Contact and proximity limit

switches

Prepared and reported by: Abdelrahman Mohamed Elshafei

Reported to: Eng. Moataz Sherif
Table of contents
1. ABSTRACT: ------------------------------------------------------------------------------------------------------ 3
2. INTRODUCTION: ---------------------------------------------------------------------------------------------- 3
3. CONTACT LIMIT SWITCH TYPES: ---------------------------------------------------------------------- 5
A) HEAVY-DUTY PRECISION OIL-TIGHT CONTACT LIMIT SWITCH: --------------------------------------------- 5
B) MINIATURE ENCLOSED REED CONTACT LIMIT SWITCH: ------------------------------------------------------ 6
C) SNAP CONTACT LIMIT SWITCHES: -------------------------------------------------------------------------------- 6
D) GRAVITY RETURN CONTACT LIMIT SWITCH: -------------------------------------------------------------------- 7
4. CIRCUITRY AND INTERCONNECTION OF CONTACT LIMIT SWITCH: -------------------- 8
5. ADVANTAGES AND DISADVANTAGES OF CONTACT LIMIT SWITCH: -------------------- 8
6. CONTACT LIMIT SWITCH APPLICATIONS: --------------------------------------------------------- 9
7. PROXIMITY SWITCH TYPES: ---------------------------------------------------------------------------- 11
A) INDUCTIVE PROXIMITY SENSORS: ------------------------------------------------------------------------------ 11
B) CAPACITIVE PROXIMITY SWITCH ------------------------------------------------------------------------------- 13
C) PHOTOELECTRIC SENSORS: -------------------------------------------------------------------------------------- 14
D) ULTRASONIC PROXIMITY SENSORS: ---------------------------------------------------------------------------- 18
8. PROXIMITY SENSORS APPLICATIONS: -------------------------------------------------------------- 19
9. COMPARISON BETWEEN DIFFERENT PROXIMITY SENSOR TYPES: --------------------- 22
10. REFERENCES: ---------------------------------------------------------------------------------------------- 23

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 1. Abstract:
In this document, I am going to compare between the contact limit switches
and the proximity limits switches, showing the interconnections of them with
control system and the various applications they are used at.

2. Introduction:
A contact limit switch detects the physical motion of an object by direct
contact with that object. An example of a limit switch is the switch detecting
the open position of an automobile door, automatically energizing the cabin
light when the door opens. The “normal” status of a switch is the resting
condition of no stimulation. A limit switch will be in its “normal” status when
it is not in contact with anything (i.e. nothing touching the switch actuator
mechanism).
Limit switches find many uses in industry, particular in robotic control and
CNC (Computer Numerical Control) machine tool systems. In many motion-
control systems, the moving elements have “home” positions where the
computer assigns a position value of zero. For example, the axis controls on a
CNC machine tool such as a lathe or mill all return to their “home” positions
upon start-up, so the computer can know with confidence the starting
locations of each piece. These home positions are detected by means of limit
switches. The computer commands each servo motor to travel fully in one
direction until a limit switch on each axis trips. A typical contact limit switch
design uses a roller-tipped lever to make contact with the moving part.

Fig. 1 Different types of contact limit switches

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 Fig. 2 Normally opened and normally closed contact limit switch
A proximity switch is one detecting the proximity (closeness) of some object.
By definition, these switches are non-contact sensors, using magnetic,
electric, or optical means to sense the proximity of objects. The “normal”
status of a switch is the resting condition of no stimulation. A proximity switch
will be in its “normal” status when it is distant from any detectable object.
Being non-contact in nature, proximity switches are often used instead of
direct-contact limit switches for the same purpose of detecting the position of
a machine part, with the advantage of never wearing out over time due to
repeated physical contact.
Most proximity switches are active in design. That is, they incorporate a
powered electronic circuit to sense the proximity of an object. The schematic
diagram symbol for a proximity switch with mechanical contacts is the same
as for a mechanical limit switch, except the switch symbol is enclosed by a
diamond shape, indicating a powered (active) device.

