Encoder Basics #1

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Encoder Basics

We will be covering:

• Common names & definitions

• Types
• Technology
• Mechanical designs
• Output
• Applications

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Different Names for Encoders

• Rotopulser
• Pulse Generator
• Digital Tachometer
• Tach
• Pulse Tach
• Shaft Encoder

A lot of names…..

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Definitions

• Tachometer – Analog device that produces a voltage

proportional to speed.
• Encoder – Digital device that produces pulses based on
rotational position

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Encoder Basics
Encoder Types:

• Incremental
– Provides identical electronic pulses at each division of shaft
rotation.
– Used for speed or velocity control of motors

• Absolute
– Provides a unique electronic piece of information at each
division of shaft position.
– Used for positioning systems

• Resolver
– Provides sine wave and cosine wave to provide both velocity
and position feedback.

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Encoder Basics
Sensing Technologies:

• Magnetic (Magneto-resistive) NORTHSTAR

– Tough and simple
– Heavy Duty enough for Mills
– No Optics (no glass breakage)
– Limited to 2048 PPR

• Optical DYNAPAR

– Higher Resolution (up to 10,000 PPR) &

– Better signal quality NORTHSTAR HD OPTICAL
– Shafted and Hollow shaft designs

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Magneto-Resistive Technology

• Features a magnetic pulse wheel

that is imprinted with numerous,
small magnetic poles.

• Rotation of the magnetic pulse wheel

creates an alternating pattern of
north-south magnetic fields for the
pick-up head.

• The electrical circuit in the sensor

produces digital pulses proportional
to motor speed.

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Optical Technology
• Utilizes a glass, plastic or metal rotating disc that operates in an
light path between a photoelectric transmitter (LED) and
receiver.

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 Encoder Mounting Styles

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Encoder Basics
Mechanical Designs: NorthStar: HSD35,
HSD37, Slim Tach HS56
• Hollow Shaft Dynapar:
– Encoder mounting on shaft HS20 & HS35
extension with bearings
and torque arm.

• Coupled
NorthStar: RIM 6200, HSD44
– Machined face, bracket,
stub shaft and a flexible Dynapar: H56 Rotopulser
coupling.

• Bearingless NorthStar:

– Frame of encoder bolts to SLIM Tach:

motor, pulse wheel mounts SL56, SL85, RL67
on shaft extension or stub RIM Tach:
shaft. RIM8500, RIM1250

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Hollow Shaft Encoders
• The lowest cost encoder to install
– No couplings to align or isolate
– No adapter (flower pot)
– No machined fan cover required on TEFC motors

• Flexible torque arm

– Allow encoder to ride freely on shaft extension
– If too rigid, provide stress on encoder bearings
– Arm must be isolated from motor to avoid motor shaft
currents from damaging encoder bearings

• Ideal for Reliance TEFC V*S Master motors

– Good for all motor enclosures

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Coupled Encoders
• Highest installation cost.
– Requires a expensive, flexible coupling
– Requires adapter (flower pot) between encoder and motor
– On larger motors, an expensive insulated coupling may be required to
protect Coupled Encoder bearings
– V*S Master TEFC motors requires a special cast iron machined fan
cover
Flexible Coupling Machined Adapter Bracket

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Bearingless Encoders
• Less space required
– No couplings to align or isolate
– Can have a thru shaft
– Can be mounted between brake and motor
– Can be mounted on drive or non-drive end

• No bearings to fail!
– Pulse wheel mounted directly on shaft extension
– Encoder housing bolted to motor bracket
– No concerns with motor currents damaging bearings

• Ideal for Reliance RPM-AC and DC motors

– Good to mount between brake and motor bracket on TENV, DPFV
and TEBC-PB enclosures
– Not recommended for V*S Master motors

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 Incremental Outputs

Magnetic & Optical

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Encoder Outputs

• Incremental encoders are usually supplied with two channels (A &

B) that are offset by 90 degrees.
• If complements are included (A, B ), the signal is “quadrature”,
providing speed of rotation AND direction of rotation.

A
A

B
Encoder
B

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Single Output, Quadrature Signal with Complements

• Signal A leads B in one direction, B leads A in the reverse

direction
• Complement pulses, A and B are used to provide electrical
noise immunity for the signal as it travels through the cable.

A
A

B
Encoder
B

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Marker Pulse
A marker pulse (reference, index or Z pulse) is a once per revolution
pulse that occurs at precisely the same mechanical point in a 360º
revolution of the encoder shaft.

Marker
Z

Although a “Marker” pulse is standard on some encoders, it is

additional feature (charge) on many encoders. Ask for one, if you
need one.

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