Encoders and Sensors

(But mostly encoders)

ME 486 - Automation

03 October 2005

Bryan Schramm

References
www.minimotor.ch/images/design/Optical_Encoder.j
peg
www.oddparts.com
www.tamagawa-seiki.co.jp
www.gipwc.shinshu-u.ac.jp
www.trelectronic.com
www.reedlink.com
www.renishaw.com
www.cui.com
www.autonomoussolutions.com
ME 486 - Automation

Objectives
Introduction
Define current state
Costs
Applications and Examples
Existing or evolving standards
Summary

ME 486 - Automation

Introduction
Encoders and sensors allow control and feedback
loops to be established
Without the knowledge of position and/or speed it is
impossible to maintain accuracy and control
Information provided by encoders and sensors is
limited by various things including data transmission
frequency and also by the physical limits of the
system being controlled
ME 486 - Automation

Encoders - Introduction
Incremental encoders emit pulses which determine
how far the device has rotated (if a rotary encoder), or
moved (if a linear encoder).

Incremental encoders may be rotary or linear. The

first key specification is the number of pulses per
revolution (PPR) or pulses per inch (or centimeter).
PPR of 250, 512, 1000, 1024, or even up to 100,000
pulses per revolution are available.
ME 486 - Automation

Encoders - Introduction
Absolute encoders are used to determine the absolute or actual
rotary or linear position of part of a machine.
Absolute encoders have multiple slit, photo-transistor, LED
sets -- most commonly 10 or 12
Resolutions of up to 1 part in 23 bits (0.00034 degrees) are
available in some rotary encoders. Other rotary encoders offer
multiple turn capability, with the ability to determine 1 part in
4096 per revolution over a total of 4096 revolutions.
Some linear encoders can measure movements as small as
10m to 10nm
ME 486 - Automation

Anatomy of Rotary Optical Absolute

Encoder

ME 486 - Automation

trelectronic.com

Encoders Types (Rotary)

Absolute optical
robots

Incremental Hollow shaft

Modular
Panel mount optical
medical devices, audio equipment

Magnetoresistive
cranes, dirty environments
ME 486 - Automation

Application of Rotary Encoders

Painting Robots (automotive)

CAT Scan machines
Precision machining equipment
Microscopes
Aerospace

ME 486 - Automation

Applications Continued

ME 486 - Automation

Vtech

Applications Continued

ME 486 - Automation

Autonomous Solutions

Costs
Basic Incremental Hollow Shaft Encoder:
~$200
Absolute Optical Encoder: ~$300
Magnetoresistive Encoders: ~$150 - ~$2000

ME 486 - Automation

Rotary Improvements
Increased optical durability and reliability
Dirty environments, corrosion etc

30 bit resolution encoder Produced by Shinshu University

230 = 1073741824
Useful for semiconductor product equipment

ME 486 - Automation

Absolute Linear Encoders

Optical linear encoders exist use reflection of
light to measure distance
Measuring principle: transit time measurement
This uses magnetic fields and is path-proportional
Time lag between generated and received pulse are
translated into either digital or analog signal

ME 486 - Automation

Anatomy of Absolute Magneto

Linear Encoder

ME 486 - Automation

trelectronic.com

Application of Linear Encoders

Hydraulic presses
Machine tools or transfer machines
Die-casting machines
Woodworking machines
Fill level detection for foodstuffs
Hard Drives

ME 486 - Automation

Applications Continued

ME 486 - Automation

Autonomous Solutions

Linear Encoder costs

Optical Linear Encoder: ~$150 to ~$5000
Magneto Linear Encoder: ~$200+
Obviously costs depend on length, resolution,
intended operating environment, shock and
movement speed

ME 486 - Automation

The Skinny on Linear Encoder

Improvements
Resolutions from 5 m to 10 nm at speeds of
up to 10 m/s
Linear encoders can be up to 160 m long with
resolution of .1 m
Goal is to maintain 5 m to 10 nm resolution
but push to speeds of about 20 m/s or more

ME 486 - Automation

Primary Encoder Vendors

Omega
Renishaw
TRElectronic
RENCO
ServoTek
AMCI
DuraCoder

ME 486 - Automation

Key Encoder Specs

You must know the following information to specify an encoder:

Absolute or Incremental Encoder

Rotary or Linear Encoder
Resolution required
Uni-directional or Bi-directional motion
Operating voltage, very commonly 5 volts, also 12 and 24 volts available

Mechanical requirements
Shaft diameter and length
Mounting holes and spacing
Overall length and diameter

Environmental considerations

Dust, moisture, etc.

Shock, Vibration, etc.
Operating temperature
RPM, duty cycle

ME 486 - Automation

Summary
Encoders allow feedback loops to be established so as
to gain complete understanding of a joints position
Resolution of 1 in 23 bits is currently achievable via
absolute rotary encoders
Resolution of ~10nm can be achieved in linear
absolute encoders
Improvements in speed and durability are being made
ME 486 - Automation

Q&A

ME 486 - Automation