Rotary encoders Manufacturers online

Rotary encoders, also known as encoders, are sensors that measure the angular position, rotary movement or speed of a shaft or axis system and convert them into electrical signals.

They are used in many areas to monitor and precisely control the movement of machines, motors and other rotating objects.

Below you will find the types of rotary encoders, the typical designs, their areas of application and their advantages:

Types of rotary encoders:

1. Incremental encoders:
Emit a certain number of pulses per revolution, which are counted relative to the starting position.
They are used in machine control systems, for example, to determine speed and direction

2. Absolute rotary encoders:
Generate a unique code per angular position so that the exact position is known even after a power failure or movement without measurement.
In applications where it is important to know the exact position after a restart or failure, such as robots or production systems.

Typical versions:

1. Optical rotary encoders:
Use light beams and a coded disk to determine position. They have high precision, but are sensitive to dust and dirt.

2. Magnetic encoders:
Use magnetic fields to measure position.They are a robust, durable solution that is insensitive to environmental influences.

3. Capacitive encoders:
Use electric fields to measure position. They are also a robust solution and are less sensitive to interference.

4. Mechanical encoders:
Use mechanical contacts for measurement. These are simpler, but less precise and more susceptible to wear.

Typical areas of application:

1. Automation technology:
Rotary encoders are used in manufacturing and assembly automation to monitor the exact position of components and machines.
Examples: Conveyor belts, robot arms, CNC machines.

2. Drive and motor control:
Encoders measure the speed and position of motors to control their movements and optimize control.
Examples: Servo drives, stepper motors, DC motors.

3. Robotics:
In robotics, accurate position and movement measurements are crucial. Encoders enable precise movements and repeat accuracy.
Examples: Joint positioning for industrial robots.

4. Elevators and crane systems:
Encoders detect the exact position of elevator cars and crane hooks to ensure safe and precise movements.
Examples: Height and motion control.

5. Medical devices:
In medical technology, encoders are used to control precise movements, such as in surgical robots or diagnostic devices.
Examples: X-ray machines, MRI systems.

6. Aerospace:
Encoders are used in airplanes and satellites to determine the position of components, such as control surfaces or antennas.
Examples: Tilt angle control, antenna alignment.

7. Automotive engineering:
In modern vehicles, rotary encoders measure positions and speeds to support driving assistance systems.
Examples: ABS systems, electric power steering systems.

Advantages of rotary encoders:

• They enable accurate measurement of angular movements and positions.
• Encoders can be used in a wide range of applications, from industrial automation to medical technology.
• Modern encoders are often robust and can withstand difficult environmental conditions such as dust, dirt, moisture and vibrations.
• They offer compact solutions for motion control in confined installation spaces.

Rotary encoders are versatile sensors that are used in many industries for the precise control and monitoring of rotary movements. Their main application is in automation and motion control, but they are also used in specialized areas such as medical technology, robotics and aviation.

Below you will find an overview of the most important criteria that you should pay attention to when purchasing encoders:

When purchasing rotary encoders (encoders), there are many factors to consider to ensure that the encoder you choose meets the requirements of the specific application.

• Incremental encoders generate a certain number of pulses per revolution, which are counted relative to the starting position. They measure speeds, directions and positions, but the position is lost after a power failure or restart.
• They are suitable for applications where relative movements and speeds are more important than the exact position (e.g. in motor controls or conveyor systems).
• With absolute encoders, each angle has a unique digital code so that the exact position is known even after a restart or power failure.
• They are ideal for applications in which the exact position must be known immediately after a restart (e.g. in robotics or in high-precision
• The resolution of an encoder indicates how many steps or pulses it generates per revolution. For incremental encoders, this is measured in pulses per revolution (PPR), for absolute encoders in bits.
• A higher resolution (more pulses or bits) enables a more precise measurement. For high-precision applications such as CNC machines or precision robots, encoders with a high resolution should be selected. A medium to low resolution is sufficient for simple speed measurements.
• Optical encoders use an optical disk and light beams for measurement. They offer very high accuracy, but are sensitive to dust and dirt.
• Choose optical encoders in clean, controlled environments where maximum precision is required.
• If your application requires positioning over multiple revolutions, consider a multiturn encoder.
• Magnetic encoders work with magnetic fields, making them more robust and resistant to dirt and vibration, but not quite as accurate as optical encoders for very high precision requirements.
• Magnetic encoders are suitable for harsh environments, such as industrial or outdoor use.
• The encoder should be able to withstand the temperature requirements of the environment. Many encoders operate between -40 °C and +85 °C, but special applications may require greater temperature tolerances.
• Depending on the environment, it may be important that the encoder is protected against dust, moisture and other environmental influences. The protection classes range from IP40 (minimum protection) to IP67 or IP68 (fully protected against dust and water).
• In harsh environments such as factory halls, construction sites or outdoors, a rotary encoder with a high protection class (IP65 or higher) should be selected.
• There are various electrical interfaces, depending on the requirements of the control system.
• Analog signals are simple and widely used, but are more susceptible to interference and offer less precision.
• Digital interfaces such as TTL or HTL provide clearer and more robust signals.
• Modern machine control systems often require fieldbus or Ethernet interfaces such as CANopen, Profibus, Profinet, or EtherCAT.
• Make sure that the interface of the encoder is compatible with the control system of your machine. Digital interfaces generally offer higher accuracy and are less susceptible to faults.
• Encoders are available in various designs and sizes, from compact, lightweight versions to robust, industrial-grade models.
• Choose a design that fits into the available space and meets the mechanical requirements of your application. Compact models are advantageous in confined spaces or where mounting conditions are tight.
• Hollow shaft encoders are often easier to install and offer flexible mounting options as they can be mounted directly onto a shaft.
• Solid shaft encoders are more stable in applications where high torques occur.
• Make sure that the encoder is designed for the expected speeds in your application. Encoders with higher limit values are required for high-speed applications.
• For safety-relevant applications, you should choose an encoder that meets the relevant safety standards and has the corresponding certificates. Some encoders offer certified safety functions in accordance with SIL (Safety Integrity Level) or PL (Performance Level)
• Analyze your requirements carefully and choose an encoder that offers a good price-performance ratio for your specific application. For simple applications, an inexpensive incremental encoder is often sufficient, while more complex applications require more precise, more expensive models.
• In safety-critical applications where reliability is critical, you should consider a redundant encoder.

A well-chosen encoder ensures precise and reliable motion detection and contributes to the efficiency and safety of machines and processes.

Encoders can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of Encoders from all over the world can be found on Exportpages.