Training Series: Level I

Introduction to Sensors
Level I

Training Series: Level I

Course Topics
Sensors Definition Sensor Building Blocks
Electrical Interface
Tell me about it:

Sensing Technology
I see it:

Housings
Looks are everything:

Level I
Sensor Basics

Level II
Products and Applications

Level III
Advance Problem Solving

Training Series: Level I

Sensor Definitions
What are we talking about ?

Sensor Definitions

What is a Sensor?
Used in Industrial Automation:
Electrical device capable of identifying change within an automated process.

Sometimes

Sensor = Switch

Sensor Definitions

Sensor Uses
Sensors in our world
Automatic opening doors Grocery check-out conveyer shut-off Safety sensors on garage doors

Sensors in Manufacturing
Part position verification Counting products Liquid level control Quality control inspection Personal safety systems

Sensor Definitions

Sensor Building Blocks

The three major components:
The sensing side
Front-end

The electrical side

Back-end

Housing

Sensor Definitions

Building Block Concept

most any

Sensing technology
most any

Housing
most any

Electrical interface

Sensor Definitions

The Building Blocks

Front-end - Sensing
Five technology choices:
Inductive Optical Capacitive Magnetic Mechanical

Selection base on: Application

Sensor Definitions

The Building Blocks

Back-end Electrical
Options:
Electrical voltage
AC/DC DC

Output type
Discrete (on-off, like a switch) Analog

Selection base on: Control System

Sensor Definitions

The Building Blocks

The Sensors Housings
Material Options:
Metal (nickel-plated brass) Stainless steel Aluminum Plastic

Shape (mounting style):

Tubular Block

Selection base on: Environment

Sensor Definitions

The Building Blocks

and the real world

Housing

Environment

Training Series: Level I

Electrical Interface
The Back-end

Electrical Interface

Electrical Interface
Divided into 2 areas:
Operating voltage
Power

Output signal type

Signal

Electrical Interface

Output Signal Types

Discrete
ON or OFF YES or NO

Analog
Speed control Position information

MIN

MAX

Signal

Electrical Interface

Operating Voltage
Direct Current (DC) Alternating Current (AC)
Current flows in only ONE direction Safe, easy-to-handle power source Current changes direction 60 times a second Readily available

Power

Electrical Interface

Basic Electrical Principals

What is electricity?
Flow (current) or potential flow (voltage) of electrons
Interesting fact:
Electron flow is similar to water flow We will use this analogy during our class

Electrical Interface

Basic Series Circuit

Using Water Analogy:
Potential Flowing
Water Valve Hydro motor Water Tank

Electrical Interface

Basic Series Circuit

Electronics:
Potential Flowing
Switch Battery

+ Electric Motor

Basic ON or OFF operation

Electrical Interface

A discrete Sensor is a Switch

Sensing Side
Electronics

Electronics

Front-end

Power Wires

Switch

Electrical Interface

Basic Sensor Circuit

Sensors with relay output

Electronics

Unlike a switch, sensors require power to operate

+ -

Electrical Interface

Types of discrete electrical outputs

Sensors of today use Solid-State outputs, not mechanical relays
Today Yesterday

PNP, 3-wire NPN, 3-wire AC/DC, 2-wire

Relay

Electrical Interface

The NPN & PNP output

Functions similar to a switch,
But current only flows in one direction
PNP Transistor Mechanical Switch

Electrical Interface

The Different Transistors

What direction do you want current to flow?
NPN
Also called Sinking

PNP
Also called Sourcing

Electrical Interface

PNP, 3-wire
Standard diagram form
As shown in our catalog

The Sensor

1 4 3
Connector Pins The Load

+ Load PNP Output -

Electrical Interface

PNP, 3-wire
Watching the current flow
Sensors Power Output Signal

1 4 3 Load

+ PNP Output -

Electrical Interface

NPN, 3-wire
Watching the current flow
Sensors Power Output Signal

1 4 3 Load

+ NPN Output -

Electrical Interface

The 2-wire AC/DC output

Functions similar to a switch,
But with a small leak
Triac Sensors Power
Supply from leakage current

Output Signal

1 3

Load

~ ~

Electrical Interface

Quick Reference:
wiring PNP & NPN

NPN PNP
Sensor is PNP
+ Load -

Positive

Negative

Electrical Interface

If given a choice, which discrete sensor type should I choose?

