Mechatronics Automation CH 3

Chapter (3)
Sensor Technology for Sequence Control
Chapter (1) Introduction to Mechatronic Automation.

Chapter (2) Pneumatic Systems
Chapter (3) Sensor Technology for Sequence Control
Chapter (4) Programmable logic controllers (PLC)
Chapter (5) PLC Programming
Chapter (6) PLC (Timers, Counters & Shift Registers )
Chapter (7) Computer simulation of a programmable pneumatic positioning system
 Course Syllabus
 Pneumatics actuators, gripper technology, control valves and pneumatic circuit
representation.
o Sequential control systems.
o Sensor technology for sequence control, optical, capacitive, inductive and magnetic.
o Programmable logic controllers (PLC). Sequential control system representation, logic
analysis and PLC programming. Relay logic ladder diagram, Timers, Counters, shift
registers.
o Computer simulation of a programmable pneumatic positioning system.
 Chapter Outlines
o Sequential control systems.
o Inductive Sensor.
o Capacitive Sensor.
o Magnetic Sensor, and
o Optical Sensor. Fall 2020
Question:3 (10 Marks)
Briefly explain the construction and working of the following sensors:
1) Inductive sensor.
2) Capacitive sensor.
3) Magnetic sensor.
4) Optical proximity sensor.
Mechatronic Automation Dr. Ali M. Gaballa
2
Chapter (3) Sensor Technology for Sequence Control Sequential Control Systems
 What is sequence (logic) control?

o It is a class of control systems where inputs, outputs and feedback are discrete set
valued (e.g. on off).
o There are many situations where control is exercised by items being switched on or
off at particular preset times or values in order to control processes and give a step
sequence of operations.
o For example, after step 1 is complete then step 2 starts. When step 2 is complete
then step 3 starts, etc.
o A sequentially controlled system controls a process that is defined as a series of tasks
to be performed

3
 What is sequence (logic) control?

o It is a class of control systems where inputs, outputs and feedback are discrete set
valued (e.g. on off).

4
 Washing machine system
Feedback from outputs of water level, water temperature, drum speed and door closed

5
 Application Examples
o Plant Start Up / Shut Down Sequencing.
o Conveyors.
o Automated Assembly Operations.
o Sequence Control in CNC Machines.
o Supervisory Control of Robots.
o Washing machine.

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Chapter (3) Sensor Technology for Sequence Control What is a Sensor
 Sensor is a device that detects a change in a physical stimulus and turns it

into a signal which can be measured or recorded.
 Sensors: Sense physical phenomena and translate (convert) it into electric
signal.
 Need of Sensors in daily life:

o Temperature Sensor in Microwave.
o Temperature and Humidity Sensors in an AC.
o Smoke Detectors with Fire Alarm.
o ATM and Detection Sensors.
o Accelerometers in an Automobile Airbag system.
 Transducer is a device that transfers power from one system to another in the same or
in the different form'. Thermistor with it associate circuit convert heat to electricity.
 Each sensor is based on a transduction principle: conversion of energy from one form
to another (transducer)

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Proximity Sensors
 Non-Contact Proximity Sensors

o Automated systems are increasingly being designed with non-contact sensors. The
three most common types of non-contact sensors in use today are the inductive
proximity sensor, the capacitive proximity sensor, and the optical proximity sensor.
o All of these sensors are actually transducers, but they include control circuitry that
allows them to be used as switches. The circuitry changes an internal switch when the
transducer output reaches a certain value.
Proximity Sensors
Inductive Magnetic Capacitive Light Ultrasonic

Sensors Sensor Sensors Sensors Sensors
o Proximity sensors or switches

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Chapter (3) Sensor Technology for Sequence Control Inductive proximity sensors
 The inductive proximity sensor is the most widely used non-contact sensor due to its
small size, robustness, and low cost. This type of sensor can detect only the presence of
electrically conductive materials.
 As the name implies, inductive proximity

sensors operate on the principle that the
inductance of a coil and the power losses in the
coil vary as a metallic (or conductive) object is
passed near to it. Because of this operating
principle, inductive proximity sensors are only
used for sensing metal objects. They will not
work with non-metallic materials.

9
 Inductive proximity sensor

10
 Inductive proximity sensor
Typical three-wire DC sensor connection
Typical two-wire proximity sensor connection

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 The basic operation of an inductive proximity sensor can be summarized as follows :

o The oscillator circuit generates a high-frequency electromagnetic field that radiates
from the end of the sensor.
o When a metal object enters the field, eddy currents are induced in the surface of the
object.
o The eddy currents on the object absorb some of the radiated energy from the sensor,
resulting in a loss of energy and change of strength of the oscillator.
o The sensor’s detection circuit monitors the oscillator’s strength and triggers a solid-
state output at a specific level.
o Once the metal object leaves the sensing area, the oscillator returns to its initial
value.
 Most sensor applications operate either at 24V DC or at 120V AC.

