Leelavati Automation Pvt ...

Beam Sensors are optical sensors widely used in industrial automation for detecting objects, presence, or motion by sensing interruptions or reflections of a light beam. They play a crucial role in safety, positioning, counting, and object detection across various manufacturing and processing industries.

Beam sensors function by emitting a focused light beamtypically infrared or visible red lightfrom an emitter toward a receiver or reflector. Detection occurs when this beam is either interrupted or reflected by an object, triggering a response from the sensor.

There are three main types:

• Through-beam (Opposed) Sensors: The emitter and receiver are separate units facing each other. When an object interrupts the beam, the receiver signal is blocked, indicating presence.

• Retro-reflective Sensors: The emitter and receiver are housed together; a reflector is positioned opposite. The beam is sent to the reflector and back. An object blocking the beam path causes detection.

• Diffuse Reflective Sensors: The emitter and receiver are in the same housing, and the sensor detects light reflected directly from the objects surface. Detection depends on the object's reflectivity.

• Emitter: Usually an LED or laser diode producing the light beam.

• Receiver: Photodiode or phototransistor that detects the light beam.

• Signal Processor: Converts received light signals into digital or analog outputs.

• Housing: Durable and often rated IP65 or higher for dust and water resistance.

• Mounting Hardware: Brackets or clamps for precise alignment and installation.

• Non-contact Detection: Prevents mechanical wear and damage to objects.

• High Speed Response: Suitable for fast-moving production lines.

• Long Sensing Range: Through-beam types can detect objects up to several meters or even tens of meters.

• Versatility: Suitable for detecting a wide range of materials and colors.

• Easy Installation and Alignment: Flexible mounting options and adjustable sensitivity.

• Reliability: Resistant to dust, moisture, and vibration in industrial environments.

1. Object Detection and Counting:
   Detect presence, passage, or absence of products on conveyor belts.

2. Safety Systems:
   Integrated into light curtains or perimeter guarding to stop machinery when a beam is broken.

3. Positioning and Sorting:
   Assist robotic arms and automated systems in locating and handling items.

4. Packaging and Labeling:
   Ensure packages are correctly positioned and labels are present.

5. Level Detection:
   Detect material or product levels in hoppers or containers.

• Ensure proper alignment between emitter and receiver for through-beam or reflector for retro-reflective sensors.

• Use mounting brackets to maintain stable positioning, especially in vibrating environments.

• Adjust sensitivity to accommodate varying target sizes, colors, and surface finishes.

• Protect sensor lenses from dust and damage by using appropriate covers or cleaning regularly.

• Avoid ambient light interference by positioning sensors away from direct sunlight or bright artificial lights.

In an automated bottling plant, beam sensors detect bottles passing on the conveyor. When a bottle breaks the beam between emitter and receiver, the sensor signals the filling machine to dispense liquid. This ensures precise filling and reduces waste.

Beam sensors provide reliable, precise, and non-contact detection essential for modern industrial automation. Their adaptability to various environments and materials, combined with fast response and long detection ranges, makes them indispensable for enhancing productivity, safety, and quality control.

We are deal in all types of Panel Builder system that are available at market leading prices. Panel Builder System refers to a complete framework, toolset, and infrastructure for designing, assembling, wiring, and testing electrical control panels or distribution boards. Panel builders serve industries like manufacturing, HVAC, process plants, energy systems, and commercial infrastructure by integrating electrical and automation hardware into safe, standardized enclosures. ower Control Center (PCC)Main distribution for high-current load centers

Motor Control Center (MCC)Controls and protects multiple motors

Automation PanelsHouses PLCs, HMIs, I/O modules for industrial automation

APFC PanelsAutomatic Power Factor Correction using capacitor banks

Lighting Distribution PanelsBreaker-fed lighting circuits

VFD / Soft Starter PanelsSpeed control of motors using drives

Synchronizing PanelsUsed with generators for load sharing

Bus Duct PanelsHigh-current, modular distribution via busbar systems Protection DevicesMCB, MCCB, ELCB, fuses

Control DevicesContactors, overload relays, timers

Automation DevicesPLC, HMI, relays, analog/digital I/O modules

SwitchgearIsolators, ACBs, SF6 breakers

Measurement DevicesEnergy meters, ammeters, voltmeters, CT/PTs

Wiring AccessoriesTerminal blocks, ferrules, cable ducts

Cooling AccessoriesPanel fans, thermostats, ventilation louvers

EnclosuresMild steel (MS), stainless steel, polycarbonate

LabelingDIN rail markers, panel front name plates

leelavati automation 

 Panel Building Workflow

Design & Planning:

Circuit layout using EPLAN, AutoCAD, or ECAD

SLD (Single Line Diagram) & wiring diagrams

Bill of Materials (BOM) and component layout

Fabrication & Assembly:

Enclosure preparation (cutouts, powder coating, earthing)

DIN rail and cable duct mounting

Component placement and fastening

leelavati automation 

Wiring:

Control and power wiring as per schematic

Ferrule numbering, wire color coding, cable termination

Testing & Quality Check:

Continuity, insulation resistance, and functional testing

Load simulation and I/O test for automation panels

Documentation:

As-built drawings, manuals, and compliance reports

Certificates of conformity (COC), FAT (Factory Acceptance Test)

 Industrial Applications

Manufacturing units – motor control, process automation

Infrastructure – lighting and energy management

leelavati automation 

Renewable energy – solar inverter panels, battery management

Utilities – water treatment, power distribution

Oil & Gas / Pharma – hazardous area certified panels (ATEX/IP65) IEC 61439Low-voltage switchgear and controlgear assemblies

IEC 60204-1Electrical safety for machinery control panels

IS 8623Indian standard for switchgear panels

NFPA 79 / UL 508ANorth American panel design & safety standards

IP Rating (IP54–IP65)Dust/water ingress protection levels Simple MCC Panel (3–4 motors)15–30 HP motors 

PLC-Based Automation Panel16–64 I/Os + HMI 

PCC Panel (400–800A)Main incoming, ACBs 

VFD Starter Panel (30–90 kW)Drive + protection 

Solar ACDB/DCDB5–100 kW plants  enclosure type, IP rating, and automation level. Standardized Panel Builder System

Faster production with modular DIN-rail and standard layouts

Improved safety through tested interlocks and protections

Customizable to meet plant-specific requirements

Reduced wiring errors via clear documentation and standard color codes

Easy maintenance with labeled components and fault indicators

Smart-ready (IoT/IIoT panels with Ethernet, Modbus, cloud connectivity)  digital design  software integration SCADA/PLC Panel Builder Configuration

leelavati automation 

We provide you to its world of wireless home security Wireless security systems combine convenience with robust monitoring and control, making them ideal for both new installations and upgrades. Their flexibility, scalability, and integration with modern IoT platforms offer a future-proof approach to safety and security.

leelavati automation 

Wireless Security Systems use wireless communication technologies (Wi-Fi, Zigbee, LoRa, Bluetooth, cellular) to connect security devices such as sensors, cameras, alarms, and control panels without the need for physical wiring. These systems offer flexible installation, scalability, and remote monitoring capabilities. Wireless Security Systems

Wireless Sensors: Motion detectors, door/window contacts, glass break sensors, smoke detectors

Cameras: IP cameras with Wi-Fi or cellular connectivity, supporting HD video and night vision

leelavati automation 

Control Panel/Hub: Central unit managing devices, often with mobile app integration

Alarms & Sirens: Audible/visual alerts triggered wirelessly

Communication Modules: Wi-Fi, Zigbee, Z-Wave, LoRa, GSM/LTE for remote alerts and control

Mobile App/Web Portal: Real-time monitoring, notifications, and system control from anywhere Factory perimeter and zone intrusion detection

Remote site monitoring where wiring is impractical

Warehouse asset protection with motion and vibration sensors

Office security with multi-zone sensors and CCTV

Access control combined with wireless badge readers and alarmsEasy and fast installation without costly wiring

Scalable and flexible — add/remove devices as needed

Remote monitoring and control via smartphones or PCs

Lower maintenance with battery-powered sensors and low-power protocols

Integration with smart home/IoT systems for automation

leelavati automation 

Cost-effective for retrofit projects i-FiHigh bandwidth, easy setupVideo streaming, smart home

ZigbeeLow power, mesh networkSensors, alarms, home automation

Z-WaveSecure mesh, interoperabilityHome security systems

LoRaWANLong range, low powerLarge industrial or campus sites

CellularWide area, reliable remote accessRemote site security

BluetoothShort-range, device pairingPersonal security devices

asic wireless door/window sensor 

Wireless motion detector 

Wi-Fi IP security camera 

Wireless siren/alarm 

Full wireless security kit (multi-sensor + hub + app)  Security & Reliability Considerations

Encryption protocols (AES 128/256) to prevent hacking

Battery life monitoring for sensors to avoid downtime

Signal interference mitigation using mesh or multi-band systems

Tamper detection on devices and communication channels

Redundancy options like cellular backup for internet outages

leelavati automation 

Signal towers are critical tools in modern industrial automation, delivering clear, real-time status indicators that enhance safety, efficiency, and communication. Their modular design, integration capabilities, and robust construction make them adaptable to nearly any industrial environment, ensuring that operators and maintenance teams stay informed and responsive to production needs. eg .  When choosing signal towers, consider:

• Number of Light Stages: Depending on the complexity of status signals.

• Color Requirements: Match industry standards and specific process needs.

• Sound Level: Ensure audible alerts are effective without causing noise pollution.

• Environmental Rating: IP protection for dust, water, and chemical resistance.

• Power Supply: Voltage compatibility (12V, 24V, 110V, 230V).

• Communication Features: Basic on/off or smart connectivity for advanced monitoring.

In a car assembly plant, signal towers are mounted on each robotic welding cell. When the cell operates normally, a green light is steady on. If a robot requires maintenance soon, the yellow light flashes. When a fault or emergency stop occurs, the red light flashes and an audible alarm sounds, alerting the floor supervisor immediately. This system minimizes downtime and ensures safety without manual checks.

Material Level Capacitance Change Sensor Signal PLC/DCS Input Control Logic Actuator Commands Process ControlA Capacitance Level Sensor measures material levels in tanks by detecting changes in capacitance between a probe and tank wall. It sends signals to a PLC/DCS, enabling automated control of pumps and valves to maintain safe levels. This ensures accurate, real-time monitoring, improves safety, reduces manual checks, and integrates smoothly into industrial automation systems.

• Accurate and reliable level measurement

• Reduced manual intervention

• Improved safety and process efficiency

• Integration with wider plant automation and SCADA systemsIn a chemical processing plant, a capacitance level sensor monitors the level of a corrosive liquid inside a storage tank. The sensor sends a 4-20 mA signal to the PLC, which controls the pump filling the tank.

  • When the level reaches a high threshold, the PLC stops the pump to avoid overflow.

  • If the level drops below a low threshold, the PLC starts the pump to refill.

  • Operators monitor the level data on the plants HMI screen and receive alarms in case of sensor faults or abnormal levels.

  • High Accuracy and Reliability: Suitable for a wide range of materials and environmental conditions.

  • Non-moving Parts: Low maintenance and longer lifespan.

  • Versatile Application: Works for liquids, powders, and solids, including corrosive or sticky materials.

  • Fast Response: Immediate feedback for real-time process adjustments.

  • Improved Safety: Automatic control prevents overflows or dry running, protecting equipment and personnel.