1st CHOICE
1 4 3 Load +

PNP or NPN, 3-wire - Fewer interface problems - Largest selection - Lowest unit costs
AC/DC, 2-wire - Many interface issues - Smaller selection - Susceptible to noise

2nd CHOICE
1 3 Load ~ ~

Electrical Interface

Normally Open (NO) vs. Normally Closed (NC)

Is it on (closed)?

Identifies the non-active state (target not present) of the sensor Is it off (open)?

Normally Open

Electronics

+ -

Electrical Interface

Normally Open (NO) vs. Normally Closed (NC)

Is it on (closed)?

Identifies the non-active state (target not present) of the sensor Is it off (open)?

Normally Closed

Electronics

+ -

Electrical Interface

Analog Outputs
Unlike a discrete output with two defined states, analog signals have an infinite number of states.
Discrete
Voltage On

Off

Time

Analog

Voltage

Max

Min

Time

Electrical Interface

Analog Uses
To provide absolute measurement or position information

Measurement
Position

Electrical Interface

Analog Applications!
What can you do with measurement information? Measure thickness Spool diameter Rotational position Position feedback Liquid level Measure tool wear Sort parts Null out machine wear Determine part Null out thermal orientation expansion Measure vibration Verify die position Measure straightness Verify bend radius Hydraulic or pneumatic Part profiling cylinder position Stack height
Expanding possibilities

Electrical Interface

Analog Data
We know analog information provides:
Measurement information Position information

What devices use analog information?

Panel meters
2 3 4 5 6 7 8 9 0 1 10

Control systems

Measurement

Electrical Interface

Analog Information
The many forms for representing measurement or position information
10 10 5

Voltage
0 20 -10 20 -5

Current
0 4

Digital Pulse

Electrical Interface

Analog Voltage
Information contained in varying voltage

Maximum Voltage Half Voltage

2 3 4 5 6 7 8 9 0 1 10

Measurement

Water Analogy

Volt Meter

Electrical Interface

Analog Current
Information contained in varying Current

Maximum Current Half Current

2 3 4 5 6 7 8 9 0 1 10

Measurement

Water Analogy

Current Meter

Electrical Interface

Digital Pulse
Information contained in digital pulse timing
Measurement range

Maximum measurement Minimum measurement Half way

Pulse Width

1 0.00 50.00 00.00

Meter
Measurement range

Start/Stop

Electrical Interface

Electrical Interface REVIEW

Operating voltage: Sensor Power
DC: Safest AC: Most available

Power

Output signal types

Signal Discrete
PNP, 3-wire NPN, 3-wire AC/DC 2-wire

Analog
Voltage Current Digital pulse

Training Series: Level I

Sensing Technologies

Sensing Technologies

Sensing Technologies
Non- Contact
No physical contact with target Preferred method for sensing end products

Contact
Contact with target Simplest method available

Sensing Technologies

Contact Sensing
Mechanical switch
Contact with plunger opens electrical contacts

Sensing Technologies

Non-Contact
Popular sensing technologies
Inductive Sensors
Metal targets

Optical Sensors
Target capable of reflecting or blocking light

Capacitive Sensors
Liquids/solids

Magnetic Field Sensors

Magnets

Sensing Technologies

Inductive
When voltage is applied, an electromagnetic field is generated and extends out the face of the sensor. When metal enters the sensing zone, an eddy current is induced in the metal.

The change in eddy current is detected and the sensors output is energized.

