Displacement sensors Manufacturers online

Displacement sensors are devices that precisely detect linear or rotational movements and convert them into an evaluable electrical signal.

They play a central role in many technical systems and are widely used in machines, vehicles, industrial plants and measuring systems.

The following is an overview of the basic principle, sensor technologies and functionalities of displacement sensors, their areas of application, advantages and challenges and limitations in their use:

Basic principle of displacement sensors:

Displacement sensors measure the linear displacement of an object along an axis or occasionally a rotary movement (in which case they are often referred to as angle sensors).
The sensor converts this movement into an electrical signal that is proportional to the movement.
The measurement can be contact-based, e.g. with wipers, cables and probes, or contactless, e.g. inductive or optical.

Sensor technologies and functions of displacement sensors:

Displacement sensors use different physical principles. Here are the most important types according to their mode of operation:

1. Potentiometric displacement sensors:
   These sensors work with a resistance element (potentiometer). A movable wiper changes the resistance depending on the position.
   The change in voltage at the output is proportional to the displacement.
   They are simple, inexpensive and provide analog signals, but are subject to wear due to mechanical contact.
2. Draw-wire displacement sensors:
   A cable permanently tensioned by a spring mechanism rotates a drum by pulling it out of the sensor.
   The rotation of the drum is detected by an internal sensor. This results in precise linear position determination.
   They are used wherever linear movements need to be measured reliably and robustly - especially over long distances.
3. Inductive displacement sensors:
   They measure changes in the magnetic field - for example, due to the displacement of a metallic core in a coil.
   These sensors are robust, durable and insensitive to dirt or moisture.
   They are often used in harsh industrial environments.
4. Magnetostrictive displacement sensors:
   These are based on the propagation of sound pulses along a magnetostrictive wire.
   A position magnet generates an interaction whose transit time correlates to the position.
   These sensors are very precise and wear-free.
5. Optical displacement sensors:
   They use light beams or lasers that are reflected or interrupted.
   The change in the light signal, e.g. through time measurement or triangulation, allows the position to be determined.
   Optical sensors offer the highest resolution, but are sensitive to contamination.
6. Capacitive displacement sensors:
   They measure the change in capacitance between two electrodes as they approach each other.
   This technology allows very precise, high-resolution measurements, but is mainly used for small travel distances and in clean environments.
7. Ultrasonic and radar-based sensors:
   They determine the distance via transit time measurement of sound or electromagnetic waves.
   These non-contact systems are well suited for long distances or difficult environments, e.g. with dust or liquids.

Areas of application for displacement sensors:

Displacement sensors can be found in numerous industries and applications. Depending on the technology and accuracy, they cover a broad spectrum:

1. Mechanical and plant engineering
Position detection of tools, grippers or conveyor systems.
monitoring movements in CNC machines, robots and presses.

2. Automotive engineering:
Detection of the pedal or seat position.
Position measurement on chassis components or electric drives.

3. Aerospace:
Control of flaps, rudders or landing gear.
Precise position control for extension mechanisms.

4. Medical technology:
Measuring the position of surgical instruments.
Linear guides in medical devices such as MRI or CT.

5. Metrology and research:
Precise position measurement in experiments or calibration laboratories.
Sensory detection of movements in scientific studies.

6. Civil engineering and geotechnics:
monitoring of settlements, deflections or deformations on supporting structures.
Linear measuring systems for test benches or strain measurement systems.

Advantages of modern displacement sensors:

• High precision: depending on the type, a resolution in the micrometer range can be achieved.
• Low maintenance: Many non-contact sensors operate wear-free.
• Robustness: Inductive and magnetostrictive sensors in particular are resistant to external influences.
• Variety: Sensors for every application - from microscope technology to telescopic extensions in mining equipment.

Challenges and limits of displacement sensors:

• Environmental influences: Dust, oil, vibration or extreme temperatures can affect some sensor types.
• Mounting accuracy: Many sensors require precise adjustment during installation.
• Costs with high accuracy: High-resolution sensors or special solutions can be expensive.
• Sensitivity to electromagnetic interference: Especially with analog outputs and long cables.

Displacement sensors are indispensable components of modern automation, measurement and control technology. The choice of the right sensor technology depends crucially on the application, the environment and the desired measurement parameters. Whether contact or non-contact, whether accurate to the micrometer or over long distances - there are suitable displacement sensor solutions for almost every technical challenge.