Fig. 3 Normally opened and normally closed proximity sensor symbols

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 3. Contact limit switch types:

Limit switch performance depends on a number of factors. In addition to the

operational parameters and mechanical specifications of a machine, these
factors include the size, mounting method, and force capacity of the switch,
as well as the stroke rate involved in the operating process. It is important for
a limit switch’s electrical rating to match that of the system into which it is
installed in order to reduce the potential for instrument failure and ensure
proper functioning. There are a large number of different contact switches
types and here are some of them:
a) Heavy-Duty Precision Oil-Tight contact limit switch:
Also known as the Type C limit switch, this device is highly reliable due to
its long electrical and mechanical lifespan. It features a straightforward wiring
arrangement and relatively easy installation. The Type C can be equipped with
a range of different head and body styles, including a more durable design that
is watertight and submersible. It is available in a standard format, as well as
with specialized reed contacts.

Fig. 4 Heavy duty precision oil tight limit switch

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 b) Miniature Enclosed Reed contact limit switch:
This limit switch, also known as Type XA, is a smaller and less expensive
device formed from die-cast zinc. It contains a contact array featuring a
hermetically sealed reed, which makes it well-suited for applications that
require a high level of contact reliability or involve environmental stresses.
The switch is normally prewired and can be placed in smaller or harder to
reach areas.

Fig. 5 Miniature limit switch

c) Snap contact limit Switches:

A snap switch is designed to instantly trigger as soon as the mechanism
attached to the switch has moved a predetermined distance, regardless of the
speed at which the moving part travels. Snap switches are commonly used in
applications that require only basic contact parameters and can work with or
without an operator. They are effective in machine systems that feature short
movements or a slow rate of operation.

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 Fig. 6 snap contact limit switch
d) Gravity return contact limit switch:
The gravity return limit switch is usually employed in production line and
conveyor operations involving small, lightweight components. This type of
switch relies on gravity to reset its contact switches by exerting force on a
lever arm and typically functions with a low level of torque. There are several
varieties of gravity return switches, including spring return, roller type, lever
type, top push, and maintained contact designs.

Fig. 7 Gravity return limit switch

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 4. Circuitry and interconnection of contact limit switch:
A limit switch with a single-station, maintained contact design will have a
“Start” button that mechanically controls the contacts. Pressing the “Start”
button causes the mechanism to maintain the contact sequence that closes the
circuit, while pressing the “Stop” button will open the contacts and break the
circuit. If a system malfunction, such as power failure or overloading, causes
the switch device to deactivate, the contacts will be unaffected and the motor
will automatically reset.

Fig. 8 Difference between sinking/sourcing PLC input channel

Note the differences in polarity and labeling between the sinking card’s
common terminal and the sourcing card’s common terminal. On the “sinking”
card, the input channel terminal is positive while the common (“Com”)
terminal is negative. On the “sourcing” card, the input channel terminal is
negative while the common (“VDC”) terminal is positive.

5. Advantages and disadvantages of contact limit switch:

Limit switches offer several advantages intrinsic to their design:
1. The designs are generally simple and straightforward
2. They work well in almost any industrial setting
3. They exhibit high accuracy and repeatability
4. They are low power consumption devices
5. They can switch high-inductance loads

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 6. They can be used to switch multiple loads
7. They are simple to install
8. They are rugged and reliable
9. They typically have heavy-duty electrical contacts meaning they can be
used to switch higher levels of current directly without the need to
utilize secondary relay control
Limit switches also have several limitations, which means they may not be
suited for every application:
1. Because they rely on mechanical action, they generally are used in
equipment that operates at relatively low speeds
2. They are contact sensors, meaning they must make physical contact
with the target for them to operate
3. The nature of their mechanical design means that the devices are subject
to mechanical wear or fatigue over time and will need eventual
replacement

6. Contact limit switch applications:

Now that you’ve seen the limit switch in action you are probably thinking
about some of the applications where you have seen them in action.
For example, you might see limit switches operated by a container on an
assembly line, or operated by a rotating machine part or by any number of
other moving mechanical objects.

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Limit switches could be used to count passing objects, or determining the
position of a hydraulic cylinder.

Fig. 9 Contact limit switch detecting a container

When you open the fridge door, a light comes on inside. How does that
happen? A limit switch is used to detect if the fridge door is open or closed.

