Servo Motors Encoders _ Optical and Magnetic, Incremental and Rotary

8/10/2019 Servo Motors Encoders _ Optical and Magnetic, Incremental and Rotary

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28/9/2014 Encoders | Optical and Magnetic, Incremental and Rotary

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Encoder Guide

What is an Encoder?

An encoderis a sensor of mechanical motion that generates digital signals in response to motion. As an electro-mechanicalan encoder is able to provide motion control system users with information concerning position, velocity and direction. Theredifferent types of encoders: linear and rotary. A linear encoder responds to motion along a path, while a rotary encoder resrotational motion. An encoder is generally categorized by the means of its output. An incremental encoder generates a trainwhich can be used to determine position and speed. An absolute encoder generates unique bit configurations to track positidirectly.

Block Diagram for Encoders

Basic Types of Encoders

Linear and rotary encoders are broken down into two main types: the absolute encoder and the incremental encoder. The cof these two types of encoders is quite similar; however they differ in physical properties and the interpretation of movement

Incremental Encoder
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An Incremental rotary encoder is also referred to as a quadrature encoder. This type of encoder utilizes sensouse optical, mechanical or magneticindex counting for angular measurement.

How do Incremental Encoders Work?

Incremental rotary encodersutilize a transparent disk which contains opaque sections that are equally spacdetermine movement. A light emitting diode is used to pass through the glass disk and is detected by a photoThis causes the encoder to generate a train of equally spaced pulses as it rotates. The output of incremental rencoders is measured in pulses per revolution which is used to keep track of position or determine speed.

A single-channel output is commonly implemented in applications in which direction of movement is not signifiInstances in which direction sensing is important, a 2-channel, quadrature, output is used. The two channels,are commonly 90 electrical degrees out of phase and the electronic components determine the direction basephase relationship between the two channels. The position of an incremental encoder is done by adding up allpulses by a counter.

A setback of the incremental encoder is count loss which occurs during power loss. When restarting, the equimust be referenced to a home position to reinitialize the counter. However, there are some incremental encodthose sold at Anaheim Automation, which come equipped with a third channel called the index channel. The ichannel produces a single signal pulse per revolution of the encoder shaft and is often used as a reference mreference marker is then denoted as a starting position which can resume counting or position tracking.

NOTE:Incremental rotary encoders are not as accurate as absolute rotary encoders due to the possibility ofinterference or a misread.

Absolute Encoder

An absolute encoder contains components also found in incremental encoders. They implement a photodetecLED light source but instead of a disk with evenly spaced lines on a disc, an absolute encoder uses a disk witconcentric circle patterns.

How do Absolute Encoders Work?

Absolute encoders utilize stationary mask in between the photodetector and the encoder disk as shown belooutput signal generated from an absolute encoder is in digital bits which correspond to a unique position. Theconfiguration is produced by the light which is received by the photodetector when the disk rotates. The lightconfiguration received is translated into gray code. As a result, each position has its own unique bit configurati

Single-Ended Encoder
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Linear Encoder

A linear encoder is a sensor, transducer or reading-head linked to a scale that encodes position. The sensor rscale and converts position into an analog or digital signal that is transformed into a digital readout. Movemendetermined from changes in position with time. Both optical and magnetic linear encoder types function usingof method. However, it is their physical properties which make them different.

How do Optical Linear Encoders Work?

The light source and lens produce a parallel beam of light which pass through four windows of the scanning rfour scanning windows are shifted 90 degrees apart. The light then passes through the glass scale and is detphotosensors. The scale then transforms the detected light beam when the scanning unit moves. The detectiolight by the photosensor produces sinusoidal wave outputs. The linear encoder system then combines the shisignals to create two sinusoidal outputs which are symmetrical but 90 degrees out of phase from each other.reference signal is created when a fifth pattern on the scanning reticle becomes aligned with an identical pattescale.

How does a Linear Encoder Work?

A Linear Encoder system uses a magnetic sensor readhead and a magnetic scale to produce TTL or analog oChannel A and B. As the magnetic sensor passes along the magnetic scale, the sensor detects the change infield and outputs a signal. This output signal frequency is proportional to the measuring speed and the displacthe sensor. Since a linear encoder detects change in the magnetic field, the interference of light, oil, dust, and

have no effect on this type of system; therefore they offer high reliability in harsh environments.