  • Easy Integration: Compatible with modern industrial control systems and communication protocols.

programmable timers, digital timer controller, sequence timer, preset timer, multifunction timer, rate indicator, digital count-down timer, programmable delay timer, 12-channel timer, precision timing, industrial automation timer, LO/HO delay, cyclic timer, industrial time switch, PLC interface timer.Microcontroller-based programmable digital timers. Features include HH:MM:SS display, ON/OFF delays, cyclic logic, RS485 Modbus RTU. Supply: 230/110VAC, 24VDC4/8/12-channel sequential timers with power-fail memory, front keypad and remote reset optionsperfect for industrial sequence controlSQT-1022 programmable digital timer (up to 12 channels), LCD display, flush mounting, delay on/off, countdown, 220240V, 6month warrantyCE-certified compact timers for automation, UV, conveyors, HVAC, water treatment, packaging, and food industries Time Range: Ensure minimum resolution and maximum range match the process. Functionality: Choose ON/OFF delay, on-off/ cyclic, sequential, or one-shot functions per need +++. Channel Count: Multi-channel units for complex operations; single-channel for simpler tasks. Output Load: Check relay/R, time specifications like 230VAC/5A. Enclosure Rating: IP65 or higher for wet/industrial environments. Power & Comms: Choose standard supply voltage; optional Modbus or remote programmability for automation systems Memory Protection: Non-volatile memory or power-fail retention ensures program integrity . Certifications: Look for CE, ISO, agency approvals for industrial compliance. Manufacturing/Assembly: Control sequence timing, cycle operations, and equipment interlocks. Packaging & Conveyors: Trigger actuators, count items, and regulate dwell times. HVAC & Lighting Control: Automate schedules in buildings, save energy. Water & Waste Treatment: Timed dosing, backwash cycles, pump control. Food Processing & Baking: Manage cook/dry/batch durations precisely . Engineered Applications: Provide delay and repetition for bag filters, dust collectors, presses, lubrication systemsleelavati automation Preset Counters & Totalizers: Count pulses/sensor inputs to trigger outputs at preset values. Ideal for batching, drilling, or positioning applications Rate Indicators & Controllers: Measure process rates (e.g., RPM, feet-per-minute) and activate alarms or outputs at predefined thresholds Preset (Delay) Timers: Execute ON/OFF-delay, interval timing, leelavati automation or cycle sequences based on external triggers. Applicable to machine cycles, event timing, and process regulation Multifunction Sequence Controllers: Combine counting, timing, and sequencing across multiple channelssupports sequential operations with flexible logic and memory backup . Analog/Solid-State Timers & Cam Timers:leelavati automation Economical analog units with synchronous motors; cam timers for mechanical sequence control in repetitive processes leelavati automation programmable timers are precision electronic devices engineered for time-based control and automation in industrial and commercial applications. They provide accurate scheduling, counting, and sequence control to enhance operational efficiency. Key Features & Benefits High Precision & Accuracy: Modern digital timers offer resolutions of 0.019999hours and precision from 0.055seconds, facilitated by quartz/crystal timing circuits with minimal drift leelavati automation Customizable Time Functions: Users can program ON-delay, OFF-delay, cyclic, one-shot, sequential & combination mode profiles. Multi-channel models (4, 8, 12 channels) support advanced sequencing User-Friendly Interface: LED or LCD displaysleelavati automation enable easy setup and real-time monitoring of countdowns/up, setpoints, and program modes Robust & Industrial Grade: Built for harsh environmentsIP20IP65 rated; tolerant to dust, vibration, and E

High-performance servo drive supporting EtherCAT, Mechatrolink II; designed for precise motion control in CNC machines, robots, packaging lines . Applications: CNC milling, robotic arms, pick-and-place systems, precision motion Powerful 5kW servo drive with EtherCAT connectivity; rugged, industrial-grade . Applications: Heavy-duty automation: injection molding machines, large conveying systems. leelavati automation Description: Compact 400W EtherCAT drive in G5 family, ideal for light automation. Applications: Small machines, lab automation, packaging robots Description: Simplified servo solution with embedded safety functions (Safe Torque Off, SIL2/PLd); excellent loop control . Applications: General-purpose motion control; educational setups Application: Paired with 1S drives for precise positioning in OEM machines or compact automation cells Black 1S AC Servo Motor 400W

Factory Automation / Robot Controllers Premier CNC motion, robot PLC controls (R-30iB Plus).

CNC machining leelavati automation centers, industrial robotics, automated assembly Custom quotes; typical robot controller + arm systems Explosion-safe sensors, encoders, RFIDused for hazard environments Oil & gas, chemical plants, leelavati automation automated doors, process instrumentation. level sensors explosion-rated units Includes DCS nodes, pressure/flow transmitters, SCADA I/O Refineries, petrochem, power plants with leelavati automation tight process control. Pressure transmitters full DCS racks High-end industrial controllers, HMIs, motion modules Machine tool controls, packaging automation, food industry plants. Controller + HMI panels on system Basic servo drives (400W)

Mid-range (1.53kW) EtherCAT drives

Heavy-duty servo drives (5kW)

Industrial-grade servo motors

FANUC robotics & CNC controllers

Process control sensors/instrumentation

DCS/Rack-level control systems Sensor Proximity Sensor Object presence ON/OFF (digital), 24V DC

Temperature Sensor Temperature C or mV (for thermocouple)

Pressure Sensor Pressure bar, psi, or 420mA

Flow Sensor Flow rate L/min or 420mAleelavati automation

Ultrasonic Sensor Distance mm or 010V analog

Photoelectric Sensor Light interruption ON/OFF, or V/mA (analog models)

Load Cell Force mV/V, then converted to kg or N

Encoder Position, speed Pulses per revolution (PPR), rpm

RTD (Pt100, Pt1000) C, F, (Ohms) Precision temperature in machines

Thermocouple (J/K/T) C, F, mV (millivolts) Furnaces, industrial ovens

Thermistor C, HVAC systems, lab equipment

RTD (Resistance Temperature Detector) -200C to +600C 0.1C to 0.5C Medium Analog (Ohms), 420mA High

Thermocouple (e.g. Type K, J, T, E) -200C to +1800C 0.5% of reading Fast mV, 420mA Very High

Thermistors -100C to +300C 0.1C Fast Resistance Moderate

Infrared (Non-contact) -50C to +3000C 1C or 1% Very Fast Digital/Analog High

Semiconductor Sensors (IC based) -55C to +150C 0.5C Medium Digital (I2C/SPI) Low temperature sensors are devices designed to measure temperature in harsh or controlled industrial environments. They convert temperature into an electrical signal for monitoring or control purposes. These sensors are critical in maintaining safe and optimal operational conditions in manufacturing, processing, and power generation industries.

Manufacturing & Process Control

Monitoring temperatures in ovens, furnaces, and kilns.

Controlling plastic extrusion, molding, and metal heat treatment. Measuring temperature in pipelines, storage tanks, and refineries. Used in explosion-proof and high-pressure zones. Power Plants Steam and boiler temperature monitoring. Generator and turbine heat management. Chemical & Pharmaceutical

Reactor vessel temperature.

leelavati automation

Cold chain and batch processing validation. HVAC & Building Automation

Room temperature sensing.

Chiller and heat exchanger efficiency control.Automotive and Aerospace

Engine temperature monitoring.

leelavati automation

Exhaust and air intake systems. Food & Beverage

Cooking and pasteurization control.

Cold storage and transport validation.ccuracy requirements

Response time needed

Environmental conditions (dust, moisture, chemicals)

Range of temperature

Output compatibility with PLCs, SCADA

leelavati automation

• Accuracy and certification (e.g., ISO, ATEX)

• Probe length and material (SS316, Inconel, etc.)

• Ingress protection (IP ratings), explosion-proof casing

• Signal conditioning (420mA, Modbus, etc.)

• Application-specific builds (e.g., autoclaves, corrosive environments)

Pressure and vacuum sensors measure the force exerted by gases or liquids. While pressure sensors measure the positive force (above atmospheric pressure), vacuum sensors measure pressure below atmospheric levels (i.e., vacuum conditions). These sensors convert physical pressure into electrical signals for monitoring and control.

leelavati automation

Gauge Pressure Sensor 0 to 10 bar / 01000 psi 0.25% to 1.0% FS 420 mA, 010 V, IC

Level Sensors measure the height or amount of liquid, powder, or bulk solids inside tanks or silos. Flow Sensors measure the rate and volume of liquids or gases moving through a pipe or duct. process control, automation, water treatment, pharma, and manufacturing. Float Level Switch Liquids Point (High/Low) Up to 10m ON/OFF, Relay 1% leelavati automation Ultrasonic Level Liquids/Solids Continuous (Non-contact) 0.2m10m+ 420 mA, RS485 0.25% Capacitive Level Liquids/Granular solids Point/Continuous Up to 5m Digital, Analog 12% Radar Level Sensor Liquids/Chemicals Continuous (Non-contact) Up to 35m+ 420 mA, HART 0.1% Hydrostatic Liquids (tanks) Continuous Up to 200m 420 mA 0.5% Turbine Flow Meter Clean Liquids Volumetric Flow 0.1 10, 000 L/min Pulse, 420 mA 0.5 1% Electromagnetic Flow Conductive Liquids Volumetric Flow 0.05 20 m/s 420 mA, Modbus 0.2 0.5% Ultrasonic Flow Meter Liquids, Gases Flow Velocity 0.1 30 m/s 420 mA, RS485 1% Vortex Flow Meter Gases, Steam Mass Flow Wide range Pulse, Analog, HART 0.5% Rotameter Low-cost liquids/gases Visual Flow Lowmedium flow Mechanical reading 25% Float Level Switch Ultrasonic Level Sensor leelavati automation Radar Level Sensor Electromagnetic Flow Turbine Flow Meter Ultrasonic Flow Meter Vortex Flow Mete Depends on steam/gas calibration Applications Level Sensors Water & wastewater plants Beverage & chemical tanks Silo grain and powder level Oil tanks and storage Flow Sensors Water supply pipelines Cooling systems leelavati automation Chemical dosing systems Steam and compressed air monitoring HVAC flow balancing Float-Based Buoyancy of liquid lifts or lowers a float connected to a switch or magnet. Ultrasonic Emits sound waves; the sensor calculates level by measuring echo return time. Radar (FMCW or Pulse) Uses microwave signals; unaffected by vapors, foam, or temperature. Capacitive Detects change in capacitance caused by liquid/material in contact with the probe. Hydrostatic Measures pressure at tank bottom to calculate height of liquid above. Optical (IR/LED) Detects light reflection through liquid or air interface. L/min (liter/min) Volumetric Flow Cooling, lubrication m/h (cubic meter/hr) Bulk flow Water, gas supply mm / cm Level sensors Tank level monitoring (ultrasonic, radar) % Relative level Chemical mixing tanks lectromagnetic (Magmeter) Faradays law: flow of conductive liquid induces voltage in a magnetic field. leelavati automation Ultrasonic (Transit-Time or Doppler) Measures time delay between upstream and downstream ultrasonic pulses. Turbine Liquid turns a rotor; rotational speed is proportional to flow. Vortex Shedding Measures vortices created downstream of an obstruction (Von Krmn effect). Thermal Mass Measures cooling effect of gas/liquid on a heated element. Positive Displacement Measures actual volume by trapping fluid in compartments and counting revolutions. Medium Type Liquid, solid, gas, slurry, corrosive, food-grade, explosive Measurement Type Point level (ON/OFF) or Continuous Range Tank depth, pipe size, flow speed Environment Temperature, pressure, humidity, dust, vibration Mounting Constraints Top, bottom, side-entry, inline, clamp-on Power Supply & Output 24V DC, 230V AC, 420 mA, Modbus, HART, relay, digital Certifications IP rating, ATEX, FDA, IECEx, CE, SIL Maintenance Non-contact types need less cleaning in dirty or corrosive media Integration in Industrial Systems Automation Platforms Supported: PLC/SCADA Systems: Siemens, Allen Bradley, Schneider DCS (Distributed Control Systems) IoT Cloud Platforms: MQTT, OPC-UA, Azure IoT, AWS IoT Edge Controllers: With RS485, Modbus RTU/TCP, CANbus Common Protocols: Analog: 420 mA, 010 V Digital: Modbus RTU, Modbus TCP, HART, Profibus, IO-Link Wireless: LoRaWAN, NB-IoT, Bluetooth (for portable apps) Water Treatment Tank levels, well monitoring Inlet/outlet flow monitoring Chemical Processing Reactor and mixer levels, toxic liquids

