Global Detection Intermediate level

F Ultrasonic sensors

E Rotary encoders

D Pressure
D switches

C Limit switches
B Inductive sensors
A Photoelectric sensors

Experts: GHD
Training: Nadia Bennour

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 E- Rotary Encoders

An encoder is an angular position sensor:

• connected mechanically to a shaft that drives it, with its shaft turning a disk attached to it. The disk comprises a
succession of opaque and transparent parts.
• uses the light emitted by Light Emitting Diodes (infrared LEDs), which passes through the notches in the disk so
that an analogue signal is created for the receiver photodiodes.
• this signal is electronically amplified and then converted into a square wave signal which is then sent to a
processing system.

An encoder is therefore made up of three parts:

ELECTRONIC
readings and output
LED signals

Reticle

MECHANICAL OPTICAL
encoder shaft graduated disk
Flex. coupling Shaft

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 E- Rotary Encoders
Incremental Encoders

-Three types of signals (channels) are provided: A, B and 0

mark. B is electrically offset by 90° in relation to A.

-The complements (A\, B\, 0\) can also be provided with the aim
or reducing the effects of any electrical interference.

-The 0 mark (or reference signal) is used to reset counting after

every revolution and thereby correct any counting errors that
may occur during a revolution.

-The A and B signal out of phase data is used to determine the

rotation direction (B comes before A: clockwise rotation).

-Used to control speed and/or count lines (relative position).

Using these encoders required resetting the machine on power
up.

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 E- Rotary Encoders
Incremental Encoders

Type of output signal:

Pulse train sent

Period or increment
(1) Electrical degree
Pulse up/down counting by the processing unit makes it possible to determine the position of the
moving part.

The signal processing (e.g. the PLC), totalises

the +1 or -1 counts, depending on the direction
of rotation:

Forward-Up counting:
Counter value +1

Reverse-Down counting:
Counter value -1

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Incremental Encoders
Mounting

Motor

Moving part
Encoder
Drive worm gear

"Initialisation point"
position

- Sometimes, systems may require an end of

travel switch as back up for the "Initialisation point"
that may be located elsewhere along the moving
part's travel.

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 E- Rotary Encoders
Incremental Encoders
Type of output stage:

5VDC - RS422 5-30V Push-pull

Advantages of RS422: Advantages of push-pull or HTL: Connection safety

• High level immunity to interference • Encoders with push-pull outputs can be incorrectly
(electrical noise and other interference) connected and withstand a polarity reversal, even a long
Encoders with RS422 or TTL outputs work in duration one (for PNP or NPN receivers).
differential mode between two channels, offering
better immunity to interference (unlike push-pull
that works with a frozen 0 VDC level).
• Encoder/Receiver range: 200 meters in 5 VDC • Maximum range: approx. 300 meters.
operation.

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 E- Rotary Encoders
Absolute Encoders

These encoders are called absolute encoders for they provide an

absolute position as soon as the machine is powered up.

-Most often, they use an optical disk with Gray code or binary tracks. Gray code is designed to allow only once
change of code for each successive state. As only one digit changes state (1 or 0), this avoids any uncertainty in
the succession of codes.
-In the same way as when using an incremental encoder, the light intensity varies for the tracks hide the light
source and generate analogue signals that are converted into square wave signals for each of the tracks.

-One signal per track is available: either 1 or 0, called a "bit". The succession of 1s and 0s forms the code that
corresponds to a single position. The encoder provides the absolute position of the complete disk/axis assembly
and consequently of the mechanism coupled to it and whose position is to be measured (motor shaft, robot arm,
etc.). There is no need to reset the point of origin every time the machine is powered up.

-The number of bits determines the resolution. The LSBs correspond to the highest precision level while the MSBs
correspond to the lowest position.