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Magnetic Rotary Encoder

A magnetic encoder consists of two parts: a rotor and a sensor. The rotorturns with the shaft and contains alternating evenly spaced north and southpoles around its circumference. The sensor detects these small shifts in theposition N>>S and S>>N. There many methods of detecting magnetic fieldchanges, but the two primary types used in encoders are: Hall Effect andMagneto resistive. Hall Effect sensors work by detecting a change in voltageby magnetic deflection of electrons. Magneto resistive sensors detect achange in resistance caused by a magnetic field.

Hall-Effect sensingThe Sensor produces and processes Hall-Effect signals producing a quadrature signal as is common with optiencoders. The output is generated by measuring magnetic flux distributions across the surface of the chip. Thaccuracy is dependent on the radial placement of the IC with respect to the target magnet. The chip face shouparallel to the magnet so the magnet to sensor air gap is consistent across the sensor face.

Magnetic encoders avoid the three vulnerabilities that optical encoders face: Seal failures which permit the entry of contaminents The optical disk may shatter during vibration or impact Bearing failures

Magnetic devices designed effectively eliminate the first two failure modes and offer an opportunity to reducefailures as well. Magnetic encoders do not make errors due to contamination because their sensors detect varmagnetic fields imbedded in the rotor and oil, dirt and water do not affect these magnetic fields.
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Hall-Effect sensors generally have lower cost and are less precise than magnetic resistive sensors. This meaHall-Effect sensors, when used in an encoder produce more "jitter", or error in the signal caused by sensor va

Commutation Encoders

A commutation encoder contains the same fundamental components as incrementalencoders but with the addition of commutation tracks alongside the outer edge of the diskfor U/V/W output.

How do Commutation Encoders Work?

Commutation encodersutilize a transparent disk which includes opaque sections that areequally spaced to determine movement. A light emitting diode is used to pass through theglass disk and is detected by a photo detector. This causes the encoder to generate a train of equally spacedit rotates. The output of incremental rotary encoders is measured in pulses per revolution which is used to keeposition or determine speed.

The outer part of the encoder disk includes commutation tracks which provide a controller with information onposition of the motor poles, so that the proper controller input can be supplied to the motor. The commutationthe encoder read the motor position and instruct the controller as to how to provide efficient and proper currenmotor to cause rotation. Commutation output for U/V/W can be in the form of differential output or open-collec(manufacturer dependent).

How are Encoders Controlled?

Encoders are controlled through the rotation the shaft it is mounted to. The shaft comes into contact with a hub which is in in

the encoder. As the shaft rotates, it causes the disc, with both transparent and solid lines, to rotate across the circuitry of theThe circuitry of the encoder contains an LED which is captured by a photoelectric diode and outputs pulses to the user. Thewhich the disc rotates will be dependent on the speed of the shaft the encoder is connected to. Anaheim Automation's opticmagneticencoder lines are powered from a single +5VDC power source, and is able to sing and source 8mA each.

Physical Properties

Linear Encoders

The key components of a linear encoder are a scanning unit, sensor, transducer or readhead, paired with a transmisreflective scale, which encodes position. The scale of a linear encoder is generally made of glass and mounted to a sand the scanning unit contains a light source, photocells, and a second glass piece called the scanning reticle. Colleclinear encoder is able to convert motion into digital or analog signals to determine the change in position over time.

Rotary Encoders

The key components of a rotary encoderare the disk, light sources and detectors, and electronics. The disk containpattern of concentric etched circles and alternates between opaque and transparent segments. This pattern providesconfigurations and is used to assign specific positions. For every concentric ring in a rotary encoder, there is a light slight detector which identify lines etched on the disk. The electronics consist of an output device which takes the signobtained from the sensor (light/detector source) to provide feedback of position and/or velocity. All of these componeenclosed in a single housing unit.
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Incremental Encoders

The key components of an incremental encoderare a glass disk, LED (light emitting diode), and a photo detector.transparent disk contains opaque sections which are equally spaced to deflect light while the transparent sections allbe passed through shown in Figure 2 below. An optical encoder utilizes a light emitting diode which shines light throutransparent portions of the disk. The light that shines through is received by the photo detector which produces an elsignal output.

Where are Encoders Used?

Encoders have become a vital source for many applications requiring feedback information. Whether an application is concspeed, direction or distance, an encoders vast capability allow users to utilize this information for precise control. With the eof higher resolutions, ruggedness, and lower costs, encoders have become the preferred technology in more and more areaencoder applications are all around us. They are utilized in printers, automation, medical scanners, and scientific equipment.

Anaheim Automation's cost-effective encoderproduct line is a wise choice for applications requiring feedback control. Anah

Automation's customers for the encoder product line is diverse: industrial companies operating or designing automated macinvolving food processing, labeling, cut-to-length applications, conveyor, material handling, robotics, medical diagnostics, anmachinery.

