Sensor Learning Course

Sensor Learning Course
12.1 Sensor Learning Course—Learning Module 23: Limit Switches,

Limit Switches
Proximity Sensors and Photoelectric Sensors 12
Overview—Eaton University Training . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-2 12
Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-4
Sensor Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-4 12
Review 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-6
12
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-7
Actuators and Operating Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-9 12
Limit Switch Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-12
Review 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-14 12
Inductive Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-15
12
Review 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-17
Inductive Proximity Sensor Influences . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-18 12
Review 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-20
Capacitive Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-21 12
12
Proximity Sensors Capacitive Proximity Sensor Influences . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-22
Review 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-23
Photoelectric Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-24 12
Photoelectric Sensor Styles and Uses . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-26
Modes of Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-27 12
Review 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-29
12
Excess Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-30
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-32 12
Review 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-32
Photoelectric Sensors
Sensor Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-33 12
Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-36
12
Output Timing Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-37
Review 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-38 12
Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-39
IEC Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-40 12
Review Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-42
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For Customer Service in the U.S. call 1-877-ETN CARE (386-2273),
in Canada call 1-800-268-3578.
12
For Application Assistance in the U.S. and Canada
call 1-800-426-9184. 12
Volume 8—Sensing Solutions CA08100010E—September 2017 www.eaton.com V8-T12-1

Revision notes
Volume 8—Sensing Solutions, CA08100010E

Tab 12—Sensor Learning Course
Revision date Section Change page(s) Description
09/08/2017 12.1 V8-T12-24 Content edit
09/08/2017 12.1 V8-T12-28–V8-T12-30 Content edit
09/08/2017 12.1 V8-T12-40, V8-T12-41 Content edit
09/08/2017 All All Revision date changed to September 2017 to match printed volume
12.1 Sensor Learning Course
Learning Module 23: Limit Switches, Proximity Sensors and Photoelectric Sensors
Contents
12 Limit Switches, Proximity Sensors and Photoelectric Sensors
Description Page
12 Learning Module 23: Limit Switches,
Proximity Sensors and Photoelectric Sensors
12 Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-4
Sensor Basics . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-4
12 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-7
Actuators and Operating Heads . . . . . . . . . . . . V8-T12-9
12 Limit Switch Types . . . . . . . . . . . . . . . . . . . . . . V8-T12-12
Inductive Proximity Sensors . . . . . . . . . . . . . . V8-T12-15
12 Inductive Proximity Sensor Influences . . . . . . .
Capacitive Proximity Sensors . . . . . . . . . . . . . .
V8-T12-18
V8-T12-21
12 Capacitive Proximity Sensor Influences . . . . . .
Photoelectric Sensors . . . . . . . . . . . . . . . . . . .
V8-T12-22
V8-T12-24
12 Photoelectric Sensor Styles and Uses . . . . . . .
Modes of Detection . . . . . . . . . . . . . . . . . . . . .
V8-T12-26
V8-T12-27
12 Excess Gain . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . .
V8-T12-30
V8-T12-32
12 Sensor Output Circuits . . . . . . . . . . . . . . . . . . .
Switching Logic . . . . . . . . . . . . . . . . . . . . . . . .
V8-T12-33
V8-T12-36
12 Output Timing Modes . . . . . . . . . . . . . . . . . . .

Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . .
V8-T12-37
V8-T12-39
12
IEC Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . V8-T12-40
Review Answers . . . . . . . . . . . . . . . . . . . . . . . V8-T12-42
12
12 Overview—Eaton University Training
12 Limit Switches, Proximity Sensors and Photoelectric Sensors
Knowledge Training at Eaton About Eaton University

12 Powers Corporation Training
Success.
12 It takes knowledge to
The following pages contain a Eaton University Training Eaton University Training
12 succeed. But, knowledge
doesn’t just happen. It’s a
complete learning course that
will take you through the
exists to keep you, our
partners, at the cutting edge
educational programs put you
directly on the path to career
continuous process of basic operation and of technical and professional success. We partner with you
12 learning. Only lifelong application of limit switches, development. We provide to determine your knowledge
learning allows you to keep inductive and capacitive education solutions, promote needs and help you apply
12 in step with a world that proximity sensors, and a learning culture and foster what you learned. And we’re
is constantly changing. photoelectric sensors. talent development for our committed to ensuring that
12 So, you need to get smarter
Whether you’re a novice
looking to get up to speed
employees, channel partners,
industry and academia.
you gain maximum return
from your time and
about learning and explore
12 new ways of thinking. You
fast, or are already
experienced in this area and We share our knowledge
investment.
need to take advantage of just want to sharpen your resources in a number of To browse the latest
12 new experiences and employ
cutting edge technologies.
skills, this course will be time ways: from traditional
classroom to paper-based
course offerings and
register on-line, visit us at
well spent.
12 Assess and develop your This course is part of the 101
distance learning programs to
a complete web-based virtual
EatonUniversity@eaton.com.
talents. Empower yourself to Basics Series from Eaton learning environment at our
12 find the answers and University Training, a electronic campus.
solutions of tomorrow. comprehensive series of
12 Learn. learning modules covering a
Succeed. wide variety of power and
12 control subjects.
12
12
12
V8-T12-2 Volume 8—Sensing Solutions CA08100010E—September 2017 www.eaton.com

12.1
Classroom Interactions
Eaton University Training ● Discover product features, And it doesn’t end there.
12
classroom activities encourage
interaction, collaboration and
benefits and applications in
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Eaton University Training
offers a full spectrum of 12
participation. You play an solutions seminar personal and professional
integral role in what happens. ● Gain hands-on experience development options. As 12
Experienced instructors maintaining electrical new learning needs are
facilitate a learning equipment or solving identified, our course 12
environment where you can simulated power quality offerings change to help
feel comfortable making
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problems in one of our
state-of-the-art laboratories
you meet new challenges.
12
questions. The result is
a seamless classroom to
● Become qualified in
Information Technology
12
on-the-job transition that
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solutions by Eaton, such
as Bid Manager or Vista, 12
your newfound knowledge, in a computer training class
making you and your ● Collaborate with your 12
company more productive
peers in one of our talent
and competitive.
development workshops 12
12
12
12
12
Virtual Campus Customized Learning 12
Our virtual campus offers Can’t find what you’re looking Start planning your customized
knowledge resources for? Please contact us. Eaton learning. E-mail us at 12
accessible from anywhere in University Training has EatonUniversity@eaton.com.
the world, 24 hours a day,
and 7 days a week. It’s
course consultants that work
with you to customize a class We look forward to helping 12
power your success.
where you go to register for
classroom opportunities,
or make recommendations
based on your personal Eaton University Training
12
participate in on-line learning needs.
courses, or search our library
at Eaton Corporation …
12
for learning tools including For example:
Knowledge
educational videos and ● Bring a class to your Powers 12
technical documentation. You location, saving you time Success.
control the content, timing
and pace of your learning
away from the plant or 12
office
program. ● Customize an existing 12
As technology evolves, Eaton class, placing emphasis on
University Training commits
to giving you access to the
the subjects your group
needs most
12
most effective learning Receive Eaton University
12
●
tools—right from your product training outside of

desktop. the regularly scheduled
courses 12
As an Eaton distributor, you
● Connect with technical
can access Eaton University
via the Distributor Resource experts who will answer 12
Center on www.eaton.com. your specific questions
Employees can access us on 12
the Eaton University Intranet.
12
12
12
12

Welcome
12
12 Typical Sensors Welcome to Module 23, which is about sensors. As the name implies,
sensors are devices that sense the presence or absence of objects.
Sensors perform a number of functions in automated manufacturing and
12 material handling systems. For example, sensors can determine if an object
is present, if tooling is broken, or if product is running down a conveyor line.
12 This module will take you through the basic operation and application of
three major sensor categories: Limit Switches, Proximity Sensors and
12 Photoelectric Sensors.
12 Like the other modules in this series, this one presents small, manageable
sections of new material followed by a series of questions about that
material. Study the material carefully then answer the questions without
12 referring back to what you’ve just read. You are the best judge of how well
you grasp the material. Review the material as often as you think necessary.
12 The most important thing is establishing a solid foundation to build on as you
move from topic to topic and module to module.
12
12 A Note on Font Styles
Key points are in bold.
12
12 Sensor Basics
A manual switch enables an Sensors have contributed Limit Switch Proximity Sensor
12 operator to interact with a significantly to recent
Limit Switch with Standard Proximity Sensor Types
machine. If, for example, an advances in manufacturing
Roller Lever
12 operator sees a problem on a
manufacturing line, he could
technology. Using a sensor
makes a process or system
move a switch to stop the more automated and
12 line. Or, think of a light switch removes the need for human
in your home. If you (the operators to monitor and
12 operator) want the light control the situation.
turned on, you have to move
12 the switch. The three main categories of
sensors are limit switches,
A sensor can be thought of proximity sensors and
12 as an automatic switch. In a photoelectric sensors. Let’s
factory, a sensor can be used take a moment to look at A limit switch is an This type of sensor uses an
12 to detect a problem on the each type of sensor. electromechanical device.
A part of the limit switch,
electromagnetic field to
detect when an object is
line and stop the line
12 automatically. Or, in your
home, a sensor could be
called an Actuator, is placed
in the path of an oncoming
near. There is no physical
contact between the object
used as a security device object, such as a box on a and the sensor. Inductive
12 to detect an open window conveyor. When the object proximity sensors detect only
or door. contacts the actuator, the metal objects. Capacitive
12 contacts in the limit switch proximity sensors can sense
are opened (or closed, both metallic and non-metallic
12 depending on the limit
switch’s design) to stop
objects.
Think of a manufacturing
12
(or start) the flow of current
in the electrical circuit. process where the alignment
of a part is critical. A
12 proximity sensor can be used
to make sure the part is
12 aligned within a certain
tolerance. If the part is not
properly aligned, the
12 proximity sensor will be
triggered.
12 This type of sensor is
generally used to sense at
12 distances less than one inch.
12

12.1
Photoelectric Sensor
A Diffuse Reflective sensor A Retroflective Sensing Most electric garage door
12
emits a light beam that must sensor emits a light beam openers include a
be reflected back to it by that is reflected back to the photoelectric sensor for 12
the target object itself for sensor from a retroreflector. safety reasons. If the
detection to occur. When an object blocks the photoelectric sensor’s beam 12
beam between the sensor is broken (by a child for
12
Diffuse Reflective— and the retroreflector, example) as the door is going
Beam Not Complete detection occurs. We’ll cover down, the sensor signals the
Source
more on these types of
photoelectric sensors later in
door opener to reverse the
direction of the door. 12
This type of sensor uses this module.
light to detect the presence
Detector
Retro-Reflective/Reflex
Although environmental
factors can affect
12
or absence of an object.
A Thru-Beam photoelectric Diffuse Reflective—
Mode—Beam Complete photoelectric sensors, these
devices have a long sensing 12
sensor uses two devices (a Object Detected range. The objects they
light source and a detector)
Source
detect can be of any material. 12
facing each other. Detection Detector
Source
occurs when an object blocks
Detector
12
or breaks the beam of light
passing between them. Retro-Reflective/Reflex
Mode—Object Detected 12
Thru-Beam—
Beam Complete 12
Source
Source Detector
Detector
12
12
Thru-Beam—
Object Detected 12
Source Detector 12
12
Sensor Comparison 12
Each of the three sensor
categories has its strengths
The table below provides
you with a comparison. 12
and weaknesses.
12
Sensor Category Comparison
Limit Switches Proximity Sensors Photoelectric Sensors 12
Method of Detection Physical contact Electromagnetic field Light beam
Sensing Range Physical contact Close: within 1 in (25.44 mm) Far: can be 800 ft (243.8 m)
12
Target Material Target must be able to withstand
physical contact
Inductive: metallic only
Capacitive: metallic and non-metallic
Can be affected by target surface, for
example, if the target is shiny or 12
transparent
Object Markings Not able to detect Not able to detect Able to detect 12
12
Cost Low Low Low to high depending upon sensing
method
12
Sensor Size Tend to be large Small to large Very small (fiber optic) to large
Environmental Sensitivity Affected by debris Inductive: electrical interference Light interference
Capacitive: humidity
Response Time Milliseconds Milliseconds Microseconds 12
12
12
12
12

