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Sensors

We will discuss
 Proximity sensors
 Optical sensors
Proximity sensors
 A proximity sensor is a sensor able to detect the
presence of nearby objects without any physical
contact.
 A proximity sensor often emits an electromagnetic
or electrostatic field, or a beam of electromagnetic
radiation(infrared, for instance), and looks for
changes in the field or return signal.
 The object being sensed is often referred to as the
proximity sensor's target.
 Different proximity sensor targets demand different
sensors. For example, a capacitive or photoelectric
sensor might be suitable for a plastic target; an
inductive proximity sensor requires a metal target.
Proximity sensor types
 Inductive
 Capacitive
Inductive proximity sensor
Theory of Operation
 These sensors use mutual inductance
between a known inductor and a conductive
material
 Commonly referred to as “eddy current”
probes
 Mutual inductance is a function of the
distance between the inductor and the
material
How “Eddy Currents” Work
 An inductive coil is
placed near a
conductive surface
 An AC voltage
(typically around
2Mhz) is applied to
the coil
 Mutual inductance
begins to occur
Source: http://www.ndt-
ed.org/EducationResources/C
How “Eddy Currents” Work
 The coil generates a
magnetic field
 Circular or “Eddy
Currents” begin to
flow in the
conductive material
 These currents
resemble an eddy in
a stream of water

http://www.ndt-
ed.org/EducationResources/C
How “Eddy Currents” Work
 The Eddy Currents
generate their own
magnetic field
 These fields have
interaction with
the coil through
mutual inductance
 This leads to a
measurable result
http://www.ndt-
ed.org/EducationResources/C
What can be measured?
 Electrical conductivity and magnetic
permeability of the target material
 The amount of material cutting through the
coils of the magnetic field
 The condition of the material(whether it
contains cracks or defects
 Lift-Off
What is Lift-Off?
 Lift-Off is a very important measurement that
can be made by Eddy Current Sensors
 It represents the distance from the coil to the
test material
 This leads to a great number of industrial,
manufacturing, and other important
applications
Sensor Output in Proximity Applications
 A demodulator demodulates the signal from
the sensor, and outputs a DC voltage which is
proportional to the distance from the sensor
to the conductive target
 This output voltage is linear over the specified
range of the specific sensor
Typical Sensor Output
 Provides very high
resolution output
over ranges on the
order of millimeters
 The range an be
increased
depending on the
application, but
typically not more
that several inches
Calibration
 From the factory, most proximity probes
are calibrated to measure 4140 steel
 Because different materials have different
conductivity and permeability, special
calibration is needed to ensure accurate
measurement of each specific material
 This usually involves some alteration of the
signal conditioning and demodulation
process
Applications
 Can be used as an
encoder that
monitors rotation
 Can measure
thing like speed
and acceleration

Source: AllenBradly.com
Encoder Output
 This is what the
output looks like when
being used as an
encoder
 The peaks represent
the teeth on the
sprocket
 Speed and
acceleration can be
determined from this
output data
Source: AllenBradly.com
Applications(Cont)
 Used in Automated
Assembly lines
 Sensor detects each
part as it passes
 Provides Accurate,
Real-Time
information about
quantity and quality
in manufacturing
processes

Source: AllenBradly.com
Another Application
 Inductive sensors
monitor automated
machinery
 They can detect
anything out of the
ordinary and serve as
a fail safe shutoff,
which can save
millions of dollars in
preventing damage
to malfunctioning
machinery.
Source: AllenBradly.com
Power Systems Applications
 High Power turbines often operate in high
temperature, strenuous environments
 Inductive Sensors and be linked to a data
system through a robust cable allowing for
the monitoring of these systems
 Information gathered by these sensors can
greatly add to the life and health of high
power turbines and generators
Turbine Shaft Orbit Monitoring
 Two inductive sensors can be used to
monitor the health of a turbine
 When placed 90 degrees apart, they can
monitor the X and Y position of the shaft as
it rotates
 When bearing start to go out, the
movement in the X and Y direction begins
to increase
 This is detected by the sensors, and the
bearings can be replaced before serious
damage occurs
Illustration of Orbit Monitoring
Vibration Monitoring
 An inductive sensor can
monitor the vibration of
a turbine shaft
 Typically, there is
maximum limit that the
shaft is allowed to
vibrate, once that point
is passed, the system is
shut down to prevent
serious damage
General Applications
 Good for many short distance, high resolution
applications
 Can be used to detect the presence or
absence of conductive material
 Good for long distance monitoring of
machinery and industrial devices
 Usually works well in extreme environments
Other Applications
 Quality Control
 Autonomous
removal of bad
parts on an
assembly line
 Reliable and
consistent results
Other Applications(Cont)
 Real-Time
information on the
position of railroad
track switches
 Reliable due to
resistance to
changing
conditions
Limitations
 Very short range of measurement
 Material being measured must be conductive
 Target must be larger than the sensor tip
 Can only measure displacement in relation to
the sensor
Conclusion
 Inductive sensors operate on the principle of
mutual induction
 They are useful in a wide variety of
applications
 They provide high-resolution, reliable outputs
 Can be used in varied conditions
Capacitive proximity sensor
Capacitive proximity sensor
Working principle
Standard targets and dielectric constant
Usage
Optical sensors
Optical sensors
 Two types
 thru-beam type
 retro reflective type
Thru-beam type optical sensor
Retro reflective type
Construction
 A complete optical proximity sensor includes a light
source, and a sensor that detects the light. The light
source is supplied because it is usually critical that
the light be "tailored" for the light sensor system.
The light source generates light of a frequency that
the light sensor is best able to detect, and that is not
likely to be generated by other nearby sources.
Infra-red light is used in most optical sensors. To
make the light sensing system more foolproof, most
optical proximity sensor light sources pulse the infra-
red light on and off at a fixed frequency. The light
sensor circuit is designed so that light that is not
pulsing at this frequency is rejected.

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