Four Steps to End Encoder
Problems
 This webinar will be available afterwards at
www.designworldonline.com & email
 Q&A at the end of the presentation
 Ha...
Moderator Presenter
Miles Budimir
Design World
Brian Winter
Nidec Avtron
Automation Corporation
4 Steps to End
Encoder Problems
Brian W. Winter
Nidec Avtron Automation Corporation
Step 1: Recognize The Kind
of Problem
• Electrical Failures
• Mechanical Failures
• Mysterious Failures
• Replacement Issu...
Electrical Failures
• The encoders will spin or move, but the outputs don’t make
your machine happy.
o Maybe the outputs a...
What Encoder
Output Should Look
Like
Incremental Quadrature Encoder
Shown
What Encoder
Output Can Look
Like
Incremental Encoder Shown
What Encoder
Output Can Look
Like
Incremental Encoder Shown
What If You Don’t
Have a Scope?
Incremental Encoder with
Overspeed Switch Shown
Mechanical Failures
• The encoders won’t spin or move or there is that funny
grinding sound…
o Maybe the bearings are fail...
What Encoder
Bearings are
Supposed to Look
Like
Rotary Encoder Shown
What Encoder
Bearings Can Look
Like
Rotary Encoder Shown
Maybe Something
Else Went Wrong
Inside?
Rotary Encoder with Glass Optical
Disk Shown
Mysterious Failures
• The encoder causes machine problems, but there are no
obvious mechanical or electrical problems
o Is...
Is this encoder
broken?
Rotary
Quadrature Encoder Shown
Are these encoders
broken?
Rotary No-Bearing
Quadrature Encoder Shown
Are these encoders
broken?
Rotary No-Bearing
Quadrature Encoders Shown
Is this encoder
broken?
Encoder with Diagnostics Shown
Don’t Open This
Can of Worms!
Absolute Encoder with Gear
Multiturn System Shown
Replacement Issues
• It’s broken for sure (we think) but we can’t find one!
o Millions of options
o Country specific
o Lon...
Step 2: Get Rid of the Claptrap
(if you can)
• Mechanical stuff outside the encoder
• Stuff inside the encoder
External Belt
Systems
Incremental Encoder with Shaft
and Belt System Shown
External Belt
Systems
Incremental Encoder with Shaft
and Belt System Shown
External Couplings
Incremental Encoder with
Overspeed Switch Shown
Internal Gears,
Multiple Sensors
Absolute Encoder with Gear
Multiturn System Shown
Step 3: Get Rugged
• What’s heavy duty mean?
• How to make it tougher!
Is This A Heavy
Duty Encoder?
Quadrature Encoder with Shaft
Shown
Are These Heavy
Duty Encoders?
Quadrature Encoders with Shaft
Shown
Beef It Up
Encoder Bearings
Don’t Let Stuff In
Absolute Rotary Encoder with
Shaft Shown
Beef It Up
Absolute Encoder with No Internal
Gears
Seal It Up
Sensor for Rotary No-Bearing
Encoder
Bolt it Right On
Incremental Rotary No-Bearing
Encoder Shown
Step 4: Get Diagnostic
• Remote Diagnostics
• Local Diagnostics
This Encoder is
Working Great!
Encoder with LED Diagnostics
Shown
Remote Diagnostics
• Get them!
o Simple relay contact
o Smart communication bus options
Summary
• Recognize the Problem(s)
• Simplify Mechanical Mouting
• Ruggedize Mechanicals
• Get Diagnostics
Thank You
Nidec Avtron makes the most reliable
encoders in the world
Questions?
Miles Budimir
Design World
mbudimir@wtwhmedia.com
Phone: 440.234.4531
Twitter: @DW_Motion
Brian Winter
Nidec Av...
Thank You
 This webinar will be available at designworldonline.com
& email
 Tweet with hashtag #DWwebinar
 Connect with...
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Four Steps to End Encoder Problems

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Four Steps to End Encoder Problems

