Training Series: Level I Introduction to Sensors Level I.
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Transcript of Training Series: Level I Introduction to Sensors Level I.
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Training Series: Level ITraining Series: Level I
Introduction to SensorsIntroduction to Sensors
Level I Level I
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Course Topics
• Sensors Definition• Sensor Building Blocks
– Electrical Interface• Tell me about it:
– Sensing Technology• I see it:
– Housings• Looks are everything:
Training Series: Level ITraining Series: Level I
Level IIIAdvance Problem Solving
Level IIProducts andApplications
Level ISensorBasics
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Training Series: Level ITraining Series: Level I
Sensor DefinitionsSensor Definitions
What are we talking about ?
What are we talking about ?
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What is a Sensor?
Used in Industrial Automation:
Electrical device capable of identifying change within an automated process.
Electrical device capable of identifying change within an automated process.
Sometimes…Sensor = SwitchSometimes…Sensor = Switch
Sensor DefinitionsSensor Definitions
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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 DefinitionsSensor Definitions
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Sensor Building BlocksThe three major components:
The sensing sideFront-end
Housing
The electrical sideBack-end
Sensor DefinitionsSensor Definitions
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Building Block Concept
Sensor DefinitionsSensor Definitions
Sensingtechnology
Electricalinterface
Housing
most any
most any
most any
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The Building Blocks
Front-end - SensingFive technology choices:
• Inductive• Optical• Capacitive• Magnetic• Mechanical
Selection base on: ApplicationSelection base on: Application
Sensor DefinitionsSensor Definitions
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The Building Blocks
Back-end – ElectricalOptions:
• Electrical voltage– AC/DC– DC
• Output type– Discrete (on-off, like a switch)– Analog
Selection base on: Control SystemSelection base on: Control System
Sensor DefinitionsSensor Definitions
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The Building Blocks
• The Sensors Housings– Material Options:
• Metal (nickel-plated brass)• Stainless steel• Aluminum• Plastic
– Shape (mounting style):• Tubular• Block
Selection base on: EnvironmentSelection base on: Environment
Sensor DefinitionsSensor Definitions
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The Building Blocksand the real world
Sen
sing
Housing
Electrical
App
licat
ion C
ontrol System
Environment
Sensor DefinitionsSensor Definitions
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Training Series: Level ITraining Series: Level I
Electrical InterfaceElectrical Interface
The Back-endThe Back-end
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Electrical Interface
Divided into 2 areas:– Operating voltage
– Output signal type
Electrical InterfaceElectrical Interface
PowerPower
SignalSignal
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Output Signal Types
• Discrete– ON or OFF– YES or NO
• Analog– Speed control– Position
information
MIN MAX
Electrical InterfaceElectrical Interface
SignalSignal
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Operating Voltage
• Direct Current (DC)– Current flows in
only ONE direction
– Safe, easy-to-handle power source
• Alternating Current (AC)– Current changes
direction 60 times a second
– Readily available
Electrical InterfaceElectrical Interface
PowerPower
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Basic Electrical Principals
What is electricity?
– Interesting fact: • Electron flow is similar to water flow • We will use this analogy during our class
Electrical InterfaceElectrical Interface
Flow (current) or potential flow (voltage) of electrons
Flow (current) or potential flow (voltage) of electrons
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Basic Series CircuitUsing Water Analogy:
Water Tank
Water Valve
Hydro motor
PotentialFlowing
Electrical InterfaceElectrical Interface
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Basic Series CircuitElectronics:
PotentialFlowing
+
-
BatterySwitch
Electric Motor
Basic ON or OFF operationBasic ON or OFF operation
Electrical InterfaceElectrical Interface
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A discrete Sensor is a Switch
Electronics
Sensing SideFront-end
Electronics
Power WiresSwitch
Electrical InterfaceElectrical Interface
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Electronics
Basic Sensor CircuitSensors with relay output
+
-
Unlike a switch, sensors require power to operate
Electrical InterfaceElectrical Interface
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Types of discrete electrical outputs
• Sensors of today use Solid-State outputs, not mechanical relays
Today Yesterday
– PNP, 3-wire Relay– NPN, 3-wire– AC/DC, 2-wire
Electrical InterfaceElectrical Interface
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The NPN & PNP outputFunctions similar to a switch,But current only flows in one direction
PNPTransistor Mechanical
Switch
Electrical InterfaceElectrical Interface
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The Different TransistorsWhat direction do you want current to flow?
