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Sensors
Sensors are devices that either measures a physical quantity or detects it.
In PLC automation, a sensor must be a transducer who can convert a physical quantity into an
electrical quantity.
It is important to know that there is no “one-fits-all” sensor that exists in this world. As engineers,
we have to solve PLC automation problems using the correct sets of devices—and it starts with
how you can monitor the physical conditions in your system.
It is also important to know what factors to consider when choosing your sensors.

Factors in choosing sensors

• Accuracy
Accuracy may be defined as the “closeness” to the actual value of the measurand. As the designer,
it is not always practical to choose a high accuracy sensor.
Most sensors in the market already have reasonable accuracy where they can almost represent the
actual values that you are measuring.
That said, some PLC automation applications do not require a very high level of accuracy in order
to work properly. As an example, if you only had one product weighing 5kg, it does not make
sense to put a weight sensor or strain gauge that can measure up to 0.0001g of accuracy. Makes
sense?
• Dynamic Range
This is the operating range of your sensor. How far depends on the application that you are
designing for.
For example, if you have to take a temperature reading from a heating oven, then it is necessary
for you to use thermocouples instead of LM35 sensors, just because thermocouples can measure
extremely high temperatures.
• Response Time
The response time is the amount of time needed by the sensor to represent the actual value being
measured.
Again, this is critical for some PLC automation applications, and for some, it may not be that
important.
• Sensitivity
In the simplest form, sensitivity determines the minimum amount of “stimulus” that a sensor
requires to produce a reading.
If you wanted to read a temperature reading of 0.01 degrees at around room temperature, then
(going back to the previous example) the thermocouple may not suffice in this scenario and the
LM35 does.
• Stability
This is the sensor’s ability to produce the same output when given a constant level of input for a
very long time. For example, if you wanted to measure, using PLC automation, the temperature of
a room for 365 days a year, then you want a sensor that is high in this regard.
Drift and Zero drift are the factors that you want to look at when considering stability. Drift is the
deviation in output over time, and zero drift is the change in output when there is zero input.
• Repeatability
The ability of the sensor to produce the same value of the output for the same value of the input is
its repeatability.
Measurands can vary from time to time during PLC automation, but your sensor must be able to
adapt to these changes and at the same time give similar results for each repeated value.
Simply put, your sensor must give output A for every reading A, and output B for every reading
B.
• Reliability
The reliability of your sensor determines the probability that the sensor will provide accurate,
repeatable readings (basically, optimal performance) in a predetermined working condition for a
specified period.
If you look at sensor datasheets, you will see that they give rated operating conditions where the
sensor operates linearly. These are the conditions where the sensor is reliable.

Two types of sensors: Analog and Discrete

Analog sensors are devices that output a continuous voltage linear to the experienced change in
the environment.
They are most extensively used in Temperature Sensing, Distance Sensing, Luminance Sensing,
Pressure Sensing, and basically in PLC applications where an exact, certain unit of measure is
involved.
In PLC automation, the typically used analog inputs vary from 0-20mA, 4-20mA, or 0-10V.
Hence, the sensing may also become current sensing or voltage sensing.
However, even though the sensor is Analog, the PLC is still a Digital Device. This is why an A/D
converter is used.
To briefly discuss, the analog values are sampled periodically by the PLC. This usually happens a
hundred to a thousand times per second (Fact: Voice analog signals AT THE MINIMUM are
sampled at 8000 samples per second in order to be the LEAST intelligible).
These samples are then converted into bit representations (how many bits is dependent on the
design of the PLC). This is called quantization. To easily visualize it, check the table below: it
shows a bit equivalent for the -3.5V to +3.5V range.

PLC Basics Quantization Table

Because the PLC has a CPU, it will then perform digital signal processing in order to process the
data and convert it to an equivalent result in the output module.
Discrete sensors, on the other hand, outputs a HIGH or a LOW voltage only. This is derived from
the Binary number system where the only possible digits are 0 and 1—which can represent LOW
and HIGH, respectively.
HIGH signals, even though they are represented as 1 even in some PLCs, are not represented by 1
Volt. PLCs usually run on 24 Volts DC.
What this means is that PLCs will read HIGH at the input side only when the voltage is at 24 Volts
DC.
These discrete sensors have internal switching circuits that classify them as either a sinking (NPN)
or a sourcing device (PNP). Basically, PNP provides +24 V as input, and NPN provides -24V as
input. Hence, the input modules must also be classified as sourcing or sinking.