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Absolute Encoders

Absolute encoders are split into two main families:

- Single revolution absolute encoders: generate codes for the position during a revolution

- Multiple revolution absolute encoders: generate codes for the position during a revolution and on
the number of revolutions measured by the encoder thanks to a revolution numbering mechanism
(that is mechanical or electronic)

Depending on the interface used, another distinction is made:

- Parallel encoders: signals are sent over one wire for each bit, e.g. for 13 bit resolution, 13 wires are
needed for the signals plus the wires used to supply the encoder.

- SSI encoders (Serial Synchronous Interface): the encoder is polled by a clock and sends the
status of each bit during a time interval. For 25 bit resolution, the poll frame will collect all of the
"answers" from the encoder on the 26th clock pulse.

- Fieldbus encoders: Profibus, CANopen. These encoders read-write words and are polled by a
Master.

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 E- Rotary Encoders
Absolute Encoders

Type of output signal:

The signal processing system directly and continually displays a value:

e.g. 10000 (for a PLC, this is found in a %MW word).

Forward-Up counting:
10000, 10001,10002...

Reverse-Down counting:
10000, 9999, 9998,...

Which may mean 10 meters… the true position of the moving part, hence the name
"absolute"!

- There is no need for initialisation, even after a power return.

- Only a control switch can be fitted to avoid any coupling break on large scale
machines

Note: 360 or 3600 points encoders allow direct angle readings in degrees.

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Absolute Encoders
Type of output stage: SSI (Synchronous Serial Interface)
(Note: SSI is defined by a standard that sets the times shown below)

Description for our range

4096 codes per revolution (12 bit), 8192 revs (13 bit) = 25 bits
8192 codes per revolution (13 bit), 4096 revs (12 bit) = 25 bits DIRECTION input

DIRECTION

Multi revolution 25 bit absolute encoders

DATA transmission is performed using a CLOCK signal.
The receiver electronics (PLC, processor) provides the clock pulses and the sensor sends back the data.
On the falling edge of the first clock signal, the sensor value is placed in memory. On the rising edge of the following
clock signal, the data bit's MSB is transferred to the receiver.
Then on each rising edge of the clock signal, the next data bit is transferred to the receiver.
After a pause, a new word can be transmitted.

CLOCK

T – 1 up to 10 μs
26*T
DATA

Multi rev. bits Single rev. bits

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Absolute Encoders

Type of output stage: SSI (continued)

Pros:
-Digital link, allowing long ranges (from less than 500 to a maximum of 1200 meters).
-High level immunity to noise and easy to connect to PLCs with SSI inputs.
-A recognised standard.

Cons:
-Requires an SSI board Æ increases costs on multiple axis applications with a number of encoders.

Note: For distances of less than 30 meters, a parallel link may be faster than SSI for all of the
pulses arrive at the same time.

Wiring diagram

Reset

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 E- Rotary Encoders
Absolute Encoders

Type of output stage: Fieldbus

8192 Pulses/
4096 revolutions

FEW WIRES

=1 PLC Bus Board

Advantages: flexibility, reduced wiring cost,

reduced hardware cost in multi-encoder applications

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Absolute Encoders

PLC + CANopen master

Bus characteristics:

-Max. number of stations: 127 nodes with addresses from 0 to 126

(127 reserved to the master, 2-89 for encoder available adresses)

-Available Speeds: 10-10-50-125-250-800-1000 KBaud

-Cable length: 4m for 1 MBaud; 5000m for 20 KBaud

The encoder power supply must be separated from the Fieldbus cable

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Absolute Encoders

PLC + Profibus DP
interface board

Bus characteristics:
• Max. stations on the bus: 126 nodes max. with addresses from 2 to 125 (2-99 for
encoder adresses)

• Max. number of nodes per segment (repeaters included): 32 (a bus is split into
segments via repeaters)

• Between two nodes, four repeaters max.

