Author: FLUX

What Are Angle Encoders? 

Angle encoders are sensors designed to measure the exact rotational angle or position of a shaft and provide precise digital feedback. They are a subset of rotary encoders, typically optimized for high-precision angular position measurement. Unlike general rotary encoders, which may measure rotation speed or incremental position, angle encoders focus on delivering accurate absolute or incremental angle data for precise motion control. In many designs, they are mounted directly on the shaft to avoid mechanical backlash errors and are widely used in robotics, automation, and industrial applications requiring high precision. 

Types of Angle Encoders 

Angle encoders vary based on their sensing technology and output type. Common technologies include: 

• Optical: High accuracy using light and coded disks. Sensitive to dust, vibration, and misalignment. 
• Magnetic: Use magnetic sensors. Robust in dirty environments but offer moderate accuracy. 
• Capacitive: Detect changes in capacitance. Resist magnetic fields but can be affected by moisture. 
• Inductive: Use electromagnetic induction to determine position. Highly resistant to contaminants, temperature changes, and EMI. 
• GMI®: A patented technology that uses changes in impedance under magnetic fields to provide precise position feedback. 
• Resistive (Potentiometric): Legacy technology. Low cost but limited in accuracy and durability. 

Encoders are available as incremental (providing relative position and requiring homing) or absolute (delivering exact position at all times). Absolute encoders are typically favoured in high-precision applications due to their ability to retain position data even after power loss. 

What Are the Key Characteristics of Angle Encoders? 

Angle encoders have key characteristics that determine their performance and suitability: 

• Accuracy & Resolution: Deliver precise angle measurements down to arcsecond levels for superior control. 
• Absolute Positioning: Provide true absolute angle feedback without requiring homing after power loss. 
• Environmental Robustness: Withstand dust, moisture, metal particles, and electromagnetic interference with high IP ratings. 
• Compact Form Factor: Slim, lightweight designs enable easy installation in tight spaces. 
• Durability: Contactless sensing ensures long service life and minimal maintenance in demanding environments. 

Applications of Angle Encoders 

Angle encoders provide precise rotational feedback essential for motion control and positioning in various industries. Common applications include

• Machine Tools: Precise position feedback for CNC machines and grinders. 
• Semiconductors: Accurate motion control in wafer processing equipment. 
• Industrial Robots: Enhanced joint and arm positioning for automation. 
• Aerospace Surveillance: Reliable tracking in surveillance and monitoring systems. 
• Satellite Communication: Precise antenna positioning for signal accuracy. 
• Drone Control: Accurate orientation feedback for UAV stability and maneuvering. 

How to Choose the Right Angle Encoder 

Choosing the right angle encoder depends on your application and environment. The key factors to consider are:

• Accuracy & Resolution: Choose encoders that meet your precision requirements, with higher-bit resolution for greater accuracy. 
• Environmental Suitability: Select encoders that can withstand dust, moisture, vibration, and electromagnetic interference based on your environment. 
• Output Type: Decide between absolute encoders for true position feedback or incremental encoders for relative motion, ensuring compatibility with your system. 
• Size & Mounting: Consider compact, frameless, or hollow-shaft designs for space-saving and easy installation. 
• Durability & Maintenance: Choose contactless encoder technologies to ensure extended lifespan and minimal maintenance requirements. 

What are Inductive Angle Encoders?

Inductive angle encoders are precision sensors that measure angular position using the principle of electromagnetic induction. These contactless devices feature a rotor patterned with electrically conductive materials (such as copper), which interact with the stator’s alternating electromagnetic field. As the rotor turns, position-dependent eddy currents are induced in the conductive structure. These currents alter the impedance of the sensing coils in the stator, which are monitored by the electronics.

Known for their high reliability and durability, inductive angle encoders excel in harsh industrial environments where dust, moisture, and vibration are present. Their robust, non-contact design minimizes wear and maintenance, making them ideal for demanding applications.

By delivering consistent, high-precision angle measurements, inductive angle encoders are essential for systems requiring accurate position feedback and long-term operational stability.

For reliable performance in extreme environments, explore FLUX’s IND-MAX inductive angle encoder, engineered to provide robust, high-precision measurement in the toughest conditions.

