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A sensor is a device that helps to detect any changes in physical quantity like
pressure, force or electrical quantity like current or any other form of energy. After
observing the changes, sensor sends the detected input to a microprocessor and
produces a readable output signal, which can be either optical, electrical, or any form
of signal that corresponds to change in input signal.
The output is basically a signal that is converted to human-readable display at the
sensor location .

• In few cases, a sensor alone may not be sufficient to analyze the obtained
signal. In those cases, a signal conditioning unit is used in order to maintain
sensor’s output voltage levels in the desired range with respect to the end
device that we use.

In signal conditioning unit, the output of the sensor may be amplified, filtered
or modified to the desired output voltage. So, a signal conditioning unit (an
amplifier) is used to increase the signal strength.

➢ Characteristics of Sensors
1. High Sensitivity.
2. Linearity.
3. High Resolution.
4. Less Noise and Disturbance.
5. Less power consumption.
 ➢ Classification of Sensors

• Active and Passive Sensors

• Analog and Digital Sensors

Active Sensors:

Active sensors are the type of sensors that produces output signal with help of external
excitation supply. Requiring an external source of energy, they give a signal such as light,
electromagnetic wave, radiation, and sound to the measurement object, and receive its
reflection, transmission, and absorption, and detect the feature quantity of the measured
.Therefore, it is also called as Self Generating Sensors.

Examples: LVDT and strain gauge.

Passive Sensors:

Passive sensors are the type of sensors that produces output signal without the help of
external excitation supply. They do not need any extra stimulus or voltage.
Example: Thermocouple.

An example of the difference is a security infrared sensor. They are selected

according to the intended use and installation location.
 • A near-infrared sensor that emits an infrared ray from the sensor itself and
detects the object to be measured by reflecting or blocking the ray is an
active sensor.

• A far-infrared sensor that receives infrared rays given from the human body
surface and detects people is a passive sensor.

Analog and digital sensor:

An analog sensor converts the physical quantity being measured to analog form
(continuous in time). Thermocouple, RTD, Strain gauge are called analog sensors. A
digital sensor produces output in the form of pulse. Encoders are example of digital
sensors.

➢ FEW EXAMPLE OF SENSORS

• An oxygen sensor in a car's emission control system detects the

gasoline/oxygen ratio

• Motion sensors in various systems including home security lights, automatic

doors and bathroom fixtures

• photosensor detects the presence of visible light, infrared transmission (IR),

and/or ultraviolet (UV) energy.

• optical sensors for Refractive index measurement, vibrational sensors for fluid
viscosity measurement

• electro-chemical sensor for monitoring pH of fluids.

 ➢ Technologies Used by Sensors

1. Acoustic 2. Capacitive 3. Doppler 4. Electro Magnetic

5. Electro- 6. Thermistor 7. Hall effect 8. Inductance

Mechanical

9. Infrared 10. Laser 11. Microwave 12. Optic

13. Radiofrequency 14. Ultrasonic 15. Giant Magento resistance (GMR)

• Sensors not only ensures measurement data is transmitted faster, but also
increase accuracy, thereby improving process control, and enhancing asset
health.

• sensors improve sensitivity during data capture, almost lossless transmission,

and continuous, real-time analysis.

• Real-time feedback, and data analytics services ensure that processes are
active, and are executed optimally.

• A new breed of sensors are capable of wired and wireless transmission, they
provide a real-time, continuous data feed from assets and processes.

• Monitor processes and assets accurately, reliably, and continuously

• Increase productivity and reduce total cost of ownership

• Lower energy wastage

FOR WIRELESS SENSOR NETWORK

• Effective in Harsh or Hostile Environments

• Offer an Easily Scaled Solution

• Enable Long-distance Data Collection and Transmission

• Can Anticipate Natural Disasters

• Can Protect Hardware and Data Assets

Proximity sensor is a type of non-contact sensor used for object detection. It
does not have any physical contact with the object. The object whose distance
is to be measured is known as target. An IR light or electromagnetic radiation
is used in a proximity sensor.

Some of the applications of Proximity Sensors are Mobile Phones, Cars

(Parking Sensors), industries (object alignment), Ground Proximity in Aircrafts.

➢ Working

A proximity sensor emits an electromagnetic or electrostatic field or a beam

of electromagnetic radiation (such as infrared), and waits for the return signal

or changes in the field.

