German ZUMBACH sensors ZUMBACH models ZUMBACH prices

ZUMBACH 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 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.

ZUMBACH sensor structure

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 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 classified into direct-receiving readheads (also known as silicon photovoltaic cell readheads, mirror-image readheads, beam-splitter readheads, and metal grating reflective readheads) based on their structural characteristics and application scenarios.

ZUMBACH sensor principle

The essence of a grating displacement sensor is to perform measurement by using the grating pitch as a standard ruler. High-resolution linear encoder 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 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 move up and down accordingly. This converts the measurement of the 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 determination. For example, for a linear encoder scale 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, differential amplifiers composed of low-drift operational amplifiers are typically used. The 4 photoelectric signal paths obtained from 4 photosensitive devices are sent to the input terminals of 2 differential amplifiers respectively. The two signal paths output from the differential amplifiers have a phase difference of π/2. To obtain direction determination and counting pulses, these two signal paths need to be shaped, first into square waves with a duty cycle of 1:1. Then, by comparing the phases of the square waves, the movement direction of the linear encoder scale can be determined. By counting the square wave pulses, the displacement and speed of the linear encoder scale can be obtained.

ZUMBACH sensor usage precautions

When plugging or unplugging the connector between the linear encoder scale sensor and the digital display unit, ensure the power is turned off. Add a protective cover whenever possible, and promptly clean chips and oil splashed onto the scale to strictly prevent any foreign matter from entering the housing of the linear encoder scale sensor. Regularly check whether the installation 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 ruling surface. To ensure the reliability of the linear encoder scale sensor, clean and wipe the scale surface and index grating surface periodically with an ethanol mixture (each 50%) to keep the glass scale surface clean. Linear encoder scale sensors are strictly prohibited from severe vibration or impact to avoid damaging the scale; if the scale breaks, the sensor will fail. Do not disassemble the linear encoder scale sensor yourself, and do not arbitrarily change the relative gap between the main scale and the secondary scale, as this may damage the sensor's precision and cause relative friction between the main and secondary scales, damaging the chrome layer and thus the grating lines, resulting in scrapping of the scale. Prevent oil and water contamination of the scale surface to avoid disrupting the grating line distribution and causing measurement errors. Avoid operating linear encoder scale sensors in environments with severe corrosion to prevent corrosion of the grating chrome layer and scale surface, which would compromise quality.

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