Chapter 2 Examples of Sensor Applications

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Industrial Automation System

Sensors and Actuators

Prepared by:

Dr. Tee Kian Sek

Date: 10 March 2014


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TABLE OF CONTENTS

1 EXAMPLES OF SENSOR APPLICATIONS ........................................................ .................................. 1

1.1 SLOT SENSORS (PHOTO SENSOR ) ......................................................... ....................................................... 1

1.2 PROXIMITY SENSOR ........................................................................................................... ....................... 2 1.3 PHOTO SENSOR VARIOUS TYPES (DIFFUSED , RETRO -REFLECTIVE , THRU BEAM ) ...................................... 5

1.4 FIBRE SENSORS ............................................................ ................................................................. ............ 7

1.5 VISION SYSTEM ............................................................ ................................................................. ............ 8

1.6 SINGLE AXIS POSITIONING ................................................................ ........................................................ 9

2 EXERCISES ........................................................ ................................................................. ..................... 10

2.1 A N AUTO GATE ............................................................. ................................................................. .......... 10

2.2 SCISSOR LIFT .......................................................................................................................................... 10

2.3 CARGO LIFT ...................................................... ................................................................. ..................... 11 2.4 HYDRAULIC PRESS ....................................................... ................................................................. .......... 12

2.5 PLASTIC I NJECTION MOULDING MACHINE .............................................................................................. 12

2.6 BOTTLE FILLING MACHINE ................................................................ ...................................................... 13

2.7 HORIZONTAL PACKING MACHINE ........................................................ ..................................................... 13

2.8 WATER LEVEL CONTROL ......................................................... ................................................................ 14

2.9 LOCK AND DAM ............................................................ ................................................................. .......... 15

2.10 CAROUSEL STORAGE SYSTEM ............................................................................................................ 15

2.11 AUTOMATIC PALLET WRAPPER ................................................................ .......................................... 16

2.12 AUTOMATED VACUUM SUCTION AND LIFTER .................................................................................... 16

2.13 CRANE AND HOIST .............................................................. ................................................................ 17


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Detects Aluminum Componentshttps://www.ia.omron.com/products/applications/case/378.html

Detects Bottle Capshttps://www.ia.omron.com/products/applications/case/381.html

Positioning at the Welding Sitehttps://www.ia.omron.com/products/applications/case/380.html
https://www.ia.omron.com/products/applications/case/378.htmlhttps://www.ia.omron.com/products/applications/case/378.htmlhttps://www.ia.omron.com/products/applications/case/381.htmlhttps://www.ia.omron.com/products/applications/case/381.htmlhttps://www.ia.omron.com/products/applications/case/380.htmlhttps://www.ia.omron.com/products/applications/case/380.htmlhttps://www.ia.omron.com/products/applications/case/380.htmlhttps://www.ia.omron.com/products/applications/case/381.htmlhttps://www.ia.omron.com/products/applications/case/378.html


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Liquid Level Control of Various Pipes and Liquidhttps://www.ia.omron.com/products/applications/case/98.html

Detects Lead Frames (Aluminum/Copper)https://www.ia.omron.com/products/applications/case/376.html
https://www.ia.omron.com/products/applications/case/98.htmlhttps://www.ia.omron.com/products/applications/case/98.htmlhttps://www.ia.omron.com/products/applications/case/376.htmlhttps://www.ia.omron.com/products/applications/case/376.htmlhttps://www.ia.omron.com/products/applications/case/376.htmlhttps://www.ia.omron.com/products/applications/case/98.html


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1.3 Photo sensor various types (diffused, retro-reflective, thru beam)


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Detects Black Tires at Long Distancehttps://www.ia.omron.com/products/applications/case/388.html

1.4 Fibre Sensors

Detects Knots in a ThreadSource: https://www.ia.omron.com/products/applications/case/397.html
https://www.ia.omron.com/products/applications/case/388.htmlhttps://www.ia.omron.com/products/applications/case/388.htmlhttps://www.ia.omron.com/products/applications/case/397.htmlhttps://www.ia.omron.com/products/applications/case/397.htmlhttps://www.ia.omron.com/products/applications/case/397.htmlhttps://www.ia.omron.com/products/applications/case/397.htmlhttps://www.ia.omron.com/products/applications/case/388.html


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Detect Black Shade on Sheetshttps://www.ia.omron.com/products/applications/case/395.html

