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Shock and vibration resistance. Versatile connections. They can connect two or three wires with an AC, AC/DC, or DC power supply and up to four-wire DC connections. Wide operating temperature range. They operate between 20 to +70 C, 10 percent. Very fast response, particularly in the DC models. These sensors can detect presence, send a signal, and reset in 50 s (2000 times per second) in DC models. Inductive proximity sensors are generally limited by their sensing distances and the material they sense. The effective range is limited to about 25 mm for most models and can be extended to only about 100 mm with the large models.
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Limit switches are mechanical position-sensing devices that offer simplicity, robustness, and repeatability to processes. Mechanical limit switches are the oldest and simplest of all presence- or positionsensing devices: contact is made and a switch is engaged. This simplicity contributes generally to the cost advantage of limit switches. Yet, they can provide the control capabilities and versatility demanded in today s error-free manufacturing environment. The key to their versatility is the various forms they can take in the switch, actuating head, and lever operator. Two-step dual-pole limit switches can detect and count two products of different sizes and can provide direct power control to segregate or process the items differently. The lever operator will rotate 10 to activate one set of contacts and 20 to activate another set. Because of the high amperage they can handle, limit switches can control up to ten contacts from the movement of a single lever. They are easy to maintain because the operator can hear the operation of the switch and can align it easily to fit the application. They are also robust. Limit switches are capable of handling an inrush current ten times that of their steady state current rating. They have rugged enclosures and also prewiring that uses suitable strain-relief bushings to enable the limit switch to retain cables with 500 to 600 pounds of force on them. Limit switches can also handle direct mediumpower switching for varying power factors and inrush stresses. For example, they can control a multihorsepower motor without any interposing starter, relay, or contactor. Reliability is another benefit. Published claims for repeat accuracy for standard limit switches vary from within 0.03 mm to within 0.001 mm over the temperature range of 4 to +200 F. Limit switches dissipate energy spikes and rarely break down under normal mode surges.
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They will not be affected by electromagnetic interference (EMI), and there are no premature responses in the face of EMI. However, because they are mechanical devices, limit switches face physical limitations that can shorten their service life even though they are capable of several million operations. Also, heavy sludge, chips, or coolant can interfere with their operation.
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In selecting a position sensor, several key factors should be considered: Cost. Both initial purchase price and life-cycle cost must be considered. Sensing distance. Photoelectric sensors are often the best selection when sensing distances are longer than 25 mm. Photoelectric sensors can have sensing ranges as long as 300,000 mm for outdoor or extremely dirty applications, down to 25 mm for extremely small parts or for ignoring background. Inductive proximity sensors and limit switches, on the other hand, have short sensing distances. The inductive proximity sensors are limited by the distance of the electromagnetic field less than 25 mm for most models and limit switches can sense only as far as the lever operator reaches. Type of material. Inductive proximity sensors can sense only ferrous and nonferrous materials, whereas photoelectric and limit switches can detect the presence of any solid material. Photoelectric sensors, however, may require a polarizer if the target s surface is shiny. Speed. Electronic devices using DC power are the fastest as fast as 2000 cycles per second for inductive proximity models. The fastest-acting limit switches can sense and reset in 4 ms or about 300 times per second. Environment. Proximity sensors can best handle dirty, gritty environments, but they can be fooled by metal chips and other metallic debris. Photoelectric sensors will also be fooled or left inoperable if they are fogged or blinded by debris. Types of voltages, connections, and requirements of the device s housing. All three types can accommodate varying requirements, but the proper selection must be made in light of the power supplies, wiring schemes, and environments. Third-party certification. Underwriters Laboratories (UL), National Electrical Manufacturers Association (NEMA), International Electrotechnical Commission (IEC), Factory Mutual, Canadian Standards Association (CSA), and other organizations impose requirements for safety, often based on
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