Fig. 10 Contact limit switch used in refrigerator

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Look at another application of a limit switch that you may encounter at home.
On many overhead garage doors, there is a limit switch that stops the
movement of the door when it reaches its fully opened position.

Fig. 11

7. Proximity switch types:

a) Inductive proximity sensors:
These non-contact proximity sensors detect ferrous targets, ideally mild steel
thicker than one millimeter. They consist of four major components: a ferrite
core with coils, an oscillator, a Schmitt trigger, and an output amplifier. The
oscillator creates a symmetrical, oscillating magnetic field that radiates from
the ferrite core and coil array at the sensing face.

Fig. 12 inductive proximity sensor elements

When a ferrous target enters this magnetic field, small independent electrical
currents called eddy currents are induced on the metal’s surface. This changes
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the reluctance of the magnetic circuit, which in turn reduces the oscillation
amplitude. As more metal enters the sensing field the oscillation amplitude
shrinks, and eventually collapses. The Schmitt trigger responds to these
amplitude changes, and adjusts sensor output. When the target finally moves
from the sensor’s range, the circuit begins to oscillate again, and the Schmitt
trigger returns the sensor to its previous output.

Fig. 13 Inductive proximity switch

If the sensor has a normally open configuration, its output is an on signal
when the target enters the sensing zone. With normally closed, its output is
an off signal with the target present. Output is then read by an external control
unit (e.g. PLC, motion controller, smart drive) that converts the sensor on and
off states into useable information. Inductive sensors are typically rated by
frequency, or on/off cycles per second. Their speeds range from 10 to 20 Hz
in ac, or 500 Hz to 5 kHz in dc.
But what inductive sensors lack in range, they make up in environment
adaptability and metal-sensing versatility. With no moving parts to wear,
proper setup guarantees long life. Special designs with IP ratings of 67 and
higher are capable of withstanding the buildup of contaminants such as cutting
fluids, grease, and non-metallic dust, both in the air and on the sensor itself.
It should be noted that metallic contaminants (e.g. filings from cutting
applications) sometimes affect the sensor’s performance. Inductive sensor
housing is typically nickel-plated brass, stainless steel, or PBT plastic.

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 b) Capacitive proximity switch
Capacitive proximity sensors can detect both metallic and non-metallic targets
in powder, granulate, liquid, and solid form. This, along with their ability to
sense through nonferrous materials, makes them ideal for sight glass
monitoring, tank liquid level detection, and hopper powder level recognition.
In capacitive sensors, the two conduction plates (at different potentials) are
housed in the sensing head and positioned to operate like an open capacitor.
Air acts as an insulator; at rest there is little capacitance between the two
plates. Like inductive sensors, these plates are linked to an oscillator, a
Schmitt trigger, and an output amplifier. As a target enters the sensing zone
the capacitance of the two plates increases, causing oscillator amplitude
change, in turn changing the Schmitt trigger state, and creating an output
signal. Note the difference between the inductive and capacitive sensors:
inductive sensors oscillate until the target is present and capacitive sensors
oscillate when the target is present.

Fig. 14 Internal circuit of capacitive proximity sensor

Because capacitive sensing involves charging plates, it is somewhat slower
than inductive sensing ... ranging from 10 to 50 Hz, with a sensing scope from
3 to 60 mm. Many housing styles are available; common diameters range from
12 to 60 mm in shielded and unshielded mounting versions. Housing (usually
metal or PBT plastic) is rugged to allow mounting very close to the monitored
process. If the sensor has normally-open and normally-closed options, it is
said to have a complimentary output.

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Due to their ability to detect most types of materials, capacitive sensors must
be kept away from non-target materials to avoid false triggering. For this
reason, if the intended target contains a ferrous material, an inductive sensor
is a more reliable option.
c) Photoelectric sensors:
Photoelectric sensors are so versatile that they solve the bulk of problems put
to industrial sensing. Because photoelectric technology has so rapidly
advanced, they now commonly detect targets less than 1 mm in diameter, or
from 60 m away. Classified by the method in which light is emitted and
delivered to the receiver, many photoelectric configurations are available.
However, all photoelectric sensors consist of a few of basic components: each
has an emitter light source (Light Emitting Diode, laser diode), a photodiode
or phototransistor receiver to detect emitted light, and supporting electronics
designed to amplify the receiver signal. The emitter, sometimes called the
sender, transmits a beam of either visible or infrared light to the detecting
receiver.

