In this tutorial we will look at a variety of devices which are classed as Input Devices and are therefore called “Sensors” and in particular those sensors which are Positional in nature.

As their name implies, Position Sensors detect the position of something which means that they are referenced either to or from some fixed point or position. These types of sensors provide a “positional” feedback.

One method of determining a position, is to use either “distance”, which could be the distance between two points such as the distance travelled or moved away from some fixed point, or by “rotation” (angular movement). For example, the rotation of a robots wheel to determine its distance travelled along the ground. Either way, Position Sensorscan detect the movement of an object in a straight line using Linear Sensors or by its angular movement using Rotational Sensors.

The most commonly used of all the “Position Sensors”, is the potentiometer because it is an inexpensive and easy to use position sensor. It has a wiper contact linked to a mechanical shaft that can be either angular (rotational) or linear (slider type) in its movement, and which causes the resistance value between the wiper/slider and the two end connections to change giving an electrical signal output that has a proportional relationship between the actual wiper position on the resistive track and its resistance value. In other words, resistance is proportional to position.

Potentiometer

Potentiometers come in a wide range of designs and sizes such as the commonly available round rotational type or the longer and flat linear slider types. When used as a position sensor the moveable object is connected directly to the rotational shaft or slider of the potentiometer.

A DC reference voltage is applied across the two outer fixed connections forming the resistive element. The output voltage signal is taken from the wiper terminal of the sliding contact as shown below.

This configuration produces a potential or voltage divider type circuit output which is proportional to the shaft position. Then for example, if you apply a voltage of say 10v across the resistive element of the potentiometer the maximum output voltage would be equal to the supply voltage at 10 volts, with the minimum output voltage equal to 0 volts. Then the potentiometer wiper will vary the output signal from 0 to 10 volts, with 5 volts indicating that the wiper or slider is at its half-way or centre position.

The output signal (Vout) from the potentiometer is taken from the centre wiper connection as it moves along the resistive track, and is proportional to the angular position of the shaft.

While resistive potentiometer position sensors have many advantages: low cost, low tech, easy to use etc, as a position sensor they also have many disadvantages: wear due to moving parts, low accuracy, low repeatability, and limited frequency response.

But there is one main disadvantage of using the potentiometer as a positional sensor. The range of movement of its wiper or slider (and hence the output signal obtained) is limited to the physical size of the potentiometer being used.

For example a single turn rotational potentiometer generally only has a fixed mechanical rotation of between 0o and about 240 to 330o maximum. However, multi-turn pots of up to 3600o (10 x 360o) of mechanical rotation are also available.

Most types of potentiometers use carbon film for their resistive track, but these types are electrically noisy (the crackle on a radio volume control), and also have a short mechanical life.

Wire-wound pots also known as rheostats, in the form of either a straight wire or wound coil resistive wire can also be used, but wire wound pots suffer from resolution problems as their wiper jumps from one wire segment to the next producing a logarithmic (LOG) output resulting in errors in the output signal. These too suffer from electrical noise.

For high precision low noise applications conductive plastic resistance element type polymer film or cermet type potentiometers are now available. These pots have a smooth low friction electrically linear (LIN) resistive track giving them a low noise, long life and excellent resolution and are available as both multi-turn and single turn devices. Typical applications for this type of high accuracy position sensor is in computer game joysticks, steering wheels, industrial and robot applications.