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2014/10/23

3 Common Applications for Discrete Output Inductive

Proximity Sensors
BY JACK MOERMOND 2 COMMENTS

Written by: Jeff Himes

Discrete (off/on) output inductive proximity sensors are used in a multitude of markets and industries. The
number of inductive sensors sold each year is in the millions. With that many pieces being sold each year,
one has to ask how are all of these sensors being used? Their uses break down into 3 common
applications.
The 3 most common applications for discrete inductive proximity sensors are:
1.) Machine position verification
2.) Part position verification
3.) Part feature verification
The most common application is machine position verification. In this type of application, the proximity
sensor is used to detect the position of a part on the machine or equipment itself.
In many cases, a cylinder or servo motor is used to move the machine component, and the proximity
sensor is used to verify the component moved to the correct location. If the movement is not verified by
the sensor, typically a fault would be generated. In this first photo an inductive sensor is being used to
detect the leftmost travel limit of a print head. There is a rightmost travel limit sensor as well. The sensors
are on adjustable mounts to allow for various print station widths. These sensors confirm the print head
has travelled the correct distance in both directions to provide accurate printing.

Position verification of a print head

Another common inductive sensor application is part position verification. In this application the sensor
is used to verify that a manually loaded or automatically loaded part is in the correct position prior to the
next operation.
Manual load stations are very common for weld cell environments. Typically multiple metal parts will be
manually loaded into a weld cell where inductive proximity sensors verify the part placement. Once the
part positions have been verified, a robot welder will weld the parts together. This next photo shows
a block style inductive sensor that is used for part placement verification in a weld cell. The tapered pin in
front of the sensor is used to help guide the manually loaded part to its correct location. The sensor is
then used to provide a true confirmation of the parts location prior to the weld operation.

Part position verification in a weld cell

A 3rd common inductive application is one of part feature verification. In this function the proximity sensor
is used to verify a unique part feature to ensure that a critical operation has occurred on the part. In some
cases this may be the confirmation of a welded on nut or stud, a bend angle, the attachment of a certain
part or the fact that a hole has been punched. Remember even though an inductive sensor is typically
used to detect the presence of a metal object it can also be used to detect the absence of a metal object
as well. This photo was taken in a part verification station where multiple part features are verified on the

final assembly. In this application the sensor is being used to verify the punch-out of a hole. If the hole is
not punched the sensor will trigger indicating that metal is present where it shouldnot be.

Part feature verification in final test fixture

Dont let the quantity of inductive sensors used on a machine or piece of automated equipment be
intimidating. In general they will all be used for one of the 3 applications shown above. Once you know to
look for these types of functions you can easier understand the sensor placement and the operation of the
machine or equipment.