© Dr.

H T Tran - IUH

SENSORS AND ACTUATORS

Dr. Toan Tran-Huu

Email: [email protected]
E-Learning: Trần Hữu Toàn
ocw.fet.iuh.edu.vn
 2.4. Encoder

ENCODERS
 1) Encoder Definitions

What is an encoder?
 An encoder is a device which converts a
mechanical information of a shaft or position into
an electrical signal

x(mm)

Encoder

α(rad/độ)
 Encoder Principle

How is this accomplished?- Principle

 As the code disc rotates, it shutters light from the
LED and is received and transmitted as square\sine
waveforms
 Principle

Incremental Encoders
 Typical Applications in Industrial System

Input Output
Controller Operation
(Application)

Feedback
Sensor

6
 2) Structure

How is this accomplished?-Structure

 As the code disc rotates, it shutters light from the
LED and is received and transmitted as square\sine
waveforms
Receiver / Sensor

Code disc

Lens

Transmitter / LightSource LED

Shaft
 2) Structure

 Transmitter(s)-Light source(s)
 LEDs or IR LEDs provide light source.
 Light is collimated using a lens to make the
beams parallel.
 Receiver(s)-Photosensor(s)
 Either Photodiode or Phototransistor.
 Code Disk
 One or more “tracks” with slots to allow light to
pass through.
 3) Advantages

High accuracy
High reliability
Relatively low cost
 4) Classification of Encoders

Encoder

Rotary Encoder Linear Encoder

Incremental Absolute Wire Draw Linear with Scale

Incremental Absolute
 4) Classification of Encoders

2 types of Optical Encoders:

1. Incremental
• Measure displacement relative to a reference point.
2. Absolute
• Measure absolute position.
• Advantages – A missed reading does not affect the
next reading. Only needs power on when taking a
reading.
• Disadvantages – More expensive/complex.
Cost/complexity proportional to resolution/accuracy.
 4) Classification of Encoders

Incremental Disk Absolute Disks

Incremental
optical
encoders
 Incremental (Quadrature)

 Light Source.
 Graduated Disk.
 Photovoltaic Cells
 Condenser Lens
 Scanning Reticle
 Incremental (Quadrature)

• Type: Single track

 Incremental (Quadrature)

• Type: Single track

 EXAMPLE

EXAMPLE 1
An incremental encoder has 240 empty slots. Starting
from the reference point, the photo sensor counts 100
pulses clockwise (CW), 30 pulses counterclockwise
(CCW), then 45 pulses CW. What is the current
position?
 EXAMPLE

EXAMPLE 1
An incremental encoder has 240 empty slots. Starting
from the reference point, the photo sensor counts 100
pulses clockwise (CW), 30 pulses counterclockwise
(CCW), then 45 pulses CW. The current position?
SOLUTION
If the disk has 240 slots, then each slot/pulse
represents 1.5° of rotation. Starting at the reference
point, we first rotated 100 pulses, then reversed 30
pulses to 130°, and finally reversed again for 45°,
bringing us finally to 175 pulses from the reference
point, thus corresponding to 262,5 °
 Incremental (Quadrature)

• Type: Single track

 Incremental (Quadrature)

• Type: Double track/Double photocell

 Incremental (Quadrature)

• Type:
Double track/Double photocell
Two photo-sensors/two track
arrangement to determine direction
A B

A
CCW—Photocell waveforms
B for counterclockwise

A
CW—Photocell waveforms for
clockwise
B
Incremental (Quadrature)
 EXAMPLE

EXAMPLE 2
For control of a mobile robot as seen in the figure
below, an incremental encoder (double track) has 600
empty slots. Starting from the reference point, the
robot runs forward 30 cm then runs back 12.5 cm.
How many pulses will we get from the encoder, given
that R=12cm?
 EXAMPLE

