What are the functions & applications of Sensors in Industrial Automation?

The implementation of automation has the potential to enhance productivity, quality, and efficiency across various sectors, including but not limited to manufacturing, transportation, and energy production.

Automatable tasks encompass the utilisation of robotics for product assembly and packaging, materials handling systems such as automated guided vehicles and conveyor belts, 3D printing, production line monitoring, machinery control, and quality control inspections. 

Various technologies, including sensors, are used to maintain the functionality of automated processes. Sensors are essential components that perform the function of detecting and quantifying diverse parameters such as temperature, pressure, humidity, flow rate, motion, and position. 

They perform analogue-to-digital conversion and transmit data in real-time to the control system, enabling intelligent and automated production. Multiple technological approaches are employed to attain the intended outcome, such as inductive, magneto-resistive, ultrasonic, and capacitive methods.

Sensors are essential in industrial automation control products as they provide real-time data and facilitate process automation, leading to manufacturing optimisation and increased productivity. 

Role of Sensors in Automated Systems

The role of sensors in the context of automation applications:

1.  Control

The process involves monitoring critical parameters such as temperature, pressure, and humidity and providing feedback to the control system to facilitate real-time adjustments. In a temperature control system, a sensor is used to detect the ambient temperature of a given space. The sensor then transmits this data to a controller, which subsequently modifies the output of a heating or cooling system to sustain the target temperature.

2. Efficiency

The process of enhancing the efficiency of machines and processes involves the quantification of variables such as velocity, temperature, and pressure to mitigate losses, decrease energy consumption, and minimise periods of inactivity.

The implementation of automation technology enables the execution of recurring tasks at an accelerated pace, surpassing the speed of human performance. This results in a reduction in cycle time and an increase in production output. The implementation of automation technology can mitigate the likelihood of workplace incidents by assuming responsibility for hazardous duties that may result in harm.

3. Safety 

The system is designed to identify potentially dangerous situations, such as elevated temperatures, noxious gases, or undue pressure, and subsequently activate an alert or cessation protocol. Proximity sensors have the capability to detect the existence of objects or individuals in areas that are potentially dangerous.

4. Quality control

The implementation of automation can guarantee the production of goods that adhere to uniform and accurate specifications. Additionally, the examination of data gathered from production procedures can facilitate the detection of patterns that may indicate quality concerns. Automated systems are capable of conducting quality inspections to identify imperfections that may not be discernible through visual examination, such as microscopic cracks.

Types of Sensors used in Industrial Automation

The most frequently used sensor types in industrial automation include:

Array Sensors

An array sensor is a type of sensor that comprises several sensing elements that are organised in a grid or array configuration. These sensors are multifunctional and frequently employed in industrial automation control components.

The system comprises a collection of discrete sensors that collaborate to furnish precise and dependable data. The applications of the system encompass object detection, counting, and sorting in assembly lines, packaging, and material handling systems.

Contrast Sensors

Contrast sensors are employed to perceive the difference in contrast between an object and its surrounding background. They are frequently employed in quality control scenarios to detect discrepancies in surface hues or patterns. The utilisation of these sensors is feasible in the packaging sector to guarantee accurate printing and labelling on merchandise. 

Displacement Sensors

Displacement sensors play a crucial role in industrial automation by providing precise measurements of an object's distance or position. They are commonly utilised in the fields of robotics and manufacturing for the purpose of achieving accurate positioning and control of movement. The sensors have the capability to monitor the degradation of machine parts by quantifying their displacement over a period of time. 

Luminescence Sensors

Luminescence sensors are employed in industrial automation for the purpose of detecting the existence or non-existence of fluorescent substances. They are utilised in the pharmaceutical sector for the purpose of validating the existence of drug labels or tamper-proof seals. The sensors have the capability to perform an examination on chemical or biological specimens to detect the existence of particular fluorescent indicators.

Photoelectric Sensors

Photoelectric sensors are extensively utilised in elements of industrial automation to detect and position objects.  They can be integrated into conveyor systems for object detection and activation of corresponding actions. 

The sensors are employed in the packaging sector to perform product counting and verification within a package.  The sensors are frequently employed in production lines to verify accurate alignment and placement of parts throughout manufacturing procedures.

Specification for Sensors used in Industrial Automation Applications

Sensor selection depends on the application and requirements, but general considerations and specifications should be kept in mind. The sensor's specifications, such as range, accuracy, and response time, must meet the application's requirements.

The sensor's output must be compatible with the system controller's input requirements, and its physical size and mounting method must be suitable for the installation location. In industrial settings, sensor accuracy and reliability are crucial despite varying temperatures, humidity, vibration, dirt, and dust.

Southern control Inc. is a leading industrial automation distributor. With the advancement of technology, innovative sensors will be developed and integrated into industrial automation systems.