1.5 Vision System
https://www.ia.omron.com/products/applications/case/395.htmlhttps://www.ia.omron.com/products/applications/case/395.htmlhttps://www.ia.omron.com/products/applications/case/395.html


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1.6 Single Axis Positioning

Positioning for Wafer Cutting Machineshttps://www.ia.omron.com/products/applications/case/375.html
https://www.ia.omron.com/products/applications/case/375.htmlhttps://www.ia.omron.com/products/applications/case/375.htmlhttps://www.ia.omron.com/products/applications/case/375.html


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2 EXERCISES

An automated system is illustrated. The students are asked to:

1. identify the locations of the sensors

2. determine the types of sensors of the pre-determined locations

3. Suggest the actuator (or actuators) and its (their) location.

2.1 An auto gate

Note: imagine the gate of your house.

2.2 Scissor Lift


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Videos: http://www.youtube.com/watch?v=6g60eUcbGZA

2.3 Cargo Lift

Source: http://www.indotara.co.id/cargo-lift
http://www.youtube.com/watch?v=6g60eUcbGZAhttp://www.youtube.com/watch?v=6g60eUcbGZAhttp://www.youtube.com/watch?v=6g60eUcbGZAhttp://www.indotara.co.id/cargo-lifthttp://www.indotara.co.id/cargo-lifthttp://www.indotara.co.id/cargo-lifthttp://www.indotara.co.id/cargo-lifthttp://www.youtube.com/watch?v=6g60eUcbGZA


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2.4 Hydraulic Press

Source: http://www.youtube.com/watch?v=LiRnt_qbwgU

2.5 Plastic Injection Moulding Machine

Source: Introduction to Manufacturing Processes by Mikell P. Groover, 2011, Wiley
http://www.youtube.com/watch?v=LiRnt_qbwgUhttp://www.youtube.com/watch?v=LiRnt_qbwgUhttp://www.youtube.com/watch?v=LiRnt_qbwgUhttp://www.youtube.com/watch?v=LiRnt_qbwgU


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2.9 Lock and dam

Lock and damSource:

http://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cu b_dams_lesson03.xml

2.10 Carousel Storage System

Horizontal Carousel Storage Systemhttp://www.drsystems.com/html/vertical_storage.html#HorizontalStorage
http://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cub_dams_lesson03.xmlhttp://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cub_dams_lesson03.xmlhttp://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cub_dams_lesson03.xmlhttp://www.drsystems.com/html/vertical_storage.html#HorizontalStoragehttp://www.drsystems.com/html/vertical_storage.html#HorizontalStoragehttp://www.drsystems.com/html/vertical_storage.html#HorizontalStoragehttp://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cub_dams_lesson03.xmlhttp://www.teachengineering.org/view_lesson.php?url=collection/cub_/lessons/cub_dams/cub_dams_lesson03.xml


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2.11 Automatic Pallet Wrapper

Source: http://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.php

See the videos for further detail on its operations!

2.12 Automated Vacuum Suction and Lifter

Vaccum Suction and LiftSource: http://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-

metal-69726-553305.html Videos: http://www.youtube.com/watch?v=8KQWEf3haS4
http://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.phphttp://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.phphttp://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.phphttp://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.phphttp://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.youtube.com/watch?v=8KQWEf3haS4http://www.youtube.com/watch?v=8KQWEf3haS4http://www.youtube.com/watch?v=8KQWEf3haS4http://www.youtube.com/watch?v=8KQWEf3haS4http://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.directindustry.com/prod/rema-hollande-bv/2-pad-vacuum-lifters-sheet-metal-69726-553305.htmlhttp://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.phphttp://www.phoenixwrappers.com/packaging-equipment/automatic/pcta-2000-overview.php


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2.13 Crane and hoist

Overhead Crane and Hoist System

Source: http://www.saturnoe.com/products/crane_kits.asp

Videos: http://www.youtube.com/watch?v=eebN63D0eF8
http://www.saturnoe.com/products/crane_kits.asphttp://www.saturnoe.com/products/crane_kits.asphttp://www.saturnoe.com/products/crane_kits.asphttp://www.youtube.com/watch?v=eebN63D0eF8http://www.youtube.com/watch?v=eebN63D0eF8http://www.youtube.com/watch?v=eebN63D0eF8http://www.youtube.com/watch?v=eebN63D0eF8http://www.saturnoe.com/products/crane_kits.asp

Chapter 2 Examples of Sensor Applications

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