Encoder

What is an encoder, what are its types, and what is it used for?
Do they serve?
It has existed for several years and many times we take it for granted. The encoder—also
called encoder or pulse generator—is a fundamental piece of engineering for the
industry and the workshop. But, what is this encoder for and what is it used for?

The encoder is an electromechanical device that allows encoding mechanical movement into
different types of electrical impulses: binary digital, analog based on a wave,
pulses, etc. In this way, an encoder is an interface between a mobile mechanical device
and a controller.

Encoder: measurement principles

There are two main types of pulse encoders or generators: linear and rotary.
each group in turn has different types of encoding (absolute and incremental) and principles
electromechanical operation that we will see next.

Magnetic sensor

magnetic linear encoder

In these sensors, a magnetized tape is used or one made with a material of
variable magnetic reluctance; the position is determined using reading heads
magneto-resistive or with solenoids.

The main problem with these sensors is that, as can be easily deduced, they are
susceptible to intense magnetic fields, which makes them not recommended in environments
where there are high electromotive forces, such as high voltage transformers or
large engines nearby.

As an advantage, they are very reliable in reading, and relatively inexpensive. They can achieve
resolutions on the order of micrometers.

Optical sensor

Optical linear encoder

These encoders work on a simpler principle than magnetic: an optical sensor
records the changes on a tape, which may be encoded in Moiré patterns, holographic
and others.

The main advantage of this type of encoder is the great precision it allows to achieve.
Order of microns. Another great advantage is that it allows operation without the need for contact.
physical between the parts, which makes it suitable for applications where friction must
to avoid oneself.

On the other hand, the main disadvantage is its great susceptibility to dirt in the form of
particles, so it is necessary to ensure the hermeticity of the assembly.
Capacitive sensor

Capacitive rotary encoder

This sensor operates by measuring the capacitance between the scale and the reader head. Because the
reading is done without physical contact, it is mainly used in measurement applications:
calibers, dials, etc.

Its disadvantage is that it is susceptible to the presence of dirt on the reading head or on the
scale, so its airtight closure must be ensured for error-free operation.

Inductive sensor
This technology is the most robust and allows its use in environments where it is impossible to isolate.
the instrument of pollutants such as refrigerants or particles. As
On the other hand, we can say that the accuracy is not as high as in the other options.

Eddy current sensor

This patented model consists of a scale on which non-intercalated materials are placed.
high and low susceptibility magnets, which allow detection through analysis of the
variation in inductance within an alternating current circuit.

This type of decoder is mostly used in rotary encoders.

Linear and rotary encoders

Beyond the technology used to carry out the measurement itself, we can differentiate
these instruments according to the type of movement they allow: a linear movement or one
rotating around an axis.
Linear encoder
It is the simplest type of pulse generator; a clear example of its existence.
it occurs in digital calipers, where the measurement is displayed on a digital screen: behind
the moving piece (slider) has a capacitive encoder that is responsible for reading, by interpolation,
the distance traveled from zero.

Basically, a linear encoder consists of a fixed module and a movable one (the one that connects to the
moving parts of the machine with which the interface will be made). The fixed module contains the sensor and
the electronics necessary to detect and measure movement, and convert it into pulses
intelligible electrical signals for another digital or analog circuit.

The reading module can use different technologies to measure the position of the movable rod.

Rotary encoder

Optical rotary encoder

On these devices, reading is done from a disk, on which side there is the
coding that allows discerning the angular position— which, as we will see later,
it can be relative or absolute—with great precision.

The most common uses occur in industrial machine controls such as spindles.
of lathes andmilling machinesCNC, robotic arms, electronic instrument controls (dials) and
It is even possible to still see them in old computer mice or in some trackballs.

Incremental and absolute encoders

The way the encoder—whether linear or rotary—detects movement
will allow setting the position in either relative or absolute form.

Incremental detection
This type of encoder detects movement—and the distance traveled in that movement—
thanks to the differential detection of two values encoded on the detectable surface.

The advantage of this system is that it is more economical than the absolute encoder, and it allows
maintain the same accuracy regardless of the length of the moving part; as
disadvantage we must point out that, to initialize, the system needs to position
list in an unspecified order.

