Inductive Eddy Current Proximity Sensor

EDDY-CURRENT SENSORS
Eddy-current sensor measures distance between the sensor head and an

electrically conducting surface.
 The sensor operation is based on eddy currents that are induced at the
conducting surface as magnetic flux lines from the sensor intersect with the
surface of the conducting material.
 The magnetic flux lines are generated by the active coil in the sensor, which is
driven at a very high frequency (1MHz).
 The magnitude of the eddy current produced at the surface of the conducting
material is a function of the distance between the active coil and the surface.
 The eddy current increase as the distance decreases.
IILUSTRATIONS
Working Principle
 Inductive proximity sensors are designed to operate by generating an electromagnetic

field and detecting the eddy current losses generated when ferrous and nonferrous metal
target objects enter the field.
 The sensor consists of a coil on a ferrite core, an oscillator, a trigger‐signal level
detector and an output circuit.
 As a metal object advances into the field, eddy currents are induced in the target. The
result is a loss of energy and a smaller amplitude of oscillation.
 The detector circuit then recognizes a specific change in amplitude and generates a
signal which will turn the solid‐state output “ON" or “OFF."
Circuit Diagram
 Changes in the eddy currents are sensed with an impedance bridge. Two coils in the
sensor are used for two arms of the bridge.
 The other two arms are housed in the associated electronic package. The first coil in
the sensor (active coil), which changes inductance with target movement, is wired
into the active arm of the bridge.
 The second coil is wired into the opposing arm of the same bridge, where it serves
as a compensating coil to balance and cancel the effects of temperature change.
 The output from the impedance bridge is demodulated and becomes the analog
signal, which is linearly proportional to distance between the sensor and the target.
 The sensitivity of the sensor is dependent on the target material, with higher
sensitivity associated with higher conductivity materials. The output for a
number of materials is a function of specific resistivity.
 For aluminum targets, the sensitivity is typically 100 mV/mil (4 V/mm).
Thus, it is apparent that eddy-current sensors are high-output devices if the
specimen material is non-magnetic. The sensitivity decreases significantly
if the specimen material is magnetic.
 For non-conducting, poorly conducting, or magnetic materials, it is possible to
bond a thin film of aluminum foil to the surface of the target at the location of
the sensor to improve the sensitivity
 Since the penetration of the eddy currents into the material is minimal, the
thickness of the foil can be as little as 0.7 mil (ordinary household aluminum
foil).
 The effect of temperature on the output of the eddy-current sensor is small. The
sensing head with dual coils is temperature compensated.
 A small error can be produced by temperature changes in the target material,

since the resistivity of the target material is a function of temperature.
 For instance, if the temperature of an aluminum target is increased by 500ºF, its

resistivity increases from 0.03 to 0.06 µΩm. It is evident that the bridge output
is reduced by about 2 eddy-current sensor is 0.004 percent per ºF.
 The range of the sensor is controlled by the diameters of the coils, with the
larger sensors exhibiting the larger ranges. The range-to-diameter ratio is usually
about 0.25.
 Linearity is typically better than ±0.5 percent and resolution is better than 0.05
percent of full scale.
 The frequency response is typically 20 KHz, although small-diameter coils can

be used to increase this response to 50 KHz.
 The fact that eddy-current sensors do not require contact for measuring
displacement is quite important. As a result of this feature, they are often used in
transducer systems for automatic control of dimensions in fabrication processes.
 They are also applied extensively to determine thickness of organic coatings that
are non-conducting.
Eddy-Current Sensor Advantages
 Tolerance of dirty environments
 Not sensitive to material in the gap between the probe and target
 Less expensive and much smaller than laser interferometers
 Less expensive than capacitive sensors
Eddy-Current Sensor Disadvantages
 Extremely high resolution

 Large gap between sensor and target is required (optical and laser are better)
Applications For Eddy-Current Sensors
 Eddy-Current sensors are useful in any application requiring the measurement
or monitoring of the position of a conductive target, especially in a dirty
environment.
 Eddy-Current sensors are basically position measuring devices. Their outputs
always indicate the size of the gap between the sensor's probe and the target.
When the probe is stationary, any changes in the output are directly interpreted
as changes in position of the target.
 Automation requiring precise location
 Machine tool monitoring
 Final assembly of precision equipment such as disk drives
 Precision stage positioning
 Drive shaft monitoring
 Vibration measurements

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EDDY-CURRENT SENSORS

Eddy-current sensor measures distance between the sensor head and an

 Inductive proximity sensors are designed to operate by generating an electromagnetic

 A small error can be produced by temperature changes in the target material,

 For instance, if the temperature of an aluminum target is increased by 500ºF, its

 The frequency response is typically 20 KHz, although small-diameter coils can

Eddy-Current Sensor Disadvantages

 Extremely high resolution

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