Classification of sensors

Sensors are classified as either :

• Contact type
• Non-contact type (proximity sensors)

Proximity sensors being the more commonly used sensor.

Classification of sensors

Sensors are further categorized as either :

• Binary
• Analogue.

Binary sensors convert a physical quantity into a binary signal which means it has two switching states.
The most common being an electrical signal ON or OFF.
Analog sensors convert a physical quantity into an analog signal which means it is continuous signal. The
most common being an electrical signal such as voltage or current.
Types of sensors
Types of sensors
Types of sensors
Types of sensors

Thermocouple
Temperature Temperature Proximity
RTD(Resistance Temperature Detector)
Sensors Sensors
Thermistor

Semiconductor

Infrared

Thermometer
Types of sensors

Pneumatic Load Cells

Weight
Load Cells Hydraulic Load Cells
Sensors
Strain Gauge Load Cells

Capacitance Load Cells

Limit switches
• Limit switches are considered to be contact sensors, as it needs to be actuated to give a signal output
Applications – Monitoring door closing
Applications – Activate brake lights
Applications – Cylinder positioning
Applications – Cylinder positioning
Reed switches
• Most widely known and used as cylinder
switches

a)

b)

1
Reed switches
24v
24v
Reed switches
Applications – Gate monitoring
Gates and doors with pneumatic drive, installed in a warehouse, are checked as to their state by use of
magnetic sensors fitted to the cylinders.
The messages “gate open” or “gate closed” will be transmitted to the house control plant.
Inductive proximity sensors

Cable or
plug-in connection
LED

Active surface
Inductive proximity sensors

High Frequency magnetic field (300 to

800 kHz) Active Surface

Resonant circuit coil

LED indicator

Connection cable
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
ON
output
OFF
signal
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
Inductive proximity sensors
• The bigger the coil, the greater the active switching distance.
• Inductive sensors can only detect metals.
• Different switching distances for different metals
• Distances of up to 250mm can be achieved.
Inductive proximity sensors
Applications – Cylinder positioning
Applications – Detecting objects on conveyor
Applications – Detecting aluminium caps
• At the Final Control of Yoghurt Tubs, the Presence of Aluminium Foils is to be Detected.
Capacitive proximity sensors

Sensor is looking for a

Electrostatic field change in capacitance
in the active field
Active surface
Active electrode
Earth electrode

LED indicator
Adjusting screw
Connection cable
Capacitive proximity sensors
• Almost similar to the inductive sensor.
• Able to detect most materials.
• Switching distance adjustable.
• Able to detect fluid level through the wall of a bottle.
Target
Sensor is adjusted so that it
does not ‘see’ the wall of the
vessel.
As the level rises the fluid
affects the sensor field.
Until the sensor switches.
Capacitive proximity sensors
• Detection of matt, black objects.
• Detecting fluid level, wall thickness must be limited.
• Monitoring the winding of electrical wires and cables.
Capacitive proximity sensors

Detection of black rubber soles

Capacitive proximity sensors
Optical proximity sensors
There are three different types of optical proximity sensors:

• Through beam optical sensor

• Retro-reflective optical sensor
• Diffuse optical sensor
Optical proximity sensors
Through beam sensor
Through beam sensor

Transmitter Receiver
Transmitter Receiver
 Target

Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Transmitter Receiver
Through beam sensor
Applications of through beam sensors

• Used as safety devices.

• Fast counting applications.
• Monitoring for broken parts.
Applications – Detecting drill breakage
Applications – Gate monitoring
While closing, the gate is monitored by through-beam sensors so as to prevent an object from being
present in the closing area.
Retro-reflective sensor
 T
R

Transmitter / Receiver Reflector

(prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
 Target

T
R

Transmitter / Reflector
Receiver (prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
T
R
 T
R

Transmitter / Reflector
Receiver (prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
 T
R

Transmitter / Reflector
Receiver (prismatic)
Applications – Counting of objects

Counting of Objects
Applications – Counting of tin cans
The tin can which arrives on a conveyor belt break the light beam of a retro-reflective sensor.
The output signal is counted and used to pack the tins on pallets of 12.
Diffuse sensor
 Target

T
R

Transmitter /
Receiver
 T
R

Transmitter /
Receiver
 T
R

Transmitter /
Receiver
T
R
 T
R

Transmitter /
Receiver
 T
R

Transmitter /
Receiver
Applications – Material flow control
A diffuse sensor controls work pieces as to their correct positioning
Applications – Positioning for cutting to length
A sheet metal strip has marks for cutting to length.
A diffuse sensor detects these marks and emits a signal to initiate the cutting process.
Applications – Checking before filling
A diffuse sensor checks the angular aperture of the cardboard boxes, before they are filled. The diffuse
sensor is adjusted in such a manner that it only emits a signal if the cover of the box is opened wide
enough.
Fibre-optic cables
Fibre-optic cables
Fibre-optic cables
Advantages of using fibre optic cables

• Detection of objects in areas of restricted access.