Fig. 15 Different types of photoelectric sensors

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 i. Thru-beam photoelectric sensor:
The most reliable photoelectric sensing is with through-beam sensors.
Separated from the receiver by a separate housing, the emitter provides a
constant beam of light; detection occurs when an object passing between the
two breaks the beam. Despite its reliability, through-beam is the least popular
photoelectric setup. The purchase, installation, and alignment of the emitter
and receiver in two opposing locations, which may be quite a distance apart,
are costly and laborious. With newly developed designs, through-beam
photoelectric sensors typically offer the longest sensing distance of
photoelectric sensors — 25 m and over is now commonplace. New laser diode
emitter models can transmit a well-collimated beam 60 m for increased
accuracy and detection. At these distances, some through-beam laser sensors
are capable of detecting an object the size of a fly; at close range, that becomes
0.01 mm. But while these laser sensors increase precision, response speed is
the same as with non-laser sensors — typically around 500 Hz.

Fig. 16 Thru-beam photoelectric sensor detecting a target

One ability unique to thru-beam photoelectric sensors is effective sensing in
the presence of thick airborne contaminants. If pollutants build up directly on
the emitter or receiver, there is a higher probability of false triggering.
However, some manufacturers now incorporate alarm outputs into the
sensor’s circuitry that monitor the amount of light hitting the receiver. If
detected light decreases to a specified level without a target in place, the
sensor sends a warning by means of a LED or output wire.

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 ii. Retro-reflective:
Retro-reflective sensors have the next longest photoelectric sensing distance,
with some units capable of monitoring ranges up to 10 m. Operating similar
to through-beam sensors without reaching the same sensing distances, output
occurs when a constant beam is broken. But instead of separate housings for
emitter and receiver, both are located in the same housing, facing the same
direction. The emitter produces a laser, infrared, or visible light beam and
projects it towards a specially designed reflector, which then deflects the beam
back to the receiver. Detection occurs when the light path is broken or
otherwise disturbed.

Fig. 17 Retro-reflective proximity sensor sensing mechanism

One reason for using a retro-reflective sensor over a through-beam sensor is
for the convenience of one wiring location; the opposing side only requires
reflector mounting. This results in big cost savings in both parts and time.
However, very shiny or reflective objects like mirrors, cans, and plastic-
wrapped juice boxes create a challenge for retro-reflective photoelectric
sensors. These targets sometimes reflect enough light to trick the receiver into
thinking the beam was not interrupted, causing erroneous outputs.

iii. Diffuse proximity switch:

As in retro-reflective sensors, diffuse sensor emitters and receivers are located
in the same housing. But the target acts as the reflector, so that detection is of
light reflected off the disturbance object. The emitter sends out a beam of light
(most often a pulsed infrared, visible red, or laser) that diffuses in all
directions, filling a detection area. The target then enters the area and deflects

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part of the beam back to the receiver. Detection occurs and output is turned
on or off (depending upon whether the sensor is light-on or dark-on) when
sufficient light falls on the receiver.

Fig. 18 Diffuse proximity sensor sensing mechanism (in sensing range)

Diffuse sensors can be found on public washroom sinks, where they control
automatic faucets. Hands placed under the spray head act as reflector,
triggering (in this case) the opening of a water valve. Because the target is the
reflector, diffuse photoelectric sensors are often at the mercy of target material
and surface properties; a non-reflective target such as matte-black paper will
have a significantly decreased sensing range as compared to a bright white
target. But what seems a drawback ‘on the surface’ can actually be useful.
Because diffuse sensors are somewhat color dependent, certain versions are
suitable for distinguishing dark and light targets in applications that require
sorting or quality control by contrast. With only the sensor itself to mount,
diffuse sensor installation is usually simpler than with through-beam and
retro-reflective types.

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 d) Ultrasonic proximity sensors:
Ultrasonic proximity sensors are used in many automated production
processes. They employ sound waves to detect objects, so color and
transparency do not affect them (though extreme textures might). This makes
them ideal for a variety of applications, including the long range detection of
clear glass and plastic, distance measurement, continuous fluid and granulate
level control, and paper, sheet metal, and wood stacking.

