Mandee Liberty & Vikram PhadkeNational Encoder Product SpecialistsEncoders Basic Training

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Typical Industrial SystemInputOutputFeedbackControllerOperation(Application)Sensor*

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Encoders within a Control System*FeedbackSensor

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What is an encoder?An encoder is a device which converts a mechanical information of a shaft or position into an electrical signal

Encoder Definitions*

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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

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*Encoder Selection Process

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*Encoder Selection Process

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EncoderRotary EncoderLinear EncoderTypes of Encoders*

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*Types of Encoders

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EncoderLinear EncoderWire DrawLinear with ScaleTypes of Encoders*

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*Types of Encoders

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EncoderRotary EncoderIncrementalAbsoluteLinear EncoderWire DrawLinear with ScaleAbsoluteIncrementalTypes of Encoders*

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*IncrementalProduces 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 positionIncremental Encoders

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Absolute Encoders*AbsoluteProvides a unique value for every shaft or linear position

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)

Absolute encoders are used in applications were position information is necessary

Code disc for absolute encoders

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Encoder Selection Process*

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EncoderRotary EncoderIncrementalAbsoluteTypes of Encoders*

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Incremental EncodersOutput ChannelsIncremental encoders produce electrical pulses or increments (usually as a square wave) with linear or rotary motion of the encoder

ResolutionThe 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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Incremental EncodersElectrical SignalsOutput Voltages Standard output voltages are HTL, TTL or Open Collector. These refer to the amplitude of the square waves

HTL (High Threshold Logic)Also known as push pullThe 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)Also known as a differential line driver or RS422The output voltage will always be 5V regardless of the supply voltage on the encoder

Open CollectorInstead 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: Name (Date)*

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*Incremental Encoder Electronic Interface Summary

Standard Supply voltages are 5VDC, 10-32 VDC, and 8-24VDCStandard outputs are TTL, HTL and Open collectorIncrementalElectronic InterfaceTTL / RS 422Supply = 5VTTL / RS 422Supply = 10 ... 32VHTL / Push PullSupply = 10 ... 32VOpen CollectorSupply = 8-24 VIncremental EncodersInterface Summary

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EncoderRotary EncoderIncrementalAbsoluteMultiturnSingleturnAbsolute EncodersSingleturn vs Multiturn Absolute Encoders*

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*Singleturn and Multiturn Absolute

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AbsoluteElectronic InterfaceSSIParallelBUS*Absolute Encoder Interfaces

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Parallel OutputFirst form of communication for absolute encoders

Connection Point-to-point communication where each output wire represents a different data bit

BenefitsDirect output to digital inputsFast (60us typically)

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Parallel Output

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Synchronous Serial Interface (SSI)Very common serial interface standard for industrial applicationsDeveloped by Stegmann in 1984 for absolute encoders now in many products

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

BenefitsSimple cabling, especially compared to parallel outputsFast communication speedsLow cost

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Network EncodersWhat 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):: Name (Date)*

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Field BusIndustrial network system that connects multiple products in a manufacturing plant or on a machine

BenefitsProducts are no longer point-to-point which allow multiple products to be connected to one controllerGenerally 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

DisadvantagesThe network topologies are generally more complexIndividual components cost more than standalone products (potential system savings, however)

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SICK Absolute Encoder Fieldbus Interfaces: Name (Date)*ATM60 SeriesAFx60 Series

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Electrical Interface SummaryThings to know when choosing an encoderIncremental Encoders

Resolution (PPR)Supply VoltageOutput Voltage (HTL, TTL or Open Collector)

Programmable Encoders:

DFS60 and DFS2x encoders let you program ALL electrical configurations except an open collector outputAbsolute Encoders

Resolution (singleturn, multiturn)Output typeParallel (output voltage needed)SSIFieldbus

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*

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Housings and ConnectionHousing SizeCable or Connector

ShaftsSolid, blind hollow, through hollowSizes, shaft load Flange Face mounting flange Servo flange Square FlangeTethersMechanical Characteristics

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Encoder Selection Process*

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Product Overview - Rotary Encoders Absolute Singleturn EncodersAbsolute Multiturn Encoders*

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Product Overview - Linear Encoders*

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Key Products in 2013Choice encoders that will solve most applications*AFx60 Series With EthernetDFS60 with PGT-10-S Programming ToolBCG Wiredraw with Analog OutputDFS20/25 Incremental EncoderHandheld, 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

USA sized encoders with SICKs F-Technology: Wide set bearings for even shaft loading Metal code disc for high vibration and temperature Programmable using the PC-based toolAbsolute single- and multi-turn encoders with EtherNet/IP, EtherCAT, and Profinet interfaces Device Level Ring (DLR) functionality with the EtherNet/IP version Superior diagnostics for temperature, speed, runtime, and many moreCompact 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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And many moreFields of applications*

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Application Examples*OVERHEAD CRANE AFM60 EtherNet/IP used to track position of craneCONVEYORS DKV60 used to track speed of conveyor

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Application Examples*WIND TURBINE Absolute encoder AFM60 for gandala and blade angle trackingBOTTLING Absolute encoder AFS60 to track position of fillers

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Application Examples*STADIUM ROOF Position with KH53 Linear EncoderLIFT APPLICATIONS Height and Width positioning using BGC Wiredraw Encoders

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Additional Resources*Demonstration Videos & Application AnimationsSICK University Tour March May 2013

Product TrainingDemo CasesTech Tuesdays Check www.sickusa.com for schedule

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Marketing Tools*Encoder Selection GuideApplication BookEncoder Catalog*Update in 2013

Thank you for your attention.

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*Other components HMI, Mechanical, etcInputI/O TypesDiscreteAnalogCommunication EncodersDiscreteAnalogCommunication

*Give everyone a selection guide: Explain the Selection Guide*Give everyone a selection guide: Explain the Selection Guide*****Absolute encoders transmit position information via serial, parallel bits or via bus communication. Parallel wires can provide position information as one bit per wire. Parallel bit communication has distance restrictions usually 10 M. Electric noise interference and power supply capabilities are limiting factors. BUS communication is very efficient, but also has distance limitations usually 100 M per drop. Serial communication can run the longest distances sometimes in excess of 1000 M. SSI (Synchronous Serial Interface) is a popular format for serial communication. *****