Mandee Liberty & Vikram Phadke National Encoder Product Specialists : Encoders – Basic Training

Mandee Liberty & Vikram Phadke

National Encoder Product Specialists

: Encoders – Basic Training

: SICK, Inc. : Confidential

Typical Industrial System

Input Output

Feedback

Controller Operation

(Application)

Sensor

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Encoders within a Control System

3

FeedbackSensor


What is an encoder?: An encoder is a device which converts a mechanical information of a shaft or

position into an electrical signal

Encoder

Encoder Definitions

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Encoder Definitions

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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

: SICK, Inc. : Confidential 6

Encoder Selection Process




Encoder

Rotary Encoder Linear Encoder

Types of Encoders

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Types of Encoders


Encoder

Linear Encoder

Wire Draw Linear with Scale

Types of Encoders

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Types of Encoders


Encoder

Rotary Encoder

Incremental Absolute

Linear Encoder

Wire Draw Linear with Scale

AbsoluteIncremental

Types of Encoders

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Incremental

Produces electrical pulses or incrementswith 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 incrementalencoder does not retain position after apower cycle

Incremental encoders are typically used forspeed or applications that do not require absolute position

Incremental Encoders


Absolute Encoders

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Absolute

Provides 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 businterfaces (Ethernet/IP, EtherCAT, Profinet,

Devicenet, CANopen, Profibus, etc)

Absolute encoders are used in applications were position information is necessary

Code disc for absoluteencoders

LEDLens

Scanning mask

Code disc Photo-

Elements



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Electrical Interface


Encoder

Rotary Encoder


Types of Encoders

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Incremental EncodersOutput Channels

: Incremental encoders - produce electrical pulses or increments (usually as a

square wave) with linear or rotary motion of the encoder

: Resolution- 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 ¼ 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 Signals

: Output 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 pull”

- The output voltage will be the same as the supplyvoltage (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 “RS422”

- The output voltage will always be 5V regardless ofthe 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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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 = 5VTTL / RS 422

Supply = 10 ... 32V

HTL / Push Pull

Supply = 10 ... 32V

Open Collector

Supply = 8-24 V

Incremental EncodersInterface Summary


Encoder

Rotary Encoder


MultiturnSingleturn

Absolute EncodersSingleturn vs Multiturn Absolute Encoders

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Singleturn and Multiturn Absolute


Absolute

Electronic Interface

SSIParallel BUS

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Absolute Encoder Interfaces


: Parallel Output- First form of communication for absolute encoders

: Connection- 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

Parallel Output


: Synchronous Serial Interface (SSI)- Very common serial interface standard for industrial applications- Developed 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)

: Benefits- Simple cabling, especially compared to

parallel outputs- Fast communication speeds- Low cost

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: Drawbacks- Point-to-point connection, topology restrictions

Synchronous Serial Interface (SSI)


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 (virtualprivate network):

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: Field Bus- Industrial network system that connects multiple products in a manufacturing plant or on a

machine

: Benefits- 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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Field Bus Interfaces


SICK Absolute Encoder Fieldbus Interfaces

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ATM60 SeriesAFx60 Series


Electrical Interface SummaryThings to know when choosing an encoder

: Incremental Encoders

- Resolution (PPR)

- Supply Voltage

- Output Voltage (HTL, TTL or Open Collector)

- Programmable Encoders:

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

: Absolute Encoders

- Resolution (singleturn, multiturn)- Output type

▪ 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

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Mechanical Considerations


: 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

Mechanical Characteristics



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Product Overview - Rotary Encoders

Absolute Singleturn Encoders Absolute Multiturn Encoders

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Product Overview - Linear Encoders

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Key Products in 2013Choice encoders that will solve most applications

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AFx60 SeriesWith Ethernet

DFS60 with PGT-10-SProgramming Tool

BCG Wiredrawwith Analog Output

DFS20/25Incremental Encoder

• 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

• USA sized encoders with SICK’s “F”-Technology:

• Wide set bearings for even shaft loading

• Metal code disc for high vibration and temperature

• Programmable using the PC-based tool

• Absolute 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 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


Handling

Wood industry

Automotive Ports & Cranes

Packaging

Machine Tooling

Print & Paper

… And many more

Fields of applications

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Application Examples

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

CONVEYORS – DKV60 used to track speed of conveyor



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WIND TURBINE – Absolute encoder AFM60 for gandala and blade angle tracking

BOTTLING – Absolute encoder AFS60 to track position of fillers



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STADIUM ROOF – Position with KH53 Linear Encoder

LIFT APPLICATIONS – Height and Width positioning using BGC Wiredraw Encoders


Additional Resources

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Demonstration Videos & Application Animations

SICK University TourMarch – May 2013

Product Training Demo Cases

Tech Tuesdays Check www.sickusa.com for schedule


Marketing Tools

40

Encoder Selection Guide

Application BookEncoder Catalog*Update in 2013

: Thank you for your attention.

Documents

Mandee Liberty & Vikram Phadke National Encoder Product Specialists : Encoders – Basic Training