• Possibility of remote installation.
• Accurate detection of small objects.
• Sensing elements can be moved.
Applications – Counting resistors
Applications – Detecting hot objects
Hot objects coming out of an enamelling oven are detected as to their presence at an ambient
temperature of some 150 Celsius.
The high ambient temperature makes it absolutely necessary to use a glass fibre optic cable with metal
cover. Polymeric fibre optic cables would melt under these conditions.
Applications – Checking capacitator leads
Capacitor leads are checked as to their correct adjustment with regard to side and elevation in a tape.
This is achieved by means of diffuse sensors and fibre optic cables.
Two sensors check the length of the leads. A third one checks the distance between the capacitors.
A connection controller evaluates the signals.
Applications – Presence of electronic components
A fibre optic cable and diffuse sensor connected are used to control the surface of circuit boards that are
difficult to access for the presence of small components.
The positions that are hard to access can only be attained by means of highly flexible polymeric fibre
optic cables.
Ultrasonic sensors
Ultrasonic Sensors
Preferred areas of application for ultrasonic sensors are;
• Storage facilities
• Transport systems
• Food industry
• Metal, glass and plastic processing
• Monitoring of bulk material
Applications – Monitoring slack between feed rollers
Applications – Sorting according to different height
Temperature sensors
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• Thermocouple
Temperature sensors
• RTD (Resistance Temperature Detector)
Temperature sensors
• RTD (Resistance Temperature Detector)
Temperature sensors
• RTD (Resistance Temperature Detector)
Temperature sensors
• RTD (Resistance Temperature Detector)
Temperature sensors
• Thermistor
Temperature sensors
• Thermistor
Temperature sensors
• Thermistor
Temperature sensors
• Semiconductor
Temperature sensors
• Semiconductor
Temperature sensors
• Infrared
Temperature sensors
• Thermometer
Temperature sensors
• Thermometer
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
• Pneumatic Load Cells
Weight Sensor (Load Cells)
• Hydraulic Load Cells

Hydraulic Load Cells

Weight Sensor (Load Cells)
• Strain Gauge Load Cells
Weight Sensor (Load Cells)
• Strain Gauge Load Cells
Weight Sensor (Load Cells)
• Capacitive Load Cells
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Weight Sensor (Load Cells)
Connection and circuit technology – Three-wire technology

BN(1) PNP normally open

+24V DC
PNP normally closed
BK(4)
L
BU(3)
0V

BN(1)
+24V DC
BK(4) PNP normally closed
L
BU(3)
0V
 BU(3)
0V
Connection and circuit technology – Three-wire technology

BN(1)
+24V DC
NPN normally open
BK(4)
L
BU(3)
0V

BN(1)
+24V DC
BK(4) NPN normally closed
L
BU(3)
0V
Connection and circuit
12.3 Four-Wire technology – Four-wire technology
Technology

BN(1) +24V DC
BK(4)
L PNP normally open/normally
WH(2) closed contacts
BU(3)
0V

BN(1) +24V DC
BK(4) L
NPN normally open/normally
WH(2) closed contacts
BU(3)
0V
Parallel and series connection

Usually logic operations of the proximity sensors are carried out by the controller.

By means of series or parallel connections it is possible to achieve the logic operation of several sensors.

With parallel connection, it is possible to effect a logic “or” connection and with series connection a
logic “and” connection.
Parallel and series connection

Advantages

• Logic operations can be achieved without using an electrical controller.

• With the use of electrical controllers, logic operations can be carried out immediately on the spot so
that only the logic operation result is signaled to the controller using a minimum amount of cabling.
Parallel and series connection

Disadvantages

• The design and construction of logic operations requires experience, as the mutual influences of
proximity sensors, increases response and drop-off times and a limit in the number of proximity
sensors connected must be taken into account.
• Maintenance becomes difficult.
Parallel connection – Two-wire technology

+24V DC

BN(1) BN(1)
BU(3) BU(3)

UV

0V
Parallel connection – Three-wire technology

+24V DC

BN(1) BN(1)
BK(4) BK(4)
BU(3) BU(3)
V

0V
Series connection – Two-wire technology

+24V DC

BN(1)
BU(3) V1

V BN(1)
BU(3) V2

0V
Series connection – Three-wire technology

+24V DC

BN(1) V1
BK(4)
BU(3)

V BN(1)
BK(4) V V2
BU(3)

0V
Degree of Protection - Definition
• The IP (Ingress Protection) standard sets
requirements for:

1. Protection of the electrical equipment by

preventing impurities (esp. dust) from
entering the enclosure
2. Protection of the electrical equipment
against damage from water (would result if
water were to enter the enclosure)
Electrical Protection – IP Protection classes (EN 60529)
Electrical Protection – IP Protection classes (EN 60529)
Electrical Protection – IP Protection classes (EN 60529)
Electrical Protection – IP Protection classes
• Importance for Process Industry: The following IP classes concerning dust are usually used:

IP5x: No complete protection against dust.

IP6x: No dust infiltration (highest protection!)

Electrical Protection – IP Protection classes

IPx5: Protection against water-jet streams

(water pressure ~ 0.3 bar)

IPx6: Protection against powerful water-jet streams (water

pressure ~ 1 bar)

IPx7: Protection against intermittent

submersion in water.
IP Test Procedure

IP 5x / IP6x IP x5/ IP x6 IP x7
Test: Water Jet Test: Submersion
Test: Dust