Benefits of an Inductive Angle Encoder

Inductive angle encoders offer a range of advantages that make them ideal for precise and reliable rotary position measurement in tough industrial settings. Known for their contactless measuring principle, inductive angle encoders provide high durability and accuracy while minimizing mechanical wear. Their robustness against shock, vibration, dust, and moisture makes inductive angle encoders well-suited for harsh environments where traditional sensors may fail.

The IND-MAX inductive angle encoder offers several benefits that make it an excellent choice for precise position measurement in challenging environments:

• Contactless operation: Utilizes a contactless measuring principle to avoid mechanical wear and extend device lifespan.
• High reliability and robustness: Built to perform reliably under shock, vibration, dust, and moisture exposure, suitable for extreme environments.
• High precision: Delivers accurate and repeatable angle measurement essential for demanding applications.
• Wide operating temperature range: Designed to operate effectively in harsh temperature conditions.

Why Are Angle Encoders Important for Satcom on the Move? 

In Satcom on the Move (SOTM) systems, maintaining uninterrupted and reliable satellite communication while in motion is crucial. Angle encoders provide precise position feedback, enabling antennas to maintain exact alignment with satellites despite the continuous movement of the platform. This precision reduces signal loss and enhances communication stability, which is important for a wide range of satellite communication applications. In contrast, inaccurate encoders can cause misalignment, leading to weak signals or complete loss of connection. 

What Are the Key Features of Angle Encoders for Satcom on the Move? 

When choosing angle encoders for Satcom on the Move applications, it’s important to consider the demanding conditions of mobile satellite communication systems. These systems operate in constantly changing environments where uninterrupted connectivity and precise antenna alignment are critical. The following features are particularly important: 

• Instant and Accurate Position Feedback: Encoders with absolute position capabilities allow antennas to realign immediately after startup or power loss. This ensures fast signal acquisition and maintains continuous satellite communication. 
• Durability in Harsh Environmental Conditions: Encoders used in Satcom on the Move systems must maintain reliable performance despite vibration, shock, temperature fluctuations, and electromagnetic interference typical of demanding field conditions. 
• Contactless Operation for Long-Term Reliability: A non-contact sensing mechanism reduces mechanical wear, minimizes maintenance, and enhances long-term stability in demanding applications. 
• Compact and Lightweight Design: Small size and low weight enable easy integration into space-constrained mobile systems without affecting system performance or mobility. 

What Types of Angle Encoders Are Used for Satcom on the Move? 

Satcom on the Move applications require encoders that are not only accurate but also highly durable and resistant to harsh environmental factors. Among the various encoder technologies available, inductive encoders stand out due to their contactless measurement principle, which delivers long-term reliability and consistent accuracy. 

FLUX’s inductive encoders use advanced inductive technology designed for precision and reliability in compact, mobile systems. Key benefits include: 

• EMI Resistance: Operates reliably in environments with strong magnetic and electromagnetic fields. 
• Ultra-Compact Design: 14 g in total weight and less than 6 mm thick for easy integration in tight spaces. 
• Absolute Position Feedback: Provides precise position detection instantly upon power-up, eliminating the need for a reference run or recalibration after power loss. 
• Plug-and-Play Setup: No field calibration required, simplifying installation and reducing setup time.
   

What Are the Best Angle Encoders for Satcom on the Move? 

Selecting the ideal encoder for Satcom on the Move means prioritizing features that ensure precision, durability, and seamless integration. Key characteristics include absolute position feedback, contactless operation, high resolution, and robust performance in demanding environments.  

FLUX’s IND-MAX Inductive Angle Encoder delivers absolute position measurement with superior robustness. It features high shock resistance, a wide operating temperature range, and reliable protection against external contaminants. These qualities make the IND-MAX Inductive Angle Encoder well-suited for demanding Satcom on the Move antenna positioning applications where uncompromising accuracy and reliability are essential. 

How FLUX Angle Encoders Enhance Satcom on the Move Performance 

Angle encoders are important components that enable Satcom on the Move systems to maintain optimal antenna alignment and uninterrupted communication. FLUX’s advanced inductive encoders deliver the precision, durability, and reliable performance needed to overcome the demanding challenges of Satcom on the Move. 

Discover how FLUX’s IND-MAX Inductive Angle Encoder can enhance the accuracy and reliability of your Satcom on the Move systems. Contact FLUX today to find the ideal encoder solution for your application.

