Unidad II: Sensores

Instrumentación y control
Ing. Amy Alejandra Márquez Palomo
[email protected]
Competencias específicas a desarrollar

Unidad II
Conocer e identificar las características
técnicas de los diferentes tipos de sensores
utilizados en los sistemas industriales.
Seleccionar y aplicar los diferentes sensores
utilizados en los sistemas industriales.
Actividades de aprendizaje, evaluación y
calendarización
Rubro Porcentaje Fecha tentativa
Trabajo de
25% 05 de marzo
investigación
17 de febrero al 02
Presentación oral 25%
de marzo
Tareas 20% 12 de marzo
Examen 30% 03 y 04 de marzo
Desglose de actividades
• Realizar trabajo de investigación en equipo y exposición oral sobre
los tipos de sensores. (Tema 2.1)
• Realizar cuadro comparativo sobre los tipos de sensores. (Tema 2.1)
• Examen escrito (Unidad II) por medio de plataforma Moodle
2.1. Sensors
Sensors

Sensors are devices that can measure

physical or chemical magnitudes, and
then transform them into electrical
magnitudes. This means that a sensor
can measure variables as temperature,
distance, force, load, humidity and
convert them into an electrical signal.
 They are used to determine the process status where they are
installed.
They transform the magnitude variations of the measured variable
Sensors into an electrical signal conditioned to be received in its destiny.
The output signal of a sensor generally goes to an indicator, to a
controller or to a register.
Characteristics of a sensor
• Accuracy. Specifies the difference between the measured value and the actual
value of the variable measured.
• Repeatability. The percentage of successive measurements that differ from one
another.
• Resolution. It is the smallest change that can be measured.
• Precision. It consists of resolution characteristics.
• Sensitivity. It is given by the minimum value of the measured variable that
produces a change in the output.
Characteristics of a sensor
• Error. It is the deviation between true value and measured value.
• Linearity. It tells us how close the correlation between input and output is to a
straight line.
• Rank. It is the difference between the upper value and the lower value that can be
measured.
• Quick response. It is the ability of the instrument to follow the variations of the
input
Sensor's
classification
End-of-stroke sensors
Definition: it is a switch that is placed in strategic places along the path of a mobile
element in order to know the position of said element.
Operation: it is based on a conventional electrical contact, that when the contact is
pressed, the internal plates close or open, depending on the case.
Classification or types: NO/NC, 12Vdc/24Vdc/120Vac, Lever/Roller/Push Button
Brands and manufacturers: SMC, Omron, Allen-Bradley, Keyence, Schneider, SICK
Applications: a window, a door, an elevator, when an object reaches the end of a
conveyor belt or to know if a cylinder piston extended or retracted.
Temperature sensors
Definition: it is a sensor used to detect temperature through changes in resistance
depending on the heat or cold detected.
Operation: it is based on the variation of the resistance of a semiconductor due to
changes in the ambient temperature, altering the concentration of charges.
Classification or types: NTC (Negative Temperature Coefficient) and PTC (Positive
Temperature Coefficient)
Brands and manufacturers: Schneider, Allen-Bradley, Bosch, Texas Instruments
Applications: protection of coils in motors and transformers, fuses, etc.
Humidity sensors
Definition: it is the one that allows detecting and controlling the percentage of water
or humidity in the air or in any material or surface.
Operation: they transform the humidity magnitudes detected into an electrical signal.
Classification or types: mechanical, capacitive, infrared, resistive, etc.
Brands and manufacturers: Vaisala, Omega, Fluke, Extech
Applications: floors and gardens, construction materials, floods and water leaks.
Mechanical sensors
Definition: they are used to measure stress or deformation; this allows verifying
whether the component is subject to safe load levels.
Operation: Stress values can be determined from strain measurements using basic
principles of solid mechanics.
Classification or types: strain gage, load cell, etc.
Brands and manufacturers: Kistler, SICK, Schneider, Keyence
Applications: deformation, force, movement, etc.
Electronic sensors
Definition: It is a device that transforms a physical quantity (temperature, position,
light intensity, etc.) into an electrical quantity (often a voltage) that can then be
integrated into a signal processing chain.
Operation: The sensor registers the physical quantities and converts them according
to the magnitude.
Classification or types: according to the variable they detect.
Brands and manufacturers: Keyence, Omron, SICK, Schneider, Kistler, etc.
Applications: Industry, processes, etc.
Photoelectric sensors
Definition: it is one that can detect a presence or some object at a distance, through
the change in light intensity.
Operation: These components require the participation of a transmitter and a
receiver; the transmitter is responsible for sending a signal in the form of light and the
receiver is responsible for detecting that beam of light sent by the transmitter.
Classification or types: barrier, retro-reflective, diffuse-reflective
Brands and manufacturers: Keyence, SICK, Allen-Bradley, Schneider
Applications: part presence, change of state in processes, etc.
Ultrasonic sensors
