Recently I decided to catalog the competitive Incremental Encoders that have populated the shelves surrounding my desk.  In doing so, I was surprised to find that many of our competitors use potentiometers in their designs.

I can understand why they need to use potentiometers.  In most designs the potentiometers are used to balance the raw analog signals produced by the Incremental Encoder sensor.   A potentiometer is the perfect component for this, you fire up the Incremental Encoder during test, lay a scope probe on it and dial the value specified by Engineering.  For most encoder designs, the only other option is to guess at some resistor values hoping that you don’t have to solder and unsolder resistors too many times until you hone in the correct signal, as that would be a very time consuming process.

While I can understand the use of Potentiometers, the reason that I am a bit shocked by their ubiquity in competitor’s designs is that potentiometers are inherently a much less reliable component.  A resistor is all one solid piece, but a potentiometer (which is a variable resistor) has a resistive track and a movable wiper that slides along to vary the resistance value. Moving parts are inherently less reliable than a non-moveable part.

Here are a few of the PCBs from various manufacturers ,  the potentiometers are circled in Red:

This next one is my favorite.  Thirteen potentiometers!

I am proud to say that Quantum Devices Encoders do not use potentiometers in their Incremental Encoder designs.  The reason we can avoid potentiometers is because of our patented phased array sensor that provides perfectly balanced complementary signals right from the sensor.

Other incremental encoder sensors suffer from having their active areas in different locations along the length of the sensor. Since the light source spreads light unevenly over the sensor, some active areas receive more light than others creating signal imbalances.

In Quantum Devices Incremental Encoders the photosensitive areas of each channel are interlaced with each another,  so all active areas receive the same amount of light.  This eliminates the need to balance any signals, which in turn eliminates the need for potentiometers in the design.

Below is an drawing of the phased array sensor Red indicates Channel A active areas, Blue indicates channel B active areas.

Related articles

• Finding the RPM of an Optical Encoder using an Oscilloscope (quantumdevices.wordpress.com)

We recently teamed up with one of our distributors to create a Demo box that showcased our QD145 optical encoder with a Delta Tau PLC and touchscreen panel.  It was sent off to a trade show where potential customers would get to spin the encoder and watch on the screen as counts were incremented and decremented and needles on dials spun.

I thought the Optical Encoder Demo box would make for a fantastic topic to write a post on, so that was my plan as soon as the demo box returned from the show.

Well… it never did come back.  I would love to tell you that I did such a great job on it that our distributor insisted on keeping it but the truth of the matter is that it was lost in shipping.

What I do have is the code and screenshot of the Optical Encoder Demo box, which should be more than enough to explain the functionality. What I don’t have are pictures, or video of the Optical Encoder Demo box in action, so you will have to use a little imagination on your part.
I  mounted the PLC, HMI and encoder to an enclosure that can set on a table.  The default screen (shown above) tells a little about the encoder. From this screen you can select a few different screens that allow you to interact with the encoder.

Count Screen:
This screen shows Pulse Count, Angle, RPM and direction.

Optical Encoder Data Screen

Degree Screen:

This screen shows mechanical degrees. The needle rotates in conjunction with encoder rotation:

Optical Encoder Mechanical Degree Screen

Pulse Count:
This screen shows the direct read count of the encoder, the needle rotates in conjunction with  encoder rotation:

Optical Encoder Pulse Count Screen

Tank Screen:
This is sort of a fun screen where rotation the encoder fills tanks in sequence, tank one fills, when tank one is full it “empties” into tank 2, when tank 2 is full it “empties” into tank 3.  Tank 3 continues to accumulate until 2 billion counts or so. The Drain button clears the levels on all of the tanks.

Optical Encoder Tank Filling Screen

ABZ screen:
This screen indicates status of inputs coming from the encoder.  Since I used a 5000 LC encoder, the screen was not be able to keep up real time when the encoder was rotated really fast, and it was nearly impossible to land on Z(Index) and have it light.

