Inductive sensor

28 February 2024 06:12 AM

An inductive sensor is a device that uses the principle of electromagnetic induction to detect or measure
objects.

An inductor develops a magnetic field when an electric current flows through it; alternatively, a current
will flow through a circuit containing an inductor when the magnetic field through it changes. This effect
can be used to detect metallic objects that interact with a magnetic field.

Non-metallic substances, such as liquids or some kinds of dirt, do not interact with the magnetic field, so
an inductive sensor can operate in wet or dirty conditions.

What is an Inductive Sensor?

At present, Inductive sensor is an essential component used in machines. These
sensors are robust devices and mainly designed depending on the requirements of
the proximity sensor. These sensors detect conductive otherwise metallic parts
where contact is difficult. These sensors are used in hygiene based and outdoor
applications.

inductive-sensor
The designing of these sensors can be done based on the particular application. For
instance, multi-voltage and high-temperature sensors. These sensors give suitable
signals for limits & positions which works like a pulse pick-up used for checking
counting tasks as well as rotational speed. When these sensors are used in a non-
contact form, then it can be last for a long time because they are not focused on any
mechanical wear & tear. And also, these sensors are opposed to severe
environmental situations like dust, vibration, & moisture to make them the perfect
choice to use within numerous industries.

Working Principle
1. The working principle of an inductive sensor mainly depends on
the electromagnetic induction principle for detecting or measuring objects.
 (-----)

2. Inductive sensor mainly includes an induction loop which is enough for

detecting electromagnetic. The working of these sensors can be done by
generating an oscillating electromagnetic field which is formed by a magnetic
object when it is in motion.

3. The moving object activates the current flow within the induction loop likewise
with Faraday’s law of induction. So that changes will have occurred within the
electromagnetic field. So it can be detected with the circuit of sensors. A
suitable signal can be an output when a magnetic metal is noticed.

Applications of Inductive Sensor

The applications of these sensors include the following.

• These sensors are extensively used in industries, military, robotics, rail, aerospace,
etc.
• Used in Proximity sensors or switches
• These sensors are used to notice ferrous metals like iron, steel, nickel, and cobalt.
• Used in the medical field for MRI (Magnetic Resonance Imaging)
• It is used to assemble the automotive body
• These sensors are used for detecting motion position & controlling the motion of an
object
• Used in the production of transformer & coil
• Used to detect lid and broken bit
• Used in traffic sensors for noticing the moving car
• These are used in eye tracking and the search coil production
• These sensors are used to detect the existence of an object within the application
like pick & place throughout inspections
• Used in machining procedures
• Used in metal detectors
• Used in automated industries
• These are used in limit switching, speed detection and generation of pulse
• Used to convey otherwise system control
• Used to measure the distance & position of the tool
Thus, this is all about the inductive sensor. The main advantages of inductive sensors
are appropriate for a range of applications, easily wearable, contact-free, as opposed
to dirt and short circuit. Here is a question for you, what are the drawbacks of an
inductive sensor?

Inductive Sensors Working

Principle
04.12.2022
Various industrial devices involve the use of various sensors,
which differ in their features and principles of operation. One of
the options that have become quite widespread is an inductive
sensor, which is actively used in lower equipment for various
systems that provide automated control of production lines.

You can meet such sensors in devices that are responsible for the
operation of food and textile industries, engineering enterprises,
and many others. Today we will take a closer look at the
proximity sensor types and working principle.

What is an Inductive Sensor?

An inductive sensor is a device whose action is based on a
changing magnetic field in an inductive coil. When an object
made of metal enters its field of action, it is captured and
recognized. A circuit built into the device produces
electromagnetic radiation. When an induced voltage appears in it,
the oscillations decrease. Inductive sensors read this
immediately.

Simply put, an inductive sensor is a proximity switch that got its

name because of the principle of operation. The sensor has a
sensor element with a magnetic circuit open towards the working
surface of the sensor.

Like various other devices, these have their pros and cons, which
become noticeable in operation. Sensors have become quite
popular due to the fact that they have several important
advantages.

 The design of these units is quite simple, it does not contain

any complex elements that require special settings. Due to
this, the sensors are highly durable and reliable, break
down infrequently, and can be constantly used in
production. It is also convenient that they do not have
sliding contacts.
 The features of the device allow you to connect devices to
an industrial voltage system without any problems.
 They have good sensitivity, so they can be used when
 working with various metal objects.
The disadvantages include the fact that during operation, the
sensors can produce errors due to the presence of various
factors. They can be affected by temperature, as well as exposure
to other fields of a similar type. Therefore, for high-quality work,
it is necessary to provide suitable conditions that would not
prevent the sensors from functioning correctly.

Where Inductive Sensors are Used?

