:

Encoders Basic Training

Mandee Liberty & Vikram Phadke
National Encoder Product Specialists

Typical Industrial System

Input

Operation
(Application)

Controller

Output

Feedback
Sensor

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Encoders within a Control System

Feedback
Sensor

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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

Encoder

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Encoder Definitions

How is this accomplished?

:

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 / LED
Shaft

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Encoder Selection Process

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Encoder Selection Process

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: Confidential

Types of Encoders

Encoder

Rotary Encoder

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Linear Encoder

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Types of Encoders

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Types of Encoders

Encoder

Linear Encoder

Wire Draw

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Linear with Scale

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Types of Encoders

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Types of Encoders

Encoder

Rotary Encoder

Incremental

Linear Encoder

Absolute

Wire Draw

Incremental

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Linear with Scale

Absolute

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Incremental Encoders

Incremental

Produces electrical pulses or increments

with linear or rotary motion

Signals can be square or sinusoidal waves

Signals start over at power up, or after a

power failure. In other words, an incremental
encoder does not retain position after a
power cycle

Incremental encoders are typically used for

speed or applications that do not require
absolute position

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13

Absolute Encoders

Absolute

Code disc for absolute

encoders

LED

Lens

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Absolute encoders retain their position after

a power cycle

Signals typically use SSI, parallel, or field bus

interfaces (Ethernet/IP, EtherCAT, Profinet,
Devicenet, CANopen, Profibus, etc)

Scanning mask
Code disc

PhotoElements

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Provides a unique value for every shaft or

linear position

Absolute encoders are used in applications

were position information is necessary

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Encoder Selection Process

Electrical Interface

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: Confidential

15

Types of Encoders

Encoder

Rotary Encoder

Incremental

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Absolute

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Incremental Encoders
Output Channels

Incremental encoders
-

Resolution
-

produce electrical pulses or increments (usually as a

square wave) with linear or rotary motion of the encoder

The number of pulses or increments per channel, per

revolution. Also known as Pulses Per Revolution, or PPR

Quadrature:
-

The standard convention is to output two square wave

channels along with their complements
Channels A and B are offset by of a cycle using all four
channels with this output, we can interpolate 4 positions
within one pulse cycle. This is known as quadrature
The 1/4th offset also allows us to see which direction the
encoder is turning based on what channel is leading. If
channel A goes high first followed by channel B, we can
determine the direction of rotation, and visa versa.

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17

Incremental Encoders
Electrical Signals

Output Voltages
-

HTL (High Threshold Logic)

-

Also known as push pull

The output voltage will be the same as the supply
voltage (e.g if the supply on the encoder is 24V,
the output signal will also be ~24V)

TTL (Transistor Transistor Logic)

-

Standard output voltages are HTL, TTL or Open Collector.

These refer to the amplitude of the square waves

Also known as a differential line driver or RS422

The output voltage will always be 5V regardless of
the supply voltage on the encoder

Open Collector
-

Instead of outputting a signal of a specific voltage or

current, the output signal is applied to the base of an
internal NPN transistor whose collector is externalized

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18

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
Supply = 5V

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TTL / RS 422
Supply = 10 ... 32V

: Confidential

HTL / Push Pull

Supply = 10 ... 32V

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Open Collector
Supply = 8-24 V

Absolute Encoders
Singleturn vs Multiturn Absolute Encoders

Encoder

Rotary Encoder

Incremental

Absolute

Singleturn

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Multiturn

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20

Singleturn and Multiturn Absolute

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21

Absolute Encoder Interfaces

Absolute
Electronic Interface

Parallel

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SSI

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BUS

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Parallel Output
:

Parallel Output
-

Connection
-

First form of communication for absolute encoders

Point-to-point communication where each output wire

represents a different data bit

Benefits
-

Direct output to digital inputs

Fast (60us typically)

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Drawbacks

Complex cabling due to separate bit wires

High cost

: Name (Date)

23

Synchronous Serial Interface (SSI)

:

Synchronous Serial Interface (SSI)