• Speeds supported: 9.6 up to 12000 kBaud
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Absolute Encoders vs Incremental Encoders

Incremental encoders Absolute encoders

Advantages Drawbacks Advantages Drawbacks

-Only generates pulses -Provides a value for the

- Low Price (relative position) absolute position -High price

-Requires an end of travel

stop for resetting the -No loss of position after a
processing system called power break
"recalibration"
--> Insensitive to mains
-Requires a little program in power breaks
the PLC to generate the --> Insensitive to spurious
signal signals
-Pre-processing may
require recalibration after a
-Can withstand complete
power break
configuration over the bus
-Sensitivity to line and troubleshooting.
interference

-Cannot reset using a “zero

point” when an oscillating type
motion is used that never
achieves a complete revolution.

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 E- Rotary Encoders
Trends and various information

The main problems customers encounter are:

• Wrong mechanical mounting: misalignment, rigid link between the encoder and motor parts, contact between
encoder and motor shafts.

• For through shaft units, use the flexible mounting supplied with the encoder, it improves the service life of the
encoder's internal ball bearings, it absorbs vibration and impacts.

• For high precision applications with solid shafts (>=1024 ppr), use the XCC RAS homokinetic coupling as
using XCC RAR is not advisable due to the possible torsion angle.

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 E- Rotary Encoders
Trends and various information

Why several encoder diameters?

•The encoder size is directly linked to the size of the ball-bearings used for shaft rotation.

•Hence the greater the diameter, the better its resistance to impact, vibration, misalignment and other
constraints (radial loads).

- Ø 40mm Æ micro-robotics (low mechanical loads and vibration), small motors.

- Ø 58mmÆ universal encoders, suitable for all types of applications (packaging, cutting, cross table
transfer, textiles, robotics, automatic tool storage…)

- Ø 90mm Æ heavy and harsh industry environments: steelmaking, glass, paper, food and beverage
industries, automakers, heavy hoisting.

Note: In our product range, solid-shaft encoders always have a longer service life than through-shaft encoders.
This is due to the ball-bearing shape: extra flat for through shaft encoders against standard ones for the solid
shaft range.

The most universal product is the Ø 58mm, 5-30VDC supply, RS422 output unit.

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 E- Rotary Encoders
Trends and various information

In brushless motors, manufacturers integrate an angular counting system. This is not an encoder but a
resolver; it is customized to motor shape and colour.

We do not market resolvers!

Basic principle:

A resolver is a rotating transformer. Let us take two windings, A and B, now if we feed winding B with a
sine wave voltage, a voltage is induced in winding A. If we rotate winding B, the induced voltage is at its
maximum when the A and B planes are parallel and at a minimum when they are at right angles.
If we introduce a third winding (C), positioned at a right angle to winding A, as we rotate B, a voltage is
induced in this winding.
If you can mea<sure the relative amplitudes of the outputs from the two windings (A and C) at a
particular point in the cycle, these two outputs are unique to that position. Rotating winding B causes the
magnitude of the induced signals to vary as a function of the angular position.

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 E- Rotary Encoders
Integration with Schneider Automation Offer

MMI

ƒ Encoders are the interface between the

mechanical part in motion and the electronic
processing of this system. Speed
drive
PLC

ƒ Encoders have to adapt to all of the constraints

generated by the machine moving parts and the
processing electronics used. and/
or
Encoders
ƒ Encoders connect to suitable counting boards or Moving
to industrial bus systems. This way the data is part Coupling
returned to PLCs, speed drives or industrial PLCs.

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 E- Rotary Encoders
What’s the best spot for encoders?

The greater the need for precision, the closer the encoder drive shaft must be to the moving part so as to avoid any
play and mechanical flaws and to ensure control over non-breakage affecting the motor-moving part coupling.
The more mechanical intermediaries (i.e. links) there are between the encoder and the true position of the moving part,
the more necessary it is to compensate for the sum of mechanical play so as to obtain high fidelity.

Encoder C

Slider

Worm drive

The optimum location is a compromise between

Encoder B the need for mechanical robustness, the space
Reduction gears
available and the need for precision.
In this example, encoder B is best placed.
Encoder A

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E- Rotary Encoders

„ End of Part D…

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