SENSORS AND

TRANSDUCERS
 Displacement,
Position and
Proximity Sensor
(After Potentiometer, Strain Gauge,
LVDT, Capacitive element)
Inductive proximity switch
 Inductive proximity switches are basically used for
detection of metallic objects.
 Figure shows the construction of inductive proximity
switch.
 An inductive proximity sensor has four components;
the coil, oscillator, detection circuit and output circuit
 An alternating current is supplied to the coil which
generates a magnetic field.
 When, a metal object comes closer to the end of the
coil, inductance of the coil changes.
 This is continuously monitored by a circuit which
triggers a switch when a preset value of inductance
change is occurred
 Applications of inductive proximity switches
 Industrial automation: counting of products during
production or transfer
 Security: detection of metal objects, arms, land
mines
Optical encoders
 Optical encoders provide digital output as a result
of linear / angular displacement.
 These are widely used in the Servo motors to
measure the rotation of shafts.
 Figure shows the construction of an optical encoder.
 It comprises of a disc with three concentric tracks of
equally spaced holes. Three light sensors are
employed to detect the light passing thru the holes.
 These sensors produce electric pulses which give the
angular displacement of the mechanical element
e.g. shaft on which the Optical encoder is mounted.
 The inner track has just one hole which is used locate
the ‘home’ position of the disc. The holes on the
middle track offset from the holes of the outer track
by one-half of the width of the hole.
 This arrangement provides the direction of
rotation to be determined.
 When the disc rotates in clockwise direction, the
pulses in the outer track lead those in the inner; in
counter clockwise direction they lag behind.
 The resolution can be determined by the number
of holes on disc. With 100 holes in one revolution,
the resolution would be,
 360⁰/100 = 3.6⁰.
Pneumatic Sensors

 Pneumatic sensors are used to measure the

displacement as well as to sense the proximity of an
object close to it.
 The displacement and proximity are transformed
into change in air pressure.
 Figure shows a schematic of construction and
working of such a sensor.
 It comprises of three ports.
 Low pressure air is allowed to escape through port
A.
 In the absence of any obstacle / object, this low
pressure air escapes and in doing so, reduces the
pressure in the port B.
 When an object obstructs the low pressure air (Port
A), there is rise in pressure in output port B. This rise
in pressure is calibrated to measure the
displacement or to trigger a switch.
 Applications
 These sensors are used in robotics, pneumatics and
for tooling in CNC machine tools.
Hall effect sensor
 Hall effect sensors work on the principle that when
a beam of charge particles passes through a
magnetic field, forces act on the particles and the
current beam is deflected from its straight line path.
 Thus one side of the disc will become negatively
charged and the other side will be of positive
charge. This charge separation generates a
potential difference which is the measure of
distance of magnetic field from the disc carrying
current.
 Application
 The application of Hall effect sensor is the
measurement of fluid level in a container.
 The container comprises of a float with a permanent
magnet attached at its top.
 An electric circuit with a current carrying disc is mounted
in the casing.
 When the fluid level increases, the magnet will come
close to the disc and a potential difference generates.
This voltage triggers a switch to stop the fluid to come
inside the container
 Advantages
 These sensors are used for the measurement of
displacement and the detection of position of an object.
 Hall effect sensors need necessary signal conditioning
circuitry. They can be operated at 100 kHz.
 Their non-contact nature of operation, good immunity to
environment contaminants and ability to sustain in
severe conditions make them popular in industrial
automation.
Velocity and
motion sensors
Tachogenerator
 Tachogenerator works on the principle of variable
reluctance.
 It consists of an assembly of a toothed wheel and a
magnetic circuit
 Toothed wheel is mounted on the shaft or the
element of which angular motion is to be measured.
 Magnetic circuit comprising of a coil wound on a
ferromagnetic material core.
 As the wheel rotates, the air gap between wheel
tooth and magnetic core changes which results in
cyclic change in flux linked with the coil.
.
 The alternating emf generated is the measure of
angular motion. A pulse shaping signal conditioner
is used to transform the output into a number of
pulses which can be counted by a counter
 An alternating current (AC) generator can also be
used as a techognerator.
 It comprises of rotor coil which rotates with the
shaft.
 The rotor rotates in the magnetic field produced by
a stationary permanent magnet or electromagnet.
 During this process, an alternating emf is produced
which is the measure of the angular velocity of the
rotor.

