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Progressus sensors are sensors that use laser technology for measurement. They consist of a laser, a laser detector, and a measurement circuit. Laser sensors are a new type of measuring instrument; their advantages include the ability to perform non-contact long-distance measurement, high speed, high precision, large measuring range, and strong resistance to optical and electrical interference.

Progressus sensor structure

It consists of two parts: the scale grating and the grating readhead. The figure on the right shows the structure of the linear encoder scale. The key component of the grating detection device is the grating readhead, which comprises a light source, a condensing lens, an index grating, photoelectric elements, and an adjustment mechanism. There are many structural forms of grating readheads. Based on the structural characteristics of the readhead and the application scenarios, they are classified into direct-receiving readheads (also known as silicon photovoltaic cell readheads, mirror-image readheads, beam-splitter readheads, and metal grating reflective readheads).

Progressus 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 adopt electronic subdivision methods. When two gratings overlap with a slight inclination angle, Moiré fringes are generated in a direction roughly perpendicular to the grating lines. As the grating moves, the Moiré fringes also move up and down. This converts the measurement of the grating pitch into the measurement of the number of Moiré fringes. Within the width of one Moiré fringe, placing 4 photoelectric devices at certain intervals enables electronic subdivision and direction determination functions. For example, for a grating ruler with 50 line pairs/mm, its grating pitch is 0.02mm. If four-fold subdivision is adopted, counting pulses with a resolution of 5μm can be obtained, which has reached a very 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 usually 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 determination 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.

Progressus sensor usage precautions

When plugging or unplugging the connector of the linear encoder sensor and the digital display unit, ensure the power is switched off. Install a protective cover whenever possible, and promptly clean away chips and oil splashed onto the scale. Strictly prevent any foreign matter from entering the housing of the linear encoder sensor. Regularly check whether the mounting 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 splash it onto the glass grating ruling surface. To ensure the reliability of the linear encoder sensor, clean and wipe the linear encoder scale surface and the index grating surface at regular intervals using an ethanol mixture (50%) to keep the glass grating 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. Otherwise, you 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, rendering the linear encoder scale unusable. Take care to prevent oil stains and water from contaminating the linear encoder scale surface, as this can disrupt the distribution of the grating lines and cause measurement errors. Avoid operating the linear encoder sensor in environments with severe corrosive effects, to prevent corrosion of the grating chrome layer and the scale surface, which would degrade the quality of the linear encoder scale.

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