distance, displacement, and position sensors play an indispensable role in ensuring accurate measurements, real-time feedback, and reliable control of mechanical systems. These sensors are crucial in monitoring the movement, location, and physical alignment of components, tools, materials, or surfaces in dynamic environments such as manufacturing plants, assembly lines, robotic arms, CNC machines, and heavy machinery. Industrial distance sensors measure the physical space between the sensor and a target object, while displacement sensors detect changes in position over a small range with high precision. Position sensors, on the other hand, determine either absolute or relative location in linear or rotary motion, enabling feedback control systems to adjust mechanical movement based on real-time data. With advances in electronics and sensing technologies, a variety of sensor types are now available, each suited to specific industrial needs. Inductive sensors, widely used in metal detection applications, operate based on electromagnetic fields and offer reliable proximity detection in short ranges, typically up to 40 mm. Capacitive sensors, capable of detecting non-metallic materials such as liquids, plastics, or powders, are commonly used in process industries to detect the presence or level of materials in containers. Ultrasonic sensors function on the principle of sound wave reflection and are used to measure distances in applications where the target may not be visible or reachable, such as liquid levels in tanks or object detection in packaging lines. For longer ranges and high accuracy, laser distance sensors are used; they employ time-of-flight or triangulation principles to provide real-time measurements in applications ranging from factory automation to precision cutting. Linear Variable Differential Transformers (LVDTs) are electro-mechanical transducers used for accurate displacement measurements in hydraulic and mechanical systems; they offer excellent repeatability and are often found in aerospace, materials testing, and servo valve control. Potentiometric position sensors are among the simplest and most cost-effective linear position sensors, converting mechanical motion into a change in resistance which is then translated into voltage output. Although limited by wear and tear due to physical contact, they remain effective for basic automation needs. In contrast, magnetostrictive sensors are non-contact linear position sensors known for their high resolution and long service life; these are extensively used in hydraulic cylinder position feedback and material handling equipment. Rotary encoders, which measure angular position and speed, are widely used in servo motors, robotics, elevators, and machine tools, offering both incremental and absolute outputs. For long-range or large-stroke applications, draw-wire or string potentiometers provide a cost-effective means to convert mechanical movement into analog or digital signals. These sensors are particularly useful in cranes, telescopic arms, or long linear slides. Depending on the application, sensor outputs can be digital (ON/OFF), analog (010V, 420mA), or digital protocols like RS485, Modbus, CANopen, IO-Link, and even wireless options for smart factories. They are designed to be integrated with PLCs, SCADA systems, or standalone controllers for automation feedback loops. Measurement units typically include millimeters (mm), meters (m), microns (m) for linear measurements, and degrees () for rotary positions, with velocity or acceleration sometimes measured in mm/s or m/s. Sensor selection depends on a range of factors such as sensing range, resolution, accuracy, environmental conditions (e.g., dust, temperature, vibration), installation constraints, and budget. Prices vary greatlyfrom as low as 300 ($4) for basic proximity sensors to over 1, 00, 000 ($1, 200+) for high-end magnetostrictive or laser measurement systems. Application industries include automoti

motion and vibration sensors play a critical role in ensuring the smooth, efficient, and safe operation of machinery and infrastructure. These sensors detect and measure various forms of physical movementranging from subtle vibrations in rotating equipment to full-scale motion detection in robotics, vehicles, or structural elements. By converting mechanical motion into electrical signals, these devices enable predictive maintenance, dynamic monitoring, collision detection, and real-time process control, making them indispensable in industries such as manufacturing, power generation, oil & gas, transportation, mining, and infrastructure health monitoring. Types and Working Principles Industrial motion and vibration sensors come in a variety of forms, each designed for specific measurement functions. The most common types include: Accelerometers (Vibration Sensors) These detect changes in acceleration due to vibration or shock. The most common types are: Piezoelectric Accelerometers, which use crystal elements to generate a charge when vibrated. MEMS (Micro-Electro-Mechanical Systems) Accelerometers, which detect capacitance change caused by motion. Available in single-axis and tri-axis models. Velocity Sensors Measure the rate of movement over time (mm/s), often used in motor diagnostics or bearing analysis. These are electrodynamic or piezo-based devices. Displacement Sensors (Vibration) Measure physical movement amplitude (usually in microns or mils), ideal for slow-speed rotating machinery. Gyroscopes (Angular Motion) Measure angular rate or orientation, used in mobile robotics, drones, and heavy machinery. Proximity & Motion Detectors Often inductive or capacitive sensors used to detect moving objects or limit positions. Seismic Sensors / Structural Vibration Sensors Measure very low-frequency vibrations from ground or building movement for geotechnical or civil engineering use. Inertial Measurement Units (IMUs) Combine accelerometers, gyroscopes, and sometimes magnetometers for full 3D motion tracking. Materials & Build Quality Industrial motion and vibration sensors are engineered with materials suited to harsh environments: Sensor Housing: Stainless steel (SS304/SS316), anodized aluminum, PBT, or reinforced polymers. Sealing: IP65 to IP68 protection against dust, water, and oil. Vibration Isolation: Rugged mounts and epoxy-filled bodies for durability. Hazardous Area Compliance: ATEX, IECEx certified enclosures for explosive zones. Some sensors come with integrated magnets, armored cables, or flameproof enclosures for use in mining or petroleum environments. leelavati automation Output Types Signal Output Typical Use Analog Voltage (010 V) Basic motion detection and automation Analog Current (420 mA) Long cable runs and PLC integration IEPE (Integrated Electronics Piezo-Electric) Standard for vibration sensors in condition monitoring Digital (Pulse / SPI / I2C / RS485) MEMS and multi-axis sensors Wireless (BLE, LoRa, ZigBee) Condition monitoring in remote/rotating systems Some systems offer data logging, frequency analysis (FFT), or Bluetooth-based app monitoring for mobile diagnostics. leelavati automation Applications Industry Use Case Manufacturing Motor health monitoring, machine tool condition, unbalanced shaft detection Power Plants Turbine vibration analysis, generator rotor alignment Cement & Mining Crusher vibration, conveyor belt monitoring Automotive Shock and road-load simulations, crash testing Oil & Gas Pump and pipeline vibration alarms HVAC Fan/motor imbalance, bearing deterioration detection Smart Infrastructure Building sway detection, bridge movement analysis Aerospace Aircraft structure testing, in-flight dynamics Railways Bogie, wheel, and track vibration condition leelavati automation Frequency range (e.g., 0.5 Hz 10 kHz for rotating equipment) Sensitivity (e.g., 100 mV/g or 420 mA for 050 mm/s) Mounting method (magnet, stud

digitally integrated manufacturing environment, industrial electrical sensors serve as essential building blocks for monitoring, control, protection, and automation across electrical systems. These sensors detect and measure critical electrical parameters such as current, voltage, power, energy, resistance, and frequencyenabling industrial plants to ensure electrical safety, reduce energy consumption, prevent equipment failure, and optimize system performance. With the global rise of Industry 4.0, smart energy management, and electrical predictive maintenance, the importance of high-precision and real-time electrical sensing has never been greater. Types & Working Principles Industrial electrical sensors come in a variety of forms, each designed to measure a specific electrical quantity. Common types include: 1. Current Sensors Hall Effect Sensors: Measure AC/DC current using the magnetic field around a conductor. Output can be analog or digital. Rogowski Coils: Flexible coils used for non-intrusive, high-current AC measurementideal for retrofit or portable systems. Current Transformers (CTs): Step down high currents for measurement by meters or protection relays. Shunt Resistors: Measure current by calculating voltage drop across a known resistance (used in DC applications). 2. Voltage Sensors Detect AC or DC voltage levels and convert them into proportional signals for meters or controllers. Types: Resistive divider, capacitive, isolation amplifier-based voltage sensors. 3. Power & Energy Meters Measure real-time power (kW, kVA), energy consumption (kWh), power factor, harmonics, etc. Work based on voltage and current input from CTs and PTs. 4. Phase Sequence & Frequency Sensors Detect phase reversal, phase loss, and frequency deviations in 3-phase systems. Crucial for generator synchronization and motor safety. 5. Insulation & Leakage Sensors Used for monitoring insulation resistance or detecting leakage current to prevent electrical faults and fire risks. Often integrated in BMS (Building Management Systems). 6. Temperature & Thermocouple Isolators Though not electrical parameters directly, these isolate and convert electrical signals from thermocouples or RTDs into standard analog outputs. CurrentAmpereA VoltageVoltV Power (Real / Apparent)Kilowatt / kVAkW / kVA EnergyKilowatt-hourkWh FrequencyHertzHz Power FactorRatioPF ResistanceOhm Materials & Construction Enclosure Material: Industrial sensors are housed in ABS, polycarbonate, aluminum, or flame-retardant plastic for panel-mounting or DIN-rail mounting. Sensor Core: CTs use high-permeability magnetic cores; Hall sensors include semiconductor elements in epoxy-sealed cases. Environmental Protection: Typically IP20 to IP65, depending on whether they are installed in switchboards, outdoor panels, or enclosures. Safety Certifications: Sensors often comply with IEC 61010, CE, RoHS, and UL standards. Outputs & Interface Types Output TypeDescriptionUse Case 05V / 010VVoltage output proportional to measured valueBasic analog monitoring 420 mALoop-powered analog output for industrial PLCsLong-distance transmission, noise-free Pulse (kWh, kVARh)For energy meters with BMS or data loggersEnergy billing, sub-metering Modbus RTU/TCPDigital protocol for real-time communicationSCADA/PLC, IoT dashboards RS485, CANbusSerial communication for data acquisitionRemote sensing and analytics Some advanced sensors come with Bluetooth, LoRaWAN, or Wi-Fi modules for wireless monitoring, particularly useful in legacy systems or remote substations. Key Industrial Applications SectorUse Case Power PlantsGenerator protection, current overload detection Manufacturing PlantsEnergy monitoring, predictive maintenance of motors Data CentersLoad balancing, branch circuit monitoring HVAC SystemsFan power monitoring, phase loss detection Oil & GasExplosion-proof current sensing in Zone 1 areas Renewables (Solar/Wind)Inverter input/output monitoring, g

