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POPADENTSCHUK sensors, also known as torque sensors, torsion sensors, torque transducers, or torque meters, are divided into two main categories: dynamic and static. Dynamic torque sensors are also referred to as torque transducers, torque-speed sensors, non-contact torque sensors, or rotary torque sensors. Torque sensors detect the twisting moment on various rotating or non-rotating mechanical components. They convert the physical changes in torsional force into precise electrical signals. Torque sensors can be used in the manufacture of viscometers and electric (pneumatic, hydraulic) torque wrenches. They offer advantages such as high precision, fast frequency response, good reliability, and long service life.

POPADENTSCHUK Sensor Classification

1) Contact Sensors: The contacts of contact sensors are actuated by the contact and compression of two objects. Common types include limit switches and two-dimensional matrix position sensors. Limit switches have a simple structure, reliable operation, and low cost. When an object moves and hits a limit switch, its internal contacts actuate to complete control. For example, if limit switches are installed at both ends of the X, Y, and Z axes of a machining center, the travel range can be controlled. Two-dimensional matrix position sensors are installed inside mechanical grippers to detect the contact position with an object. 2) Proximity Sensors: A proximity switch is a switch that emits an "actuation" signal when an object approaches within a set distance, without requiring direct contact. There are many types of proximity switches, mainly including electromagnetic, photoelectric, differential transformer, eddy current, capacitive, reed switch, and Hall effect types. The application of proximity switches on CNC machine tools mainly includes tool selection control for the tool turret, worktable travel control, and piston stroke control for oil and air cylinders.

POPADENTSCHUK Sensor Working Principle

Crankshaft position sensors are typically installed at the front end of the crankshaft (at the pulley), at the rear end near the large flywheel, or in the middle of the crankshaft. In early vehicle models, they were also installed inside the distributor. They are one of the most important sensors in the control system. Their functions include detecting engine speed, hence they are also called speed sensors; and detecting the piston top dead center (TDC) position, hence they are also called TDC sensors. This includes detecting TDC signals for each cylinder used for ignition control, and the TDC signal for the first cylinder used for sequential fuel injection control.

POPADENTSCHUK Sensor Industry Applications

1) Brushless DC Motors: Position sensors are one of the three main components of a brushless DC motor system and are the primary feature distinguishing them from brushed DC motors. Their function is to detect the position of the main rotor during motion, converting the position signal of the rotor magnet poles into electrical signals. This provides correct commutation information to the logic switching circuit to control their conduction and cutoff, causing the current in the motor armature windings to commutate sequentially with changes in rotor position. This forms a stepwise rotating magnetic field in the air gap, driving the permanent magnet rotor to rotate continuously. Brushless DC motors require position sensors to measure rotor position; the motor controller uses these signals to synchronize inverter commutation with the rotor, driving continuous motor operation. Although brushless DC motors can detect rotor position via back electromotive force (back-EMF) generated in the stator windings, thereby eliminating the need for position sensors, the back-EMF signal is too weak to be detected during startup due to low speed. Hall effect sensor chips used as position sensors for brushless DC motors are divided into switching and latching types. For e-bike motors, both types of Hall sensor chips can be used to accurately measure the position of the rotor magnets. The performance of brushless DC motors made with these two types of Hall sensor chips, including output power, efficiency, and torque, shows no difference, and they are compatible with the same motor controllers. The application of position sensors reduces motor operating noise, improves motor life and performance, and achieves energy savings. The application of position sensors undoubtedly provides strong impetus to the development of the motor market. 2) Crankshaft and Camshaft: The function of the position sensor is to collect crankshaft rotation angle and engine speed signals and input them to the Electronic Control Unit (ECu) to determine ignition timing and fuel injection timing. To distinguish it from the Crankshaft Position Sensor (CPS), the Camshaft Position Sensor is generally denoted as CIS. The function of the camshaft position sensor is to collect the position signal of the camshaft controlling valve timing and input it to the ECU, allowing the ECU to identify the compression TDC of cylinder 1, thereby enabling sequential fuel injection control, ignition timing control, and knock control. Additionally, the camshaft position signal is used to identify the first ignition timing during engine start-up. Because the camshaft position sensor can identify which cylinder's piston is about to reach TDC, it is also called a cylinder identification sensor.

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