Optical Encoder Incremental Signals Screen

Programming

The Delta Tau was pretty easy to program, with only a couple hiccups.  The manual was a little vague in its explanation of the way two registers were used for some of the counter functions, but a little troubleshooting showed me which bits were activated when the counter set point was hit.

The Ladder Logic

This first rung of code is needed to do some basic housekeeping to ensure that D1022 is properly configured with a “1″ on the first program scan. It is set by  M1002 and forever latched by M110.  The value of 1 tells the high speed input that we want a double frequency selection A/B phase counter.

The second rung sets up our high speed counter and checks the count to see if we have gone negative in value. If so, bit M120 is set high.

Rung three turns on a physical output Y11 if the counter set point has been hit.

Rung four moves the set point of 5000 back into the counter if we have gone negative in value. This allows the needles on our display screens to rotate continuously and not peg out to a high or low value.

Rung five updates Register D300 with our counter value every 10mS via the handy M1011 10 mS clock pulse.

Rung six divides the counter value by 16 and moves the answer into Register D302. This is where we start our math for the degree conversion. The rest is scaled by the configuring the screen register in the screen editor software.

Run seven uses the trailing edge of our 10 mS clock pulse to move the counter value into register D310.  This value is held for comparison in time to get RPM.

Rung eight uses the leading edge  of our 10mS clock pulse to find the difference in our stored value and put it out to register D312.  D312 is then doubled and sent out to register D350.

For any of you interested in repeating the project, I have included the BOM below.

Of course, I also used some miscellaneous wire and hardware to construct the Optical Encoder Demo box, but the list below includes all the big ticket items.

From Cymatix:

QD145-5/26-5000-0-02-T1-01-02 Optical Encoder

DOP-AS35THTD 3.5” Color touch screen

DVP12C11T Micro programmable Logic controller 8 inputs 4 High Speed outputs

DRP024V060W1AZ CliQ 24 Vdc, 60 Watt power supply

DVPACAB2A30 3 Meter connection cable

From Automation Direct:

DN-R35S1 Din Rail 35mm X7.5mm

WC12C12  N12 Desktop enclosure 12”X12”X9”

DN-T12A Terminal Blocks

DN-EB35MN End Brackets

DN-LAB terminal block labels

We only need to measure one of the incremental channels in order to calculate the RPM of an optical encoder.  Using an oscilloscope to measure the period of one incremental channel A cycle.

We will need to find the frequency of the incremental signal. Keep in mind that converting from time to frequency is just a simple press of the “one over X” button on a scientific calculator.

Frequency =(1/X time)

Time = (1/X Frequency)

To find RPM Once you have the frequency, Multiply by sixty and divide by the line count.

RPM = (Frequency X 60)/Line count of encoder

The encoder in the video is a 5000 Line Count encoder.  Channel A is outputting pulses at a frequency of 224.2 Khz

RPM = (224.2Khz X 60)/5000

RPM = (13452000)/5000

RPM = 2690.4 RPM

I often use this method to either verify the speed of a motor controller I have built, or if I know the RPM of the motor, I will sometimes use this as a quick way to verify the line count of an encoder.

You can also use the handy Web-based QDI optical encoder calculator  as well.

Jim

Hi Jim,

The data channels are not symmetrical and there appears to be something superimposed on the index. Attached are pictures. Can I return these for your evaluation?

Regards,

Al

Below are the screen shots that he sent:

My response was as follows:

Hi Al,

What you are seeing is normal and expected for an encoder with a ribbon cable with unlodaded channel termination. What you are seeing is crosstalk between the channels, and possibly some external signal noise else being picked up by the cable.

When the channels are loaded the irregularities in the signals go away (as shown in the second photo).

Jim

Channels with 220Ohm differential loading

We just added a new page to the main Quantum Devices Inc. web site that provides a way to calculate RPM, Frequency, or line count (optical encoder resolution) by entering in the other two variables.

