In industrial automation, sensors play a vital role to make products intelligent and hyper-automated. Sensors help people detect, analyze, measure and process various changes, such as changes in position, length, height, exterior and misalignment that occur in industrial production sites.
A sensor is a device that identifies electrical or physical or other quantitative progress and delivers benefits in a way that confirms production progress. Simply put, industrial automation sensors are input devices that provide an output (signal) about a specific physical quantity (input).
Sensors also play a pivotal role in predicting and preventing numerous potential processes, thus fulfilling the needs of many industrial sensing applications.
Here are the various sensors used in automation:
1. Pressure sensor A pressure sensor is an instrument that senses pressure and converts it into an electrical signal, the amount of which depends on the applied pressure. The main pressure sensors used in industrial automation include pressure sensors and vacuum sensors. Pressure Sensors: Pressure sensors are widely used in industrial and hydraulic systems, and these high pressure industrial automation sensors are also used in climate control systems. Vacuum Sensors: Vacuum sensors are used when the vacuum pressure is below atmospheric pressure and it is difficult to detect mechanically. These sensors typically rely on a heating wire whose resistance is temperature dependent. As the vacuum pressure increases, convection decreases and the wire temperature increases. The resistance increases proportionally and is calibrated near pressure for effective measurement of vacuum. Applications of pressure sensors: used to measure sub-atmospheric pressure at a given location; used in meteorological instruments, aircraft, vehicles and other machinery that has implemented a pressure function; used in systems to measure other variables such as fluid/gas flow, Speed, water level and altitude.
2. Temperature sensor A temperature sensor is a device that gathers information about temperature from a resource and changes it into a form that other devices can understand. It is a common class of sensors that can detect temperature or heat, and can measure the temperature of a medium. The main temperature sensors used in automation include digital temperature sensors and temperature and humidity sensors. Digital Temperature Sensors: Digital temperature sensors are silicon-based temperature sensing ICs that provide an accurate output by digitally representing the temperature measured. This simplifies the design of the control system compared to methods involving external signal conditioning and analog-to-digital converters (ADCs). Temperature and Humidity Sensor: The temperature and humidity sensor combines a temperature sensor and a humidity sensor, which is then attributed to the measured digital signal output. By utilizing this technology and humidity sensing with temperature and limited digital signal acquisition, a high degree of consistency and excellent long-term stability is ensured. Applications of temperature sensors: continuous measurement of temperature in air, soil or water; for measurements in complex industrial applications; for measurements in harsh working conditions.
3. MEMS sensors (Micro Electro Mechanical Systems) MEMS industrial automation sensors convert the measured mechanical signals into electrical signals. Important sensors used in industrial automation are acceleration and motion MEMS. Accelerometers: Micro-Electro-Mechanical Systems (MEMS) accelerometers are one of the main inertial sensors. And with dynamic sensor capabilities, it has a wider range of sensing capabilities. Motion Sensors: Micro-Electro-Mechanical Systems (MEMS) motion sensors use data processing algorithms designed on a motion interaction platform that integrates numerous low-cost MEMS motion sensors with ZigBee wireless technology for personalization while working with machines interact. The sensor signal processing system mainly solves the problems of noise elimination, signal smoothing, gravity effect partition, coordinate system change and position information recovery, etc. It is widely used in ABS technology in the automotive industry. Applications of MEMS Sensors: MEMS sensors are used in a wide range of applications ranging from industry, entertainment, sports to education. For example, triggering airbag deployment or monitoring nuclear reactors. As well as for measuring static acceleration (gravity), tilt of objects, dynamic acceleration in airplanes, vibrations to objects in cars, and vibrations of cell phones, washing machines or computers. Also for detecting motion and more.
4. Torque Transducers Torque transducers have basic mechanical stops that increase overload capacity and provide additional protection during installation and operation. Important sensors used in industrial automation include rotational torque and torque sensors. Rotary Torque Sensors: Rotary torque industrial automation sensors are used to measure the reaction force of rotational torque. These torque meters are equipped with basic mechanical stops to increase remaining capacity and provide additional safety during installation and operation. Torque Transducers: Torque transducers utilize superior strain gage technology to meet the most challenging demands of transducer static and dynamic applications. Applications of torque sensors: for measuring rotational speed and maintenance necessity; for measuring mass and mass moment of inertia; amount of torque to be calculated from the point of view of a quasi-static process; for measuring maximum rotational speed, oscillating torque.
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