PRODUCTIVITY IMPROVEMENT AND CENTER OF EXCELLENCE

Introduction
The following set of exercises was designed for the SENSORS training case. It includes practical
exercises for the basic equipment as well as for the additional equipment. This training kit
serves to impart knowledge about operating principles, parameters and industrial application
possibilities of inductive, capacitive, photoelectric, magnetic field- and ultrasonic sensors.
The exercises are divided into different groups:
1. introductory experiments
2. basic experiments
3. additional experiments
4. experiments for the complementary construction kit NAMUR
The introductory experiments serve to demonstrate the behavior of the sensors. The aim is to
determine which sensor can detect which material and which material cannot be detected. The
SENSORS Training Package contains a manual and solution sheets in which the basic theory
of the test results is explained.
By means of the basic experiments the most important parameters for the use of the individual
sensors are determined.
1. operating range/detection range/range and hysteresis
2. reduction factor
3. response curve
4. switching frequency
By means of the questions included in the exercises the student is supposed to become aware
of the specific data of the sensor and the resp. problems. These are treated in the solution
sheets. Additional hints for the practical use are included.
The additional experiments demonstrate examples for practical applications of the sensors in
different industrial sectors. Moreover, special interference factors for individual sensors shall be
analysed.
The experiments for the complementary construction kit NAMUR treat the special
characteristics
of NAMUR-modules.
All experiments are usually described as follows:
1. short description of the aim of the experiment
2. device list
3. arrangement (plan)
4. testing method
5. evaluation, results, hints
The device list includes all necessary components including part numbers.
The indicator unit optical/acoustical (optional)that is mentionned in some descriptions serves
exclusively for a better signal indication and is no essential component of the basic equipment.
With the experimental set-up the user is supported in order to prepare the respective experiment
without difficulties. The descriptions are usually arranged in a way that the student can
read the experimental set-up and regard the photo of the set-up at the same time.
Under evaluation, result, hints tables are offered, in which the measurement results can be
entered.
The table on the following page offers an overview on all experiments and simplifies the search

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for the desired setting up of the experiments.

Introductory experiments (EV)
This group of experiments serves to get to know the sensors. It is not intended that any specific
measurements are made. It is merely intended to become acquainted with the sensors and to
check their functionality. Besides, fundamental characteristics of the sensors are shown, which
will be examined more closely during the complementary experiments.
Device list
mounting plate/mounting plate case 1 827 003 552
elevation compensation 1 827 003 640
guide carriage with sample carrier 1 827 003 641
and device for distance measurement
distribution box 1 827 003 587
indicator unit optical/accoustical (optional) 1 827 003 586
inductive sensor NJ (8 mm) 1 827 003 645
inductive sensor NJ (2 mm) 1 827 003 647
capacitive sensor CJ (8 mm) 1 827 003 648
magnetic field sensor MJ (60 mm) 1 827 003 649
reflection light scannersOJ (500 mm) 1 827 003 654
optical wave guide ELG 1 827 003 657
optical wave guide TLG 1 827 003 656
reflex photoelectric sensor OBS (3000 mm) 1 827 003 638
retro reflectort
ultrasonic sensor (300 mm) 1 827 003 637
sample case 1 827 003 173
Experimental set up
The experiments EV1 to EV3 have the same set up, only the sensors are changed. If these three
experiments are completed one after the other, it is not necessary to rearrange all the devices.
Also the experiments EV4 to EV6 are similar. If you place the guide carriage with sample carrier
and the device for distance measurement further up in the middle of the transverse mounting
plate, you can quickly adapt the conditions to the individual experiments

1: Behaviour of inductive sensor

Experimental set up, testing method
Mount the inductive sensor NJ (8 mm) onto the elevation compensation in the middle of
the
mounting plate and complete the electrical connections (see assembly diagram).
Move different material samples from the table one after another in front of the sensor
(manually).
Please observe the state of the LEDs.
Note down, which materials the sensor detects.

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Wiring diagram

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Evaluation, result
Compare the characteristics of the material samples, that have been detected by the sensor.
What do they have in common? Try to explain this behavior.

EV3: Behaviour of magnetic sensors Material Material detected?

