Motion Control and Encoder Technology: A Tutorial By Jeremy Jones, Lead Engineer, Encoders Baumer Electric

Sensors and encoders are used everyday in manufacturing environments and high precision equipment to monitor the proximity or presence of an object, as well as the position, distance, direction, and speed of rotating equipment. Encoders enable design engineers to control motion by providing reliable feedback within the process loop. Optical rotary encoders are the most widely used method of transforming mechanical rotary motion into electrical output. Within this classification of encoders are three basic configurations: incremental, absolute, and multi-turn absolute encoders. Containing the same basic components and operating under the same basic principle, each of these configurations deliver different performance characteristics, capabilities, and end use benefits. How Encoders Work: Diagram 1: The Basic Components of an Encoder ***

1. Shaft or Hollow Shaft connects to the rotating object and transfers rotary motion to the pulse disc. 2. Pulse Disc has one or more tracks of alternating clear/opaque segments that are photoelectrically scanned by the light source. 3. Light Source with high quality LED. 4. Grid Diaphragm or Mask splits the light source into a second signal. 5. Photodiode/Decoding Circuitry receives light and converts the information into electrical signals. 6. Connector/Cable transfers signals to the control unit. Diagram 1. The Basic Components of an Encoder Most optical encoders operate on the same basic principal. The light source (3) emits a beam of light through the grid diaphragm or mask (4), which splits the light into a second channel 90 out of phase, an output style called quadrature. The two light channels (A and B), pass through the tempered glass, polycarbonate or metal pulse disc (2) onto the photodiode array (5). The pulse disc (2) is attached via a shaft to the monitored process. As the disc turns, its clear and opaque segments create a light/dark pattern that is read and processed by the photodiode array and encoding circuitry (5). Separate diodes receive each of the two light beams (A and B) and convert them into two squarewave signals (Diagram 2), which are fed into a controller device such as a PLC or counter that monitors the number of pulses generated in order to provide the end user with speed, position, distance or directional data.

Diagram 2. Incremental and Absolute Encoder Outputs The pulse range of an encoder is dictated by the number of tracks of clear and opaque lines located on the disc. Pure and uninterpolated, a pulse disk with a single track of 200 lines would have a pulse range of 200 pulses per revolution (ppr). Each of the three-encoder configurations has different types of pulse discs that allow the encoder to monitor and provide different types and amounts of information.

*** Incremental Encoders The simplest encoder configuration available, incremental encoders are designed to provide only on/off information, and can monitor only the speed, direction, or distance of travel of a device or process. The incremental pulse disc consists of a single track of evenly spaced clear and opaque segments (Diagram 2). Incremental pulse ranges of more than 10,000 ppr are available; however, the maximum ppr can often be improved through interpolation of the quadrature output, making values as high as 131,072 ppr possible. A counter measures the speed of a process simply by timing how fast pulses are supplied by the encoder. Clockwise or counter-clockwise direction is determined as the controller monitors which channel, A or B, rises first. By simply counting the number of pulses that have been supplied since movement began, the counter is able to determine the distance of travel. If power fails, all positional information is lost and a reset or homing cycle must be performed to synchronize the encoder with the control device.

Incremental encoders are commonly used in applications where absolute position is not critical. Among the diversity of potential end uses are length measurement applications such as paper feed monitoring in web presses and wire length oversight in winding/unwinding processes. In these applications, the encoder would be mounted directly to the spool shaft and the pulse count would be converted via the controller into usable length-of-travel information. Incrementals are also found in speed control applications such as conveyors, where the encoder is mounted to the drive motor shaft or roller shaft. Certain positioning applications are also suitable for these devices, including X-Y tables and SMD pick and place machinery where the encoder would be mounted to the servomotors driving the larger process. Absolute Encoders Somewhat more complex, the absolute encoder is capable of monitoring distance, speed, direction and absolute position. These encoders offer a special pulse disc with a series of tracks that make up a binary code (Diagram 2). Each track, executed as a binary bit, has its own series of clear and opaque lines that create an on/off signal. For example, a 12-bit encoder would have 12 individual tracks, each track acting much like a distinct incremental encoder. The absolute pulse range is measured in steps per revolution (spr) and is dictated by the number of bits provided, ranging from 2 to 18. To illustrate, a 12-bit encoder would have 212, or 4096, spr. Read in conjunction with the other tracks on the disc, an absolute encoder provides a unique signal in the form of a binary code for certain angular positions within 360 of rotation. The 12bit encoder mentioned above would be capable of dividing 360 into 4096 steps, resulting in an angular resolution of approximately 5 minutes, 16 seconds. Positional information is not lost if power is interrupted. Absolute encoders are commonly used in robotics, where accurate positional information is critical to the safety of the operation. In a robotic arm application, an absolute encoder can be mounted at each joint, with the encoder body mounted to the stationary portion of the joint and the shaft coupled to the axis spindle of the arm. From this position, the encoder can track exact arm angle and position. In the event of a mid-operation power loss, positional information is retained and the robotic arm knows its position upon power restoration. Increasingly, absolute encoders are designed into high-end satellite dish and radio telescope systems where they verify extremely precise dish positioning on the 360 horizontal plane and the 180 vertical plane. Multi-Turn Absolute Encoders While an absolute encoder technologies provides information over one revolution, multi-turn absolute encoders supplies absolute position of a spindle or process over many revolutions. Like absolute encoders, multi-turns have a unique code for each position within the 360 of rotation, and also offer unique codes for each revolution.

