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Cleware GmbH sensor precisely measures the actual displacement value of the detected product by detecting the absolute position of the movable magnetic ring through internal non-contact measurement and control technology; the high precision and high reliability of this sensor have been widely applied in thousands of actual cases. Since the movable magnetic ring used for position determination and the sensitive element do not come into direct contact, the sensor can be used in extremely harsh industrial environments and is not easily affected by oil stains, solutions, dust, or other contaminants. In addition, the sensor uses high-tech materials and advanced electronic processing technology, enabling it to operate in high-temperature, high-pressure, and high-vibration environments. The sensor output signal is an absolute displacement value; even if the power is interrupted and reconnected, data will not be lost, and there is no need to re-zero. Since the sensitive element is non-contact, repeated detection will not cause any wear to the sensor, greatly improving detection reliability and service life.

Cleware GmbH 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, classified according to structural characteristics and application scenarios into direct-reception readheads (also known as silicon photovoltaic cell readheads, mirror-image readheads, beam-splitter readheads, and metal grating reflection readheads).

Cleware GmbH 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 a 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 certain intervals enables electronic subdivision and direction judgment functions. For example, for a grating ruler with 50 line pairs/mm, the grating pitch is 0.02mm. If four-fold subdivision is used, counting pulses with a resolution of 5μm can be obtained, which achieves very high precision in general industrial measurement and control. Since displacement is a vector, both its magnitude and direction must be detected, requiring at least two photoelectric signals with different phases. To eliminate common-mode interference, DC components, and even harmonics, differential amplifiers composed of low-drift operational amplifiers are 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.

Cleware GmbH sensor usage precautions

When plugging and unplugging the connector between the grating ruler sensor and the digital display unit, the power should be turned off. Add a protective cover whenever possible, and promptly clean chips and oil splashed onto the ruler to strictly prevent any foreign matter from entering the grating ruler sensor housing. Regularly check whether the installation connection screws are loose. To extend the life of the dust-proof sealing strip, apply a thin layer of silicone oil evenly on the sealing strip, taking care not to splash it onto the glass grating engraved surface. To ensure the reliability of the grating ruler sensor, clean and wipe the grating ruler surface and index grating surface with an ethanol mixture (each 50%) at regular intervals to keep the glass grating ruler surface clean. Grating ruler sensors are strictly prohibited from severe vibration and impact to avoid damaging the grating ruler; if the grating ruler breaks, the sensor becomes invalid. Do not disassemble the grating ruler sensor yourself, and never arbitrarily change the relative spacing between the main grating and the secondary grating, as this may damage the sensor's precision and cause relative friction between the main and secondary gratings, damaging the chrome layer and thus the grating lines, resulting in scrapping of the grating ruler. Care should be taken to prevent oil and water contamination of the grating ruler surface to avoid disrupting the distribution of grating lines and causing measurement errors. Grating ruler sensors should avoid working in environments with severe corrosion to prevent corrosion of the grating chrome layer and grating ruler surface, which would degrade grating ruler quality.

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