When would you want to use such a tool?  You might find it useful under the following circumstances:

Solving for Resolution:

When trying to determine the line count of an unknown encoder if you spin the encoder at a given RPM, then use an oscilloscope and find the output frequency, you can find out the resolution of an unknown encoder.

Solving for frequency:

If you know the RPM and line count of your optical encoder you can calculate the output frequency. This is a useful check when you are designing in an encoder to make sure you do not overrun a the input frequency limit of a drive, controller, or other device.

Solving for RPM:

This is often times used to validate the actual speed at which a machine or motor is running.

To do these calculations by hand you can check out the other blog post we have on calculating optical encoder output frequency.

Quantum Devices is a manufacturer of rotary encoders.  Incorporating QDI’s patented sensor technology, our QPhase^TM Family of Encoders feature high resolution, increased frequency response and superior reliability over temperature (0 to 120 degrees C). QDI incremental and absolute encoders set a new standard and are backed by a 2 year factory warranty. We invite you to request an evaluation unit, additional information or price quotations.

Image via Wikipedia

Why do my incremental encoder signals disappear?

Today I was called to the production floor after one of the test Technicians noticed that the encoder signals disappeared from the oscilloscope when they ran the encoders “unloaded”.

I asked one of the techs if the encoders being tested were of the open collector variety. The answer was  “No, they’re line drivers”

I immediately pictured our standard 26C31 line drivers, which are push-pull devices.

When I checked the label on the line driver IC on the encoder. I saw that it was an ET7273. This meant that the right answer was that they were both a line driver and an open collector device. The ET7273 is used in our optical encoder when a customer wants complementary open collector outputs, or incremental side open collector outputs

The problem was that I, as well as the Tech I talked to, am guilty of using the term “line driver” to synonymously mean “push pull” outputs.

Open collector style outputs are used when you want to be able to pull up to a different voltage level from the rest of the system. For example most of the optical encoders we sell are 5V devices, but the open collector output can be pulled up to many times that level. The ET7273 has a max spec of 30Vdc.

So why was she not seeing any outputs when the encoder wasn’t loaded?

The term “open collector “refers to the fact that there is no electrical connection to the collector side of the output transistor.  It is up to the user to put the correct value of load resistor between the positive voltage rail and the output in order to make the transistor start switching.  The value of this resistor depends on the desired current through the device and the maximum rating of the transistor.

When the Tech was testing the encoder while it was electrically loaded, the resistor internal to the encoder test station was in series with the transistor pulling it up to the positive voltage rail. When the Tech took the loading off, the resistor was removed from the circuit, making an open, and causing the signals to flat line.

The test personnel are used to seeing the 26C31 line drivers day in and day out.  Since the 26C31 line driver is a push pull device, signals are present whether or not the encoder is under load.

I am proud of the fact that the test Tech took the time to ask “why” instead of just writing it off as an anomaly they didn’t understand.

I think things like that help to make Quantum Devices the best optical encoder manufacturer around.

Jim

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Quantum Devices Inc is a leading manufacturer of optical rotary encoders.

Jim can be reached at 608.924.3000 or by e-mail at jmiller@quantumdev.com

In the QD145 and QD200 series of encoders the index pulse fires when the mark on the top cover of the optical incremental encoder and the mark on the encoders shaft are aligned.

This mark also indicates the rising edge of the U channel for commutated optical incremental encoders.  Knowing the location of this edge is useful for the initial rough timing of Brushless DC motors.

Quantum Devices is a leading manufacturer of Optical Incremental Encoders.

Jim can be reached at 608.924.3000 or by e-mail at jmiller@quantumdev.com

Well, the brushes of course.

Yeah, but what does that mean?

