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Guide to choosing industrial sensors - tips and comparisons

July 26, 2024
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Guide to choosing industrial sensors - tips and comparisons-0

Industrial sensors are at the heart of modern manufacturing and process control systems, ensuring efficiency, reliability, and safety. Did you know that choosing the right sensor can make a huge difference to the performance of your production processes? In this guide, you will learn how to choose the right industrial sensors based on different factors and needs. By reading this article, you will gain practical knowledge and tips to help you optimize your industrial processes and increase productivity.

In this article, we will look at the main factors to consider when choosing industrial sensors and give an overview of the different types of sensors.

Table of contents:

Sensor applications and objectives

The first step in selecting industrial sensors is to define the purpose of the application clearly. Where, what, and how will be sensed and monitored. You also need to understand the factors related to the environmental conditions in which the sensors will operate.

  • Environmental conditions: Consider factors such as temperature, humidity, pressure, and the presence of dust, moisture, or chemicals. Sensors must be able to endure environmental conditions without compromising their performance.
  • Facility size: Determine the physical constraints of the area where the sensors will be installed. Consider factors such as available space, mounting options, and maintenance access.
    Number of tasks: Assess the complexity of the tasks to be performed by the sensor. Determine whether multiple sensors are required to monitor different parameters or whether a single multifunctional sensor is sufficient.
  • Degree of durability and housing protection: Assess the level of protection of the sensors against mechanical shock, vibration, and exposure to chemicals or harsh environments.
  • Cost: Although cost is an important consideration, it should not be the sole determining factor. Consider the long-term benefits and reliability of the sensors compared to the initial investment.

Industrial position sensors

Each type of industrial position sensor offers unique features and benefits to meet specific application requirements. No matter what your application, whether it's detecting the presence of objects, monitoring positioning accuracy, or sorting objects by color or contrast.

Criteria for selecting position sensors

  • Response time: the time it takes for the sensor to detect an object and transmit an output signal
  • Operating range: The maximum distance over which the sensor can reliably detect objects.
  • Resolution: The smallest detectable change in distance or position.
  • Sensitivity: The ability of a sensor to detect objects with low reflectivity or small cross-sections.
  • Electrical connection: Select sensors with compatible electrical connections so that they can be easily integrated into existing systems
  • Power supply: Determine the power requirements of the sensor and ensure compatibility with available power supplies.
  • Mechanical connection: Consider mounting options and mechanical compatibility of the sensor with the application.
  • Process temperature: Ensure that the sensor can operate within the temperature range of the application without degradation of performance.

Types and applications of position sensors

Mechanical limit switches

Gala slēdzis XCKNMechanical limit switches are simple but mechanically robust physical contact switches that provide discrete on/off signals when a moving object reaches a predefined position or limit. They will be a reliable solution for end-of-motion detection or condition monitoring in industrial machinery and equipment. One of the most important parts of mechanical switches is the actuator, or switch head, which is in physical contact with the object to be detected; its selection must take into account the characteristics of the object to be detected and its movement.

Photoelectric sensors

Foto devējs 50x50 1m, PNP, DC , XUK5APANM12 TelemecaniquePhotoelectric or simply photo sensors use a beam of light to detect the presence or absence of objects. They are available in a variety of configurations and will be suitable for a very wide range of applications in industrial environments, but there are a number of aspects to consider when selecting photo sensors.

Working principles of photosensors

  1. The light beam is reflected from the object itself. Note that the reflection properties of the object are important.
  2. The light beam is reflected from the reflector. Advantage in the detection of various transparent or shiny objects.
  3. A passing beam of light between two components - transmitter and receiver. Suitable for longer distances and more difficult working environments.

Type of light beam

  1. Visible diffuse light beam. Suitable for most object detection solutions.
  2. Infrared light beam. Better able to detect objects in dusty and harsh working conditions.
  3. Visible laser beam. Suitable for small and precise parts.

Inductive sensors

Inductive sensor XS118B3PAM12 TelemecaniqueInductive sensors use electromagnetic induction to detect the presence of metal objects without physical contact. They are commonly used to determine the position of various metal parts, for example, to detect the presence of components in production equipment or to monitor the movement of a conveyor belt.

