Global Detection Intermediary level

F Ultrasonic sensors

E Rotary encoders

D Pressure
D switches

C Limit switches
B Inductive sensors
A Photoelectric sensors

Experts: GHD
Training: Nadia Bennour

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 B- Inductive sensors
How they work

Principle

An inductive detector comprises an oscillator

whose coils represent the sensitive side.

The coils generate an alternative magnetic field.

When a metallic object is placed in this field,
induced currents form an additional load that
causes the oscillations to stop.

Then the detector processes the data by

generating a corresponding output signal on a
normally open (NO) or normally closed (NC)
contact.

Click on the target to move it

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 B- Inductive sensors
Pros and Cons

STRONG POINTS WEAK POINTS APPLICATIONS

z Adapted to difficult z Limited to metal z Detection of metal

environment : detection. parts:
robustness, easy z Short sensing distance – presence,
installation. (up to 60mm within our – position,
z Popular and well-known offer) – rotation
technology. monitoring.

Global Detection – Date (2006/09/31)

B- Inductive sensors
Flush-mountability: a must

Metal environment
Î flush-mountable
inductive sensors

The automotive industry often

requires flush-mountable inductive
sensors

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 B- Inductive sensors
Flush-mounting criteria

Magnetic
field
„ Requirements for "flush" mounting in a metal
lines
support

The field lines cross the metal support.

Consequences:
– Increase in the actual sensing distance
– Risk of continuous detection from 1.10 to 1.25 Sn.
– Significant hysteresis increase (2 to 6).

Metal
support Sn

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 B- Inductive sensors
Flush-mounting criteria

„ Solutions:

– Use a flush-mountable detector (coil / ferrite core Flush-mountable Sn

assembly shielded) Metal
support
Detector tube
z Flush-mountable detectors have magnetic
Magnetic
shielding designed to prevent any magnetic shielding
interference.
z This has a direct effect on the sensing distances
of products with identical characteristics and
Ferrite core
diameters.
Coil
– Alter the metal support

Non-flush-mountable Sn
hDetach the front part of the detector from the
metal support (see next page).

Sn (non flush-mountable) ~ 1.5 Sn (flush-mountable).

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 B- Inductive sensors
Flush-mounting criteria

„ Rules to be followed for mounting

Versions which can be Versions which cannot be

flush-mounted in metal flush-mounted in metal

Object to be detected Object to be detected

„ No lateral clearance required. „ Lateral clearance required.

„ All Osiconcept models can be flush-mounted in metal with The sensing distance is greater than that for a standard model.
reduction in the sensing distance and provide detection of „ With the Osiconcept system there is no need for lateral
objects in front of metal backgrounds. clearance.

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B- Inductive sensors
Osiconcept OSIPROX

„ Innovation through flush-mountability

„ New flat format Î compactness

„ Teach-in feature

„ Range of fast fixing and substitution accessories

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 B- Inductive sensors
Formats and materials

Rectangular
“C Form” Form J Form F Form E Form C Form D

Accessories
For flat sensors forms E, C and D

Precabled or with
connector

elbowed straight Screw-terminal

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 B- Inductive sensors
Plastic casing Metal casing

Cylindrical

Diam 8mm Diam 12mm Diam 18 Diam 30

XSZB1** : Fixing Plastic fixing

clamp with clamp
indexing pin XUZB2005
Long Short

Cylindrical: Food
6 L
and Beverage i nl e ss Steel 31
Sta
Industry
XS212SA XS218SA XS2L2SA XS230SA
Stainless steel Non-Flush Non-Flush Non-Flush Non-Flush
fixing clamp
diam 12, 18, 30

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 B- Inductive sensors
Sensing distances

To enable a reliable comparison and choice of products by the customer, standard IEC 947-5-2 defines the various sensing distances
(ranges), including:

• The nominal sensing distance Sn

Conventional sensing distance used to designate the device. It does not take account of variations (manufacture, temperature, voltage)

• Real sensing distance Sr

The real sensing distance is measured at the nominal supply voltage (Un) and at the nominal ambient temperature (Tn). It must be between
90% and 110% of the nominal sensing distance Sn.
Standard metal target
ON output OFF output

Sensing face
Action performed

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 B- Inductive sensors
Actual sensing distance Sa

• Usable sensing distance Su

The usable sensing distance is measured within the permitted temperature limits Ta and the supply voltage Ub. It must be
between 90% and 110% of the real sensing distance Sr.