In the Workplace Review 1

12
12 As a conveyor moves the stacked boxes onto a turntable, a Answer the following questions without referring to the material
just presented. Begin the next section when you are confident
sensor detects the boxes in position and tells the machine to
12 start the turntable and index the wrapping material. Another
sensor monitors the play out of wrapping material to detect an
that you understand what you’ve already read.
12 empty spool and alert set-up personnel. Once the operation

ends, the wrapped boxes move on to their shipping destination.
1. Sensors can detect the ___________ or __________ of
objects.
12 2. The three main sensor categories are:
12 ________________________
________________________
12 ________________________
12 3. A limit switch is an _____________________ device that
12 relies on physical contact with the target.
12 4. The sensor type that can only detect metallic objects is the
_________________ sensor.
12
The Sensor “Sees” the Box and Tells the Wrapping
5. The sensor type that uses a broken beam of light to detect
12 Machine to Begin Operating objects is commonly referred to as a ____________________
Thanks to sensors, the repetitive and tedious work done in sensor.
12 this factory is handled precisely and reliably by machinery
and control systems working together. Answers to Review 1 are on Page V8-T12-42.
12
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12.1
Limit Switches
Let’s now take an in-depth Strengths and Weaknesses
12
Limit Switch Components
look at the limit switch. It is
a commonly used device. If
As with all devices, the limit
switch has its strengths and
A limit switch consists of 12
three main components.
you look around your kitchen,
you can find a number of limit
weaknesses:
12
switches. For example, limit Limit Switch Attributes Limit Switch Components
switches stop your micro- Attributes 12
wave oven from operating
unless the door is closed, and
they ensure the light in your
Strengths
Can be used in almost any industrial
Actuator/Operating Head
12
refrigerator is only on when
12
environment because of its rugged design
the door is opened. Can switch high inductance loads up to
10 amps
Remember, a limit switch is
a mechanical device that Very precise in terms of accuracy and
12
Switch
repeatability
requires the physical
contact of an object with Low cost
Body
12
the switch’s actuator to
make the contacts change
Weaknesses
Moving mechanical parts wear out
12
state. The term limit switch
is derived from this operation Must touch target to sense Receptacle/
Terminals Receptacle/
12
of the switch. As the object Relatively slow (five times/sec.) compared
Terminals
(or target) makes contact
with the operator of the
to electronic devices
12
switch, it eventually moves
the actuator to the “limit” Applications The actuator is the part of The switch body is the 12
where the contacts change Limit switches are used in a the limit switch that physically component that contains the
state. variety of applications. comes in contact with the
target. In some limit switches,
electrical contact mechanism.
12
Consider these: The terminal screw or screw/
the actuator is attached to an
Limit Switch with
Adjustable Roller Arm Limit switches can be used to operating head. The clamp assembly necessary 12
turn off a washing machine if operating head translates a for wiring is referred to as the
the load becomes rotary, linear or perpendicular receptacle. 12
unbalanced. In automobiles, “triggering” motion into the
they turn on lights when the
door is opened.
motion type needed to open
or close the electrical
12
In industry, limit switches are
contacts of the switch.
12
used to limit the travel of
machine parts, sequence In the Workplace 12
operations or to detect
moving items on a conveyor
system. At the Marathon T-Shirt Company, boxes of apparel approach
12
the end of the packaging line, ready to be stacked onto pallets.
A palletizer with suction-cup grippers picks up a box and swings 12
This mechanical action either it around to a waiting pallet.
opens (in a Normally Closed 12
[NC] circuit) or closes (in a
Normally Open [NO] circuit)
the electrical contacts. The
12
contacts then start or stop
the flow of current in the 12
electrical circuit.
12
The switching function can
be used to control loads from
simple relays to high-current
12
solenoids, from logic devices
to PLCs. 12
A Limit Switch in Action
12
How does the unit know it has reached its sixth layer of boxes?
When the pivot arm reaches the top of its vertical travel rod, the 12
arm hits a limit switch. The switch signals the system to send
the full pallet down line and sets up an empty pallet to restart 12
the process.
12

Limit Switch Movement Limit Switch Movement Definitions

12 Let’s take a closer look at what actually happens as a limit Here are a few other terms The total travel is the
switch is activated. Imagine a target object moving toward a that are used in describing maximum allowable distance
12 limit switch actuator. the movement of the limit the actuating element can
switch actuator: travel.
12 Limit Switch Movement
The operating force is the The ability of a switch to
Pre-Travel
12 Operating
Point
force required to move the
actuating element.
repeat its characteristics
precisely from one operation
to the next is called the
12 Initial Position
The minimum return force
is the minimum force
switch’s repeat accuracy.
12 Over-Travel
required to return the
actuator to its initial position.
12
In the Workplace
12
Reset Point
Inside this sawmill, a high-speed saw quickly reduces logs to
12 construction beams.
12
Differential
12
12
12 1. The actuator is at its 4. The differential is the
initial position. The limit difference between
12 switch contacts are in the operating and release
their normal point. Differential is
12 “untriggered” position. engineered into the
switch to guard against
2. Contact is made with the
12 target object and the
the effects of vibration
and rapid ON/OFF
actuator moves its pre- oscillations of the Limit Switches Working Where People Cannot
12 travel distance. Contacts switch right at the In the process, chips and dust hang in the air. Breathing is
are still in their normal operating point. impossible in the area without a mask. Even with goggles, it
12 “untriggered” position. would be impossible to inspect the cutting.
3. The actuator reaches its
12 operating point where The production department devised a system of limit switches
to do the inspecting automatically. A remote operator can
the contacts change
12 from their normal
“untriggered” position to
configure a set of limit switches to allow the log to be cut to the
desired dimensions.
12 their “triggered”
position.
12
12 Notes
In the case of a lever actuator, there is some over-travel allowing the
12 lever to move beyond the operating point.
12
On plunger actuators, the overtravel distance is a safety margin for the
sensor to avoid breakage.
12 The actuator begins the return to its initial position. The contacts return to
their normal “untriggered” position as the actuator reaches its release
12
point and resets the contacts.
12
12
12

12.1
Actuators and Operating Heads
Choosing the proper actuator Operating heads fall into two With a maintained contact Actuators can take the form
12
(also called an operating
head) for a limit switch
broad types: Maintained
Contact and Momentary
operating head, the contacts
remain in the “triggered”
of rotary levers or plungers.
We will look at specific 12
depends on a number of Contact. Momentary position even after the actuator types on the next
application-specific factors. contacts return to their actuator has been released. few pages. 12
To select an actuator, you normal state as soon as They are reset only by
need to know shape, the actuator passes its further mechanical action 12
speed, direction and total release point. This type of of the operating head. For
travel specifications. operating head is also called
“spring-return.”
example, on rotary operating
heads, the contacts are
12
reset by rotation in the
opposite direction. 12
Rotary Lever Actuators 12
A typical lever actuator The rotation may be A rotary lever actuator is Let’s take a look at the
functions something like this:
a cam or plate hits the end
momentary (spring-returned)
or maintained. A lever arm
usually the best choice for
the majority of applications. It
different rotary lever actuator
types available.
12
of the lever arm, which
rotates a shaft and
can be a rod or a roller of a
fixed or adjustable size. It
can be used in any application
where the cam moves 12
operates the contacts in the may be made from any perpendicular to the lever’s
switch. number of materials. rotational shaft. This type of 12
actuator also offers the
benefit of a long life. 12
Rotary Lever Actuators and Limit Switches 12
Lever Type Application
Standard Roller Standard roller Used for most rotary lever applications. Available in various lengths. Roller 12
typically made of Nylatron® for smooth operation and long wear.
12
12
Ball Bearing Roller Ball bearing roller Used where abrasive dust would cause undue wear of standard nylatron rollers.
Also used with high-speed cams. 12
12
12
Adjustable Length Adjustable length Used where the length of arm required is not known when devices are ordered or
12
where the target size or location may change from day to day. An operator can
adjust the arm length before beginning production. 12
12
Forked Forked Used with maintained contact style switches. When rollers are on opposite
sides, one cam will trip the switch and the second will reset the switch. When
12
12
rollers are on the same side, one cam trips and resets the switch. Applied where
the target approaches from two sides, such as a grinder that works back and
forth.
12
Offset Offset Used to obtain different cam track dimensions.
12
12
12
12
12
12

Rotary Lever Actuators, continued

12 Lever Type Application
12 One-Way Roller One-way roller Used with reversible cams where operation in one direction only is required.
12
12
12
12 Rod or Loop Rod or loop Used where unusual shape is required. Rod is typically made of steel or nylon.
The loop is made of Nylatron.
12
12
12
Spring Rod Spring rod Used on conveyors where jam-ups may occur. Flexible rod moves in any direction
and eliminates damage to arm or switch.
12
12
Plunger Actuators
12 A typical plunger actuator A plunger actuator is the best Lets take a look at the
functions something like this: choice to monitor short, different plunger actuator
12 a cam or plate hits the end controlled machine types available.
of the plunger, which is movements, or where space
12 pressed in and operates the
contacts in the switch.
or mounting restrictions will
not permit the use of a lever
12 actuator.
12 Plunger Actuators of Various Limit Switches

12 Top Push Rod Top push rod Actuation must be done in line with plunger axis. Care should be taken to avoid
exceeding the overtravel stated by the manufacturer. A mechanical stop should
12
be used where the possibility of overtravel exists.
12
12
12 Side Push Rod Side push rod Should be used where the mounting permits operating from the side only and not
the top. As with the top push rod, avoid exceeding recommended overtravel.
12
Available in both momentary and maintained styles.
12
12
Top and Side Top and side push roller The function is similar to push rod styles, except there is a roller attached to the
12 Push Roller end of the rod. Typically used where a lever arm will not fit for lateral actuation.
Roller can be positioned either vertically or horizontally.
12
12
Pin Pin Most often used where extremely small differentials and operating forces are
12 required.
12
12

12.1
Plunger Actuators, continued
12
Straight Straight Used where the actuating element travels in same axis as plunger. Available in
standard and extended lengths. 12
12
12
Lever Lever Used in applications where the cam actuates in line with the plunger but may
require a larger differential or where an appreciable side thrust is present. 12
12
12
Roller Level Roller level Used in applications where the cam will pass by the switch laterally. 12
12
12
12
Roller Plunger Roller plunger Used in applications where the cam may present some degree of side thrust.
Roller helps deflect this. 12
12
12
Cat Whisker and Cat whisker and wobble stick Typically used in conveyor applications to count objects as they pass by. Can be 12
Wobble Stick actuated in any direction.
12
12
12
12
12
Mounting Considerations
When applying mechanical limit switches, consideration of the type of actuation needed,
12
the mounting locale of the device and the speed of actuation are very important.
12
Cam Design Cam Design When using side-push or top-
The cam angle should equal 48° 48°
push plunger actuators, be 12
the lever arm angle for sure the cam operates in line
applications where the cam with the push rod axis. Do 12
will not overtravel the Cam not use the limit switch
actuator. Where relatively body to act as a mechanical
stop for the cam in
12
fast motions are involved, the 48°
cam should be of a shape
that does not allow the
overtravel applications.
Some other type of barrier 12
actuator to receive a severe must be provided as the stop.
impact, or that releases the 12
actuator suddenly allowing it
to snap back freely. 12
12
12

Mounting Location
12 Limit switches should In applications where In the Workplace
never be mounted in machining chips or other
12 locations that could allow debris accumulates, the limit
false operations by normal switch should be mounted in At this leading frozen food processor, an automatic pallet
12 movements of operator or a location, or at such an stacking system is used. This system uses a wobble stick limit
machine components. They angle, that minimizes buildup switch to detect when the pallets have been loaded to their
12 should be mounted rigidly, be
maintenance accessible and
on the operating head. desired level.
12 have the cover plate facing

that access point.
12 If liquid intrusion is a
possibility, the switch should
12 be mounted face down to
allow gravity to prevent
seepage through the seals on
12 the operating head. All
conduit connections should
12 be tightly sealed.
12
12
12 Into the Freezer
The switch then signals the conveyor to send the load through
12 an automatic vertical rise door into the freezer for quick freezing.
12 Limit Switch Types

12 There are three basic classifications of limit switches available.
● Standard industrial
12 ● Hazardous location
● Precision
12 Let’s spend some time looking at each.
12 Standard Industrial Switch