1. Temperature Sensor
Temperature sensor uses to detect the temperature and heat energy and convert it into an electrical
signal (in form of voltage or current).
There are several types of temperature sensors used.
• Thermometer
• Thermocouple
• Resistance Temperature Detector (RTD)
• Thermistor Temperature Sensor
• Semiconductor Temperature Sensor
• Vibrating Wire Temperature Sensor
The temperature sensor is used in a computer, refrigerator, automobile, medical device, cooking
appliances, electrical motor, etc.
2. Pressure Sensor
The pressure sensor is called a Pressure Transducer or Pressure Transmitter or Piezometer.
A pressure sensor detects the pressure of air, gas, water and provides an electrical signal to the
controller.
According to different uses and many more features, it is divided into different parts like,
• Vacuum Pressure Sensor
• Absolute Pressure Sensor
• Gauge Pressure Sensor
• Differential Pressure Sensor
Pressure sensors are used in many systems like pneumatic, hydraulic, vacuum systems, etc.
3. Touch Sensor
The touch sensor is called a Tactile sensor. It is an electronic sensor that is used for detecting and
recording physical touch.
Capacitive touch sensors, resistive touch sensors are the best example of the touch sensor.
It is used in industrial applications like switches for turning on/off lights, remote control by the air
conditioner (AC), door open/close operation, elevator, and robotics, smartphones, so on.
An oximeter is one of the best examples of a touch-based sensor to detect oxygen levels in the
human body.
In this COVID pandemic, Pulse Oximeter is in huge demand. It is easy to handle and operate, even
at your home. You can easily buy an online Pulse Oximeter.
4. Image Sensor
The image sensor is an electronic device that is used to detect the image pixels and provide
information to the display devices.
There are analog and digital types of sensors. Generally, an electronic image sensor is classified
into two main types.
• Charge-Coupled Device (CCD)
• Active Pixel Sensor
For the digital camera, closed-circuit television (CCTV), medical imaging equipment, thermal
imaging devices, radar, sonar, etc., image sensors are used.
5. Motion Sensor
Motion sensor measures and records physical activities or movements. It is classified into different
types.
• Active Motion Sensor
• Passive Motion Sensor
• Tomographic Motion Sensor
• Gesture Motion Sensor
The motion sensor is used in home security, automatic doors operation, microwaves, robotics,
ultrasonic waves, gesture detector, etc.
6. Light Sensor
The light sensor is a photoelectric device. This sensor detects and converts the brightness or
luminescence of light or photon into an electrical signal.
There are three types of the light sensor.
• A Photoresistor or Light Dependent Resistor (LDR)
• Photodiode
• Phototransistor
It is widely used in the solar system, automobile, agriculture sector (automatic sprinkler system),
and electronic-based project devices like Arduino.
7. Vibration Sensor
Sometimes, a vibration sensor is known as Piezoelectric Sensor.
The vibration sensor detects and records any movement or activities. And it provides data or
signals to connected machines or systems.
This sensor helps to send acknowledgment if there is any hazardous activity.
In industrial areas such as gas and oil, food and beverage, mining, metalworking, paper, wind
power, power generation, vibration sensors are needed.
8. Humidity Sensor
A humidity sensor is also known as a Hygrometer.
For detecting moisture in air and soil, the humidity sensor is very essential. Mostly, it is used in
Air Conditioner (AC) systems.
WS1 Pro is an example of a wireless humidity sensor.
9. Proximity Sensor
A proximity sensor can easily detect nearby objects without any physical touch. It is divided into
different types-
• Capacitive Proximity Sensor
• Inductive Proximity Sensor
It is widely used in smartphones, tablet computers, machines, robotic systems, roller coasters, etc.
You will find many manufacturers of Proximity sensors, worldwide.
10. Colour Sensor
The Colour sensor is the type of photoelectric sensor.
It helps to sense the color of an object and recognize the color mark. This sensor uses RGB (red,
green, and blue) color scale.