These sensors exhibit nonlinearity error of

about ± 0.15% and are employed for the rotations
up to about 10000 rev/min.
Pyroelectric sensors

 These sensors work on the principle of

pyroelectricity, which states that a crystal material
such as Lithium tantalite generates charge in response
to heat flow.
 In presence of an electric field, when such a crystal
material heats up, its electrical dipoles line up,
called as polarization.
 On cooling, the material retains its polarization.
 In absence of electric field, when this polarized
material is subjected to infra red radiation, its
polarization reduces., which is measure of detection
of movement of an object.
 Pyroelectric sensor consist of a thick element of
polarized material coated with thin film electrodes
on opposite faces .
 Initially the electrodes are in electrical equilibrium
with the polarized material.
 On incident of infra red, the material heats up and
reduces its polarization.
 This leads to charge imbalance at the interface of
crystal and electrodes.
 To balance this disequilibrium, measurement circuit
supplies the charge, which is calibrated against the
detection of an object or its movement.
 Applications of Pyroelectric sensors
 • Optothermal detector
 • Pollution detector
 • Position sensor
 • Solar cell studies
 • Engine analysis
Strain Gauge as force Sensor

 Strain gauge based sensors work on the principle of

change in electrical resistance.
 When, a mechanical element subjects to a tension or
a compression the electric resistance of the material
changes.
 This is used to measure the force acted upon the
element.
 It consist of cylindrical tube to which strain gauges
are attached.
 A load applied on the top collar of the cylinder
compress the strain gauge element which changes its
electrical resistance.
 Generally, strain gauges are used to measure
forces up to 10 MN.
 The non-linearity and repeatability errors of this
transducer are ±0.03% and ±0.02% respectively.
Fluid Pressure
Sensor
Fluid pressure

 Various types of instruments such as diaphragms,

capsules, and bellows are used to monitor the fluid
pressure.
 Chemical, petroleum, power industry often need to
monitor fluid pressure.
Diaphragm Pressure gauge
 Strain gauges doped in diaphragms are generally
used to measure the inlet manifold pressure in
applications such as automobile
 Application of pressurized fluid displaces the
diaphragm.
 This displacement is measured by the stain gauges
in terms of radial and/or lateral strains.
 These strain gauges are connected to form the arms
of a Wheatstone bridge.
Capsule and Bellow
 Capsule is formed by combining two corrugated
diaphragms.
 It has enhanced sensitivity in comparison with that of
diaphragms.
 A stack of capsules is called as ‘Bellows’.
 Bellows with a LVDT sensor measures the fluid
pressure in terms of change in resultant voltage
across the secondary coils of LVDT.
Piezoelectric sensor

 Piezoelectric sensor is used for the measurement of

pressure, acceleration and dynamic-forces such as
oscillation, impact, or high speed compression or
tension.
 It contains piezoelectric ionic crystal materials such
as Quartz.
 On application of force or pressure these materials
get stretched or compressed.
 During this process, the charge over the material
changes and redistributes. One face of the material
becomes positively charged and the other
negatively charged.
 The net charge q on the surface is proportional to the
amount x by which the charges have been displaced.
The displacement is proportion to force. Therefore we
can write,
 q = kx = SF
 where k is constant and S is a constant termed the
charge sensitivity.
Tactile sensors