Definition: it is a sensor used to detect the distance of an object through sound
waves.
Operation: it is based on sending a sound signal to a specific place and waiting for
this signal to bounce off an object and return to the same sensor, these devices have
a transmitter and a receiver that work together.
Classification or types: chemical resistant, hygienic, etc.
Brands and manufacturers: Banner, SICK, Allen-Bradley, Schneider
Applications: detection of transparent objects, liquids, etc.
Inductive sensors
Definition: it is one that can detect metallic objects without physical contact, if they
are within the sensing range.
Operation: it is constituted by a coil in which a magnetic field is induced when it is
energized. When detecting a metallic object, a magnetic field is generated that is
different from the direction of the field induced by the coil.
Classification or types: DC two-wire, DC three-wire (PNP or NPN), AC two-wire. NO or
NC
Brands and manufacturers: Omron, Keyence, Allen-Bradley, SICK, Schneider.
Applications: Presence of part, change of state in processes, etc.
Capacitive sensors
Definition: it is an electronic switch that works without contact. These sensors take
advantage of the effect that materials such as paper, glass, plastic, oil, water, as well as
metals, it must increase the capacity of the sensor when they are within the generated
electric field.
Operation: They consist of a capacitor that generates an electric field. This capacitor is
part of a resonator circuit, so when an object approaches this field, the capacitance
increases, and the circuit begins to resonate.
Classification or types: DC two-wire, DC three-wire (PNP or NPN), AC two-wire. NO or NC
Brands and manufacturers: Omron, Keyence, Allen-Bradley, SICK, Schneider.
Applications: Presence of part, change of state in processes, fluid detector, etc.
Analog sensors
Definition: these are the devices that produce analog output in correspondence to
the quantity being calculated.
Operation: these sensors detect a variable into a range and convert them into an
electrical signal, this can be a voltage.
Classification or types: Accelerometers, light sensors, sound sensors, pressure
sensors, analog temperature sensors, etc.
Brands and manufacturers: Omron, Keyence, Allen-Bradley, SICK, Schneider
Applications: Parking sensors, object alignments, cell phones, industrial fabrications,
automobiles, robotics, etc.
Digital sensors
Definition: these are the devices that produce digital output according to a n
operation condition.
Operation: these sensors detect a variable and transform it into a signal of 1-0,
depending on an operation condition.
Classification or types: Accelerometers, temperature sensors, etc.
Brands and manufacturers: Omron, Keyence, Allen-Bradley, SICK, Schneider
Applications: Parking sensors, object alignments, industrial fabrications, automobiles,
robotics, etc.
Presence sensors
Definition: these devices detect if there is or not any presence of an object or person
into a defined space.
Operation: they work detecting movements around it and this is enough to activate
them
Classification or types: ultrasonic, photoelectric, capacitive, inductive, etc.
Brands and manufacturers: Schneider, Allen-Bradley, Omron, etc.
Applications: security, industrial process, change of state, etc.
Proximity or distance sensors
Definition: are devices that can detect the movement of an object or determine its
relative position measured from an established reference point.
Operation: detect the movement of an object and can be used to trigger action (such
as illuminating a floodlight or activating a security camera).
Classification or types: Potentiometric (resistance-based), Inductive, Eddy Current-
Based, Capacitive, etc.
Brands and manufacturers: Omron, Keyence, SICK, Schneider
Applications: detect position of many elements in processes.
Speed sensors
Definition: it´s a device that can detect the speed or velocity of an object or vehicle.
Operation: it is a permanent magnet generator, as the speed of the vehicle increases,
the frequency and voltage increase, so the automotive computer converts that
voltage into Km/hr, which it uses for its calculations.
Classification or types: electromagnet, optic sensor, etc.
Brands and manufacturers: Schneider, Omron, Allen-Bradley, etc.
Applications: mainly in vehicles.
Acceleration sensors
Definition: it´s a device that can detect the acceleration of an object or vehicle.
Operation: the seismic mass of the sensor causes a change in electrical charge in the
piezoelectric element, which can be read out as a charge that is proportional to the
acceleration.
Classification or types: piezoelectric, strain gauges, MEMS, capacitive sensors, etc.
Brands and manufacturers: Althen, Schneider, Omron, Allen-Bradley, etc.
Applications: used to measure vibration, shock, displacement, velocity, inclination
and tilt
Force sensors
Definition: a transducer that converts an input mechanical load, weight, tension,
compression or pressure into an electrical output signal that can be measured, converted
and standardized.
Operation: Strain gauges are electrical conductors tightly attached to a film in a zigzag
shape. When this film is pulled, it — and the conductors — stretches and elongates. When it
is pushed, it is contracted and gets shorter. This change in shape causes the resistance in
the electrical conductors to also change.
Classification or types: In-line, column, s-beam, thru hole, pancake, etc.
Brands and manufacturers: Futek, Kistler, Schneider, etc.
