Linear displacement sensors are precision measurement devices widely used in industrial automation, machinery manufacturing, aerospace, and other fields. By extending and retracting a wire rope, these sensors measure the displacement of objects, offering high accuracy, reliability, and easy installation. This guide outlines the operation and application of linear displacement sensors to help you understand and use these devices better. If you are interested in Briterencoder linear displacement sensors or have any questions, please contact the Briterencoder team.
1. Choosing the Right Linear Displacement Sensor
①、Clarify Measurement Requirements
Range Selection: Choose the sensor range based on the actual distance to be measured. The range should cover the required distance with enough margin to avoid exceeding the sensor’s capacity. For example, if you need to measure around 80mm, select a sensor with a 100mm range. Briterencoder offers custom linear displacement sensors with ranges up to 10 meters.
Accuracy Requirements: Select the appropriate sensor accuracy level based on your precision needs. Digital signals typically offer higher linear accuracy, while analog signals might have slightly larger errors, influenced by environmental factors. Briterencoder’s high-precision linear displacement sensors can achieve up to 0.1% accuracy, with repeatability as high as 0.01%.
②、Consider the Working Environment
Temperature: Ensure that the sensor operates within the required temperature range. Extreme temperatures can affect the sensor’s performance and lifespan. Briterencoder linear displacement sensors operate safely between -40°C and 85°C.
Protection Level: Choose a sensor with an adequate protection level based on environmental factors such as dust or moisture. In dusty environments, select sensors with a higher protection level. Briterencoder offers sensors with IP68 waterproofing, suitable for underwater use. Intrinsically safe and explosion-proof models are also available for environments like mining and oil fields.
③、Match Power Supply and Signal Output
Power Supply Voltage: Choose a sensor compatible with the system’s power supply. Linear displacement sensors typically operate with common supply voltages such as DC5V, DC5-12V, or DC5-24V. Ensure the sensor’s voltage matches your system’s requirements. Briterencoder sensors support DC5-24V for digital signals and DC12-24V for analog signals.
Signal Output: Select the appropriate output signal type based on the system’s interface and signal requirements. Linear displacement sensors can output both digital and analog signals. Digital signals generally offer higher accuracy, while analog signals provide wider compatibility. Briterencoder supports various communication interfaces to meet different needs.
④、Consider Other Factors
Installation Space: Select a sensor that fits the available installation space. While linear displacement sensors typically have compact dimensions, different models may vary in size and shape. Briterencoder also offers miniature models, which are as small as a coin in width.
Lifespan: Consider the sensor’s durability and reliability. Choosing a robust sensor ensures long-term stable performance. Briterencoder sensors have undergone rigorous testing, with over 5 million safe extraction cycles under normal conditions.
Cost-Effectiveness: Balance precision and performance with cost to choose a sensor with the best value for your needs.
2、Installation and Fixing
Mounting Brackets: Secure the mounting brackets at the measurement location, ensuring they are stable.
Sensor Installation: Attach the linear displacement sensor to the mounting bracket using the mounting holes, ensuring the sensor is aligned with the measurement direction.
Wire Rope Extension: Slowly extend the wire rope to its maximum range, keeping it parallel to the sensor’s side to avoid friction.
Adjustment and Calibration: Align the sensor with the measurement points, following the calibration instructions to ensure accurate readings.
3、Operation and Measurement
Manual Reset: Place the sensor in the position to be measured, ensuring it is stable and in the correct measurement posture. Gently pull the string by hand to bring the sensor to the zero point or the set starting point. Press the zero button to reset the current measurement to zero or the set starting value. Place the sensor in the position to be measured. Depending on the specific model and functions of the sensor, activate the automatic zeroing function. This may involve pressing a specific button, sending a specific command, or changing certain sensor parameters. Wait for the sensor to automatically recognize and perform the zeroing operation. The Brit Stretch Rope Displacement Sensor can set the zero point quickly through the functional wire provided at the factory. By short-circuiting the black and yellow wires for 100ms when powered on, zero can be easily set, and factory settings, midpoints, etc., can also be quickly restored through the functional wire, making the operation very efficient.
Measurement process: Adjust the length of the wire rope as needed, and read the position information output by the sensor.
4、Maintenance and Care
Regular Inspection: Check the installation, mechanical components, and cables for any damage.
Sensor Cleaning: Clean the sensor and the wire rope to ensure proper operation.
Rope Protection: Avoid contact between the wire rope and sharp objects.
Vibration Reduction: Minimize vibrations and, if necessary, install anti-vibration components.
Avoid Overloading: Ensure the sensor operates within its range to avoid damage.
5、Precautions
Wiring: Ensure the power is off when wiring to avoid damage.
Operating Speed: Slow down the operating speed to extend the sensor’s lifespan.
Screw Fixing: Do not loosen the screws or move the locking ring.
Storage: Store the sensor in a dry, well-ventilated area to prevent moisture or corrosion.
By following these guidelines, you can optimize the operation and application of linear displacement sensors, ensuring accurate measurements and long-term performance. If you encounter any issues or have questions, consult the user manual or contact Briterencoder for assistance.
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