• Actual sensing distance Sa

This is the area within which the device will operate. It must be between 0 and 81% of the nominal sensing distance Sn.

Standard metal target

• Standard metal target
The sensing distance in standard IEC 60947-5-2 defines the target or “standard” metal
target as being a square plate, 1 mm thick, made of mild steel, grade Fe 360.
The side of the square is equal to the diameter of the circle marked on the sensing
face of the detector or to 3 times the nominal sensing distance Sn

Actual sensing distance

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 B- Inductive sensors
Actual sensing distance Sa
• Correction factors

• Dimensions of the object to be detected:

Apply a correction coefficient Kd, which is to be determined according to the curve
opposite. When calculating the sensing distance in order to choose a detector,
preferably use Kd = 1

Typical curve for steel shielding on a cylindrical

model 18 diameter

• Influence of the ambient temperature:

Apply a correction coefficient KO according to the curve opposite.

• Variation in the supply voltage:

In all cases apply a correction coefficient Kt = 0.9

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 B- Inductive sensors
Actual sensing distance Sa
• Correction factors

• Influence of the object to be detected:

Apply a correction coefficient Km which is to be determined according to the table
opposite.
In order to calculate the sensing distance under different conditions of use, the
following factors which influence the sensing distance must be taken into account.
Models with fixed sensing distance for ferrous/non-ferrous materials, for detecting
Stainless steel Brass Copper Lead objects at a fixed distance, whatever the type of metal
Steel Alu. Cast iron Bronze

Special case of very thin shielding made of non-ferrous material.

Thickness of shielding (mm)

Typical curve for copper shielding on a cylindrical

model 18 diameter

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 B- Inductive sensors
Terminology
Sensing distances
• Calculation of operating distance Sa

Sa = Sn x Km x Kd x Ktheta(temperature) x Kt(voltage) x Kthickness

Specific applications

Target: - is made of material other than steel,

- is of different dimension,

Environment: - temperature,
- voltage,

d : minimum distance between the object and the sensing face.

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 B- Inductive sensors
Terminology

Sensing distances
Km Kd
• Calculation of operating distance Sa 1 1
0,9
0,8
0,7
0,6
0,5 0,5
0,4
„ Example
0,3
0,2
0,1

You can use again the previous example of screw Magn. Type Type A37 UZ33 AU4G Cu Sn 2 Sn 3 Sn 4 Sn
316 304 Dimensions
Stainless steel Steel Brass Alu. Copper of the item
head detection: side to detect

Data:
Apply a coefficient of correction Km to be Apply a coefficient of correction Kd from the
The customer wants to detect at 3 mm-head screw by specified from the above table. above curve.
means of a diffuse sensor of diameter 18.
Screw : stainless steel 316. Material variation Target size
Dimension : 6 mm-diameter.
Temperature : 20°C.

Sa calculation : 1,1
3 Real
sensing
= 6,35 mm distance
0,9

0,7 x 0,75 x 1 x 0,9 -25 0 20 50 70

Temperature °C
The nominal sensing distance of the diffuse
sensor to be selected is:
Apply a coefficient of correction Kθ to be In all cases, apply a coefficient of correction
specified from the above table Kt = 0,9
Sa
Sn > Temperature Power supply
0,81

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 B- Inductive sensors
Calculating the actual sensing distance Sa
• Calculation example

„ Choosing a detector for a given application: Km Kd

1
Characteristics of the application: 1 0,9
0,8
0,7
- Characteristics of the part = material: cast iron (Km = 0.9) 0,5
0,6
0,5
0,4
dimensions: 30 x 30 mm 0,3
0,2
0,1
- Temperature = from 0 to 20°C (K = 0.98) Magn. Type Type A37 UZ33 AU4G Cu Sn 2 Sn 3 Sn 4 Sn
Dimensions
316 304
of the side of
- Detection distance = 3 mm +- 1.5 mm Stainless steel Steel Brass Alumin. Copper
the object to
be detected
i.e. Sa max = 4.5 mm Variation in material Dimensions of object
to be detected
- Use Kd = 1 Apply a correction coefficient Km, which is to Apply a correction coefficient Kd, which is to
be determined according to the above table be determined according to the above curve

