How can you troubleshoot common automation sensor issues?

We need to check cable routing of sensor wires should have proper bend,no twist,away from power cable, should not have joined Sensors issue are tobe cross check with mechanical movement, mostly people adjust sensor position but it need to rectify why the position changes, secondly for reed switch need to cross check with piston magnetic ring

First, figure out if the problem is with a part or how things are running. If it's the process causing trouble, check if the machine stops in the middle or messes up at the end. If it stops, connect to the PLC online to see where it gets stuck and if it's waiting for a signal. Keep an eye on the input/output using the PLC's indicators. Finally, fix any issues with the sensor, transducer, coil, or relay connections.

Frist step define the issue, do you trust the data? what is it not doing, what is it doing. Is the issue intermitment or constance fault. Checking basic like connectors and wires is a must before going down deep rabbet holes.

A common issue, especially in new installations is a sensor cable (low voltage) being run in parallel with high voltage cables. The current through high voltage cables induces a slight magnetic field that will introduce noise in the sensor cable.

In my experience start with the furthest point which would be the sensor. 1. Clean the area and the sensor. 2. Check that the sensor is correctly aligned to make the positioning flag. (Yes/No) 3. With a proximity sensor inspect the face of the sensor for damage. (Yes/No) 4. Bring an Allan key close to the face of the sensor to see if it activates where an indicator light would illuminate. (Yes/No) 5. Inspect the wiring back to the IO unit for damage. (Yes/No) 6. Check if the wiring into the IO unit is correct and conducting the signal. (Yes/No) 7. Check that the output signal reaches the Input socket on PLC. (Yes/No) Break the problem up into smaller sections to isolate and repair.

Yes. To finding the type and get to know the cause can solve the issue permanent. This is valid input. In automobile electrical and sensor issue. It's not like only replacing and isolating the part can solve the problem. Need to know the root cause and look for the permant and long lost solution can build your confident from customer towards your knowledge and work

To troubleshoot common automation sensor issues, follow these steps: 1. Check the sensor's power supply and wiring connections. 2. Verify proper sensor alignment and positioning. 3. Clean or replace dirty or damaged sensors. 4. Adjust sensor settings or sensitivity. 5. Check for interference from other devices or environmental factors. 6. Test the sensor with a known good input or simulated signal. 7. Consult the manual or manufacturer support. Remember to follow safety guidelines when working with automation equipment.

Check the sensor wiring and connections for any loose, broken, or shorted wires by using a multimeter or an oscilloscope to measure the voltage, current, and resistance of the sensor circuit.Clean or replace the sensor.

Once you are able to identify the current state of the sensor, and understand how it is interacting with the rest of the system, then you can start to identify the desired state of the system. This allows you to map out how the sensor needs to properly function to achieve this desired state.

Something to always remember is to test the mechanical movement after a repair. There is nothing worse than spending hours on a repair to have it destroyed by a misaligned part or flag. If possible, conduct testing in "Crawl" mode to prevent damage.

Once you have the current, and desired state of the sensor understood, it provides constraints to work within. This allows for faster troubleshooting. It will point out the variable that would otherwise be easily missed. You then can test the sensor, to determine why its not functioning correctly, and make necessary changes to achieve that previously mentioned "desired state."

3. If sensor output LED does not change state when presented with the proper test material within its sensing range, check for proper voltage at the sensor itself. 4. If sensor is getting the proper voltage at the actual sensor and its output LED does not change state, perform steps 2. A) & B). A) If sensor is not passing voltage through its internal switch, check sensor settings, if applicable. B) If sensor settings are correct and no output voltage is present on the output/load wire of the sensor or PLC input, replace the sensor.

When technician has identified the issue. The sensor individual integrity shall be verified by testing on the test bench. All the recommendations of the OEM shall be followed and also FMEA shall be executed to do the RCA for the identified failure.