light and color sensors play a crucial role in ensuring product quality, automation accuracy, and production efficiency. These sensors are designed to detect, measure, and differentiate light intensity, presence, and color properties in a wide range of processes. Used extensively in automated sorting, printing, packaging, food processing, electronics, automotive, and textile industries, these sensors enable high-speed, non-contact inspection and real-time process control by detecting visual attributes that are invisible to conventional proximity or motion sensors. light and color sensors operate based on optical sensing technology, often involving LEDs, photodiodes, and spectral analyzers. Photoelectric Sensors Diffuse Type: Emits light that reflects off the target and returns to the sensor. leelavati automation Retroreflective Type: Uses a reflector to bounce light back to the sensor; detects presence or absence. Through-beam Type: Uses a separate transmitter and receiver; highly accurate and resistant to environmental noise.Ambient Light Sensors Measure overall light levels in an area to adjust illumination or detect product exposure to light-sensitive environments. olor Sensors Identify specific colors using RGB detection or full-spectrum analysis. Work by shining white or RGB LED light and analyzing reflected wavelengths using filters or photodiodes. Contrast Sensors Designed to detect transitions between light and dark marks (e.g., print marks on packaging). Operate at high speeds to synchronize cutting, labeling, or printing operations. Luminescence Sensors Detect invisible markings (fluorescent inks, glues) that emit UV or visible light when exposed to UV illumination.Gloss & Reflectivity Sensors Measure surface finish quality (e.g., shiny vs. matte) by analyzing specular vs. diffuse reflection. Light IntensityLux, candelalx, cd Wavelength RangeNanometersnm Color DetectionRGB / HSV values Switching FrequencyHertzHz Response TimeMillisecondsms Detection DistanceMillimeters / Metersmm / m Food & BeverageCap color verification, label presence, fill level detection AutomotivePart sorting by color, paint quality inspection, ambient light detection PharmaceuticalPill color recognition, blister pack verification PackagingPrint mark detection, barcode alignment, transparent object sensing TextilesYarn color sorting, pattern alignment, gloss detection ElectronicsLED color grading, connector presence, PCB component detection Plastic & Injection MoldingMolded part color consistency, defect detection Printing & LabellingInk contrast detection, registration mark verification Sensor Materials & Designleelavati automation Sensors are engineered with robust materials to withstand factory conditions: Housing: Polycarbonate, PBT, stainless steel (SS304) for harsh/clean environments. Lenses: Glass or acrylic lenses with anti-reflective coatings. Sealing: IP65/IP67 enclosures for dust- and splash-proof operation. Mounting: DIN-rail, bracket, or panel mount with adjustable optics. PNP/NPN (Digital)On/off object detection in automation Analog (010V / 420mA)Light intensity / gloss variation Serial (RS232/RS485)Color value output or light-level logging IO-LinkSmart sensor configuration and monitoring Modbus / EthernetIntegration into SCADA or PLC systemsDistance to object and object size Surface reflectivity and ambient light conditions leelavati automation Speed of the production line Color or contrast variation range Required switching frequency Electrical interface compatibility (PNP/NPN, analog, Modbus, etc.) Basic Photoelectric Sensor Advanced Contrast Sensor Color Sensor (RGB/HSV) Gloss/Luminescence Sensor leelavati automation IO-Link Enabled Smart Sensor Most sensors carry a warranty of 12 to 24 months, extendable based on manufacturer policies. Rugged industrial models from brands like SICK, IFM, Keyence, Baumer, Pepperl+Fuchs, Banner, Leuze, OMRON, Panasonic, Contrinex, and Balluff offer: High repe

Looking to optimize your automation system? Choose the ideal relaymechanical or solid-statefor your factory process. Contact us for volume pricing or a custom relay configuration

Electromechanical Power Relays

Function: Mechanical contact switching via energized coil

Applications: Motor starters, solenoid control, heater elements

Coil Voltage: 12V/24V DC or 110V AC

Contact Rating: 10A16A

Mount: DIN-rail or socket

Clear contact indication (LED/mechanical flag)

Normally Open (NO) / Normally Closed (NC) configurations Easy to replace

Low cost

Supports basic PLC interface logic

Miniature General-Purpose Relays

Function: Compact form relay for low to medium switching loads

Applications: Interface modules, I/O expansion, signal switching

Key Specs:

Contact Rating: 5A 10A

Dielectric Strength: up to 5kV

Coil Isolation: 1, 000 M

Slim enclosure with DIN-rail mountable sockets

High-density installation possible Saves panel space

Suitable for compact control systems

Standardized pinouts for easy wiring

Solid-State Relays (SSR)

Function: Semiconductor-based relay with no mechanical contacts

Applications: Resistive heating control, HVAC, industrial ovens, clean zones Load Current: 2A 40A

Switching Time:

CNC (Computer Numerical Control) controllers serve as the central intelligence of CNC machines, forming the operational backbone of various industries including metalworking, woodworking, plastic forming, electronics, and high-precision tool manufacturing. These controllers interpret programmed instructions and translate them into precise, coordinated motions of machine tool components. The design and configuration of CNC controllers depend on factors such as the number of controlled axes, onboard features (like toolpath optimization and collision detection), software compatibility, and whether the unit is a basic retrofit module or a fully integrated industrial control solution. High-performance models are widely used in applications that demand reliability, accuracy, and speed, especially in high-volume manufacturing. Complementing these systems are industrial robots, particularly high-speed 6-axis articulated arms used for welding, material handling, palletizing, and precision assembly tasks. These robots are designed to manage significant payload capacities and are built with servo-driven joints, harmonic gear reducers, high-resolution encoders, and advanced motion controllers. Integration with industrial communication protocols such as EtherCAT and other fieldbus networks ensures seamless connectivity with plant-wide automation systems. Their performance is enhanced by embedded computing capabilities, safety-rated communication modules, and advanced path-planning algorithms. Servo drives and motor systems form the backbone of motion control in automation environments. These systems offer fast response, high torque accuracy, and low vibration, making them ideal for robotic arms, packaging systems, conveyor automation, and CNC machinery. Advanced drives are often equipped with real-time communication interfaces and support feedback from absolute or incremental encoders, enabling high-precision closed-loop control. The motors are typically brushless, compact, and optimized for energy efficiency and thermal management. Programmable Logic Controllers (PLCs) and Distributed Control Systems (DCS) provide centralized logic and distributed control for machines and processes. These systems are scalable and can be configured for everything from small standalone machines to large, plant-wide automation setups. Key features include modular I/O, real-time operating capabilities, integrated safety functions, redundancy support, and enhanced cybersecurity protocols. Their architecture often allows hot-swappable components and robust connectivity options, making them suitable for both discrete and process automation. Industrial routers and network gateways play a critical role in securing and managing industrial communication across distributed assets. These devices offer firewall protection, VPN access, remote diagnostics, and data logging, and are often built to withstand harsh industrial environments. Compliance with industrial certifications and support for various communication standards makes them essential in modern industrial networks and IIoT infrastructures. Human-Machine Interfaces (HMIs) allow operators to visualize, monitor, and control automated systems through graphical interfaces. They are available in various screen sizes, with features such as multi-touch input, real-time data logging, alarm management, and integration with multiple protocols. Variable Frequency Drives (VFDs), on the other hand, are used to regulate the speed and torque of AC motors, improving energy efficiency and enhancing motor protection. These drives are commonly deployed in pumps, fans, conveyors, and machine tools, and support both analog and digital control interfaces. High-precision field instruments and transmittersused for measuring pressure, temperature, flow, and levelare critical for process control. These devices are engineered to perform reliably under extreme conditions, including corrosive, explosive, and high-temperature environments

PLC (Programmable Logic Controller): A rugged digital computer used to automate electromechanical processes, from small machines to full production lines. Ideal for discrete, sequential, or batch control.

leelavati automation

DCS (Distributed Control System): A networked control system ideal for continuous or complex processes where real-time data from multiple field instruments must be monitored and acted upon centrally.

ScalabilityScalable for small to mid-size machinesScalable for large, complex, multi-unit operations

SpeedFast scan cycles, ideal for high-speed machinerySlightly slower but optimized for process control

ModularityEasy to add I/O and modulesDistributed across nodes with shared responsibilities

Real-Time ControlPrecise real-time logic controlReal-time process monitoring and control with redundancy

IntegrationWorks well with SCADA, HMIs, and sensorsIntegrates seamlessly with fieldbus, advanced analytics

RedundancyLimited, mostly optionalNative redundancy (CPU, I/O, power, networks)

Cost EfficiencyLower for small-scale automationHigher initial cost but ideal for large-scale savings

Basic PLC Kit (24 I/O)

Mid-range PLC (Modular)

Advanced PLC System

Compact DCS Starter Unit

Full-Scale DCS Solution

User Interface (UI) & Experience

For PLC Systems

HMI Panels (text or graphical, touchscreens)

SCADA Interfaces (software like WinCC, iFIX, Citect)

Real-time tag visualization, alarms, and trend graphs

leelavati automation

Basic password protection and maintenance logs

For DCS Systems

Centralized Operator Workstations (OWS) with process overview

Multi-monitor setups for complex visualization (PID loops, trends, alarms)

Engineering Workstations (EWS) for design, simulation, and deployment

Redundant servers, hot-standby terminals

OPC-UA, Modbus, Profibus, and smart instrument diagnostics Integrated asset management

Predictive maintenance dashboards

Secure web/mobile access

leelavati automation

Conveyor belts, motors, and machinesOil refineries, power generation

Water treatment plantsChemical and pharmaceutical batch plants

Packaging automationBoiler and turbine control

CNC machines, injection moldingCement kilns, steel plants

Elevator, lighting & HVAC controlWater desalination, large utilities

Sensors

Photoelectric and inductive sensors are critical components in industrial automation systems. Designed for non-contact object detection, they ensure reliability, speed, and safety across conveyor systems, packaging lines, CNC machines, robotics, elevators, and production processes. These sensors enable real-time feedback for controlling position, presence, metal detection, and material movement.

1. Photoelectric Sensors

Working Principle:

Photoelectric sensors work by emitting a light beam (LED, infrared, or laser). Detection occurs when this beam is interrupted or reflected back by an object.

Types:

Through-Beam:

Uses separate transmitter and receiver

Long sensing distance (up to 10 meters or more)

High precision

Retro-Reflective:

Uses a reflector; detects interruption in the return beam

Easy alignment; range up to 46 meters

Diffuse Reflective:

Senses light reflected directly from the object

Sensing range: 10 cm to 1.5 m

Laser-Based:

leelavati automation

Sharp, narrow beam for accurate, small-part detection

Used in fine assembly and positioning tasks

2. Inductive Proximity Sensors

Working Principle:

Inductive sensors detect metallic objects by generating an electromagnetic field. When metal enters the field, it changes the inductance, triggering a signal.

