Translated from Spanish to English - www.onlinedoctranslator.
com
ECCI University
SENSORS AND APPLICATIONS IN INDUSTRY
Sebastián Castillo, Stephanie Corredor, Iván A. Valbuena, Duvan D. Castro
ABSTRACT
This work focuses on the operations, applications,
facilities, advantages and disadvantages of industrial
sensors from their inception to the present, taking as a
focus the most relevant events and their importance in
the industry. They resemble a series of events from the
beginning which have made an importance to the most
reliable way whose technification of processes,
providing improvements in automation systems.
(I) -INTRODUCTION
A sensor is a device capable of transforming physical
or chemical quantities, called instrumentation
variables, into electrical quantities. The
instrumentation variables depend on the type of sensor
and can be for example: temperature, light intensity,
distance, acceleration, inclination, displacement,
pressure, force, torque, humidity, pH, etc. An electrical
quantity obtained can be an electrical resistance (as in
an RTD), an electrical capacity (as in a humidity
sensor), an electrical voltage (as in a thermocouple), an
electrical current (as a phototransistor), the sensor is
Unlike a transducer in that the sensor is always in
contact with the variable to be measured or controlled.
There are sensors that not only serve to measure the
variable, but also to convert it through electronic
circuits into a standard signal (4 to 20 mA, 1 to 5VDC
...) to have a linear relationship with the changes of the
measured variable within a range (span), for control
purposes of said variable in a process. It can also be
said that it is a device that takes advantage of one of its
properties in order to adapt the signal it measures so
that it can be interpreted by another device. For
example, the mercury thermometer that takes
advantage of the property of mercury to expand or
contract due to the action of temperature. A sensor can
also be said to be a device that converts one form of
energy into another. It can also be said that it is a
device that takes advantage of one of its properties in
order to adapt the signal it measures so that it can be
interpreted by another device. For example, the
mercury thermometer that takes advantage of the
property of mercury to expand or contract due to the
action of temperature. A sensor can also be said to be a
device that converts one form of energy into another. It
can also be said that it is a device that takes advantage
of one of its properties in order to adapt the signal it
measures so that it can be interpreted by another
device. For example, the mercury thermometer that
takes advantage of the property of mercury to expand
or contract due to the action of temperature. A sensor
can also be said to be a device that converts one form
of energy into another.
(II) - GENERAL CHARACTERISTICS IN
INDUSTRIAL SENSORS
Among the typical technical characteristics of a sensor,
the following stand out.
 Measurement range: domain in the measured
quantity in which the sensor can be applied
 Accuracy: is the maximum expected
measurement error
 Offset or deviation from zero: value of the
output variable when the input variable is null.
If the measurement range does not reach null
values of the input variable, usually another
reference point is established to define the
offset
 Sensitivity of a sensor: ratio between the
variation of the output quantity and the
variation of the input quantity.
 Linearity or linear correlation: has to do
with the degree of agreement between the
calibration curve and a given straight line.
 Resolution: minimum variation of the input
magnitude that can be seen at the output.
 Quick response: it can be a fixed time or
depend on how much the magnitude to be
measured varies. It depends on the capacity of
the system to follow the variations of the input
magnitude
 Drift: are other quantities, apart from the
measurement as input quantity, that influence
the output variable. For example, it can be
environmental conditions, such as humidity,
 temperature or others such as aging (oxidation, constant of the material to be detected, its mass, size,
wear, etc.) of the sensor. and distance to the sensitive surface of the detector.
 Repeatability: expected error when repeating
the same measurement several times.
(II) -CAPACITIVE SENSOR
(III) -SENSOR
A sensor is a device that is able to detect external
actions or stimuli and respond accordingly. These
devices can transform physical or chemical quantities
into electrical quantities. ... If a person approaches the
sensor, it emits a corresponding signal.

(I) -MAGNETIC LIMIT SWITCH SENSORS

There are two main types of auto switches for
pneumatic actuators:
+ Reed type: Switch with mechanical contacts.
Pneumatic actuators internally have a magnetic ring,
the contact of the detector consists of a metal sheet
that, in the proximity of the magnetic field generated
by the actuator ring, is attracted towards it, closing the
contact.
(I) -MAGNETIC RACING SENSOR
When a conductive object approaches the active face
of the detector, the object acts as a capacitor.
The change in capacitance is significant over a long
distance. If a non-conductive object is approached, (>
1) there is only a small change in the dielectric
constant, and the increase in its capacitance is very
small compared to conductive materials. Note the
correction factors when comparing the different
sensing distances.

