
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Photoelectric
Applications
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Photoelectric
Applications
?
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Ultrasonic sensors
detects objects which reflect or absorb sound. Ultrasonic operation distance up to 12 m.
U
reaction time > 35 ms. max ambient temperature 70 C. max. protection class IP 67. lower noise immunity. not sensitive to dirt.
Ultrasonic sensors
Block Diagram
Transducer
Ultrasonic
U
Decoupling layer
Integral foam Ultrasonic transducer
Piezo ceramic Signalprocessing
Output
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Ultrasonic sensors
Physical Basics
Ultrasonic
U
Infra Audible Ultra Hypersonic
Velocity of Sound c (m/s)

Pressure [hPa]
Temperature [C)
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Ultrasonic sensors
Advantages/Disadvantages
Advantages

Ultrasonic
U
detects solids, fluids, granulates. insensitive against dust. no reduction factor ==> switching distance is no function of material (except foam, foamed material). possibility to change the direction of the signal.
Disadvantages /Problems

sensitive against environmental conditions (temperature, pressure, ...) blind range. switching distance is a function of the form of the target.
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Ultrasonic sensors
Detection characteristic
Ultrasonic
U
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Ultrasonic sensors
Adjustment
blind range
sensing range
Ultrasonic
U
target opening angle
A1
minimum switching distance
A2
measuring window maximum switching distance
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Ultrasonic sensors
Operation
Ultrasonic
U
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Ultrasonic sensors
Applications
Ultrasonic
U
Glass detection
Level Control
41
Pattern sensors
Label arragement
Reverse Label Check

Label check
42
Image recognition
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Summary
What you have learned
There are six common types of proximity switches and their uses. Type of connections. Basic principles of many kinds of proximity switches/sensors. Typical applications of sensors.
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44

Giảng viên: Th.S Phạm Bạch Dương

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Giảng viên: Th.S Phạm Bạch Dương

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Ging vin: Th.

S Phm Bch Dng

CAC PHN T CUA H THNG C IN T

Block Diagram of Control Unit

Sensor Actual value Process computer

max. protection class IP 68.

Ferrite core Support IC Printed board Housing Support ring

Position Detection of Doors

Cylinders Position Detection

Primary circuit: sensor coil

Secondary circuit: target

sn = Rated operation distance sr = Effective operating distance

0.9* sn < sr < 1.1*sn su = usable operating distance

Steel Fe360 (1)

Stainless steel (0.65 ... 0.85) Brass (0.25 ... 0.55)

Aluminium (0.2 ... 0.5)

Target / no target ratio = 1:2

10 VDC ... 30 VDC 10 VDC ... 60 VDC 5 VDC ... 60 VDC

Voltage range: 98 VAC ... 253 VAC Frequency range: 48 Hz ... 62 Hz

10 VDC . .. 30 VDC 24 VAC ... 240 VAC

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

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

Advantage: Two types of output in one housing.

Disadvantage: Higher price.

Potentiometer 21/08/2012 http://www.hcmute.edu.vn 20

C = f(e0, er, A, s-1)

Fire Works Production

switching frequency up to 1 kHz.

max. protection class IP 67.

Application: Detection of magnets thru NFE-metals

If the magnet is turned of 90 this happens 2 switching points.

Signal converter receiver

Through-Beam Sensor Problems with materials like glass.

Integral foam Ultrasonic transducer

Piezo ceramic Signalprocessing

Velocity of Sound c (m/s)

target opening angle

Reverse Label Check

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