A Complete Guide to the Structure of Magnetic Scale Readers

In the operation of automated production lines, CNC machine tools, and robotic equipment, the magnetic scale is a key component for displacement measurement. Its function is to collect displacement data in real time, providing a basis for the precise control of equipment. The measurement accuracy and stability of the magnetic scale depend on its well-designed structure, with all components working together to ensure the proper functioning of the measurement system.

1. Core Component: Scale Body
The scale body serves as the measurement reference carrier. Its main materials include stainless steel (wear-resistant, corrosion-resistant, suitable for complex industrial environments) and glass fiber reinforced plastic (lightweight, tough, suitable for weight-constrained scenarios).
The surface of the scale body features a magnetic signal layer, where evenly spaced magnetic grid stripes are recorded using specialized processes (mainstream spacing at the micrometer level, high-precision products at the nanometer level). Each stripe corresponds to a specific positional coordinate, directly affecting measurement accuracy.

2. Core Component: Magnetic Head
The magnetic head is responsible for collecting magnetic signals and converting them into electrical signals recognizable by equipment. It consists of:

·Magnetic-sensitive elements (Hall elements, magnetoresistive elements, etc., which generate weak electrical signals in response to magnetic field changes)

·Signal processing circuits (amplifying, filtering, and shaping signals)

·Housing (protecting components and ensuring stable gap positioning between the head and scale body)

The gap between the magnetic head and the scale body must be strictly controlled, as deviations—too large or too small—reduce measurement accuracy.

3. Auxiliary Components

1. Mounting Accessories: Include brackets, rails, and fastening screws, used to fix the scale body and magnetic head and ensure relative positional accuracy. Screws must be anti-loosening, and manufacturers provide various specifications to suit different scenarios.

2. Protective Devices: In harsh environments such as high temperature or high humidity, protective covers (to block debris) and sealing gaskets (to prevent infiltration) are required. Materials are chosen based on the environment (e.g., high-temperature resistant materials for hot conditions).

3. Signal Cables: Connect the magnetic head to the control system. Typically shielded to resist electromagnetic interference, with length and flexibility designed according to installation needs to avoid operational impact or damage.

4. Relationship Between Structure and Performance

·The material of the scale body and the precision of the magnetic signal layer determine the accuracy of the reference.

·Sensitivity of the magnetic head components and circuit performance affect measurement resolution and response speed.

·Mounting accessories ensure installation accuracy, protective devices extend lifespan, and cables ensure reliable signal transmission.

In practical applications, magnetic scales provide precise data for mold processing, machine tool measurement, and production line positioning. In the future, their structure will evolve toward greater refinement and intelligence, further enhancing performance to meet the needs of smart manufacturing.