Encoders are used in Many Industries

Encoders have become an essential component to applications in many different industries. The following is a partialindustries making use of encoders:

Automotive The automotive industry utilize encoders as sensors of mechanical motion may be applied tospeed.

Differential-Type Encoder
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Consumer Electronics and Office Equipment In the consumer electronics industry, encoders are widelyoffice equipment such as PC-based scanning equipment, printers, and scanners. Industrial In the industrial industry, encoders are used in labeling machines, packaging and machine toolisingle and multi-axis motor controllers. Encoders can also be found in CNC machine control. Medical In the medical industry, encoders are utilized in medical scanners, microscopic or nanoscopic mocontrol of automated devices and dispensing pumps. Military- The military also utilizes encoders in their application of positioning antennas.

Scientific Instruments Scientific equipment implement encoders in the positioning of an observatory tele

Applications for Encoders

An encoder can be used in applications requiring feedback of position, velocity, distance, etc. The examples listed below illuvast capabilities and implementations of an encoder:

Assembly Machines Packaging X and Y Indication Systems Printers Testing Machines CNC Machines

How to Select an Encoder

There are several important criteria involved in selecting the proper encoder: 1. Output 2. Desired Resolution (CPR) 3. Noise and Cable Length 4. Index Channel 5. Cover/Base

Output

The output is dependent on what is required by the application. There are two output forms which are incremental anabsolute. Incremental output forms take form of squarewave outputs. For an application requiring an incremental encoutput signal is either zero or the supply voltage. The output of an incremental encoder is always a squarewave due tswitching of high (input voltage value) and low (zero) signal value. Absolute encoders operate in the same manner aincremental encoders, but have different output methods. The resolution of an absolute encoder is described in bits.of absolute encoders is relative to its position in a form of a digital word. Instead of a continuous flow of pulses as seincremental encoders, absolute encoders output a unique word for each position in form of bits. Equivalent to 1,024revolution, an absolute encoder is described to have 10 bits (210 = 1024).

Desired Resolution (CPR)

The resolution of incremental encoders is frequently described in terms of cycles per revolution (CPR). Cycles per reare the number of output pulses per complete revolution of the encoder disk. For example, an encoder with a resoluti1,000 means that there are 1,000 pulses generated per complete revolution of the encoder.

Noise and Cable Length

When selecting the proper encoder for any application, the user must also take into account noise and cable length.cable lengths are more susceptible to noise. It is crucial to use proper cable lengths to ensure the system functions cis recommended to use shielded, twisted-pair cables with preferably low capacitance value. The rating for capacitancnormally in capacitance per foot. The importance of this rating is for well defined squarewave pulse outputs from therather than "jagged" or "saw-toothed" like pulses due to the interference of noise.

Index Channel

The index channel is an optional output channel which provides a once per revolution output pulse. This pulse allowsuser to keep track of position and establishes a reference point. This output channel is extremely valuable for increm

encoders when an interruption of power occurs. In instances with a power failure, the last sustained index channel caas a reference marker for a restarting point. Therefore, when such an occurrence takes place, an index channel canbe quite valuable in applications utilizing incremental encoders. Absolute encoders do not have an issue with losing tposition in power loss situations, because every position is assigned a unique bit configuration.

Cover/Base

Cover and base options are considerations for specific application requirements. Enclosed cover options help protectencoder from dust particles. Base options play a significant role in large vibration environments. Such mounting optiotransfer adhesives which stick directly on the back of the encoder to the mounting surface, molded ears for direct mo

Anaheim Automation also offers various base options for mounting purposes.

Robotics Labeling Machines Medical Equipment Textiles Drilling Machines Motor Feedback


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Anaheim Automation offers a selection of cover and base options to meet your application needs.

Cover Options:

E-Option: Enclosed Cover H-Option: Hole Diameter

Base Options:

3-Option: All five Hole diameters become .125 A-Option: Adds Alignment Shoulder

G-Option: Molded Ears R-Option: 3-slot Adapter Plate T-Option: Transfer Adhesive

How to Install an Encoder

After selecting the appropriate motor, it is important to know how to properly install it. The installation of each encodedependent upon its mounting or base option. If an encoder is to be mounted to a motor shaft, then a centering tool cto align the hole of the encoder to the shaft. The different mounting options have varying functionalities. An R-optiona +/- 15 degree play of motion in which the encoder can rotate back and forth. A T-Option however, uses adhesive tothe back of a motor.

For step by step instructions on installing an Anaheim Automation encoder, watch our video tutorials here. AnaheimAutomation also provides the option of an encoder adder, where we mount the encoder for you, hassle free!