(III) -INDUCTIVE SENSORS

Inductive sensors are a type of electrical sensor. They
are used to detect ferrous metallic materials. They are
widely used in the industry, both for positioning
applications and for detecting the presence of metallic
objects in a certain context (presence or absence
control, detection of passage, jam, positioning, coding
+ Solid state type: They contain a magneto-sensitive
and counting).
resistance that reacts to a magnetic field in the same
way as the resistance of a photosensitive element (III) -INDUCTIVE SENSOR

when it is influenced by light. An electronic circuit

converts the resistance change into ON / OFF
behavior. These detectors can be 2 or 3-wire, the
latter being classified as PNP and NPN. The
fundamental difference between the types resides in
the way of connection of the load of the same ones.

They have been designed to work by generating a

(II)-CAPACITIVE SENSORS
Capacitive sensors are a type of electrical sensor. The
function of the capacitive detector is to signal a change
of state, based on the variation of the stimulus of an
electric field. Capacitive sensors detect the presence of
metallic or non-metallic objects, measuring the change
in capacitance, which depends on the dielectric
magnetic field and detecting the current losses of said
field generated when ferrous and non-ferrous objects
are introduced into it. The sensor consists of a ferrite
core coil, an oscillator, a signal trigger level sensor,
and an output circuit. Approaching a "metallic" or
non-metallic object induces hysteresis currents in the
object. Due to this there is a loss of energy and a
lower amplitude of oscillation. The sensor circuit then
recognizes a specific change in amplitude and
generates a signal that switches the solid state output • Compact size: Dimensions of the flat model: 19 alt. x
or the "ON" and "OFF" position. 12 wide x 3.5 depth (mm)

PHOTOELECTRIC SENSORS • Red Beam Visible - Simplifies alignment for

installation and service
Photoelectric sensors are a type of electrical sensor. A
photoelectric sensor is an electronic device that • Photoelectric integrated circuit in a chip
responds to change in light intensity. These sensors
• Capable of detecting extremely small objects, with a
require an emitting component that generates the
precise 0.8mm beam
light, and a receiving component that "sees" the light
generated by the emitter (photodetectors). The • Retroreflective coaxial model
construction of this type of sensors is based on the
use of a light signal source (lamps, LED diodes, laser • IP67 housing
diodes, etc.) and a receiving cell for said signal, such (V) - TYPES (II)
as photodiodes, or phototransistors. If this emission
and detection of light occurs, we can divide this type
of sensor into: barrier sensors, or reflection sensors.
Through-beam sensors detect the existence of an
object because it interferes with the reception of the
light signal.

(IV) -PHOTOELECTRIC SENSOR - TYPES (I)

There are different variants of photoelectric sensors
based on their physical medium and presentation
format. Some of them are: + Cylindrical M18: There
are both a barrier version and a reflection version; both
on a mirror and on an object. Its main characteristics
are:
• IP67, IP69K for maximum water resistance
• High immunity to electromagnetic noise and ambient
light • Special barrier models
(VI) -PHOTOELECTRIC SENSOR - TYPES (III)
Optical fiber: There are both a barrier version and a
reflection version; both on a mirror and on an object.
They are used in environments where you need to
work at high temperatures and with aggressive
chemicals, characterized by a combination of high
precision needs with limited mounting space. Its main
characteristics are:
• Very reliable high precision object detection

• High power LEDs to compensate for dirt in the • Simple installation

environment and misalignment
• Long sensor life for all common applications.

• Highly flexible fibers and 90 ° cable outlet to avoid

TYPES (I) breakage

• Hexagonal models for a much easier assembly

• Sizes from M3 to M6

(VI) -TYPES (III)

(V) -PHOTOELECTRIC SENSOR - TYPES (II)

