POSITION SENSORS
Nothing touches. So nothing wears.
Gill Blade position sensors measure linear and rotary movement without physical contact between the sensor and its moving target. With no contact surface in the sensing mechanism, there is nothing there to wear against the movement being measured.
The range covers short and long linear travel, full 360° rotation and applications requiring redundant output. Start with how the mechanism moves, then choose the sensor around it.
Simulated movement. Move your pointer side to side to drive both targets.
- Linear and rotaryUp to 60 mm of travel and full 360° rotation
- Non-contact sensingNothing in the sensing mechanism wears against the movement
- Sealed to IP67Across all four Blade sensors
- Analogue and digital outputsIncluding PWM and RS232 or RS485, by model
The technology
The sensor never has to touch the thing it is measuring
Blade uses a two-part design. The sensor measures the position of a separate activator, so the moving mechanism does not make physical contact with the sensing element. That removes the contact surface found in many mechanical position-sensing arrangements.
There is no wiper running across a track, no physical interface to wear and no mechanical sensing element being moved back and forth as part of the measurement. The result is a non-contact approach designed for applications where mechanical wear is something worth taking out of the equation.
Non-contact sensing
Sensor and activator stay separate, so nothing in the sensing mechanism wears.
Linear and rotary
Up to 60 mm of linear travel, 90° angular or full 360° rotation.
Analogue and digital
PWM, RS232 or RS485 by model, plus a dual-channel analogue option.
Sealed to IP67
Sealed for temporary immersion (1 m for 30 min) across all four Blade sensors.
The range
Four ways to measure movement
All four Blade sensors use the same fundamental approach: the sensor and activator remain separate, while the measurement is made electronically. The difference is what the mechanism needs to do.
Blade25
For movement up to 25 mm. Short linear travel or up to 90° angular measurement, with configurable range and analogue and digital output options.
Blade60
For movement up to 60 mm. The longer-travel option for linear movement, with up to 60 mm of configurable travel or 90° angular measurement.
Blade360
For movement that keeps going. Full 360° rotary measurement with a configurable range and a IP67 construction, sealed for temporary immersion (1 m for 30 min).
Blade Dual Output
When one signal isn't enough. A two-part, non-contact design with single or dual-channel analogue output for a redundant second channel.
No single Position sensors does all of that. Our team can suggest a pairing.
Choosing the sensor
How does it move?
You don't need to start with four datasheets. Start with the movement. Every model is set against the same specifications, from the datasheets; not stated means that datasheet does not give the figure.
| Specification | Short travel, up to 25 mmBlade25 | Long travel, up to 60 mmBlade60 | Full rotationBlade360 | Two independent outputsBlade Dual Output |
|---|---|---|---|---|
| Choose it when | The part moves up to 25 mm in a line, or up to 90° around a point | The part moves up to 60 mm in a line, or up to 90° around a point | The part rotates, through up to a full 360° | You need one or two output channels from a single sensor |
| Measurement | Linear ±12.5 mm configurable, angular ±45° configurable | Linear ±30 mm configurable, angular ±45° configurable | 0 to 360° configurable | Rotary ±45°, linear range governed by activator shape |
| Range accuracy | ±0.1 mm or equivalent | ±0.1 mm or equivalent | ±0.5% FS over temperature range | ±3% over full temperature range |
| Output | Analogue 0 to 5.6 V, PWM 250 Hz or 1 kHz, RS232 / RS485 optional, switch | Analogue 0 to 4.2 V, PWM 250 Hz or 1 kHz, RS232 19.2K 8N, switch | Analogue 0 to 5.5 V, PWM 1 kHz, RS485 19.2K 8N, switch | Single analogue, single 5 V ratiometric, or dual analogue |
| Supply voltage | 4.8 to 32 V DC | 4.8 to 30 V DC | 4.8 to 32 V DC | 6 to 30 V DC |
| Resolution | 10 bit over configured range | 10 bit over configured range | 10 bit over configured range | 10 bit |
| Sample rate | 1 kHz | 1 kHz | 1 kHz | 1 kHz |
| Ingress protection | IP67 | IP67 | IP67 | IP67 |
| Operating temperature | -40°C to +85°C at 32 V DC max, -40°C to +125°C optional at 14 V DC max | -40°C to +85°C standard, -40°C to +125°C optional | -40°C to +85°C at 32 V DC max, -40°C to +125°C at 14 V DC max | -40°C to +85°C standard |
| Sensor to activator clearance | 0.5 to 2 mm | 0.5 to 2 mm | 0.5 to 2 mm, concentricity <0.5 mm | Not stated |
| Weight | 21.0 g excluding cable | 25.6 g excluding cable | 22.8 g excluding cable | 34 g |
| Datasheet | Datasheet | Datasheet | Datasheet | Datasheet |
Built for integration
The sensor is only half of the system
Blade sensors are designed to integrate into the equipment they are measuring, with configurable ranges, multiple output options and built-in diagnostics.
Range and output characteristics can be configured using the BladeCom GUI, allowing the sensor to be set to the requirements of the application rather than treated as a fixed-range component. For OEM applications, the activator is designed as part of the customer's mechanism, with standard activator designs available as a starting point.