Types:

Flush (Embeddable):

Mounts level with surfaces

Offers short sensing distances

Non-Flush (Protruding):

Extends from mounting surface

Provides longer sensing distances

Analog Output Inductive:

Offers continuous distance feedback (not just ON/OFF)

Specifications & Units

ParameterPhotoelectric SensorsInductive Sensors

Sensing Distance10 mm 10 m+1 mm 40 mm

Target DetectionAny object (opaque/reflective)Only metallic objects

Output TypesPNP/NPN, Relay, Analog, IO-LinkPNP/NPN, Analog, IO-Link

Voltage Range1030V DC or 24V AC1030V DC

Operating Temperature25C to +70C25C to +80C

Protection RatingIP65 / IP67 / IP69KIP65 / IP67 / IP68

Applications

Photoelectric SensorsInductive Sensors

Detect objects on conveyorsDetect metal parts in automated assemblies

Label and package detectionPosition sensing in metal machinery

Transparent object sensing (e.g., bottles)End-stop detection in actuators

Print mark and barcode sensingShaft position monitoring

Color or edge detection in printing/textilesProximity sensing in welding, cutting, robots

leelavati automation

Construction & Materials

Housing: Stainless steel, nickel-plated brass, ABS, or polymer blends

Lens/Window: Acrylic or tempered glass

Connectors: M8/M12, cable tail, or terminal block

Protection: IP65IP69K for dust, water, and chemical resistance

Sensors can be designed for:

Harsh outdoor conditions

High-pressure washdowns

Hazardous/explosive environments

Signal Outputs

Output TypeFunction

PNP/NPNDigital switching output for logic control

Analog (010V / 420 mA)Variable signal based on distance

RelayMechanical switch, slower but rugged

IO-LinkDigital communication for smart diagnostics

leelavati automation

Price Range (Indicative)

Sensor Type

Basic Inductive Sensor

Analog Inductive Sensor

Basic Photoelectric Sensor

Laser Photoelectric Sensor

IO-Link Enabled Smart Sensor

based on sensing range, output type, housing material, and certifications.

Warranty & Reliability

Typical warranty: 12 to 24 months

Lifecycle: Up to 100 million switching operations

Features:

Built-in LED indicators

Overload and reverse polarity protection

Self-teach or auto-tune options

leelavati automation

Sensor health diagnostics in smart models

Smart Factory Integration

Advanced sensors support:

Predictive maintenance

Remote diagnostics

Edge computing

IoT dashboards

Energy-efficient operation

They integrate seamlessly into modern PLC, SCADA, and BMS systems via IO-Link, Modbus, or analog inputs, supporting Industry 4.0 applications.

industrial sensors and field instruments are the essential building blocks for real-time monitoring, control, and process optimization. These devices translate physical phenomena such as temperature, pressure, flow, level, vibration, distance, and humidity into electrical signals that can be interpreted by control systems like PLCs, SCADA, DCS, and IIoT platforms. Used across diverse sectors including automotive, food & beverage, chemicals, textiles, electronics, packaging, metalworking, and pharmaceuticals, they enable enhanced efficiency, quality control, safety, and predictive maintenance. categories & Functions Temperature Sensors Types: RTDs (Pt100), Thermocouples (J/K/T), Infrared, Thermistors Function: Measure heat in processes like curing, welding, drying, fermentation, and HVAC. Units: C, F leelavati automation Applications: Furnace monitoring, motor winding protection, injection molding, boilers Pressure & Vacuum Sensors Types: Gauge, Absolute, Differential, Vacuum Transmitters Function: Detect system pressure in hydraulic, pneumatic, and fluid systems. Units: bar, psi, Pa, mmHg Applications: Compressors, filters, vacuum packaging, tank monitoring Level Sensors Types: Ultrasonic, Capacitive, Float, Radar, Conductive Function: Detect liquid or bulk solids level in tanks and silos. Units: mm, m, % Applications: Chemical storage, wastewater treatment, beverage bottling Flow Sensors & Meters Types: Electromagnetic, Turbine, Vortex, Mass Flow, Ultrasonic Function: Measure liquid, gas, or steam flow in pipelines. Units: LPM, m/h, kg/h Applications: Water distribution, fuel flow, HVAC, process control Proximity Sensors Types: Inductive (for metals), Capacitive (for solids/liquids), Ultrasonic (non-contact) Function: Detect object presence or position without physical contact. Units: mm, ON/OFF Applications: Packaging lines, machine safety, counting systems leelavati automation Photoelectric Sensors Types: Through-beam, Retro-reflective, Diffuse Function: Detect presence, edges, or colors using light beams. Applications: Object detection, label sensing, transparent material detection Vibration & Motion Sensors Types: MEMS, Piezoelectric, Accelerometers, Gyros Function: Detect machine movement, imbalance, or wear. Units: g, mm/s, Hz Applications: Predictive maintenance, motor condition monitoring Humidity & Environmental Sensors Types: Capacitive RH, Dew Point, Air Quality Function: Measure moisture content and air conditions. Units: %RH, C dew point, ppm (gas) Applications: HVAC, clean rooms, electronics assembly Distance, Position & Displacement Sensors Types: Laser, Ultrasonic, LVDT, Magnetic Function: Measure distance or linear position with high accuracy. Units: mm, m, m Applications: Robotics, cutting, level detection Electrical Sensors Types: Voltage, Current, Frequency, Power Function: Monitor electrical parameters in real time. Units: V, A, Hz, kW Applications: Motor protection, energy monitoring, automation panels 11. Light & Color Sensors Types: RGB, Luminescence, Contrast, Ambient Function: Detect light intensity, surface color, or print marks. Applications: Quality control, packaging, labeling, printing Time & Logic Control Modules Devices: Timers, Counters, Logic Relays, Sequencers Function: Control time-based or logical operations in automation. Applications: Cycle control, safety delay, batch counting 13. CNC Controllers Function: Control multi-axis movement in machine tools. Applications: CNC milling, turning, engraving, plasma cutting Key Benefits & Features Non-contact operation for reliability and durability leelavati automation High-speed sensing (milliseconds response) Wide temperature and pressure ranges IP65/IP67-rated housings for harsh environments Smart communication protocols: IO-Link, Modbus, Profibus, CANopen, EtherCAT Calibration options for precision industries Self-diagnostics and erro

Variable Frequency Drives (VFDs) Industrial Use Overview A Variable Frequency Drive (VFD)also known as an AC drive, frequency converter, or inverteris a type of motor controller that varies the frequency and voltage supplied to an electric motor. VFDs are primarily used to control motor speed and torque, resulting in energy savings, process optimization, and extended equipment life in industrial automation. They are extensively used across manufacturing plants, HVAC systems, water treatment plants, machine shops, conveyors, compressors, and more. Working Principle VFDs operate by converting the incoming AC power to DC through a rectifier and then inverting it back to variable frequency AC using an IGBT-based inverter. By adjusting the frequency (Hz), the drive regulates the speed of the AC motor. Torque and voltage are also proportionally controlled to ensure stable performance. leelavati automation Types of VFDs TypeDescription Volts per Hertz (V/f)Basic, low-cost drive for simple applications Vector Control DrivesBetter torque control, used in moderate precision applications Sensorless Vector DrivesSimulate feedback for better dynamic response Closed-Loop VFDsUse encoders for precision control in critical applications Regenerative DrivesFeed braking energy back into the grid Multi-Axis VFDsControl multiple motors from a single unit Applications in Manufacturing IndustryApplication HVAC & Building MgmtFans, pumps, chillers, AHUs AutomotiveAssembly lines, press operations Food & BeverageConveyors, mixers, dosing systems Water & WastewaterPumps, blowers, aerators PharmaceuticalsTablet coating, clean room fans Metal & MiningCrushers, hoists, rolling mills PackagingForm-fill-seal machines, labelers, sorters TextileSpinning, weaving, dyeing machines PlasticsExtruders, injection molding machines leelavati automation Specifications & Ranges ParameterTypical Range Power Rating0.2 kW 500 kW+ Voltage Input230V / 400V / 690V AC Frequency Range Output0 400 Hz (programmable) Control ModesV/f, Vector, Torque, PID, S-curve Motor Type SupportedInduction, Synchronous, PMSM, BLDC User Interface & Controls Digital Keypad / HMI: Built-in keypad with display for programming and monitoring External HMIs: Touchscreens for enhanced diagnostics and control Communication Ports: RS485, Modbus RTU, CANopen, Profibus, Ethernet/IP, Profinet Remote Control: Via SCADA/PLC integration or wireless access PC Software: For parameter upload, logging, and tuning Mobile Apps (in smart VFDs): Wireless setup, live status, alerts Benefits & Advantages Energy Savings: Adjust motor speed to match load; reduce electricity costs by 3060% Process Optimization: Precise speed and torque control Soft Start/Stop: Reduces mechanical stress and extends equipment life Reduced Downtime: Built-in protections (overload, overvoltage, phase loss) Remote Monitoring: Supports Industry 4.0 and IIoT environments Lower Maintenance Costs: No mechanical speed control devices needed Harmonic Filtering: Built-in or optional filters reduce electrical noise Protection & Safety Features Overcurrent & short-circuit protection Overvoltage & undervoltage protection Motor stall detection Ground fault monitoring Password locking and fault history logs 0.37 kW to 2.2 kW (13 HP) 3.7 kW to 7.5 kW (510 HP) 11 kW to 22 kW (1530 HP) 30 kW to 75 kW (40100 HP) 100 kW leelavati automation features (like regenerative braking, IP rating, communication protocols), input voltage, and motor compatibility. Warranty & Compliance Standard Warranty: 12 to 24 months MTBF: Often >100, 000 hours Certifications: CE, UL, ISO, RoHS, BIS Enclosures: IP20 (standard), IP55/IP65 for harsh environments Cooling: Air or fan-cooled; some offer heat sink or liquid cooling Smart Features & Industry 4.0 Compatibility Modern VFDs offer: Auto-tuning for motor optimization Energy monitoring and kWh calculation Modular expansion (I/O cards, fieldbus

HMI Panels Human-Machine Interface in Industrial Automation HMI Panels (Human-Machine Interfaces) are digital control interfaces that enable real-time communication between operators and machines, allowing for effective monitoring, operation, and diagnostics of industrial equipment and processes. These panels are used extensively in factory automation, packaging, process plants, robotics, water treatment, HVAC systems, and more. They replace traditional control systems with intuitive graphical displays, improving efficiency, productivity, and safety. Function & Role in Industry Monitor machine status (temperature, flow, pressure, speed, alarms) Visualize data from PLCs, sensors, and field devices Control processes through touch commands (start/stop/reset) Display diagnostics and faults Provide secure user access and control HMI panels are integrated with PLCs, DCS, VFDs, and SCADA systems, forming a crucial part of Industry 4.0 and IIoT ecosystems. leelavati automation Types of HMI Panels TypeDescription Basic Text HMILCD/monochrome display for simple control and diagnostics Graphic HMIColor screen with buttons and variable graphics Touchscreen HMIFull-color TFT or capacitive display with navigation via touch Web-based HMIAccessible remotely via browser on PC/mobile Panel PCIndustrial PC with HMI software, multi-screen control, and Windows/Linux OS Modular HMIExpandable units with slots for communication, memory, and function modules Applications in Manufacturing Packaging: Control of filling, sealing, labeling, and conveying machines Textile: Monitor weaving, spinning, and dyeing processes Food & Beverage: Set recipes, cleaning cycles, temperature, and timers Pharmaceutical: Monitor cleanroom environment, batch data, alarm history Water Treatment: Pump control, level display, flow regulation Automotive: Robotic line monitoring, motor diagnostics, assembly stations HVAC & BMS: Set temperatures, schedules, energy consumption tracking Technical Specifications ParameterTypical Range / Value Display Sizes3.5 " 21.5 " (diagonal) Resolution320240 (QVGA) to Full HD (19201080) Touch TypeResistive / Capacitive / Multitouch Communication PortsRS232, RS485, Ethernet, USB, CAN, Modbus, Profibus Memory128 MB 4 GB flash / 256 MB 16 GB RAM Input Voltage12V DC, 24V DC, or 230V AC MountingPanel mount / Wall mount / DIN rail Enclosure RatingIP65 front (standard), IP67/IP69K (optional) Operating Temp. Range20C to +60C User Interface Features Customizable screens (buttons, meters, graphs, alarms) Trend charts for historical data analysis Multi-language support Password-protected user levels leelavati automation Data logging and export via USB/SD Real-time event handling and status indicators Remote access (via web server or VNC) Benefits & Advantages Simplified operation with intuitive graphics Real-time visibility of process data and alarms Reduces downtime with diagnostic info and alerts Enhances safety with password levels and interlocks Saves time in commissioning and maintenance Remote access improves monitoring and response time Data collection for reports and analytics Connectivity & Integration Connects to PLCs, sensors, drives, relays, and field instruments Supports protocols like Modbus RTU/TCP, Ethernet/IP, CANopen, OPC UA Integrates with MES, ERP, and SCADA platforms Can be used as a gateway between systems Smart Features (Industry 4.0 Ready) Cloud integration for remote monitoring Edge computing capability in high-end models Predictive maintenance alerts QR/barcode scanner input for batch control Mobile device control via wireless or web-based UI IIoT sensors connectivity via MQTT/OPC-UA protocols leelavati automation 4.3 " 7 " Basic HMI 7 " 10 " Touch HMI 10 " 15.6 " Advanced HMI Industrial Panel PC with HMI SW screen size, ports, CPU, memory, protocols, and durability (IP ratings). Warranty & Compliance Warranty: 12 to 24 months

