Sensors
Automation and Control Engineering
Types
1. Position/Displacement sensors : Potentiometer, Optical rotary
encoders, and linear variable differential transformers.
2. Proximity sensors : Limit switches, optical proximity switches, and
Hall-effect switches.
3. Load sensors : Bonded-wire strain gauges
4. Pressure sensors : Bourdon tubes, Bellows.
5. Temperature sensors : Bimetallic temperature sensors,
thermocouples.
6. Flow sensors : Orifice plates, venturis, pitot tubes
Application
• Position sensors:
1. Potentiometer: Found in control systems, robotics, and automotive applications.
2. Optical rotary encoders: Used in robotics, CNC machines, and motion control systems.
3. Linear variable differential transformers (LVDTs): Common in industrial automation, aircraft, and hydraulic
systems.
• Proximity sensors:
1. Limit switches: Commonly used in industrial machinery, conveyor systems, and door/window sensors.
2. Optical proximity switches: Found in automation, robotics, and packaging equipment.
• Load sensors:
1. Bonded-wire strain gauges: Used in scales, force measurement systems, and structural health monitoring.
• Pressure sensors:
1. Bourdon tubes: Common in pressure gauges, hydraulic systems, and industrial machinery.
• Temperature sensors:
1. Bimetallic temperature sensors: Found in thermostats, HVAC systems, and industrial temperature
monitoring.
2. Thermocouples: temperature measurement systems, and scientific research.
• Flow sensors:
1. Orifice plates, venturis, pitot tubes: Common in industrial flow measurement, and aircraft instrumentation.
Displacement Sensor
• Potentiometer
Potentiometers work by varying the position of a sliding contact across a
uniform resistance. In a potentiometer, the entire input voltage is applied
across the whole length of the resistor, and the output voltage is the voltage
drop between the fixed and sliding contact as shown below.
Types
There are two main types of
potentiometers:
Rotary potentiometer
Linear potentiometer
Displacement Sensor
Rotary Potentiometer
A circular resistive material, like conductive plastic, forms a single-turn
potentiometer with uniform resistivity, facilitating precise voltage division.
The slider, or wiper, taps off a value along the resistor's length, providing a
variable output within the potentiometer's limited 350° range.
Displacement Sensor
Displacement Sensor
Displacement Sensor
Optical Encoder
Provides a digital output as a result of an angular or linear
displacement
Incremental encoders
Absolute encoders
Displacement Sensor
Optical Encoder
Incremental encoders
• Single track with evenly spaced slots for position detection.
• Position determined by counting passing slots, each representing a
known angle.
Displacement Sensor
Optical Encoder
Incremental encoders
Displacement Sensor
Optical Encoder
Incremental encoders: Detecting CW and CCW rotation
Displacement Sensor
Optical Encoder
Incremental encoders
Displacement Sensor
Optical Encoder
Absolute encoders
Track-1
010 001
Track-2
011
000
Track-3
100 111
101 110
Displacement Sensor
Optical Encoder
Absolute encoders: Gray Code
Displacement Sensor
Optical Encoder
Absolute encoders: Gray Code
Displacement Sensor
Optical Encoder
Absolute encoders: Resolution
The disk is divided into 16 sectors, so the
resolution in this case is 360°/16 = 22.5°.
For better resolution, more tracks would be
required. For example, eight tracks
(providing 28 = 256 states) yield 360°/256 =
1.4°/state, and ten tracks (providing 1024
states) yield 360°/1024 = 0.35°/state
Displacement Sensor
Optical Encoder
Absolute encoders v Incremental Encoder
An advantage of absolute encoder is that the output is in straightforward
digital form and, like a pot, always gives the absolute position. This is in
contrast to the incremental encoder that, as will be shown, provides only a
relative position.
A disadvantage of the absolute encoder is that it is relatively expensive
because it requires that many photocells be mounted and aligned very
precisely.
Displacement Sensor
Linear Variable Differential Transformer (LVDT)
The central coil is the primary coil and the
other two are identical secondary coils which
are connected in series. Secondary coils have
equal number of turns but opposite to each
other.
It has a relatively short range of about 2 in.,
but it has the advantage of no sliding
contacts.
Displacement Sensor
Linear Variable Differential Transformer (LVDT)
CASE-1
Iron Core is at the middle
Emf = E1 - E2 = 0
Displacement Sensor
Linear Variable Differential Transformer (LVDT)
CASE-2
Iron Core is at left
Emf = E1 - E2 = +E
Displacement Sensor
Linear Variable Differential Transformer (LVDT)
CASE-3
Iron core is at right
Emf = E1 - E2 = - E
Displacement Sensor
Linear Variable Differential Transformer (LVDT)
Proximity Sensor
Limit Switch
Proximity Sensor
Optical Proximity Sensor
Optical proximity sensors, sometimes called interrupters, use a light source
and a photo sensor that are mounted in such a way that the object to be
detected cuts the light path.
Load Sensor
Strain Gauge
A strain gauge is a sensor used to measure strain
or deformation on an object. It typically consists
of a thin conductive wire or foil arranged in a
zigzag pattern on a flexible backing material
Load Sensor
Strain Gauge
R
G
R
ΔR = Change in resistance due to strain
R = Original resistance
G = Gauge factor
ε = Strain (mm/ mm)
Load Sensor
Strain Gauge
Pressure Sensor
Bourdon Tube
Temperature Sensor
Bimetallic Strip
Temperature Sensor
Thermocouple
A thermocouple, also known as a "thermoelectrical thermometer", is an electrical device consisting of two
dissimilar electrical conductors forming an electrical junction.
Seebeck effect, a phenomenon whereby a voltage that is proportional to temperature can be produced from a circuit
consisting of two dissimilar metal wires.
When two different materials are joined together, a potential difference occurs across the junction. The potential
difference depends on the two metals used and the temperature of the junction. A thermocouple involves two such
junctions.
Temperature Sensor
Thermocouple
Flow Sensor
Orifice Meter
Flow Sensor
Venturi Meter
Flow Sensor
Pitot Tube
Thank You!
Prepared by,
Abhro Shome Pias
PT
Dept of IPE, BUTEX