12 Often the first choice for
industrial applications, this
Standard Industrial Switch Most limit switches on the
market today are a plug-in
Non plug-in types are a
popular design for DIN rail
switch functions in a variety type design, which means mounted limit switches.
12 of rugged industrial that the operating head, These switches are built to
environments. This type switch body and receptacle meet dimensional and
12 of switch can be subjected 1 are separate components. If operational standards set in
to oil, grease, dirt, high- the switch becomes Europe. They have typically
12 pressure wash-down,
shock, vibration, and so on.
damaged or fails, it can be
replaced in the field in less
the same electrical contact
and enclosure ratings as
12 Typically, these devices
meet NEMA® enclosure
than a minute, without
rewiring the switch. Simply
the regular heavy-duty
switches, but often their
ratings of 1, 3, 3S, 4, 6, 12 remove the switch body, and electrical and mechanical
12 and 13. An explanation of the wiring remains intact in life is not as long. They are
these ratings can be found the receptacle. The majority an economical alternative for
12 in “Enclosure Ratings” of new industrial applications applications where the switch
on Page V8-T12-39. 2 3 use the plug-in type due to its is not subjected to physical
12 flexibility and ruggedness. abuse.
12 1 Actuator/Operating Head
2 Switch Body
12 3 Receptacle/Terminals
12
12

12.1
Hazardous Location Switch
The hazardous location Hazardous Location Switch This switch type generally
12
switch is ideal for use in meets NEMA 1
harsh or dangerous requirements, and the 12
environments. This switch is hazardous location
tough enough to contain an requirements of NEMA 7, 12
explosion within itself. Class I, Groups B, C and D;
The one-piece switch body/
and NEMA 9, Class II, Groups
E, F and G. Some
12
receptacle is much heavier
and thicker in construction
manufacturers offer models
rated NEMA 4X and 13 as 12
than standard oil-tight well (see “Enclosure
switches. Like standard oil-
tight switches, hazardous
Ratings” on Page V8-T12-39 12
for more information).
location switches have
removable actuating heads 12
attached to the switch body
with four screws. 12
12
Precision Limit Switch 12
The precision limit switch is Precision Limit Switches Precision switches are
widely used in both
commercial and industrial
typically available in two
types: basic precision and
12
applications, ranging from
appliances to farm
enclosed precision. The basic
precision switch is of one- 12
equipment. It is often piece construction. The
chosen for its precise enclosed precision switch is 12
operating characteristics, simply a basic switch inside a
small size and low cost. die cast housing. Basic 12
precision switches are
generally not given a NEMA
enclosure rating, while some
12
enclosed precision switches
can be rated NEMA 4 or 13. 12
12
12
Special Purpose Limit Switch 12
Some applications require Special Purpose— This type of switch is used to
a limit switch to perform a
special detection function.
Safety Guard ensure safety for the operator
of a dangerous machine. A
12
Let’s take a look at some
of the special purpose
standard limit switch could be
false tripped or false 12
limit switches. actuated, posing a danger to
the person operating the 12
machine.
Actuation of this switch 12
occurs only when a keyed
interlock is inserted into 12
the key slot. The key is
usually mounted on a safety 12
door or machine guard so that
when it is closed, the key
slides into the slot, actuating
12
the switch.
12
12
12
12

Special Purpose— Special Purpose— Special Purpose—

12 Gravity Return Neutral Position Two Step
12 Object
CW
CCW
10° 10°
CW
moves
12 lever CCW 20°

20°
12
12 Weight of lever (gravity)
returns it to free position
12 Unlike other rotary limit With this limit switch, the This switch operates to
switches, this switch has no direction of operation can perform two functions with
12 spring return mechanism.
The weight of the operating
be detected. one switch. One set of
contacts is activated after the
One set of contacts is
12 lever must provide the
force to return it to its free actuated when the lever is
lever is rotated 10°, and
another set is activated at a
position. This switch is moved in one direction, and a 20° rotation (in the same
12 usually mounted with the second set of contacts is
actuated when the lever is
direction).
operating head facing down.
12 It is often used in applications
moved in the other direction. This switch can monitor an
object’s height, orientation,
where very low operating position, completeness of
12 forces from the target are assembly, and so on.
required.
12
12 In the Workplace
Review 2
12 In some manufacturing plants, rooms need to be closed off
Answer the following questions without referring to the material
quickly because of contamination or fire. To help facilitate this
12 process, high-speed doors have been developed. These doors
may move as quickly as six feet per second.
12 1. The three main components of a limit switch are:

________________________
12 ________________________
12 ________________________
12 Match the terminology to the proper description:

2. Initial position ______ A. Distance the actuator can
12 travel safely beyond the
operating point
12 3. Pre-travel distance ______ B. Maximum allowable
distance the actuator can
travel
12 4. Operating point ______ C. Actuator and contacts are
in the normal, or
12 Limit Switches Help Operate This High-Speed Door
untriggered position
5. Overtravel ______ D. Actuator’s position at
12 At such speeds, the door would destroy itself quickly, if not for
which the contacts
change state
the use of limit switches. The limits switches are used to slow
12 the door just before it is fully opened or fully closed.
6. Release point ______ E. Actuator position where
the contacts are reset to
their normal “untriggered”
12 state
7. Total travel ______ F. Actuator travel from
12 contact with the target
until the operating point
12 8. The ability of a switch to repeat its characteristics from
one operation to the next is called the switch’s repeat
12 accuracy. TRUE FALSE
12 Answers to Review 2 are on Page V8-T12-42.

12.1
Inductive Proximity Sensors
The inductive proximity Strengths and Weaknesses Applications
12
sensor can be used to
detect metal objects. It Inductive Proximity
Proximity sensors are used in
a variety of applications.
When a robot arm swings
around for a pick and place
12
does this by creating an Sensor Attributes
electromagnetic field. Attributes
Consider these: operation, a proximity sensor
makes sure the arm actually 12
Proximity sensors can be has a part in its grippers.
With the ability to detect
at close range, inductive
Strengths
Immune to adverse environmental
used to detect the end of
travel on a positioning table, In metal machining, proximity
12
proximity sensors are
12
conditions to determine speed by sensors can make sure the
very useful for precision High switching rate for rapid response counting a gear’s teeth, or be workpiece is mounted in the
measurement and applications used to check if a valve is fixture, and that the drill bit
inspection applications.
Can detect metallic targets through non- fully opened or closed. has not broken off. 12
metallic barriers
Long operational life with virtually
Proximity sensors can be
used to detect the presence
12
unlimited operating cycles
Solid-state to provide a “bounce free” input
or absence of a metallic
workpiece or metallic pallets 12
signal to PLCs and other solid-state logic on conveyor lines.
devices
12
Weaknesses
Limited sensing range 12
(4 in or 100 mm maximu m)
Detects only metal objects 12
May be affected by metal chips
accumulating on sensor face 12
How an Inductive Proximity Sensor Works 12
Inductive proximity sensors
produce an oscillating and
Components
Let’s look at the components
Hysteresis
12
The ferrite core shapes the Hysteresis is an engineered-
invisible radio frequency (RF)
field at the sensor face.
and the process step-by-step: field and the size of the coil
determines the sensing
in difference between the ON
and OFF points.
12
When metal objects are Components range.
brought into this field, this If they were exactly the same 12
oscillating field is affected. The oscillator circuit causes point, there would be a
Each type and size of sensor
has a specific sensing range
the field to cycle at a specific
set radio frequency (100 kHz
chattering—a very rapid on-
off-on-off cycle. That would
12
switch point so that metal
target detection is very
to 1 MHz). The presence of
metal causes a change in the
cause a lot of needless stress
on components activated by 12
accurate and repeatable. oscillation, and an eddy the circuit.
current forms on the target.
Hysteresis
12
The presence of a metallic The metallic object induces a
target interrupts the field and
alters (by damping) the
change in the magnetic field.
This change creates a
Motion Hysterisis 12
current in the sensor coil
12
damping effect on the Operate
(eddy current kill) causing Point
amount of signal that cycles
the detector circuit to sense Release
back to the sensor coil.
the change. The sensor then
Point
12
triggers an output to a The detector circuit senses
connected device. the change and switches ON
at a particular set point
12
(amplitude). This ON signal
generates a signal to the 12
solid-state output.
The output circuit remains
12
A metal object, or target, active until the target leaves
the sensing field. The 12
enters the sensing field.
oscillator responds with an With hysteresis, the operate
The sensor coil is a coil of increase in amplitude, and point and the release point 12
wire typically wound around a when it reaches the set point, are slightly different
ferrite core. If you could see the detector circuit switches distances from the 12
the electromagnetic field OFF. The output returns to its sensor face.
created by it, it would be
cone shaped. The target will
normal state.
12
pass through this field.
12

Proximity Sensor Types

12 Proximity sensors come in a wide variety of designs to meet the requirements of almost any
industrial application. Let’s take a brief look at the types that are available.
12
Proximity Sensors
12 Type Application
12 Modular Limit
Switch Type
Modular limit switch type The modular design can be tailored for many application types. Components can
be easily switched out for short-run manufacturing changes.
12
12
12
12
12
Unitized Limit Unitized limit switch type The sealed body protects the components in corrosive environments.
Switch Type
12
12
12 Tubular Tubular This is the design of choice for a growing number of applications. The small size
allows for easy mounting in a fixture or for use in tight spaces found on many
assembly lines.
12
12
12 Right Angle Tubular Right angle tubular This style enables mounting in tight locations.
12
12 High Current Tubular High current tubular Enables the smaller tubular design to carry extremely large inrush and continuous
currents. Excellent for heavy equipment such as lift trucks.
12
12
Composite Housing Composite housing This corrosion-resistant unit performs well in high wash-down areas such as food
12 processing, or places where caustic chemicals abound.
12
12
Pancake Pancake The extra wide coil on this unit achieves the widest and farthest range available:
12 3.94 in. Ideal for oil rig applications and assembly of large parts.
12
12
12
12
12
12
12

12.1
12
Without proximity sensors, the tips of the digits on the grippers just presented. Begin the next section when you are confident 12
of a robotic arm would be numb. that you understand what you’ve already read.
1. Match the sensor component name to the correct picture. 12
12
1 a. Oscillator ______ 12
b. Output ______
c. Detector ______
12
d. Sensor coil ______ 12
2
12
12
Proximity Sensors Allow a Robotic Arm to Safely Handle Fragile Components
Coupled with the robot’s software control program and the 3

responsive sensing ability of proximity sensors, a robot can
grasp an object and not crush it.
12
4 12
Match the proximity sensor component with its function. 12
2. Sensor coil ______ A. Sets up an
electromagnetic field to 12
create a wave pattern
3. Oscillator ______ B. Alerts the electrical 12
circuit that an object
has been detected 12
4. Detector ______ C. Shapes the
electromagnetic field 12
5. Output ______ D. Looks for a change in
frequency 12
6. Hysteresis is the gap between the operate point 12
and the release point to smooth the operation of
the sensor. TRUE FALSE 12
Answers to Review 3 are on Page V8-T12-42.
12
12
12
12
12
12
12
12
12
12
12

Inductive Proximity Sensor Influences

12
When applying inductive Target Size Target Approach
12 proximity sensors, it is
important to understand the The size of the target also How the target approaches The target should not pass
matters. If you run a target the sensor matters as well. closer than the basic
12 sensing range and the factors
that influence that range. The smaller than the sensor’s When an object comes at the tolerance built into the
sensing range refers to the “standard size,” sensing sensor straight on, that’s an machine design. Targets
12 distance between the range will decrease. This is axial approach. With this bumping into your sensor are
sensor face and the target. because a smaller target type of approach, you will a sure guarantee of eventual
12 It also includes the shape of creates a weaker eddy
current. However, a bigger
need to protect the sensor
physically. Allow for 25%
poor sensor performance.
the sensing field generated For both approach types,
12 through the coil/core. target does not mean a
longer sensing range.
overtravel.
make sure the target
There are four main concerns Axial Approach passes not more than 75%
12 when selecting and applying The thickness of the target
does not impact sensing 2 Sn
of the sensing distance
from the sensor face. It is in
proximity sensors:
12 ● Target considerations
range much. However, a very
thin non-ferrous target can
Sn
Core
this “tip” area that variations
in the sensing range occur.
(material, size, shape and actually achieve a greater
12 approach) sensing range because it
● Coil size and shielding generates an eddy current on
12 ● Sensor mounting both sides (known as the foil
requirements effect).
12 ● Environment So, how big should the target
Hysteresis tends to be
greater for an axial approach
be? The rule of thumb is:
12 the size of the sensor’s
than a lateral approach.
Target Material diameter, or three times the Lateral Approach
12 You need to know the
sensor’s sensing range,
whichever is greater. Recommended
Sensing Area
12 target’s material. This
information will help you D
determine the maximum
12 sensing distance. Exceed this
Target Shape 0.75 x D
Target
distance, and the damping The shape of the target can
12 effect necessary to trip the have an impact on the
sensor’s output will not be sensing range. A round Sensing
12 created—and the sensor will
fail to sense the target.
object, or an object with a
rough surface can affect the
Distance of
Target Used
(Will Be Sn
12 Proximity sensors work
damping effect of the sensor,
and may require a closer
for Standard
Target)
best with ferrous metals.
sensing distance. Using a
12 Though these sensors detect
other metals, the range will
larger sensor size or an On a slide-by, or lateral
extended range sensor will approach, the target
12 not be as great. Generally,
the less iron in the target, the
also minimize this effect. approaches the center axis
of the sensing field from
closer the target has to be to the side.
12 the sensor to be detected.
12 Manufacturers generally
provide charts showing the
necessary correction factors
12 for various types of metals
when applying their sensors.
12 Each sensor style will have a
correction factor to enable
12 calculation for a particular
target material.
12
12
12
12
12

