This year, SPS again opens its doors to the world of automation, and FLUX is right there with them, presenting our cutting-edge encoder solutions. We are looking forward to connect with our valued partners and customers in Nuremberg. Catch us at Hall 3A, Booth 141!
The innovations in automation and robotics, which are occurring at an increasingly rapid pace, have shown that new ideas were needed, especially for capturing rotational and linear motion sequences. Specifically, there was a need for ultra-fast, ultra-light, and ultra-thin sensors and encoders that could keep up with the rapid development of Industry 4.0. The specialists at FLUX, a sensor company founded in 2017 in Braunau am Inn, Austria, found an answer to this challenge: the patented GMI technology (Giant Magneto Impedance). The GMI effect occurs when certain materials change their impedance, that is, their alternating current resistance, when exposed to an external magnetic field. This process, in turn, affects the so-called skin effect, which is caused by applying an alternating current to the GMI material. In this way, a signal can be generated depending on the position between the sensor (GMI film) and the measuring tape (external magnetic field). Although the principle behind the GMI effect had been known for some time, it had never been used for position determination until FLUX implemented it in an encoder.
Applying this knowledge to the production of an encoder, as FLUX has successfully done, results in a significant added value. This opens up possibilities for applications that were previously considered impossible because conventional sensors and encoders were simply unsuitable due to their size or inertia. FLUX’s GMI encoders combine the highly accurate performance of an optical encoder with the robustness of an inductive encoder and the wide mounting tolerance and operating range of a magnetic encoder. Furthermore, they operate without hysteresis and provide real-time position detection, meaning that the current position is available without delay at all times. They combine the features and functions of previous encoder systems into a single device, which saves costs for:
• Energy
• Installation
• Integration
• Operation
• Maintenance.
FLUX’s GMI encoders offer numerous additional advantages in addition to those already mentioned:
FLUX encoders are used, for example, as load and motor encoders in the joints of industrial robots and cobots. They are also employed in the latest generation of machine tools or in torque motors. With their exceptional accuracy and repeatability, they play a significant role in demanding manufacturing processes, such as semiconductor manufacturing. Their low mass makes them ideal for applications in gyro-stabilized, gimbal-mounted camera or instrument holders, commonly known as gimbals, which can be mounted on drones or manned aircraft.
© konstruktionspraxis
FLUX is expanding its range of products with two new sizes for its INDUCTIVE Rotary Encoder series. These compact encoders deliver unmatched performance and now include two powerful models with even smaller diameters: 34mm and 45mm and less than 10g of total weight. The two new sizes, IND-ROT-034 and IND-ROT-045, are designed to expand FLUX’s existing range of IND-ROT Encoder Series. The numbers indicate the outer diameter of the housing in millimeters. Inductive encoders from this series have been practically unmatched for many applications yet due to their four sizes with outer diameters of 55, 69, 80, and 96 millimeters, as traditional encoders are either not compact enough or too inaccurate.
With the miniaturized INDUCTIVE Rotary Encoders, FLUX launches the flattest and most compact encoder design available on the market in its accuracy range and thereby ensures reduced engineering costs and time by simplified system integration options for improved performance:
Typical applications for the IND-ROT Series are found in:
Especially in places where extremely small, robust, lightweight, and interference-insensitive encoders are required, FLUX encoders demonstrate their strengths with patented technology.
As the third product group in the portfolio, the INDUCTIVE Rotary Encoder series complements FLUX’s other two encoder lines based on patented GMI technology (Giant Magneto Impedance). With its unique know-how in this area, FLUX has literally set new impulses in the field of inductive rotary encoders.
Apart from its technical expertise, FLUX and its engineers have many years of experience designing and manufacturing position encoders based on well-known physical principles, such as optoelectronic, capacitive, and inductive ones. However, all these approaches are severely limited when it comes to encoder accuracy, repeatability, and resolution. Today’s rapid advancements in automation and robotics and the requirement of keeping up with Industry 4.0 encouraged the company’s engineers to develop an advanced method of designing and manufacturing ultra-fast, ultra-light and ultra-flat sensors and encoders to meet future demands of the industry.
Therefore, FLUX sets new standards by offering patented technology in the field of developing and manufacturing rotary encoders and measuring devices which has never been used before: FLUX GMI technology.
Known as the Giant Magento Impedance (GMI) effect, the principle is based on the well-known phenomenon of a drastic change in impedance of certain materials when exposed to magnetic fields. This in turn influences the so-called skin effect, which is caused by applying an alternating current to the GMI material. In this way, a signal can be generated depending on the position between the sensor (FLUX GMI Foil) and the scale (external magnetic field). By utilizing the GMI effect in a pioneering manner to determine position, FLUX GmbH provides its customers with significant added value through the design and manufacture of innovative encoders.
