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This section provides an overview for sensor controllers as well as their applications and principles. Also, please take a look at the list of 12 sensor controller manufacturers and their company rankings. Here are the top-ranked sensor controller companies as of December, 2024: 1.Real Tech Inc., 2.DEETERELECTRONICS, 3.Hypersen Technologies Co., Ltd..
Table of Contents
A sensor controller is a device that applies an electric current to a sensor and outputs a control signal.
There are direct current and alternating current versions, transistor outputs and relay outputs. They receive sensor signals and output signals. Some small sensors, for example, have a built-in controller.
Since there is a wide variety of sensors themselves, it is necessary to select the controller that best suits the application. There are also panel controllers that display on a panel.
Sensor controllers use a wide variety of sensors, such as photoelectric sensors, laser sensors, and flow sensors, each of which is connected to and controlled by a controller.
Controllers that are mutually compatible are sold as long as the standards such as current, voltage, and plug shape are matched. An increasing number of products are now available that allow multiple sensors to be controlled by a single controller. However, it should be noted that some of them may not work unless they are made by the same manufacturer as the sensors.
For example, when a sensor is used to detect the presence or absence of bottle caps in a factory, the controller receives input signals from two sensors and comprehensively determines the presence or absence, turning the output on or off.
The controller not only supplies power to the sensors, but also has the ability to check and control the sensor values from a distance, even if the location where the sensors are installed is small.
The controller must also have a high information-processing capability to control the sensor in a short period of time and with sufficient accuracy based on the values measured by the sensor. Selection of control variables such as current, rotation speed, and position, as well as system accuracy, is important.
Sensor controllers are available with either relay or transistor contacts, and it is important to select the appropriate product for the application.
Relay output is an output method that has a mechanical contact mechanism and can be used for both DC and AC. Since the switch is turned on and off by a mechanical contact, the contact has a life span and the contact open/close response is slower than the transistor output method described below, which are disadvantages.
On the other hand, if the output unit has multiple terminals, it can handle both DC and AC, so loads with different circuit voltages, such as 200 VAC and 24 VDC, can be connected.
Transistor output is a non-contact output type that has no mechanical contact and can handle loads from 12 VDC to 24 VDC. The disadvantage is that the current value that can be handled is 0.5A per point, which is smaller than the 2A of the relay output type. However, since there is no mechanical contact point, it has a long service life, and the contact opening/closing response is faster than the relay type.
Although only DC loads are supported, AC loads can also be driven via a relay. Basically, it compares the setting signal input from the outside with the signal sent from the sensor to control the signals so that they match and stabilize the operation.
Sensor controllers are often used in photoelectric sensors. The greatest advantage of sensor controllers is that they can isolate the sensor portion from the output portion. Because of this feature, sensor controllers are used in the following ways:
First, it is used when the type of sensor is changed. In the past, many photoelectric sensors with 200 VAC contact switching were sold, but currently 24 VDC is the most common power supply for instrumentation. If the power supply is not available at 200 VAC when the latest model is made, the sensor controller can supply the sensor with 24 VDC voltage while sending electrical signals with 200 VAC relay contacts.
Next, it is used when increasing the number of contacts. Generally, sensors in the field have only one contact point. By using a sensor controller, multiple contact outputs can be realized while insulating the power supply between the field and the control panel. Relays can be substituted, but sensor controllers have a higher response time.
In addition, sensor controllers are often multifunctional. A timer may be installed to prevent sensor chattering, but a controller with a built-in timer can be used to save space. Some other types of sensor controllers allow the sensitivity of the sensor to be changed.
Sensor controllers may be connected to sensors with I/O connectors. Basically, the sensor has only lead wires coming out of it, which can be crimped or terminal lifted. Education and training are required to replace them, as they require the use of crimping pliers and electrical work.
By using an I/O connector for wiring to the sensor controller, the sensor can be connected with a single touch, eliminating the need for training. This not only saves time and labor in installation work, but also facilitates maintenance.
*Including some distributors, etc.
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Honeywell International Inc. was founded in 1885 and headquartered in Charlotte, North Carolina. Honeywell is a diversified technology and manufacturing company to global customers in many industries such as aerospace, building technologies, performance materials, manufacturing, and safety. Honeywell produces hardware and software solutions for each industry it serves. In building technologies, Honeywell designs access controls, electrical and wiring, fire life safety, and employee training services. In aerospace, Honeywell designs cockpit systems and displays, engines, cabin management and cleaning, and health and usage monitoring.
Mor Electric Heating was founded in 1958 and is a distributor and supplier of electric heating products and controls based in Comstock Park, Michigan, United States. The company sells various electric heating products such as heating cable, comfort heaters, unit heaters, thermostats and controls, and fans and ventilation. Various manufacturers brands' products are distributed by the company including EasyHeat, Qmark, Raychem, Markel, Schaefer, and King Electric. The company listed all the clearance and discounted products on the website. Same day shipping for customers from United States and Canada are provided as service by the company.
CKD Corporation, established in 1943 under the name of Japan Aircraft Electric Co., Ltd., is a Japanese manufacturer of automation machinery and manufacturing components, headquartered in Komaki, Aichi. Their diverse portfolio includes pneumatic and fluid control components, fine system components, drive components, and labor-saving components. The company has also developed various types of automation machinery, such as transparent object inspection systems, pharmaceutical products packaging machines, and more. These products find applications in various industries, for example their automated food packaging systems are designed for maintaining food quality and hygienic conditions. Their fluid control components are used in the solar cell manufacturing process.
