The Role of Linear Potentiometers in Optimizing Position Feedback Systems

Engineers use a linear potentiometer as a precise, ratiometric position transducer. The slider moves along a resistive element, producing a voltage that is proportional to its travel and referenced to a stable supply. When read ratiometrically, the scale remains accurate despite supply drift. Effective resolution, linearity across the usable stroke, contact stability at low speeds, and controlled wiper current all contribute to how clearly small movements can be detected. Proper alignment to avoid side loads and a mechanism that returns to the same point help keep deadband levels low and tuning predictable.

ETI Systems designs linear sensing elements specifically for control applications and supports clients from selection through to commissioning. We customize solutions by mapping stroke, mounting, resistance value, and track technology to fit your circuit and application requirements. Our options include guided and unguided rods, conductive plastic, wirewound, or cermet tracks, sealed builds, and redundant elements for critical axes. 

Units can be shipped with a comprehensive acceptance package that includes a baseline sweep, step response at key points, approach direction repeatability, noise measurements at low speeds, and recorded scaling. As a result, the startup is faster, rechecks after service only take a few minutes, and all records remain ready for audit.

Calibrating Linear Potentiometer Resolution and Scale

Control depends on clear signals and effective mechanisms that ensure alignment within a system. Implementing these choices enhances accuracy and facilitates quick verification, allowing for smoother and more efficient operation overall.

1. Track Selection

Choose by duty and environment: wirewound tolerates heat and heavy cycling, conductive plastic delivers smooth, low‑noise motion with long life, and cermet maintains tight linearity across temperature swings. Balance required resolution, expected temperature range, and cycle profile with your controller’s ADC so small moves are visible without added noise.

2. Resolution and Linearity

Verify total resistance and usable stroke, then measure linearity across the actual working range, not just the nameplate. Read ratiometrically to cancel supply drift, keep wiper current low to protect the track, and confirm the smallest repeatable step while creeping the slider. Align ADC resolution, sample rate, and filtering so the loop sees true motion rather than quantization or ripple.

3. Mounting for Accurate, Repeatable Readings

Use rigid, straight mounts that avoid side load and allow clean axial travel. Add rod ends or guides where misalignment exists, set a small free play so the slider is not forced, and route cables with strain relief to prevent lead stress. Verify endpoints and reference marks so the electrical stroke matches the mechanism and remains repeatable after thermal expansion and service.

4. Service Life and Maintenance

Start with the duty profile, cycles, dwell, reversals, and ambient conditions—then select track material and wiper force accordingly. Limit wiper current, choose seals for the site, and run a short endurance test that trends resistance, noise, and repeatability. Use the results to set calibration intervals, keep focused spares, and document a baseline for quick post-service checks.

Environmental Readiness of Linear Potentiometer Installs

Environmental conditions dictate the requirements for sensors. Specify sealing, materials, wiring, and checks to ensure readings remain stable in the operating conditions of the sensor.

1. Choose the IP level to match cleaning pressure and exposure. Use sealed shafts, O‑rings, and rated cable glands with strain relief to block capillary ingress, and add a hydrophobic breather to manage condensation. Verify sealing with a directed spray test, then check the position at reference marks to confirm sealing stayed stable.
2. Define the ambient range and duty, then verify performance at the extremes. Bearings and retainers keep alignment near rotating equipment while locking hardware maintains preload. Run hot and cold soaks and a vibration sweep, recording stroke time and drift before and after to confirm the sensor holds calibration.
3. Match elastomers and housings to site media, FKM, EPDM, or PTFE for seals, and coated or anodized bodies for corrosion resistance. Use filtered breathers and covered ports to keep fines away from contacts. Validate the choice with a short exposure trial followed by a slow sweep to confirm a smooth response and steady scale.
4. Route power and analog separately, use twisted pairs, and land shields at a single point to avoid loops. Bond the body to the ground and keep runs short. During commissioning, inject a small disturbance and confirm the trace stays flat so you know the reading reflects motion rather than noise.

