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Capacitive Displacement Sensor Review

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Electrical Capacitive Displacement Sensor Review

Electrical Capacitive displacement sensors are non-contact devices that are capable of high-resolution measurement of the position. Theses sensors are also used in applications measure the thickness or density of non-conductive materials.

Basic Operation Theory:

Capacitive sensors use the electrical characteristics of "Capacitance Displacement Sensor" to sense measurements. Changes in the distance and dielectric between adjacent surfaces changes capacitance. The change of capacitance is what capacitive sensors use to indicate changes in position of a target.


Precision positioning

One of the more common applications of capacitive sensors is for precision positioning. Capacitive displacement sensors can be used to measure the position of objects down to the nanometer level. This type of precise positioning is used in the semiconductor industry where silicon wafers need to be positioned for exposure. Capacitive sensors are also used to pre-focus the electron microscopes used in testing and examining the wafers.

Disc drive industry

In the disc drive industry, capacitive displacement sensors are used to measure the runout (a measure of how much the axis of rotation deviates from an ideal fixed line) of disc drive spindles. By knowing the exact runout of these spindles, disc drive manufacturers are able to determine the maximum amount of data that can be placed onto the drives. Capacitive sensors are also used to ensure that disc drive platters are orthogonal to the spindle before data is written to them.

Precision thickness measurements

Capacitive displacement sensors can be used to make very precise thickness measurements. Capacitive displacement sensors operate by measuring changes in position. If the position of a reference part of known thickness is measured, other parts can be subsequently measured and the differences in position can be used to determine the thickness of these parts. In order for this to be effective using a single probe, the parts must be completely flat and measured on a perfectly flat surface. If the part to be measured has any curvature or deformity, or simply does not rest firmly against the flat surface, the distance between the part to be measured and the surface it is placed upon will be erroneously included in the thickness measurement. This error can be eliminated by using two capacitive sensors to measure a single part. Capacitive sensors are placed on either side of the part to be measured. By measuring the parts from both sides, curvature and deformities are taken into account in the measurement and their effects are not included in the thickness readings.

The thickness of plastic materials can be measured with the material placed between two electrodes a set distance apart. These form a type of capacitor. The plastic when placed between the electrodes acts as a dielectric and displaces air (which has dielectric constant of 1, different than the plastic). Consequently the capacitance between the electrodes changes. The capacitance changes can then be measured and correlated with the material's thickness.

Capacitive sensors circuits can be constructed that are able to detect changes in capacitance on the order of a 10−5 picofarads (10 attofarads).

Non-conductive targets

While capacitive displacement sensors are most often used to sense changes in position of conductive targets, they can also be used to sense the thickness and/or density of non-conductive targets as well. A non-conductive object placed in between the probe and conductive target will have a different dielectric constant than the air in the gap and will therefore change the Capacitance between probe and target. (See the first equation above) By analyzing this change in capacitance, the thickness and density of the non-conductor can be determined.

Machine tool metrology

Capacitive displacement sensors are often used in metrology applications. In many cases, sensors are used “to measure shape errors in the part being produced. But they also can measure the errors arising in the equipment used to manufacture the part, a practice known as machine tool metrology”. In many cases, the sensors are used to analyze and optimize the rotation of spindles in various machine tools, examples include surface grinders, lathes, milling machines, and air bearing spindles. By measuring errors in the machines themselves, rather than simply measuring errors in the final products, problems can be dealt with and fixed earlier in the manufacturing process.

Assembly line testing

Capacitive displacement sensors are often used in assembly line testing. Sometimes they are used to test assembled parts for uniformity, thickness or other design features. At other times, they are used to simply look for the presence or absence of a certain component, such as glue. Using capacitive sensors to test assembly line parts can help to prevent quality concerns further along in the production process.



Capacitive Sensor Theory, Application and Design

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