A detector must be chosen for which: 1,1

Real
sensing
0,9 tage and
Sn>= Sa / Kq x Km x Kd x Kt
distance
Variation in supply vol
manufac tur ing var iations
-25 0 20 50 70
Sn >= 4.5 / O.98 x 0.9 x 1 x 0.9
Temperature °C
Sn >= 5.67 mm
per ature
Variation in ambient tem
Apply a correction coefficient Kθ which is to In all cases apply a correction coefficient
be determined according to the above table Kt = 0.9

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 B- Inductive sensors
Switching frequency

„ Definition
The switching frequency given in the catalogues is the maximum frequency permitted by the detector. It corresponds
to the maximum appearance - disappearance speed of targets triggering activated or non-activated detector output
signals.

Beyond this speed or frequency, the detector remains locked (outputs activated even when the target
disappears from the detector).

„ Measurement method

The nominal switching frequency of products is measured using the following method (standard EN 50010).

T= T on + Toff = period
Potentiometer TON
Output signal
LED 1
t Time
0
TOFF
T

Metal shielding f=
1
(T on + Toff)

Diam. of sensor
Non-metal material

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 B- Inductive sensors
Switching frequency

„ Switching frequency

Nota: The switching frequency, like the various delays, depends on the type of oscillator used.

SWITCHING FREQUENCY
PRODUCT DIAMETER
OF THE DETECTOR

XS6 08B1PAL2 8 2,5 kHz

1 kHz
XS5 30B1PAL2 30

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 B- Inductive sensors
Outputs
„ Discrete outputs

2-wire non-polarised AC, AC DC and DC products are directly programmed to operate as NO or NC. The PNP or NPN
functions are directly obtained by wiring.

3-wire products are programmed by wiring.

PNP: NO or NC contacts NPN: NO or NC contacts

4-wire products with additional output are programmed:

PNP: NO + NC contacts NPN: NO + NC contacts

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 B- Inductive sensors
Outputs

„ Analog outputs

z Main applications
Example of sorting parts
Analog output proximity sensors are solid state sensors
designed for controlling movements and not for measurement.
They are suitable for applications in many fields, and in particular for:
- Controlling distortions and movements
- Controlling ripple amplitude and frequency
- Evaluation of positioning
- Controlling concentricity or offset

z Operating principle

Analog output sensors deliver an output signal, a current whose I

intensity is proportional to the “Target/Sensing face” distance. Imax

Their operation is based on the principle of damping an oscillator.

The oscillator converts the approach of metal shielding on the sensing face of the
detector to a variation in the output current proportional to the “sensing face-
shielding” distance.
In
Sn d

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 B- Inductive sensors
Outputs

„ Analog outputs

z Operating range or excursion range of the products

- Schneider has products which meet the requirements of both output current standards:
• Output current 4..... 20 mA ⇒ ∅ 12, 18, 30 flush-mountable or non flush-mountable products
• Output current 0..... 10 mA ⇒ ∅ 12, 18, 30 non flush-mountable products.

- These two output current standards are used for controlling most control system components which require an
analog input: PLC input cards, variable speed drive cards, etc.

z All analog output detectors are products which use 3-WIRE TECHNOLOGY
They can be used for 2-wire connection.

2-wire connection ⇒ 4.... 20 mA excursion.

3-wire connection ⇒ 0.... 10 mA excursion.

The choice of excursion and thus the choice of 2 or 3-wire connection is defined by the type of device to
be controlled by the detector.

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 B- Inductive sensors
Outputs

„ Analog outputs

z 2-wire connection

Definition 2-wire connection

IA = Power supply
Ir = residual current
Is = output current
Equation
is = Ir + IA

Excursion
4..... 20 mA

Output current Value of R (R = Load impedance)

24 V 4...14 mA ≤ 640 Ω
24 V 4...20 mA ≤ 450 Ω
48 V 4... 14 mA ≤ 2350 Ω
Maintain a min. voltage of 15 V between the + and the - (terminal 3) of detector

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 B- Inductive sensors
Outputs

„ Analog outputs

z 3-wire connection
3-wire connection

Equation
Is = IA: no current to earth or residual current in the output current Is.

