Proximity Sensor

Objective: To learn Working Principle, Internal Mechanism, Various Types, Wiring with PLC or
contactor, Application

Introduction:

Most industrial proximity sensors  (inductive, capacitive, ultrasonic and photo electric) are solid state.
The term solid state refers to the type of components used within the sensor. Solid state electronic components
such as transistors are used to switch the output of the sensor upon detection of an object.

Two specific types of 3 wire sensors are available; PNP and NPN. The difference is a result of the internal
circuit design and type of transistors used.

A key point to observe is that PNP and NPN has nothing to do with whether the sensor is normally open (N/O)
or normally closed (N/C), i.e. a PNP sensor may be either N/O or N/C as can an NPN be either N/O or N/C.
 
Why two types?

The selection of a PNP sensor verses an NPN sensor is determined by the nature of the circuit the device is to
be used in. When used in a traditional relay type control circuit, it is normally possible to use either the PNP or
the NPN type of sensor as shown below. PNP sensors tend to be more commonly used. 
Traditional relay type control circuit wiring:

                    
Use with a programmable logic controller (PLC).

When selecting a sensor to be used with a PLC, it is very important that the sensor matches the type
of PLC input card to be used.
Two types of input cards exist, those that 'sink'  current (also known as positive logic) and those that 'source'
current (also known as negative logic). It is worth mentioning, that whilst the terms sinking / sourcing and
positive / negative logic are well known in some industries, they are not always commonly used terms. It is
therefore important to identify the type of sensor to be used with the PLC card based on the
PLC manufacturer's documentation and / or wiring diagrams.
Most common in Europe is the 'sinking' type of input, these will be used with the PNP sensor as shown below.
Less common nowadays are input cards that 'source', these were popular in Asia and require the NPN type of
sensor in order to operate correctly. Many modern PLC input cards can be configured and wired to be either
'sinking' or 'sourcing'  although it will usually necessitate all inputs on a particular input card being configured
the same. 

 
Industrial Sensing Fundamentals – Back to the Basics: NPN vs PNP
When it comes to wiring a sensor, you can think of the “N” as standing for “Negative”
and the “P” as standing for “Positive”. With respect to sensors, an NPN device is one
that can switch the negative side of the circuit while a PNP device switches the positive
side.

The next question to ask is, what direction do you want the current to flow?

PNP sensors are sometimes called “sourcing sensors” because they source positive

power to the output. NPN sensors are sometime called “sinking sensors” because they
sink ground to the output.

 The term “load” identifies the device the sensor powers. The load could be a lamp,
pneumatic valve, relay or PLC input.
Types of Discrete Electrical Outputs – The majority of sensors used today use Solid-
State outputs, not mechanical relays

The drawing below shows 2 wires for sensor power and 2 for the switch. Most sensors
use only 3 wires by having one wire do double duty, carrying both power and output
signals. This is similar to a bathroom with only one line carrying water to both the sink
and toilet as opposed to individual lines for each. Solid-state discrete sensors functions
similar to a switch, but current only flows in one direction. Solid-state devices are
reliable, economical, small and fast. The only drawback is, that you have to know the
direction of current flow. NPN and PNP are technical terms for the type of transistor
used to switch the output. The type of transistor determines the direction of current flow.
Basic Operating Principle of an Capacitive
Proximity Sensor
A basic proximity sensor is used to sense the presence of objects or materials. What
differentiates them from other sensors is that they don’t make physical contact with the
object being sensed, and hence they’re also known as non-contact sensors.

The diagram shows the internal construction of a capacitive proximity sensor with the
internal plate connected to the oscillator (sensor electrodes), and the other being the sensed
object, which is detected within the electric field.

One of the most common sensor types is the capacitive proximity sensor. As the name
suggests, capacitive proximity sensors operate by noting a change in the capacitance
read by the sensor. A typical capacitor consists of two conductive elements (sometimes
called plates) separated by some kind of insulating material that can be one of many
different types including ceramic, plastic, paper, or other materials.
 Typical capacitive proximity sensors, such as those shown here from AutomationDirect,
feature variable sensing distances, in this case from 2 up to 40 mm and can sense metal and
non-metal objects. They also feature LED status indicators to help easily verify operation and
are IP65 and IP67 rated for use in extreme environments.

The way a capacitive proximity sensor works is that one of the conductive elements, or
plates, is inside the sensor itself while the other one is the object to be sensed. The
internal plate is connected to an oscillator circuit that generates an electric field. The air
gap between the internal plate and the external object serves as the insulator or
dielectric material. When an object is present, that changes the capacitance value and
registers as the presences of the object.

Capacitive proximity sensors are useful in detecting a wide range of objects. The
easiest types of objects to detect are ones with a high density (such as metals) or a high
dielectric constant (i.e. water). And detecting these objects doesn’t require that the
sensors be fairly close to the objects to be detected, another plus if used in settings with
little space to work in. Overall, good sensing targets for capacitive sensors include
solids and liquids such as various metals, water, wood and plastic.

A typical sensing range for capacitive proximity sensors is from a few millimeters up to
about 1 in. (or 25 mm), and some sensors have an extended range up to 2 in. Where
capacitive sensors really excel, however, is in applications where they must detect
objects through some kind of material such as a bag, bin, or box. They can tune out
non-metallic containers and can be tuned or set to detect different levels of liquids or
solid materials
Basic Operating Principle of an Inductive
Proximity Sensor
At the heart of an Inductive Proximity Sensor is an electronic oscillator consisting of an
inductive coil made of numerous turns of very fine copper wire, a capacitor for storing
electrical charge, and an energy source to provide electrical excitation. The size of the
inductive coil and the capacitor are matched to produce a self-sustaining sine wave
oscillation at a fixed frequency.  The coil and the capacitor act like two electrical springs
with a weight hung between them, constantly pushing electrons back and forth between
each other.  Electrical energy is fed into the circuit to initiate and sustain the oscillation.
Without sustaining energy, the oscillation would collapse due to the small power losses
from the electrical resistance of the thin copper wire in the coil and other parasitic
losses.

The oscillation produces an electromagnetic field in front of the sensor, because the coil
is located right behind the “face” of the sensor.  The technical name of the sensor face
is “active surface”.

When a piece of conductive metal enters the zone defined by the boundaries of the
electromagnetic field, some of the energy of oscillation is transferred into the metal of
the target. This transferred energy appears as tiny circulating electrical currents called
eddy currents.  This is why inductive proxes are sometimes called eddy current sensors.

The flowing eddy currents encounter electrical resistance as they try to circulate. This
creates a small amount of power loss in the form of heat (just like a little electric heater).
The power loss is not entirely replaced by the sensor’s internal energy source, so the
amplitude (the level or intensity) of the sensor’s oscillation decreases.  Eventually, the
oscillation diminishes to the point that another internal circuit called a Schmitt Trigger
detects that the level has fallen below a pre-determined threshold.This threshold is the
level where the presence of a metal target is definitely confirmed.  Upon detection of the
target by the Schmitt Trigger, the sensor’s output is switched on.

 The short animation to the right shows the effect of a metal target on the sensor’s
oscillating magnetic field.  When you see the cable coming out of the sensor turn
red, it means that metal was detected and the sensor has been switched on.
When the target goes away, you can see that the oscillation returns to its
maximum level and the sensor’s output is switched back off.

Supporting Video:

1.https://www.youtube.com/watch?v=ltY_IN13KJw
2.https://automation-insights.blog/2014/03/05/basic-operating-principle-of-an-inductive-
proximity-sensor/

3. https://www.youtube.com/watch?v=kNVaIqmKUoI