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ENCODERS

Presented by Jianguo (Max) Wang

October 4, 2004

Concepts related to encoders

What is a sensor? A sensor is a device that detects the state of the environment such as energy, heat, light, magnet, supersonic, etc. and convert them to electric signals.

Concepts related to encoders

What is an encoder? An encoder is a sensor for converting rotary motion or position to a series of electronic pulses

Basic architectures of encoders

Linear architecture
Linear encoders, which consist of a long linear read track (analogous to the code disk of a rotary encoder), together with a compact read head, address these concerns. We offer three grades of linear encoders, to suit a variety of application requirements.

Basic architectures of encoders

Rotary architecture
Rotary encoders serve as measuring sensors for rotary motion and for linear motion when used in conjunction with mechanical measuring standards such as leadscrews, and convert rotary motion (incremental or absolute) into electrical signals. They are both effective and low cost feedback devices. In high-accuracy applications, a number of error sources (leadscrew cumulative and periodic error, thermal expansion, and nut backlash, for example) render rotary feedback inadequate.

The types of encoders

Absolute encoders

Absolute encoders have a unique code that can be detected for each angular position Absolute encoders are much more complex and expensive than incremental encoders

The types of encoders

Incremental encoders

Pulses from LEDS are counted to provide rotary position Two detectors are used to determine direction (quadrature) Index pulse used to denote start point Otherwise pulses are not unique

The applications

Positioning

While a lead screw or rack-and-pinion converts rotary motion to linear motion, an encoder converts the same motion into electronic pulses. The pulses typically are used as input signals for counters, PLCs, or numerical-control equipment

The applications

Length measurement

Roll or sheet materials need to be measured during transport through converting or cut-to-length machinery. An encoder, when combined with a measuring wheel or coupled to a roller, will produce electronic pulses equal to units of length. Since fractional units may be measured, very precise operation is possible

Current state
Encoders are wildly used in industry machine tools textile machinery printing presses wood working machines handling technology conveying and storage technology robotics

Costs of encoders
From less than 100$ to more than 10,000 $. It depends on your requirement.

Rules and limitations of encoders

Linear & rotary


Linear encoders are more accurate.

Absolute & incremental


Absolute encoders are more expensive. Incremental encoders spend more time for startup

Rules and limitations of encoders

Magnetic & Optical


Magnetic Encoders
Unaffected by Contamination

Optical Encoders
Very Susceptible to Contaminates Limited Temperature Range -25 to +80 Optical Rotors and Electronics Connections are Susceptible Absolute Encoders Not Available in same Price Range Higher Cost due to 50% more Components Optical encoders typically use a potentiometer to compensate for manufacturing tolerances. Potentiometers within all optical encoders are a primary source of field failures and manufacturing defects.

Increased Temperature Range -40 to +125 Improved Shock Resistance Absolute and Incremental Outputs Reduced Cost

No Tuning or Mechanical Adjustments

Vendors

Heidenhain Renco Renishaw autonics Stegmann Pepperl+Fuchs

How to Choose an encoder

What the encoder is used for? Cost Working environment Resolution Requirement for the output standard of the encoder Dimensions Limits such as warm-up or startup time, maximum operating speed, bear life and so forth Choose an appropriate model and type of encoder

An example for choosing an encoder

Specification examples

Linear encoders

Specification examples

Rotary encoders

How to integrate

Application examples
Model 716 (Cube Encoder) made by ECP were equipped on the lumber devices to produce up to 15% more lumber from each log

Application examples
The Company of Ground Force mounts EPC encoder on the trucks used at mining operations to measure the rotation of pump shafts and of augers. The pumps deliver wet ingredients, while the augers deliver the dry ingredients.

Application video

Class Application

Robots uses rotary encoders wildly

References

H.R. Everett,Sensor for Mobile Robots, page41-45. http://machinery.articleinsider.com http://www.sick.de http://web6.automationdirect.com http://www.euchner-usa.com http://news.managingautomation.com http://www.renco.com http://www.ssirobotics.com http://www.senix.com http://www.heidenhain.com http://www.ab.com http://www. encoderdevices.com

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