Inductive Sensor Explained | Different Types and Applications

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⌚Timestamps:
00:00 - Intro
00:59 - Sensing range
03:24 - Parts
04:11 - Working principle
04:28 - Types
04:56 - Advantages
05:25 - Mounting
06:59 - Applications

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In this video, we will explain what an inductive sensor is, how an inductive sensor works, some of the different types of inductive sensors, and we will also talk about some of the ways these sensors are used in automation.

An inductive sensor is an electronic device that can detect ferrous metal targets without physical contact. Inductive sensors will also detect non-ferrous metal targets. But using non-ferrous metal targets decreases an inductive sensor's sensing range.

The sensing range of an inductive sensor is the distance from the sensor’s face to the maximum distance the sensor can detect a metal target.

The sensing distance can be found on the sensor's datasheet. The datasheet will also show some correction factors when you want to detect a non-ferrous metal.

Brass, aluminum, and copper are examples of non-ferrous metals.
If the object is a non-ferrous metal, meaning it does not have a significant amount of iron within it, you need to consider a simple correction factor when defining the sensing distance.

The four major external parts of an inductive sensor are the body of the sensor, the sensor’s face, the indicator light, and the cable end or cable connector end.

Inside the sensor’s body is where the circuitry that makes the sensor work is located.
The face is the part of the sensor that detects the targets.
The indicator light turns on when the target is within the sensors sensing range.

The sensor’s cable has three different colored wires in it, brown, blue, and black. These sensors are available with a cable that is already attached or they can have a connector that the cable screws on to.

How inductive sensors work is the sensor creates an electromagnetic field that emits from the sensor’s face. Putting a metal target near the sensor’s face will disrupt the electromagnetic field, causing the sensor’s output and indicator light to turn on.

Inductive sensors are available in a lot of different configurations. They can be AC or DC, shielded or unshielded, normally open or normally closed, NPN or PNP just to name a few.

They also make inductive sensors for hazardous, high-temperature, and washdown locations.
For washdown locations, we need to use a shielded inductive sensor.

Inductive sensors are solid-state and do not have any moving parts. This makes them very reliable because they usually only need to be replaced when they get physically damaged.

Things like dirt, sawdust, oil, and grease will not affect how inductive sensors detect targets.

Depending on the type, some of these sensors can be mounted by just bolting them in place or drilling and tapping a hole that is the same size and thread as the sensor.

To connect the sensor to the tester, connect the brown wire to the sensor voltage + terminal, connect the blue wire to the sensor voltage - terminal, and connect the black wire to the sensor outputs #1 or #2 terminal.

When we move the bolt into the inductive sensors sensing range, the indicator light turns on and stays on. When we move the bolt away from the sensor, the indicator light turns off.

If this sensor’s output was normally closed, the indicator light would be turned off when the bolt is at the sensor and the light would be turned on when the bolt is away from the sensor.

Inductive sensors can be used to detect part in place at workstations, at conveyor stops, and even at robots.

They can be used to detect if an air cylinder is extended or retracted and if a pallet stop or chain transfer is raised or lowered.

Inductive sensors can be used to detect if a pallet is centered on a turntable before it starts to rotate. Let’s say this turntable is rotated by a motor with a gearbox and the motor is controlled by a VFD. Inductive sensors can be used to tell the VFD when to slow down and stop.

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