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 Inductive Proximity Sensor Internal Components

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 Inductive Proximity Sensor Internal Components

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Fall 2020 Question:3 (10 Marks)

Briefly explain the construction and working of the following sensors:
1) Inductive sensor.
2) Capacitive sensor.
3) Magnetic sensor.
4) Optical proximity sensor.

15
 Figure below demonstrates its operating principle. The supply DC is used to generate AC in an
internal coil, which in turn causes an alternating magnetic field. If no conductive materials are
near the face of the sensor, the only impedance to the internal AC is due to the inductance of the
coil. If, however, a conductive material enters the changing magnetic field, eddy currents are
generated in that conductive material, and there is a resultant increase in the impedance
 to the AC in the proximity sensor. A current sensor, also built into the proximity sensor, detects
when there is a drop in the internal AC current due to increased impedance. The current sensor
controls a switch providing the output.

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 To understand how inductive proximity sensors operate, a mounted coil just inside the face of
the sensor (on the left end) which is part of the tuned circuit of an oscillator. When the
oscillator operates, there is an alternating magnetic field (called a sensing field) produced by
the coil. This magnetic field radiates through the face of the sensor (which is non-metallic).
The oscillator circuit is tuned such that as long as the sensing field senses non-metallic
material (such as air) it will continue to oscillate, it will trigger the trigger circuit, and the
output switching device (which inverts the output of the trigger circuit) will be off. The sensor
will therefore send an “off” signal through the cable extending from the right side of the
sensor.
 When a metallic object (steel, iron, aluminum, tin, copper, etc.) comes near to the face of the
sensor, the alternating magnetic field in the target produces circulating eddy currents inside
the material. To the oscillator, these eddy currents are a power loss. As the target moves
nearer, the eddy current loss increases which loads the output of oscillator. This loading effect
causes the output amplitude of the oscillator to decrease.
 As long as the oscillator amplitude does not drop below the threshold level of the trigger
circuit, the output of the sensor will remain off. However, as shown in Figure, if the target
object moves closer to the face of the sensor, the eddy current loading will cause the oscillator
to stall (cease to oscillate). When this happens, the trigger circuit senses the loss of oscillator
output and causes the output switching device to switch “on”.

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Chapter (3) Sensor Technology for Sequence Control Magnetic Sensor
 Hall effect sensors

o A Hall-effect sensor is a non-contact type sensor that is based on the Hall effect,
which was discovered by Hall in 1877.
o The Hall effect states that a voltage difference is developed in a current-carrying
conductor when subjected to a magnetic field. This voltage is perpendicular to
both the current and the magnetic field.
o Hall effect sensors can be used to as position, displacement and proximity sensors if the
object being sensed is fitted with a small permanent magnetic

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𝐕 = 𝑲𝑯 𝑩 𝑰 𝒅
o Schmitt Trigger

19

o Liquid Level Sensors
 Hall effect sensors can be used to determine the level of fuel in an automobile fuel tank

20

o Wheel Speed Sensor -RPM

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 Reed sensor
o A reed relay is a type that uses an electromagnet or permanent magnet to control
one or more reed switches.
o The contacts are of magnetic material and the electromagnet acts directly on them
without requiring an armature to move them. Whereas electromechanical wearing
occurs and reduces life .
o Hermetically sealed in along, narrow glass tube, the contacts are protected from
corrosion.

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 Reed sensor
o When power is applied to the coil or permanent magnet placed near the relay, the
resulting magnetic field cause the reeds to move and the contact is closed.
o Advantages of reed relay

 High reliable – longer mechanical and electromechanical relays.
 Fast Switching – can switch about ten times faster than an electromechanical
relay with similar rating.
 Small size – small, industry standard packaging.

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Capacitive Sensors
 Capacitive proximity sensors

o Capacitive proximity sensors sense "target" objects due to the target's ability to be
electrically charged. Since even non-conductors can hold charges, this means that just
about any object can be detected with this type of sensor. Figure below demonstrates the
principle of capacitive proximity sensing.
o Inside the sensor is a circuit that uses the supplied DC power to generate AC, to
measure the current in the internal AC circuit, and to switch the output circuit
when the amount of AC current changes.

