How To Select Potentiometric Position

Sensor
Making the right decision while selecting a component is a big deal as it could
make or break your product. Selecting a potentiometer becomes a big issue
especially when the market has a lot of alternatives, and that is where this
article comes in.
By Sneha Ambastha

Position sensors are considered to be a large family with many different types of sensors, however each
sensor in this family is unique with respect to the principle on which it works and its construction. So is the
case with potentiometric position sensors, which are considered to be the most inexpensive of all position
sensors.
One important thing that I would like to clarify first is that, we are not talking about 'potentiometric sensors'.
Potentiometric sensors are used to measure the electrical potential of an electrode while no current is flowing
through it. They are a type of chemical sensor.
On the other hand, the star of this story is the potentiometric position sensor, which is used to measure
the rotary or linear displacement or position of an object using the technology developed for potential military
applications which then were adapted to industrial segments. They are also referred to as Potentiometers.
Some of these require physical contact with the moving targets whereas there are other types of
potentiometers that are non-contact types, use the Hall effect IC technology and have long life as compared
to the latter ones. One can refer a potentiometer as a normal circuit where the resistance can be changed
manually with the help of sliding contacts.

Classification
It becomes very important to understand the classification of the product we are going to purchase, as this
would help us narrow down our search. There are many different ways to classify Potentiometers. The
broader categorization is based on their function or the area of application:

Angle Sensor: These are usually round, rotary sensor used to measure the angular displacement of
the body it is in contact with. They are also referred to as rotary potentiometers.

Linear Sensor: These are found in different shapes and sizes which does not affect the linear
displacement of the body it measures.

Another way to classify them is based on the materials they are made of:

Wire wound potentiometers: These types of potentiometers are made by winding several rounds of
wire around the shaft of a material that is non-conducting. An adhesive is used to bond the turns of
the coil together. Now when body to which this is in contact with moves, the slider moves on the track
of the potentiometer and makes contact with successive turns of the coil. It is considered that larger
the number of turns of the coil, better is the coil resolution. Mathematically resolution is inversely
proportional to the number of turns, so lower the value of resolution, the better it is. The wire wound
potentiometers have low noise and are considered to be rough and tough mechanically.

Carbon film potentiometers: They are made by depositing carbon composed ink on an insulating body.
The insulating body in most of the cases is phenolicresin, which is one of the most commonly used
materials for potentiometers. These are cheap and are better in resolution than the wire wound
potentiometers. They have reasonable life and tolerable noise levels.

Plastic film potentiometers: These potentiometers are made of specially saturated plastic material with
resistance characteristics that can be controlled properly. These are used for both rotary as well as
translational slider movements. They have better resolution than the wire wound potentiometers, can
be used for a longer period of time without much wear and tear and produce low noise.

Then we can also classify them based on their design structure.

Linear taper potentiometer: In this the device has a resistive element of constant cross-section. It
does not describe the geometrical characteristics of the resistive element however it explains the
electrical characteristics of the device. In this type of sensor the resistance between the wiper and any
one end of the terminal is proportional to the distance between them.

Logarithmic potentiometer: The resistive element that it has is either tapered in from one end to the
other or the potentiometer is made of a material with varying resistivity from one end to the other. It
is called as a logarithmic potentiometer because in this the output voltage is a logarithmic function of
the slider position. They can also be simulated with a linear potentiometer using an external resistor,

however this simulation would not result in a very accurate device. These type of sensors are more
expensive.

Finally, they can be classified on their working style-contact and non-contact. All the types of potentiometers
discussed above can be classified under these categories:

Contact type: These potentiometers consist a moveable contact on an electrically resistive component.
All the earlier versions of this sensor were made from a resistive wire (like Nichrome) that was wound
around an insulating former. The moveable contact that acts as a wiper, makes some contact with the
wire that is wound and slides along it. The wiper acts as a variable resistor also known as Rheostat.
Thus this sensor works on the principle of changing resistance of the wire with respect to its length.
The resistance of the wire is considered to be directly proportional to its length, so if the length
increases, resistance does too. In order to measure the angular displacement, only two terminals of a
potentiometer are used. It works on the principle that resistance changes with change in angle. The
variable value of resistance helps us to find the actual angular displacement.

"Due to its working principle it is also sometimes referred to as Resistive Potentiometer. It is a

very special resistor with three terminals".