Why Are Rugged Encoders Important for Construction Robots?

Construction robots operate in extremely harsh environments. They are constantly exposed to heavy vibrations, dust, dirt, moisture, and temperature changes. These conditions can cause some types of encoders to fail or lose accuracy.

Rugged encoders are designed specifically to withstand such tough environments. They provide reliable and precise feedback on position and speed even when exposed to shocks and vibrations. This durability is essential for construction robots to maintain safe and efficient operation on the site.

What Types of Encoders Are Used in Construction Robots?

Among various encoder technologies, inductive encoders are highly suitable and an ideal choice for construction robots. Inductive encoders use electromagnetic induction to sense position without physical contact. This non-contact measurement provides excellent resistance to debris and mechanical wear.

FLUX’s inductive encoder technology is based on inductive sensing and enables the design of extremely compact absolute encoders without compromising performance. It delivers stable position signals even under mechanical stress and environmental interference.

The technology offers high immunity to magnetic and electromagnetic disturbances, allowing integration into a wide variety of applications. Its lightweight and modular structure supports scalable and customizable solutions. These features make FLUX’s inductive encoder technology a great fit for the demanding needs of construction robots.

How to Choose the Best Encoder for Construction Robots

When selecting an encoder for construction robots, it’s important to prioritize durability, precision, and reliability. The encoder must be able to withstand harsh conditions while maintaining accurate and consistent feedback. It should deliver precise position and speed measurements to ensure smooth and safe robot operation. Additionally, reliability over long-term use with minimal maintenance is crucial to reduce downtime and costs.

FLUX’s IND-MAX inductive angle encoder stands out as the best rugged encoder solution.

Key benefits of the IND-MAX inductive angle encoder include:

• Durability: High resistance to shocks and vibrations typical in construction environments.
• Maintenance-free: Non-contact sensing means no wear and tear over time.
• Precision: Reliable and accurate signal output for precise position and speed feedback.
• Easy integration: Compact design suitable for various robotic applications.
• Extended temperature range: Built to operate reliably in extreme cold and sub-zero temperatures.

Final Thoughts on Rugged Encoders in Construction Robotics

Rugged encoders are essential components in construction robotics. FLUX’s innovative inductive encoder technology offers exceptional resistance to dust and electromagnetic interference, ensuring reliable performance across a wide range of industries. FLUX’s IND-MAX angle encoder is the optimal rugged encoder for construction robots, offering reliability in high-shock environments, a wide operating temperature range and maintenance-free operation.

Check out the IND-MAX inductive angle encoder and discover why it’s an ideal option for rugged construction robots.

What Is an Exoskeleton and How Does It Work?

Exoskeletons are wearable robotic systems designed to enhance, support, or restore human mobility. These devices, which can be powered or passive, work in coordination with the body to provide mechanical assistance. Exoskeletons are used in a variety of fields, including healthcare, manufacturing, defense, and personal mobility, to help improve physical performance and support movement.

Common applications of exoskeleton technology include:

• Medical Rehabilitation: Assisting patients recovering from stroke, spinal cord injuries, or neurological conditions to regain mobility and independence.
• Industrial Settings: Helping workers perform physically intense tasks while reducing fatigue and preventing injuries.
• Military and Defense: Improving performance by increasing endurance and load-carrying capacity during long missions.
• Elderly Mobility Assistance: Supporting elderly people with limited mobility so they can move with greater safety and confidence.

What Is the Role of a Compact Encoder in Exoskeletons?

Compact encoders are important components in wearable robotics, especially in exoskeleton systems. Encoders convert mechanical motion into electrical signals, allowing exoskeletons to track and respond to human movement with high precision. This real-time feedback allows exoskeletons to respond accurately and efficiently to the user’s actions.

By providing detailed motion data, encoders help maintain coordination between the user and the robotic system. This ensures that movement feels natural and stable, allowing the exoskeleton to adapt to different environments and user needs with precision.

What Are the Key Encoder Requirements for Exoskeletons?

