German THERMATEC PROCESS sensor, THERMATEC PROCESS model, THERMATEC PROCESS price

THERMATEC PROCESS sensors are components that convert changes in non-electrical quantities (such as speed and pressure) into changes in electrical quantities. Depending on the non-electrical quantity being converted, they can be classified into pressure sensors, speed sensors, temperature sensors, etc., and serve as parts and accessories for measurement and control instruments and equipment.

THERMATEC PROCESS 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 scale. The key part of the grating detection device is the grating readhead, which consists of a light source, a condenser lens, an index grating, photoelectric elements, and an adjustment mechanism. There are many structural forms of grating readheads, which are classified into direct-reception readheads (also known as silicon photovoltaic cell readheads), mirror-image readheads, beam-splitter readheads, and metal grating reflection readheads based on their structural characteristics and application scenarios.

THERMATEC PROCESS sensor principle

The essence of a grating displacement sensor is to measure position using the grating pitch as a standard ruler. High-resolution grating scales are generally expensive and difficult to manufacture. To improve system resolution, Moiré fringes need to be subdivided; grating scale sensor systems mostly use electronic subdivision methods. When two gratings overlap at a slight angle, 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 the grating pitch into the measurement of the number of Moiré fringes. Within the width of one Moiré fringe, placing 4 photoelectric devices at specific intervals enables electronic subdivision and direction determination. For example, for a grating scale with 50 line pairs per mm, the grating pitch is 0.02mm. With four-fold subdivision, 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, 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. The two signals output from the differential amplifiers have a phase difference of π/2. To obtain direction determination and counting pulses, these two signals must first be shaped into square waves with a duty cycle of 1:1. Then, by comparing the phases of the square waves, the movement direction of the grating scale can be determined. By counting the square wave pulses, the displacement and speed of the grating scale can be obtained.

THERMATEC PROCESS 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 splashed 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 splash it onto the glass grating etched 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%), keeping 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 linear encoder sensor will fail. Do not disassemble the linear encoder sensor yourself, and never arbitrarily change the relative spacing between the main scale and the secondary scale. Doing so may compromise the accuracy of the linear encoder 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. Take care to prevent oil 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 linear encoder scale surface, which would degrade the quality of the linear encoder scale.

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