SMC corporation was founded in 1959 and is headquartered in Tokyo, Japan. SMC Corporation manufactures and sells automatic control equipment and filtration equipment. SMC has production facilities in 30 countries, technical development centers in Japan, the United States, Europe, and China, and sales offices, globally. SMC product lines divided by them include filter replacements, condensation prevention, heat resistance, thermos-chilling, and others. SMC provides a video library as well as product selection guide to assist customers in finding solutions and optimizing product efficiency.
DEETERELECTRONICS was established in Hughenden Valley, Bucks, UK, and the company is a designer and manufacturer of electronic sensors, switches, and control and instrumentation systems. The portfolio of the company includes a range of standard sensor products, and completely customized sensors for a wide range of applications across a broad spectrum of industries, consisting of Food & Beverages, Marine, Oil & Gas, Aerospace, Automotive, and Scientific/Medical. The company is working towards innovating and modernizing the design, development, and prototype of its products. The company has been certified by ATEX/IECEx, ISO 9001-2015, and BV Marine for all kinds of location classes.
Real Tech Inc. is a manufacturer of water quality monitoring and testing solutions, established in 2004 with headquarters in Whitby, Ontario, Canada. The company provides real-time detection of many critical water quality parameters and compounds, including UVT, nitrate, nitrite, algae, permanganate, as well as ammonium, pH, conductivity, and much more. Some of its products include water quality testing instruments, water quality photometers and colorimeters, total organic carbon (TOC) analyzers, oil in water monitors, and UV and visible spectrometers. These products are designed to provide continuous information for rapid detection of events, data-driven decision-making, and improved water quality for effluent compliance assurance.
Hypersen Technologies Co. Ltd. is a manufacturer of precision sensors established in 2015 and based in Shenzhen, China. The company produces standard and custom mechanical or optical sensing devices. These include 6-axis force torque sensors, laser cross beam sensors for edge detection or alignment, and 3D solid-state LiDAR for 3D environment scanning or mapping. The company primarily serves clients in the medical device production, industrial automation, and security sectors. Some of its notable clients include Bosch, Foxconn, and Apple.
Autonics Corporation, established in 1977 and based in Busan, South Korea, is a developer and manufacturer of automation products, which are marketed worldwide. Some of its products include sensors, peripheral connection equipment, motion devices, control devices, and process automation instruments. The automation products are used in various industries, including automotive, packaging, machine tools, metal, and marine. The company has 12 international offices spanning over 100 countries, a fully automated warehouse system, and various international quality certifications, including RoHS, CE, UL, and EAC. Its safety products meet the functional safety standards IEC 61508 and mechanical safety standards ISO 13849.
Omron Corporation, started in 1933 and headquartered in Kyoto, Japan, is a manufacturer of automation components, equipment, and systems, and it developed the first contactless proximity switch in 1960. It has four domains, including industrial automation, electronic components, healthcare, and social systems, and it provides products and services in around 120 countries and regions. Some of its products include microsensing devices, access control systems, industrial robots, surveillance cameras, and blood pressure monitors. In 1971, it developed the first online cash machine, and in 1972, it established Japan’s first welfare factory.
Spirax Sarco is a manufacturer and supplier of steam system solutions, providing products and services to industries, including food and beverage, pharmaceuticals, chemicals, and more. The company was established in the UK in 1888 and has since expanded to over 60 countries worldwide, with its US headquarters based in Blythewood, South Carolina. One of their products is the TD62 Thermodynamic Steam Trap, which offers high efficiency and reliability for condensate removal in steam systems. They received awards like 2019 Innovation Award from the Institute of Chemical Engineers (IChemE) for their EasiHeat engineered system.
TDC Power Products Co. Ltd. has been a manufacturer of transformers and related power supply products since 1993, headquartered in Taiwan. The company's diverse offerings include transformers, adaptors, ballasts, photocell time sensors, and cables. These products are essential components in various electrical and electronic devices and systems. These products also adhere to international standards, meeting the requirements of the United States, Europe, and Australia. With a strong emphasis on quality standards, the company is ISO9001 certified, ensuring its products are manufactured with strict standards.
Better Fuel Technology is a manufacturer and supplier of fuel-saving equipment such as hydrogen generators and engine controllers established in 2006 and headquartered in Ottawa, Ontario, Canada. The company’s hydrogen generator product portfolio includes CarKit which is used for vehicles with an engine size of 0-4.0 liters, SuperKit for vehicles with a 4.1-8.0liters engine, TruckKit for 8.1-12.0-sized engines, and ProKit for 12.1-16.0-sized engines. It also offers reservoirs intended for a 1-3 liter and 3-16 engine capacity. The company also offers the ProTuner, a universal fuel reduction system compatible with all engines.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Real Tech Inc. |
20.5%
|
| 2 | DEETERELECTRONICS |
12.3%
|
| 3 | Hypersen Technologies Co., Ltd. |
11.0%
|
| 4 | Honeywell International Inc |
9.6%
|
| 5 | Mor Electric Heating |
8.2%
|
| 6 | Better Fuel Technology |
6.8%
|
| 7 | Autonics Corporation |
6.8%
|
| 8 | CKD |
5.5%
|
| 9 | Spirax Sarco Inc. |
5.5%
|
| 10 | SMC Corporation. |
5.5%
|
Derivation Method
The ranking is calculated based on the click share within the sensor controller page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
2 | 28.6% |
|
Japan
|
2 | 28.6% |
|
Canada
|
2 | 28.6% |
|
United Kingdom
|
1 | 14.3% |
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