Inductive sensors are known for their reliability and safety in
harsh environments. This makes them the best choice for the
military, aerospace, railroad, and heavy industries. Inductive
sensors are also used in machine tools, machines for the textile
industry, the automotive industry, assembly lines, etc. They are
used to detect metal parts in difficult environments and where
fast moving parts need to be inspected.

An inductive type sensor is designed to control the movement of

the working body without direct contact with it. This sensor
creates an electromagnetic field in the area of sensitivity and has
a semiconductor switch.

The scope of application of inductive sensors is largely

determined by their high reliability and resistance to external
factors. Many environmental factors do not affect their readings
and operation: moisture, condensation, accumulation of dust and
dirt, and ingress of solid particles. Such features are provided by
their device and design data.

What are the Two Types of Inductive

Sensors?
In practice, there is a huge variety of inductive sensors, all of
which can be divided into two large categories, depending on the
type of supply current - AC and DC. Depending on the state of the
contacts, inductive sensors are:

1. Closing - when the controlled object is moved, it is switched

to the on position.
2. Opening - in case of impact, the inductive sensor switches
the contacts to the off position.
3. Switching - simultaneously combines both previous options,
for one switching it puts one output on, the second, in the
off position.
According to the number of measuring circuits, inductive
sensors are divided into single and differential. The first of them
has one coil and one measurement circuit. The second type
implies the presence of two sensors, the measuring circuits of
which are included in the antiphase to compare readings. A single
inductive sensor contains one measuring branch and a
differential one-two.

In a differential inductive sensor, when the measured parameter

changes, the inductances of two identical coils change
simultaneously, and the change occurs by the same amount, but
with the opposite sign.

Differential inductive sensors are a combination of two non-

reversible sensors and are made in the form of a system
consisting of two magnetic circuits with a common armature and
two coils. Differential inductive sensors require two separate
power supplies.

According to the method of data transmission, inductive sensors

are divided into analog, electronic and digital. In the first case, the
same coils and ferromagnetic cores are used. Electronic ones use
a Schmidt trigger instead of ferromagnets to obtain a hysteresis
component. Digital ones are made in the format of printed circuit
boards on microcircuits. In addition, the types are divided
according to the number of sensors leads two, three, four, or five.

Working Principle of Inductive Sensor

This type of sensor, due to its internal structure, has a certain
inductive sensor working principle. It uses a unique generator
that produces a certain amplitude of oscillation. When an object
consisting of a metallic or ferromagnetic material enters the field
of action of the unit, the vibrations begin to change, which
indicates the presence of an object. Because of this, the sensors
work only with similar materials and are useless in other cases.

When starting work, the limit switch is energized, which

contributes to the formation of a magnetic field. It is it that
affects the eddy currents, which, in turn, change the amplitude of
the oscillations of a working generator.

The result of all these transformations is an output signal, which

can vary depending on the distance between the working sensor
and the object under study. Then, using a special device, the
analog signal is converted into a logical one.

An inductive sensor is also needed to recognize the position of

metal objects. This can play an important role in production. If
products follow along the line, on which metal parts must be
arranged in a certain order, then the sensors will check the
correctness of this arrangement. If an error is detected, the
device will signal the conveyor and the software will take further
action to correct the problem.

In addition to the response range or sensitivity, the inductive

proximity sensor working principle is characterized by
the following performance characteristics:

 The size (diameter) of the fitting thread, for various

samples, takes values from 8 to 30 mm.
 Rated supply voltage at a temperature of plus 20 degrees,
up to 90 Volts DC, and up to 230 Volts AC.
 The overall length of the housing - its value depends on the
operating voltage.
 The latter indicator for different samples can vary
significantly.

For the sensitive or active zone of the device, another parameter

is introduced, called the guaranteed response limit. Its lower limit
is zero, and the upper limit is 80 percent of the nominal value.
This figure is sometimes referred to as the operating clearance
correction factor.

An equally important indicator of the functionality of a sensitive

device is the number of connecting wires in the connector.
Usually, there are two or three of them: two supply and one to
activate the circuit. However, connection options are possible, the
arrangement of which uses four or five contact points. Such
samples, in addition to two supply conductors, contain two
outputs to the load. In this case, the fifth conductor is used to
select the operating mode of the device itself.
Applications of Inductive Sensors
A typical application of inductive sensors in industrial automation
is similar to the function of limit switches (or limit switches). Such
sensors are one of the popular devices used to detect the
presence of objects in industrial automation and automated
production control systems.

Inductive sensors are triggered when a metal object approaches

(it can be geared teeth, cams, a metal part, etc.). Thus, the
sensors are not sensitive to interference and work even under
harsh industrial conditions.

Also, the inductive sensor works for such industrial niches as:

 Medical devices.
 Appliances.
 Automotive industry.
 Robotic equipment.
 The industrial technology of regulation and measurement.