YES NO
plastic, any colour
copper
paperboard
aluminium
magnet, perpendicular, (circular surface
faces
the sensor)
magnet, parallel (zylinder wall faces the
sensor)
The different behaviour with perpendicular and parallel approach of the magnet will be
examined
more detailed in experiment V11 (response curve of the magnetic sensor).
5: Behaviour of through beam sensors
The through beam sensor is simulated with the direct detection sensor with mounted
through
beam fibre optics ELG. This experiment is supposed to show, which materials are
detected by
the through beam sensor. Using the photoelectric sensor the sample should pass the
optical
axis at right angles. For this reason we use the guide carriage.
Experimental set up
The white plastic plate (40 mm) serves as reference measuring flag.
Turn the mounting plate transversely. Mount the guide carriage with sample carrier and
the device
for distance measurement (1 827 003 641) in the middle of the mounting plate. Mount
one
elevation compensation at the bottom of the mounting plate and at right angles to the
guide rail
and the second elevation compensation at the top of the mounting plate. Then mount on
both
elevation compensations the brackets of the two heads of the ELG fibre optics, in a way
that
their optical outlets/optical entries (protective cap!) face each other. This way you can
set up a
through beam sensor with a sensing range of approx. 300 mm, if you place the fibre
optics onto
the direct detection sensor. Place this sensor onto one of the both elevation
compensations or
outside the sensing range on the mounting plate.

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Mounting of the fibre optics onto the sensor optics: Release the green cap nut, carefully
remove
the orange mineral glass disk and the small black bar. These small parts should be
stored carefully!
Fix the ELG fibre optics with the adaptor nut to the optical system and see to it that the
„eyes“
are set into the appropriate deepenings.
Place the devices on the mounting plate according to the assembly diagram and fix the
white
sample at the stationary sample carrier.
Switch on the power supply unit.
The analogueue value of the distance measurement sensor is without significance for
this experiment.

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Wiring diagram

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Testing method
Adjustment of the sensitivity at the light scanner: Aim from the closer fibre optics head
at the
other fibre optics head. Both have to be on one (optical) axis.
First turn the small slotted screw LTW anti clockwise, until the yellow LED extinguishes
(in case
it was on). Turn back the screw (clockwise), until the yellow LED just lights up. For the
time being
ignore the red flashing LED. Its meaning -static or dynamic pre-fault indicator- will be
explained
in the additional experiments ZV20, ZV2.
After the white sample, move all other material samples from the common table (EV4 ...
6)
through the light barrier and observe the switching state of the LED display.

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Rotation of the mirror: Release the mirror from the sample carrier and move it in the
optical axis
by hand.
Evaluation, result
Enter the results in the common table for the experiments EV4, EV5 and EV6.
What do the detected materials have in common?
Why is it possible to have different results with the same metal?
Which material cannot be detected by the through beam sensor? Which differences in
the function
of light scanner and light barrier can be realised?
Behaviour of light scanner / light barrier / through beam fibre optics
Light scanner light barrier through beam fibre optics
light barrier material detected? material detected?
material
detected?
YES NO YES NO YES NO
plastic, clea
paperboard
aluminium
aluminium, light
grey
brass
sheet of paper

6:Behaviour of the reflex photoelectric sensor OBS

This experiment is supposed to show, which materials can be detected from the reflex
photoelectric
sensor. Using the photoelectric sensor the sample should pass the optical axis at right
angles. For this reason we use the guide carriage.
Experimental set up
The white plastic plate (40 mm) serves as reference measuring flag.
Turn the mounting plate transversely. Mount the guide carriage with sample carrier and
the distance
measuring system (1 827 003 641) above in the middle of the plate.The angle with
retroreflector

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is placed at the top of the matrix base.

Mount the white sample at the stationary sample carrier. Mount the elevation
compensation at
the bottom of the plate and at right angles to the guide rail. Snap the reflex photoelectric
sensor
on it, in a way that its optical system aims exactly to the reflector at the angle. This way
you have
set up a reflex photoelectric sensor with a range of approx. 350 mm.
Switch on the power supply unit.
The analogue value of the distance measurement sensor is without significance for this
experiment

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Wiring diagram

Testing method
Adjust the sensitivity of the sensor in a way that the reflector is detected with certainty:
Move
the sample aside. Carefully turn the small slotted screw anti clockwise, until the yellow
LED extinguishes
(in case it was on). Then turn it back clockwise, until the yellow LED lights up and
then add approx. 45 degrees.
Note: The NC/NO switching of this reflex photoelectric sensor is defined via
programmable wiring!
After the white sample, move all other material samples from the common table (EV4 ...
6)
through the light barrier and observe the switching state of the LED display.
Rotation of the mirror: Release the mirror from the sample carrier and move it in the
optical axis
by hand.
Evaluation, result
Enter the results in the common table for the experiments EV4, EV5 and EV6.
How is the programmable wiring used in practice?
What do the detected materials have in common?
Why is it possible to have different results with the same metal?
Which material cannot be detected by the through beam sensor? Which differences in
the function
of light scanner and light barrier can be realised?

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