Selecting the optimal encoder for a high-performance exoskeleton involves evaluating several important factors:

• Size and Weight: The encoder needs to be compact and lightweight to ensure user comfort and maintain natural mobility.
• Durability: The encoder should be able to withstand harsh conditions such as vibrations, moisture, and temperature variations.
• Accuracy and Resolution: High-resolution feedback is essential for precise measurement of joint and limb movements.
• Power Efficiency: Low power consumption helps extend battery life in mobile exoskeleton systems.
• Non-Contact Sensing: Inductive encoders detect position without physical contact, eliminating mechanical wear and increasing reliability.

How to Select the Best Compact Encoder for Exoskeletons?

When selecting the best encoder for exoskeletons, inductive rotary encoders are an optimal choice. One standout option is FLUX’s inductive rotary encoder, which combines a compact and lightweight design, high accuracy and resolution, and reliability, making it ideal for wearable robotics.FLUX’s inductive rotary encoder features an ultra-flat and narrow, lightweight design that fits into tight spaces common in wearable robotics. With FLUX’s innovative IND technology, the encoder delivers absolute performance in narrow spaces and exceptional immunity to magnetic and electromagnetic interference. Combined with a wide mounting tolerance and plug-n-play setup, it provides precise performance ideal for exoskeletons and other robotic applications.

Final Thoughts on Compact Encoders in Exoskeleton Technology

Compact encoders play an important role in the functionality and performance of exoskeletons. Selecting a high-quality encoder enhances motion precision, system durability, and overall user experience. FLUX’s inductive rotary encoder is the standout option for exoskeletons and wearable robotic systems, thanks to its compact and lightweight design, accuracy and immunity to magnetic and electromagnetic interference.

What Is an Inductive Encoder?

An inductive encoder uses electromagnetic induction to detect position, speed, and direction. It senses changes in the electromagnetic field caused by a patterned rotor made of materials that influence induction. These materials may enhance the field through magnetic permeability, reduce it through the creation of eddy currents, or affect it in both ways. As the rotor moves, the resulting changes in induction are captured by the stator’s sensor and converted into precise position data through signal processing.

Learn more about FLUX inductive encoders.

How Do Inductive Encoders Work?

Inductive encoders operate based on the principle of electromagnetic induction. They utilize a system of transmitter and receiver coils to sense the position of a moving conductive target. In contrast to optical encoders that use light, inductive encoders detect changes in inductance caused by movement. This makes them ideal for use in demanding environments and applications that require high accuracy.

Characteristics and Benefits of Inductive Encoders

Inductive encoders are a reliable solution for modern motion control applications, offering a range of key features and performance benefits.

• Exceptional Durability: Designed to resist dust, moisture, and chemicals, making them ideal for demanding industrial conditions.
• High Precision and Resolution: Inductive encoders offer outstanding positional accuracy, often reaching sub-micron levels. This makes them ideal for tasks that demand fine control, such as robotic systems, CNC machinery, and semiconductor processes. Sophisticated signal processing minimizes errors and delivers repeatable, high-quality results.
• Extended Lifespan: Built with no contacting parts, they experience less wear and tear, ensuring a longer operational life.
• Environmental Resilience: Less susceptible to temperature fluctuations or lighting changes compared to other sensor types.
• Space-Saving and Lightweight: The compact and lightweight build of inductive encoders makes them optimal for applications where size and weight are critical factors. This is especially valuable in applications where space limitations require efficient, precise components.
• Long-Term Cost Effectiveness: While the initial cost of inductive encoders may be higher than other options, their durability, reduced maintenance, and long service life can often result in lower total costs. This makes them a smart investment for applications requiring consistent performance and reliability over time.

Discover the benefits of FLUX’s innovative IND technology for inductive encoders.

Inductive Encoder Applications

Inductive encoders are used across a wide range of industries due to their reliability, versatility and performance, including:

UAVs, Aerospace & Defense

• Landing Gear Position Monitoring: Ensures correct deployment and retraction of the aircraft’s landing gear.
• Tracking Flight Control Surfaces: Monitors movements of rudders, flaps, and stabilizers.
• Targeting Alignment for Missile and Weaponry Systems: Real-time feedback for precision targeting.
• Autonomous UAV Navigation and Landing: Detects positional changes for smooth takeoff and landing.

Manufacturing and Heavy Equipment

• Precision Feedback for Robotic Arms: Provides accurate motion control for automation.
• CNC Machine Tool Position Sensing: Maintains machining accuracy and repeatability.
• Automated Conveyor Positioning: Tracks material handling system alignment.