Industrial DCS Installations in Manufacturing & Process Automation A Distributed Control System (DCS) is a centralized yet distributed automation platform designed to monitor and control complex industrial processes. Used extensively in manufacturing plants, refineries, power plants, chemical units, water treatment, pharmaceuticals, food processing, and metallurgical industries, DCS improves process reliability, operational efficiency, safety, and scalability. leelavati automation In a DCS, intelligence is distributed across multiple controllers, field devices, operator stations, and servers ensuring robust, real-time process control. Core Functions of a DCS Continuous process control and regulation Collection and logging of plant data (real-time and historical) Alarm management and safety interlocks Recipe control and batch management Centralized operator monitoring and remote diagnostics Integration with PLCs, sensors, actuators, drives, and SCADA systems Typical Industries & Use Cases IndustryDCS Application Oil & GasRefinery operations, pipeline control, tank farm systems Power GenerationBoiler control, turbine regulation, grid synchronization Chemicals & PetrochemReactor control, distillation, flow and mixing operations Food & BeverageRecipe management, pasteurization, bottling lines PharmaceuticalsBatch control (cGMP compliant), HVAC, cleanroom controls Water & WastewaterPumping stations, filtration, chlorination Pulp & PaperPulping, drying, cutting, coating automation Steel & CementKiln control, rolling mill operations, material handling leelavati automation DCS Architecture Engineering Station (ES) Design, configuration, and diagnostics Operator Workstation (HMI/OS) For real-time monitoring, alarm handling, and control Controllers / Process Stations (PS) Distributed logic processing units connected to I/O Field I/Os & Smart Devices Interface with process variables (temperature, pressure, flow, etc.) Redundant Network / Bus Ethernet-based communication (Profinet, Modbus TCP, FOUNDATION Fieldbus, etc.) Historian Server Long-term data storage and reporting Remote I/O & Substations For larger distributed systems over wide areas Key Features & Capabilities Real-time control with deterministic execution Redundancy at CPU, power, and network levels for fault tolerance Modular & scalable design to support small to large plants Integrated alarm management and safety protocols (SIL support) Multi-protocol compatibility (Modbus, OPC UA, Profibus, Ethernet/IP, HART) Batch management & recipe handling (ISA-88 compliant) Historian database for data analytics and audits Remote monitoring & control via SCADA and cloud platforms Technical Specifications (Typical) SpecificationValue / Range System RedundancyCPU, network, I/O redundancy (hot-standby) Communication ProtocolsModbus RTU/TCP, Profibus, EtherNet/IP, OPC, HART Supported I/O TypesAI, AO, DI, DO, RTD, Thermocouple, Frequency Scan Time1 ms 100 ms (configurable) Data LoggingReal-time & historical with backup Alarm Response Time< 1 second Operating Environment10C to +60C; IP20IP65 enclosures available Power Supply24V DC, 48V DC, 110/230V AC Advantages of DCS Over PLC/SCADA FeatureDCSPLC/SCADA ArchitectureCentralized + DistributedModular (often standalone) Best forContinuous and batch process controlDiscrete/Sequential automation ScalabilityHigh suitable for large plantsMedium cost rises with scale RedundancyBuilt-in at multiple levelsOptional IntegrationSeamless integration with sensors, drives, MES/ERPCan require multiple bridges/interfaces Batch/Recipe SupportAdvanced, native support (ISA-88)Possible but complex leelavati automation Smart Features & IIoT Integration Cloud connectivity via MQTT, OPC UA Predictive maintenance using AI/ML algorithms Edge computing enabled I/O stations Real-time energy monitoring Advanced analytics dashboards Cybersecurity with encrypted protocols and firewa

Servo Motors & Drives in Industrial Manufacturing Servo motors and drives are high-precision motion control systems widely used in automated industrial machinery to perform controlled rotational or linear movement. Unlike standard motors, servo systems provide precise position, speed, and torque control, making them ideal for robotics, CNC machines, pick-and-place, packaging, and textile automation. A servo drive (or amplifier) interfaces between the control system (like PLC or CNC) and the servo motor, ensuring real-time feedback-based motion control. Working Principle The servo system operates via a closed-loop feedback mechanism: The controller sends motion commands to the servo drive. The drive energizes the servo motor. An encoder or resolver attached to the motor shaft sends position/speed feedback. The drive adjusts current/voltage to correct deviations, ensuring precise motion. This real-time correction enables high-speed and high-accuracy motion control. Types of Servo Motors TypeDescription AC Servo MotorsMost common; used in automation, CNC, packaging DC Servo MotorsSimple control; used in low-power applications Brushless Servo Motors (BLDC)High efficiency and long life; low maintenance Synchronous Servo MotorsConstant speed; used in robotics and textile machines Linear Servo MotorsProvide direct linear motion without mechanical linkages Applications in Manufacturing IndustryApplication AutomotiveRobotic arms, part alignment, welding stations PackagingCarton folding, cutting, sealing, labeling TextileYarn tensioning, weaving, precision rollers CNC/MetalworkingTool positioning, axis control, spindles ElectronicsPick-and-place, soldering arms, lens adjustment Pharma/FoodCapsule filling, labeling, conveyor sorting PrintingColor register control, printhead positioning Technical Specifications (Typical) ParameterRange / Value Torque Output0.1 Nm 150 Nm+ Rated Power50 W 15 kW+ Voltage Range24V DC 480V AC Speed Range0 6, 000 RPM (programmable) Feedback DevicesIncremental encoder, Absolute encoder, Resolver Communication ProtocolsModbus, EtherCAT, CANopen, Profibus, Profinet Position Accuracy0.01 mm or better Ingress Protection (IP)IP54, IP65, IP67 (depending on model) Key Benefits & Advantages Precision Control: High-resolution encoders enable micro-level position control Dynamic Response: Fast acceleration and deceleration for high-speed operations Compact & Lightweight: High torque in a small footprint Programmable: Supports multi-axis coordination and motion profiles Energy Efficient: Regenerative braking and optimized current draw Maintenance-Free (BLDC types): No brushes = longer life and reduced wear Safe Operations: Overload, over-temperature, and stall protection Integration & User Interface Drive Programming: Via built-in keypad, PC software, or touchscreen HMI Control Inputs: Analog (010V), Digital I/O, Pulse train, Fieldbus Feedback Support: Multiple encoder types; high-resolution signal handling Multi-axis Support: Master/slave configuration for coordinated movements Remote Diagnostics: Error logs, real-time status, parameter read/write Smart Features & IIoT Integration Auto-tuning for load inertia and optimal performance Data logging for predictive maintenance and performance analysis IIoT communication via OPC-UA, MQTT, or Ethernet/IP Remote access for parameter setting, alarms, and live monitoring Safety integrated functions: Safe Torque Off (STO), Safe Stop 1 (SS1) 100 W 750 W (basic packaging/CNC) 750 W 1.5 kW (CNC/robotics) 1.5 kW 5 kW (multi-axis/automation) >5 kW high-performance (multi-axis) torque, feedback type, protocol support, and drive configuration. Warranty & Reliability Standard Warranty: 1224 months Typical Service Life: 20, 000+ hours (brushless types) Certifications: CE, RoHS, UL, ISO 9001 Maintenance: Low to zero for BLDC and sealed units Environmental Ratings: IP54/IP65/IP67 for dust, oil, and water prot

Industrial PCs (IPCs) and Edge Controllers are ruggedized computing platforms used to perform real-time control, data processing, visualization, and edge analytics in factory environments. Unlike consumer-grade PCs, these systems are designed for 24/7 operation in harsh conditions such as vibration, heat, dust, and electrical noise. They serve as critical components in smart manufacturing, bridging the gap between field-level devices (PLCs, sensors, HMIs) and enterprise-level systems (MES, ERP, cloud)Edge Controllers in Industrial Automation Edge Controllers are compact, industrial computing systems that perform real-time control, data processing, and communication functions directly at the edge of the production lineclose to machines, sensors, and actuators. Unlike traditional controllers, Edge Controllers combine PLC-style control, IT-level processing, and IIoT connectivity, making them ideal for smart factories and Industry 4.0 deployments. These devices bridge the gap between operational technology (OT) and information technology (IT), offering local decision-making without relying solely on cloud infrastructure. Architecture & Functionality Core Components: Real-Time Processor or Microcontroller Integrated I/O (DI/DO, AI/AO) Communication Interfaces (Ethernet, Serial, Fieldbus) Edge Analytics Engine Local Data Storage or SD/SSD Optional Display or Web Interface Key Functions: Collect & process sensor data Perform control logic (PID, ladder, structured text) Analyze data locally (Edge AI/ML) Communicate with PLCs, HMIs, SCADA, cloud Convert protocols (e.g., Modbus MQTT) Trigger alerts, alarms, or actuator events Host dashboards or APIs for integration Industrial Use Cases & Applications IndustryEdge Controller Application AutomotivePredictive maintenance, robotic cell management PharmaceuticalCleanroom monitoring, batch data logging Food & BeverageLine performance tracking, traceability, vision analytics TextileQuality control and energy monitoring PackagingLabel verification, device coordination CNC & MetalworkingReal-time spindle monitoring, adaptive speed control UtilitiesPump control, water quality monitoring User Interface & Connectivity Web-Based HMI: Accessible via browser from any device Cloud Connection: Azure, AWS, Google Cloud, private servers Protocol Support: OT: Modbus RTU/TCP, CAN, Profibus, EtherNet/IP IT/IoT: OPC UA, MQTT, REST API, SNMP Edge Software: Node-RED Python / C scripts Docker for containerized apps Built-in logic editors (ladder, FBD, ST) Technical Specifications (Typical) ParameterValue / Range CPUARM Cortex-A, Intel Atom/i3/i5 RAM512 MB 8 GB Storage8 GB 128 GB (eMMC, SSD, SD) Digital/Analog I/O4 to 64+ (expandable) ProtocolsModbus, MQTT, OPC UA, CANopen, Ethernet/IP Power Supply24V DC (typical), with surge protection Operating Temp.20C to +60C (industrial-grade) MountingDIN-rail, wall, or panel mount CertificationsCE, UL, FCC, RoHS, ISO Key Benefits & Advantages Real-Time Processing: Ensures immediate local action and control Reduced Latency: No need to wait for cloud decision-making Lower Bandwidth Usage: Only relevant/filtered data sent upstream High Uptime: Runs autonomously during network or cloud outages Protocol Bridging: Unifies legacy and modern industrial systems Cybersecure: Encrypted communications, firewalls, user access control Edge AI Capable: Supports ML algorithms and image/sound processing Smart Features & IIoT Readiness Auto-tagging of devices using device templates Local data historian for analytics and audits Rule-based alerts and edge decisions (e.g., if temp > X, shut pump) API integration with MES, ERP, or CMMS systems Digital Twin Hosting: Run simulations or diagnostics based on real data Over-the-Air Updates (OTA) for firmware and application patches Edge-to-Cloud Sync: Customizable data flow strategies (push/pull, real-time/batch) Basic Edge I/O Controller Mid-Tier Edge Gat

