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NEWSTEO sensor is a device that converts optical signals into electrical signals. Its working principle is based on the photoelectric effect. The photoelectric effect refers to the phenomenon where electrons in a material absorb photon energy when light irradiates certain substances, resulting in corresponding electrical effects. Based on the different phenomena of the photoelectric effect, it is classified into three categories: external photoelectric effect, internal photoelectric effect, and photovoltaic effect. Photoelectric devices include phototubes, photomultiplier tubes, photoresistors, photodiodes, phototransistors, and photocells. The performance and characteristic curves of photoelectric devices are analyzed.

NEWSTEO sensor structure

It consists of two parts: the scale grating and the grating readhead. The figure on the right shows the structure of the grating ruler. The key part of the grating detection device is the grating readhead, which consists of a light source, condensing lens, index grating, photoelectric elements, and adjustment mechanisms. There are many structural forms of grating readheads, which are divided into direct-receiving readheads (also known as silicon photocell readheads, mirror-image readheads, beam-splitter readheads, and metal grating reflective readheads) based on structural characteristics and application scenarios.

NEWSTEO sensor principle

The essence of a grating displacement sensor is to measure position using the grating pitch as a standard ruler. High-resolution grating rulers are generally expensive and difficult to manufacture. To improve system resolution, Moiré fringes need to be subdivided; grating ruler sensor systems mostly use electronic subdivision methods. When two gratings overlap with a slight inclination, Moiré fringes are generated in the direction roughly perpendicular to the grating lines. As the grating moves, the Moiré fringes move up and down accordingly. This converts the measurement of grating pitch into the measurement of the number of Moiré fringes. Within one Moiré fringe width, placing 4 photoelectric devices at specific intervals enables electronic subdivision and direction judgment functions. For example, for a grating ruler with 50 line pairs/mm, its grating pitch is 0.02mm. If four-fold subdivision is used, counting pulses with a resolution of 5μm can be obtained, which achieves high precision in general industrial measurement and control. Since displacement is a vector, both its magnitude and direction must be detected; therefore, at least two photoelectric signals with different phases are required. To eliminate common-mode interference, DC components, and even harmonics, a differential amplifier composed of low-drift operational amplifiers is typically used. The 4 photoelectric signals obtained from 4 photosensitive devices are sent to the input terminals of 2 differential amplifiers respectively. The two signals output from the differential amplifier have a phase difference of π/2. To obtain direction judgment and counting pulses, these two signals need to be shaped, first into square waves with a duty cycle of 1:1. Then, by comparing the phase of the square waves, the movement direction of the grating ruler can be determined. By counting the square wave pulses, the displacement and speed of the grating ruler can be obtained.

NEWSTEO sensor usage precautions

When plugging and unplugging the connector of the linear encoder sensor and the digital readout unit, ensure the power is turned off. Install an external protective cover whenever possible, and promptly remove chips and oil that splash onto the scale to strictly prevent any foreign matter from entering the housing of the linear encoder sensor. Regularly check whether the mounting and connection screws are loose. To extend the service life of the dust-proof sealing strip, apply a thin, even layer of silicone oil to the strip, taking care not to let it splash onto the glass grating etched surface. To ensure reliable operation of the linear encoder sensor, periodically clean and wipe the linear encoder scale surface and the index grating surface with an ethanol mixture (50%) to keep the glass linear encoder scale surface clean. The linear encoder sensor must not be subjected to severe vibration or impact, as this may damage the linear encoder scale; if the scale fractures, the sensor will fail. Do not disassemble the linear encoder sensor yourself, and never arbitrarily change the relative gap between the main scale and the secondary scale. Doing so may compromise the accuracy of the sensor and cause relative friction between the main and secondary scales, damaging the chrome layer and thus the grating lines, which renders the linear encoder scale unusable. Prevent oil and water from contaminating the linear encoder scale surface to avoid disrupting the distribution of the grating lines, which can cause measurement errors. Avoid operating the linear encoder sensor in environments with severe corrosive effects to prevent corrosion of the chrome layer and the scale surface, which would degrade the quality of the linear encoder scale.

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