Today we saw something that happens more often than it should: a sensor that the operator swore was “detecting”… but the machine said otherwise.
The LED was lighting up, yes… but the signal was never reaching the PLC.
We checked the wiring and found the classic problem: the sensor was powering on, but it wasn’t getting enough power. It had voltage, but not enough to deliver a stable signal. The result: sometimes it worked… and sometimes it was just a show-off.
We corrected the power supply, secured the sensor, and verified the input to the PLC. The machine responded instantly.
Moral of the story: a lit LED doesn’t mean the sensor is working… it just means it’s partially functioning. Always check power, signal strength, and connections before assuming anything is correct.