The patented FLUX GMI technology combines the high-precision performance of an optical encoder with the robustness of an inductive encoder and the large mounting tolerance and working range of a magnetic encoder. Furthermore, they work without hysteresis and provide real-time position detection; that is, the current location is always available without delay. All in all, FLUX encoders differ from conventional measuring principles by delivering the best of all worlds in one encoder: outstanding performance, excellent precision, and small and narrow where conventional encoders are too large and heavy.
As a result, the efficiency of previous encoder systems is combined in a single device, resulting in a reduction of total costs for implementation related to energy use, installation, integration, operation, and maintenance. The founder and CEO, Paul Tutzu, sums it up as follows: “The fast pace of technical progress and constantly changing framework conditions call for high flexibility. By using FLUX encoders, we guarantee our customers maximum adaptability and reliability while providing added value through superior technical performance.”
Besides the advantages already mentioned, the FLUX GMI technology has a lot more to offer and may be used in a wide range of applications. Due to the large working range and excellent signal-to-noise ratio, the encoders perform at highest resolution across a wide range of work areas while maintaining large assembly tolerances. The compact size of the sensors allows the encoder to be integrated into even the most space-constrained applications, such as joint assemblies for cobots. The frameless design of the encoder eliminates any additional static or rolling friction in the system.
Because of the encoder’s holistic design, the sensor is not limited to scanning only segments, but rather scans the entire measuring ring for 360° rotation. In contrast to one-point scanning performed with optical or magnetic encoders, the FLUX GMI encoder is highly resilient to inaccuracies like eccentricities and lateral displacements. Since it is a real-time encoder, it provides a position that is independent of a calculation time. Every time the encoder receives a position query, it is ready to transmit the current position directly and without time uncertainty (jitter) to the controller. Therefore, a real-time encoder from FLUX offers the same level of accuracy at low and high speeds and is consequently suitable for applications that require speed or torque control. Furthermore, they can also be used as load and motor encoders for all types of robot applications, such as compact and slim collaborative robots. These advantages are equally useful in slip rings and motor applications, such as brushless DC motors or stepper motors. Machine tools or so-called “gimbals”, which are intended to keep the moving camera steady in e.g., camera mounts and drones, are also relevant areas of application.
The current FLUX GMI product portfolio includes the GMI-ANGLE and GMI-ROTARY series in various sizes and designs. Their unique characteristics make them an appropriate choice for applications with high demands that cannot be met by conventional encoders. Furthermore, a series of rotary encoders based on an inductive PCB design is available to complement the existing product line. Compact and lightweight, the IND-ROTARY encoder is ideal for applications that require high performance in small spaces.
As of now, the first generation of FLUX encoders is available on the market and is being successfully used in applications that require positional, speed, and torque control. With its headquarters located in Braunau am Inn, Austria, FLUX offers its customers a worldwide network of experienced distributors and sales partners in the field of encoder technology.
If you are interested in further information about FLUX and its innovative products, please find your appropriate contact person here.
Special applications require special solutions. For precisely these cases, a company from Austria has innovative sensor technology with interesting properties in its portfolio – thanks to a physical effect. The encoders for position determination are also used where usual devices are too large and heavy.
Long before its founding in 2017, FLUX from Austria was already a self-confessed specialist in sensor technology, with decades of experience and great know-how in the field of magnetic, inductive and optical technologies. At a certain point, however, it became apparent that it was time for new developments, especially in the detection of rotational and linear motion sequences. The reasons for this were far-reaching innovations in automation and robotics, which were also taking place ever faster. Ultra-fast, ultra-light and ultra-flat sensors and encoders that could keep pace with the rapid development of Industry 4.0 applications were in demand.
The Austrian answer is the patented GMI technology (Giant Magneto Impedance). The principle behind it is well known: The GMI effect is that certain materials change their impedance, i.e. their AC resistance, as soon as they are exposed to an external magnetic field. This in turn affects the so-called skin effect, which is caused by applying an alternating current in the GMI material. In this way, a signal can be generated depending on the position between the sensor (GMI foil) and the measuring tape (external magnetic field). This is a novelty, because the GMI effect had never been used for position determination before. If this knowledge is transferred to the production of an encoder, as FLUX has succeeded in doing, it results in enormous added value: applications are now conceivable that previously seemed impossible because conventional sensors and encoders were simply not suitable due to their size or inertia. The GMI encoders combine the high-precision performance of an optical encoder with the robustness of an inductive encoder and the large mounting tolerance and operating range of a magnetic encoder. In addition, the GMI encoders operate hysteresis-free and offer real-time position detection; that is, the current position is available at any time without delay. They combine the features and functions of previous encoder systems in one device – saving costs for energy, installation, integration, operation and maintenance.