24
Capacitive Sensors

o The principle of operation of the capacitive sensor is that an internal oscillator will
not oscillate until a target material is moved close to the sensor face. The target
material varies the capacitance of a capacitor in the face of the sensor that is part
of the oscillator circuit. They will work with both non-metallic materials and
metallic materials.
o Capacitive Proximity Sensor Signals

25
Capacitive Sensors
o Capacitive proximity sensor liquid detection

26
Capacitive Sensors
 Liquid Level Sensors
𝝐𝟎 𝝐𝒓 𝑨
𝑪=
𝒅

27
Chapter (3) Sensor Technology for Sequence Control Ultrasonic Sensors
 Basic principle of operation:

o Emit a quick burst of ultrasound (50kHz), (human hearing: 20Hz to 20kHz)
o Measure the elapsed time until the receiver indicates that an echo is detected.
o Determine how far away the nearest object is from the sensor
𝑫 = 𝒗 ∗ 𝒕 D = round-trip distance, v = speed of propagation(𝟑𝟒𝟎 𝒎/𝒔), and t =
elapsed time
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 Ultrasonic Sensors
o Figure below illustrates a practical application in which the returning echo signal
is electronically converted to a 4- to 20-mA output, which supplies a monitored
flow rate to external control devices. The operation of this process can be
summarized as follows:
 The 4-20 mA represents the sensor’s measurement span.

 The 4-mA set point is typically placed near the bottom of the empty tank, or the
greatest measurement distance from the sensor.
 The 20-mA set point is typically placed near the top of the full tank, or the
shortest measurement distance from the sensor.
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o The sensor will proportionately generate a 4-mA signal when the tank is empty and a
20-mA signal when the tank is full.
o Ultrasonic sensors can detect solids, fluids, granular objects, and textiles. In addition,
they enable the detection of different objects irrespective of color and transparency
and therefore are ideal for monitoring transparent objects.
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Chapter (3) Sensor Technology for Sequence Control Optical Sensors
 Optical sensors are used for detecting light intensity.

 Humans have two light sensors. Do you know what they are called?
 Photo detector: is the fundamental element of optical receiver, followed by
amplifiers and signal conditioning circuitry.
 There are several photo detector types:
Vacuum Tube Photo sensors, Photon multipliers, Photo-resistors Photodiodes,
Phototransistors, Photovoltaic (Solar) Cells ,Thermoelectric Optical Sensors, etc.
Light wave

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1. Photoresistor
 Based on variation of resistance with light.
 Photoconductor: light  R Design of a Low-Cost Solar Cells Sun Tracking
Using LDR Sensor Arrays
 LDR: Light Dependent Resistor
Light Sources
LED
LASER

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2. Photodiodes
 Photodiode convert photons to electrons or convert optical signal (light) to electrical signal.
Current to Voltage
 Photodiode convert photons to electrons: 𝐼 = 𝑞 𝑁 = 𝜂𝑞 ℎ 𝑓 𝑃 = (𝜂𝑞𝜆 ℎ 𝐶)𝑃

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3. Phototransistors
Optical Coupler Magnetic Coupler

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 Photoelectric proximity
o Photoelectric proximity sensors comprise an infrared light-emitting diode (LED)
source and a light sensitive switch known as a detector. There are different
configurations of photoelectric proximity sensors: (A) the diffuse reflector, (B) the
retro reflector, (C) the through beam, (D) the fixed focus type, and (E) fiber
optics.
(A) The Diffuse Reflector
(B) The Retro Reflector

35
 Photoelectric proximity
(C) The Through Beam (D) The Fixed Focus Type
(E) Fiber Optics

36
 A photoelectric sensor is an optical control device that operates by detecting a visible

or invisible beam of light and responding to a change in the received light intensity.
Photoelectric sensors are composed of two basic components: a transmitter (light
source) and a receiver (sensor), as shown in Figure below

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 The basic operation of a photoelectric sensor can be summarized as follows:

o The transmitter contains a light source, usually an LED along with an oscillator.
o The oscillator modulates or turns the LED on and off at a high rate of speed.
o The transmitter sends this modulated light beam to the receiver.
o The receiver decodes the light beam and switches the output device, which
interfaces with the load.
o The receiver is tuned to its emitter’s modulation frequency and will only amplify
the light signal that pulses at the specific frequency.
o Most sensors allow adjustment of how much light will cause the output of the
sensor to change state.
o Response time is related to the frequency of the light pulses. Response times may
become important when an application calls for the detection of very small objects,
objects moving at a high rate of speed, or both.

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 Retro reflective scan
o Sensing distance : 1/2 to 1/3 of through-beam type

o Not suitable for reflective or transparent targets
o Target should be larger than the reflector

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 Through-beam scan
o Long sensing distance: up to 30 meters with some devices

o Will detect all but very transparent materials
o Must be accurately aligned

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 Fiber optic sensors

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 Bar code technology is widely implemented in industry to enter data quickly and
accurately.
 Bar code scanners are the eyes of the data collection system.
 A light source within the scanner illuminates the bar code symbol; those bars absorb
light, and spaces reflect light.
 A photo detector collects this light in the form of an electronic-signal pattern
representing the printed symbol.
 The decoder receives the signal from the scanner and converts these data into the
character data representation of the symbol’s code.