Marine and Underwater Robotics

• Positioning of ROVs and AUVs: Supports underwater robotic navigation.
• Feedback for Diver Propulsion Systems: Enhances control in underwater movement.
• Subsea Valve Monitoring: Ensures safety in critical offshore infrastructure.
• Sonar and Imaging Device Alignment: Maintains accurate positioning for underwater cameras.

Medical Robotics and Healthcare Devices

• Real-Time Positioning for Surgical Robots: Enables precise control in robot-assisted surgeries.
• Sensors Compatible with MRI Environments: Tracks movement without magnetic interference.
• Motion Sensing for Prosthetics and Exoskeletons: Improves user mobility and responsiveness.
• Accurate Positioning in Automated Medical Equipment: Supports drug delivery and diagnostic devices.

Types of Inductive Encoders 

There are several types of inductive encoders, each designed to meet specific motion control requirements:

• Absolute Inductive Encoders: These encoders provide an instant and accurate position value at power-up, which eliminates the need for homing procedures. This makes them an optimal choice for systems that require precise, fail-safe positioning right from the start.
• Incremental Inductive Encoders: Output pulses based on shaft movement and are typically used for speed monitoring and direction sensing.
• Single-Turn Encoders: Detect angular position within one rotation, which makes them suitable for limited-range applications.
• Multi-Turn Encoders: Track shaft position over multiple revolutions, allowing them to be used for machinery that operates across larger angular ranges.
  

Optical Encoders vs Inductive Encoders

Both optical and inductive encoders serve to track position, speed, and direction in motion systems, but their technologies and use cases differ significantly. Optical encoders rely on a light source and photodetector to read patterns on a rotating disc, offering high resolution ideal for clean, controlled environments. However, they are sensitive to dust, oil, and temperature extremes, and can fail under vibration or shock.

Limitations of Optical Encoders:

• Vulnerability to Contaminants: Optical sensing elements can be disrupted by dust, oil, moisture, or dirt, which may lead to degraded performance or signal loss.
• Sensitive Components: Optical encoders feature intricate components that are vulnerable to damage from high shock, vibration, or physical impact.
• Environmental Sensitivity: Optical encoders may struggle in extreme temperature conditions, which can affect their reliability and accuracy

In contrast, an inductive encoder uses electromagnetic induction to detect movement, without the need for optical components. This makes them highly durable and resistant to contaminants, mechanical stress, and electromagnetic interference. As a result, inductive encoders excel in harsh industrial, outdoor, or EMI-prone settings, such as manufacturing plants, medical devices, or heavy-duty equipment.

Read the article comparing optical encoders vs. inductive encoders and discover why inductive encoders are the better choice in harsh environments.

Capacitive Encoders vs Inductive Encoders

Capacitive and inductive encoders are both non-contact technologies, but they differ significantly in their operating principles and environmental performance. Capacitive encoders detect position through changes in capacitance caused by variations in a rotor’s electrical permittivity. Known for high resolution and compact design, they’re a good fit for clean, space-limited applications like precision robotics or semiconductors.

Limitations of Capacitive Encoders:

• Vulnerability to Contaminants: Capacitive encoders depend on electric field interactions, which can be disrupted by dust, moisture, or oil, leading to reduced accuracy or failure.
• Environmental Sensitivity: These encoders may struggle in harsh conditions, where external factors affect their performance and reliability.

In contrast, inductive encoders use electromagnetic induction to detect position and motion. They tolerate wide temperature shifts, resist EMI and mechanical shocks, and are less affected by environmental contaminants. Their mechanical robustness and thermal compatibility, especially when integrated into systems with matching materials, make them ideal for demanding industrial, aerospace, and defense environments.

Read the article comparing capacitive encoders vs. inductive encoders and discover why inductive encoders are the superior option in harsh environments.

Accuracy and Resolution in Inductive Encoders

An inductive encoder offer a balance of accuracy and resolution, making them ideal for demanding environments:

• Accuracy: Valuable for applications such as robotics, medical devices, and motion control, where precise positioning is needed. Inductive encoders ensure reliable, sub-degree accuracy, even in challenging conditions.
• Resolution: High-resolution outputs are a key feature of advanced inductive encoders, allowing for smooth motion control and fine adjustments. However, a high-resolution encoder without sufficient accuracy may introduce errors due to mechanical tolerances or signal distortion.
• Stability: Inductive encoders maintain consistent performance across a range of environmental challenges, such as temperature fluctuations, vibration, and electrical noise.
• Integration: Their compact size and frameless design make them ideal for integration into embedded systems, where space is limited but performance requirements remain high.

