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Magnetic encoder is a sensor that converts mechanical geometric displacement on the output shaft into pulses or digital quantities through photoelectric conversion. This is currently the most widely used sensor. Photoelectric encoders consist of a light source, a code disk, and photosensitive elements. The grating disk has several rectangular holes evenly distributed on a circular plate of a certain diameter. Since the photoelectric code disk is coaxial with the motor, when the motor rotates, the grating disk rotates at the same speed as the motor. The detection device composed of electronic components such as light-emitting diodes detects and outputs several pulse signals. By calculating the number of pulses output by the photoelectric encoder per second, the current speed of the motor can be reflected. In addition, to determine the direction of rotation, the code disk can also provide two pulse signals with a phase difference of 90º.

Magnetic encoder installation and use

Mechanical installation and use of absolute rotary encoders: The mechanical installation of absolute rotary encoders includes various forms such as high-speed end installation, low-speed end installation, and auxiliary mechanical device installation. High-speed end installation: Installed at the drive motor shaft end (or gear connection). The advantage of this method is high resolution. Since multi-turn encoders have 4096 turns, and the number of motor rotations is within this range, the full range can be utilized to improve resolution. The disadvantage is that there is gear backlash error during forward and reverse motion after passing through reduction gears. It is generally used for unidirectional high-precision control positioning, such as roll gap control in steel rolling. In addition, if the encoder is directly installed on the high-speed end, motor vibration must be small; otherwise, the encoder is easily damaged. Low-speed end installation: Installed after the reduction gear, such as at the shaft end of a hoist wire rope drum or the last stage of the reduction gear shaft. This method eliminates gear backlash, provides more direct measurement and higher accuracy. This method is generally used for long-distance positioning measurements, such as various lifting equipment and feeding cart positioning. Auxiliary mechanical installation: Common methods include rack and pinion, chain and belt, friction wheels, and rope winding mechanisms.

Magnetic encoder component differences

From single-turn absolute encoders to multi-turn absolute encoders. For an absolute rotary single-turn absolute encoder, unique codes are obtained by measuring the tracks on the photoelectric code disk during rotation. When the rotation exceeds 360 degrees, the code returns to the origin, which does not conform to the principle of unique absolute coding. Such coding can only be used for measurements within a rotation range of 360 degrees and is called a single-turn absolute encoder. To measure rotations exceeding 360 degrees, multi-turn absolute encoders are used. Encoder production employs clockwork gear mechanics. When the central code disk rotates, another set of code disks (or multiple sets of gears and code disks) is driven via gear transmission. On the basis of single-turn coding, turn counting is added to expand the measurement range of the encoder. Such absolute encoders are called multi-turn absolute encoders. They also determine coding by mechanical position, with each position code being unique and non-repeating, requiring no memory. Another advantage of multi-turn encoders is that due to the large measurement range, there is often considerable margin. Therefore, it is not necessary to struggle to find the zero point during installation; a certain intermediate position can be used as the starting point, greatly simplifying the difficulty of installation and debugging.

Magnetic encoder working principle

Slots of equal angular width (divided into transparent and opaque parts) are opened on the edge of a code disk. Light sources and photosensitive elements are installed on both sides of the slotted code disk. When the code disk rotates together with the working shaft, each time it passes a slot, a change in light intensity occurs. After shaping and amplification, electrical pulse output signals with a certain amplitude and power can be obtained. The number of pulses equals the number of slots passed. This pulse signal is sent to a counter for counting, and the angle rotated by the code disk can be determined from the measured digital value. To determine the direction of rotation, two sets of photoelectric conversion devices can be used. Their relative spatial positions are arranged to ensure that the signals they produce have a phase difference of 1/4 cycle.

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