ENCODERS

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 Encoders
• Encoders are electromechanical sensing devices that provide feedback.
• Convert motion to an electrical signal.
• Signal read by some type of control device in a motion control system,
such as a counter or PLC.
• It is used to determine position, count, speed, or direction. A control
device can use this information to send a command for a particular
function.
• Used to measure one or more specific parameters about the object,
such as its speed, position, direction, or to provide a count of the
object or some related value.
• Encoders are normally digital displacement transducers.
• Consist of a mechanical element and a sensing head, typically of
optical type.
• A simple example of how an encoder might be used is in a cut-to-
length application.

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 Working Principle:
• Encoders use different types of technologies to create a signal, including:
o Mechanical
o Magnetic
o Resistive
o Optical – optical being the most common.
• In optical sensing, the encoder provides feedback based on the interruption
of light.
• A beam of light emitted from an LED passes through the Code Disk.
• Disc is patterned with opaque lines. Serves as ‘code’.
• As encoder shaft rotates, the light is interrupted by the opaque lines on the
Disk.
• Phototransistor behind disc to detect light.
• This produces a pulse signal: light = on ; no light = off .
• The signal is sent to the counter or controller, which will then send the signal
to produce the desired function.

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• Displacement is obtained by counting number
of times that transitions occur between logical
values “0” and “1”.
• This allows the transformation of physical
quantities by converting the angular
displacement variations into electrical type
signal output that is translated into logical
values by suitable electronics.
• The counting of the number of transitions that
occur is related to the concept of resolution.
• It is the smallest change in a quantity under
measurement causing a noticeable change in
the corresponding outcome.

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 Types of Encoders:
• Linear encoders

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 • Rotary encoders • Angle encoders

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 • Absolute encoders • Incremental encoders

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 Advantages of Encoders:
• Highly reliable and accurate
• Low-cost feedback
• High resolution
• Integrated electronics
• Fuses optical and digital technology
• Can be incorporated into existing applications
• Compact size

Disadvantages of Encoders:
• Subject to magnetic or radio interference (Magnetic Encoders)
• Direct light source interference (Optical Encoders)
• Susceptible to dirt, oil and dust contaminates

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 Applications of Encoders:
Encoders play an integral role in almost every system that involves motion
monitoring or control.
There are a variety of types that work with different kinds of motion with different
options for how they detect and communicate.

• Aerospace • Conveyor Belts

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 • XY Positioning • Robotics

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 • Packaging Industry

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 Case Study: Kirk-Rudy’s Engineering Dilemma

Problem: Solution:
• When they developed the latest generation of • Programmable model 25SP encoder
their inkjet printers, they needed to find a
• Using optional programming module with the model
way retrofit them into their systems.
25SP, users can:
• Engineers would constantly have to re- • Choose from 6 different out types
engineer drive pulleys and shafts in order to • Choose from 32 waveforms
incorporate our newest generation of inkjet • Program any resolution from 1 to 65,536 CPR
printers into existing systems.
• Incredibly versatile, offering shaft sizes from 3/8” all the
• The engineers were forced to waste valuable way to 10 mm.
time engineering and retrofitting to get
everything to work together. • Three different mounting faces and eight different
connector types to choose from.
• They needed a shaft encoder that was rugged
enough to handle their applications, but • Flexibility of the programmable has allowed Kirk-Rudy
versatile enough to work in many different to save machining time.
applications.

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Kirk-Rudy’s manufacturing line and inventory department.

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 Case Study: Tru-Trac™ Keeps this Frankenstein Alive
Problem: Solution:
• As huge metal sheets move, it’s critical that • Model TR2 Tru-Trac™ encoder
the feedback of the motion is absolutely
• Encoder with rack & pinion gear integrated into one
correct.
compact unit
• To provide motion control feedback for the
• Easily installed in a vertical, horizontal or upside down
massive Frankenstein, they needed a linear
orientation
measurement solution.
• Operates at speeds up to 400 feet per minute
• With that heavy-duty of a product, and with
the distance traveled, they needed a robust, • Spring-loaded torsion arm eliminates gear backlash
fixed, rack & pinion track system.
• Integrated module simplifies your system design
• The track system had to be stainless steel to
withstand the environment.
• The encoder solution would need to provide
bi-directional feedback.

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 Peninsula Iron Work's Frankenstein machine (Right). Encoder fitted on the Frankenstein’s track (Left).

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 Thank you

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