Linear displacement sensors are primarily used in wire crimping machines to monitor the position and stroke of the crimping head in real time. By providing high-precision feedback, they enable automated and precise pressure control, ensuring processing quality.

Based on the resistive voltage divider principle, they convert mechanical displacement into a linear electrical signal output.

Position Feedback: Real-time measurement of the press head’s displacement relative to the reference plane ensures consistent wire crimping depth.

Closed-Loop Control: The displacement signal is transmitted to a PLC or controller, where it is compared against the setpoint to dynamically adjust the hydraulic or servo system, preventing over- or under-pressure.

Key Points for Installation and Commissioning

To ensure measurement accuracy in the high-vibration, high-load environment of a wire crimping machine, observe the following precautions:

Alignment and Parallelism: The sensor’s pull rod or measuring rod must be strictly parallel to the direction of motion of the object being measured (the crimping head) to avoid wear or measurement errors caused by lateral forces.

Interference Suppression: Wire crimping machines are often subject to interference from motor variable-frequency drives. Use shielded cables to connect signal terminals and ensure the sensor housing is properly grounded to the machine’s metal parts to eliminate static electricity and high-frequency interference.

Zero and Full-Scale Calibration: After installation, adjust the zero offset and full-scale output. For example, adjust the output to zero when there is no pressure, and calibrate the full-scale voltage at the maximum stroke to ensure linearity.

Maintenance and Selection Recommendations

Environmental Protection: Since wire crimping machines operate in oil-contaminated environments, it is recommended to select sensors with a high protection rating (such as IP67 or higher) and to periodically inspect seals for signs of aging to prevent oil or water from entering the interior and affecting brush contact.

Stability Check: If the displayed data fluctuates, prioritize checking the stability of the supply voltage (fluctuations must be less than ±0.1%) and whether the insulation of the connecting cables is damaged.