12.1
Coil/Core Size Mounting Considerations
12
An important factor in the For an inductive proximity A shielded sensor can be fully Mounting two sensors
range of the sensor is the
construction of the coil/core.
sensor, the sensor coil that
generates the field fits inside
embedded in a metal
mounting block without
closely together can also be
a problem. If you position
12
An open coil with no core will
produce a field that could be
of a ferrite core. This cup-
shaped piece of ferrite
affecting the range. It is
sometimes referred to as a
two proximity sensors too
close together—either side 12
actuated by a target from any material is called a cup core. flush mount sensor. by side or facing each other
direction. That wouldn’t be This core directs the field and
A non-shielded sensor needs
head to head—the two fields 12
very practical for industrial shapes it. will clash with one another.
applications. clearance around it (called the
metal-free zone) which is
Each sensor needs to be 12
mounted at least three
Coil/Core Construction determined by its sensing
range. Otherwise, the sensor
times its own sensing
range away from the other.
12
will sense the metal
12
The use of an alternative
mounting and be frequency head on one of the
continuously operating. sensors will prevent adjacent
Cap Coil Cup Sensor The design of a sensor can sensors’ sensing fields from 12
Core Head interacting.
affect how it is mounted.
A protective cap prevents Clear Zone
12
dust or other environmental
hazards from entering the 12
sensor.
12
12
12
Shielding
12
To focus the intensity of the Shielding In the Workplace
field, the coil can be
shielded. In a standard range
12
sensor, the ferrite cup core
shapes the field to emanate
At an auto manufacturing plant, a drilling operation is performed
on the valve blocks to allow for mounting the cover plates. The
12
straight from the sensing
face of the sensor. In a
operation is totally unmanned.
12
sense, shielding it.
An extended range coil/core
12
12
assembly does not use the
standard cup core, just a core
of ferrite. This unshielded
device allows the extension 12
of the sensing range. There is
less ferrite to absorb the
electromagnetic field, so its
12
Shielded Non-shielded
range is wider and a little
longer. An Inductive Proximity Sensor Monitors Drilling Operation
12
The decision to use a non- The drill bit must form holes in an extremely hard material. 12
shielded sensor will impact Breaking drill bits is a fairly common occurrence. For this
the mounting of the sensor,
as we will discuss that next.
reason, a proximity sensor is in place. If a break occurs, the 12
sensor signals the system to stop the operation so the drill
bit may be replaced.
12
12
12
12
12
12

Environment
12
The sensor’s environment Radio transceivers (such as Sensing Distance Tolerances
12 can affect its performance
dramatically. Let’s take a look
a walkie-talkie) can
produce a signal with the Target 125%
A
Sensor
75%
12 at some of these
environmental factors.
same frequency as the
oscillator circuit of the
sensor. This is called radio
12 Debris can accumulate on
the sensing cap, changing
frequency interference (RFI).
Most manufacturers have
12 the range of the sensing
field. In an application where
taken steps to provide the
maximum protection against
metal chips are created, the
12 sensor should be mounted to
RFI and false operation of the
sensor. C B
prevent those chips from
12 building up on the sensor Electrical interference from A = Rated Sensing Range
B = Maximum Usable Sensing Range
face. If this is not possible, nearby motors, solenoids, C = Maximum Reset / Release Range
12 then coolant fluid should be
used to wash the chips off
relays and the like could have
an affect on sensor operation
12 the face. An individual chip
generally doesn’t have
as well. An induced line or
current spike (called a
In the Workplace
enough surface area to cause showering arc or EFT) can
12 the sensor to turn on, but cause a false operation of On the automated processing line at Harris House Paints, a can
several of them could extend the sensor. This spike can be would occasionally come through the packaging process without
12 the sensing range and produced by the electrical arc a lid. Lids entered the line through a gravity feed and
interfere with the accuracy of created when an electrical/ occasionally a lid would get momentarily hung up.
12 the sensor. mechanical switch or a
contactor closes. If the lines
Magnetic fields caused by
12 electrical wiring located in
connecting the sensor and
these devices are adjacent
the vicinity may affect and parallel to one another,
12 sensor operation. If the field
around the wires reaches an
the spike will affect the
sensor. Most codes and
12 intensity that would saturate
the ferrite or the coil, the
specifications call for a
separation of control and
sensor will not operate. An Inductive Proximity Sensor Keeps a Lid on Things
12 Sensors used in areas with
power leads so this is not
often a problem. By mounting an inductive proximity sensor over the passing
high frequency welders can
12 also be affected. To The ambient temperature cans, the line could reject a can with a missing lid.
compensate for a welder, can affect sensing range.
12 weld field immune sensors
can be installed. Or, if the
The effect is referred to as
temperature drift. The Review 4
12
sensor is used with a PLC, a sensing range can change by
time delay can be as much as ±10%. Answer the following questions without referring to the material
programmed to ignore the just presented. Begin the next section when you are confident
12 signal from the sensor for the Because sensing ranges can
vary due to component,
time period that the welder is 1. Inductive proximity sensors work best with
12 operating. circuit and temperature
variations, along with the _____________ metals.
effects of normal machine
12 wear, sensors should be 2. The target size rule of thumb is: the size of the sensor’s
selected based on sensing diameter, or three times the sensor’s sensing range,
12 the target at 75%, and whichever is greater. TRUE FALSE
releasing at 125% of the
12 rated sensing distance. 3. A target with a rough surface has no impact on the sensing
range. TRUE FALSE
12 4. A slide-by approach to the sensor is called a lateral
approach. TRUE FALSE
12
5. A straight on approach is called an axial approach.
12 TRUE FALSE
6. When two sensors are to be mounted side-by-side, the
12 use of an alternate frequency head on one of the sensors
12 will not prevent the sensors’ sensing fields from interacting.

TRUE FALSE
12 Answers to Review 4 are on Page V8-T12-42.

12.1
Capacitive Proximity Sensors
12
Let us now turn our attention Strengths and Weaknesses Operation of the Capacitive Proximity Sensor
to another proximity sensor,
the capacitive proximity
Consider these strengths and A capacitor consists of two The distance between the 12
weaknesses of the capacitive metal plates separated by a plates determines the ability
12
sensor. This sensor
proximity sensor: insulator (called a dielectric). of the capacitor to store a
operates much like an
inductive proximity sensor, The operation of this type charge.
12
Capacitive Proximity of sensor is based on
but its means of sensing is Sensor Attributes Measuring the change in
much different. dielectric capacitance,
capacitance as an object
which is the ability of a
12
Attributes
Capacitive Proximity dielectric to store an electrical enters the electrical field
Strengths can be used as an ON/OFF
Sensors charge.
Can detect both metallic and nonmetallic
objects at greater ranges than inductive
switching function. 12
sensors Capacitor Operation
High switching rate for rapid response
12
applications (counting)
12
Plates
Can detect liquid targets through non-
metallic barriers (glass, plastic)
Long operation life, solid-state output for 12
“bounce free” signals
Weaknesses 12
Affected by varying temperature, humidity
Capacitive proximity and moisture conditions 12
sensors are designed to Switch
Not as accurate as inductive proximity
detect both metallic and
nonmetallic targets. They
sensors Dielectric 12
are ideally suited for liquid
level control and for sensing Applications When this principle is applied Capacitive proximity sensors 12
Here are some examples to the capacitive proximity can detect any target that has
powdered or granulated
material. showing how the detection sensor, one capacitive plate
is part of the switch, the
a dielectric constant greater
than air. Liquids have high
12
power of capacitive proximity
sensors is used: enclosure (the sensor face)
is the insulator. The target
dielectric constants. Metal
also makes a good target. 12
● Liquid level detection is the other “plate.” Ground
applications, such as is the common path. 12
preventing overfilling or
underfilling, are common in Capacitive Proximity Sensor Operation 12
the packaging industry
● Material level control
applications, such as
12
assuring that a sleeve of
labels on a labeling line is
12
not empty
● Counting applications, 12
The capacitive proximity As an object approaches the
such as tracking units
passing a point on a
sensor has four basic
elements: a sensor (which is
sensor, the dielectric
constant of the capacitor
12
conveyor
● Induction molding
a dielectric), an oscillator
circuit, a detector circuit and
changes. The oscillator
circuit’s oscillation begins 12
process, detection of level an output circuit. when feedback capacitance
of plastic pellets in feed is detected. This is just the 12
hopper opposite in the inductive
proximity sensor, where the 12
oscillation is damped when
the target is present.
12
12
12
12
12
12

Oscillator Damping In the Workplace

12
Inductive Capacitive
12 100% 100% As oil pours into this storage tank, a capacitive proximity sensor
near the top signals the fill valve to close once the tank reaches
12
Current
Current
capacity.
12
12 0
Distance mm
0
Distance mm
12 The detector circuit The output circuit remains

monitors the oscillator’s active until the target leaves
12 output. When it detects the sensing field. The
sufficient change in the oscillator responds with a
12 field, it switches on the
output circuit.
decrease in amplitude, and
when it is no longer receiving
12 sufficient capacitance
feedback, the detector circuit
switches OFF.
12 There is a built-in difference Capacitive Proximity Sensors in a Liquid Level Detection Application
12 between the operate and
release amplitudes to Another sensor near the bottom alerts the filling system if the
provide hysteresis. level of the tank becomes too low.
12
12
12 Capacitive Proximity Sensor Influences
12 Many of the same factors
that influence the sensing
Sensing distance for
capacitive proximity
Sensitivity Adjustment Target Material and Size
range of inductive proximity sensors is dependent on Most capacitive proximity A capacitive sensor should
12 sensors, also influence the plate diameter. With sensors are equipped with not be hand-held during set
sensing range of capacitive inductive proximity sensors, sensitivity adjustment up. Because your hand has a
12 proximity sensors. the size of the coil is the potentiometers. Because the
sensor measures a dielectric
dielectric constant greater
than air, the sensor may
determining factor.
12 Typically, capacitive sensors gap, it is important to be able detect your hand rather than
have a greater sensing range to compensate for target and the intended target.
than inductive sensors. application conditions and
12 adjust the sensing range. Capacitive sensors can detect
both ferrous and non- ferrous
Typical Proximity Sensing Ranges
12 Sensor with a Inductive Capacitive
materials equally well. There
is no derating factor to be
Tubular Diameter of: Unshielded Sensor Unshielded Sensor
applied when sensing
12 18 mm 8 mm 15 mm metal targets. But, other
30 mm 15 mm 25 mm materials do affect the
12 34 mm — 35 mm
sensing range.
Because they can be used to
12 detect liquid through a
nonmetallic material such as
12 glass or plastic, you need to
ensure that the sensor
12 detects just the liquid, not the
container. The transparency
12 of the container has no
effect on the sensing.
12 For all practical purposes, the

target size can be determined
12 in the same manner as was
discussed in “Target Size” on
Page V8-T12-18 for inductive
12 proximity sensors.
12