EXAMPLE 2

2  2 R
2 R  
R

 (rad )  L   R
2

If ( A  B ) then
 
   0, 6 
360
 
1 Pulse
1    2,5(rad )  143,3   
L1 30  600
R 12 n  143,3
 239 Pulse  143,3 
 0, 6 
 EXAMPLE

EXAMPLE 2

If ( B  A ) then
 
1 Pulse   0, 6 
360

2    1, 04(rad )  59, 7 
 
L1 12, 5 600
R 12 n  59, 7
 100 Pulse  59, 7 
 0, 6 
 Incremental (Quadrature)

Block diagram of an incremental encoder system

 Incremental (Quadrature)

Decoding direction
from V1 and V2

A decoder for an
incremental optical
encoder.
 EXAMPLE

EXAMPLE 3
A position-sensor system (figure below) uses a 250-slot
disk. The current value of the counter is 00100110.
What is the angle of the shaft being measured?

SOLUTION
For a 250-slot disk, each slot represents 360°/250 = 1.44°,
and a count of 00100110 = 38 decimal, so the position is 38
×1.44° = 54.72°
 Incremental (Quadrature)

An incremental encoder interface circuit

showing how the latch is inhibited from
changing when the counter is updated
 Incremental (Quadrature)

A circuit diagram of
optical-encoder-
tomicrocontroller
interface
 EXCERCISE

Cho S là Encoder loại tương đối, 1 kênh với độ phân

giải là 240 xung/vòng.
Hãy nêu kết quả tính toán từ cảm biến S để bộ
điều khiển (controller) hiểu được vị trí bàn
máy(Worktable) khi nó di chuyển sang phải 9.5 mm.
Giả sử vị trí bàn máy đang là vị trí ban đầu (vị trí O)
trùng với vị trí tham chiếu của Encoder.
Biết bước vít-me (Leadscrew) là P=3 mm; số mối
ren trên ổ là Z=30. Company Logo
 Incremental Encoders
Interface Summary

Incremental Encoder – Electronic Interface Summary

• Standard Supply voltages are 5VDC, 10-32 VDC, and 8-24VDC

• Standard outputs are TTL, HTL and Open collector

Incremental
Electronic Interface

TTL / RS 422 TTL / RS 422 HTL / Push Pull Open Collector

Supply = 5V Supply = 10 ... 32V Supply = 10 ... 32V Supply = 8-24 V
 Absolute optical encoders

Absolute optical
encoders
Absolute optical encoders
 Absolute optical encoders

The resolution in this case?

The resolution in this case is

360°/16 = 22.5°

Similarly, eight tracks (providing

256 states) yield 360°/256 =
1.4°/state, and ten tracks
An absolute optical encoder (providing 1024 states) yield
using straight binary code. 360°/1024 = 0.35°/state.
 Absolute optical encoders

An absolute optical encoder showing how an

out-of-alignment photocell can cause an
erroneous state. (Note:Dark areas produce a
1, and light areas produce a 0.)
 Absolute optical encoders

When more than 1 bit

changes at a time, say, from
sector 7 (0111) to 8 (1000)

An absolute optical
encoder using a grey code
PCB for absolute rotary encoders
absolute encoders
Magnetic Rotary Encoder
• A high-speed rotary magnetic
encoder designed for use in
harsh environments.
• The traditional design enables
easy integration on existing
machines.
• A magnet is mounted to the
shaft within the encoder’s body.
• Rotation of this magnet is
sensed by a custom encoder
chip within the body, and
processed to give the required
output format.
 Absolute optical encoders

An absolute optical encoder 4-bit

 Absolute optical encoders

The simplest case: An absolute optical encoder 2-bit

Absolute optical encoders
Absolute optical encoders
Absolute optical encoders
 Absolute optical encoders

 The absolute encoder that is sketched above uses

four bits to encode the position of the disc.
 Four light detectors are needed to determine the
absolute position of the disc.
 The right figure shows a simple binary scheme of
encoding.
 This type of encoding has the disadvantage that
at the transition from 1111 to 0000 all four bits
change at a time.
 This may lead to decision errors when the
transition is not done exactly simultaneous.
 There are some ways to overcome this problem,
that are shown in the next slides.
Gray Code