SEN-11195 is the best example of a color sensor.
For color painting and printing, cosmetic material, textile area, medical diagnosis, computer color
monitor, and process control, colour sensor is used.
11. Radiation Sensor
A radiation sensor is an electronics instrument that senses and measures the radiation particles like
alpha, beta, gamma, neutrons, X-rays.
Also, it senses electromagnetic radiation like waves, cosmic radiation (sunlight).
Radiation sensor includes three different types.
• Gas-filled Radiation Sensor
• Scintillation Radiation Sensor
• Solid-state Radiation Sensor
This sensor is used for nuclear energy, medical imaging modalities, and monitoring of
environmental radioactivity.
12. Level Sensor
The main role of the level sensor is to measure the level or height of different materials like solid,
liquid, and gaseous.
It is classified into different parts.
• Laser Level Sensor
• Float Sensor
• Capacitive Level Sensor
• Resistive Level Sensor
• Ultrasonic Level Sensor
• Hydrostatic Level Sensor
• Optical Level Sensor
• Electromagnetic Level Sensor
It is widely used in vessels, containers, water tanks, fuel tank bins, etc for water level checks.
13. Position Sensor
The position sensor determines the displacement and the position (like linear and rotational).
Basically, position sensors are available in different types.
• Optical Position Sensor
• Linear Position Sensor
• Rotary Position Sensor
• Inductive Position Sensor
• Capacitive Position Sensor
• Fiber-Optic Position Sensor
• Ultrasonic Position Sensor
For example, a potentiometer contains a rotational position sensor that can vary with angular
movement.
The position sensor is used in domestic and industrial applications like door closing/opening, valve
monitoring, motor controlling, throttles for controlling the flow of fuel or power to an engine.
14. Gas or Smoke Sensor
A gas sensor is used to detect different types of gasses, toxic or explosive gasses, smoke in the air.
Some of these sensors are also capable to measure gas concentration.
The gas or smoke sensor is divided into three parts.
• Optical Type Smoke Sensor
• Ionization Type Smoke Sensor
• Laser Type Smoke Sensor
The smoke sensor is used in plants, industries, buildings, ships, airplanes, etc.
15. Flame Sensor
The flame sensor easily detects fire or flame of nearby materials. These detected signals are passed
to the connected control devices.
It is used in industrial areas for alarm systems, natural gas plants, fire suppression systems, and
Arduino-based design fire detector projects.
16. Leak Sensor
A leak sensor is used in a closed vessel or vacuum for detecting water leakage, fluid leakage, air
leakage, etc.
As per the working role, it is divided into two main parts.
• Spot Leak Sensor
• Flow Leak Sensor
17. Accelerometer
An accelerometer is an instrument that measures motion acceleration or velocity.
It is used in many applications such as hand gesture controlled robots, navigation systems for
aircraft and missiles, process and control systems, vehicle acceleration, and other rotating
electronic equipment like a turbine, roller, fan, compressor, pump.
18. Tilt Sensor
The tilt sensor detects and varies with an angular movement, angular slope, angular motion, axes
of the reference plane.
It is mostly used for monitoring the angle and auto-rotating operation in mobile, tablet, hand-held
games, boats, vehicles, aircraft, etc.
19. Mark Sensor
Mark sensor works as a photoelectric type of sensor. It is used to sense colour marks in the presence
of objects.
Mark sensor is widely used in the printing and packaging industries.
20. Flow Sensor or Float Sensor
Flow sensor measures and detects virtually any process fluid. This detected data will be provided
to the controller system.
It is used in industrial areas, power generating instruments, power plants, etc.
In this tutorial, I have covered 20 different types of sensors with their uses. Every sensor has its
own features and functionalities. They can be used for a specific purpose.
For the handheld or wireless-based electrical and electronics project, various types of sensors are
used.
Also, sensors are used in PLC projects, robotics systems, Arduino circuit boards, raspberry, IoT,
etc. have completed maste