Absolute detection
In this case, the encoding on the surface of the moving part includes the actual position from
the zero point of the scale; in this way, it is possible for the instrument to know its position without
need to move it. This is something particularly useful when for some reason the machine—
to which it offers interface—restarts.

The disadvantage is that more coding cues are needed to include the information of
position; something that, as more length is required with the same precision, becomes more expensive
more the necessary electronics.
Encoders, Applications in Industry
Encoders are widely used in the industry for motion control.
specifically by manufacturers of conveyor belts, of customized machines.
They are also used in material handling systems, similarly in the industry.
printing and labeling, of packaging. Although there are many more applications such as
custom cutting, markers, robotics, packers, automation
classification, filling, etc., Next, some of the previously mentioned applications will be revisited
mentioned to gain a better understanding of how to use the encoder and the
benefit that comes from putting them into practice. Hoping that the information provided is
of great use, to undertake or improve the optimization of your industry.

Figure 1. Encoders in the industry

What is an encoder?

Before entering their applications, we must start by defining the concept of encoder. Therefore, a
an encoder is a detection device that provides a response. Encoders convert the
movement in an electrical signal that can be read by some type of control device in a
system of control of movement such how a counter o PLC.
The encoder sends a response signal that can be used to determine the position, count,
speed or direction. A control device can use this information to send a command to
a specific function. Likewise, this rotary transducer, through an electrical signal
generally a pulse or a sine wave indicates the rotated angle. Furthermore, this rotary sensor to
mechanically connecting it with a wheel or a screw will also allow for measuring linear distances. For
to understand a little more about how encoders work, read the following [Link] and
types of Encoders
Figure 2. Descriptive image of the structure of an encoder

APPLICATIONS IN THE INDUSTRY

USED BY CONVEYOR BELT MANUFACTURERS

In this case, the products made by these manufacturers are focused on material handling.
products come in various shapes including bands, strips, rollers, etc., packaged in different ways
combinations of motor y actuation.
Since most conveyors do not use a servo motor that has a device of
feedback positioning. In addition to being composed of standard AC or DC motors and without
feedback device that makes the control package an OPEN-LOOP system. Therefore,
which, if required, the manufacturer must offer the option of an electric feedback system
CLOSED-LOOP, this will lead to the use of rotary encoders (encoder) and that are
mounted on the drive shaft or the friction coupled to the belt to measure the speed or the
position.
Figure 3. Application of encoder for the manufacture of belts

MATERIAL HANDLING

Conveyors are used to transfer material from one place to another in almost all parts of a
material handling system. The encoder provides electrical feedback to the drive
of the conveyor motor. The encoder is used to calculate the speed (tachometer) and provide
position information. The encoders are specially designed to be mounted above or
below the conveyor and mount on the belt. They can also be mounted on the motor or on the shaft.

Thanks to the applications that Big Data has had today, the process of seeking positioning
and interest in business markets, it is practical and even more so because of the equipment that exists today for
the acquisition and processing of data that help carry out these tedious statistical calculations and
sometimes complex, depending on the size of the data. At the same time in the studies of
current markets can receive quick feedback from it, even on a global level
without having to wait a long time, which was what was done before with a 'focus group' or survey.
Figure 4. Application of encoder in the material handling industry (transport).

PRINTING AND LABELING INDUSTRY

The printing and labeling industry uses many types of automated machinery. The coders
Rotaries are crucial for all these applications to provide position feedback and
speed. They are used in processes such as: inkjet printing, band guide, feeders
paper, alignment and positioning of labels, high-speed automation, alignment of
labels in paper y the coordination of axes of rollers multiple.
The printing team generally measures and generates images with resolutions measured in dots per
inch (DPI) or pixels per inch (PPI). Resolution is a keyword for the industry of
printing. The coincidence pulses (PPR) per revolution against (DPI) are very important for
optimize the correct alignment of a printing application. When encoders are specified
rotating for certain printing applications, the resolution of the disk is generally correlated with
the print resolution. For example, many industrial inkjet printing systems
they use a rotary encoder to track the movement of the object to be printed. This allows for
Print head applies the image to a precisely controlled location on the object.
Figure 5. Application of encoders in the printing and labeling industry.