12.1
Environment In the Workplace
Many of the same factors ● Ambient atmosphere—the 12
that affect inductive proximity amount of humidity in
sensors, also affect the air may cause a On the fill line at Bud Springs Natural Water, two liter plastic 12
capacitive sensors, capacitive sensor to bottles pass along beneath a fill nozzle.
only more so. operate even when no 12
target is present
12
● Embeddable mounting—
capacitive sensors are
● Welding magnetic fields—
generally treated as non- capacitive sensors are
shielded devices, and generally not applied in a
welding environment
12
therefore, are not
embeddable ● Radio Frequency
Interference (RFI)—in the
12
● Flying chips—they are
same way that inductive
more sensitive to both
metallic and nonmetallic proximity sensors are 12
affected, RFI interferes
●
chips and residue
Adjacent sensors—more
with capacitive sensor 12
circuitry
space between devices is
required due to the
● Showering arc (EFT)— 12
greater, non-shielded induced electrical noise A Capacitive Proximity Sensor “Sees Through” a Wall to Find the Target
sensing range affects these sensors in
the same way it does for As water fills each bottle, a capacitive proximity sensor detects
12
● Target background— when the water reaches the specified level. As the sensor is
because of both the
an inductive sensor
more sensitive to water than it is to plastic, the sensor can “see 12
greater sensing range, and through” the bottle wall.
its ability to sense metallic
and nonmetallic materials,
12
greater care in applying
these sensors is needed 12
when background
conditions are present
Review 5
12
Answer the following questions without referring to the material 12
12
1. The operation of a capacitive proximity sensor is based on
12
dielectric capacitance. TRUE FALSE
12
2. The four main parts of a capacitive proximity sensor are:
________________________ 12
________________________
________________________
12
________________________ 12
3. By measuring the change in capacitance as an object enters 12
the field generated by the oscillator, it can be used for an on/
off switching function. TRUE FALSE 12
4. When feedback capacitance is detected, the oscillation 12
ends. TRUE FALSE
12
5. When sensing metal targets, a derating factor must be
12
applied. TRUE FALSE
6. The transparency of the container has no effect on the

12
sensing. TRUE FALSE 12
Answers to Review 5 are on Page V8-T12-42. 12
12

Photoelectric Sensors
12 The photoelectric sensor is a Applications Modes of Operation
12 device with tremendous
versatility and relatively low
Photoelectric sensors can
provide solutions to a number
We will briefly introduce you to these modes, and fully explain
cost. Photoelectric sensors them later.
12 can detect objects more
of sensing situations. Some
of the common uses for Photoelectric Sensor Operation Modes
quickly and at further photoelectric sensors
12 distances than many include: Mode Description
competitive technologies. For Thru-Beam Thru-beam A source unit in one location sends a
12 these reasons, photoelectric
sensors are quickly becoming
Material Handling. A sensor
can ensure that products Target
light beam to a detector unit in another
location. An object is detected when it
move along a conveyor line in passes between the source unit and
12 one of the most popular
forms of automatic sensing an orderly manner. The the detector unit, interrupting the light
beam.
used in manufacturing. sensor will stop the operation
12
Detector
if a jam occurs. And items Source

Photoelectric Sensors can be counted as they move
12 down the line. Reflex Reflex (retro-reflective) The source and detector are housed in
one package and placed on the same
Packaging. Sensors can
12
Target
side of the target object’s path. When
verify that containers are the object passes by, the source signal
filled properly, labeled is reflected back to the detector by a
12
Retroreflector
properly and have tamper- retroreflector.

proof seals in place. Reflex
Sensor
12 Machine Operation.
Sensors can watch to verify Diffuse Reflective Diffuse reflective The source and detector are housed in
12 that a machine is operating one package and placed on the same
side of the target object’s path. When
properly, materials are the object passes by, the source signal
12
Target
present and tooling is not is reflected back to the detector off the
broken. Diffuse
Reflective
target object itself.
12
Sensor
Paper Industry. Sensors can

detect web flaws, web Background Rejection Background rejection This is a special type of diffuse
12 splice, clear web and paper
presence, while maintaining
(Perfect Prox®) reflective sensor that includes two
detectors. This arrangement allows the
sensor to detect targets reliably within
12 high web speeds. Target
a defined range, and to ignore objects

just outside of this range. Unlike a
Design Flexibility
12 Fixed Focus
Background standard diffuse reflective sensor, color
Photoelectric sensors offer Perfect Prox
Sensor
or reflectivity has minimal effect on the
design flexibility to handle sensing range of a Perfect Prox sensor.
12 many types of situations.
There are a variety of ways
In the Workplace
12 the transmitter and receiver
can be arranged to meet the
needs of the application.
12 At the tollbooth, the gate raises only when you have tossed
in your coins. But how does the gate know when to drop
12 back into place?
12
12
12
12
12
12 A Photoelectric Sensor Prevents Commuters from Following
You Through the Toll Booth for Free
12 The gate is controlled by a photoelectric sensor that detects
your car as it passes through the beam.
12
12

12.1
Basic Operation of Photoelectric Sensors
12
The operation of the When an object moves into
photoelectric sensor is quite
simple. A source LED sends
the path of the light beam,
the object is detected.
12
a beam of light, which is
picked up by a Let’s look at how a 12
photodetector. photoelectric sensor works.
12
Photoelectric Sensor Operation
12
a b
c d 12
Lens Target or
12
12
Reflector
12
Lens
12
12
e f g h 12
Notes 12
1 Power Supply: Provides regulated DC 5 Output: Performs switching routine 7 Detector Amplifier: Blocks current
voltage and current to the sensor
circuitry.
when directed to do so by the
demodulator.
generated by the background light. It
also provides amplification of the
12
12
2 Modulator: Generates pulses to cycle 6 Demodulator: Sorts out the light detected signal to a usable level, and
amplifier and LED at desired frequency. thrown out by the sensor from all other sends it through to the demodulator.
3 Source Current Amplifier light in the area. If the demodulator 8 Photodetector: Either a photodiode or a
4 Source LED decides the signals it receives are okay,
it signals the output.
phototransistor device, selected for a
maximum sensitivity at the source LEDs
12
emitted light wave-length. Both the
source LED and the detector have
protective lenses. When the detector
12
12
picks up the light, it sends a small
amount of current to the detector
amplifier.
The Light Source

12
The light generated today
by a photoelectric sensor
12
comes from light emitting
diodes, called LED. Using 12
LEDs offers many significant
advantages: 12
Can be rapidly switched
12
●
and instantly turned ON

and OFF
● Extremely small 12
Consume very little power
12
●
● Generate a negligible
amount of heat
● Life exceeds 100,000 12
hours (11 years)
continuous use 12
● Easily modulated to block
false sensor triggering 12
from ambient light
12
12

Photoelectric Sensor Styles and Uses

12
General Purpose
12
General Purpose Photoelectric Sensors
12 Style Application
Limit Switch Type
12
Limit switch type A modular head, sensor body and receptacle enable use in a variety of situations.
Wide detection range. Popular replacement for standard limit switch
applications.
12
12
12
12
Tubular Tubular Small, easy to mount body enables mounting within machinery and other tight
12 places. This sensor comes end sensing and right angle view packages, depending
upon the type of mounting required.
12
12 Harsh Duty Harsh duty Heavy-duty construction makes this sensor ideal for rugged environments.
12
12 Compact Compact A family of high performance AC/DC and DC photoelectric sensors in a
familiar package.
12
12
12
12
Fiber Optics Fiber optics Made for fast response and for sensing in very tight areas. The cables are
12 made of individual glass or plastic fibers and contain no electronics.
12
Terminal Base Terminal base Self-contained in an impact-resistant, resin-molded case, these devices have
12 pre-wired cables or terminal connections.
12
12
12 Miniature Miniature A complete line of miniature photoelectric sensors for optimum placement and
protection with no compromise in performance.
12
12
12
12
12
12
12

12.1
Fiber Optics Modes of Detection
Applying fiber optic current—travels down these In most applications, photoelectric sensors generate an output
12
technology to photoelectric cables, the signal is
sensors means applications unaffected by
any time an object is detected.
12
with space restrictions are electromagnetic Light Operate vs. Dark Operate
not a problem. A fiber optic interference (EMI) and If this occurs when the photodetector sees light, the sensor is 12
cable can detect objects in vibration. The design also said to be working in the light operate mode.
locations too jammed for a
standard sensor. Fiber optic
has built-in immunity to
electrical noise and the Light Operate and Dark Operate—Reflex Mode Example 12
cable is available in sizes as
small as 0.002 inches in
inaccurate readings regular
sensors can get. Source
Reflector
Source
12
diameter.
Glass Fiber Optic Cable
Fiber optics can withstand
high temperatures; plastic
Detector Detector
12
Photo Sensor Sees Light: Photo Sensor Sees Dark:
Glass Fibers
up to 158°F (70°C), standard
glass up to 480°F (249°C),
Load Is Operated
Light Operate Mode
Load Is Not Operated
12
Embedded in
and specialized high
Epoxy
temperature versions up to 12
Source Source
900°F (482°C). Glass fibers
can stand up to the harsh Detector Detector
12
wash-down chemicals used Photo Sensor Sees Light: Photo Sensor Sees Dark:
Stainless
Steel Ferrule
in many food, beverage and
pharmaceutical applications.
Load Is Not Operated
Dark Operate Mode
Load Is Operated
12
A glass fiber optic cable is However, fiber optics have 12
made up of a large number of their disadvantages. They If the control generates an output when the photodetector
individual glass fibers, have a limited sensing
distance, so they can be
does not see light, the control is said to be working in the dark 12
sheathed for protection operate mode.
against damage and excess used only in tight areas. The
maximum distance for the Earlier, we briefly described Let’s now take some time to 12
flexing. Plastic fiber optic
thru-beam design is just 15 the four basic operating understand how each
cables include a single plastic
fiber in a protective coating. inches. Also, these sensors modes that photoelectric method works. 12
have a small sensing area. A sensors offer. These are:
Neither type of cable contains
electronics. small drop of water or piece ● Thru-beam 12
of dirt can easily fool fiber
Reflex (retro-reflective)
12
●
Because light—rather than optics.
● Diffuse reflective
In the Workplace
● Background rejection
(Perfect Prox)
12
12
In this cookie kitchen, fiber optic photoelectric sensors are Thru-Beam
placed in a hot oven. As long as the sensors detect motion as
Separate light source and Thru-Beam Operation
12
the trays of cookies move by, the oven stays on.
detector units face one
another across an area. The Detector 12
column of light traveling in
a straight line between the
Field of
View e
12
two lenses is the effective tiv
ec
sensing beam. An object EffBeam
12
crossing the path has to Field of
completely block the beam to
be detected.
View
12
Source
Thru-Beam Attributes Normal State
12
Detector
Attributes
Strengths
12
Long sensing distance (up to 800 ft)
12
Highly reliable
Can see through opaque objects Object Blocks
Beam 12
A Photoelectric Sensor Prevents Cookies from Being Burned Weaknesses
If the conveyor stops, the sensors will detect light or dark for
Two components to mount and wire
Source
Target Detected
12
12
too long, and the output device will shut the oven down. Alignment could be difficult with a longer
distance detection zone
12

Reflex or Retro-Reflective Diffuse Reflection

12 The source and detector are Reflex Attributes The source and detector are Diffuse Reflection
positioned parallel to each positioned on the same side
12 other on the same side of the
Attributes
of the target. The two
Operation
object to be detected. Strengths components are aligned so