BCD Disk

Gray disk
Gray Code Disc vs. Binary Code Disc
 Absolute Disk Codes

 Example: 3 bit binary code

Angle Binary Decimal

Bit 0
0-45 000 0
Bit 1 45-90 001 1
Bit 2 90-135 010 2
135-180 011 3
Bit 0 180-225 100 4
225-270 101 5
Bit 1
270-315 110 6
315-360 111 7
Bit 2
 Problem with Binary Code
Angle Binary Decimal

One angle shift 0-45 000 0

results in multiple 45-90 001 1

bit changes.
Example: 1 => 2
90-135 010 2

 001
135-180 011 3
(start at 1)
 000
180-225 100 4
(turn off bit 0)
 010
225-270 101 5
(turn on bit 1)
270-315 110 6

315-360 111 7
 Problem with Binary Code
Angle Binary Decimal

One degree shift 0-45 000 0

results in multiple 45-90 001 1

bit changes.
Example: 1 => 2
90-135 010 2

 001
135-180 011 3
(start at 1)
 000
180-225 100 4
(turn off bit 0)
 010
225-270 101 5
(turn on bit 1)
It looks like we 270-315 110 6

went from 1 => 0 315-360 111 7

=> 2
 Gray Code

 One bit change per angle change.

Angle Binary Decimal

Bit 0 0-45 000 0

Bit 1 45-90 001 1

Bit 2 90-135 011 2

135-180 010 3
Bit 0
180-225 110 4

Bit 1 225-270 111 5

270-315 101 6
Bit 2
315-360 100 7
Converting from Gray Code to Binary Code

1. Copy MSB.
2. If MSB is 1, write 1s until next 1 is met. If
MSB is 0, write 0s until next 1 is met.
3. When 1 is met, logically switch what you
are writing (1=>0 or 0=>1).
4. Continue writing the same logical until
next 1 is met.
5. Loop back to step 3.
Example:Convert 0010 to Binary Code

 Copy MSB: 0_ _ _
 Write 0s until next 1 is met: 00_ _
 Switch to writing 1s: 001_
 Write 1s: 0011
 Example: Convert 1110 to Binary Code

Copy MSB: 1_ _ _
Write 1s until next 1 is met: 1_ _ _
Switch to writing 0s until next 1 is
met: 10_ _
Switch to writing 1s until next 1 is
met: 1011
 Encoder Reliability and Errors

 Resolution
 Incremental  
360
where N=# of windows.
N
• Resolution can be increased by reading both rising
and falling edges (   360 ) and by using quadrature
(   4 N ).
360 2N

 Absolute  
360
where n=# of tracks.
2n

   90
360
4
 Encoder Selection Process

Type (Rotary, Linear, Incremental, Absolute)

Electrical Interface

Mechanical Considerations
 Types of Encoders

Rotary Linear

• Convert Angular • Convert Linear distance

Position into Analog or movement to Analog or
Digital Signal Digital Signal

• Encoders for measuring

• Encoders for rotary distance travelled,
motion and measuring positioning, location
angle, speed or velocity information.
 Types of Encoders
Wiredraw With Scale

• Convert pulled wire • Two part devices; Active

length distance to Head, Passive Scale
feedback • Absolute Positioning
• Absolute and Incremental • Scale : Magnetic Tape or
Elements
• Analog, digital or Bus
• Hiperface, SSI, Bus
feedback interfaces
Interfaces
• Distance: up to 50m
• Distance: up to 1700m
 Absolute Encoders

Absolute

 Provides a unique value for every shaft

or linear position
Code disc for
Absolute encoders  Absolute encoders retain their position
after a power cycle


LED
Lens
Scanning mask Signals typically use SSI, parallel, or field
Code disc Photo- Bus interfaces (Ethernet/IP, EtherCAT,
Elements Profinet, Devicenet, CANopen, Profibus, etc)

