An encoder is a device used to change a signal
or data into a code. These encoders are used in metrology instruments
and high precision machining tools ranging from digital calipers
to CNC machine tools. |
| ( 2.1) Incremental encoders |
With incremental linear encoders, the current
position is determined by stating a datum and counting measuring
steps. The output signals of incremental rotary encoders are
evaluated by an electronic counter in which the measured value
is determined by counting "increments". These encoders
form the majority of all rotary encoders. Incremental rotary
encoders with integral couplings used for length measurement
are also in the market.
The resolution of these encoders can be increased by means of
electronic interpolation. There are, of course, the precision
rotary encoders specifically designed for angle measurement.
If finer resolution is required, standard rotary encoders often
utilize electronic signal interpolation. Rotary encoders for
applications in dividing heads and rotary tables, with very
small measuring steps (down to 0.36 arc second) have in principle
the same basic design features as standard rotary encoders,
but incorporate some overall varying construction. |
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Figure 24.2 Rotary encoders
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| ( 2.2 ) Absolute encoders |
Absolute linear encoders require no previous
transfer to provide the current position value. Absolute rotary
encoders provide an angular position value which is derived
from the pattern of the coded disc. The code signal is processed
within a computer or in a numerical control. After system switch-on,
such as following a power interruption, the position value is
immediately available. Since these encoder types require more
sophisticated optics and electronics than incremental versions,
a higher price is normally to be expected. Apart from these
two codes, a range of other codes have been employed, though
they are losing their significance since modern computer programs
usually are based on the binary system for reasons of high speed.
There are many versions of absolute encoders available today,
such as single-turn or multi-stage versions to name only two,
and each must be evaluated based on its intended application. |
| ( 2.3 ) Rotary and Linear encoders |
A linear encoder is a sensor, transducer paired
with a scale that encodes position. The sensor reads the scale
in order to convert the encoded position by a digital readout
(DRO). Linear encoder technologies include
capacitive, inductive, eddy current, magnetic and optical.
A rotary encoder, also called a shaft encoder, is an electro-mechanical
device used to convert the angular position of a shaft to a
digital code, making it a sort of a transducer.
Rotary encoders serve as measuring sensors for rotary motion,
and for linear motion when used in conjunction with mechanical
measuring standards such as lead screws. There are two main
types: absolute and relative rotary encoders. Incremental rotary
encoder uses a disc attached to a shaft. The disc has several
radial lines. An optical switch, such as a photodiode, generates
an electric pulse whenever one of the lines passes through its
field of view. An electronic control circuit counts the pulses
to determine the angle through which the shaft has turned.
As the present trend of machine tools evolves toward increasingly
higher accuracy and resolution, increased reliability and speeds,
and more efficient working ranges, so too must feedback systems.
Currently, linear feedback systems are available that will achieve
resolutions in the submicron range. |
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Figure 24.3: Exposed and
sealed linear encoders
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Submicron resolutions, for example, are required
in the semiconductor industry and in ultra-precision machining.
Achieving these resolutions is possible with the use of linear
scales which transmit displacement information directly to a
digital readout. As in rotary, linear scales operate on the
same photoelectric scanning principle, but the linear scales
are comprised in an overall straight construction, and their
output signals are interpolated or digitized differently in
a direct manner. One of these signals is always used by the
accompanying digital readout or numerical control to determine
and establish home position on the linear machine axis in case
of a power interruption or for workpiece referencing. Overall,
there are two physical versions of a linear scale: exposed or
enclosed as shown in the figure 24.3. With an enclosed or "sealed"
scale, the scanning unit is mounted on a small carriage guided
by ball bearings along the glass scale; the carriage is connected
to the machine slide by a backlash-free coupling that compensates
for alignment errors between the scale and the machine tool
guide ways.
A set of sealing lips protects the scale from contamination.
The typical applications for the enclosed linear encoders are
primarily machine tools. Exposed linear encoders also consist
of a glass scale and scanning unit, but the two components are
physically separated. The typical advantages of the non-contact
system are easier mounting and higher traversing speeds since
no contact or friction between the scanning unit and scale exists.
Exposed linear scales can be found in coordinate measuring machines,
translation stages, and material handling equipment.
Another version of the scale and scanning unit arrangement is
one that uses a metal base rather than glass for the scale.
With a metal scale, the line grating is a deposit of highly
reflective material such as gold that reflects light back to
the scanning unit onto the photovoltaic cells. The advantage
of this type of scale is that it can be manufactured in extremely
great lengths, up to 30 meters, for larger machines. Glass scales
are limited in length, typically three meters. There are several
mechanical considerations that need to be understood when discussing
linear encoders. It is not a simple matter to select an encoder
based just on length or dimensional profile and install the
encoder onto a machine. These characteristic considerations
include permissible traversing speeds, accuracy and resolution
requirements, thermal behaviour and mounting guidelines. |
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Figure 24.4: Principle of
rotary and linear encoders
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