Problem:

Need to detect two glass plates picked up together. The glass plate is of 97 mm diameter and it
is of 1.1 mm thickness (should be low cost). Pick three possible sensing principles (sensor
classes) for the task. Then identify a suitale sensor manufacturer (refer sensor data sheets) and
pick the most suitable sensor (item number) for this application. Provide a report with the
mentioned details. Include any references and data sheets etc.

Solution:
The task is to detect two glass plates picked up together, where each plate has a diameter of 97
mm and a thickness of 1.1 mm. The following are three possible sensing principles (sensor
classes) that can be used for this task, along with suitable sensors from different manufacturers.
1. Capacitive proximity sensor
2. Optical sensor
3. Ultrasonic sensor
To evaluate the cost-effectiveness of each sensor, we need to consider not only the unit price
of the sensor, but also the installation, maintenance, and operation costs, as well as the
performance, accuracy, and reliability of the sensor.

Capacitive proximity sensors:

These sensors can detect changes in capacitance caused by the presence or absence of objects,
regardless of their material, shape, or color. Capacitive proximity sensors can sense through
non-conductive materials, such as glass, and can measure the thickness or density of objects. A
suitable sensor for this task is the Balluff BCS M30T4G2-PSM60C-EP02 Capacitive Proximity
Sensor (item number: BCS018W), which has a sensing range of 0.5 to 15 mm, an adjustable
sensitivity, and a metal housing. The sensor can be mounted on a robot arm or a gripper and
can detect the difference between one and two glass plates based on the capacitance change.

The Balluff BCS M30T4G2-PSM60C-EP02 Capacitive Proximity Sensor has a unit price of
about 50000 LKR. The installation cost is low, as the sensor can be easily mounted on a robot
arm or a gripper. The maintenance cost is also low, as the sensor has a metal housing that
protects it from dust, moisture, and shock. The operation cost is moderate, as the sensor requires
an external power supply and a signal conditioner. The performance of the sensor is good, as it
can detect the difference between one and two glass plates based on the capacitance change.
The accuracy of the sensor is high, as it has an adjustable sensitivity and a resolution of 0.1
mm. The reliability of the sensor is high, as it has a long service life and a high immunity to
electromagnetic interference.

Optical sensors:
These sensors can detect objects by emitting and receiving light, either in the visible or infrared
spectrum. Optical sensors can measure the distance, position, shape, or color of objects, as well
as the transparency or opacity of materials. A suitable sensor for this task is the Banner Q4X
Analog Laser Distance Sensor (item number: Q4XAFV100CQ5), which has a sensing range
of 25 to 300 mm, an analog output, and a stainless steel housing. The sensor can be mounted
on a fixed position and can measure the distance to the glass plates, as well as the thickness of
the plates based on the light reflection.

The Banner Q4X Analog Laser Distance Sensor has a unit price of about 150000 LKR. The
installation cost is moderate, as the sensor can be mounted on a fixed position and aligned with
the glass plates. The maintenance cost is moderate, as the sensor has a stainless steel housing
that resists corrosion and abrasion, but may need occasional cleaning of the lens. The operation
cost is moderate, as the sensor requires an external power supply and a signal conditioner. The
performance of the sensor is good, as it can measure the distance to the glass plates, as well as
the thickness of the plates based on the light reflection. The accuracy of the sensor is high, as
it has a resolution of 0.05 mm and a repeatability of 0.02 mm. The reliability of the sensor is
high, as it has a long service life and a high immunity to ambient light and dust.

Ultrasonic sensors
These sensors can detect objects by emitting and receiving sound waves, either in the audible
or inaudible range. Ultrasonic sensors can measure the distance, position, shape, or size of
objects, as well as the presence or absence of liquids or solids. A suitable sensor for this task is
the Pepperl+Fuchs UC500-30GM-IUR2-V15 Ultrasonic Sensor (item number: 104065), which
has a sensing range of 50 to 500 mm, a switching and analog output, and a plastic housing. The
sensor can be mounted on a robot arm or a gripper and can measure the distance to the glass
plates, as well as the thickness of the plates based on the sound reflection.

The Pepperl+Fuchs UC500-30GM-IUR2-V15 Ultrasonic Sensor has a unit price of about

90000 LKR. The installation cost is low, as the sensor can be easily mounted on a robot arm or
a gripper. The maintenance cost is low, as the sensor has a plastic housing that is resistant to
chemicals and moisture. The operation cost is moderate, as the sensor requires an external
power supply and a signal conditioner. The performance of the sensor is good, as it can measure
the distance to the glass plates, as well as the thickness of the plates based on the sound
reflection. The accuracy of the sensor is moderate, as it has a resolution of 0.18 mm and a
repeatability of 0.5 mm. The reliability of the sensor is moderate, as it has a long service life,
but may be affected by temperature, humidity, and acoustic noise.
Based on this analysis, we can conclude that the capacitive proximity sensor is the most cost-
effective sensor for this detecting glass plates problem, as it has the lowest unit price,
installation cost, and maintenance cost, and the highest accuracy and reliability. The optical
sensor is the second most cost-effective sensor, as it has the highest performance and accuracy,
but also the highest unit price and installation cost. The ultrasonic sensor is the least cost-
effective sensor, as it has the lowest accuracy and reliability, and a moderate unit price and
operation cost.

References:
Lecture Slides – Dr.W.A.D.M. Jayathilaka
Sensors Handbook – Prof. Sabrie Soloman
An Analysis of Cost-Effectiveness of Optical Technology | HBM
Design of Cost-effective Wearable Sensors with integrated Health Monitoring System | IEEE
Conference Publication | IEEE Xplore
Developing Cost-Effective Sensors for Mass Markets: The Issues (azosensors.com)