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12 views

Week 4 Lecture 2

Uploaded by

Star Youtuber Prashant
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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NPTEL online certification course on

Automation in Manufacturing

Dr. Shrikrishna N. Joshi


Associate Professor
Department of Mechanical Engineering
Indian Institute of Technology Guwahati
Guwahati PIN 781 039
Assam, India
Week 4: Sensors
Lecture 2: Displacement, position and
proximity sensors - I
Outline
❖ Displacement, position and proximity sensors
➢ Principle of operation
➢ Construction and working
➢ Applications
❖ Strain gauge based sensors
❖ Capacitive elements
❖ Linear Variable Differential Transformer (LVDT)
❖ Eddy current based sensor
❖ Inductive proximity switch
Strain-gauge element

◼ Electric-resistance strain ◼ G = constant of


gauge proportionality, Gauge factor
◼ Metal wire, metal foil strip, a ◼ G = 2-4, Calibration based on
strip of semiconductor actual experiments
material ◼ Constantan alloy: copper-
◼ ∆R/R = Gε nickel (55-45%) alloy
Strain
guages

◼ Foils - Constantan alloy (copper-nickel 55-45% alloy)


◼ Bonding to plastic (ployimide) - epoxy or glass fiber
reinforced epoxy
◼ Secured to the workpiece - epoxy or Cyanoacrylate
cement Eastman 910 SL.
Wheatstone’s resistance bridge
Resistance change into voltage
change
Strain gauges
◼ Deflection or deformation of flexible
elements
◼ Attach to flexible elements viz.
cantilevers, pipes, U-shaped
elements
◼ Linear displacement in the order of
1 to 30 mm
◼ Nonlinearity error 1% of the full
range
◼ Effect of temperature
Strain gauge
Applications
◼ experimental stress analysis and diagnosis on machines
and failure analysis
◼ multi-axial stress fatigue testing, residual stress and
vibration measurement, torque measurement, bending
and deflection measurement, compression and tension
measurement and strain measurement
◼ machine tools : hydraulic or pneumatic press
◼ safety in automotive
◼ impact sensors in aerospace vehicles
Capacitive element

◼ Monitoring of displacement
◼ Non-contact type
displacement sensor
◼ C = (εr εo A)/d
◼ εr = relative permittivity of
dielectric between the
plates A = area of overlap
εr = 1 for vacuum d = plate separation
◼ εo = permittivity of free Permittivity relates to a material's ability
space ε0 ≈ 8.854×10−12 F to transmit (or "permit") an electric field.
m–1
Capacitive element sensors

Capacitive proximity sensor

Push – pull displacement sensor


http://www.mtiinstruments.com/products/capac
itancemeasurement.aspx
Capacitive element sensor
◼ Feed hopper level monitoring
◼ Grease level monitoring
◼ Level control of liquids
◼ Metrology applications
◼ to measure shape errors in the part being
produced
◼ to analyze and optimize the rotation of spindles in
various machine tools such as surface grinders,
lathes, milling machines, and air bearing spindles
by measuring errors in the machine tools
themselves
Capacitive element sensor
◼ Assembly line testing
◼ to test assembled parts for uniformity, thickness
or other design features
◼ to detect the presence or absence of a certain
component, such as glue etc.
Linear variable differential transformer (LVDT)
◼ Important transducer
◼ Operating range ± 2 to ± 400
mm
◼ Non-linearity error ± 0.25% of
full range
◼ Absolute position sensor
◼ Good repeatability and
reproducibility
◼ Highly reliable
◼ Non-contact, no friction or
sliding
◼ Completely sealed
◼ Servomechanisms, automated
measurement in machine tools
◼ Works with phase sensitive
demodulator and low pass
filter
Roller spacing

http://www.itargets
ensors.com/html_ne
ws/lvdt-application-
18.html
Injection molding machine
◼ to control and measure the
opening and closing of the
mold
◼ to control feeding and other
hydraulic and pneumatic
actuators.

http://www.itargets
ensors.com/html_ne
ws/lvdt-application-
18.html
Valve opening and closing

http://www.itargets
ensors.com/html_ne
ws/lvdt-application-
18.html
LVDT: applications
◼ Measurement of spool position in a wide range of servo valve applications
◼ To provide displacement feedback for hydraulic cylinders
◼ To control weight and thickness of medicinal products viz. tablets or pills
◼ For automatic inspection of final dimensions of products being packed for dispatch
◼ To measure distance between the approaching metals during Friction welding process
◼ To continuously monitor fluid level as part of leak detection system
◼ To detect the number of currency bills dispensed by an ATM
RVDT (rotary variable differential
transformer)

◼ Cardioid-shaped
magnetic material
◼ Linearity error ±0.5%
Eddy current proximity sensors
◼ Electrical impedance is the measure of
the opposition that a circuit presents
to a current when a voltage is applied.

◼ AC current -> AC magnetic field ->


Metal objects -> Eddy currents ->
formation of own magnetic field ->
distorts original magnetic field ->
changes the impedance -> amplitude
of AC current -> triggering a switch

Daniel J. Sadler, Chong H. Ahn, On-chip eddy current sensor for proximity sensing and crack detection, Sensors and Actuators A:
Physical, Volume 91, Issue 3, 15 July 2001, Pages 340-345, ISSN 0924-4247, http://dx.doi.org/10.1016/S0924-4247(01)00605-7.
Eddy current proximity switches
◼ Machine tool monitoring
◼ Measuring the dynamics of a continuously moving target, such
as a vibrating element
◼ Drive shaft monitoring
◼ Vibration measurements
Inductance
◼ Inductance is the property of a conductor by
which a change in current in the conductor
"induces" (creates) a voltage (electromotive
force) in both the conductor itself (self-
inductance) and in any nearby conductors
(mutual inductance).
Inductive proximity switches
◼ Coil wound on a core -> close to a metallic
object -> inductance changes -> triggers a
switch
◼ Detection of metallic objects
Applications
◼ Industrial automation: counting of products during
production or transfer
◼ Security: detection of metal objects, arms, land mines
Summary
❖ Strain gauge based sensors
❖ Capacitive elements
❖ Linear Variable Differential Transformer (LVDT)
❖ Eddy current based sensor
❖ Inductive proximity switch
Week 4 : Lecture 3
❖ Optical encoders
❖ Electric connection based switches
❖ Pneumatic sensors
❖ Hall effect based sensors

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