12
Target
Another element, called a Medium range sensing distance that their fields of view cross. Object
retroreflector, is placed Low cost
When the target moves
12 across from the source and
detector. The retroreflector is Ease of installation
into the area, light from the
source is reflected off the
12 similar to a reflector on the
back of a bicycle. The
Alignment does not need to be exact
Polarizing filter allows detecting shiny
target surface back to the
detector.
Source/
retroreflector bounces the
12
surfaced objects without false tripping Detector
light from the source back to
Weaknesses Normal State
the detector. Diffuse Reflective
12 When a target object
Reflector must be mounted
Attributes Object Reflects
Problems detecting clear objects
passes between the Beam
12
Attributes
source/detector unit and Dirt on retroreflector can hamper operation
Strengths
the retroreflector, the beam Not suitable for detecting small objects
12 is no longer reflected, and Application flexibility
the target is sensed. The Reflex Operation Low cost Target
12
Object Is
target has to block the entire Retro- Easy installation Source/ Detected
beam. Reflector
Easy alignment Detector
12 In some cases, a reflex Target
Object Many varieties available for many Target Detected
sensor can be falsely application types
12 triggered by reflections from
a shiny target’s surface. To
Weaknesses
12 avoid this, a polarized reflex

sensor can be used. The
Short sensing distance (under 10 ft)
Sensing distance depends on target size,
polarizing filter on the sensor Source/
12
surface and shape
Detector
ensures that only the light
reflected by a retroreflector is Normal State
12 recognized by the sensor.
Retro- Background Rejection (Perfect Prox)
12
Reflector This detection scheme is 24 inches. Its far detector has
Object Does Not really a special type of a range of 6 to 24 inches.
Reflect Beam
diffuse reflective sensor. It
12 combines extremely high Objects closer than six inches
sensing power with a sharp are detected only by the near
12 Target optical cut-off. This allows detector. Objects between 6
and 24 inches are detected
Object Is the sensor to reliably detect
by both detectors.
12 Source/
Detector
Detected targets regardless of color,
reflectance, contrast or If the near signal is stronger
12 Target Detected surface shape, while ignoring
objects just outside of the
than the far signal, the
sensor output is ON. If the
target range.
12 This method uses two
far signal is stronger or
equal to the near signal, the
output is OFF. The result is a
12 different photo-detectors.
For the Perfect Prox unit with sensor with high excess gain
a six-inch range, the near for six inches, followed by a
12 detector has a range of 0 to sharp cut-off.
12 Perfect Prox Sensor

Near Detector Field
12
12
12 Sensor
12 Cut-Off Far Detector

Distance Field
12
12

12.1
12
Hobbes Gear wanted to reduce the number of gears rejected on Answer the following questions without referring to the material
12
their line. One critical process is the automatic drilling of the
gear’s mounting hole. To increase the reliability of the inspection
process, Hobbes installed a Perfect Prox sensor.
12
Perfect
1. The four modes of detection are:
12
Prox ________________________
Detection
Sensor
Detection
________________________ 12
________________________
12
Cutoff Distance Zone
Distance
________________________
Gear
Cut-away
2. If the photoelectric sensor control generates an output
12
when the photodetector does not see light, the control is 12
working in the dark operate mode. TRUE FALSE
12
Match the mode of detection with its definition.
3. Mode of detection that ______ A. Reflex 12
senses by reflecting light
off the objects 12
4. Sensing mode that has ______ B. Perfect Prox
the longest range 12
5. Sensing mode that ______ C. Thru-beam
combines extremely high 12
sensing power with a
12
A Perfect Prox is “Inspector #12”
sharp optical cut-off
The sensor is set to check for the presence of the machined 6. A polarizing filter used ______ D. Diffuse reflective
hole in the gear. If the hole is present, the sensor’s light shines
through it, to the conveyor belt. The belt is just beyond the
with this sensing mode 12
ensures that only the
sensor’s sensing distance. If a missing hole is detected, the
sensor signals an air-operated cylinder plunger to reject the gear.
light reflected by a retro- 12
reflector is recognized
by the sensor 12
12
12
12
12
12
12
12
12
12
12
12
12
12

Excess Gain
12
Definition Thru-Beam Diffuse Reflection
12 Excess gain is a This type of sensor’s excess Nearly every diffuse A short-range sensor
measurement of how much gain is the simplest to reflective sensor has a delivers high excess gain
12 sensing power a
photoelectric sensor has
measure. Excess gain is
almost exclusively a
unique combination of
lenses and beam angles.
over a short sensing
distance and drops off
12 available beyond the power
required to detect an
function of the separation
between the source unit
As a result, nearly every
sensor has a unique excess
quickly. The source’s beam
and the detector’s field of
object. and the detector unit. gain curve. view converge a short
12 distance from the lenses.
An excess gain of 1.00 at a When implementing the Diffuse Reflection Ranges The energy present in that
12 given range means there is
exactly enough power to
excess gain for an
application, start with the Long Range Perfect Prox
area is very high, allowing
the detection of small
Example
12
detect an object under excess gain chart for the thru- targets. The sensor also
perfect conditions at that beam sensor. Then consider: 4000 ignores objects in the near
range. In other words, the
12 ● Misalignment of the two 1000
background.
range at which the excess
gain equals 1.00 is the units Short-Range and
12 maximum range of the
sensor.
● Dirt in the environment
reduces gain
100
Long-Range
12 Every model of sensor comes Typical Gain Curve for a 10

with an excess gain chart to Thru-Beam
12 help you determine the 1000
1
excess gain for an 0.1 10 20 30 40 50 60 70 100
12 application’s sensing Short Range Proximity

Long Range (in)
distance. 100
12 However, we have to take Short Range

into consideration the
12 following real-world variables: 10 X 1000
● Target size
12 ● Target color 1
0.1 1 10 100
100 Long Range Proximity
● Target surface texture
12 ● Ability to block the beam
Range (ft)
A long-range sensor’s source
10 beam and detector’s field of
12
● Background How to read the gain view are positioned close
● Application environment graph. If these sensors are together on the same axis.
12
spaced 30 ft apart, the 1 The ability to sense extends
In the real world, there is excess gain at that distance 0.1 1 10 100
contamination—dust, quite a distance. Excess gain
would be an excess gain Short Range (in)
12 humidity and debris—that can
settle on the lenses and
of “10”.
peaks out several inches
from the sensor, then drops
Focused Diffused Reflective off slowly over distance.
12 reduce light transmission.
Furthermore, each individual RANGE (mm) To sense into holes or
target may vary slightly from 2.5 25 254 2540
12 cavities, or to pick up very

1000
the next in color, reflectivity small objects, use a
or distance from the sensor. focused diffuse reflective
12 sensor. Or, a sensor with a
EXCESS GAIN
If you use a sensor with an 100
excess gain of exactly 1.00, very small light spot size. The
12 you stand an excellent source and detector are
chance of not sensing the 10
positioned behind the lens in
12 target reliably. To cover order to focus the energy to a
point. The excess gain is
yourself, you need a sensor 8
12 with the highest excess

gain possible at the
1
0.1 1
9
10 100
extremely high at this point
and then drops off on either
RANGE (inches)
side of the sensing zone.
12 intended range. This
ensures the sensor will 8. 13102A Typical
continue to operate reliably 9. 13102A Minimum
12 when you need it. As the
Sensing range of diffuse
level of contamination gets
12 worse, more excess gain will
be needed to get past the
mode sensors referenced to
90% reflective white target.
12 poor visibility.
12

12.1
Reflex Corner Cube Retroreflector and Reflex
Calculating the excess gain operating range also depends In the case of the corner cube Glass Bead
12
for a reflex (retro-reflective) upon lens geometry and reflector, range and excess
sensor is similar to the detector amplifier gain. gain depend upon on Light Ray
12
method used for diffuse reflector quality.
reflective sensors. The effective beam is defined
as the actual size of the Corner cube reflectors
12
12
With this type of sensor, reflector surface. The target provide the highest signal
excess gain and range are must be larger than the return to the sensor. Cube
related to the light reflector before the sensor style reflectors have 2000-
bouncing back from the will recognize the target and 3000 times the reflectivity of
Opaque
Material 12
reflector. Maximum switch its output. white paper.
Effective Reflex Sensor Beam Corner cube reflectors 12
consist of three adjoining
sides arranged at right angles Glass bead retroreflectors are 12
Source Radiation to one another. available in tape form for use
Effective Beam Retroreflector
Corner Cube Reflector
in dispensers for package
coding on conveyors. They
12
Detector Field of View are also available in sheet
form that can be cut to size. 12
The bead surface is typically
Light Curtain
rated at 200 to 900 times the 12
reflectivity of white paper.
A light curtain is a
specialized reflex sensor
The distance from the lens to
the reflector strip, together Only corner cube reflectors 12
can be used with polarized
head. It has four transmitters
and four detectors side by
with the length of the
reflector, serve to define the reflex sensors. The light 12
side behind a cylindrical lens. effective detection area. Light Ray returned from the cube’s
The light curtain emits a fan- surface is depolarized with 12
shaped beam, which provides respect to the light it
a wide viewing area. When a ray of light strikes
one of the three adjoining
received. Glass bead
reflectors cannot be used
12
Effective Light Curtain Sensor Beam sides, the ray is reflected to with polarized retro-reflective
the second side, then to the sensors. 12
third, and then back to its
source in a direction parallel 12
to its original course.
Thousands of these cube
shapes are molded into a
12
rugged plastic reflector or
vinyl material. 12
Effective Detection Area Graph 12
+3 12
+2
Deviation from +1
–
12
Beam Center
in ft –1
–2 12
–3
12
2 ft 4 ft 6 ft 8 ft 10 ft
Curtain of Light Beam Profile

12
12
12
12
12
12
12

Contrast Diffuse Environment

12 Contrast measures the This mode is affected by: The list below ranks the level To further complicate
ability of a photoelectric
12 sensor to detect an object.
● Distance of the object or
of contamination in a range of
typical application
matters, with the reflex and
thru-beam modes, the source
The contrast of a sensor is a surface from the sensor
environments. and reflector can be in
12 ratio of the excess gain under ● Color or material of the
As you work your way down
different locations with
light conditions to the excess object or surface different levels of
12 gain under dark conditions. A
ratio of 10:1 is desired.
● Size of the object or
surface
the list, the excess gain
needed to overcome what’s
contamination.
hanging in the air gets higher. For outdoor use, the
12 Contrast is important when
a sensor has to detect The ideal application provides environment can range from
semi-transparent objects or infinite contrast ratio of the lightly dirty to extremely dirty.
12 extremely small objects. detection event. This is the
case when 100% of the Level of Contamination Ranking
12 Each mode handles contrast
differently.
beam is blocked in reflex or
thru-beam modes. For diffuse
Minimum
Excess Gain
12
sensing, this occurs when Ranking Description Required
nothing is present.
Relatively No dirt buildup on lenses or reflectors 1.5 X
Thru-Beam and Reflex Understanding the contrast
12 These modes are affected by: ratio is critical when this
clean
Slightly Slight buildup of dust, dirt, oil, moisture, and so on, on lenses 5 X
situation does not exist, such
12 ● Light transmissivity of an dirty or reflectors. Lenses should be cleaned on a regular schedule.
as when detecting
object or surface semitransparent objects. In Moderately Obvious contamination of lenses or reflectors. Lenses are 10 X
dirty cleared occasionally or when necessary.
12 Size of an object in relation some cases, it might be
●
to the beam size necessary to use a special Very dirty Heavy contamination of lenses. Heavy fog, mist, dust, 50 X
low-contrast sensor designed smoke or oil film. Minimal cleaning of lenses takes place.
12 for these applications, like a
clear object detector version.
12
12 In the Workplace Review 7
12 A thru-beam pair is positioned ten inches apart to detect a

12 semi-transparent plastic bottle moving through the sensing
zone. But the sensor is not picking up the bottle. 1. Excess gain is a measurement of how much sensing power
12 a photoelectric sensor has available beyond the
________________________
12 ________________________
12 2. Name the three factors that can affect excess gain.