 Absolute encoders are used in applications

were position information is necessary
 Encoder Reliability and Errors

 Encoder errors
1. Quantization Error – Dependent on digital
word size.
2. Assembly Error – Dependent on eccentricity
of rotation (is track center of rotation=center
of rotation of disk)
3. Manufacturing tolerances – Code printing
accuracy, sensor position, and irregularities
in signal generation.
 Encoder Reliability and Errors

 Comment on pulse irregularity

 It is a result of noise in signal generation,
variations in light intensity, and imperfect
edges.
 It can be mitigated using a Schmidt Trigger,
but this can lead to hysteresis.
 Using 2 adjacent sensor will negate this
problem.
 Encoder Reliability and Errors

 More encoder errors

4. Structural Limitations – Disk Deformation,
physical loads on shaft.
5. Coupling Error – Gear backlash, belt
slippage, etc…
6. Ambient Effects – Vibration, temperature,
light noise, humidity, etc…
 Application

 Machine tools and Robotics

 Inspection equipment
 Aerospace and Aviation
 Medical imaging ( MRI, x-ray imaging )
 Semiconductor manufacturing
 Surveying and Telescopes
 Application

Measuring Length
with Wheels and Rolls

Ballscrew Position
Table Example
 Applications

 Any linear/rotary position/velocity sensing

 DC Motor control – robotics/automation
 Mechanical computer mouse
 Digital readouts for measurement gauges
 Tachometers – planes, trains and automobiles
linear Magnetic encoder
Fiber optics components
 Fiber optics components

Incremental encoder with integrated transmitter

Fiber optics decoder
with 2 output blocks
Incremental encoder with fiber HTL and/or TTL
optics connection

Copper cable

Fiber optics

For all series available

 Separate Fiber Optics Components

Fiber optics decoder

Copper cable with 2 output blocks
HTL and/or TTL
Fiber optics transmitter
for switch boards

Copper cable
Fiber optics

Incremental encoder with

electrical signal transmission

Fiber optics transmitter protection class IP66

 Separate Fiber Optics Components

Fiber optics decoder

with 2 output blocks
HTL and/or TTL
Copper cable Fiber cable transmitter
for switch boards

Fiber optics cable Copper cable

Incremental encoder with

electrical signal transmission

Fiber optics transmitter protection class IP66

 Key Products in 2013
Choice encoders that will solve most applications

DFS60 with PGT-10-S DFS20/25 AFx60 Series BCG Wiredraw

Programming Tool Incremental Encoder With Ethernet with Analog Output

• Handheld, battery • USA sized encoders with • Absolute single- and • Compact wiredraw
operated programming SICK’s “F”-Technology: multi-turn encoders with encoder for applications in
tool EtherNet/IP, EtherCAT, tight spaces
• Wide set bearings for and Profinet interfaces
• Easy menu structure for even shaft loading • Up to 10m of measuring
fast setup and flexibility • Device Level Ring (DLR) length
• Metal code disc for high functionality with the
vibration and temperature EtherNet/IP version
• Can be used for • Analog output scalable
diagnostics with the directly on the encoder for
display or as a cloning • Programmable using the • Superior diagnostics for fast commissioning
module PC-based tool temperature, speed,
runtime, and many more
Fields of applications
Packaging Print & Paper Wood industry

Machine Tooling Automotive Ports & Cranes Handling

… And many more

 Application Examples
OVERHEAD CRANE– AFM60 EtherNet/IP used to track position of crane

CONVEYORS – DKV60 used to track speed of conveyor

 Application Examples
WIND TURBINE – Absolute encoder AFM60 for gandala and blade angle tracking

BOTTLING – Absolute encoder AFS60 to track position of fillers

 Application Examples
STADIUM ROOF – Position with KH53 Linear Encoder

LIFT APPLICATIONS – Height and Width positioning using BGC Wiredraw Encoders
 Additional Resources

SICK University Tour

March – May 2013

Tech Tuesdays
Check www.sickusa.com for
schedule

Product Training Demo Cases Demonstration Videos &

Application Animations
 Marketing Tools

Encoder Catalog Encoder Selection Guide Application Book

*Update in 2013
[email protected]

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