Advantages of an Encoder

- 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 an Encoder

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

Troubleshooting

PLEASE NOTE:Technical assistance regarding its Encoder line, as well as all the products manufactured or distributed byAutomation, is available at no charge. This assistance is offered to help the customer in choosing Anaheim Automation prod
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specific application. However, any selection, quotation, or application suggestion for an Encoder, or any other product, offerAnaheim Automation's staff, its' representatives or distributors, are only to assist the customer. In all cases, determination ofthe custom Encoder in a specific system design is solely the customers' responsibility. While every effort is made to offer solregarding the Encoder product line, as well as other motion control products, and to produce technical data and illustrationsaccurately, such advice and documents are for reference only, and subject to change without notice.

Problem:No output

Solution:No output may be a result of various factors. Steps can be taken to ensure the proper functionality of the encoder.mechanical movement results in any signal being output from the encoder. To correct this issue, observe if the encoder is roVerify all wring between the encoder and the driver/controller is correct and the appropriate voltage supply is used. Having lconnections or improper voltage supply may not allow the encoder to function properly. Finally, ensure the correct signal typopen collector, pull-up, line driver or push-pull) is being used for your application. If the problem persists, swap encoders, ifto determine if the encoder is the issue.

Problem:Unable to find index pulseSolution:The index pulse, or reference marker, is a once per revolution output of an encoder and is best found using an osVerify all the wiring between the encoder and the driver/controller is correct and the appropriate voltage supply is used. If thsolve the issue, try lowering the RPM of the motor, as the driver/controller may not be able to identify the index pulse at veryRPM values.

Problem:Count output indicates incorrect directionSolution:If the count output indicates an incorrect direction then check for the wire configuration. See if any wires are reverthey are reversed, simply swap wires.

NOTE:If your application is using index, reversing the wire configuration causes the reference alignment to also change. Ifmake the appropriate changes to your application.

Problem:Encoder is not rotatingSolution:When encoders are exposed in open environments, dust and debris particles may accumulate around the shaft.clean the exposed area and ensure that there are not objects obstructing the encoder from rotating.

Problem:Noise InterferenceSolution:To improve the noise immunity of encoders it is strongly advised that no other electrical equipment be nearby or ba fair distance. Encoder cables should also be shielded and proper wires should be grounded to minimize electrical noise.

Problem:Distorted or incorrect outputSolution:Distorted or incorrect output can be any combination of loose wiring connections, encoder output not compatibledriver/controller, electrical noise or improper alignment. Check for wire connections, compatibility issues with the encoder andriver/controller, alignment of the encoder and the shaft to solve this issue.

Formulas

The relationship between the encoder CPR frequency and the speed of the motor (RPM) is given by the following eq

f = (cycles/rev)*(rev/sec)/1000 = kHz

RPM = Revolution per MinuteCPR = Cycles per Revolution

Distance Conversion:

(PPR) / (2*pi*radius of shaft) = pulses per inch(Pulses per inch)^-1 = inch per pulse

Glossary

Absolute Encoder- provides the shaft position in a bit configuration and is able to maintain or provide absolute position evinstances of power loss/failure.

Accuracy difference in distance between the theoretical and the actual position.

Cycles Per Revolution (CPR)- Cycles per revolution are the number of output pulses per complete revolution of the encod

Encoder- is a sensor of mechanical motion that generates digital signals in response to motion.

Incremental Encoder- device that provides a train of pulses due in response to mechanical motion. The output of this encform of a squarewave.

Index- a separate output channel which provides a single pulse per shaft revolution. It can be used to establish a reference
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Line Driver - is a sourcing output. This means that when in ON' state the line driver will supply Vcc and in thestate the driver will float. A sinking input is required for line driver applications.

Push-Pull - is a combination between a line driver and an open collector. In the OFF' state it will be groundedthe on ON' state it will supply Vcc.

7. Which of the following are encoder advantages?

A. Low costB. High resolutionC. High reliability and accuracyD. Compact sizeE. Integration between optical and digital technologyF. All of the Above

8. Quadrature channels are out of phase by how many electrical degrees?

A. 45B. 120C. 60D. 90

9. List the criteria for selecting an encoder:

1. Output2. Desired Resolution (CPR)3. Noise and Cable Length4. Index Channel5. Cover/Base

10. Calculation: If an encoder has a resolution of 1024 and is mounted to a shaft of diameter 1", what will be the pulses per iinch per pulse with this combination?