Multi-turns incorporate standard absolute technology, but add another internal counting process to monitor and track the number of rotations. Some multi-turn manufacturers rely upon an accurate gear driven tracking system, which can be complex, expensive, and prone to breakage and wear. Other encoder manufacturers rely upon a non-contact, longer-life tracking system that counts revolutions and monitors directional information through the use of a two-poled magnetic rotor and an array of reed switches. This system, designed with a battery back up for the multiturn stage electronics will save all positional information in the event of a power loss.

Multi-turns are commonly used in elevators, where they monitor, via a pulley shaft, the exact position of the car. Due to the many rotations of this pulley, the multi-turn is the only encoder capable of offering exact positioning information for the entire route of the car. Multi-turns are also used in medical equipment, such as CAT scan machines, where they are mounted to the drive system of the patient carriage to monitor exact position for fine scanning. These encoders have also been used to monitor the position of screw-driven overhead gantries. Styles and Technical Specifications In order to accommodate the many mounting needs of industrial processes, the three styles of optical encoders are available in a wide array of sizes and housing styles. These encoders are available in shaft, hollow shaft and through shaft versions. Housing sizes vary from smaller than 18 mm in diameter to well over 150 mm, with shafts as small as 1.5 mm to larger than 40 mm. In hollow and through-shaft versions, encoders are commonly designed to accept shafts from less than 2 mm in diameter to 50.8 mm (two inches). Protection ratings run as high as IP 68 (NEMA 6). Cable and connector versions are available. What you will need to specify an encoder: Incremental or absolute? Does the application require memorization of position? Is the information required over one revolution, or many? Electrical input/output? What are the electrical requirements? Physical mounting needs (shaft/housing dimensions) Pulse Range (ppr or spr) Degree of environmental protection Connection requirements (radial or axial, bus system considerations)

Encoders can be ordered with 4.5 to 30 Volt outputs, with additional features such as TTL compatibility, Line Driver capability, Short Circuit and Reverse Polarity Protection, Push-Pull outputs, and PNP and NPN Open Collector Transistor outputs. Additionally, absolute and multiturn encoders are available with different types of binary code outputs, such as Natural Binary Code, Gray Code, and Binary Coded Decimal (BCD). For todays industrial world, the newest multi-turn encoders offer resolutions as high as 36-bit capability (18 for steps per revolution, 18 for total revolutions), creating a need for other interfaces, due to wiring complexities, aside from standard parallel outputs. For this reason, many manufacturers have turned to simpler interfaces, such as Synchronous Serial Interface (SSI). Additionally, in order to simplify the integration of products into plant systems, many

manufacturers have added Bus system interfaces, such as Profibus-DP, CANbus, CANopen, Interbus-S, DeviceNet, and Suconet-K. Additionally, RS-485 interface encoders are available. In Mounting encoders, certain precautions must be taken. For shafted encoders, end users must either manufacture or purchase the coupling devices used for mating to the shaft, as well as the equipment used to mate the actual encoder housing to the device. Hollow shaft encoders have eliminated the need for coupling devices, and have greatly simplified the mating of the encoder by mounting and fixing directly to the shaft to be monitored, dramatically reducing installation times.