Machine Vision Systems in Manufacturing Factories  Overview Machine Vision Systems are advanced automation tools that use cameras, sensors, and image-processing algorithms to visually inspect, measure, guide, and monitor parts or products in real-time. These systems play a critical role in modern smart manufacturing, enabling non-contact, high-speed, and highly accurate visual analysis of components during production.   Used extensively in automotive, electronics, pharmaceuticals, food & beverage, packaging, and metal fabrication, machine vision improves product quality, process speed, and production consistency.    How It Works A typical machine vision system includes:   Vision Cameras (2D or 3D): Capture high-resolution images of the target area or part   Lighting Modules: Provide consistent and uniform illumination   Image Sensors (CMOS or CCD): Convert light into digital signals   Vision Controllers / Processors: Analyze image data using algorithms leelavati automation Machine Vision Software: Handles inspection, measurement, barcode reading, pattern recognition, OCR, etc.   Output Signals: Trigger machine action (eject, accept, sort, stop) based on the result    Applications in Manufacturing IndustryMachine Vision Use Case AutomotivePaint defect inspection, surface finish analysis, part verification ElectronicsSolder joint inspection, PCB alignment, connector presence PharmaceuticalBlister pack inspection, pill counting, label verification Food & BeverageFill level check, packaging seal inspection, label OCR TextileFabric pattern consistency, weave flaw detection CNC & MetalworkingDimensional verification, hole alignment, burr detection PackagingBarcode reading, cap presence, orientation check    Functions Performed by Vision Systems Defect Detection (scratches, cracks, blemishes)   Part Identification (barcode, QR, OCR)   Measurement (length, width, angle, position)   Color Detection & Sorting   Presence/Absence Verification   Pattern Matching for orientation or assembly checking   3D Scanning for height, volume, or surface contour analysis   Robotic Guidance (vision-guided pick and place) leelavati automation  Technical Specifications (Typical) ParameterTypical Range Camera Resolution0.3 MP – 21 MP (megapixels) Frame Rate30 – 200+ FPS Sensor TypeCMOS, CCD InterfaceUSB 3.0, GigE, Camera Link, CoaXPress, EtherCAT Lens TypeFixed, Zoom, Telecentric Lighting OptionsRing, Bar, Dome, Coaxial, Infrared, UV Power Supply12V/24V DC, PoE (for GigE cameras) Environmental RatingIP40 to IP67 (dust, oil, splash resistant) Software SupportWindows/Linux SDKs, drag-drop platforms, AI models     Advantages & Benefits High-Speed Inspection: Detect defects at production-line speeds   Non-Contact & Non-Intrusive: Ideal for sterile or high-speed environments   Consistent Quality Control: 100% inspection eliminates human error   Scalability: Easily integrates with PLCs, HMIs, SCADA, and MES systems   Traceability & Reporting: Record image logs and measurement data   Flexible Deployment: Works across product sizes, shapes, and materials   Supports AI Integration: Deep learning enhances decision-making for complex visuals    Smart Features & Industry 4.0 Integration AI Vision Processing: Deep learning to detect subtle or varying defects   Edge Vision Systems: Local processing on the camera to reduce latency   Cloud Analytics & Image Storage   MQTT / OPC UA Support for IoT integration   Remote Monitoring via browser or mobile apps   Adaptive Lighting & Autofocus for real-time adjustments   Integration with MES/ERP for closed-loop quality feedback     Basic 2D Smart Camera  High-Res GigE or USB Vision Cam  3D Machine Vision Camera  Vision System Controller  Complete Integrated System    resolution, processing power, lens, lighting, and software features.    Reliability & Compliance Warranty: 1–3 years standard   Certifications: CE, FCC, RoHS, ISO 9001   Operating Life: 20, 000+ hours MTBF   Environmental Ratings: IP65/IP67 options for washdown or ha

Industrial Safety Systems: Light Curtains & Laser Scanners   In modern manufacturing, safety systems are critical to ensuring the well-being of personnel, protection of equipment, and compliance with safety regulations. Among these, Light Curtains and Laser Scanners are widely used non-contact safety devices designed to detect human presence or intrusion into hazardous zones such as robotic cells, presses, conveyor lines, CNC machines, and packaging units.   These systems help create safe work environments without compromising productivity, offering flexible protection solutions that adapt to complex layouts and dynamic processes.   leelavati automation  What Are Light Curtains & Laser Scanners?  Light Curtains An array of infrared beams between a transmitter and receiver unit   If a beam is interrupted (e.g., by a hand or body), a safety stop signal is triggered   Used in areas where frequent human interaction with machines occurs     Laser Scanners Emit a rotating laser beam to create a 2D safety zone map   Continuously monitor for object or person entry into defined areas   Allow programmable zones and differentiated response based on intrusion distance    Applications in Manufacturing Factories IndustryApplication AutomotiveRobotic cell perimeter protection, press brakes, part handling PackagingPalletizer entry points, carton formers, conveyor ends TextileHigh-speed roll winding zones, machine access points PharmaceuticalBarrier-free entry to filling or inspection zones CNC/MetalworkingOperator hand protection in stamping, shearing, or cutting ElectronicsSafe zone enforcement in pick-and-place and automated test cells Food & BeverageHygienic machine guarding and washdown zone monitoring   Key Features & Capabilities Light Curtains: Resolution options: Detect fingers (14 mm), hands (30 mm), or full body (90 mm)   Compact or cascade models for flexibility in installation   Muting & Blanking: Allow temporary bypass (e.g., object movement but not people)   Built-in diagnostics via LED indicators or remote monitoring   Range: 0.3 m to 20 m (depending on resolution and model)     Laser Scanners: Programmable detection zones: Warning and safety zones   Angular coverage: 190°–270° scanning range   Zone switching for mobile or dynamic workspaces   2D or 3D mapping of hazardous areas   Diagnostic logging and Ethernet/IP or PROFIsafe communication   leelavati automation   Technical Specifications (Typical) ParameterLight CurtainLaser Scanner Sensing Range0.1 m – 20 m0.1 m – 9 m Detection Resolution14 mm – 90 mm30 mm – 70 mm (object size) Response Time5 – 20 ms60 – 100 ms Protection Height100 mm – 1800 mm2D field (customizable) Output TypeOSSD (PNP/NPN)OSSD, Ethernet/IP, Profisafe MountingSide brackets, pole mountWall, pole, machine-mounted Operating Temp.–10°C to +55°C–10°C to +50°C Enclosure RatingIP54, IP65IP65, IP67 Safety CertificationType 2 / Type 4 (ISO 13849-1)SIL 2 or SIL 3, PL d or e     Advantages & Benefits Non-contact protection: No physical barriers needed   Faster reset time than mechanical guarding   Flexible layouts: Easy to reconfigure as production changes   High visibility with minimal interference in operations   Improved machine accessibility for maintenance and setup   leelavati automation Enhanced safety compliance with OSHA, ISO, IEC standards   Programmable logic for zone control, muting, or cascading devices    Smart & IIoT Capabilities Remote diagnostics and health monitoring   Fieldbus and Ethernet connectivity (e.g., Profinet, EtherCAT, CIP Safety)   Event logging and fault history analysis   Live data for dashboards or plant safety KPIs   Integration with SCADA/HMI systems for alerts and visualization   Automatic zone adaptation for mobile robots or AGVs     Basic Type 2 Light Curtain  Advanced Type 4 Curtain  Basic Laser Scanner  Advanced Safety Scanner     scanning range, safety certification, response time, and interface type.    Compliance & Warranty Standards:   ISO 13849-1 (Performance Level

Field Instruments in Industrial Manufacturing (Transmitters & Flow Meters)   Field Instruments are key components of industrial automation systems. Installed directly in the process field, they measure, transmit, and monitor critical process parameters like pressure, temperature, flow, and level. The most common types include Transmitters (for pressure, temperature, level) and Flow Meters (for measuring fluid/gas flow rate).   They serve as the primary data acquisition sources in process plants, refineries, water treatment plants, chemical factories, pharmaceutical units, and FMCG packaging lines, enabling real-time control, monitoring, and safety enforcement.   Key Components of Field Instrumentation Transmitters Convert raw physical signals (like pressure or temperature) into standardized electronic signals (4–20 mA, HART, Modbus) for control systems. leelavati automation Types of Transmitters:   Pressure Transmitters: Gauge, absolute, or differential   Temperature Transmitters: RTD, thermocouple-based   Level Transmitters: Ultrasonic, radar, hydrostatic   pH / ORP Transmitters: Chemical process monitoring   Conductivity / TDS Transmitters: Water quality control   Flow Meters Measure the volume or mass of liquids, gases, or steam flowing through a pipe or duct.   Types of Flow Meters:   ElectromagneticWater, slurry, chemical (conductive liquids) UltrasonicCustody transfer, water, oil, large pipes CoriolisMass flow of oil, fuel, chemical, pharma TurbineClean liquids and gases VortexSteam and gas flow Positive DisplacementOil, viscous fluids Thermal MassGas flow (compressed air, natural gas) leelavati automation Specifications ParameterTransmittersFlow Meters Output Signal4–20 mA, HART, Modbus, ProfibusPulse, 4–20 mA, Modbus, HART, Ethernet Accuracy±0.1% to ±0.5% FS±0.1% to ±1% of rate Operating Temp Range–40°C to +125°C–40°C to +180°C Pressure Range–1 bar to 600+ barUp to 400 bar (depending on meter) Ingress ProtectionIP65 to IP68IP65, IP67, NEMA 4X Material of ConstructionSS304/316, PTFE, ceramics, PVDFSS316, PTFE-lined, Hastelloy, etc. CertificationsCE, ATEX, IECEx, SIL2/3ISO, CE, RoHS, ATEX MountingField, Panel, Pipe, FlangeInline, clamp-on, insertion, flanged    Advantages & Features Transmitters: High Accuracy & Repeatability   HART/Modbus Communication for integration   Explosion-Proof & Intrinsically Safe models   Built-in Diagnostics and self-calibration options   Remote Configuration via handheld or software tools   2-Wire Technology reduces cabling complexity   Flow Meters: Non-intrusive Clamp-on Options for ultrasonic meters   Bidirectional Measurement capability   No Moving Parts (for electromagnetic, vortex, ultrasonic) = Low maintenance   High Turndown Ratio for variable flow conditions   Suitable for Clean and Dirty Fluids, including slurries   Real-Time Mass or Volume Flow Output leelavati automation Smart Features & Digital Integration IIoT-Ready: Connectivity via HART-IP, OPC-UA, MQTT   Data Logging: Store flow and process data for audit/compliance   Wireless Models: Battery-operated flow sensors for remote sites   Self-Diagnostics: Alerts for sensor drift, wear, or obstruction   Digital Display & Touch Interface (local display on device)   Integration with DCS, PLC, SCADA or Cloud platforms     Pressure/Temp Transmitter Level Transmitter Electromagnetic Flow Meter Ultrasonic Flow Meter Coriolis Mass Flow Meter range, material, size, protocol, and brand.   Warranty & Service Warranty: 1 – 3 years standard (extended available)   Calibration: Factory calibrated; on-site calibration options   Maintenance: Minimal (especially for non-mechanical meters) leelavati automation Compliance: SIL2/3, ISO 9001, CE, Ex-proof as required   Environment: Models for hazardous zones (Zone 1/2, Class 1 Div 1/2)   Accessories & Installation Options Signal conditioners, isolators   Manifolds and mounting brackets   Flanges and gaskets   Remote displays or control heads   Wireless transmitters or gateways   Bluetooth/HART modems f