-

Connection
-

Very common serial interface standard for industrial applications

Developed by Stegmann in 1984 for absolute encoders now in many products

Point-to-point connection from a master (PLC, microcontroller) to a slave (encoder)

Benefits
-

Simple cabling, especially compared to

parallel outputs
Fast communication speeds
Low cost

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Drawbacks

Point-to-point connection, topology restrictions

: Name (Date)

24

Network Encoders

What do we (or the customer) mean when we say network

encoder?
- A network is a collection of products (sensors, HMIs, processes, etc) that are
connected to a central controller or share information between parts.
- Also known as Field Bus

- Example: an Internet VPN (virtual

private network):

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Field Bus Interfaces

:

Field Bus
-

Benefits
-

Industrial network system that connects multiple products in a manufacturing plant or on a

machine

Products are no longer point-to-point which allow multiple products to be connected to one
controller
Generally does not require as many cables as a point to point configuration, and cables do not
need to be as long. This saves on system costs.
Typically the controller has more flexibility for configuration and information gathering

Disadvantages
-

The network topologies are generally more complex

Individual components cost more than standalone products (potential system savings, however)

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: Name (Date)

26

SICK Absolute Encoder Fieldbus Interfaces

AFx60 Series

ATM60 Series
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27

Electrical Interface Summary

Things to know when choosing an encoder

Incremental Encoders
- Resolution (PPR)
- Supply Voltage
- Output Voltage (HTL, TTL or Open
Collector)

Absolute Encoders
- Resolution (singleturn, multiturn)
- Output type

- Programmable Encoders:
DFS60 and DFS2x encoders let you
program ALL electrical configurations
except an open collector output

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Parallel (output voltage needed)

SSI
Fieldbus

- Programmable Encoders
Programmable options for SSI encoders to
program the resolution. All field bus
encoders are programmable over their
respective networks

: Name (Date)

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Encoder Selection Process

Mechanical Considerations

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Mechanical Characteristics

Housings and Connection

-

Housing Size

Cable or Connector

Shafts
-

Solid, blind hollow, through hollow

Sizes, shaft load

Flange
-

Face mounting flange

Servo flange

Square Flange

Tethers

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Encoder Selection Process

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31

Product Overview - Rotary Encoders

Absolute Singleturn Encoders

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: Confidential

Absolute Multiturn Encoders

32

Product Overview - Linear Encoders

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33

Key Products in 2013

Choice encoders that will solve most applications
DFS60 with PGT-10-S
Programming Tool

Handheld, battery
operated programming
tool
Easy menu structure for
fast setup and flexibility
Can be used for
diagnostics with the
display or as a cloning
module

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DFS20/25
Incremental Encoder

USA sized encoders with

SICKs F-Technology:

Wide set bearings for

even shaft loading

Absolute single- and multiturn encoders with

EtherNet/IP, EtherCAT,
and Profinet interfaces

Device Level Ring (DLR)

functionality with the
EtherNet/IP version

Metal code disc for high

vibration and temperature
Programmable using the
PC-based tool

: Confidential

BCG Wiredraw
with Analog Output

AFx60 Series
With Ethernet

Superior diagnostics for

temperature, speed,
runtime, and many more

Compact wiredraw
encoder for applications in
tight spaces

Up to 10m of measuring
length

Analog output scalable

directly on the encoder for
fast commissioning

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Fields of applications

Machine Tooling

Packaging

Print & Paper

Wood industry

Automotive

Ports & Cranes

Handling

And many more

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35

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

CONVEYORS DKV60 used to track speed of conveyor

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36

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

BOTTLING Absolute encoder AFS60 to track position of fillers

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37

Application Examples
STADIUM ROOF Position with KH53 Linear Encoder

LIFT APPLICATIONS Height and Width positioning using BGC Wiredraw Encoders

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38

Additional Resources

SICK University
Tour
March May 2013

Tech Tuesdays
Check www.sickusa.com for
schedule

Product Training

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Demo Cases

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Demonstration Videos
& Application
Animations

39

Marketing Tools

Encoder Catalog
*Update in 2013

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Encoder Selection
Guide

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Application Book

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Thank you for your attention.