Applications: Industrial processes, presses, assembly of elements
Torque sensors
Definition: a transducer used for torque measurement (torque sensing) that converts an
input mechanical torque into an electrical output signal that can be measured, converted
and standardized.
Operation: when torque is applied (clockwise or counterclockwise), the metal body acts as
a “spring” and is slightly deformed, and unless it is overloaded, it returns to its original
shape. As the flexure deforms, the strain gage also changes its shape and consequently its
electrical resistance.
Classification or types: Rotational, dynamic, etc.
Brands and manufacturers: Futek, Kistler, Schneider, etc.
Applications: Industrial processes, presses, assembly of elements, motors, etc.
Deformation sensors
Definition: transducers that transform a distance variation into a change in the path
unbalance between two optical fibers that can be measured and transformed into an
electrical output.
Operation: A load-bearing structure is slightly deformed by forces and weights which are
applied to it. These tiny deformations can be measured by strains sensors which are
mounted on the load-bearing structure. Because the deformation is proportional to the
applied force, the load can be determined by using a strain sensor.
Classification or types: dynamic, static, etc.
Brands and manufacturers: Futek, Kistler, Schneider, etc.
Applications: Industrial processes, presses, assembly of elements, motors, etc.
Coordinate measuring systems (CMM)
Definition: is a device or system that measures the geometry of physical objects by
sensing discrete points on the surface of the object.
Operation: Each axis has a sensor that monitors the position of the probe on that axis,
typically with micrometer precision. When the probe contacts (or otherwise detects) a
particular location on the object, the machine samples the three position sensors, thus
measuring the location of one point on the object's surface, as well as the 3-dimensional
vector of the measurement taken.
Classification or types: Bridge, Gantry, Cantilever, Portable, Optical, etc.
Brands and manufacturers: Keyence, Omron,
Applications: measuring.
Vision systems
Definition: It’s a complete system that can be configured to detect almost every
geometry we want to detect.
Operation: It is composed by a camera and the operator sets what the system should
see, or measure and it detect some similar patterns for measuring or detecting.
Classification or types: 1D, 2D, 3D, Linear/Area, etc.
Brands and manufacturers: Keyence, Omron, Cognex, etc.
Applications: industrial, medical, transportation, sports, etc.
Sistemas de
medición por
coordenadas
Máquinas de
medición por
coordenadas
Una máquina de medición por
coordenadas, también conocida como
CMM, es un equipo que mide las
geometrías de objetos físicos.
Las CMM utilizan un sistema de
palpado para detectar puntos discretos
en la superficie de los objetos.
Máquinas de
medición por
coordenadas
Las CMM se utilizan con mayor frecuencia
para probar una pieza o montaje para
determinar si respeta o no la intención del
diseño original.
Las CMM se integran dentro de los flujos de
trabajo de aseguramiento de la calidad o
de control de calidad para verificar las
dimensiones de los componentes
fabricados para prevenir o resolver
problemas de calidad.
CMM de Puente
Las CMM de puente cuentan con un
sistema de palpado que se mueve a lo
largo de tres ejes: X, Y y Z; estos ejes son
ortogonales entre sí en un sistema de
coordenadas cartesiano. Cada eje tiene
un sensor que monitorea la posición de
la sonda (en micrómetros) mientras se
mueve a lo largo de un objeto y detecta
puntos en la superficie del objeto.
CMM de pórtico
Las CMM de pórtico son similares a las
CMM de puente; sin embargo, suelen ser
mucho más grandes. Debido a que están
diseñadas para eliminar la necesidad de
levantar una pieza sobre una mesa y
ofrecen niveles de precisión similares a
las CMM de puente, las CMM de pórtico
se utilizan regularmente para piezas muy
pesadas o grandes.
CMM en voladizo
Una CMM en voladizo se diferencia de
una CMM de puente en la que el
cabezal de medición solo está unido a
un lado de una base rígida. Las CMM
en voladizo brindan acceso abierto a
los técnicos de inspección en los tres
lados para facilitar la operación.
CMM de brazo
horizontal
Las CMM de brazo horizontal, como su
nombre lo indica, tienen sondas montadas
horizontalmente a diferencia de las sondas
montadas verticalmente como otras CMM.
Están diseñadas para medir objetos largos y
delgados que no podrían inspeccionarse con
CMM verticales, como láminas de metal. Las
CMM de brazo horizontal también se utilizan a
menudo para inspeccionar geometrías que
son difíciles de alcanzar.
CMM de brazo de
medición portátil
Las CMM de brazo de medición portátil son
máquinas de medición por coordenadas que
pueden tomar medidas de piezas directamente
en los talleres, lo que permite obtener resultados
rápidos y análisis en tiempo real.
A diferencia de los inspectores que llevan los
componentes a un laboratorio para medirlos, los
técnicos utilizan un brazo articulado, con un
sistema de seis o siete ejes, para medir los
componentes donde sea necesario.
CMM óptica
Las CMM ópticas son dispositivos
portátiles sin contacto. Estas CMM utilizan
un sistema sin brazos con métodos de
triangulación óptica para escanear y
adquirir mediciones 3D de objetos.
Gracias a la sofisticada tecnología de
procesamiento de imágenes, las CMM
ópticas son ultrarrápidas y garantizan una
precisión de grado de metrología.
Marcas