Test the sensor manually by placing part infront of sensor and check. 1. Input signal coming or not( indicator light glowing or not). 2. Using multimeter check whether voltage is coming or not. 3. Adjust amplifier values If not rdplace a sensor with new one.

Depending on type of issue, we can repair or replace, If it is physical damage/malfunctioning, It is better to replace sensor with new one. If it is wire damage/mounting/settings issue we can repair it.

Replacing a component would result in a new sensor that would have a longer service life with proper setup. In FMCG, time is money. The client will rely on your judgement as you are familiar with machines. I would do everything in my power to save a component. But at the same time, I would always encourage a component to be replaced in order to have peace of mind for the future.

Identify the sensor with problem and replace it. Of course it will be needed to find the root case of overall problem. Analyse 4M.

Proper documentation of troubleshooting, as well as root cause analysis is extremely important. You can determine the frequency of the issue, document the process, create training material, plan for improvements, all very easily with the information you have gathered. Then even quantify results!

From my experience, it depends a lot on the case, but for some cases it might be cheaper to directly replace the sensor in the first place. For example, cheap sensor that are quick and easy to replace, the replacement can be done almost immediately, in those cases the down time + repair time might be higher than the cost of debugging the sensor itself.

Once the repair is finished, fill out a job card listing all the steps you took and the parts you used. This way, everyone will have the information they need about your repair. Make sure you have the original markers, such as the sensor number or the drawing placement, after you’ve worked in the sensor’s area. If you’ve made any adjustments, let the next technician know by giving them the adjustments. It’s always better to have more information. If you have made any changes to the electrical drawing, make sure to include the changes on the right page.

I think it is important to ensure that reliability studies are done on the chosen sensors by the suppliers. And the same needs to be audited as a measure for prevention. We can also use Failure mode analysis and AI/ML to forecast failure time data, potential causes and similar statistics of the sensors which will help as well.

Firstly, you need to understand sensor`s function, type and make. then you can replace it with the OEM. After completing your work, you record everything you have done on a job card and 5 why documentation.

Process and masters hygiene becomes paramount while working with any sort of digital systems; hence the heightened need for adherence to SOPs for predictive and preventive maintenance. Documentation of any form of updates or changes with respect to the ongoing process is also essential to ensure a clean handover process especially while updating the system.

Perform a root cause analysis and correct the issue to prevent reoccurrence. Document your change in your company’s maintenance system.

Few Things we can consider while resolving a sensor problem are as follows - 1) Use Elimination technique to pin point the failure if direct failed element is now known. Like Rule out each element one by one by confirming its healthiness. 2) Check for Root cause by why-why analysis. So that we will be able to avoid reoccurrence of the problem. Cause can be anything like - Failure of sensor, Loose fitting, Wrong supply, Broken Cables, Interference with other part causing wrong signal to generate, Wrong selection etc 3) Carry out the repair/replacement. 4) Check the other stations where similar configuration is there to avoid its failure in near future and do the needful. 5) Record the work history for future use.

Bring along someone who has not become proficient in this task. Spread the knowledge. Empower your peers, and teach what you know. This will only solidify your troubleshooting skills, communication skills, help build a granular understanding of the systems you work with, and improve the effectiveness of your entire team. Do good work!

There is a need to understand the nature of the process. Sensors go awry for many reasons not related to the sensor itself. False signals from reflections, positional issues from collisions, vibration,etc;, can cause issues. Changes to materials and equipment, changes in line of sight can impact sensor feedback and of course environmental issues like, humidity/steam, dirty processes, poor cleaning regimes and of course cleaning processes themselves.

Verify sensor connections and power supply to ensure proper electrical connections. Calibrate or replace sensors if readings are inconsistent, ensuring accurate and reliable automation in manufacturing processes.

Mit Kollegen sprechen die Schon l?nger im Betrieb sind in der jeweiligen Abteilung um eventuell aus deren erfahrungsschatz zulernen und den Maschinen Charakter kennen zulernen