Ultra-compact: There are both a barrier version and a
reflection version; both on a mirror and on an object.
Its encapsulation is miniature and made of plastic,
offering an ideal solution for detection when space is
at a minimum. Its main characteristics are:
 could be directed to be shipped down one lane, while a
blue piece could be directed down a separate lane.
(VII) -VISION SENSORS
Vision sensors are image processing systems in
photocell format, but in contrast to traditional FUNCTIONING
photoelectric sensors, they help machines inspect,
Vision sensors are made up of two main elements,
analyze and reject defective parts or products. Sensors
hardware and software. The camera and controller
are a critical part of industrial manufacturing
constitute the hardware, and the software consists of
processes, optimizing productivity and quality by
the control system, the user interface, and the image
detecting defective parts and products before they
processing algorithms. While the hardware determines
leave the production line. While traditional
a range of product features and efficiencies, it is the
photoelectric sensors interpret data from only a single
software that implements the functional feature set, the
point, vision sensors offer a comprehensive alternative
graphical user interface, and ultimately the actual
solution for more demanding applications. Vision
performance.
sensors basically work by acquiring an entire scene in
image, and delivering a pass or fail signal.

 Acquisition: the camera takes a photo of the (VIII) CHROMATIC SENSORS

part or product to be evaluated.
(VIII) -CHROMATIC SENSORS
 Analysis: this image is transferred to a
memory, processed, examined and compared
with previously established parameters.
 Determination: the vision sensor makes a
decision for each parameter based on user-
defined tolerances, finally delivering the
results as output.

The color sensor detects colors based on the fact that

APPLICATIONS
In packaging applications, vision sensors are
frequently used to verify that only the correct parts or
products are on the conveyor before being packed.
Vision sensors can also verify the position of labels on
objects on a packaging line. For example, bottles of a
shaving gel are guided along a vision sensor that
verifies that the label is present and correctly
positioned. Color vision tools allow vision sensors to
inspect products for colors to match hue and intensity,
offering benefits in many applications. The same
technology can be applied to classification
applications. Instead of connecting outputs to product
reject mechanisms, they are used to classify parts with
different characteristics. For example, a red piece
the reflection ratio of a primary color (ie red, green or
blue) reflected by an object varies with the
chromaticity of the object.
Using an advanced technology multilayer polarized
filter called FAO (Free Angle Optics), the device emits
red, green and blue light in a single optical axis. The
color sensor receives the light reflected from the
detected objects through the receiver and processes the
proportion of red, green and blue light to discriminate
the color of the detectable object.
OPERATION (II)
The detection level indicators light according to the
degree of conformity between the registered and
detected colors. Fine color differences are
discriminated by setting the threshold to a higher level.
(Precise discrimination is foreseen).
Sensor errors that can result from minor differences in
tint or impurity retentions can be avoided by setting
the threshold lower. (Inaccurate discrimination is
expected).

