Inductive Proximity Sensor

Hoang Nguyen
U36842290

ABSTRACT
Nowadays, sensors are widely applied in a lot of technical devices and systems. Inductive
proximity sensor is used to detect a metallic object which appears within an inch or less of the
sensing surface. In this research, we will discuss about the operating principle of an inductive
proximity sensor, responds characteristic of the sensor, sensing distance and technical issues
relating to mounting or single and multiple inductive proximity sensors.
INTRODUCTION
Inductive proximity sensor was first invented in the early 1960s [1]. It has used very
commonly in a lot of areas such as food industry, plating line, machine tools, etc. The
fundamental operating principle of inductive proximity sensor is based on electromagnetic. We
will discover in detail how an inductive proximity sensor is designed, how electromagnetic is
used in the sensor to detect a metallic object.
OPERATING PRINCIPLE
In order to understand how operating principle of an inductive proximity sensor works, we firstly
need to know about Eddie current (figure 1). According to electrical engineering dictionary,
Eddy current is a circulating current in magnetic materials that is produced as a result of timevarying flux passing through a metallic magnetic material. [2].
Next, we will find out how an inductive proximity is designed and the influence of Eddy
current on operating principle of an inductive proximity sensor. An inductive proximity sensor

always includes four parts: the coil, an LC oscillator, a trigger circuit and an output circuit
(figure 2). The coil is a metal strand that is wounded around the sensors face. The oscillator is
an inductive capacitive circuit producing an alternating electromagnetic field around the
detection coil of the inductive proximity sensor. When a metallic target entering the field, the
electromagnetic field emitted around the sensing face of the coil produces Eddy current
circulating around the surface of the detectable object. This Eddy current generates an opposing
electromagnetic field that influences the oscillation field. The Eddy currents increases when the
detectable object getting closer to the sensing face. It dampens or decreases the amplitude of
electromagnetic field induced by the sensor. [3] The decreasing of the field will be evaluated at
trigger circuit. When the amplitude of the electromagnetic field goes down to a certain level, it
will ignite the output switch (on or off) from its normal state (off or on). When the detectable
object is absent from the sensing range, the sensors magnetic field increases again; the changing
switches the output circuit back to its normal. The sensing range or the distance of the detectable
target between two state on and of the sensor calls hysteresis zone. This is how the inductive
proximity sensor indicates a metallic target detected. (Figure 3)
SHIELDED AND NON-SHIELDED INDUCTIVE PROXIMITY SENSOR
There are two kinds of inductive proximity sensor: shielded and non-shielded inductive
proximity sensor. The shielded inductive proximity sensor has housing surrounding sensor coil,
and only the active face is exposed in the sensor. The cover restricts the lateral radiation of
electromagnetic field induced by the sensor (figure 3). For this reason, the shielded model often
has a smaller rated sensing range compared with the non-shielded sensor.

In difference, the non-shielded inductive proximity sensor has the cap and coil exposing
at one end of the sensor. This allows the non-shielded sensor emerge the larger electromagnetic
field pattern. Thus, the non-shielded inductive proximity sensor has a larger rated sensing range.
Because of difference in design and rated sensing range, they have a different metal free
zone (figure 4, 5). If a shielded sensor is mounted, the distance between the metal surface
(locating in front of the sensing surface) and the sensing face has to equal at least 3 times the
rated sensing distance. Differently, the non-shielded sensor is affected by the metal object not
only in front of the sensing face but also surround the sensing face. For this reason, the metal free
zone of the non-shielded sensor is three times of rated sensing distance in front and 2 times
around of the sensing face [3].
STANDARD TARGET, SENSING DISTANCE, AND CORRECTION FACTOR
The standard detectable target of an inductive proximity sensor is defined as a 1mm-thick
iron object with plat and smooth surface, and its height and width equal to that inductive sensors
diameter (figure 6). The sensing distance is the distance between the sensing face of the sensor
and the standard detectable object locating in front of the sensing face [1]. The sensing distance
of a target is significantly influenced by thickness, the size and material of the target. The object
with higher thickness is harder to detect. If a target has a smaller size than the standard target the
sensing distance will decrease. However, if the target is bigger than the standard target, the
sensing distance will be still the same. Each material has different conductivity which affects the
Eddy current circulating in the target; thus, the electromagnetic field emerged by the Eddy
current changes. This changes the sensing capability or the sensing distance of the sensor.
Because there are so many factors that affect the sensing range, the correction factor must
be applied when using the inductive proximity sensor. To calculate the sensing distance of a

target (Sn), we use this formula: Sn = Srated

correction factor. Srated is the theoretical sensing

distance of a standard detectable object regardless of factors such as heat, material, supply
voltage, etc. Tables below will show correction factors of targets which have different sizes and
thicknesses to the standard target [3]. For example, if the size of the target is 25 % of the
standard target of a shielded inductive proximity sensor. The sensing distance can be calculated
as Sn = 1mm x 0.56 = 0.56 mm (assuming Srated of the shielded inductive sensor is 1mm)
Size of target

