Rotary encoders / Rotary rate encoders / Angles

A rotary encoder is a mechanical or electronic component that is used to measure the rotational movement of an object. It usually consists of a rotating element and a sensor that detects the rotary movement and converts it into an electrical signal.

Rotary encoders are used in various applications to detect the position, speed or direction of a rotating shaft. They are used, for example, in measurement technology, automation technology, robotics, medical technology, vehicle technology and many other areas.

A common example of the use of encoders is the control of motors. Here they are used to determine the exact position of the rotor and adjust the speed or direction of the motor accordingly. Rotary encoders are also used in CNC machines, printing machines, photo cameras and many other devices where precise detection of the rotary movement is required.

A rotation rate sensor, also known as a gyroscope, is a sensor that detects the rotational movement of an object. It measures the rotation rate or the change in orientation in relation to a specific axis.

There are various types of angular rate sensors, including

1. Mechanical rotation rate sensor: This type of sensor uses mechanical components such as gyroscopes or oscillating masses to detect the rotational movement. These sensors are robust and can tolerate high accelerations and vibrations. They are used in applications such as airplanes, vehicles and robots.

2. Optical rotation rate sensor: With this type of sensor, light is used to measure the rotational movement. An optical angular rate sensor consists of a light source, a mirror and a detector. When the object rotates, the position of the mirror changes and the reflected light is directed onto the detector. The change in light intensity is measured and converted into a rotational movement.

3. MEMS rotary encoder: MEMS stands for "Micro-Electro-Mechanical Systems" and refers to a technology in which mechanical and electronic components are integrated on a single chip. MEMS angular rate sensors use tiny silicon structures that deform when rotated and thus generate an electrical voltage. These sensors are inexpensive, small and energy-efficient, which is why they are often used in portable devices such as smartphones, tablets and fitness trackers.

The mode of operation of a rotation rate sensor is based on the principle of inertia. When an object rotates, it has an inertia that causes it to resist changes in its orientation. The rotation rate sensor detects this inertia and converts it into an electrical signal that represents the rotational movement. This signal can then be processed and used by a microcontroller or other control unit.

The use of a rotary encoder offers several advantages over other measuring methods:

1. High accuracy: Rotary encoders provide precise measured values and enable accurate positioning. They can offer high resolutions, which is important in many applications.

2. Fast response time: Encoders provide real-time measurement values so that changes in position or speed can be quickly recorded. This is particularly important in applications that require fast feedback.

3. Robustness: Rotary encoders are generally very robust and can be used in different environments and conditions. They are often shock and vibration resistant, which makes them suitable for use in industrial environments.

4. Versatility: Encoders can be used in various applications, including positioning, speed measurement, speed control and more. They can be attached to motors, machines, robots and other devices.

5. Low wear and tear: Rotary encoders often have a long service life and are less susceptible to wear compared to other measuring methods such as potentiometers or optical encoders.

6. Simple integration: Encoders are usually easy to integrate and can communicate with various devices and systems, including controllers, computers and other electronic devices.

Overall, encoders offer a reliable and precise measuring solution with many advantages over other measuring methods.

A rotary encoder can be used for angle measurement and position detection by measuring the rotation of an object or an axis and converting the corresponding information into electrical signals.

There are different types of encoders, including incremental and absolute encoders.

With an incremental encoder, the position is determined by counting pulses generated by the rotation. Each pulse corresponds to a specific angle or position. The absolute position or the relative angle can be determined by counting the pulses.

With an absolute rotary encoder, the exact position is output directly as a binary code or via a digital interface. This allows the position to be determined precisely without counting the pulses.

Rotary encoders are used in various areas such as robotics, automation technology, mechanical engineering and aviation. They are used, for example, in servo motors, CNC machines, control systems and positioning systems.

By using a rotary encoder for angle measurement and position detection, accurate and precise information about the rotation and position of an object can be captured, which is crucial in many industrial applications.

Encoders generally have a high level of accuracy, which can vary depending on the type and quality of the encoder. The accuracy is usually specified in pulses per revolution or in degrees.

There are various factors that can influence the accuracy of an encoder. These include:

1. Resolution: The resolution of the encoder determines how finely the positioning can be detected. The higher the resolution, the more accurate the encoder. The resolution can be improved by using encoders with a higher number of pulses per revolution or by using a higher number of bits in a digital encoder.

2. Mechanical tolerances: The accuracy of an encoder can also be influenced by mechanical tolerances. Careful assembly and precise mechanics can improve accuracy.

3. Interpolation: For encoders with a low resolution, the accuracy can be improved by using interpolation methods. Additional intermediate values are calculated between the pulses to enable more precise position detection.

4. Signal processing: Accuracy can also be improved by precise signal processing. This can be achieved by using filters or by reducing signal interference.

It is important to note that the accuracy of an encoder also depends on the application and the requirements. In some cases, high accuracy may be required, while in other cases lower accuracy may be sufficient.

The service life of an encoder can be influenced by various factors, including

1. Quality of the material: The choice of high-quality materials for the manufacture of the encoder can increase its service life.

2. Environmental factors: The environment in which the encoder is used can affect its service life. Factors such as humidity, temperature, dust, vibrations and chemical influences can lead to premature wear.

3. Load: The load to which the encoder is exposed can affect its service life. Excessive load due to high speeds, torques or mechanical stress can lead to premature wear.

4. Maintenance and care: Regular maintenance and care can increase the service life of the encoder. This may include cleaning the components, lubricating moving parts and checking for wear or damage.

5. Construction and assembly: A high-quality design and precise mounting can improve the service life of the encoder. Careful selection of components and correct installation ensure optimum performance and durability.

6. Operating conditions: The type of application and the operating conditions can influence the service life of the encoder. For example, an application in which the encoder is frequently started and stopped can lead to increased wear.

It is important to note that these factors should not be considered in isolation, but can act in combination with each other. Careful selection, installation and maintenance of the encoder are crucial to maximize its service life.

To calibrate and adjust encoders and ensure accurate measurement results, the following steps can be followed:

1. Check the mechanical alignment of the rotary encoder: Ensure that the rotary encoder is properly mounted and correctly aligned. Check that all fastening elements are correctly tightened.

2. Check the electrical connection: Ensure that all electrical connections between the rotary encoder and the measuring device or control unit are properly established. Check the cables for damage or looseness.

3. Zero point adjustment: Make sure that the zero point of the rotary encoder is set correctly. This may vary depending on the model and manufacturer. As a rule, the zero point is adjusted using special software or using adjustment screws on the encoder itself.

4. Linearity adjustment: Check the linearity of the encoder to ensure that it provides accurate measurement results for different positions. This can also be done using special software or adjustment screws.

5. Speed and acceleration calibration: If the encoder also performs speed and acceleration measurements, these should also be calibrated. This can be done by comparison with a known speed or acceleration measuring device.

6. Regular inspection and maintenance: To ensure accurate measurement results in the long term, encoders should be checked and maintained regularly. Check for wear, damage or soiling and clean or repair the rotary encoder if necessary.

It is important to follow the manufacturer's specific instructions for your encoder, as the exact steps and settings may vary depending on the model and manufacturer.