Fig. 19 Ultrasonic proximity sensor sensing principle

The most common configurations are the same as in photoelectric sensing:
through beam, retro-reflective, and diffuse versions. Ultrasonic diffuse
proximity sensors employ a sonic transducer, which emits a series of sonic
pulses, then listens for their return from the reflecting target. Once the
reflected signal is received, the sensor signals an output to a control device.
Sensing ranges extend to 2.5 m.
Ultrasonic retro-reflective sensors also detect objects within a specified
sensing distance, but by measuring propagation time. The sensor emits a series
of sonic pulses that bounce off fixed, opposing reflectors. The sound waves
must return to the sensor within a user-adjusted time interval; if they don’t, it
is assumed an object is obstructing the sensing path and the sensor signals an
output accordingly. Because the sensor listens for changes in propagation time
as opposed to mere returned signals, it is ideal for the detection of sound-
absorbent and deflecting materials such as cotton, foam, cloth, and foam
rubber.

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Similar to through-beam photoelectric sensors, ultrasonic thru-beam sensors
have the emitter and receiver in separate housings. When an object disrupts
the sonic beam, the receiver triggers an output. These sensors are ideal for
applications that require the detection of a continuous object, such as a web
of clear plastic. If the clear plastic breaks, the output of the sensor will trigger
the attached PLC or load.

8. Proximity sensors applications:

i. Inductive proximity sensor applications:
 Position Detection on a Mechanical Moving Part
The process of inserting items into packages or cartons using metal flags fitted
on conveyor chains is relatively simple. At the same time, it is also an extremely
precision-driven function. The responsiveness and reliable detection qualities of
inductive proximity sensors ensures consistent alignment and follow-through
functions. That results in less waste and fewer system interruptions.
 Gear Tooth Detection for Motion Monitoring
Reliable, repeatable results are also critical when monitoring the position of
chain guides or flexors, which drives other components of conveyor system.
 Valve Position Control during Processing
Most high-hygienic processes such as dairy or yogurt production utilize valves
to switch system feeds from ingredients to cleaning solutions, then back when
sanitation process is complete. Because a well-manufactured inductive proximity
sensor is more resistant to wear than mechanical limit switches, processors have
greater assurance of long-term, consistent valve operation.
 Foil Seal Detection Inside Plastic Caps
With a wider range of foil seal material now being used, certain colors and
textures may be missed by photoelectric sensors. This can result in false readings.
Because an inductive proximity sensor looks merely for the presence of metal,
the seal material’s qualities are irrelevant.
 Can Position Detection on a Beverage Line
 Detection of metal objects, armory, land mines, etc.

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 ii. Capacitive proximity sensor applications:
 Sensor is adjusted so that it does not detect the wall of the vessel of a filling tank,
so that it only detects the level of the fluid.
 Application detecting milk in cartoons.
 Application of detecting the presence of can and if the can is full

Fig. 20 Different applications of capacitive proximity sensor

iii. Ultrasonic proximity sensor applications:
 Distance measurement.
 Automation production processes.
 Automotive applications.

Fig. 21 Automotive applications using ultrasonic proximity sensor

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  Fluid detection.
 Unmanned aerial vehicles (UAVs) for object monitoring.
 Robotics.

Fig. 22 Different applications using ultrasonic proximity sensor

iv. Photoelectric proximity sensor applications:
 Counting and monitoring over longer distances e.g. conveyor, packaging and
handling systems.
 Bottling and canning plants.
 Food making.
 Sorting by height detection.
 Controlling doors, gates and corridors.
 With fibers counting, checking and sorting of small objects, as in some
production environments, small items will fall from a vibrating conveyor belt into
a packaging system or bag – and a photoelectric sensor can count them.
 Detecting colors: by scanning independently in red, green and blue light, with
applications in multiple processes in the printing and packaging sectors.

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9. Comparison between different proximity sensor types:

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 10. References:
www.instumentationtools.com
www.realpars.com
www.springercontrols.com
www.thomasnet.com
library.automationdirect.com
www.seedstudio.com
Lessons in industrial instrumentation

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