APPLICATIONS
Examples of applications where color sensors are
beneficial include color identification, checking and
selection. The color sensor is widely used in the field
of robotics, automation, quality control, and in various
production processes. Examples:
 Detection of a mixture of pieces of different
color.
 Detection of marks that are difficult to
discriminate (yellow marks on a white
background, etc.)
 Color discrimination and classification of
bottles by a type of barrier fiber optic sensor. •
Extraction and classification by color.
 Directional alignment detection for packing.
 Detection of small marks using a type of
reflective optical fiber
(IX) -LASER SENSOR
In recent years, the accelerated evolution of sensors in
general - and laser sensors in particular - has been
motivated by the needs of the industrial market that
has demanded equipment to improve quality controls,
maximize production times with less time interruption,
increase inspection speed and achieve greater
versatility in detection solutions. In short, greater
flexibility in the manufacture of machinery thanks to
the ability to detect at great distances and
homogeneous and linear beams and savings in
installation space.
FUNCTIONING
Laser sensors can be used as distance detectors by
interference analysis (LASER interferometry). The
principle of operation is based on the superposition of
two waves of equal frequency, one direct and the other
reflected. The resulting wave passes through maximum
and minimum values as the phase of the reflected
signal varies. Industrial sensors generate a beam of
light that is divided into two orthogonal parts by a
separator. One beam is applied on a fixed plane mirror,
while the other reflects on the object whose distance is
to be determined. The two beams overlap again at the
spacer, so that as the object is separated, maxima and
minima are generated at each multiple of the beam's
wavelength. The distance is measured by counting
these oscillations or fringes, obtaining a high precision
digital output.
APPLICATIONS (I)
Laser sensors are widely used in industrial
applications, especially in object measurement tasks
and in part discrimination systems, Discrimination
systems: These types of laser sensors incorporate a
single sensor head that, combined with the available
beam converters It can work with three types of laser
beam: spot beam, to detect tiny elements in very
precise positions; line beam, for the detection of
moving objects, and area beam, for the detection of
printed marks. With a detection distance of up to 1
meter, the sensor can be moved away from moving
parts in a production line without risk of being
damaged, thus reducing maintenance costs and
facilitating installation.
Object measurement systems: These are mainly used
in high precision applications in 3 measurement areas
 OFFSET / DISTANCE: Accurate distance
measurement can be carried out using laser,
inductive or tactile triangulation principles.
 Laser sensors represent a powerful platform
that offers precision and technology.
 PROFILE MEASUREMENT: The profile of an
object is analyzed with a laser beam.
Depending on the height, the laser beam is
reflected differently and creates the profile
information. By moving the sensor or object,
the entire surface can be inspected.
 POSITION / DIAMETER / WIDTH: Precisely
determine the position or diameter of an
object. The object interrupts the laser beam,
allowing the edges of the object to be
determined.
(X)-TEMPERATURE SENSORS
A temperature sensor is a device that collects
information about the temperature from a source and
changes it into a form that can be understood by
another device. It is a category of commonly used
sensors that detect temperature or heat and also
measure the temperature of a medium.
The main temperature sensors used in automation
include digital temperature sensors and humidity and
temperature sensors.
THERMOMETERS
(XI) -DIGITAL TEMPERATURE SENSORS
These digital temperature sensors are temperature
sensing ICs made of silicon that provide accurate
output through digital data of the temperatures they are
measuring. This simplifies the design of the control
system, compared to methods that involve external
signal conditioning and an analog-to-digital converter
(ADC).
Temperature sensor applications:
 They are weather resistant and designed for
continuous temperature measurement in air, soil
or water.
 Exceptional precision and stability.
 For measurements in complex industrial
applications.
 For measurements in difficult operating
conditions.
(XII) -PRESSURE SENSORS
A pressure sensor is a device that captures pressure
and changes its amount into an electrical signal
depending on the pressure at which it is applied.
Pressure (rotary) sensors and vacuum sensors are some
of the main pressure sensors used in industrial
automation.
Pressure sensors (rotary)
This is a high pressure industrial automation sensor
that is widely used in industrial and hydraulic systems
and also in climate control systems.
APPLICATIONS OF PRESSURE SENSORS (XIV)-TORQUE SENSORS

 It is used to measure the pressure below

atmospheric pressure at a certain position.
 Used for meteorological instrumentation,
aircraft, vehicles and all other machines with
pressure function.
 In the system, pressure sensors can be used to
measure other variables such as fluid / gas flow,
velocity, water level, and altitude.

(XIII) MEMS SENSORS

The torque sensor has the necessary mechanical stop
function, increases overload capacity and provides
additional protection during installation and operation.
Rotating torque sensors and torque transducers are
some of the important sensors used in industrial
automation.

ROTATING TORQUE SENSORS

This industrial automation MEMS (Micro-Electro-
Mechanical Systems) sensor converts the mechanical
signals measured into electrical signals.
Acceleration and motion MEMS are some of the
important sensors used in industrial automation.
Acceleration sensors
MEMS acceleration sensors are one of the main
inertial sensors. Dynamic sensors with a wider range
of sensing capabilities.
This industrial rotary torque automation sensor is used
to measure the rotary torque response. Equipped with
the necessary mechanical stops, this torque wrench
increases excess capacity and provides additional
safety during assembly and operation.
Torque transducers
The torque transducer uses superior strain
measurement technology to meet the most demanding
needs in dynamic and static sensor applications.