Excursion

0..... 10 mA

Output current Value of R (R = Load impedance)

24 V 0...10 mA ≤ 1800 Ω
24 V 0...16 mA ≤ 1125 Ω
48 V 0...10 mA ≤ 4200 Ω
Maintain a min. voltage of 5 V between the + and the detector output (terminal 4)

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 B- Inductive sensors
Outputs
„ Analog outputs

z How to choose the correct analog product and set it up

What type of device is to be controlled? ⇒ 2 or 3-wire connection.

What is the supply voltage? ⇒ 24 V or 48 V.

Get as close as possible to the values of resistance Rnom given in the catalogue to obtain:

R > Rnom (catalogue value)

The max. current excursion will not be reached (saturation of the current generator).
Example: 0.5 mA instead of 0 to 10 mA for R = 3.6 kΩ
instead of the recommended 1.8 kΩ.
Solution: add Radd = 3.6 kΩ in parallel on R to Example of 3-wire mounting
obtain Req = 1.8 kΩ.

R < Rnom (catalogue value)

The max. voltage excursion will not be reached.
Example: if R = 900 Ω , Vsmax = 9 V instead of 18 V Is
where Rnom = 1.8 kΩ.
Solution: check the compatibility in the application R Radd Vs=Req.Is

(0 - 10 V input).

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 B- Inductive sensors
Switched currents

„ Switched currents

z All 2-wire products (AC, DC and AC/DC) switch currents can vary between a few mA to several hundred mA (they
all have a residual current Ir which must not switch the output on its own).

z All 3-wire products (DC only) or more (4 or 5-wire) switch currents of between 0 and Imax (100 or 200 mA). As they
have open collector outputs, the leakage current is very low (< 0.1 mA and they are very well suited to switching low
loads (for example, PLC inputs).

z The maximum currents which are switched range from 100 to 500 mA (average: 100 to 200 mA).

z The value of these currents:

- increases with the size of the product
- is always higher in AC products than in DC products.

– AC only : Is max from 200 to 500 mA.

– AC/DC : Is max from 100 to 300 mA.
– DC only : Is max from 100 to 200 mA.

**

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 B- Inductive sensors
Switched currents

„ Switched currents

Product shape Power supply Protection against overloads and Technology Switched output
short-circuits current (mA)

∅ AC and AC/DC No ⇒ fuse 2-wire Min: 5 → 300 max

5 - 6.5 - M8 DC Yes 2-wire Min: 1.5 → 100 max

M12 - M18 - M30 DC Yes 3 and 4-wire Min: 0 → 200 max

AC and AC/DC No ⇒ fuse 2-wire Min: 5 → 500 max

DC Yes 2-wire Min: 1.5 → 100 max

DC Yes 3 and 4-wire Min: 0 → 200 max

**

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 B- Inductive sensors
Switched currents
„ Residual current Ir - Residual voltage Ud

z The 2 characteristics Ir and Ud only concern 2-wire, 3-wire and 4-wire detectors.

Definition Representation Typical values Consequences

Residual current (Ir) M8 : 0.8 → 1.5 mA • The switched current must always be >
Ir
Corresponds to the current crossing the M12 : 0.6 → 1.5 mA
detector in locked state. Characteristic • ⇒ Min. switched current ≥ 5 mA
specific to 2-wire detectors mA M18 : 0.6 → 1.5 mA
Xs • Care must be taken with the minimum
Power supp. M30 : 0.6 → 1.5 mA drop-out current for control system
relays + the minimum current of PLC
Load inputs.

Residual voltage (Ud) M8 : ≤ 5.5 V • with serial connection of detectors.

Corresponds to the voltage between the M12 : 5.2 V AC/DC to 7 V (AC) • The voltage drop caused by UD can
terminals of the detector in conducting M18 : 5.2 V → 5.5 V be considerable.
state. This value is measured for the
nominal current of the detector. M30 : 5.2 V → 5.5 V
⇒ Low voltage power supplies: 12, 24,
48 V ⇒ boost the power supply by X
Xs V Power (volts).
supp.
M8 : ≤ 2 V
Load M12 : ≤ 2.6 V
3 or 4-wire technology
M18 : ≤ 2.6 V
M30 : ≤ 2 to 2.6 V

Notes: For the same product, Ir when the supply voltage **

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B- Inductive sensors

„ End of Part C…

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