Keyence Mitutoyo
Aplicaciones
• Medición
• Control de calidad
• Inspección
• Control de procesos
• Certificación de procesos
• Calibración de instrumentos
Sistemas de visión
Sistemas de visión
Los sistemas de visión artificial son métodos
automatizados e inteligentes que permiten,
de forma precisa y detallada, procesar y
analizar las imágenes de los productos en las
líneas de montaje.
Los sistemas de visión comparan lo observado
mediante cámaras con patrones que han sido
predefinidos por el usuario.
Sistemas de visión
Gracias a los diferentes software instalados en los
sistemas y en las cámaras de visión artificial, las
máquinas automatizadas pueden llegar a detectar o
identificar anomalías en los productos.
Por tanto, pueden efectuar cualquier acción para
corregir tales detalles siguiendo los parámetros
establecidos por el operador.
Es por esto que la visión artificial es una herramienta
imprescindible para inspeccionar y detectar cualquier
error en los procesos de producción
Sistemas de visión
1D
La visión 1D analiza una señal digital de una
línea a la vez, en lugar de ver la imagen en su
conjunto, como evaluar la variación entre el
grupo más reciente de diez líneas analizadas y
un grupo anterior. Esta técnica suele detectar
y clasificar defectos en materiales fabricados
en procesos continuos, como papel, metal,
plástico y otros bienes en hojas o rollos no
tejidos.
Sistemas de visión
2D
Las cámaras de inspección más
comunes realizan escaneos de área
que suponen tomar instantáneas en 2D
de diferentes resoluciones. Otro tipo
de visión artificial 2D, el escaneado
lineal, construye una imagen 2D línea
por línea.
Sistemas de visión
3D
Los sistemas de visión artificial 3D suelen abarcar
múltiples cámaras, o uno o más sensores láser de
desplazamiento.
La visión 3D con múltiples cámaras en
aplicaciones de guía robótica brinda al robot
información con respecto a la orientación de la
pieza. Estos sistemas cuentan con múltiples
cámaras montadas en diferentes ubicaciones y
“triangulación” sobre la posición de un objetivo
en un espacio 3D.
Marcas

Keyence Cognex
Aplicaciones

• Procesos industriales
• Campo médico
• Automóviles
• Smartphones
• Sistemas de seguridad
• Meteorología