Sensing Technologies

Inductive
Two basic Sensing types
Flush mount
Shorter range Sensor can be buried in metal

Non-flush mount
Longer range Sensor can NOT be buried in metal

Sensing Technologies

Optical
Regardless of the operating mode, all optical sensors share the same operating principle:

Operation
Emits a light beam then detects or measures changes in received light. Light emitter
Visible red Laser Infrared

Light receiver

Sensing Technologies

Optical
Optical sensors offer three main sensing modes
Thru-beam Retroreflective Diffuse

Note: There are other sensing modes available, but they are covered in other courses.

Sensing Technologies

Optical: Thru-Beam
Separate emitter and receiver Beam-break operation
Target blocks beam

Emitter

Receiver

Great for long range and dirty environments

Sensing Technologies

Optical: Retroreflective
Emitter and receiver in one unit Requires a reflector Beam-break operation
Target block light beam
Reflector Emitter

Provides good range in well defined area

Sensing Technologies

Optical: Diffuse
Emitter and receiver in one unit Convenient stand-alone design Beam-make operation
Light reflects off target
Target

Simple point and shoot operation

Sensing Technologies

Capacitive
Detects target based on density Electrostatic field established Target detected when field properties change
Target

Simple point and shoot operation

Sensing Technologies

Magnetic
Detects magnetic field Magnetic field can travel through aluminum Used extensively with pneumatic cylinders
Magnet

Sees through aluminum

S N

Sensing Technologies

Sensing Technologies
Head-to-Head
Mechanical: Popular, simple
Inductive: Rugged, cost-effective Optical, Thru-beam: Long range Optical, Retro: Mid range Optical, Diffuse: Short range Capacitive: Liquid & bulk targets Magnetic: Pneumatic cylinders

Training Series: Level I

Housings
Physical looks

Housings

Housing Function
Protection from environment Mounting provisions Electrical connection

Housings

Protection from environment

Multiple degrees of protection liquids

IP65: Protects against water mist IP67: Protects against temporary immersion IP68: Protects against continuous immersion

Multiple level of physical abuse

Metal housing Plastic housing

Housings

Mounting Provisions
Depends on shape of housing
Tubular
Popular for short range sensors Range adjustments made by moving sensor in and out

Block
Popular for optical sensors Easy to align horizontally and vertically

Housings

Easy mounting and range adjustment

Inductive Sensor Capacitive

Tubular Housings

Optical Sensor

Magnetic

Housings

Block Housings
Provides Inductive Sensor thru-holes for mounting bolts Allows for easy beam alignment

Optical Sensor

BOS-SR2

Housings

Combination Housings
Combination Inductive Sensor of tubular and block housings

Optical Sensor

Housings

Application Specific Shapes

Magnetic

Inductive Sensor

Hydraulic Cylinder

Ring Sensor

Valve Position

Clamp Position

Optical Sensor

Slot Sensors

Pneumatic Cylinders

Windows

Fiber-optics

Housings

Electrical Connection
Cable Out version
Economical: no additional cable to purchase Difficult to replace sensor

Connector version
Cost: must purchase mating cable Much easier to replace sensor

Housings

Cable Connection Options

Cable Lengths
Standard lengths: 2m, 3m & 5m

Jacket Material
PVC: Standard, low cost jacketing PuFlex: For flexing applications

Housings

Connector Options
Industry standard connector sizes:
Micro (M12)
Most popular, mid-size Available in 3, 4, 5 and 8 pins

Nano (M8)
Smallest size Available in 3 and 4 pins

Mini
Largest size Available in 3 and 4 pins

Housings

Sensor Housings REVIEW

Protection from environment

IP65, IP67, IP68

Mounting provisions
Tubular, Block, Combination, Application specific shapes

Electrical connection
Cable out and connectors

Sensors Definitions

Sensor Fundamentals
Questions & Answers

Housing Environment

Training Series: Level I

Sensor Basics