One of the main characteristics of the sensor to be considered in the selection is the settling distance factor, i.e. the operating distance of the sensor at different metal types, the basic range of the sensor specification is the settling distance for steel, for other metals such as aluminum, brass, copper or stainless steel the settling distance decreases. There are also special versions of inductive sensors with a reduction factor of 1, where the operating distance on all metals is the same.

Colour and contrast sensors

Krāsu un kontrasta sensorsColour and contrast sensors detect differences in colour or contrast between objects or surfaces, allowing precise identification and sorting of certain objects. They are commonly used in packaging, printing and quality control solutions. Given that the processes in these solutions are typically fast, the response time required for the sensor to detect the object and transmit an output signal must be taken into account when selecting these sensors.


Industrial distance sensors

Distance sensors measure the distance between a sensor and a target object.

Distance sensor choice factors

  • Accuracy: The degree of precision and accuracy of the sensor measurement.
  • Resolution: The smallest detectable change in distance or position.
  • Range: The maximum distance at which the sensor can reliably detect objects.
  • Error: The margin of error in a sensor measurement.
  • Signal-to-noise ratio: The ratio between the desired signal and the background noise that affects the reliability of a sensor in a noisy environment.
  • Output type: Select sensors with output signals (analog, digital, or serial) that are compatible with the control system.

Distance sensor types and applications

Ultrasonic sensors

Ultraskaņas sensorsUltrasonic sensors use sound waves to measure the distance to an object. These sensors emit a high-frequency ultrasonic pulse and measure the time it takes for the echo to return after bouncing off the object. The distance is calculated based on the speed of sound in air.

When choosing an ultrasonic sensor, consider

  1. Range,
  2. Accuracy,
  3. Surrounding environment,
  4. The properties of the reflecting object.

The range depends on the power of the sensor, the size of the sensor and the angle of the receiver. Larger sensors can emit and receive stronger signals, while the angle of the sensor beam influences the scattering power. A narrow beam angle focuses sound waves in a particular direction, which can increase range. On the other hand, wider beam angles scatter sound waves over a larger area, which can reduce the range but increase the coverage area.

The accuracy of measurements is generally not affected by environmental conditions such as dirt, dust or fog, but the temperature or humidity of the environment may affect the speed of sound and therefore the accuracy of the measurement.

Surface characteristics of the object - smooth and hard surfaces reflect ultrasound waves better, ensuring high accuracy. On the other hand, soft or absorbent surfaces, such as fabric or foam, may absorb ultrasound waves, reducing the effective range and accuracy.

Laser distance sensors

Laser distance sensors use a beam of laser light to measure distance. They emit a pulse of laser light and measure the time it takes for the pulse to bounce off the object and return to the receiver. These sensors are known for their high accuracy and long range capabilities.

Benefits of choosing laser distance sensors:

  • High accuracy: the ability to measure distances to millimeter or even micron accuracy.
  • Wide range capability: depending on the sensor model, distances from a few millimeters to several kilometers can be measured.
  • Fast response time: suitable for dynamic and fast distance sensing solutions

One of the most important limiting factors is the ambient conditions such as dust, fog or rain, which can scatter the laser light beam and affect the accuracy of the measurement.

Sensor comparison

Sensor type Advantages Operating conditions
Mechanical limit switches Reliable, mechanically robust End-of-motion detection
Photoelectric sensors Versatile configurations Detection of various objects in industrial environments
Inductive sensors Detection without physical contact Detection of metallic objects
Color and contrast sensors Fast operation, precise object sorting Packaging, printing, quality control
Ultrasonic sensors Use of sound waves, precision Dirt, dust, fog, but sensitive to temperature and humidity
Laser distance sensors High accuracy, wide range  High accuracy but sensitive to environmental conditions

 

Each sensor type offers unique features and benefits to suit your individual application requirements. Whether it's object detection, positioning, or distance sensing, industrial sensors play a vital role in improving automation, efficiency, and productivity in industrial environments.

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Contact the manager
Juris Vuškāns
Juris Vuškāns
Industrial Sensor Specialist
+371 2411 0541
juris@lasma.eu
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