Case Study

Custom Encoder Created for Large Rotational Applications

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Introduction

In large-scale rotational applications, precise motion feedback is critical for optimal performance, safety, and efficiency. A new custom encoder design leverages a spring-loaded gear or wheel system to provide absolute motion feedback for high-demand use cases. This innovative solution is purpose-built for applications such as forklifts, MRI machines, mobile equipment, and stagecraft turntables, where reliable and accurate positioning of a rotational element, very often a ring gear, is non-negotiable.

 

 

Summary of encoder requirements for this application:

  • Minimal application redesign
  • Compatibility with specific terminal block connector
  • Overall responsiveness and speed of delivery

The Challenge

Large-diameter rotary motion introduces unique challenges in industrial applications. Traditional encoders often struggle to provide accurate feedback due to factors such as:

  • Extreme rotational diameters: Accurate tracking of large diameters requires specialized designs, which can often involve large, fragile, difficult to install and very expensive optical sensor rings.

  • Environmental durability: Applications like forklifts and mobile equipment demand encoders that can withstand harsh environments.

  • Space constraints: MRI machines and stagecraft turntables require compact, reliable solutions that can integrate seamlessly.

  • Precision and reliability: Absolute motion feedback is critical for safety and operational control.

  • Gear Ratios: Gear ratios that result in irrational numbers can be difficult to work with.  We offer gear slewing technology that allows our encoders to calculate the correct position of a large ring gear when installed on a smaller drive gear, using any gear ratio.

The Solution

Encoder Products Company addresses these challenges with a fully customizable solution, combining the housing from the popular TR1 Tru-Trac® wheeled encoder and the stability of the A36 absolute encoder, with a spring-loaded gear or wheel system tailored to each application's unique requirements.

1. Customization: At Encoder Products Company, we specialize in creating fully customized encoders to fit any application. We deliver an all-in-one solution, eliminating the need for engineers to spend valuable time piecing together parts and assembling components themselves. 

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Model A36R Absolute Encoder

Key Features:

  • Single turn/multi-turn absolute encoder (22 Bit ST / 24 Bit MT)
  • BiSS C or SSI communication
  • Standard 36 mm dia. package (1.42")
  • Low profile – 1.0" (25.4 mm) depth
  • Flex mount options eliminate couplings and are ideal for motors
  • Optional battery/backup power interface for data retention in the absence of primary power
  • Available with bore sizes up to 10 mm

2. TR1 Tru-Trac® Housing: Rugged and versatile, the TR1 housing provides robust protection against environmental factors such as dust, moisture, and vibrations. Its modular design allows seamless integration into diverse systems.

3. A36 Absolute Encoder: Known for its compact size and exceptional performance, the A36 encoder delivers precise absolute motion feedback in a range of demanding environments.

4. Gear or Wheel System: The inclusion of a spring-loaded gear or  wheel mechanism enables precise tracking of large-diameter rotary motion, ensuring accuracy in absolute positioning.

Key Applications

1. Forklifts

  • Use Case: In forklifts, precise motion feedback is critical for lift height, fork position, and vehicle steering and control.

  • Impact: The custom encoder ensures enhanced safety and operational efficiency by providing reliable data on rotational movements such as steering angle and vehicle speed.

2. MRI Machines

  • Use Case: In medical imaging, maintaining precise motion control within a compact design is vital.

  • Impact: The compact size and accuracy of the encoder make it ideal for use in CAT scan or MRI systems, where smooth and controlled movement ensures patient safety and image quality.

  • Reliability:  Our solution is more robust, and less costly, than solutions that use a large diameter glass or plastic positioning ring that are difficult to install and can be easily damaged during machine service. 

3. Mobile Equipment

  • Use Case: Mobile equipment such as construction and agricultural machinery rely on encoders to monitor and control movement under harsh conditions.

  • Impact: The rugged TR1 housing ensures durability in challenging environments, while the A36 encoder delivers the precision needed for reliable operation.  Internal software within the encoder adjusts for user-defined gear ratios, ensuring accurate overall angular position is maintained over time.

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4. Stagecraft Turntables

  • Use Case: In stagecraft, turntables must rotate smoothly and precisely to create seamless theatrical or production experiences.

  • Impact: The spring-loaded gear or wheel system enables accurate large-diameter motion and position tracking, ensuring flawless operation in high-pressure settings.  The encoder can be used as secondary feedback for safety, giving position data right at the point of motion itself.

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Why Choose Encoder Products Company?

  • All-in-One Solutions: We handle the engineering, design, and assembly to provide a complete, plug-and-play encoder system tailored to your application.

  • Time Savings: Our ready-to-use solutions free engineers from the hassle of piecing parts together, allowing them to focus on their core tasks.

  • Custom Designs: We specialize in creating encoders and hardware that meet exact specifications, ensuring your unique application requirements are fulfilled.

Performance Highlights

  • Absolute Feedback: A custom encoder provides accurate, absolute positioning data, which is crucial for safety and precision.
  • Rugged Durability: The TR1 housing protects against harsh environmental factors, ensuring long-lasting performance.
  • Versatility: Suitable for a wide range of applications, from industrial forklifts to high-tech medical equipment.
  • Compact Design: The space-efficient A36 encoder integrates easily into systems with limited room for additional components.
  • Large-Diameter Tracking: The gear and wheel system is specifically engineered for large-scale rotational applications.

Conclusion

Encoder Products Company’s custom encoder solutions are redefining motion feedback technology across industries. By combining the rugged TR1 Tru-Trac® encoder housing, high-performance A36 absolute encoder, and a precision gear and wheel system, we deliver an all-in-one solution that provides engineers with the tools they need—without the hassle of assembly. Whether used in forklifts, MRI machines, mobile equipment, or stagecraft turntables, our customizable encoders ensure precision, reliability, and efficiency.

We spend the time to get it right.  When you need a motion feedback solution, Encoder Products Company is your partner for success.  Start your custom project today!  https://www.encoder.com/custom-engineering

Find Out More

Do you have a question about which encoder is right for your application? When you contact EPC, you talk to engineers and encoder experts who can answer your toughest encoder questions. You’ll get answers that make sense for your application.

With our industry-leading three-year warranty, if something does go wrong, we’ve got you covered.

Contact EPC to find the right encoder for your application.

Our 100,000 square foot manufacturing facility in Sagle, Idaho, is vertically integrated. Watch to learn more.

 

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