➢ Applications

• Object detection
• Counting of pieces
• Velocity measurements
• Rotation
• Positioning objects / containers
• Detection of materials
• Determine the direction of movement
• Monitoring of tools
TYPES OF PROXIMITY SENSOR

1. Inductive Proximity Sensor

The inductive proximity sensors are useful to detect the metallic object which
is present next to their active side.

2. Optical Proximity Sensor

A complete optical proximity sensors includes a light source, and a sensor that
detects the light.

3. Capacitive Proximity Sensor

The capacitive proximity sensors can detect both metallic and non-metallic targets
in powder, granulate, liquid, and solid form.

4. Magnetic Proximity Sensor

this sensor only detects the magnetic field. They sense the presence of a magnetic
object, commonly referred to as the target.
5. Ultrasonic Proximity Sensor

Ultrasonic sensors emit an ultrasonic pulse which is reflected by objects in its path

An optical sensor converts light rays into an electronic signal. The purpose of
an optical sensor is to measure a physical quantity of light and, depending on
the type of sensor, then translates it into a form that is readable by an integrated
measuring device. Optical Sensors are used for contact-less detection,
counting or positioning of parts. Optical sensors can be either internal or
external.

The measurands possible by different optical sensors are Temperature,

Velocity Liquid level, Pressure, Displacement (position), Vibrations, Chemical
species, Force radiation, pH- value, Strain, Acoustic field and Electric field

TYPES OF OPTICAL SENSOR

• Photodetector: It uses light sensitive semiconductor materials like

photocells, photodiodes to work as photodetector
• Fiber Optics: Fibers optics carry no current, So its immune to electrical
& electromagnetics
• Pyrometer: It estimates the temperature of an object by sensing the
color of the light
• Proximity & Infrared: Proximity use light to sense objects nearby and
Infrared are used where visible light would be inconvenient.
An ultrasonic sensor is as sensor which measures the distance of respective object by
sending the sound wave of specific frequency. This sound wave is reflected after the
collision with respective object and this wave is received by the ultra-sonic receiver.
Distance is measured by calculating sending and receiving time of this sound wave.

Figure 1 The Basic Operation Diagram of Ultrasonic Sensor

Distance is measured by the formula
Distance = Sound speed x time taken / 2

➢ Applications

1. Ultrasonic sensor is used in oil, chemical, milk or water tanks for level
measurements or for liquid level control.
2. This sensor is used in thru beam detection for high speed counting.
3. This sensor is used in robotic industry for robot sensing.

➢ Working

The working principle of the ultrasonic sensor is based on the reflection of

sound waves and used to detect the presence of a specific object in front of
it, it operates in the region above the frequency of sound waves from 40KHz
-400Khz.

RFID is abbreviation of Radio Frequency Identification. RFID sensor

systems pass data from tagged objects to RFID readers. An RFID
system consists of two parts: the RFID tag and the RFID reader or
interrogator. Tags are classified as active, passive, or passive with
battery assist. A passive tag needs to be interrogated by the RF signal
from an active readout device. Readout devices can be classed as active
or passive.
This small chip is competent of accumulating approx 2000 bytes of data or
information. RFID devices is used as a substitute of bar code or a magnetic
strip which is noticed at the back of an ATM card or credit card, it gives a unique
identification code to each item.
RFID technology is used in a number of industries to carry out various tasks
such as:

• Asset tracking
• Inventory management
• Controlling access to confined areas
• Personnel tracking
• Supply chain management
• ID badging

The products sold in the markets has a Universal Product Code (UPC) which is
a 12 digit code. Five of the numbers signify the manufacturer and other five
signify the product. The first six digits are represented by code as light and dark
bars. The first digit signifies the type of number system and the second digit
which is parity signifies the accuracy of the reading. The remaining six digits
are represented by code as dark and light bars reversing the order of the first
six digits.

The sensor in the barcode scanner detects the reflected light from the
illumination system (the red light) and generates an analog signal that is
sent to the decoder. The decoder interprets that signal, validates the
barcode using the check digit, and converts it into text.

A Typical Image Of Bar Code Scanned By Bar Code Reader

➢ Braking and Traction control:

Antilock Braking System (ABS) Sensors connected to the wheel, measures the
speed of the wheel and braking pressure and keeps sending them to ABS
controlling When the driver applies sudden brake, ABS system.

➢ Air Bags – Anti Cushion Restraint System (ACRS):

Crush sensors and accelerometers placed in the vehicle measures the force and
sends it to During accidents on sensing the force exceeds the limit, ACRS will
activate the Airbag and save the life of passengers.