Non Contact type: These potentiometers have a pair of planar magnets that are disposed opposite yet
parallely to each other on a magnetic yoke. The polarity of these magnets are arranges in such a way
that they form parallel magnetic fields around magnetic detection element. This detection element is
retained on a support shaft that connects to a rotary shaft on an actuator and can rotate freely
relative to the stationary one. As soon as this rotary shaft is rotated, there is a change in the output of
the magnetic detection element which allows the detection of the rotation angle of the shaft. The noncontact types of potentiometers are considered over the contact type due to their long life and
reliability. These sensors are extremely small in number due to which Hall effect position sensors
are used as their replacement.

How to Select?
Now let us suppose a situation where we enter a shop to buy a potentiometric position sensor and find
ourselves in a dilemma of how to select one, as the shop has so many options and we do not want to buy
something that would not be accurate as per our requirement. This is a real difficult situation because the
shopkeepers cannot help us unless we tell them our requirements. In such situations a good understanding of
the different parameters of the device helps a lot. In order to select a potentiometric position sensor following
parameters should be considered are as follows.
Linear or Rotary?
This defines the motion of the sensor in order to identify it's track of movement. It helps to identify if the
sensor would be useful in calculating the angular displacement or the linear displacement.
Dimensions and Weight
This parameter is very helpful to identify the application this sensor can be used for. If a sensor is of larger
size and is very heavy, it cannot be used in smaller applications. Dimension is usually measured in millimeter
(mm) whereas weight in grams (g).
Life
These sensors are all contact type sensors where mechanical wear and tear hamper deteriorates their
working capability and thus their life. The life of a pod is expressed in number of movements.

Measurement Range
It provides the range of operation of the sensor within which it can provides an accurate value. It may be
calculated either in degrees or in mm depending upon the type of potentiometric position sensor being used.
Repeatability
It is the variations in measurements by a single person or sensor on the same device under same conditions.
Independent Linearity
It is the maximum deviation of the actual function from the straight line that acts as a reference with the
slope and the position that has been chosen in order to minimize any deviations. It is expressed as a percent
of the total applied voltage.
Operating Temperature
It defines the range of temperature within which this sensor can operate without being affected by the
environment. It is expressed usually in degree Celsius.
Vibration
It is the frequency of oscillation of the sensor about an equilibrium position. It is expressed in hertz (Hz).
Shock/ Noise
It is a disturbance in the function of the sensor due to an unexpected impact. It is a form of vibration that
may be described in terms of acceleration, force, velocity or displacement.
Output
A potentiometer may give either a digital or an analog output which makes it an important parameter that
should be considered for the application we would use it for.

Table to help select potentiometeric position sensor

Comp Model Lin Conta Material
Resol Repeat Indep Life Dime Wei Opera Vibr Shock Applicati
any Number ear/ ct/Non
ution ability enden
nsion ght ting ation /Noise on
Rot Conta
t
Tempe
ary ct
Linea
rature
rity
Panas EWVYE Rot Contac
300
3 % 30000 Outer
47 mV onic /YK/YM ary t
max. cycles diame
max Temperatu
Electr
min. ter-39
re/blower
onic
mm
control or
Comp
Cente
mode
onents
r
switching
space
for car
diame
air
ter-20
conditione
mm
rs
-Volume

control for
car audio
equipment
Penny
+Giles
RCP05

Virtua
Rot Contac Conductive lly
ary t
Plastic
Infinit
e

+/-1%
to
0.5%

RCP08

Virtua
Rot Contac Conductive lly
ary t
Plastic
Infinit
e

+/-1%
to
0.1%

HLP190 Lin Contac

Hybrid
FS
ear t

RCP11

Virtua
0.2
lly
< 0.01
%-
Infinit mm
0.3 %
e

Virtua
Rot Contac Conductive lly
ary t
Plastic
Infinit
e

+/-1%
to
0.075
%

Body
diame
7
tergm
12.7
mm
Body
diame
12
tergm
19.3
mm

-65 C
to
+130
C

50 x
135
106
gm
cycles Body
-30 C
at
diame
210 to +85
25m ter-19
gm C
m
mm
(BS
stroke
)
length
Body
-65 C
diame
28 to
tergm +130
27.2
C
mm

Bourn
s

Infinit
e

500,0
. 5 % 00
cycles

3400 Rot Contac Wirewound 0.010

ary t
%0.020
%

0.15 1,000
%
hours,
5Watt
s

Lin Contac
3046
ear t

-65 C
to
+130
C

automated
controllers
, volume
control on
audio
-55 C
10- 50 G equipment
to
2K for
, joystick
+125
Hz 7ms controllers
C
, satellite
dish
positionin
g, and
robotics.
21 +1 C 10 G 50 G production
gm to
equipment
+125
, industrial
C
test and
measurem
ent
equipment
, and
medical
equipment