How to Select the Best Inductive Encoder for Your Design Requirements

Selecting the right inductive encoder for your design requirements depends on several factors. To ensure optimal performance and long-term reliability, the following should be considered:

• Application Requirements: Determine the required resolution, accuracy, and response time for your inductive encoder application.
• Environmental Conditions: Evaluate the operating conditions such as temperature, dust, moisture, and vibration levels.
• Mounting Constraints: Select a suitable encoder form factor that’s based on your mechanical design.
• Signal Output & Interface: Verify the encoder is compatible with your system interface, such as SSI, BiSS, or analog output.
• Maintenance Expectations: Choose a contactless inductive encoder design to minimize wear and reduce the need for maintenance. 

Ensuring Reliable Performance of Inductive Encoders

Inductive encoders often operate in harsh industrial environments where reliability is imperative. To ensure consistent performance, consider the following environmental factors:

• IP Rating: Choose encoders with a high IP rating, offering protection against dust, oil, and moisture.
• Operating Temperature Range: Select inductive encoders that can operate accurately in both high and low temperatures.
• Resistance to Vibration and Shock: Ensure mechanical stability and longevity by selecting encoders designed to withstand shock and vibration.
• Electromagnetic Compatibility: Select inductive encoders that are resistant to electromagnetic interference (EMI) to maintain signal accuracy in electrically noisy environments.

Custom Inductive Encoders

Custom inductive encoders are designed to meet the exact mechanical and electrical requirements of your application. Unlike off-the-shelf models, these encoders are designed to fit unique form factors, output interfaces, and environmental conditions, making them ideal for challenging use cases.

Built for durability, inductive encoders are inherently resistant to dust, oil, vibration, and EMI. With no contacting parts, they offer long-term reliability in harsh environments such as aerospace, robotics, heavy machinery, and oil & gas. Their rugged construction and sealed housings (IP67/IP69K) make them true industrial-grade sensors. 

While standard encoders may offer quicker turnaround, custom solutions provide greater design flexibility. Engineers can specify everything from shaft size and mounting configuration to preferred communication outputs. This level of customization ensures optimal integration and performance in space-constrained or high-demand systems. From robotic joints to subsea equipment, custom inductive encoders deliver accurate, maintenance-free motion feedback, making them a smart choice for modern automation and control systems.

Leading Inductive Encoder Manufacturer 

FLUX GmbH is a leading manufacturer of inductive encoders, specializing in advanced inductive technology that delivers high performance in the smallest package. Our inductive encoders are designed with exceptional immunity to magnetic and electromagnetic interference, allowing direct integration into all motor types. The lightweight, modular design enables extensive customization and flexible scalability.

Our inductive encoders deliver precise, contactless position feedback while being robust in challenging environmental conditions. FLUX focuses on providing reliable encoder solutions suitable for demanding industrial applications, supporting diverse customer needs with innovative technology.

Discover FLUX’s IND-MAX inductive angle encoder, delivering exceptional performance, durability, and a range of additional benefits even in harsh environments. 

Legged robots are revolutionizing robotics with their agility and versatility, and one key technology enabling their advanced movement is high-performance encoder systems. This article explores the role of encoders in legged robots, defines a legged robot, discusses key considerations for selecting an encoder, and explains why inductive encoders are a highly effective option. 

Understanding Encoders for a Legged Robot

Encoders are devices that convert mechanical motion into an electrical signal, allowing it to be read by a control system. In the context of legged robots, encoders ensure that every step, rotation, and adjustment is accurately tracked. This real-time data information provides accurate control over the robot’s movements, ensuring balance and dynamic interaction with its environment. With the rapid advancement of robotics, choosing the right encoder is essential to achieve optimal legged robot performance.

What Is a Legged Robot?