Correction factor

Correction Factor
Material

compared to
standard target

Shielded

Shielded

Unshielded

Mild Steel, Carbon

1.00

1.00

Unshielded

25%

0.56

0.50

Aluminum Foil

0.90

1.00

50%

0.83

0.73

300 series Stainless steel

0.70

0.80

75%

0.92

0.90

Brass

0.40

0.50

Aluminum

0.35

0.45

100%

1.00

1.00
Copper

0.30

0.40

Figure 7 shows how the thickness affects the sensing distance of the target.
HOW TO MOUNT MULTIPLE INDUCTIVE PROXIMITY SENSORS
Many factors should be considered when mounting multiple inductive proximity sensors.
Each inductive proximity sensor produces its own magnetic field pattern and has its own free
metal-free zone. When multiple sensor are mounted adjacently; off course, their sensing field can
be mutually interfered. This could cause the failure in detection and change the sensing distance
of those inductive proximity sensors. Therefore, we need to look at the specification of the
sensor manufacture to minimize the possible mutual interference.
For example, assuming the sensors are used in this situation are BERO proximity sensors.
If the inductive proximity sensors are mounted adjacently, they must be separated by two times
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the sensor faces diameter (for the shielded sensors) and three times the sensor faces diameter
(for unshielded inductive sensors)[3].
PROBLEMS AND APPLICATION
The inductive proximity sensor is one of the best sensing technologies ever invented. It is
widely used in many technical systems. However, there are many issues should be considered in
order to select sensor accurately and effectively. Firstly, surrounding environment has a
significant effect on sensor function. Extremely harsh weather conditions could reduce the
operating life of the sensor. An inductive proximity sensor could be more sensitive under
extremely high temperature condition. In contrast, under cold weather, the sensor could perform
poorly. Secondly, the inductive sensors could be damaged or cracked if they are used in chemical
environment for a long period of time. Lastly, operation of the sensor could be failed by setup
errors because of not following specification of the sensor manufacturer.
Inductive proximity sensor has been applied in variety of industrial systems. It is a
perfect tool to detect broken parts made of metal in the machine such as the drill, saw, etc. Also,
inductive proximity sensor can be used to moderate the speed of the cam in the technical
systems. Moreover, we use inductive proximity sensor to detect metal products such as metallic
can, cap bottle, etc (figure 8).

SUMMARY
In order to detect a metallic target located within an inch in front of the sensor, inductive
proximity sensor comes out as the best solution. Fundamental operating principle of inductive
proximity sensor bases on Eddy current circulating surround the detectable target and changing
of electromagnetic induced by the sensor. The unshielded inductive proximity sensor emerges

the larger electromagnetic field pattern. Therefore, it has a bigger sensing distance than the
shielded sensor whose electromagnetic field is restricted by the housing wrapping around the
sensor coil. Sensing distance of inductive proximity sensor is significantly influenced by the
size, thickness, material of the target. Thus, correction factors are used to calculate the exact
sensing distance of a target. Because inductive proximity sensor is widely used in various areas,
considering all factors affecting the operation of the sensor such as environmental conditions,
mutual interference of multiple sensor, etc is very necessary.

FIGURES

Figure 1: Magnetic field created by Eddy

current that influences the field produced by
the sensor's detection coil [2]

Figure 2: design of an inductive proximity

sensor

Figure 3: the change of Amplitude of the sensor's electromagnetic field when detecting a target
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Figure 4: the construction of shielded and non- shielded inductive proximity sensor

Figure 5: Shielded inductive proximity sensor

Figure 6: Non-shielded inductive proximity sensor

Figure 7: Target thickness increase cause the decreasing of sensing distance

Figure 8: Inductive proximity sensor is widely used in bottle cap detection,

broken tool detection, cam follower, part and product detection
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REFERENCES
[1] Suffi, G. "Consider All The Factors When Selecting The Proper Inductive Proximity Sensor."
Electronic Design -New York Then Hasbrouck Heights- 48.(2000): 107-114. British Library
Document Supply Centre Inside Serials & Conference Proceedings. Web. 14 Apr. 2013.

[2] Philip, Ed, and Laplante A. Electrical Engineering Dictionary. Boca Raton: CRC Press LLC,
2000. eBook. <http://ee.sharif.edu/~lcsl/useful/Electrical Engineering Dictionary.pdf>.

[3] Esmaeilzadeh, . N.p., 16 Dec 2012. Web. 15 Apr 2013.

<http://een.iust.ac.ir/profs/Esmaeilzadeh/Instrumentation/sensors.pdf>.
[4] Allen, Bradley. N.p.. Web. 15 Apr 2013. <http://teacher.en.rmutt.ac.th/ktw/04-710409/Proximity Sensors 2922.pdf>.
[5] ed. "Inductive Proximity Sensor Control Technology." HTMElectronics Industries. N.p..
Web. 15 Apr 2013. <http://www.htmsensors.com/prox/inductive_proximity_control_technology.htm>.