Posital Fraba Webinar. Sensing a Revolution: How Magnetic Sensing Technologies are Changing How You Use Rotary Encoders

Sensing a Revolution: Magnetic Sensing Technologies

are Changing How You Use Rotary Encoders

Presented by: Jarrod Orszulak, Product Manager, POSITAL-FRABA Inc

ELECTROMATEToll Free Phone (877) SERVO98

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Meet The Presenter

Jarrod Orszulak

Product Manager POSITAL-FRABA Inc

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Thank You To Our Sponsors ELECTROMATE

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Contents

• History of Encoders • Status of Optical Encoders • Status of Magnetic Encoders • Kit Solutions • Choosing an Encoder • New Applications & Opportunities



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• Optical encoders were developed for space flight – Higher resolution – Longer lifetime

• Relied on detecting light through an optical code disk

History – 1950 ELECTROMATE


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History – Cont.

• Incremental encoder – Output is processed by external electronics – Encoder outputs pulses as the shaft is turned – Encoder must be homed, otherwise only

relative position is known – Also used for speed applications – A and B pulses can be used so

counting direction can be known



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History 1960’s

• Introduction of LEDs – Stable lighting conditions

• Encoders in new applications – Start to move outside of space and defense



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History 1970’s

• Absolute optical encoder – Each position of the code disk gives a unique

value – No homing is required – Multiturn ability through gear sets



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1980’s Fieldbus

• New complexity supported by encoders – Absolute position – Velocity – Status information

• Simplified wiring • New applications

– Mobile machinery – Material handling



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2000’s – Ethernet

• New connectivity and topology • ‘Real Time’ sensing



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2000’s – Magnetic Encoders Singleturn • Hall effect sensor

Multiturn • Weigand effect • Batteries • Gearing



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• Advantages – Compact – Low cost – Robust

• Disadvantages – High latency time

• Not good for high speed applications

– Susceptible to EMC – Temperature Drift – Limited resolution and

accuracy

2000’s – Magnetic Encoders ELECTROMATE


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2000’s – Weigand Technology

• Traditional gear sets don’t compliment magnetic encoder’s strengths

• Batteries are bulky, have a short life time and difficult to dispose of

• Weigand technology offers reliable counting, even with no power



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2000’s – Weigand Technology • Self Powered Counter • Energy & Position Information @ 0 rpm



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Mechanical Advantage ELECTROMATE


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History - Review ELECTROMATE


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Forget Everything You Know About Encoders

• New microprocessors address previous shortcomings in magnetic encoders – (32-bit microprocessor and all other

electronics on one 35mm board) – Latency time on par with optical encoders – Better accuracy (0.09°) and resolution (16 bit) – Maintain advantages of magnetic technology

• Robust • Compact



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Advances – Mass Customization

• Options are software based, not hardware – More options available

• Larger ‘standard’ selection • Customization is easier • Software changes can be made in-field

• Shorter lead times • Economical



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Advances - Latency

6000 rpm, 10,000 rad/s²

•OCD – Reference (°) •UCD – Reference (°) •MCD – Reference (°)



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Advances - Kit Solutions

• Mount the magnet directly to the shaft • Hall effect sensor is mounted flush to it • Advances in micro processing have

addressed: – Off-centric – Increased accuracy and resolution



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Advances - Kit Solutions • Absolute ST & MT on a single

PCB • No gears, no batteries • Compact & robust • Digital interfaces (SSI, BiSS,

SPI, Inc, UVW) • Shielding solutions • Low cost



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Choosing an Encoder

Shaft

Resolution

Flange

Singleturn/Multiturn

Electrical Interface

Housing Material

Communication



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Applications



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Applications – Food & Bev • Compact

– Easier to seal • Result in IP68/69k sensors that are appropriate for high

temperature, high pressure washdown

– Economical • Food grade stainless steel is expensive

• Easy installation – Variety of communication options make new and

retrofitting old applications easy • Hazardous environment (UL, ATEX, IECEx)



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Applications – Off Highway

• Robust – High shock and vibration resistance – No glass code disc or gearing – High temperature/washdown

• IP68/69k

• 16 bit resolution • Low cost for OEM applications • Customization



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Applications - Material Handling

• Programmable pulse count – Incremental and absolute encoders – Allows for fine tuning during installation – Significantly reduces stocking requirements

• Easy wiring – Fieldbus and Ethernet support a variety of

cable topologies



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Applications – Motors + Drives

• Compact • Recent advances in shielding • Many options

– Singleturn or multiturn – Absolute or incremental – Interfaces



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In Summary

• Optical encoders are proven technology, but with limitations

• New generation of magnetic encoders address shortcomings of earlier magnetic encoders

• More compact, economical kit solutions opens new doors



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