A legged robot is an autonomous mobile machine engineered with articulated legs to enable dynamic, agile movement. Legged robots are designed to mimic the natural movement of animals and are built to traverse uneven terrain, climb obstacles, and execute complex maneuvers. These examples of versatility and mobility make legged robots highly valuable where precision and adaptability are essential. Designed to operate in challenging environments, legged robots integrate advanced control systems and robust encoder technology to ensure smooth, coordinated movement. 

Key Considerations for Choosing an Encoder for a Legged Robot

When selecting an encoder for a legged robot, there are several key performance considerations to help ensure reliable and precise operation in dynamic environments:

• Resolution and Accuracy: High precision is essential to track the subtle and rapid joint movements in legged robots. An encoder with high resolution ensures accurate position feedback, which is a crucial factor for balance and coordination.
  
• Robustness: Legged robots typically operate in unpredictable environments; therefore, a robust encoder must be able to tolerate vibrations, shocks, dust, and wide temperature variations without compromising performance.
  
• Mounting Tolerance and Working Range: Encoders with a large mounting tolerance and broad working range simplify integration and alignment.
  
• Size and Weight: Compact and lightweight encoder designs are important for maintaining the agility and efficiency of the legged robot, especially in mobile applications.
  

Understanding and applying these considerations can help designers and engineers select the right encoder to meet the technical demands of a legged robot and enhance its overall performance.

Selecting the Best Encoder for a Legged Robot

A legged robot requires precise, real-time feedback to maintain balance and adapt to dynamic environments. FLUX inductive encoders are engineered to meet these demands with exceptional accuracy, robustness, and ease of integration.

FLUX inductive rotary encoders are compact and ultra-lightweight, making them ideal for space-constrained legged robot joints. They deliver high-resolution absolute position data, ensuring reliable motion tracking for smooth, coordinated movement. Their frameless design allows for flexible installation with wide mounting tolerance, while immunity to magnetic and electromagnetic interference ensures stable performance.

For more extreme conditions, FLUX IND-MAX inductive angle encoders offer high-precision measurement and superior durability, pushing the boundaries of what’s possible for a legged robot in harsh operating scenarios.

With their advanced design and robust performance, FLUX inductive encoders are a top choice for engineers developing the next generation of legged robots.

Conclusion

Selecting the right encoder is essential for both the performance and precision of legged robots, as it can ensure smooth and coordinated movement. The high-precision performance, robustness, and wide mounting tolerance of FLUX inductive encoders highlight them as a highly effective option. These benefits make FLUX encoders ideal for demanding environments that require high accuracy and reliability, such as legged robot applications. FLUX inductive encoders can enable designers and engineers to ensure that their legged robots meet the challenges of real-world operation while pushing the boundaries of innovation.

Selecting the most suitable absolute encoder for your system is key to ensuring reliable performance in demanding applications and harsh conditions. This article explores what an absolute encoder is, reviews the different types of absolute encoders available, and explains why absolute inductive encoders offer a more reliable solution for tough environments.

What Is an Absolute Encoder?

An absolute encoder is a type of sensor that provides a unique digital output for angular position, allowing the position to be tracked with high accuracy even in the case of loss of power. Absolute encoders provide a different code for each possible angular position so that the system will be aware of its precise position at power-up without needing a reference or homing sequence. This feature makes absolute encoders ideal for applications requiring high precision, dependability, and continuous performance, such as robotics, automation industries, and CNC machinery. 

Absolute Encoder vs Incremental Encoder

In contrast to absolute encoders, which give a specific position reference for each angular position, incremental encoders only give relative position information. Incremental encoders monitor movement by creating pulses as the axis turns, and the position is calculated by counting these pulses from a known reference point. While incremental encoders are less complex, they require a homing sequence after power loss or system reset to determine the exact position. 

Therefore, they are not suitable for applications where position accuracy must be maintained and recovered instantaneously after a power disruption. However, incremental encoders remain widely used in situations where relative position and motion tracking are sufficient, such as in basic speed monitoring, rotary switches, and motion control systems in some instances.

