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At extremely high rotational speeds, mechanical and often even inductive measurement methods reach their physical limits. Optical speed monitoring provides a highly precise, non-contact, and completely wear-free solution for the reliable detection of rotational speeds up to 100,000 revolutions per minute.
Operating Principle and Signal Acquisition
The system is based on an optical high-speed sensor that is permanently aligned with the rotating component to be monitored (e.g., a shaft or spindle). An optical contrast is created on the rotor – typically by alternating light and dark segments, reflective tapes, grooves, or gear teeth.
The sensor emits a focused light beam and detects the reflections modulated by the rotating object. The integrated high-performance electronics convert these optical pulses into a clean, high-frequency square-wave signal without delay. The frequency of this signal is exactly proportional to the current rotational speed and can be analyzed in real time by evaluation units, PLCs, or oscilloscopes.
ATEX Certification and Use in Hazardous Areas
The highest safety requirements apply to sensors used in potentially explosive atmospheres. For safe operation in plants with gas or dust explosion hazards, our optical speed sensors are designed for use in defined ATEX zones (e.g., Zone 1/2 or Zone 21/22). Intrinsically safe (Ex i) circuitry and a hermetically sealed, highly robust stainless-steel housing reliably prevent the ignition of explosive atmospheres. This makes optical speed monitoring fully suitable for critical hazardous areas in the chemical, petrochemical, and milling industries.
Technical Advantages at a Glance
Wear-Free Measurement:
The completely non-contact sensing principle generates no friction whatsoever. This protects the measured object and guarantees an exceptionally long sensor service life.
Highest Signal Quality at High Speed:
The extremely short response time of the optical system enables the precise detection of rotational speeds up to 100,000 rpm without signal loss or jitter.
Maximum Robustness:
Housed in a premium cylindrical stainless-steel enclosure with a durable optical front lens, the sensor is optimally protected against mechanical stress and aggressive media.
Easy Integration:
Thanks to its compact design and standardized thread, the system can be integrated flexibly, space-efficiently, and precisely into existing test benches, machine designs, or ATEX-certified installations.
Typical Applications
Optical high-speed rotational speed measurement is indispensable in demanding industrial environments where maximum precision and operational safety are required:
Process Engineering & Chemical Industry:
Monitoring of high-performance centrifuges and agitators in hazardous Ex zones.
Machine Tools:
Monitoring of high-speed spindles (HSC milling and grinding applications).
Test Bench Technology:
Power measurement and rotational speed monitoring of electric motors, gearboxes, and turbines.
Automotive & Aerospace:
Testing of turbochargers and high-speed compressors.