(1024*4)/(2*pi*.5) = 1303.79 pulses per inch(1303)^-1 = .000767 inch per pulse

Encoder FAQs

Q: What is an encoder?A:An encoder is a sensor of mechanical motion that generates digital signals in response to motion.

Q: How do you install an Encoder?A:For step by step tutorials on how to install Anaheim Automation's encoders, click here.

Q: What is the difference between absolute and incremental encoders?A:Absolute and incremental encoders are different in two ways: - Every position of an absolute encoder is unique - An absolute encoder never loses its position due to power loss or failure. Incremental encoders lose track of position uploss or failure

Q: What is a channel?A:A channel is an electrical output signal from an encoder.

Q: What is a quadrature?A:A quadrature has two output channels, with repeating squarewaves, which are out of phase by 90 electrical degrees. Frophase difference, the direction of rotation can also be determined.

Q: What is an index pulse?A:The index pulse, also referred to as a reference or marker pulse, is a single output pulse produced once per revolution.
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Q: What other types of encoder technologies are there?A:There are two types of encoder technologies. - Optical: This type of technology uses a light shining into a photodiode through slits in a metal/glass disk. - Magnetic: Strips of magnetized material are placed on rotating discs and are sensed by Hall-Effect Sensors or magnetosensors.

Q: What types of applications are encoders implemented in?A:They are frequently utilized in stepper motors, automation, robotics, medical devices, motion control and many other aprequiring position feedback.

Q: Does any encoder disk (codewheel) work with any encoder module?A:No, each resolution and each disk diameter works with a different encoder module.

Q: What is PPR?A:PPR stands for pulse per revolution in rotational motion for rotational motion and pulse per inch or millimeter for linear m

Q: When can a single output channel be used in an incremental encoder?A:A single output channel for an incremental encoder can be used when it is not important to sense direction. Such applicamake use of tachometers.

Q: Will Anaheim Automation mount an encoderto motors?A:Yes, a special part number would be created for including the encoder attached to a motor.

Required Maintenance

Encoders require very little maintenance due to their ruggedness and reliability. However, it is recommended to minimize anexposure to dust particles or debris and also, unless designed for exposure to water or moisture. Also, under duress of shocvibrations, encoder discs may become scratched resulting in encoder failure. If such an event occurs, the disc may need toreplaced to provide accurate readings.

Environmental Considerations for an Encoder

The following environmental and safety considerations must be observed during all phases of operation, service and repairencoder. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of anPlease note that even with a wellbuilt encoder, products operated and installed improperly can be hazardous. Precaution mobserved by the user with respect to the load and operating environment. The customer is ultimately responsible for the proselection, installation, and operation of the encoder.

The atmosphere in which an encoder is used must be conducive to good general practices of electrical/electronic equipmenoperate the encoder in the presence of flammable gases, dust, oil, vapor or moisture. For outdoor use, the encoder must be

from the elements by an adequate cover, while still providing adequate air flow and cooling. Moisture may cause an electrichazard and/or induce system breakdown. Due consideration should be given to the avoidance of liquids and vapors of any kContact the factory should your application require specific IP ratings. It is wise to install the encoder in an environment whicfrom condensation, dust, electrical noise, vibration and shock.

Additionally, it is preferable to work with encoders in a nonstatic, protective environment. Exposed circuitry should always bguarded and/or enclosed to prevent unauthorized human contact with live circuitry. No work should be performed while powapplied. Don't plug in or unplug the connectors when power is ON. Wait for at least 5 minutes before doing inspection workencoder after turning power OFF, because even after the power is turned off, there will still be some electrical energy remaiinternal circuit of the encoder circuitry.

Plan the installation of the encoder in a system design that is free from debris, such as metal debris from cutting, drilling, tapwelding, or any other foreign material that could come in contact with the circuitry. Failure to prevent debris from entering thcan result in damage and/or shock.

Lifetime of an Encoder

The lifetime of an encoder is dependent on various factors such as environmental exposure and application use. By limitingexposure of the encoder to electrical equipment, temperatures above recommended values, condensation, and vibration anand using the encoder as directed by the manufacturer can extend the lifetime of an encoder.

Accessories

Along with the encoder line, Anaheim Automation carries a comprehensive line of single-ended and differential encoder cafour, six, and eight leads, cable lengths up to 16 feet, and encoder centering tools. Additionally, Anaheim Automation offersextended line of stepper, brushless, and servo motorswhich can implement encoders for your application needs.
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Servo Motors Encoders _ Optical and Magnetic, Incremental and Rotary

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Transcript of Servo Motors Encoders _ Optical and Magnetic, Incremental and Rotary