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Which sensor types are used in Automation

  • Dec 30, 2024
  • 3 min read

Updated: Jan 3

twin robot automation machine
Many sensors are used throughout the Automation industry!

In the world of automation, sensors serve as the eyes, ears, and nerves of machinery. These devices enable precise monitoring, control, and optimization of processes, ensuring smooth and efficient operations. Here’s an in-depth look at the different types of sensors commonly used in automation machinery, their applications, and some leading suppliers.


Proximity Sensors

Inductive Sensors

  • Detect metallic objects within a specific range using electromagnetic fields.

  • Applications: Machine tool position detection, assembly line monitoring.

  • Suppliers: SICK, Balluff, Omron.

Capacitive Sensors

  • Detect both metallic and non-metallic objects, such as plastic or liquids, by measuring changes in capacitance.

  • Applications: Liquid level detection, paper counting.

  • Suppliers: Keyence, Schneider Electric, IFM.

Ultrasonic Sensors

  • Use sound waves to detect object presence and measure distance.

  • Applications: Long-range object detection, irregular shapes.

  • Suppliers: Pepperl+Fuchs, Banner Engineering, Baumer.

Photoelectric Sensors

  • Detect objects using emitted and reflected light.

  • Applications: Counting parts, positioning on conveyors.

  • Suppliers: Leuze, Honeywell, Allen-Bradley (Rockwell Automation).


Position and Motion Sensors

Encoders

  • Incremental: Provide relative position changes.

  • Absolute: Provide precise, absolute positioning.

  • Applications: Robotics, conveyor systems, motor control.

  • Suppliers: Renishaw, Heidenhain, BEI Sensors.

Limit Switches

  • Mechanical devices triggered by physical contact.

  • Applications: Safety stop points in presses or CNC machines.

  • Suppliers: Omron, Telemecanique, Honeywell.

Linear Position Sensors

  • Measure straight-line movements using potentiometers or magnetic fields.

  • Applications: Actuator control, injection molding machines.

  • Suppliers: Novotechnik, MTS Systems (Temposonics), Meggitt.

Gyroscopes and Accelerometers

  • Measure angular velocity or acceleration.

  • Applications: Drone navigation, machinery vibration analysis.

  • Suppliers: Bosch, STMicroelectronics, Analog Devices.


Pressure Sensors

  • Measure fluid or gas pressure in systems.

  • Applications: Hydraulic systems, pneumatic controls.

  • Suppliers: WIKA, Honeywell, Ashcroft, Gems Sensors.


Temperature Sensors

Thermocouples

  • Measure temperature changes via voltage differences.

  • Applications: Kilns, furnaces, injection molding.

  • Suppliers: Omega Engineering, Fluke, Jumo.

RTDs

  • High precision and stability for industrial use.

  • Applications: Food processing, HVAC systems.

  • Suppliers: Siemens, Yokogawa, Pyromation.

Thermistors

  • Sensitive to rapid temperature changes.

  • Applications: Overheat protection in motors.

  • Suppliers: Honeywell, TE Connectivity, Vishay.


Force and Torque Sensors

  • Measure applied forces or rotational torques.

  • Applications: Robotic arms, presses, quality control.

  • Suppliers: Kistler, ATI Industrial Automation, Futek.


Level Sensors

  • Detect material levels using ultrasonic, radar, or float-based mechanisms.

  • Applications: Liquid tank monitoring, hopper level control.

  • Suppliers: Endress+Hauser, VEGA, Rosemount (Emerson).


Flow Sensors

  • Measure the flow rate of liquids or gases through a system.

  • Applications: Water flow in cooling systems, gas flow in HVAC.

  • Suppliers: ABB, Krohne, Siemens.


Vision Sensors

  • Combine cameras with processing units for object recognition and quality inspection.

  • Applications: Barcode scanning, defect detection.

  • Suppliers: Cognex, Keyence, Teledyne DALSA.


Current and Voltage Sensors

  • Monitor electrical currents and voltages in circuits.

  • Applications: Detecting overloads, energy efficiency monitoring.

  • Suppliers: LEM, CR Magnetics, Eaton.


Gas and Chemical Sensors

  • Detect specific gases or chemical concentrations.

  • Applications: Leak detection, air quality monitoring.

  • Suppliers: Dräger, Honeywell, Figaro.


Humidity Sensors

  • Measure moisture levels.

  • Applications: Cleanrooms, material drying processes.

  • Suppliers: Sensirion, Vaisala, Amphenol.


Vibration Sensors

  • Monitor machinery for abnormal vibrations to predict maintenance needs.

  • Applications: Predictive maintenance, machinery fault detection.

  • Suppliers: SKF, Wilcoxon, IMI Sensors.


Magnetic Sensors

  • Detect magnetic fields for proximity or position sensing.

  • Applications: Speed detection, linear motion sensing.

  • Suppliers: Honeywell, Allegro MicroSystems, TDK.


Infrared (IR) Sensors

  • Detect heat or infrared radiation.

  • Applications: Object counting, temperature measurement.

  • Suppliers: Optris, FLIR Systems, Excelitas Technologies.


Light Sensors

  • Measure ambient light intensity or specific wavelengths.

  • Applications: Light-sensitive manufacturing processes.

  • Suppliers: Osram, Rohm, AMS AG.


Conclusion

Automation relies on a wide range of sensors to ensure precision, efficiency, and safety. By understanding the capabilities and applications of these sensor types, businesses can select the right tools for their specific needs. Collaborating with reliable suppliers ensures access to cutting-edge technologies that can enhance operations and maintain competitiveness in an evolving industrial landscape.


 

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