Proven Linear Potentiometer Setups in Production

Brief examples show how better sensing shortens setup and steadies control.

1. Web Tension Dancer Arm Position

A low-noise linear element maintains dancer position, ensuring tension remains in the band. Baseline sweeps and step tests facilitate smooth speed transitions during roll swaps.

• Align mounts to remove side load on the rod
• Record stroke time and position at key setpoints
• Shield wiring and confirm noise at crawl

2. Hydraulic Cylinder Feedback on Press Control

Conductive plastic tracks ensure stable feedback for closed-loop cylinder positioning. Saved traces facilitate quick recalibration after seal work.

• Map the electrical stroke to cylinder travel with a margin
• Verify repeatability from both approach directions
• Use sealed connectors and strain relief at the gland

3. Pick‑and‑Place Linear Axis

Tight resolution and clean scaling enhance placement accuracy and minimize retries. Teach-point checks identify drift early.

• Specify stroke and resolution to match the controller’s ADC
• Keep a baseline pack: end limits, step response, stroke time
• Set a maintenance trigger for drift beyond your band

Step-by-Step Linear Potentiometer Selection Checklist

Turn requirements into a clear choice that installs cleanly and reads true.

Motion Range and Usable Stroke

Define total travel and how the slider moves, then align the electrical stroke with mechanical limits so the reading matches the design. Clear references and repeatable endpoints keep scaling stable and make checks fast.

• Note total and usable stroke with reference marks
• Confirm endpoints and allowable free play against the drawing
• Check the sliding force and any side load across the range

Track Type and Resistance Selection

Pick wirewound, conductive plastic, or cermet based on duty, noise tolerance, and temperature; size resistance and taper for your circuit so the ADC sees clean steps. The right pairing protects track life and keeps small moves visible.

• Match resistance to input impedance and cable length
• Verify linearity and the smallest repeatable step in the working band
• Consider redundant elements for critical axes and diagnostics

Mounting, Guides, and Alignment

Use rigid, straight mounts so the slider runs true, and add guides or rod ends where misalignment exists. Proper alignment avoids binding, preserves resolution, and reduces wear.

• Select bearings or guides that match life and load
• Align to avoid binding through the full stroke and thermal shifts
• Add strain relief and routing that protects leads

Environment, Wiring, and Acceptance Checks

Protect the device for the site and leave evidence you can trust. Proper sealing and wiring keep readings quiet, and a repeatable test pack proves performance at startup and after service.

• Match IP rating and sealing to washdown and dust
• Separate power and analog; use twisted pairs and a single‑point ground
• Save a baseline sweep, step test, and stroke time for later comparison
• Note total and usable stroke with reference marks
• Confirm endpoints and free play against the drawing
• Check the sliding force and any side load

Why Choose ETI Systems for Linear Potentiometers

ETI Systems specializes in designing and manufacturing rotary and linear sensing elements for control applications. Our linear product offerings include both guided and unguided rods, custom stroke lengths, wire-wound and conductive plastic options, cermet tracks, as well as panel or servo mounts. We also provide redundant configurations and sealed variants that are suitable for harsh environments.

To support engineering efforts, we offer 2D/3D CAD files, wiring diagrams, selection guides, and RoHS and REACH documentation, along with clear change notifications. Additionally, our portfolio includes rotary potentiometers, industrial joysticks, turn-counting dials, and electric actuators. These products share signal conventions and mounting options, ensuring that your linear potentiometer integrates seamlessly and that spares, connectors, and accessories can be standardized across your machinery.

When you need a reliable linear potentiometer, we prioritize aligning the motion profile, resolution, and linearity targets with the appropriate track, resistance, and mechanical fit, while also considering input impedance and environmental conditions. Our units can be shipped with a brief acceptance package that includes a baseline sweep, approach-direction repeatability, step response at critical set points, noise measurements at low speeds, and recorded scaling.