________________________
12 ________________________
________________________
12 3. Nearly every diffuse reflective sensor has a unique excess
12 gain curve because nearly every sensor has a unique

combination of lenses and beam angles. TRUE FALSE
12 4. Only corner cube style reflectors should be used with
polarized reflex sensors. TRUE FALSE
12 The Right Sensor Type Makes the Difference Between
Reliable Sensing and No Sensing at All
5. Contrast is not important when sensing semi-transparent
12 Given that the excess gain at that range is 100, and the bottle
blocks only 5% of the light energy, the contrast ratio is close targets. TRUE FALSE
to 1 (100/95). This does not meet the advised 10:1 ratio. The
12 thru-beam pair is just too powerful. Answers to Review 7 are on Page V8-T12-42.
12 Using a focused sensor positioned three to four inches from

the bottle changes things. In this detection zone, the excess
12 gain is between 20 and 100. (See Effective Detection Area
Graph on Page V8-T12-31.)
12
12

12.1
Sensor Output Circuits
As we learned earlier, Otherwise, an input like a
12
Two-Wire Sensors
sensors interface to other
control circuits through the
PLC (Programmable Logic
Controller) might see the
Most sensors are three-wire If more than one two-wire 12
devices, but some switch is wired in series with
output circuit. The control voltage as being an ON
voltage type is a determining signal. Most sensors are 1.7
manufacturers offer two-wire
devices. They are designed
the load, there is a cumulative
voltage drop across the
12
factor when considering mA. If a particular PLC
output type. Control voltage requires less than 1.7 mA, a
to be easy replacements for
limit switches without the
switch. When more than one
two-wire switch is connected 12
types, whether AC, DC or loading resistor is added in
need to change wiring and in parallel with a load, there is
AC/DC, can be categorized as
either load-powered sensor
parallel to the input to the
PLC load. The resistor lowers
logic. a cumulative effect on the 12
leakage current. This
or line-powered sensor. the current seen by the PLC
so it doesn’t false trigger.
Because two-wire switches
“steal” their operating
increased off-state leakage 12
Load-Powered—Two-Wire current could cause a PLC to
power from the load circuit,
Sensors The current required to
maintain the sensor when
there is a voltage drop across
receive a false ON signal.
12
Load-powered devices are the switch when it is on
similar to limit switches. They
are connected in series with
the target is present, is
called the minimum load or
(about 7–9 volts in AC 12
powered devices).
holding current. This current
the controlled load. These
devices have two is about 5 mA depending on 12
connection points to the the sensor specification. If
circuit and are often the current drawn by the load Output Types 12
referred to as two-wire is not high enough, then the
There are three output types For the majority of
switches. The operating sensor cannot operate.
Sensors with a 5 mA or less
available—Relay, Triac and applications, these limitations 12
current is drawn through Transistor. cause no problems, or can
minimum holding current can
the load.
be used with PLCs without A relay is a mechanical
easily be minimized. Relay 12
outputs are very commonly
Load Powered/Two-Wire concern. device that can handle load
Circuit
Line-Powered—Three-Wire
currents at higher voltages.
used in sensors.
12
This allows the sensor to A triac is a solid-state
Sensors
Line-powered switches
directly interface with device designed to control 12
motors, solenoids and other AC current. A triac switch
Sensor Load derive their power from the
line and not through the load.
inductive loads. They can
switch either AC or DC
turns on in less than a
microsecond when its gate
12
They have three connection
points to the circuit, and
loads. (control leg) is energized, and
shuts off at the zero 12
are often referred to as Relays are subject to contact crossing of the AC power
When the switch is not three-wire switches. wear and resistance build up,
but contact life depends on
cycle. 12
operated, it must draw a
minimum operating current
Load Powered/Three-Wire
Circuit
the load current and the
frequency of operations. Due
Because a triac is a solid-
state device, it is not subject 12
referred to as off-state
to contact bounce, they can to the mechanical limitations
leakage current. Off-state
leakage current is also
produce erratic results with of a relay. Switching 12
counters, programmable logic response time is limited only
sometimes referred to as
residual current. This current
Load controllers and other such to the time it takes the 60 Hz 12
devices, unless the input to AC power to go through one-
is used to keep the sensor
electronics active while it
those devices are filtered.
Because relays are
half cycle. 12
“looks” for a target. Residual
current is not a problem for
mechanical, they can add
10 to 25 milliseconds to a 12
loads such as relays, motor
sensor’s response time.
starters, and so on (with low
impedance). However, loads Triac Output Circuit
12
such as programmable logic
controllers (with high
The operating current the
switch pulls from the line,
Triac Snubber 12
impedance) require a leakage Opto-Coupler
current of lower than 2 mA.
is called the burden current.
This is typically 20 mA.
Triac Driver 12
Because the operating G
current doesn’t pass through
Inductive
or Capacitive
To AC
Load 12
the load, it is not a major Control Circuit Circuit
concern for circuit design. 12
12
12
12

AC Power Cycle Bilateral FET Device

12 Photosensors have another develop the fixed voltage
60 Hz 1 Cycle = 16.66 ms
output type called a bilateral drop across its terminals like
12
1 Cycle
1/2 Cycle = 8.33 ms
FET output. This output has other solid-state switches. It
many advantages over the also does not require any
12 Contact 0
other types of outputs: residual or leakage current to
Vac keep the electronics powered
12 Switching of either AC or
●
in the OFF-state.
DC voltages
Low “OFF-state” leakage FET switches are
12
●
Time ● Extremely fast response independent of voltage or

time current phase and can be
12 As long as a triac is used as the output switch. There ● Interface direct to TTL and
configured in circuits that will
control either AC or DC
CMOS circuits (for PLCs
12 within its rated maximum
current and voltage
are two types used,
depending on the switching and industrial computers)
voltages. For circuits using
PLCs, computers or other
specification, life expectancy function. One is called NPN ● Does not self-generate line sensitive devices, FETs are
12 is virtually infinite. Triac (current sink) open noise good because they do not
devices used with sensors collector. The output generate any switch induced
12 are generally rated at 2A transistor is connected to the FET is for Field Effect
Transistor, and may become
line noise like relay and triac
loads or less, and can be negative DC. Current flows switches.
the most popular output in
12 directly interfaced with PLCs
and other electronic devices.
from the positive terminal
through the load, to the the future because of its near Like the other solid-state
Triacs do have some sensor, to the negative ideal operating outputs, they cannot tolerate
12 limitations in that an inductive terminal. The sensor “sinks” characteristics. line spikes or large inrush
load directly connected can the current from the load. currents. In the illustration
The voltage applied to the
12 false trigger it. A snubber
The second type used is gate (G) controls the
above, a transorb is used to
circuit can be used to protect the FET from voltage
conduction resistance
12 minimize the problem.
Shorting the load will destroy
called PNP (Current Source).
The sensor is connected to between the source (S) and
spikes and dissipate the
energy as heat.
the positive DC. Current drain (D). Because an FET is a
12 a triac, so the device should
be short circuit protected to flows from the positive resistive device, it doesn’t
avoid this. terminal through the sensor, Bilateral FET Device (AC/DC Switch)
12 to the load, to the negative
A transistor is a solid-state terminal. The sensor Opto-Coupler Photo Bilateral FET Transorb
12 device designed to control

DC current. They are most
“sources” the current to
the load.
Voltaic Diode Stack
+ G
D
commonly used in low

12 voltage DC powered sensors To
S
To
Photoelectric AC/DC
12 Transistor Output Circuit (Sinking) Control Circuit Load
Circuit
S
12 B
C
+V G
Circuit Output D
12 E 36V
12 Common
12 Transistor Output Circuit (Sourcing)
12 C
+V
B 36V
12 Circuit
E Output
12 Common
12
12
12
12
12

12.1
Output Configurations
12
Single Output Complementary Output
As in other control devices, common and NO is the most A complementary output The output logic for the 12
several output configurations common. Fixed single output sensor has two outputs, 1NO normally open and normally
are available for sensors. sensors cannot change and 1NC Both outputs closed contact configurations 12
Fixed single outputs, either configuration to the other change state simultaneously for an inductive proximity
1NO or 1NC, are very circuit. when the target enters or
leaves the sensing field.
sensor is shown in the table
below.
12
12
Single Output
Complementary Output
Brown +
N.C. N.O.
–
12
Load
Blue
Load 2
Load
12
1 4
3 12
12
Output Logic
12
Programmable Output
A programmable output selected using a switch. On Output Configuration Target Output State
sensor has one output, NO or photoelectric sensors this is
NC, depending on how the called a light/dark switch. This
NO Absent Non-conducting (OFF)
12
Present Conducting (ON)
output is wired when it’s allows you to program the
installed. Sometimes the sensors output normally open NC Absent Conducting (ON) 12
output configuration is (NO) or normally closed (NC). Present Non-conducting (OFF)
Programmable Output
12
No Wiring Option 12
L1 L2
12
1 2
Load
12
3 4 12
12
12
12
Accessory Considerations 12
The choice of control circuit, Application output Connected logic device— Other considerations are
12
● ●
of using single, programmable requirements—While NO Probably the most whether the sensor will need
or complementary outputs is the most commonly important factor for sensor LED indication of its status
are dependent upon: used, certain applications circuit and output and whether there is short 12
may require the circuit configuration is the device circuit protection, reverse
● Voltage available—Does
the control circuit have
logic provided by NC, or to which the sensor is to polarity protection or wire 12
even the complementary be connected. What type termination needed
provisions for supplying
DC? Some control circuits
configured sensors of input the PLC, counter,
relay, and so on, can accept
12
have interfacing circuitry
● Switching speed
for DC sensors even if the requirements—For
applications requiring high
is the determining factor
for which sensor output is 12
main control voltage chosen
12
source is AC speed, such as counting,
DC sensors may be
● Control circuit current required. AC circuits are
requirements—If the
circuit requires a current
limited by operations per 12
second (because of the
greater than the rating on
the sensor, an interposing
AC sine wave), and are
typically slower than DC
12
relay can be used
12

Switching Logic
12
Output Logic Functions
12 The outputs of two or more sensors. For these reasons,
sensors can be wired series and parallel
12 together in series (and) and connections for logic
parallel (or) to perform logic functions is not commonly
12 functions. Factors that need
to be taken into
done. It is usually easier to
connect direct to a PLC’s
12 consideration, however, are
excessive leakage current or
inputs and perform the logic
functions through the PLC
voltage drop and inductive program.
12 feedback with line powered
12
Output Response Time and Speed of Operation Response Time and Release Time for an
12 Photoelectric, inductive When a system is first Inductive Proximity Sensor
and capacitive sensors can powered up, the sensor
12 operate considerably faster cannot operate until the
Operate Release
than a limit switch, making electronics are “powered
12 them better choices for high- up.” This is referred to as IN
Target
speed operations such as time before availability.
OUT
12 counting or sorting. The time
it takes to respond, its speed For AC sensors, this delay is Response
Time
Release
Time
typically from 35 milliseconds
12 of operation, is based on
several factors. Let’s take a up to as high as 100
milliseconds. For a ON
moment to consider them.
12 DC sensor, the delay is
typically 10 milliseconds.
Sensor
OFF
Operate Release
12 Time Delay Before Availability
Point Point
12 Selector
ON
Time Delay
Similarly, when the target there is a similar delay for the
Switch Before Availability leaves the sensing field there load to operate. This is called
12 OFF is a slight delay before the the load response time. The
ON
switch is restored to the total times combined are
12 Sensor
OFF
OFF state. This is referred
to as the release time.
referred to as system
response time. Similarly,
An AC sensor typically there are load release time
12 releases in one cycle (16.66 and system release time for
Target milliseconds) and DC devices when the target exits the
12 usually in 1 millisecond, sensing field. In order to
or less. ensure reliability and
12 In order to properly achieve
repeatability, the target must
stay in the sensing field long
Load high-speed operations, there
12 ON
are some basic principles
enough to allow the load to
respond. This is referred to as
that need to be applied. In dwell time.
12 Sensor addition to the sensor’s
response and release times,
12 Once the target enters the is called response time. For
sensing range and the an AC sensor this is usually
12 detector causes the output to
change state, a certain
less than 10 milliseconds.
DC devices respond in
12 amount of time elapses. This 1 millisecond or less.
12
12
12
12
12

12.1
Output Timing Modes
When a sensor is operated Some sensors are available Let’s look at each logic
12
without a logic module, the
output is generated for the
with a logic module to allow
setting timing functions.
function, as shown in the
following illustrations. 12
length of time the object is
detected. 12
Logic Functions
12
Retriggerable Underspeed 12
ON Delay Logic ON/OFF Delay Logic One-Shot Logic Detection Logic
Input Input Input Input 12
Signal Signal Signal Signal
12
Output Output Output Underspeed
12
Signal Signal Signal
Output
Signal
ON ON ON OFF One-Shot One-Shot
12
Delay Delay Delay Delay Pulse Pulse
This allows the output signal This logic function combines This mode generates an Operates identically to a 12
to turn on only after the the ON delay logic and OFF output of predetermined retriggerable one-shot. It
target has been detected for
a predetermined period of
delay logic—the output is
only generated after the
length whenever an object is
detected. The sequence
detects speeds that fall
below a certain
12
12
time. The output turns off as target has been detected for restarts each time an object predetermined level.
soon as the target passes out a set period of time, and will is detected, and will remain
of range. remain on after the target is triggered as long as a stream In addition, the underspeed
ON delay is useful in bin fill or

no longer detected for a set of objects are detected detector has a built-in latch
feature that shuts the system
12
period of time. before the one-shot times
jam detection because the
sensor will not false trigger The mode smooths the
out. A retriggerable one-shot
is useful in detecting
down completely when the
speed slows to a preset level. 12
on the normal flow of objects output of the sensor for This prevents the one-shot
going past. applications such as jam
underspeed conditions on
conveyor lines. from retriggering once it 12
detection, fill level detection times out, eliminating erratic
and edge guide. switching while the motor is 12
winding down.
Underspeed/Overspeed 12
OFF Delay Logic One-Shot Logic Delayed One-Shot Logic Detection Logic
Input Input Input Input
12
Signal Signal Signal Signal
12
Output Output Output Underspeed Overspeed
12
Signal Signal Signal
Output
Signal
One-Shot One-Shot Delay Delay
12
OFF OFF OFF Pulse Pulse
Delay Delay Delay One-Shot One-
Pulse Shot
Pulse
12
For applications where there
is a problem with signal loss
This type of logic generates
an output of a set length no
Combines on delay and one-
shot logic. The one-shot
Detects both overspeed and
underspeed conditions. The
12
matter how long an object is
12
in the system, this function feature is delayed for a detector is set to count a
turns the output on when the detected. A one-shot can be predetermined period of time certain number of objects in a
object is detected, and then programmed to trigger on the after an object is detected. A specified amount of time. If
holds the ON signal for a set leading or trailing edge of a delayed one-shot is useful the system operates either at 12
period of time after the object target. A one-shot ON signal where the photoelectric a higher or lower rate, an
is no longer detected. must time out before it can
detect another input.
control cannot be mounted
exactly where the action is
output is generated. 12
This logic is useful in
taking place. This includes
applications like paint booths,
12
applications that require an high temperature ovens or
output of specified length. drying bins. 12
12
12