The principle behind the internal working of both a brushless DC motor and a brushed DC motor are essentially the same.  When the motor windings become energized, a temporary magnetic field is created that repels(and/or attracts) against permanent magnets.  This force is converted into shaft rotation, which allows the motor to do work.  As the shaft rotates, electric current is routed to different sets of windings, maintaining electromotive repulsion/attraction,  forcing the rotor to continually turn.

Construction differences

Brushes inside  electric motors are used to deliver current to the motor windings through commutator contacts.  Brushless motors have none of these current carrying commutators.  The field inside a brushless  motor is switched via an amplifier triggered by a commutating device, such as an optical encoder.

Windings are on the rotor (Rotating part of motor) for brush motors and on the stator (stationary part of motor) for brushless motors.

Brush Motor: windings on rotor, magnets on stator

By positioning the windings on the outside stationary portion of the Electric motor the need for brushes can be eliminated.

Brushless Motor: Windings on stator, magnets on rotor

There are hints of Brush motors being first developed in the 1830s, by Michael Faraday

Brushed motor Advantages:

Simplified  wiring:  Brush motors can be wired directly to DC power and control can be a simple as a switch.

Low cost:

Brushed Motor Disadvantages:

Less efficient

Electrically noisy: The switching action of the commutators constantly creating and breaking inductive circuits creates a great deal of electrical and electromagnetic noise.

Lifespan:  As they are in perpetual physical contact with the shaft,  brushes and commutators wear out.

Showing Brushes and Commutators

Showing Motor Brushes with Rotor removed

Brushless Motor Advantages:

Long lifespan: No brushes to wear out
low maintenance: No brushes to replace
High efficiency

Brushless Motor disadvantages:

High initial cost: Need for commutating device  like an encoder and a drive or controller

Brushless motor stator

Brushless Motor Rotor

Here is a cool video of a home made Brushless DC motor.  Notice the amount of arcing in the reed switch as fields are switched. This is due to the release of latent energy stored in the windings as they are switched off.

The real take away on this video is that the magnets are on the rotating portion of the home built motor.

Brusheless motor vs brush motor efficiency:

Brushless motors are typically 85-90% efficient whereas brushed DC motors are around 75-80% efficient.

This difference in efficiency means that more of the total power used by the motor is being turned into rotational force and less is being lost as heat.

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Jim is an Application Engineer for Quantum Devices Inc, a leading manufacturer of  Rotary Incremental Encoders.  He can be reached at jmiller@quantumdev.com.

Lets say you needed to identify where the index pulse was firing on your incremental encoder, but you left your oscilloscope in your other jacket pocket, and now all you have on hand is a DMM.

Well fear not, finding the index with a multimeter is possible although a bit tedious.

The index fires once per revolution and at higher line counts this makes it VERY easy to miss.  Since there is some delay in a multimeter’s display time, you will need to rotate the encoder very slowly to catch a change in voltage level.

The Blue box has a nine-volt battery inside that I regulated down to 5Vdc for the encoder power.  I have pulled out connections to ground (Black wire) and the index channel (Orange wire). When the index fires, the voltage will go from zero to five volts.

Jim is an Applications Engineer with Quantum Devices Inc. A leading manufacturer of Optical Encoders.

Quantum devices QD145 and QD200 Optical Encoders feature an extra black & white-stripped wire that serves as an alternate grounding connection for the encoder.

This wire is intended to be used in situations where the encoder flex mount is not case grounded.  The Black/white wire is at the same potential as the Optical Encoder’s conductive polymer housing and  flex mount.

Internally the electrical path of the black-white wire is tied to the optical encoder housing and flex mount through the circuit board.  Our optical encoders tend to live on the back of hardware like Brushless DC motors, where the motor housing is at ground potential.  In cases like this it is usually best to leave the black-white wire tied off and floating.

Arrow showing flex mount grounding Optical Encoder to Motor.

Jim is an application engineer for Quantum Devices INC, a leading manufacturer of optical encoders.

Jim reached at jmiller@quantumdev.com.