TORQUE SENSORS APPLICATIONS

Motion sensors
 It is used to measure rotation speed and
Motion sensors integrate MEMS motion sensor data
maintenance needs.
with wireless technology, using data processing
 It is used to measure the mass and the
algorithms designed on machine-powered motion
moments of inertia of the mass.
interaction platforms to perform personalized
 The amount of torque to calculate in terms of a
exchanges.
semi-static process.
Sensor signal processing systems primarily address  Maximum rotation speed, used for vibration
noise rejection. As well as, the smoothing of the signal, torque measurement.
the division of the influence of the intensity, the
change of coordinate system and the recovery of the (XV) -ULTRASONIC SENSORS
position information.
Widely used in the automotive industry with ABS
technology.
In all industrial areas where sensors can be affected by  http://m.automatica.mex.tl/imagesnew/5/0/1
environmental conditions such as dust, smoke or /4/2/ELECTRO%20GUIA%202.pdf
steam, ultrasonic sensors present the ideal solution for  http://www1.udistrital.edu.co:8080/documen
non-contact position determination and distance ts/138588/931dd135-88be-47ed-ae22-
measurement. Objects made of various materials can b4afecea3912
be detected with an accuracy of millimeters, regardless
of color or surface. Ultrasonic sensors have proven
their reliability and accuracy especially in the wood (VI) -QUESTIONS REGARDING RELATED
and furniture industry, the building materials industry, SENSORS
agricultural equipment, construction equipment and in
level control applications. However, ultrasonic
technology is not used exclusively in harsh industrial
environments.
1) In magnetic sensors There are two main types
Pepperl + Fuchs ultrasonic sensors include twelve of magnetic switches for pneumatic actuators
different mechanical designs for barrier, direct and a) Reed Type and Solid State Type
reflection sensing modes. Customer-specific solutions, b) None
tailored to the specific needs of the application, c) Redd type and stable
highlight our technological expertise, which is d) All of the above
characterized by the following distinctive features:
ULTRASONIC SENSORS AT A GLANCE
2) Capacitive sensors are a type of electrical
■ For quick and easy installation: devices with teach-in sensor
function a) If they are 100% electric
b) They are not electric
■ Software that simplifies programming: ULTRA
c) They are combined
3000 service program
d) All of the above
■ Temperature compensation: compensates for
deviations in the speed of sound due to temperature
fluctuations 3) Inductive sensors are a type of electrical sensor
They serve to
■ Synchronization input: to prevent crosstalk when
a) Detect plastics and other polymers
installing two sensors in close proximity to each other
b) Detect metallic and ferrous materials
■ Sensors with digital and analog outputs c) All of the above
d) None of the above

(IV) -CONCLUSIONS 4) There are different variants of photoelectric

sensors based on their physical medium and
In this study it is found that to increase the presentation format. Some of them are:
competitiveness, relevance and validity of the results
in each principle or test according to material and a) Cylindrical M18 and IP67, IP69K for
structures, it is necessary to substitute muscular maximum water resistance
strength and human ability, for mechanical strength b) Tapered and plastics
and precision. In this way, tests can be carried out with c) All of the above
several systems d) None of the above

5) The photoelectric sensor - types (ii) its

(V) -BIBLIOGRAPHY Compact size Dimensions of the model is:

a) flat: 19 alt. x 12 wide x 3.5 depth (mm)

 echanical and electrical engineering / Bolton b) curved 19 atl x 50 wide x 3pro, m
 https://es.slideshare.net/acpicegudomonagas/se c) None of the above
nsores-y-transmisores-analogicos-unidad- d) It's totally flat mind
 https://es.slideshare.net/omarmarcelomagueog
or/presentacion-sensores-digitales-y-
6) The photoelectric sensor - types (iii) They are a) changes its quantity in an electrical signal
used in environments where you need to work depending on the pressure at which it is
at: applied
b) captures all temperature around
a) room temperature c) it doesn’t pick up anything but pressure
b) high temperatures d) all of the above
c) low temperatures
d) adapts to all temperatures
13) Acceleration and motion MEMS are widely
used in:
7) Vision sensors are image processing systems
and help to: a) automotive industry with ABS technology.
b) Metallurgical industry
a) machines to inspect, analyze and reject c) Recycling industry
defective parts or products. d) None of the above
b) Project images to aid sequences
c) Inspect system failures 14) The torque sensor has the function of
d) All of the above
a) Mechanical shutdown required, increases
overload capacity and provides additional
8) The color sensor detects colors based on protection during installation and
operation.
a) reflection ratio of a primary color (i.e. b) Provides mechanically necessary and
red, green, or blue) automated functions
b) proportion of a secondary color (i.e. c) It is not a sensor
yellow, white, black) d) All of the above
c) provide all colors
d) None of the above 15) ultrasonic sensors present the ideal solution to
determine
9) Laser sensors can be used as a) position and measure distance without
contact
a) distance detectors for interference b) the connection points
analysis c) temperature function
b) substance detectors
c) metal detectors
d) all of the above

10) A temperature sensor is a device that collects

information from

a) metallic traces
b) traces of pastures at -100ºc
c) ATM traces
d) None of the above

11) In digital temperature sensors they are

manufactured with

a) Heavy metals
b) Silicon
c) Copper
d) Silver and gold

12) A pressure sensor is a device that captures

pressure and: