Product- Magnetic Proximity Sensor

Design team- Nitin Choudhary Sagar Chachondia

Introduction Proximity Sensors

Proximity sensor is a sensor that is able to detect the presence of nearby objects without any physical contact. A proximity sensor often emits an electromagnetic or electrostatic field, or a beam of electromagnetic radiation and looks for changes in the field or return signal. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target. Proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object. There are four basic types of proximity sensors Infrared Acoustic Capacitive Magnetic (Inductive)

Magnetic Proximity Sensors

Magnetic proximity sensors are non contact proximity devices which utilize inductance, Hall effect principles, variable reluctance or magneto resistive technology. Magnetic proximity sensors are characterized by the possibility of large switching distances, available from sensors with small dimensions. They detect magnetic objects (usually permanent magnets), which are used to trigger the switching process. As the magnetic fields are able to pass through many non-magnetic materials, the switching process can also be triggered without the need for direct exposure to the target object. By using magnetic conductors (e.g iron) the magnetic field can be transmitted over greater distances so that the signal can be carried away from high temperature areas. The body style of proximity sensors, magnetic can be barrel, limit switch, rectangular, slot, or ring. A barrel body style is cylindrical in shape and typically threaded. A limit switch body style is similar in appearance to a contact limit switch. The sensor is separated from the switching mechanism and provides a limit of travel detection signal. A rectangular or block body style is a one piece rectangular or block shaped sensor. A slot style body is designed to detect the presence of a vane or tab as it passes through a sensing slot, or "U" channel. A ring shaped body style is a "doughnut" shaped sensor where object passes through center of ring. Electrical connections for magnetic proximity sensors can be fixed cable, connector(s), and terminals. A fixed cable is an integral part of sensor and often includes "bare" stripped leads. A sensor with connectors has an integral connector for attaching into an existing system. A sensor with terminals has the ability to screw or clamp down. Important specifications for magnetic proximity sensors include operating distance, repeatability, field adjustable, and minimum target distance. Rated operating distance is the distance at which switching takes place. Repeatability is the distance within which the sensor repeatably switches. It is a measure of precision. Field adjustable sensors can be adjustable while in use. Depending on the sensor's technology, there can be minimum target size requirements.

Circuit Diagram

List of Components IC CD4013 IC 555 SPDT relay Reed switch Transistor BC107 Diode 1N4007 LED Resistances o 1K o 2.2K o 10K o 470K Capacitances o 0.01F o 2.2F

Description of Components

IC CD4013 IC CD4013 consists of two identical, independent

data-type flip-flops. Each flip-flop has independent data, set, reset and clock inputs and Q and Q outputs.

Features
Set-Reset capability. Static flip-flop operation. Medium speed operation-16MHz at 10V. Standardized symmetrical output characteristics. o 100% tested for quiescent current at 20V. o o o o

IC 555 - 555 Timer IC is an integrated circuit used in a variety of

timer, pulse generation and oscillator applications. The IC was designed by Hans R. Camenzind in 1970 and brought to market in 1971 by Signetics. The 555 has three operating modes: o Monostable mode : In this mode, the 555 functions as a "one-shot". Applications include timers, missing pulse detection, bounce free switches, touch switches, frequency divider, capacitance measurement, pulse-width modulation (PWM) etc o Astable : Free running mode: the 555 can operate as an oscillator. Uses include LED and lamp flashers, pulse generation, logic clocks, tone generation, security alarms, pulse position modulation, etc. o Bistable mode or Schmitt trigger : The 555 can operate as a flipflop, if the DIS pin is not connected and no capacitor is used. Uses include bounce free latched switches.

SPDT Single Pole Double Throw. A common terminal connects to

either of two others. Including two for the coil, such a relay has five terminals in total.

Reed Switch - Reed switch is an electrical switch operated by an

applied magnetic field. It was invented at Bell Telephone Laboratories in 1936 by W. B. Ellwood. It consists of a pair of contacts on ferrous metal reeds in a hermetically sealed glass envelope. The contacts may be normally open, closing when a magnetic field is present, or normally closed and opening when a magnetic field is applied. The switch may be actuated by a coil, making a reed relay or by bringing a magnet near to the switch. Once the magnet is pulled away from the switch, the reed switch will go back to its original position.

Diode 1N4007 - The 1N4007 is a general purpose plastic encapsulated silicon rectifier.

LED - A light-emitting diode (LED) is a semiconductor light

source. LEDs are used as indicator lamps in many devices and are increasingly used for lighting. Introduced as a practical electronic component in 1962 early LEDs emitted low-intensity red light. But modern versions are available across the visible, ultraviolet and infrared wavelengths with very high brightness.

Working

The magnetic proximity switch circuit, in principle, consists of a reed switch at its heart. When a magnet is brought in the vicinity of the sensor (reed switch) it operates and controls the rest of the switching circuit. In place of the reed switch we can also use a general-purpose electromagnetic reed relay (by making use of the reed switch contacts) as the sensor, if required. These tiny reed relays are easily available as they are widely used in telecom products. The reed switch or relay to be used with this circuit should be the normally open type. When a magnet is brought or placed in the vicinity of the sensor element for a moment, the contacts of the reed switch close to trigger timer IC1 wired in monostable mode. As a consequence its output at pin 3 goes high for a short duration and supplies clock to the clock input (pin 3) of IC2 (CD4013 dual D-type flip-flop). LED D2 is used as a response indicator. This CMOS IC2 consists of two independent flip-flops though here only one is used. The flip-flop is wired in toggle mode with data input (pin 5) connected to the Q (pin 2) output. On receipt of clock pulse, the Q output changes from low to high state and due to this the relay driver transistor T1 gets forward-biased. As a result the relay RL1 is energised.

Applications
Magnetic proximity sensors sense distance to objects by generating magnetic fields. They are similar to metal detectors. It involves use of Proximity sensing, a technique of detecting the presence or absence of an object using a critical distance. A position sensor determines an object's coordinates (linear or angular) with respect to a reference, displacement means moving from one position to another for a specified distance (or angle).

Magnetic proximity sensors are used to determine the position of points and mechanical locking of a switch machine to ensure safe passage of trains. The technique involves multiple sensors and the way in which the status ON can be distinguished from the shorted and OFF may be distinguished from open.

Magnetic proximity sensors are widely used in door and window sensors in burglar alarm systems and tamper proofing methods.

It is suitable in variant range of industrial detection processes. The

adaptability and portability of magnetic proximity sensors make them an ideal choice of panel building industries.

They also find extensive use in hostile welding environments.

They also are used in Reliable diagnostics. It is extremely important

for high-throughput machines. These machines depend on the ability to identify process quality issues in real-time. Examples of these types of machines can be found in the printing and paper converting industries. The sensors on these machines need to be highly reliable and have their proper functioning guaranteed.