  1. 1. Four Steps to End Encoder Problems
  2. 2.  This webinar will be available afterwards at www.designworldonline.com & email  Q&A at the end of the presentation  Hashtag for this webinar: #DWwebinar Before We Start
  3. 3. Moderator Presenter Miles Budimir Design World Brian Winter Nidec Avtron Automation Corporation
  4. 4. 4 Steps to End Encoder Problems Brian W. Winter Nidec Avtron Automation Corporation
  5. 5. Step 1: Recognize The Kind of Problem • Electrical Failures • Mechanical Failures • Mysterious Failures • Replacement Issues
  6. 6. Electrical Failures • The encoders will spin or move, but the outputs don’t make your machine happy. o Maybe the outputs are failing? o Maybe the guts are failing? o Maybe there is nothing wrong with the encoder…the problem is somewhere else?
  7. 7. What Encoder Output Should Look Like Incremental Quadrature Encoder Shown
  8. 8. What Encoder Output Can Look Like Incremental Encoder Shown
  9. 9. What Encoder Output Can Look Like Incremental Encoder Shown
  10. 10. What If You Don’t Have a Scope? Incremental Encoder with Overspeed Switch Shown
  11. 11. Mechanical Failures • The encoders won’t spin or move or there is that funny grinding sound… o Maybe the bearings are failing o Maybe something else is failing inside?
  12. 12. What Encoder Bearings are Supposed to Look Like Rotary Encoder Shown
  13. 13. What Encoder Bearings Can Look Like Rotary Encoder Shown
  14. 14. Maybe Something Else Went Wrong Inside? Rotary Encoder with Glass Optical Disk Shown
  15. 15. Mysterious Failures • The encoder causes machine problems, but there are no obvious mechanical or electrical problems o Is this encoder broken? o Don’t open that can of worms!
  16. 16. Is this encoder broken? Rotary Quadrature Encoder Shown
  17. 17. Are these encoders broken? Rotary No-Bearing Quadrature Encoder Shown
  18. 18. Are these encoders broken? Rotary No-Bearing Quadrature Encoders Shown
  19. 19. Is this encoder broken? Encoder with Diagnostics Shown
  20. 20. Don’t Open This Can of Worms! Absolute Encoder with Gear Multiturn System Shown
  21. 21. Replacement Issues • It’s broken for sure (we think) but we can’t find one! o Millions of options o Country specific o Long lead times
  22. 22. Step 2: Get Rid of the Claptrap (if you can) • Mechanical stuff outside the encoder • Stuff inside the encoder
  23. 23. External Belt Systems Incremental Encoder with Shaft and Belt System Shown
  24. 24. External Belt Systems Incremental Encoder with Shaft and Belt System Shown
  25. 25. External Couplings Incremental Encoder with Overspeed Switch Shown
  26. 26. Internal Gears, Multiple Sensors Absolute Encoder with Gear Multiturn System Shown
  27. 27. Step 3: Get Rugged • What’s heavy duty mean? • How to make it tougher!
  28. 28. Is This A Heavy Duty Encoder? Quadrature Encoder with Shaft Shown
  29. 29. Are These Heavy Duty Encoders? Quadrature Encoders with Shaft Shown
  30. 30. Beef It Up Encoder Bearings
  31. 31. Don’t Let Stuff In Absolute Rotary Encoder with Shaft Shown
  32. 32. Beef It Up Absolute Encoder with No Internal Gears
  33. 33. Seal It Up Sensor for Rotary No-Bearing Encoder
  34. 34. Bolt it Right On Incremental Rotary No-Bearing Encoder Shown
  35. 35. Step 4: Get Diagnostic • Remote Diagnostics • Local Diagnostics
  36. 36. This Encoder is Working Great! Encoder with LED Diagnostics Shown
  37. 37. Remote Diagnostics • Get them! o Simple relay contact o Smart communication bus options
  38. 38. Summary • Recognize the Problem(s) • Simplify Mechanical Mouting • Ruggedize Mechanicals • Get Diagnostics
  39. 39. Thank You Nidec Avtron makes the most reliable encoders in the world
  40. 40. Questions? Miles Budimir Design World mbudimir@wtwhmedia.com Phone: 440.234.4531 Twitter: @DW_Motion Brian Winter Nidec Avtron Automation Corporation brian.winter@nidec-avtron.com Phone: 216-642-1230 Twitter: @AvtronEncoders
  41. 41. Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #DWwebinar  Connect with Design World  Discuss this on EngineeringExchange.com

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