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Position Sensing Technologies: Mechanical, Optical, and Magnetic Solutions

Explore the various position sensing technologies used in automation and robotics, including mechanical, optical, and magnetic solutions. Learn about microswitches, their hysteresis and actuators, as well as advancements in optical sensing with LEDs and photodiodes, featuring modulated and unmodulated light systems. Discover magnetic sensors such as Hall sensors and reed switches, as well as inductive proximity sensors. We will also discuss discrete position sensors like capacitive and ultrasonic types, alongside advanced encoder technologies, including incremental and absolute encoders, and magnetostrictive position sensors.

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Position Sensing Technologies: Mechanical, Optical, and Magnetic Solutions

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  1. Position Sensing • Mechanical • Optical • Magnetic

  2. Mechanical Sensing - Microswitch

  3. Microswitch Operation Switch exhibits mechanical hysteresis.

  4. Microswitch Actuators

  5. Optical Sensing • LED’s and Photodiodes • Transmissive/Reflective • Modulated/Unmodulated • Light-on/Dark-on • Fiber optic

  6. Transmissive & Reflective Sensors

  7. Beam Pattern and Reflectance

  8. Specular Reflection

  9. Modulation • “Chop” LED on and off at many kHz rate • Bandpass filter after photodiode at the same frequency as chopping • Threshold circuit after BPF generates on/off output

  10. Magnetic Position Sensors • Reed switches (sense permanent magnet) • Inductive proximity sensors (eddy current) • Hall Sensors (sense permanent magnet)

  11. Inductive Proximity Sensor

  12. Inductive Proximity Sensors

  13. Hall Sensors • Hall effect: • constant voltage forces a constant current in semiconductor sheet • magnetic field flux lines perpendicular to current cause proportional voltage across sheet. • discovered by E.F.Hall in 1879 • Linear sensor needs voltage regulator and amplifier • Switch also needs threshold circuit, with hysteresis

  14. Hall Switch • Magnet motion • head-on • bypass or slide-by • Total effective air gap (TEAG) • Sensitivity, Hysteresis, & Temperature

  15. Other Discrete Position Sensors • capacitive • ultrasonic • variable reluctance (coil around magnet, senses moving ferrous material)

  16. Incremental Encoders

  17. Incremental Encoders • Encoders typically run on +5V, not +24V • Outputs are typ. not 24V compatible either

  18. Absolute Encoders • doubling resolution requires adding another photodiode/LED pair • cost is much higher than incremental • does not require seeking to establish reference location

  19. Potentiometer • A potentiometer (or pot) is a variable resistor wired to obtain a variable DC voltage proportional to position

  20. Magnetostrictive Pos. Sensor • Pulse sent down magnetostrictive material • Pulse reflects off position magnet’s field • Position is proportional to trcvd - tsent • Pulse propagates at ~2800 m/s • Resolution is ~.001” with tupdate ~1msec/in.

  21. Magnetostrictive Sensor

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