The linear displacement sensor operates on a principle similar to that of a sliding rheostat. It functions as a voltage divider, providing an output voltage that corresponds to the actual position being measured. For optimal performance, several conditions must be met:
First, if the electronic ruler has been in use for a long time, and the sealing components have aged, or if there are many contaminants such as water or oil, this can significantly increase the brush contact resistance. As a result, the displayed readings may fluctuate continuously. In such cases, it is likely that the electronic scale of the linear displacement sensor has suffered damage and requires replacement.
Second, if the power supply capacity is insufficient, various issues may arise. A stable and sufficient power supply is essential. If the power is inadequate, it could lead to erratic behavior in the display—such as fluctuations when the glue moves or when the mold shifts, resulting in inaccurate measurements. Additionally, if the solenoid valve’s drive power is used simultaneously with the electronic scale’s power, the problem becomes more pronounced. In severe cases, a multimeter might show voltage fluctuations. If these fluctuations aren't caused by high-frequency or static interference, they could be due to an underpowered supply.
Third, electromagnetic interference (EMI) and static electricity can also cause the digital display of the linear displacement sensor to jump. To prevent this, the signal Cable of the electronic ruler should be separated from the high-voltage lines using a dedicated wire channel. The electronic ruler must be grounded properly, and its casing should maintain good contact with the ground. A shielded cable should be used for the signal line, and a portion of the electrical box should be connected to the shield. If high-frequency interference is present, the multimeter might show normal voltage, but the display will still flicker. Static interference produces similar symptoms. To check for static, you can short the cover screw of the electronic ruler with a metal part of the machine. If the interference stops immediately, it was likely static. However, high-frequency interference is harder to eliminate through this method. Devices like frequency converters or robots often cause high-frequency interference, so try turning them off to see if the issue resolves.
Fourth, during operation, if the display data at a certain point shows regular fluctuations, or if the data disappears altogether, it's important to check for damaged insulation in the connecting wires or any short circuits caused by the wires touching the machine's casing.
Fifth, the power supply voltage must remain stable. Industrial applications typically require a stability of ±0.1%. For example, if the reference voltage is 10V, a fluctuation of ±0.01V is acceptable. Otherwise, the display may show unstable readings. However, if the fluctuation in the display doesn't exceed the voltage variation, the sensor is likely functioning correctly.
Sixth, the alignment of the linear displacement sensor must be precise. While parallelism can tolerate an error of up to ±0.5mm, and angular deviation up to ±12°, excessive errors in either can cause the display to jitter. In such cases, adjustments to both parallelism and angle are necessary.
Lastly, during installation, care must be taken to ensure that the three wires of the electronic ruler are connected correctly. The power line and output line must not be swapped. Incorrect wiring can result in significant linearity errors, poor control accuracy, and frequent display jitter.
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