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SYSCONA encoders use a photoelectric pulse generator synchronized with the spindle, transmitting synchronously via gears on an intermediate shaft in a 1:1 ratio. There is no direct mechanical connection between the rotation of the CNC lathe spindle and the feed motion. To machine threads, the number of pulses given to the feed servo motor must correspond to the spindle speed; the spindle pulse generator links spindle rotation to feed motion. A thread consists of continuous ridges and grooves of identical profile formed along a helix on a cylindrical or conical surface. Threads formed on a cylindrical surface are called cylindrical threads, and those formed on a conical surface are called conical threads. Threads formed on the outer surface of a body of revolution are called external threads, and those formed on the inner surface are called internal threads. There are many methods for machining threads. When cutting threads on a lathe, the lathe clamps the cylindrical workpiece with a three-jaw chuck and drives it at a constant rotational speed. The lathe feed mechanism drives the cutting tool (standard threading tool) in a constant linear motion along the cylinder axis. The tool tip cuts triangular grooves into the workpiece surface to form triangular threads. During thread machining, there is a trajectory start point (A point, i.e., the tool entry point) and a trajectory end point (B point, i.e., the tool exit point). In the thread machining trajectory, sufficient acceleration entry distance δ and deceleration exit distance δˊ are provided to ensure proper thread machining and eliminate pitch errors caused by servo lag.

SYSCONA encoder operating principle

A magnetic encoder consists of an optical code disk with a central shaft, featuring concentric light and dark graduation lines. Photoelectric emission and reception devices read these lines to obtain four sets of sine wave signals, combined into A, B, C, and D. Each sine wave has a phase difference of 90 degrees. Inverting the C and D signals and superimposing them on the A and B phases enhances signal stability. Additionally, one Z phase pulse is output per revolution to represent the zero reference position. Since the A and B phases differ by 90 degrees, the direction of rotation (forward or reverse) of the magnetic encoder can be determined by comparing which phase leads. The zero reference position is obtained via the zero pulse. Code disk materials for magnetic encoders include glass, metal, and plastic. Glass code disks have very thin graduation lines deposited on glass, offering good thermal stability and high precision. Metal code disks use direct light and dark lines; however, due to the thickness of the metal, precision is limited, and thermal stability is an order of magnitude worse than that of glass. Plastic code disks are an economical option. The principle of a magneto-optical encoder is similar to that of an optical encoder, but it uses magnetic field signals. Inside a magnetic encoder, a magnetic rotor and magnetoresistive sensors are used. The rotation of the magnetic rotor causes changes in the internal magnetic field strength. The magnetoresistive sensors detect these changes, and the signal is processed by the circuitry to output the final signal. The number of magnetic poles on the rotor, the number of magnetoresistive sensors, and the signal processing method determine the resolution of the magnetic encoder. The advantage of using magnetic field principles for signal generation is that magnetic signals are not affected by dust, moisture, high temperatures, or vibration.

SYSCONA encoder operating principle

The optical code disk of the series absolute encoder has many channels of graduation lines. Each channel is arranged sequentially with 2 lines, 4 lines, 8 lines, and 16 lines. At each position of the encoder, reading the light and dark states of each channel yields a unique 2-ary code (Gray code) ranging from the zeroth power of 2 to the n-1th power of 2. This is referred to as an n-bit absolute encoder. Such an encoder is determined by the mechanical position of the optical code disk and is unaffected by power outages or interference. Absolute encoders determine the code based on mechanical position; they require no memory, no search for a reference point, and no continuous counting. The position is read whenever it is needed. Thus, the anti-interference characteristics and data reliability of the encoder are significantly improved.

SYSCONA encoder troubleshooting

Encoder internal fault: This refers to a failure of the encoder's own components, preventing it from generating and outputting correct waveforms. In this case, the encoder must be replaced or its internal components repaired. Encoder connection cable fault: This is the most frequent fault, often encountered during maintenance, and should be the primary consideration. It is usually caused by open circuits, short circuits, or poor contact in the encoder cable. In such cases, replace the cable or connector. Pay special attention to whether loose cable fixing has caused loosening, leading to open solder joints or broken wires; if so, secure the cable tightly. Encoder +5V power drop: This refers to the +5V power supply being too low, typically not below 4.75V. Causes include power supply faults or excessive resistance in the power transmission cable causing losses. In this case, repair the power supply or replace the cable. Absolute encoder battery voltage drop: This fault usually triggers a clear alarm. Replace the battery. If the reference point position memory is lost, perform the return-to-reference-point operation. Encoder cable shield wire not connected or detached: This introduces interference signals, destabilizing waveforms and affecting communication accuracy. Ensure reliable welding and grounding of the shield wire. Loose encoder installation: This fault affects position control accuracy, causing excessive position deviation during stopping and movement, and may even trigger servo system overload alarms immediately upon startup. Pay special attention. Grating contamination: This reduces signal output amplitude. Gently wipe off oil stains with degreasing cotton soaked in anhydrous alcohol.

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