 Tactile sensors are used to sense the contact of

fingertips of a robot with an object, manufacturing
of ‘touch display’ screens of visual display units
(VDUs) of CNC machine tools.
 Piezo-electric polyvinylidene fluoride (PVDF) based
has two PVDF layers separated by a soft film which
transmits the vibrations.
 An alternating current is applied to lower PVDF
layer which generates vibrations due to reverse
piezoelectric effect.
 These vibrations are transmitted to the upper PVDF
layer via soft film.
 These vibrations cause alternating voltage across
the upper PVDF layer.
 When some pressure is applied on the upper PVDF
layer the vibrations gets affected and the output
voltage changes.
 This triggers a switch or an action in robots or touch
displays.
Temperature
and light
sensors
Bimetallic strips

 Bimetallic strips are used as thermal switch in

controlling the temperature or heat in a
manufacturing process or system.
 It contains two different metal strips bonded
together.
 As the strips bend, the soft iron comes in closer
proximity of the small magnet and further touches.
 Then the electric circuit completes and generates an
alarm.
 In this way bimetallic strips help to protect the
desired application from heating above the pre-set
value of temperature.
Resistance temperature detectors (RTDs)

 RTDs work on the principle that the electric

resistance of a metal changes due to change in its
temperature.
 On heating up metals, their resistance increases and
follows a linear relationship as
Rt = R0 (1 + αT)
where Rt is the resistance at temperature T (⁰C) and
R0 is the temperature at 0⁰C and α is the constant for
the metal termed as temperature coefficient of
resistance.
 The sensor is usually made to have a resistance of
100 Ω at 0 °C
 It has a resistor element connected to a Wheatstone
bridge.
 The element and the connection leads are insulated
and protected by a sheath.
 A small amount of current is continuously passing
though the coil. As the temperature changes the
resistance of the coil changes which is detected at
the Wheatstone bridge.
 RTDs are used in the form of thin films, wire wound
or coil. They are generally made of metals such as
platinum, nickel or nickel-copper alloys. Platinum
wire held by a high-temperature glass adhesive in
a ceramic tube is used to measure the temperature
in a metal furnace.
 Other applications are:
 • Air conditioning and refrigeration servicing
 • Food Processing
 • Stoves and grills
 • Textile production
 • Plastics processing
 • Petrochemical processing
 • Micro electronics
 • Air, gas and liquid temperature measurement in pipes and
tanks
 • Exhaust gas temperature measurement
Thermistors

 Thermistors follow the principle of decrease in

resistance with increasing temperature.
 The material used in thermistor is generally a
semiconductor material such as a sintered metal
oxide (mixtures of metal oxides, chromium, cobalt,
iron, manganese and nickel) or doped
polycrystalline ceramic containing barium titanate
(BaTiO3) and other compounds.

 As the temperature of semiconductor material
increases the number of electrons able to move
about increases which results in more current in the
material and reduced resistance. Thermistors are
rugged and small in dimensions. They exhibit
nonlinear response characteristics.
 Thermistors are available in the form of a bead
(pressed disc), probe or chip.
 It has a small bead of dimension from 0.5 mm to 5
mm coated with ceramic or glass material.
 The bead is connected to an electric circuit through
two leads. To protect from the environment, the
leads are contained in a stainless steel tube.
Applications of Thermistors
 • To monitor the coolant temperature and/or oil temperature
inside the engine
 • To monitor the temperature of an incubator
 • Thermistors are used in modern digital thermostats
 • To monitor the temperature of battery packs while
charging
 • To monitor temperature of hot ends of 3D printers
 • To maintain correct temperature in the food handling and
processing industry equipments
 • To control the operations of consumer appliances such as
toasters, coffee makers, refrigerators, freezers, hair dryers,
etc.
Thermocouple

