Top Tips

Specifying an Incremental Encoder

Specifying an incremental encoder is essentially a process of elimination in

which the number of candidate products is reduced as various considerations
are addressed.

1
Integrating the Encoder into the Equipment
Integration of the encoder depends to a large extent on the equipment itself, and the first consideration is how the encoder
will be mounted, for which there are two basic options. As their names suggest, thru-bore or hollow-bore encoders slide
over and clamp to a shaft, attaching directly to the motor frame through a flexible mount. Shaft encoders usually mount
to a fixed surface and couple to a driven shaft.
Each mounting type has its advantages and disadvantages, and they vary with the equipment. Something else to consider
is the use of a quick electrical disconnect that makes it easy to connect and disconnect the encoder for maintenance and
allows it to be used in multiple locations. Some encoder products have swappable bore sizes, and some are programmable,
so the electronic specifications can be adjusted.

2 Determining Desired Resolution

This key metric is more difficult to specify than it might appear, because if the resolution is too high, encoder cost will
increase unnecessarily and will exceed the output frequencies of the controller. The encoder should remain within the
specifications of the controller. It’s also important to consider that many applications do not require extremely high
resolution, so there’s no need to over-specify it. Conversely, resolution that is too low will likely limit the system’s ability
to accurately control speed or position.

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3 Selecting the Output Type

Output selection depends on what the controller is designed to accept, and there are four basic types: differential line
driver, push-pull, open collector, and pull-up (sometimes called open collector with internal pull-up resistors). Differential
outputs have high noise immunity achieved through “common mode rejection,” in which the differential receiver cancels
the noise on the line by rejecting any spikes in the signal that do not have a matching inverse on the differential line.
It’s the best choice when longer cable lengths are used, and it meets RS-422 standards for operation at 5 VDC. Some
Encoder Product Company Accu-Coder™ encoders also have a 5-VDC regulated output that accepts higher input voltage
and regulates the output.
The second output type is push-pull, which does not have the noise immunity of a differential line driver. This output
can sink or source current, can act as a single-ended line driver, and is also often compatible with PNP-type circuits.
The third type is the NPN open collector, which is a current-sinking output type that requires a pull-up resistor apart
from the encoder, typically integrated within the receiving device. This type has the benefit of being able to perform
level shifting, in which the encoder is “pulled up” to a different voltage. For example, it can be powered by 5 VDC, but
the output can be increased to 24 VDC.
The last type is called pull-up. It is the same as the open collector type but contains the pull-up resistor within the
encoder, and is useful when neither level shifting or use of external pull-up resistors is desired.
Overall, remember that the controller is ultimately what determines the encoder’s output configuration. If there are
questions about this, Encoder Products Company Technical Services can help.

4 Environmental Considerations
Encoders must be able to endure the same levels of environmental hostility as the
machine they’re part of. If these conditions are not recognized and accommodated when
the encoder is specified, unnecessary maintenance may be required, and operating life
may be reduced. Hostile environmental conditions include exposure to large amounts
of dust, moisture, and caustic chemicals, and possibly even physical damage in the
most demanding cases.
The temperatures to which the encoder will be exposed also a critical consideration.
Encoder Products Company offers both standard and custom products that can withstand
wide temperature extremes, ranging from −40ᵒC to 120ᵒC. A wide variety of environmental
options are available for all encoders, including the ability to meet various IP seal levels.
In the most extreme cases, encoders can be housed in a sealed, corrosion-proof enclosure. While this adds cost to the
system, it will almost certainly add to the encoder’s operating life and reliability. It may also be possible to use a flexible
drive shaft to the encoder that allows the latter to be located remotely and out of the hostile environment.

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5 Use a 3D Model
Ensuring the encoder package will fit properly into a design is a vital step in selecting the correct
product. The ability to visualize an encoder is helpful during the specification process. Encoder
Products Company offers an online 3D “configurator” that makes it much easier to match
an encoder to its application. It supports the native models of Autodesk, Solid Edge,
Solidworks, and many other tools.
Simply choose a product category and a specific product within it, launch the
configurator, and then add the specifications such as bore size, mounting, resolution,
communication type, operating temperature, certification, output, and connector
types. After this, select the CAD format from a drop-down list, and the 3D model will
be shown with full rotation and other capabilities. All the specifications are retained
throughout the process and can be used to order the product once it’s configured.

6
Consider a Programmable Encoder
Programmability allows the encoder to be configured to the exact requirements of an application. Encoder Products
Company’s programmable encoders offer six different output types, 32 different waveforms, and any resolution from 1
to 65,536 CPR. This allows a single encoder to be configured for multiple applications, which simplifies inventory and
downtime for replacement.
Encoder Products Company’s programmable encoders are available in shaft, hollow-bore, and thru-bore styles in a wide
range of bore and shaft sizes, mounts, and connector types, and offer sealing to IP67.

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