Configuration
Set the sensor around the movement
BladeCom provides configuration of the measurement range, switch points, output limits and dropout level through a graphical interface. That means the same sensor platform can be configured around different mechanical arrangements rather than requiring a different fixed-range sensor for every installation.
Configuration can also include write protection, helping prevent unwanted changes once the sensor has been commissioned.
Diagnostics
It can tell you when something isn't right
Position sensing is only useful if you can trust the signal. Blade sensors provide built-in health information including sensor fault status, activator position and approximate temperature and environmental health.
That gives the host system more information than simply the position value, helping identify whether an unexpected reading is actually a change in position or an indication that something else needs attention.
- Sensor fault status
- Activator in range
- Approximate temperature
- Environmental health
Standard activator designs
The Blade technical manual gives standard activator designs as a starting point for your own mechanism.
Read the technical manual →Match the host interface
Output options vary by model and include analogue, PWM, RS232 and RS485. Check the host interface before choosing.
Compare outputs →Help before you specify
Our technical team can help with activator design, travel, output, host interface, configuration and OEM integration.
Make an enquiry →See it work
Position sensing with nothing to wear out
Precision behind performance
A short film on non-contact position measurement, and where an unlimited service life is the reason it gets specified.
Prefer to watch them together? Watch them all on the Gill Group channel
Specification
Four products. One quick comparison.
| Specification | Blade25 | Blade60 | Blade360 | Blade Dual Output |
|---|---|---|---|---|
| Measurement | 25 mm linear / 90° angular | 60 mm linear / 90° angular | 360° rotary | Linear or angular |
| Output | Analogue and digital, PWM, RS232, RS485 | Analogue and digital, PWM, RS232 | Analogue and digital, PWM, RS485 | Analogue |
| Ingress protection | IP67 | IP67 | IP67 | IP67 |
| Configuration | Configurable range | Configurable range | Configurable range | Single / dual channel |
| Datasheet | PD1484 Iss 7 | PD1508 Iss 6 | PD1498 Iss 7 | PD1356 Iss 6 |
Supply voltage, operating temperature, resolution and linearity should be taken from the released datasheet for each part number. IP67 is an ingress-protection rating, not a pressure rating.
Applications
Where movement matters, contact can become the weakest link
Blade sensors are suited to applications where position needs to be measured repeatedly without introducing a mechanical sensing interface into the moving mechanism. The application ultimately determines the required travel, output, environmental protection and configuration.
MotorsportMotorsport, including Formula One, puts sensors into hot, vibrating and wet environments where a contacting potentiometer can become a service item.Motorsport and high performance →
Defence equipmentDefence equipment can demand long service in rough handling and wet conditions. With the sensor and activator separated, there is no contact surface to wear through repeated cycling.Defence and security →
Mobile equipmentApplications where vibration, environmental exposure and service access influence component selection.Off-highway and construction →
Industrial machineryLinear and rotary position measurement where repeated movement makes mechanical wear a consideration.Industrial process →Technical resources
Everything you need to specify, configure and install a Blade sensor
Questions
Frequently asked questions
What is a non-contact position sensor?
A non-contact position sensor measures the position or movement of a target without physical contact between the sensing element and the moving mechanism. Gill Blade sensors use a separate activator and sensor, so there is no contact surface to wear.
What are the advantages of non-contact position sensing?
Removing physical contact from the sensing mechanism eliminates a mechanical wear surface and can make non-contact sensing useful where movement is frequent, access is difficult or long mechanical life is important.
Can a position sensor measure both linear and rotary movement?
Yes. Gill Blade sensors cover both. Blade25 and Blade60 measure linear travel or up to 90° angular movement, while Blade360 measures full 360° rotation. Blade Dual Output supports linear or angular applications.
Which Gill Blade position sensor should I choose?
Start with how the mechanism moves. Blade25 is for up to 25 mm linear travel, Blade60 for up to 60 mm, Blade360 for full 360° rotation, and Blade Dual Output where single or dual-channel analogue output is required.
What is an activator in a Blade position sensor?
The activator is the separate moving target detected by the sensor. It does not physically contact the sensor, and its mechanical arrangement can be incorporated into the customer's mechanism.
Can I configure the Blade sensor to suit my application?
Yes. BladeCom allows the measurement range and other configuration parameters to be set for the application, including minimum and maximum travel, switch points, output limits and dropout level.
Are Gill Blade sensors suitable for OEM applications?
Yes. The two-part sensor and activator design allows the activator to be incorporated into the OEM mechanism. Gill provides standard activator designs as a starting point.
How long do non-contact position sensors last?
Because Blade sensors have no physical contact between the sensor and activator, there is no contact surface within the sensing mechanism to wear. Gill describes the range as having unlimited mechanical life.
Can Gill help me choose a position sensor?
Yes. Tell us how the mechanism moves, the travel or angle involved, the required output and the environment in which the sensor will operate. Gill can then help identify the appropriate Blade model and configuration.
Have an application to discuss?
Speak to our team
Tell us what you need to measure, where and under what conditions. We’ll help you work out the appropriate approach.
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- We aim to respond in one working day. Monday to Friday.
- No obligation. Just honest advice on whether Gill is the right fit.