 Thermocouple works on the fact that when a junction

of dissimilar metals heated, it produces an electric
potential related to temperature.
 As per Thomas Seebeck (1821), when two wires
composed of dissimilar metals are joined at both
ends and one of the ends is heated, then there is a
continuous current which flows in the thermoelectric
circuit.
 The net open circuit voltage (the Seebeck voltage) is
a function of junction temperature and composition
of two metals. It is given by,
 ΔVAB = α ΔT
 where α, the Seebeck coefficient, is the constant of
proportionality.
Applications of Thermocouples
 • To monitor temperatures and chemistry throughout the
steel making process
 • Testing temperatures associated with process plants
e.g. chemical production and petroleum refineries
 • Testing of heating appliance safety
 • Temperature profiling in ovens, furnaces and kilns
 • Temperature measurement of gas turbine and engine
exhausts
 • Monitoring of temperatures throughout the production
and smelting process in the steel, iron and aluminium
industry
Light sensors
Light sensors
 A light sensor is a device that is used to detect light.
 There are different types of light sensors such as
photocell/photoresistor and photo diodes being
used in manufacturing and other industrial
applications.
Photoresistor
 Photoresistor is also called as light dependent
resistor (LDR).
 It has a resistor whose resistance decreases with
increasing incident light intensity.
 It is made of a high resistance semiconductor
material, cadmium sulfide (CdS).
 The resistance of a CdS photoresistor varies
inversely to the amount of light incident upon it.
 Photoresistor follows the principle of
photoconductivity which results from the generation
of mobile carriers when photons are absorbed by
the semiconductor material.
 The CdS resistor coil is mounted on a ceramic
substrate.
 The assembly is encapsulated by a resin material.
 The sensitive coil electrodes are connected to the
control system though lead wires.
 On incidence of high intensity light on the
electrodes, the resistance of resistor coil decreases
which will be used further to generate the
appropriate signal by the microprocessor via lead
wires.
Applications of photo resistor
 • Computers, wireless phones, and televisions, use
ambient light sensors to automatically control the
brightness of a screen
 • Barcode scanners used in retailer locations work using
light sensor technology
 • In space and robotics: for controlled and guided
motions of vehicles and robots. The light sensor enables
a robot to detect light. Robots can be programmed to
have a specific reaction if a certain amount of light is
detected.
 • Auto Flash for camera
 • Industrial process control
Photo diodes

 Photodiode is a solid-state device which converts

incident light into an electric current.
 It is made of Silicon.
 It consists of a shallow diffused p-n junction,
normally a p-on-n configuration.
 When photons of energy greater than 1.1eV (the
bandgap of silicon) fall on the device, they are
absorbed and electron-hole pairs are created.
 The depth at which the photons are absorbed
depends upon their energy. The lower the energy of
the photons, the deeper they are absorbed.
 Then the electron-hole pairs drift apart. When the
minority carriers reach the junction, they are swept
across by the electric field and an electric current
establishes.
 Photodiodes are one of the types of photodetector,
which convert light into either current or voltage.
 These are regular semiconductor diodes except that
they may be either exposed to detect vacuum UV or
X-rays or packaged with a opening or optical fiber
connection to allow light to reach the sensitive part
of the device.
 It is constructed from single crystal silicon wafers.
 It is a p-n junction device. The upper layer is p
layer. It is very thin and formed by thermal diffusion
or ion implantation of doping material such as
boron.
 Depletion region is narrow and is sandwiched
between p layer and bulk n type layer of silicon.
 Light irradiates at front surface, anode, while the
back surface is cathode.
 The incidence of light on anode generates a flow of
electron across the p-n junction which is the measure
of light intensity.
Applications of photo diodes
 Camera: Light Meters, Automatic Shutter Control, Auto-focus,
Photographic Flash Control
 Medical: CAT Scanners - X ray Detection, Pulse Oximeters, Blood
Particle Analyzers
 Industry
 • Bar Code Scanners
 • Light Pens
 • Brightness Controls
 • Encoders
 • Position Sensors
 • Surveying Instruments
 • Copiers - Density of Toner
 Safety Equipment
 • Smoke Detectors
 • Flame Monitors
 • Security Inspection Equipment - Airport X ray
 • Intruder Alert - Security System
 Automotive
 • Headlight Dimmer
 • Twilight Detectors
 • Climate Control - Sunlight Detector
 Communications
 • Fiber Optic Links
 • Optical Communications
 • Optical Remote Control