12
12 Paper breaks in a web printing press can result in time- Answer the following questions without referring to the material
just presented.
consuming manual re-threading of the paper if the break is not
12 immediately detected. A photoelectric sensor can detect this
condition instantly, and do it in this tight space Match the output circuit reference to its definition.
12 1. The current required to maintain A. Residual current
the sensor when a target is (leakage)
12 present _____
2. Having three connections B. Burden current
12 (three-wire) to the circuit _____
3. The operating current the C. Load-powered
12 switch pulls from the line _____
4. Having two connections D. Line-powered
12 (two-wire) to the circuit _____
A Photoelectric Sensor Minimizes Downtime for this Printing Press
12 High excess gain and sharp optical cut-off of a diffuse mode
5. The initials designating a transistor output that sinks current
from the load are ______________
12 Perfect Prox ensure that background machinery is ignored.
Meanwhile, paper is detected, regardless of texture, color or 6. The initials designating a transistor output that sources
printing on it.
12 current to the load are ______________
12 In questions 7 through 13, match the term used to describe

the following:
12 7. The delay of a sensor when the A. Release time
system is first powered up _____
12 8. The period during target sensing B. Dwell time
and the detector causing output
12 to change to ON state _____
9. The period during target exiting C. ON delay logic
12 the sensing range and the output
changing to OFF state _____
12 10. The period during which the D. One-shot logic
target must stay in range to allow
12 the load to respond _____
11. Logic module that allows output E. Time before
12 signal only after target detection availability
for a set period of time _____
12 12. Logic module that allows output F. OFF delay logic
signal to be held ON for a set
12 period of time _____
13. Logic module that allows output G. Response time
12 signal to be a specific length
regardless of target physical size
12 or detection timing _____

12
12
12
12
12
12
12

12.1
Enclosure Ratings
12
Index of Enclosure Protection—General
12
The UL®, NEMA® and IEC
organizations (and other
international groups) define
12
degrees of protection
provided by electrical
12
enclosures with respect to
personnel, equipment within 12
the housing and the ingress
of water. 12
Subtle differences do exist
between the test procedures 12
and specifications of these
organizations. 12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12

IEC Ratings
12 IEC Environmental Enclosure Ratings
12 Examples of Designations
12 IP 4 4 IP 2 3
12
1st Characteristic Numeral 1st Characteristic Numeral
12 See table below See table below
12 2nd Characteristic Numeral 2nd Characteristic Numeral

See table below See table below
12
An enclosure with this designation is protected An enclosure with this designation is protected
12 against the penetration of solid objects greater against the penetration of solid objects greater
than 1.0 mm and against splashing water. than 12 mm and against rain.
12
Index of Enclosure Ratings—IEC 60529
12 1st Characteristic Numeral 2nd Characteristic Numeral
12 Numeral Description Numeral Description
Protection Against Contact and the Penetration of Solid Bodies 0 Not protected
12 0 Not protected 1 Protection against dripping water
1 Protection against solid objects greater than 50 mm 2 Protection against dripping water when tilted up 15 degrees
12 2 Protection against solid objects greater than 12 mm 3 Protection against rain
12 3 Protection against solid objects greater than 2.5 mm 4 Protection against splashing water
4 Protection against solid objects greater than 1.0 mm 5 Protection against water jets
12 5 Dust protected 6 Protection against heavy seas

6 Dust-tight 7 Protection against the effects of immersion
12 8 Protection against immersion
12
91 Protection against high pressure and temperature water jetting
NEMA Definitions Pertaining to Non-hazardous Locations—NEMA Standard 250

12
Type 1 Type 4 Type 6 Type 12
12 Enclosures are intended for
indoor use, primarily to
Enclosures are intended for
indoor or outdoor use,
indoor use, primarily to
12 provide a degree of
protection against contact
primarily to provide a degree
of protection against
of protection against the
provide a degree of
protection against dust,
with the enclosed equipment. windblown dust and rain, entry of water during falling dirt, and dripping non-
12 splashing water and hose- occasional temporary corrosive liquids.
Type 3 directed water. submersion at a limited
12 Enclosures are intended for depth. Type 13
outdoor use, primarily to Type 4X Enclosures are intended for
12 provide a degree of Enclosures are intended for Type 6P indoor use, primarily to
protection against windblown indoor or outdoor use, Enclosures are intended for provide a degree of
12 dust, rain, sleet and external
ice formation.
of protection against
protection against dust,
spraying of water, oil and
corrosion, windblown dust of protection against the non-corrosive coolant.
12 Type 3R and rain, splashing water and entry of water during
Enclosures are intended for hose-directed water. prolonged submersion at a
12 outdoor use, primarily to limited depth.
provide a degree of
12 protection against falling rain,
sleet and external ice
12 formation.
12 Note
1 Products that indicate approval to IP69K were evaluated to DIN 40 050 Part 9 which has been superseded by IEC60529. IEC60529 was updated in 2013 to edition 2.2
to include the IPX9 rating to high pressure and temperature water jets. The IEC standard does not use the additional suffix K as used in the DIN standard.
12

12.1
NFPA 70 (NEC) Definitions Pertaining to Hazardous Locations—Article 500
E51 Limit Switch Type Proximity Switches are rated for use in the following locations: 12
Class I Division 2, Groups A, B, C Class II Division 2, Groups F Class III Division 2—Indoor Use 12
or D—Indoor Use and G—Indoor Use For the definition of a Class III
For the definition of a Class I For the definition of a Class II Division 2 location, see 12
Division 2 location, see Division 2 location, see National Electrical Code
National Electrical Code
Article 500-5, paragraph (b).
National Electrical Code
Article 500-6, paragraph (b).
Article 500-7, paragraph (b). 12
For the definitions of Class III
For the definitions of Class I For the definitions of Class II Classifications, see the 12
Group A, B, C, D Group F and G National Electrical Code
Classifications, see the Classifications, see the Article 500-7. 12
National Electrical Code National Electrical Code
Article 500-3, paragraph (a). Article 500-3, paragraph (b).
12
NEMA/IEC Enclosure Type Cross-Reference

12
Enclosure Type Cross-Reference 12
The following chart converts NEMA type ratings to IEC classification designations.
DO NOT USE THIS CHART FOR CONVERTING IEC CLASSIFICATION DESIGNATIONS TO NEMA TYPE RATINGS.
12
NEMA 12
Enclosure
IP10
IP20
IP21
IP22
IP23
IP30
IP31
IP32
IP33
IP40
IP41
IP42
IP43
IP50
IP51
IP52
IP53
IP54
IP55
IP56
IP60
IP61
IP62
IP63
IP64
IP65
IP66
IP67
IP68
Rating
12
1 X X — — — — — — — — — — — — — — — — — — — — — — — — — — —
2 X X X X — — — — — — — — — — — — — — — — — — — — — — — — — 12
3R X X X X X — — — — — — — — — — — — — — — — — — — — — — — —
3RX X X X X X — — — — — — — — — — — — — — — — — — — — — — — —
12
3
3X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
12
3S X X X X X X X X X X X X X X X X X X X — — — — — — — — — — 12
3SX X X X X X X X X X X X X X X X X X X X — — — — — — — — — —
4 X X X X X X X X X X X X X X X X X X X X X X X X X X X — — 12
12
4X X X X X X X X X X X X X X X X X X X X X X X X X X X X — —
5 X X X X X X X X X X X X X X X X X — — — — — — — — — — — —
6 X X X X X X X X X X X X X X X X X X X X X X X X X X X X —
12
6P X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
12 X X X X X X X X X X X X X X X X X X — — — — — — — — — — — 12
12K X X X X X X X X X X X X X X X X X X — — — — — — — — — — —
13 X X X X X X X X X X X X X X X X X X — — — — — — — — — — — 12
Cross-reference example 12
A product with a degree of protection equal to or greater than an IEC IP67 rating is required.
What NEMA ratings exceed the IEC IP67 rating? 12
NEMA Types 6 and 6P tests exceed the test requirements for an IEC IP67 rating.
12
12
12
12
12
12
12

Review Answers
12
Review 1 Answers Review 4 Answers Review 6 Answers Review 8 Answers
12 1. Presence, absence 1. Ferrous 1. Thru-Beam. Reflex (or 1. A
Retro-Reflective),
12 2. Limit Switch, Proximity 2. True Diffuse Reflective, 2. D
Sensor, Photoelectric Background Rejection
3. False 3. B
12 Sensor (or Perfect Prox)
3. Electromechanical 4. True 4. C
2. D
12 4. Inductive proximity 5. True 5. NPN
3. C
12 5. Photoelectric 6. False
4. B
6. PNP
7. E
12 5. A
8. G
12 Review 2 Answers Review 5 Answers Review 7 Answers 9. A

10. B
12 1. Operating Head,
Switch Body,
1. True 1. Power required
2. Sensor (or Dielectric), 2. Target size, color, 11. C
Receptacle
12 Oscillator Circuit, texture; Contamination 12. F
2. C Detector Circuit, (dust, humidity,
12 3. F
Output Circuit debris); Application
(distance, background,
13. D
3. True
12 4. D reflectivity)
4. False 3. True
5. A
12 6. E
5. False 4. True
6. True
12 7. B 5. False
8. True
12
12 Review 3 Answers
12 9. a. 2 b. 4 c. 3 d. 1
12 10. C
11. A
12 12. D
12 13. B
14. True
12
12
12
12
12
12
12
12
12
12

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Sensor Learning Course

12.1 Sensor Learning Course—Learning Module 23: Limit Switches,

Volume 8—Sensing Solutions CA08100010E—September 2017 www.eaton.com V8-T12-1

Volume 8—Sensing Solutions, CA08100010E

12 Output Timing Modes . . . . . . . . . . . . . . . . . . .

12 Limit Switches, Proximity Sensors and Photoelectric Sensors

Knowledge Training at Eaton About Eaton University

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tools—right from your product training outside of

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In the Workplace Review 1

12 empty spool and alert set-up personnel. Once the operation

12 relies on physical contact with the target.

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Limit Switch Movement Limit Switch Movement Definitions

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Rotary Lever Actuators, continued

12 Plunger Actuators of Various Limit Switches

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12 have the cover plate facing

12 Limit Switch Types

12 Standard Industrial Switch

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Special Purpose— Special Purpose— Special Purpose—

12 lever CCW 20°

12 1. The three main components of a limit switch are:

12 Match the terminology to the proper description:

12 Answers to Review 2 are on Page V8-T12-42.

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Proximity Sensor Types

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Coupled with the robot’s software control program and the 3

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Inductive Proximity Sensor Influences

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12 will not prevent the sensors’ sensing fields from interacting.

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Oscillator Damping In the Workplace

12 The detector circuit The output circuit remains

12 For all practical purposes, the

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6. The transparency of the container has no effect on the

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if a jam occurs. And items Source

properly and have tamper- retroreflector.

Paper Industry. Sensors can

a defined range, and to ignore objects

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The Light Source

and instantly turned ON

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Photoelectric Sensor Styles and Uses

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