Paul Tutzu, FLUX founder and CEO, sums it up like this: “Rapid technical progress and constantly changing framework conditions require a high degree of flexibility. By using our encoders, we enable our customers to achieve maximum adaptability and reliability while offering added value through superior technical performance.” Servotecnica has benefited from this important know-how since 2021, on the one hand as the exclusive distributor for FLUX’s products for Germany and Italy, and on the other hand as a cooperation partner for further developments in the field of encoder technology and slip rings. The current product portfolio of distributed encoders with GMI technology includes GMI angle encoders (GMI Angle series) as well as GMI rotary encoders (GMI Rotary series) in various sizes and designs. The range is additionally complemented by a series of particularly compact and lightweight encoders based on induction. In addition to the advantages already mentioned, the GMI encoders have numerous other advantages over conventional absolute encoders. For example, their measuring principle works in a larger operating range and they have a very good signal-to-noise ratio. As a result, this leads to comparatively large mounting tolerances in combination with high resolution and accuracy over the entire operating range. The frameless design of the GMI encoders prevents additional, parasitic friction from being introduced into the system, as often happens with encapsulated systems that introduce additional static and rolling friction into the rotary axis.
GMI encoders also work holistically: the sensor does not scan the scale tape selectively, but over the entire 360 degrees of a revolution. This makes it largely insensitive to inaccuracies such as eccentricities or an offset between sensor and scale tape. As a real-time encoder, it also provides an initial position that is independent of a calculation time: it can transmit the current position to the controller immediately and without time uncertainty (jitter) with every query. This means that GMI encoders have consistently high precision at both low and very high speeds and are particularly suitable for applications that require speed or torque control. FLUX encoders are used, for example, as load and motor encoders in joints of industrial robots and cobots, as well as in the latest generation of machine tools or in torque motors. With their outstanding accuracy and repeatability, they also play a major role in demanding manufacturing processes, for example in the production of semiconductors. With their low mass, they are also ideally suited for applications in gyro-stabilised, gimbal mounts for cameras or measuring instruments, so-called gimbals, which can be mounted on drones or manned aircraft. To find the right solution for drives, sensors and automation in each case, Servotecnica is one of the right contacts. The GMI and induction-based encoders from FLUX open up another field for users with numerous new possibilities, some of which are pioneering.
“Automated applications are becoming more and more demanding and faster. When it comes to detecting rotational and linear motion sequences, conventional sensor technology is reaching its limits. FLUX’s patented GMl technology opens up completely new possibilities: GMl encoders from FLUX combine the precise performance of an optical encoder with the robustness of an inductive one. They operate hysteresis-free and provide position data i real time – a superior technical performance. Sales partner for FLUX’s GMI encoders is Servotecnica.”
Paul Tutzu, CEO, FLUX, Braunau am Inn, Austria
Patented FLUX GMI technology combines the 𝙝𝙞𝙜𝙝 𝙥𝙧𝙚𝙘𝙞𝙨𝙞𝙤𝙣 performance of an optical encoder with the 𝙧𝙤𝙗𝙪𝙨𝙩𝙣𝙚𝙨𝙨 of an inductive encoder and the large 𝙢𝙤𝙪𝙣𝙩𝙞𝙣𝙜 𝙩𝙤𝙡𝙚𝙧𝙖𝙣𝙘𝙚 and 𝙬𝙤𝙧𝙠𝙞𝙣𝙜 𝙧𝙖𝙣𝙜𝙚 of a magnetic encoder.
The Giant Magento Impedance (GMI) effect is a phenomenon, based on the skin effect, in which certain materials exhibit a drastic change in impedance when exposed to external magnetic fields. Thus, a signal can be generated in response to the position of the sensor with respect to the scale.
For the first time, we presented our product portfolio and the revolutionary GMI encoder technology to the interested public as an exhibitor.
This is exactly where FLUX GmbH and its encoder portfolio offer customization options that allow accuracy and flexibility without any compromises and contribute to an overall reduction in costs for integration, operation, and maintenance for medical robot applications.
Find out more about potential applications for surgical robotics and visit our Surgical Robotics Technology
FLUX is backed up by engineers with extensive interdisciplinary experiences including expertise in technology research, analog-digital hardware, firmware, and mechanical designs. Seeing the importance of staying one step ahead, we’ve assembled a dedicated network of experts who are constantly exploring the limits of what’s possible, no matter the challenges.
Find your appropriate contact person to learn more about the innovative FLUX GMI encoder technology by checking our WORLDWIDE distribution partners.
It has been a long-term challenge to combine the hysteresis-free performance of optical encoders with the robustness of inductive encoders and the large mounting tolerance and working range of magnetic encoders.
The Giant Magneto Impedance technology capitalizes in an exceptional way the interaction between magnetic field and electromagnetic induction and enables FLUX GmbH to combine all of the advantages of existing encoder technologies into one encoder solution.
Hysteresis-free, absolute performance combined with robustness and large mounting tolerances guarantee flexibility in any situation and provide highest accuracy, repeatability, and resolution without compromises.
Aluminium or steel housing, IP67 ingress protection for use in harsh environments as well as plug-and play options make the GMI Rotary Encoder a reliable all-rounder for a limitless area of operations.