Here is an overview of the most important points to consider when purchasing displacement sensors.

When purchasing displacement sensors, it is crucial to know the exact requirements of the specific application and to compare these with the technical and economic possibilities of the available sensor solutions. As displacement sensors are used in many industries with different conditions, a structured selection is particularly important to ensure reliability, accuracy, long-term stability and cost-effectiveness.

• Different sensor types are suitable for different applications. Common technologies include:
• Potentiometric. Inexpensive, but susceptible to mechanical wear.
• Inductive: Robust and wear-free for harsh industrial environments.
• Magnetostrictive: Highly precise and durable, but more expensive.
• Optical (laser, triangulation): Very high resolution, sensitive to contamination.
• Capacitive: For very fine movements over short distances.
• Draw-wire based: Ideal for long travel distances and simple installation.
• The selection should be based on the location, required accuracy and environmental conditions.
• A key point is the actual measuring path required. If this is too short, the sensor may be mechanically damaged or may not evaluate the end range correctly. If it is too large, the resolution and dynamics often suffer.
• The installation situation is just as important: Is there enough space? Will the sensor or the object to be measured be moved? Are there swiveling or curved movements? The design and mechanics must be well planned, especially in cramped or difficult to access installation locations.
• Depending on the application, a certain measuring accuracy is required. This includes
• Resolution: How the smallest changes are detected.
• Repeat accuracy: Whether a point is always detected in the same way with multiple movements.
• Linearity error: Deviation from the ideal line between position and output signal.
• For precision measurements, e.g. in test benches or robotics, high demands are placed on these values. In other cases, e.g. rough position monitoring, simpler sensors are sufficient.
• The type of output signal must match the control or evaluation unit used:
• Analog signals e.g. 0-10 V, 4-20 mA: Easy to integrate, but susceptible to interference with long cables.
• Digital signals e.g. SSI, CANopen, IO-Link, RS485: Higher interference immunity, often also more functions e.g. diagnostics, parameterization.
• Incremental or absolute encoders: Relevant for rotary movements or position systems with feedback.
• The selection depends heavily on the existing control technology.
• The sensor must be matched to the physical conditions on site:
• Temperature range: Relevant in outdoor areas or in applications close to motors or heating elements.
• Moisture, dust, oil, chemicals: Observe housing with IP protection class and material resistance.
• Vibrations and shocks: Select mechanically stable sensors with internal damping behavior.
• EMC resistance: Especially with analog sensors or in environments with strong electromagnetic interference, e.g. welding systems, protection against electromagnetic influences is required.
• A sensor that fits technically but is difficult to install can become a source of errors in everyday life. Therefore:
• Ease of mounting: standard holes, mounting aids, flexible brackets are advantageous.
• Mounting tolerances: Some sensors need to be precisely aligned, others are insensitive to small misalignments.
• Calibration: Check whether and how the sensor needs to be adjusted initially - especially for analog outputs.
• The economic life of a sensor is highly dependent on the type of application. Important questions are:
• How many motion cycles can the sensor mechanically withstand?
• Are there any wearing parts, e.g. in the case of potentiometric or cable-based sensors?
• Does the sensor need to be recalibrated regularly?
• Is there experience or field reports on long-term stability?
• In series systems or systems that are difficult to access, maintenance-free and durable solutions should be used wherever possible.
• A sensor is only as good as its manufacturer and its quality assurance. Please note:
• Proven manufacturers with references in similar industries.
• Long-term availability - particularly important in series production or spare parts strategies.
• Technical support and documentation - from installation to fault diagnosis.
• Certifications - such as ISO 9001, CE, RoHS, REACH or industry-specific standards, e.g. railroad technology, medical technology, automotive industry.
• An inexpensive sensor can become more expensive if it fails frequently or does not fit optimally into the system architecture.

Purchasing displacement sensors requires a good combination of technical analysis, knowledge of the environmental conditions and strategic selection of reliable components. In addition to key technical data such as measuring range, accuracy or interface, ease of installation, long-term availability, robustness and service quality are also crucial. The best possible sensor solution always results from the context of the application - blanket decisions without reference to the application often lead to problems during operation.

Displacement sensors can be obtained from various suppliers. Comprehensive information about manufacturers and suppliers of Displacement sensors from all over the world can be found on exportpages.