➢ Avoiding Collisions:

Proximity sensors in the front, back, and sides of the vehicle forewarn the driver
of a possible Infrared, Video assistance, Ultrasonic technologies assist drivers
while parking their vehicles.

➢ Engine Data:

Sensors provides so much data on Engine performance such as Ignition, b.

Combustion, c. Exhaust gas oxygen, d. Fuel mix, e. Exhaust gas recycling, f.
Transmission control .

➢ Sensors used in industrial Automation:

• Temperature Sensors
• Pressure sensors
• MEMS Sensors
• Torque Sensors
• Inductive sensors
• Color sensors
• Capacitive sensors
 ➢ Temperature Sensors :

Digital Temperature Sensors:

These Digital Temperature Sensors are silicon-based temperature- sensing ICs that
provide accurate output through digital representations of the temperatures they are
measuring. This simplifies the control system’s design.

Humidity & Temperature Sensors

The Temperature & Humidity sensors attribute a temperature & humidity sensor
complex with a measured digital signal output. By utilizing the technique and temperature
& limited digital-signal-acquisition humidity sensing technology, it ensures high consistency
and exceptional long-standing stability.

Applications of Temperature Sensors:

• They are weatherproof & designed for continuous temperature measurement in air, soil,
or water
• For measurements in complex industrial applications
• For measurements under rough operating conditions

➢ Pressure Sensors:
Turned parts for Pressure Sensors and Vaccum Sensors are few of the major pressure
sensors used in Industrial automation.

Turned parts for Pressure Sensors

 These Pressure sensors are widely used in Industrial and hydraulic systems, these are
high pressure industrial automation sensors also used in climate control systems.

Vaccum Sensors

Vaccum Sensors are used when the Vaccum pressure is below atmospheric pressure
levels and it can be difficult to sense through mechanical methods.

Applications of Pressure Sensors:

• Used to measure pressure below than the atmospheric pressure at a given location
• Used in weather instrumentation, aircrafts, vehicles, and any other machinery that has
pressure functionality implemented
• Pressure sensors can be used in systems to measure other variables such as fluid/gas
flow, speed, water level, and altitude

➢ MEMS Sensors (Micro-electro-mechanical Systems)

These MEMS industrial automation sensors convert measured mechanical signals into
electrical signals. Acceleration and Motion MEMS are few important sensors used in
industrial automation.

Acceleration sensors
 Micro-electro-mechanical Systems (MEMS) Acceleration Sensors are one of the main
inertial sensors; and are dynamic sensor competent of have a greater range of sensing
capabilities.

Motion sensors

Micro-electro-mechanical system (MEMS) motion sensors use data processing algorithms

designed on a motion interaction platform which integrates numerous low-cost MEMS
motion sensors with ZigBee wireless technology to carry personified interactions

Applications of MEMS Sensors:

• These have numerous applications ranging from industry, entertainment, sports to

education. For example, triggering airbag deployments or monitoring of nuclear reactors
• Used to measure static acceleration (gravity), tilt of an object, dynamic acceleration in an
aircraft, shock to an object in a car, vibration of an object. Cell phones, washing machines
or computers

➢ Torque sensors

The torque sensors complete with essential mechanical stops, raise overload capacity and
offer additional guard during mounting and operation.Rotating Torque & Torque
Transducers are few important sensors used in industrial automation.

Rotating Torque Sensors

This Rotating Torque industrial automation sensors used for measuring reaction of rotating
torque. These torque meters complete with essential mechanical stops increase surplus
capacity and offer extra safety during mounting and operation.

Torque Transducers
 These torque transducers utilize superior strain gage technology to indulge the most
challenging necessities for static and dynamic applications of sensors.

Applications of Torque Sensors:

• Used to measure Mass and mass moment of inertia

• The amount of the torque to be calculated, from the point of vision of quasi-static
• Used to measure the highest speed of rotation, oscillating torque

• Accelerometer and Gyroscope used in mobile phone for detecting liner and angular
motion
• Digital compass or magnetometer sensor used for the navigation of maps
• PIRS sensors used as a motion sensor
• Temperature and Humidity sensors are used in electronic machines such as air
coolers , air conditioners, refrigerators for automatic operation
• LDRS used for automatic outdoor switching operator
• Photoelectric sensor used for packaging, material handling, parts detection
• Inductive sensor used in industrial machines and tools.
• Capacitive sensor for level sensing
• Ultrasonic sensor used for the anti-collision, doors, level control, web brake.
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