NPNAlso called Sinking
Electrical InterfaceElectrical Interface
PNPAlso called Sourcing
+--+
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PNP, 3-wire
1
4+
PNP Output3 -
Load
Standard diagram formAs shown in our catalog
The Sensor
The LoadConnector
Pins
Electrical InterfaceElectrical Interface
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PNP, 3-wire
1
4+
PNP Output3 -
Load
Watching the current flow
Sensors Power
Output Signal
Electrical InterfaceElectrical Interface
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1
4+
NPN Output3 -
Load
NPN, 3-wireWatching the current flow
Sensors Power
Output Signal
Electrical InterfaceElectrical Interface
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1 ~
3 ~
Load
The 2-wire AC/DC outputFunctions similar to a switch,
But with a small leak
Sensors Power Supply from leakage current
Output Signal
Triac
Electrical InterfaceElectrical Interface
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Quick Reference:wiring PNP & NPN
N P NP N P
+
-
Load
First side of load
Second side of load
Switched side
Positive
Negative
Sensor is PNP
Electrical InterfaceElectrical Interface
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If given a choice, which discrete sensor type should I choose?
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
1st CHOICE
2nd CHOICE
1
4+
3 -
Load
1 ~
3 ~
Load
Electrical InterfaceElectrical Interface
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Normally Open (NO)vs.
Normally Closed (NC)Identifies the non-active state (target not present) of the sensor
Electronics
+
-
Normally Open
Is it off (open)?
Is it on (closed)?
Electrical InterfaceElectrical Interface
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Normally Open (NO)vs.
Normally Closed (NC)Identifies the non-active state (target not present) of the sensor
Electronics
+
-
Is it off (open)?
Is it on (closed)?
Normally Closed
Electrical InterfaceElectrical Interface
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Analog OutputsUnlike a discrete output with two defined states, analog signals have an infinite number of states.
Discrete
Analog
On
Off
Voltage
Time
Max
Min
Voltage
Time
Electrical InterfaceElectrical Interface
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Analog UsesTo provide absolute measurement or position information
MeasurementPosition
Electrical InterfaceElectrical Interface
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Analog Applications!What can you do with measurement information?
– Measure thickness– Position feedback– Measure tool wear– Null out machine wear– Null out thermal
expansion– Verify die position– Verify bend radius– Part profiling– Stack height
– Spool diameter– Rotational position– Liquid level– Sort parts– Determine part
orientation– Measure vibration– Measure
straightness– Hydraulic or
pneumaticcylinder position
Expanding
possibilities
Expanding
possibilities
Electrical InterfaceElectrical Interface
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Analog Data• We know analog information provides:
– Measurement information– Position information
• What devices use analog information?
0 10987654321
Measurement
Panel meters Control systems
Electrical InterfaceElectrical Interface
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Analog Information• The many forms for representing
measurement or position information
10
0
10
-10
5
-5
20
0
20
4
Voltage
Current
Digital Pulse
Electrical InterfaceElectrical Interface
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Analog VoltageInformation contained in varying voltage
Maximum Voltage
0 10987654321
Measurement
Half Voltage
0 10987654321
Measurement
Water Analogy Volt Meter
Electrical InterfaceElectrical Interface
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Analog CurrentInformation contained in varying Current
0 10987654321
Measurement
0 10987654321
Measurement
Maximum CurrentHalf Current
Water Analogy Current Meter
Electrical InterfaceElectrical Interface
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Digital PulseInformation contained in digital pulse timing
100.00Maximum measurementHalf wayMinimum measurement
50.000.00Pulse Width
Meter
Start/Stop
Electrical InterfaceElectrical Interface
Measurement range
Measurement range
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Electrical Interface REVIEW
• Operating voltage: Sensor Power– DC: Safest– AC: Most available
• Output signal types– Discrete
• PNP, 3-wire• NPN, 3-wire• AC/DC 2-wire
– Analog• Voltage• Current• Digital pulse
Electrical InterfaceElectrical Interface
PowerPower
SignalSignal
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Training Series: Level ITraining Series: Level I
Sensing TechnologiesSensing Technologies
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Sensing Technologies
Non- Contact– No physical contact with target– Preferred method for sensing end products
Contact– Contact with target– Simplest method available
Sensing TechnologiesSensing Technologies
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Contact Sensing
Mechanical switch– Contact with plunger
opens electrical contacts
Contact
Sensing TechnologiesSensing Technologies
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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 TechnologiesSensing Technologies
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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 sensor’s output is energized.
