Project Background
A leading domestic CNC equipment manufacturer encountered a severe testing challenge while developing a new generation of ultra-large gantry machining centers. The X-axis travel of the gantry was a massive 25 meters. To verify the dynamic performance and positioning accuracy over the full travel, an ultra-high-precision position feedback system was urgently required.
The Challenges
The Splicing Nightmare of Linear Scales: A traditional 25-meter linear scale requires multiple segments spliced together, which introduces significant cumulative errors. Furthermore, long-travel scales demand extremely strict surface flatness and time-consuming alignment during installation.
The Fragility of Interferometers: While traditional laser interferometers offer high precision, setting up a 25-meter optical path is a nightmare. It is highly sensitive to shop-floor air turbulence and temperature fluctuations, and the micron-level alignment usually takes engineers days, severely delaying the R&D schedule.
Thermal Expansion Issues: Physical scales deform due to thermal expansion and contraction in varying temperatures, making it impossible to maintain constant accuracy over such long distances.
The Dynatronic Solution
After rigorous comparison, the client selected the Dynatronic DT-SE Series (Standard Sealed) Interferometric Laser Encoder, customized to a 25-meter scale length.
Configuration: DT-SE-1P-BiSS-0.1UM-25M-5M
Core Technology: Photonic Integrated Circuit (PIC) & FMCW Modulation.
Implementation & Results
True "Scale-Free" Measurement: Thanks to the interferometric principle, the Dynatronic encoder provides a single, continuous 25-meter measurement without any physical scale splicing. Cumulative splice errors are completely eliminated.
±0.3mm Tolerance for Lightning-Fast Installation: Our patented focused reflector allows a lateral tolerance of ±0.2 to 0.3 mm. Unlike traditional scales or interferometers that require rigorous alignment, field engineers completed the installation and rough alignment along the 25-meter guide rail in just a few hours, drastically reducing machine downtime.
Real-Time Environmental & Material Compensation: To address the extreme temperature sensitivity of a 25-meter span, the built-in sensors and VibroSoft PC suite continuously monitor ambient temperature, pressure, and humidity. The system performs real-time compensation for wavelength and material thermal expansion, ensuring stable operation at 1 ppm accuracy.
Superior Dynamic Response: As the reflector moves at high speeds with the gantry slide, the ultra-lightweight reflector module demonstrates excellent dynamic tracking, perfectly matching the high-speed feed testing requirements of the gantry.
Customer Value
"We originally thought testing over 25 meters would take weeks to splice and debug. However, the Dynatronic laser encoder was virtually plug-and-play with its massive optical tolerance and no length limitations. It not only solved the splice error issue but multiplied our R&D testing efficiency." — Lead Test Engineer