Absolute Encoder Types 

Absolute encoders come in various technology types, each suited for different applications. The most common types are:

• Optical Encoders: Optical encoders use a light source, typically an LED, and a photodetector to read patterns on a rotating disk. Known for their high resolution and accuracy, these encoders are typically used in applications where precision is essential. However, they can be sensitive to dust and contaminants, which may impact their reliability in certain environments.
• Magnetic Encoders: Magnetic encoders rely on magnetic fields to detect position, a method that often results in lower accuracy and can be prone to interference from external magnetic sources. These limitations can significantly reduce their reliability, especially in demanding applications that require high precision or consistent performance in variable conditions.
• Capacitive Encoders: Capacitive encoders detect position by sensing changes in the electrical permeability of the rotor, which in turn affect the capacitance of the stator’s sensor. These encoders have high resolution and low power consumption with high-frequency signals. Capacitive encoders can be sensitive to contaminants like dust or water, which can affect performance. While immune to magnetic fields, they can be susceptible to electromagnetic interference (EMI), but this can be countered by design.
• Inductive Encoders: An inductive encoder uses electromagnetic induction to measure position. It detects changes in the electromagnetic field caused by a patterned rotor, generating signals that are processed into precise positional data. Inductive encoders are resistant to environmental contaminants, electromagnetic interference, and mechanical wear, making them ideal for demanding applications.
• GMI Encoders: GMI encoders use the Giant Magneto Impedance effect to detect positional changes based on the interaction of magnetic fields with specially treated sensor materials. Unlike incremental encoders, they provide a unique position value at every point, ensuring precise absolute position detection even after power loss. These encoders combine high resolution and exceptional angular accuracy with strong resistance to shock, vibration, and environmental contaminants. Their inherent immunity to magnetic interference and robust signal integrity make them ideal for applications requiring both the highest precision and durability in dynamic environments.
  

How do I Choose an Absolute Encoder?

Choosing the right absolute encoder is dependent on several factors. To ensure the right absolute encoder is selected, consider the following:

• Resolution & Accuracy: Determine the required precision for your application. Higher resolution encoders provide finer position feedback.
• Environmental Conditions: Assess exposure to dust, moisture, or extreme temperatures to help choose an encoder with the appropriate protection rating (e.g., IP65 or higher).
• Communication Protocol: Ensure compatibility with your system by selecting the right interface.
• Mounting & Form Factor: Choose an encoder that fits within your space constraints, whether it’s shaft, hollow shaft, or PCB-mounted.
• Durability & Lifespan: Consider the operating conditions and expected longevity.

Which Absolute Encoder Is Best for Tough Environments?

When it comes to choosing an encoder for harsh and demanding applications, absolute inductive encoders stand out. Their robust construction and reliable performance in adverse conditions make them the superior choice over other absolute encoder technologies. In environments where dust, moisture, vibration, and temperature extremes are prevalent, an absolute inductive encoder delivers consistent, accurate position feedback while minimizing maintenance and repair costs.

What is an Absolute Inductive Encoder?

An absolute inductive encoder operates on the principles of electromagnetic induction to determine position by detecting changes in the electromagnetic field. The rotor incorporates a patterned structure made of materials that affect induction within the stator’s sensor. These materials can enhance induction through permeability, reduce it via eddy currents, or influence both simultaneously. The resulting variations in electromagnetic induction generate position signals, which are then processed and converted into highly accurate positional data.

Absolute Inductive Encoder Advantages

Absolute inductive encoders offer a variety of advantages over other absolute encoder technologies:

1. Exceptional Durability in Harsh Environments: Absolute inductive encoders thrive in settings exposed to dust, moisture, and grease, making them an optimal choice for industrial and manufacturing applications.
2. High Contaminant Tolerance: Absolute inductive encoders remain unaffected by dust, dirt, grease, or moisture, ensuring optimal performance in challenging industrial conditions.
3. Superior EMI & Noise Immunity: Their inherent resistance to electromagnetic interference makes them ideal for environments with high EMI, such as factories with heavy machinery, aerospace systems, and medical equipment facilities.
4. Broad Temperature Resilience: Designed to operate reliably from freezing conditions to extreme heat, these encoders maintain stability without the need for extra humidity protection.
5. Mechanical Robustness: Built to withstand shock and vibrations, absolute inductive encoders ensure consistent performance even in applications subject to high mechanical stress.

Conclusion

In summary, while absolute encoders are crucial for accurate position tracking, only certain technology types are suitable for tough environment applications. Absolute inductive encoders are the preferred choice as they combine durability, reliability, and cost-effectiveness, ensuring optimal performance even under extreme conditions.