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 Optical proximity sensors generally cost more than inductive proximity sensors, and about
the same as capacitive sensors. They are widely used in automated systems because they
have been available longer and because some can fit into small locations. These sensors are
more commonly known as light beam sensors of the thru-beam type or of the retro-
reflective type. A complete optical proximity sensor includes a light source, and a sensor
that detects the light.

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 The light source is supplied because it is usually critical that the light be "tailored"
for the light sensor system. The light source generates light of a frequency that the
light sensor is best able to detect, and that is not likely to be generated by other
nearby sources.
 Infra-red light is used in most optical sensors. To make the light sensing system
more foolproof, most optical proximity sensor light sources pulse the infrared light
on and off at a fixed frequency.
 The light sensor circuit is designed so that light that is not pulsing at this
frequency is rejected. The light sensor in the optical proximity sensor is typically a
semiconductor device such as a photodiode, which generates a small current when
light energy strikes it, or more commonly a phototransistor or a photo Darlington
that allows current to flow if light strikes it.
 Early light sensors used photoconductive materials that became better conductors,
and thus allowed current to pass, when light energy struck them.
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 Sensor control circuitry is also required. The control circuitry may have to match
the pulsing frequency of the transmitter with the light sensor. Control circuitry is
also often used to switch the output circuit at a certain light level. Light beam
sensors that output voltage or current proportional to the received light level are
also available.
 Through beam type sensors are usually used to signal the presence of an object that
blocks light. If they have adjustable switching levels, they can be used, for
example, to detect whether or not bottles are filled by the amount of light that
passes through the bottle.

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Chapter (3)

Sensor Technology for Sequence Control

Chapter (1) Introduction to Mechatronic Automation.

 What is sequence (logic) control?

Mechatronic Automation Dr. Ali M. Gaballa

 What is sequence (logic) control?

Mechatronic Automation Dr. Ali M. Gaballa

 Washing machine system

Mechatronic Automation Dr. Ali M. Gaballa

Mechatronic Automation Dr. Ali M. Gaballa

 Sensor is a device that detects a change in a physical stimulus and turns it

 Need of Sensors in daily life:

Mechatronic Automation Dr. Ali M. Gaballa

 Non-Contact Proximity Sensors

Inductive Magnetic Capacitive Light Ultrasonic

o Proximity sensors or switches

Mechatronic Automation Dr. Ali M. Gaballa

 As the name implies, inductive proximity

Mechatronic Automation Dr. Ali M. Gaballa

 Inductive proximity sensor

Mechatronic Automation Dr. Ali M. Gaballa

 Inductive proximity sensor

Typical three-wire DC sensor connection

Typical two-wire proximity sensor connection

Mechatronic Automation Dr. Ali M. Gaballa

 The basic operation of an inductive proximity sensor can be summarized as follows :

 Most sensor applications operate either at 24V DC or at 120V AC.

Mechatronic Automation Dr. Ali M. Gaballa

 Inductive Proximity Sensor Internal Components

Mechatronic Automation Dr. Ali M. Gaballa

 Inductive Proximity Sensor Internal Components

Mechatronic Automation Dr. Ali M. Gaballa

Fall 2020 Question:3 (10 Marks)

Mechatronic Automation Dr. Ali M. Gaballa

Mechatronic Automation Dr. Ali M. Gaballa

Mechatronic Automation Dr. Ali M. Gaballa

 Hall effect sensors

Mechatronic Automation Dr. Ali M. Gaballa

 Hall effect sensors

Mechatronic Automation Dr. Ali M. Gaballa

 Hall effect sensors

Mechatronic Automation Dr. Ali M. Gaballa

 Hall effect sensors

Mechatronic Automation Dr. Ali M. Gaballa

Mechatronic Automation Dr. Ali M. Gaballa

o Advantages of reed relay

Mechatronic Automation Dr. Ali M. Gaballa

 Capacitive proximity sensors

Mechatronic Automation Dr. Ali M. Gaballa

 Capacitive proximity sensors

o Capacitive Proximity Sensor Signals

Mechatronic Automation Dr. Ali M. Gaballa

 Capacitive proximity sensors

o Capacitive proximity sensor liquid detection

Mechatronic Automation Dr. Ali M. Gaballa

 Liquid Level Sensors

Mechatronic Automation Dr. Ali M. Gaballa

 Basic principle of operation:

 The 4-20 mA represents the sensor’s measurement span.

 Optical sensors are used for detecting light intensity.

Mechatronic Automation Dr. Ali M. Gaballa

 LDR: Light Dependent Resistor