Smart Actuators & Valves in Industrial Automation Smart Actuators and Valves are advanced flow control devices integrated with sensors, digital communication interfaces, and onboard intelligence. Unlike traditional actuators and valves, smart versions offer remote control, feedback, diagnostics, and self-adjustment, playing a vital role in Industry 4.0 and IIoT ecosystems. They are widely used in oil & gas, chemical, water treatment, power generation, food processing, pharmaceuticals, HVAC, and manufacturing automation where precision, safety, and efficiency are essential. Core Components Valve: Controls the flow of liquids, gases, or steam Actuator: Provides the mechanical force to open/close or modulate the valve Smart Features: Position sensors, control modules, digital communication protocols, self-diagnostics Types of Smart Valves & Actuators Smart Actuators TypeDescription ElectricUses motors to control valve movement (on/off or modulating) PneumaticUses compressed air to drive valve movement HydraulicUses fluid pressure for high-force applications Electro-PneumaticHybrid systems with digital positioners and feedback Valves TypeApplication Ball ValvesOn/off control of water, gases, slurries Butterfly ValvesCompact design, large volume control Globe ValvesPrecision flow modulation Gate ValvesIsolation of pipelines Diaphragm ValvesCorrosive or sanitary fluids (pharma, food, chemicals) Control ValvesPrecise flow or pressure regulation using PID logic Specifications ParameterTypical Range Actuator Torque10 Nm 10, 000 Nm Operating Voltage24V/110V/230V AC or DC (electric actuators) Pressure RatingUp to 250 bar (valve type dependent) Communication ProtocolsModbus, HART, Profibus, Foundation Fieldbus, Ethernet/IP Position Feedback0100%, analog or digital Fail-Safe OptionsSpring return, battery backup Ingress ProtectionIP65 IP68, NEMA 4X / 6 Housing MaterialSS304/316, cast iron, brass, PVC, PTFE-lined Temperature Range40C to +180C CertificationsCE, SIL2/3, ATEX, IECEx, RoHS Applications in Manufacturing & Process Industries IndustryExample Use Water & WastewaterValve automation in filtration and pump systems Oil & GasFlow regulation and pipeline control PharmaceuticalSterile flow control in reactors and batch tanks Food & BeverageHygienic valves in CIP/SIP and bottling lines Power PlantsSteam valve control and cooling systems ChemicalCorrosion-resistant flow control in reaction vessels HVAC SystemsChiller and air duct flow balancing Advantages & Smart Features Remote Monitoring & Control via SCADA/PLC/DCS Position Feedback for real-time tracking Self-Diagnostics: Detects valve stiction, leakage, misalignment Data Logging & Trend Analysis Predictive Maintenance Alerts Adaptive Control: Automatically compensates for process variations Fail-Safe Behavior during power or signal loss Digital Calibration through handhelds or software Smart Capabilities & IIoT Integration Cloud Connectivity (via gateways) for remote control and analytics Edge Processing in actuator controllers Security Protocols for cyber-safe operations Plug-and-Play Configuration via HART/Modbus tools Support for AI-based Valve Health Monitoring Interoperability with MES/ERP systems Smart Electric Actuator Smart Pneumatic Actuator Automated Ball Valve Unit Smart Control Valve Valve Positioner (digital) Size, pressure class, material, certification, and smart features. Warranty, Support & Maintenance Warranty: 1236 months standard Maintenance: Low due to digital calibration and diagnostics Support Tools: Mobile apps or handheld communicators Software for diagnostics, configuration, and tuning Certifications: SIL2/3, CE, ATEX, ISO, RoHS Recommended Spare Parts: Seals, seats, controllers, solenoids Optional Accessories Position feedback modules (analog or digital) Smart solenoid valves Control signal converters (e.g., 420 mA to digital) Flameproof enclosures (Ex d) for hazardous areas Ma

Fiber Optic Networks

Description: High-speed communication using light through glass fibers. Used for broadband internet, enterprise backbones, and long-distance communication.

 Up to 100 Gbps+

ISPs, data centers, smart cities 

5G Wireless Networks

Description: The fifth generation of mobile networks, offering ultra-fast wireless communication, low latency, and IoT support.

 1 Gbps+ (theoretical), 100–500 Mbps practical

Mobile internet, smart devices, industrial automation

Wi-Fi 6 / Wi-Fi 7 Networks

Description: Latest wireless LAN technology for high-speed indoor wireless internet.

 Up to 9.6 Gbps (Wi-Fi 6), 46 Gbps (Wi-Fi 7)

Offices, homes, public hotspots

LAN / WAN (Wired Ethernet)

Description: Local and wide-area networks built using Ethernet cables and switches.

 1 Gbps to 100 Gbps (with fiber backbone)

Offices, campuses, enterprises

Satellite Communication Networks

Description: Internet and communication using satellites, useful in remote and rural areas.

 25–150 Mbps (Starlink, OneWeb, etc.)

Rural broadband, defense, remote operations

IoT Networks (LoRaWAN, NB-IoT, Zigbee)

Description: Specialized low-power networks for smart devices and sensors.

 Low (Kbps to Mbps)

Smart meters, agriculture, home automation

rivate 5G / Industrial Networks

Description: Customized, secure mobile networks for factories, ports, campuses.

 Comparable to public 5G, with higher reliability

Industry 4.0, automation, logistics

Fiber Optic1 Gbps–100 GbpsInternet backbone, campuses 

5G Mobile100 Mbps–1 GbpsMobile, IoT, urban coverage 

Wi-Fi 6/79.6–46 GbpsIndoor broadband 

Ethernet LAN/WAN1–100 GbpsLocal wired networks  (switches etc.)

Satellite (e.g. Starlink)25–150 MbpsRemote areas 

IoT NetworksKbps–MbpsSensors, automation  (device/node)

Private 5GUp to 1 Gbps+Industry, large campuses

HMI touchscreen is a digital interface that allows human operators to interact with machines, systems, or processes in industries like manufacturing, utilities, and automation.

It displays data, allows input commands, and often shows real-time system performance, alarms, and controls.Features:

Touchscreen Interface: Capacitive or resistive touchscreen

Communication Ports: RS232, RS485, Ethernet, USB, CAN

Protocols: Modbus, Profinet, Ethernet/IP, OPC UA

Display Sizes: 4.3”, 7”, 10.1”, 12.1”, 15”, and above

Resolutions: Ranges from 480x272 to Full HD (1920x1080)

Operating System: Some use embedded OS, others support Windows/Linux

Data Logging: Real-time trend, historical data storage

Durability: Industrial-grade, shock & dust resistant (IP65 or higher) HMI Touchscreen Types:

Basic HMI (Monochrome) Simple operations, pump control, elevators 

Color Graphic HMI PLC-based automation, conveyors 

Advanced HMI SCADA interface, process control

PC-Based HMI PanelsHigh-end control rooms, plants 

Smart HMI (IIoT enabled)Cloud support, remote monitoring 

INTEGRATED BUILDING MANAGEMENT SYSTEMS (IBMS)

We offer fully Integrated Building Management Systems that bring together critical services into one centralized smart control platform. Our systems are designed for high-rise buildings, commercial complexes, industrial plants, and institutional infrastructure.Contact mobile number Plus ninety-one, nine nine six seven eight six one two nine four

Scope of IBMS Integration

• HVAC Automation: Intelligent temperature and air quality control

• Lighting Automation: Adaptive lighting and daylight integration

• Energy Monitoring: Real-time consumption tracking, load balancing

• Fire Detection & Suppression: Smart alarms, sensors, integrated emergency protocols

• CCTV & Surveillance: Networked cameras, motion analytics, storage solutions

• Access Control: Biometric, RFID card, and facial recognition systems

• Elevator Management: Smart lift control and integration with access control

• Public Address (PA) Systems: Multi-zone communication for public safety and convenience

• Water Supply & Drainage Automation: Pressure control, leak detection, water level monitoring

• Parking Management: Smart parking guidance, occupancy sensors, ticketing, EV charging integration

Method Statement IBMS

1. Survey of site and requirement mapping

2. System design using modular scalable architecture

3. Integration of devices, sensors, controllers, and software

4. Configuration, wiring, and programming of equipment

5. Testing, commissioning, and end-user training

6. AMC and remote diagnostics support available

WARRANTY POLICY

All waterproofing, fit-out, and systems integration works are backed by a standard workmanship warranty of 12 to 36 months, depending on material class and scope. Extended AMC and re-coating refurbishment services available on request.

Thank you again for considering our team for this opportunity. We promise to work hard and do a good job. We will follow all safety rules and ensure everything is done correctly. We will work tirelessly to meet your expectations and ensure your complete satisfaction.

CPS sensor detects the exact position and rotational speed RPM of a crankshaft.

Its a key input for the engine control unit ECU to Determine ignition timing when to fire spark plugs Control fuel injection timing

Monitor engine speed for safety systems A toothed wheel reluctor ring is attached to the crankshaft. The CPS sensor uses magnetic inductive or Hall-effect technology to detect passing teeth. Each tooths passing generates an electrical pulse. The ECU counts pulses calculates crank angle & RPM. Inductive type generates voltage when a metal tooth passes Hall-effect type uses a magnet + semiconductor switch for more precise digital output Optical type uses light interruptions rare in CPS Cars, trucks, generators, marine engines Industrial machinery with large combustion engines CPS sensors integrate with MEMS sensors in modern industrial control systems, both show up in smart HVAC and generator sets.

MEMS (Micro-Electro-Mechanical Systems) sensors are miniature devices that integrate microscopic mechanical parts and microelectronics on a silicon chip. They detect and measure physical parameters such as acceleration, rotation, pressure, or sound, and convert them into electrical signals.

MEMS Accelerometer vibration sensor, tilt sensor, motion detection, inertial sensor

MEMS Gyroscope angular velocity sensor, rotation measurement, IMU (inertial measurement unit)

MEMS Pressure Sensor barometric sensor, duct pressure monitor, HVAC pressure transducer

MEMS Microphone digital mic, acoustic sensor, sound level

MEMS Flow Sensor airflow measurement, gas flow, microfluidic sensor

MEMS Temperature Sensor micro thermal sensor, HVAC temp probe

Gyroscope (3-axis

Combined IMU (Accel + Gyro)

Pressure Sensor (low-range)

MEMS Microphone

Flow Sensor

HVAC duct monitoring

High-precision automotive/medical MEMS

calibration and rugged