1. Four Steps to End Encoder
Problems

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. Moderator Presenter
Miles Budimir
Design World
Brian Winter
Nidec Avtron
Automation Corporation

4. 4 Steps to End
Encoder Problems
Brian W. Winter
Nidec Avtron Automation Corporation

5. Step 1: Recognize The Kind
of Problem
• Electrical Failures
• Mechanical Failures
• Mysterious Failures
• Replacement Issues

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. What Encoder
Output Should Look
Like
Incremental Quadrature Encoder
Shown

8. What Encoder
Output Can Look
Like
Incremental Encoder Shown

9. What Encoder
Output Can Look
Like
Incremental Encoder Shown

10. What If You Don’t
Have a Scope?
Incremental Encoder with
Overspeed Switch Shown

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. What Encoder
Bearings are
Supposed to Look
Like
Rotary Encoder Shown

13. What Encoder
Bearings Can Look
Like
Rotary Encoder Shown

14. Maybe Something
Else Went Wrong
Inside?
Rotary Encoder with Glass Optical
Disk Shown

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. Is this encoder
broken?
Rotary
Quadrature Encoder Shown

17. Are these encoders
broken?
Rotary No-Bearing
Quadrature Encoder Shown

18. Are these encoders
broken?
Rotary No-Bearing
Quadrature Encoders Shown

19. Is this encoder
broken?
Encoder with Diagnostics Shown

20. Don’t Open This
Can of Worms!
Absolute Encoder with Gear
Multiturn System Shown

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. Step 2: Get Rid of the Claptrap
(if you can)
• Mechanical stuff outside the encoder
• Stuff inside the encoder

23. External Belt
Systems
Incremental Encoder with Shaft
and Belt System Shown

24. External Belt
Systems
Incremental Encoder with Shaft
and Belt System Shown

25. External Couplings
Incremental Encoder with
Overspeed Switch Shown

26. Internal Gears,
Multiple Sensors
Absolute Encoder with Gear
Multiturn System Shown

27. Step 3: Get Rugged
• What’s heavy duty mean?
• How to make it tougher!

28. Is This A Heavy
Duty Encoder?
Quadrature Encoder with Shaft
Shown

29. Are These Heavy
Duty Encoders?
Quadrature Encoders with Shaft
Shown

30. Beef It Up
Encoder Bearings

31. Don’t Let Stuff In
Absolute Rotary Encoder with
Shaft Shown

32. Beef It Up
Absolute Encoder with No Internal
Gears

33. Seal It Up
Sensor for Rotary No-Bearing
Encoder

34. Bolt it Right On
Incremental Rotary No-Bearing
Encoder Shown

35. Step 4: Get Diagnostic
• Remote Diagnostics
• Local Diagnostics

36. This Encoder is
Working Great!
Encoder with LED Diagnostics
Shown

37. Remote Diagnostics
• Get them!
o Simple relay contact
o Smart communication bus options

38. Summary
• Recognize the Problem(s)
• Simplify Mechanical Mouting
• Ruggedize Mechanicals
• Get Diagnostics

39. Thank You
Nidec Avtron makes the most reliable
encoders in the world

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. Thank You
 This webinar will be available at designworldonline.com
& email
 Tweet with hashtag #DWwebinar
 Connect with Design World
 Discuss this on EngineeringExchange.com