Sensing TechnologiesSensing Technologies
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• 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
Inductive
Sensing TechnologiesSensing Technologies
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OpticalRegardless of the operating mode, all optical sensors share the same operating principle:
Light emitter• Visible red• Laser• Infrared
Light receiver
OperationEmits a light beam then
detects or measures changes in received light.
Sensing TechnologiesSensing Technologies
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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 TechnologiesSensing Technologies
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Optical: Thru-Beam• Separate emitter and receiver• Beam-break operation
Target blocks beam
Emitter Receiver
Great for long range and dirty environments
Sensing TechnologiesSensing Technologies
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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 TechnologiesSensing Technologies
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• Emitter and receiver in one unit• Convenient stand-alone design• Beam-make operation
Light reflects off target
Optical: Diffuse
Simple point and shoot operation
Target
Sensing TechnologiesSensing Technologies
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Capacitive• Detects target based on density
Simple point and shoot operation
Target
• Electrostatic field established• Target detected when field properties change
Sensing TechnologiesSensing Technologies
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Magnetic• Detects magnetic field• Magnetic field can travel through aluminum• Used extensively with pneumatic cylinders
Magnet
NS
Sees through aluminum
Sensing TechnologiesSensing Technologies
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Sensing TechnologiesHead-to-Head
Mechanical:
Inductive:
Optical, Thru-beam:
Optical, Retro:
Optical, Diffuse:
Capacitive:
Magnetic:
Popular, simple
Rugged, cost-
effective
Long range
Mid range
Short range
Liquid & bulk
targets
Pneumatic
cylinders
Sensing TechnologiesSensing Technologies
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Training Series: Level ITraining Series: Level I
HousingsHousings
Physical looksPhysical looks
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Housing Function• Protection from environment• Mounting provisions• Electrical connection
HousingsHousings
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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
HousingsHousings
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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
HousingsHousings
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Inductive SensorInductive Sensor
Tubular HousingsEasy mounting and range adjustment
Optical SensorOptical Sensor
CapacitiveCapacitive
MagneticMagnetic
HousingsHousings
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Block Housings
Provides thru-holes for mounting bolts
Allows for easy beam alignment
Inductive SensorInductive Sensor
Optical SensorOptical Sensor
BOS-SR2
HousingsHousings
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Combination HousingsCombination of tubular and block housings
Inductive SensorInductive Sensor
Optical SensorOptical Sensor
HousingsHousings
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Application Specific ShapesInductive SensorInductive Sensor
Optical SensorOptical Sensor
MagneticMagnetic
HydraulicCylinder
RingSensor
ValvePosition Clamp
Position
SlotSensors
WindowsFiber-optics
Pneumatic Cylinders
HousingsHousings
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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
HousingsHousings
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Cable Connection Options
• Cable Lengths– Standard lengths: 2m, 3m & 5m
• Jacket Material– PVC: Standard, low cost jacketing– PuFlex: For flexing applications
HousingsHousings
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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
HousingsHousings
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Sensor HousingsREVIEW
• Protection from environment– IP65, IP67, IP68
• Mounting provisions– Tubular, Block, Combination, Application
specific shapes• Electrical connection
– Cable out and connectors
HousingsHousings
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Sensor Fundamentals
Sen
sing
Housing
Electrical
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