0.030
3500/350 Rot Contac Wirewound/ %1
ary t
Hybritron 0.019
%
ELAP
Indust
rial
PLS
Lin
Auto series
ear
matio
n
BEI
Senso
rs
1201R10 Rot
0L.5
ary

601R1K Lin
L.7
ear
Contel
ec

PL20

PL300

Rot
ary

conductive
Contac plastic
Infinit
t
resistance e
element

20,00

0,000
0.075
motio
%-
ns no
0.1 %
load

2
Body
millio
320
diame
Contac
n
Wirewound to
None 0.5 %
tert
shaft
358
0.875
revol
in
utions
10
Within
Body
Contac Conductive Infinit
millio
0.0005 0.7 %
diame
t
Plastic
e
n
in
tercycle
1
20m
Contac Conductive Very
Mio. m x
3 %
t
Plastic
good
Move 16m
ments m

Rot Contac Conductive Very Max.

ary t
Plastic
good 0.1

Spectr
a
Symb
ol

MP1

1,000
0.25 hours,
%
2
watts

Non
Lin
Contac Magnet
ear
t

Honey Series 70 Rot Contac Conductive

well
ary t
Plastic or
Cermet

Body
10
diame
Mio.
1 %
terMove
22.2m
ments
m

Depen
ds on
the
exteri
or
magn
et
streng
th and
distan
ce to
the
Magn
etoPot
5%

production
equipment
-40 C
, industrial
21 to
15 G 50 G test and
gm +125
measurem
C
ent
equipment
- 25
C to
15 G 50 G
+85
C

- 55
C to
+125
C
- 55
C to
+125
C
- 25
Readout
C to
10 G 50 G potentiom
+85
eter
C
-Valve
- 25
controls
C to
10 G 50 G
+85
Joysticks /
C
Master
switches

Heigh
>1
-:
millio 3.50m
n
m
cycle (0.13
8")

up to
+85C

100,0 Shaft
00
diame
cycles ter1/8"

- 55 2%- 2%C to 5% 5%
+120
C

-Ideal for
Hydraulic
and
Pneumatic
Position
Sensing
-Liquid
Level
Sensing
Capability

or "

Lin
SENSOF ear
OIL foil &
based
Rot
ary

Contac
t&
Standard/Ma
Non
gnet/Hybrid
Contac
t

0.5
mm1.0
mm

Lin
SENSOF ear
OIL FR4 &
based
Rot
ary

Contac
t&
Standard/Ma
Non
gnet/Hybrid
Contac
t

0.5
mm1.0
mm

Hoffm
ann +
Kripp
ner

Thick
ness:
0.7m
m
(Stan
dard),
> 1 1.7m
2.00% Millio m
n
(Mag
netic),
and
0.7m
m
(Hybr
id)
Thick
ness:
0.7m
m
(Stan
dard),
> 1 1.7m
2.00% Millio m
n
(Mag
netic),
and
0.7m
m
(Hybr
id)

up to
+125
C

up to
+125
C

Pros & Cons

Every product in this world has some positive as well as negative features and so do the Potentiometric
position sensors. The disadvantages, although few in number, are with respect to the contact type sensors.

Inertial loading: These types of sensors are affected highly by the environment, at times. Dust gets
easily accumulated between the resistive surface and the slider thus increasing the resistance than the
actual value. This results in incorrect output voltage or in some cases loss of total voltage.

Limited Bandwidth: Precautions need to be taken so that the working of these types of sensors is very
smooth and slow, so that they can measure the accurate and continuous voltage. Now if the slider is
moved very fast, chances are there that the contact would bounce, which would result in an
intermittent output voltage.

Wear and Tear: At times the frictional forces between the slider and the resistive surface increases so
much so that the actual movement of the body is also limited. Again the more the frictional forces, the
more is the wear and tear of the sensor. This also limits the number of operating cycles.

The negative points are just not enough because if we want to select a sensor for the different applications,
we should also be able to identify it's advantages for the right selection.

Ease of implementation: Due to their mechanism, they are easy to use and do not require any
additional implementation assistance

Low price: They have quite low price so are widely used.

Analog output: They provide high amplitude, analog output thus no signal processing is required and
the output can be accessed easily.

Proven technology

Ease to add additional channels to increase reliability

Easy Availability

-Sneha Ambastha is a technical journalist at EFY Gurgaon