In many industrial, vehicular, and defense-related systems, accurate position feedback is required in tight mechanical envelopes, under harsh environmental conditions, and with long-term reliability as a non-negotiable requirement.
One sensor technology that consistently meets these demands is the spring-loaded linear position sensor.
These devices provide a simple, robust, and field-proven method for linear position measurement where space is limited and environmental stresses such as vibration, shock, and temperature extremes are part of daily operation.
What Is a Spring-Loaded Linear Position Sensor?
A spring-loaded linear position sensor is a contact-based linear potentiometer that uses an internal return spring to maintain constant contact between the sensing plunger and the moving mechanical element.
This design offers several inherent advantages:
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Continuous position feedback without complex electronics
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Immediate mechanical return to the extended position
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High tolerance to vibration and shock
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Predictable, repeatable behavior over millions of cycles
Because of these characteristics, spring-loaded linear sensors are widely used in mission-critical mechanical feedback loops.
Key Characteristics Engineers Look For
When specifying a spring-loaded linear position sensor for demanding applications, engineers typically evaluate the following parameters:
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Electrical travel in the 10-40 mm range, commonly around 25 mm
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Resistive output, enabling simple signal conditioning
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Defined actuation force from an internal spring
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High mechanical life, often exceeding 1 million full cycles
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Wide operating temperature range
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Compact housing suitable for space-constrained designs
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Resistance to shock, vibration, and humidity
These criteria are especially relevant in platforms where redesign is costly and long-term availability matters.
The KTP Series – A Practical Implementation of the Technology
The KTP Series spring-loaded linear position sensors from VARIOHM were developed specifically to address the requirements of space-limited, harsh-environment position feedback applications.
The KTP Series combines a compact mechanical design with robust construction and stable electrical performance, making it suitable for both industrial and ruggedized systems.
Core Features of the KTP Series
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Electrical travel options up to 25.4 mm
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Linearity of ±2% over active electrical travel
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Maximum operating voltage of 60 V AC/DC
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Mechanical life of 1,000,000 full cycles and 5,000,000 dither cycles
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Operating temperature range of -40°C to +135°C
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Internal return spring with controlled actuation force
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High resistance to vibration, shock, and humidity
These characteristics allow the KTP Series to be integrated into existing mechanical architectures with minimal system impact.
Designed for Harsh Operating Conditions
In many real-world applications, sensors are exposed to far more than just clean laboratory conditions. The KTP Series is engineered to perform reliably in environments that include:
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Continuous vibration
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Mechanical shock events
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High humidity
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Wide temperature fluctuations
This makes the series suitable for platforms where sensor access is limited and maintenance intervals are long.
Typical Applications
Spring-loaded linear position sensors from the KTP Series are commonly used in:
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Actuator position feedback
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Valve and damper position monitoring
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Mechanical travel and displacement sensing
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Industrial automation and robotics
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Vehicle and off-road systems
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Ruggedized and defense-oriented platforms
In many of these applications, the sensor becomes an integral part of the mechanical system and must operate reliably throughout the product lifecycle.
Design Considerations When Selecting a Sensor
When selecting a spring-loaded linear position sensor, it is important to evaluate more than just electrical specifications. Key considerations include:
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Mechanical envelope compatibility
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Electrical vs. mechanical travel margins
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Actuation force and stop strength
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Environmental robustness
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Long-term availability and manufacturer support
The KTP Series was designed with these system-level considerations in mind, helping engineers reduce integration risk.
A Proven Solution for Demanding Systems
For engineers and procurement teams seeking a robust, compact, and well-documented spring-loaded linear position sensor, the KTP Series provides a practical and proven solution.
Its combination of mechanical simplicity, environmental resilience, and predictable electrical behavior makes it a strong choice for both new designs and long-term production platforms.