CUSTOM MACHINE MANUFACTURERS

Custom machine manufacturers produce highly integrated and customized machines in

many industrial sectors, such as medical, automotive, food and beverage, and management of
materials. These machines are used in processes such as assembly, testing, inspection, manufacturing
adjusted and many other automation procedures. All the equipment produced by a generator
custom machine requires some type of position or speed feedback device
to determine the rotation position of various parts. In the packaging industry, the equipment /
Machinery generally involves a rotational movement. This includes movements or procedures.
such as indexing, transport, gluing or sealing, flying trimmings, as well as other functions of the
machine that offers a rotating axis. To control all these packaging procedures and maintain the
precision, a rotary encoder is needed.
Figure 4. Application of encoders to manufacture special machines

Packaging

In the packaging industry, equipment/machinery generally involves a rotational movement.

This includes movements or procedures such as indexing, transporting, gluing or sealing,
flying cuts, as well as other functions of the machine that offer a rotating axis. To control all
These packaging procedures and maintaining accuracy require a rotary encoder.
Logicbus presents us with the following encoders from the Tri-Tronics brand that offers this industry many
options that will work for several applications suitable for carrying out this function.

Figure 7. Application of the encoder in the packaging industry

Logicbus presents us with the following encoders from the Tri-Tronics brand, which offers this industry many
options that will work for various applications suitable for carrying out this function

R22-P240AJB/8-30S3MW1-0
DAQ HAT card for Raspberry Pi. 8 Common terminal Analog Inputs, 12 bit, 100KS/s. Range +
-10VDC. Power supply: 333 V provided by the Raspberry Pi. Up to eight can be stacked.
MCC devices 118. Raspberry Pi not included

Figure 8. Image of the R22-P240AJB/8-30S3MW1-0

An incremental encoder that uses precision measuring wheel(s) to measure directly the
movement of a conveyor belt, or to accurately measure the material in motion. The
wheel encoders provide more accurate tracking of the conveyor belt or other material that
the axis encoders. Two problems with the axis encoders in this application are:
(1) The sliding of the cinta carrier in the roller.
(2) The inaccuracy of the diameters of the rollers.
Both contribute to the inaccuracies that reduce the overall efficiency of a classification system.
material handling a precision omeasurement system.
Unlike wheel encoders that move directly over the material in
movement, using a tread that has a high coefficient of friction and has a torque
of very low startup that practically does not produce wheel slip on the belt. Additionally, the
wheels if they grind with precision with tolerances exactly.
Incremental encoders with wheels are used for measurement in the printing industry.
precision for directly measuring the movement of a set of printing or labeling rollers.
The wheel encoders can be mounted directly on a drive roller to determine the
speed or positioning feedback. In addition, the wheels are precisely ground.
to the exact tolerance.

Series R

The shaft encoders are designed for direct coupling to a device shaft. Therefore,
They generate a specific output pulse for each revolution of that axis of the Device. To adapt or adjust.
the angular and rotational misalignment between two shafts; Tri-Tronics recommends a shaft coupling
flexible or similar. Direct mounting is not recommended and can minimize or reduce the lifespan of
bearing. The R20 incorporates high-strength bearings that can be used to drive a shaft of
distribution and/or pulley system.
Series HS

The hole axis encoders are designed with a through shaft or a shaft with a blind hole, and they are
designed to be mounted directly on a motor or other shaft. This eliminates the need for a
shaft to shaft coupling and mounting adapter, which helps save space and money. The encoder
floats on the motor axis. A flexible mounting anchor or support prevents the encoder from rotating, but it
adapt to axis misalignment.

CONCLUSIONS

It is advisable to use encoders for shafts as it helps to avoid precision issues.

measurements in diameters of the rollers used in conveyor belts, in addition to providing us with a
more accurate tracking if we need to transport the equipment or products that we produce.
Further optimizing your industry