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Positionencoders are found in a wide range of applications and industries and feature a range of technical concepts and terminology.

This article aims to explain optical encoders in simple terms: it covers descriptions of what an encoder is, the different types of encoder, how they work and where they are used.

An encoder is an electromechanical device that converts information from one format or code into another. A position encoder, such as those made by Renishaw, converts linear or rotary motion into an electrical signal that provides information on position, speed, and direction of motion.

Magnetic encoder systems use a magnetised scale featuring a series of alternating magnetic poles. Motion along the scale is determined by a readhead that contains a sensor that detects the change in magnetic field as the readhead moves and converts this change into an electrical signal.

Laser encoder systems use the wavelength of a laser light as their measurement unit by detecting the path length difference between a fixed reference path and a variable measurement path. Laser encoders offer high accuracy position measurement with fine resolution.

Optical encoders are devices that use a light source and a photo-detector moving past scale lines to produce an electrical signal. This signal can be read by a control device (or controller) within a motion control system. Renishaw has more than thirty years of experience in the design, manufacture and support of high-performance optical encoders.

Optical encoder scales can take many forms, such as flexible linear, rigid linear, discs and rings. These different forms enable the measurement and control of different types of motion such as linear, full rotation, partial arc rotation, or a combination of these movements.

An open optical encoder features a scale and readhead that are separated by a small gap, known as the rideheight, and configured to measure linear, rotary or partial arc motion. Its non-contact design benefits from zero friction and no mechanical wear or hysteresis.

In enclosed encoder systems, the scale and readhead are mounted in a sealed enclosure which protects the encoder from contamination with solid debris and ingress of fluids in harsh environments. For example, enclosed encoders are typically used on machine tools, where high accuracy and resistance to contamination from machining debris and cutting coolants are important.

Rotary encoders report angular position of a rotating part by means of a scale shaped like a ring or a disc. These encoders enable the control of rotary motion, such as in a rotary table or the joints of a robot.

A key difference between the behaviours of incremental and absolute encoders is how they respond to a loss of power. If an absolute encoder loses power, the readhead will still be able to correctly report its current position when the power is restored, even if it moved during the power outage. Incremental encoders lose their position information during a power cut and require their datum position to be reacquired when power is restored.

Another key distinction is related to communication: absolute encoders feature two-way serial communication between the controller and readhead, whilst incremental encoders provide one-way communication via analogue or digital signals from readhead to controller.

An incremental encoder commonly outputs its position information in the form of two analogue waveforms 90 degrees out of phase with each other, like a sine and cosine wave, or as two digital signals 90 degrees apart, known as quadrature. These signals can be interpreted by the controller to calculate the magnitude and direction of movement along the encoder scale.

In an absolute encoder system, specific position information is coded within all sections of the scale, like a ruler with numbers. These specific positions are defined by sets of parallel lines with some of the lines missing, rather like a barcode. This non-repeating pattern allows the readhead to find its position immediately on start-up.

The controller will periodically request position information from the readhead, which then captures a snapshot of the scale and decodes the image into a specific position, which is then reported back to the controller via a serial communications protocol.

Incremental encoders are used in a wide variety of motion control applications such as factory automation, co-ordinate measuring machines (CMMs) and semiconductor manufacturing equipment. Incremental encoders enable accurate position measurement at fine resolutions and at high scanning speeds.

Absolute encoders are well-suited to machines that need to retain position information through power cycle events. Applications include surgical robots and machines where homing cycles to a fixed reference mark are not desirable.

With the optical measurement, a code disc, which is divided into optically different fields, rotates with the motor shaft. A light beam directed at the disc is interrupted by the fields or reflected with interruptions. The analysis of the pulse sequence supplies the information about speed and relative position of the shaft. Optical encoders are insensitive to magnetic interference. They can achieve a very high position accuracy and repeatability.

With the magnetic measurement, a sensor magnet rotates with the motor shaft. Here, Hall sensors or special ICs detect the changes in the magnetic field that result from the rotary movement. Magnetic encoders are insensitive to dust, humidity, and thermal and mechanical influences.

An incremental encoder does not measure absolute positions, but rather relative positions. Incremental encoders determine a position relative to another reference position and transmit a specific number of uniformly distributed lines per revolution.

An absolute encoder, on the other hand, outputs an absolute position value, like a clock, which displays an absolute time. It does not need a reference variable and can determine the angular position of its shaft at any time. With single-turn absolute encoders, this applies for one shaft revolution. Multi-turn absolute encoders also detect the number of revolutions. Their signals can be used, e.g., to precisely determine the position in applications with lead screws.

The sensor pulses of the FAULHABER encoders are processed by special electronic components and converted into standardized output signals. Through interpolation, the physically recorded pulses can be mathematically divided into multiple signal periods. This allows the resolution to be increased many times over.

FAULHABER offers a wide selection of encoders, which are designed for optimum combination with FAULHABER motors. The range of devices includes magnetic and optical two- and three-channel incremental encoders with a standard resolution of 16 to 1024 lines per revolution as well as single- and multiturn absolute encoders. Single-turn absolute encoders are available with a resolution of up to 10,000 steps.

You are looking for the perfect drive for your application? The FAULHABER Drive Calculator is the perfect tool for developers to find a suitable drive system for a specific application in record time.

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US Digital products include an extensive line of absolute and incremental encoders (both kit- and shaft-styles), advanced inclinometers and a wide array of accessories, hardware, interfaces, motor drivers and power supplies to support these best-in-class motion-control sensors. These products set the benchmarks for accuracy, control, reliability and precision. READ MORE

With a vast product portfolio, US Digital can quickly and efficiently serve the industries that depend on quality motion control. Customers across a range of industries rely on the support and lead times that keep their innovations in motion. READ MORE

Since day one our mission has been to make our customers successful by inventing, manufacturing and rapidly delivering the most practical motion control components available worldwide. We have made this mission a daily practice now for almost 40 years. READ MORE

Wherever precision in motion is of the essence, an encoder is likely to be found. Indeed, it's hard to name an industry that does not benefit from encoder technology. It's found everywhere, from mission-critical applications in the most rugged environments to routine workplace applications that demand uncompromising repeatability.

Fundamentally, encoders translate rotary or linear motion into a digital signal for monitoring or controlling speed, direction, distance, or position. US Digital offers more than one million high-quality, off-the-shelf encoder configurations of two primary types: absolute and incremental. Absolute encoders report a precise shaft angle within a single 360-degree shaft rotation. In contrast, incremental encoders provide a relative position with respect to a home or zero position. US Digital encoder designs may utilize optical or magnetic sensors depending on the required precision and environmental harshness.

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