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Encoder

The document provides a comprehensive overview of encoder systems used in drive engineering, detailing their types, functions, and applications at SEW-EURODRIVE. It covers the technical specifications, mechanical mounting, and installation notes for various encoder types, including incremental and absolute encoders. Additionally, the document serves as a practical guide for technical specialists involved in project planning and implementation of encoder technology.
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0% found this document useful (0 votes)
7 views64 pages

Encoder

The document provides a comprehensive overview of encoder systems used in drive engineering, detailing their types, functions, and applications at SEW-EURODRIVE. It covers the technical specifications, mechanical mounting, and installation notes for various encoder types, including incremental and absolute encoders. Additionally, the document serves as a practical guide for technical specialists involved in project planning and implementation of encoder technology.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Drive Technology \ Drive Automation \ System Integration \ Services

Drive Engineering –
Practical Implementation

Encoder Systems from SEW-EURODRIVE

Edition 11/2009 16742028 / EN


SEW-EURODRIVE—Driving the world
Contents

Contents
1 Introduction ......................................................................................................... 4
1.1 Product names and trademarks .................................................................. 4
2 What Are Encoder Systems? ............................................................................. 5
2.1 What are the tasks of encoder systems? .................................................... 5
2.2 Which types of encoder systems are there? ............................................... 5
2.3 How do encoder systems work? ................................................................. 7
2.4 Which encoder with which motor? ............................................................ 26
3 How Are Encoder Systems Used At SEW-EURODRIVE? .............................. 29
3.1 Which encoder systems does SEW-EURODRIVE use? .......................... 29
3.2 What is the structure of the type designation of those encoder systems? 30
3.3 Which products are the encoder systems used with?............................... 31
3.4 How do you perform the project planning for encoder systems? .............. 35
4 What Are The Technical Data Of These Encoder Systems? ......................... 37
4.1 Incremental rotary encoders with spread and plug-in shaft ...................... 37
4.2 Incremental rotary encoders with solid shaft............................................. 39
4.3 SSI absolute encoder................................................................................ 40
4.4 Resolver .................................................................................................... 42
4.5 Absolute encoder with asynchronous-serial interface............................... 43
4.6 Built-in encoder ......................................................................................... 48
4.7 Proximity sensor ....................................................................................... 48
4.8 Mounting device........................................................................................ 49
5 How Is The Encoder Mounted Mechanically? ................................................ 50
5.1 Spread-shaft encoder (DR and DT/DV motors) ........................................ 50
5.2 Plug-in shaft with end thread (DR motors only) ........................................ 51
5.3 Built-in encoder (only DR-motors)............................................................. 52
5.4 Mounting device (DR and DT/DV motors) ................................................ 53
5.5 Hollow-shaft encoder (only DR 315) ......................................................... 54
5.6 Cone shaft enccoder (CMP motors) ......................................................... 55
6 What Are The Setting Specifications For The Encoder Assembly?............. 57
6.1 Setting specifications for motors with HIPERFACE® encoders ................ 57
6.2 Resolver setting specifications for SEW motors CM71 – 112................... 58
7 What General Installation Notes Must Be Observed? ................................... 59
7.1 Encoder line shield on inverter.................................................................. 59
7.2 Encoder line shield on encoder................................................................. 60
8 Terms And Definitions...................................................................................... 61
Index................................................................................................................... 62

Drive Engineering – Practical Implementation – Encoder Systems 3


kVA n Introduction
1 f
Product names and trademarks
i
P Hz

1 Introduction
SEW-EURODRIVE is one of the leading companies in the world market for electrical
drive engineering. The company headquarters are in Bruchsal, Germany. Components
for the SEW-EURODRIVE modular drive system are manufactured to the highest quality
standards in production plants sited in Germany, France, Finland, the United States,
Brazil and China. The individual drive systems are assembled with a consistently high
quality standard and very short delivery times from stocked components in 67 assembly
plants located in 47 industrialized countries all over the world. SEW-EURODRIVE sales,
consulting, customer and spare parts services are available in more than 60 countries
around the world.
Its global presence, extensive product range and broad spectrum of services make
SEW-EURODRIVE the ideal partner for demanding automation solutions.
The volume before you from the series "Drive Engineering - Practical Implementation"
is aimed at technical specialists and provides clear information on the design and theory
of operation of common components of encoder technology as well as their applications
and project planning.

SEW-EURODRIVE – driving the world.

Bruchsal, November 2009

1.1 Product names and trademarks


The brands and product names contained within this issue are trademarks or registered
trademarks of the titleholders.

4 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
What are the tasks of encoder systems?
f 2
i
P Hz

2 What Are Encoder Systems?


2.1 What are the tasks of encoder systems?
Depending on the respective requirements, encoder systems have to perform different
tasks in drive systems.
One of the most common task is to allow for a positioning of the drive system. This po-
sitioning can be incremental or absolute. The encoder can be mounted to the motor or
to the track. Encoder systems can also be used for speed control purposes. With a direct
motor feedback, you can significantly improve the speed quality and the control re-
sponse even with major load changes. With synchronous motors, the feedback of the
rotor position is required in order to set the rotating field for the dynamic control with
varying load conditions.
With the suitable encoder and the ideal combination of the signals for control processes
and positioning, you can implement an optimized drive system.

2.2 Which types of encoder systems are there?


2.2.1 Overview of conventional encoder systems with respect to electrical interfaces

Encoder systems

incremental absolute analog

analog digital analog digital

singleturn singleturn multiturn

sin/cos TTL, HTL Resolver asynchron. serial, synchron. serial Speedom.

1516926603
Fig. 1: Overview of conventional encoder systems

Drive Engineering – Practical Implementation – Encoder Systems 5


kVA n What Are Encoder Systems?
2 f
Which types of encoder systems are there?
i
P Hz

The different encoders provide the following data:


Data
Encoder system
Rotor angle Position Speed
Single-turn absolute encoder x x (x)
Multi-turn absolute encoder x x (x)
Incremental encoder (x) (x) (x)
Resolver x (x) x
Tacho generator - - x

x direct evaluation, (x) available with additional evaluation

The robustness of an encoder system is a crucial criterion for the encoder selection. As
some encoders are installed directly on the motor, they have to be temperature- and vi-
bration-resistant, as they could get damaged otherwise. The encoder system's suscep-
tibility to interference is another crucial factor as well In the event of a power failure, the
absolute encoder keeps the latest track information whereas the incremental encoder
loses it. This is why the absolute encoder is susceptible to external interference. Once
the interference has decayed, the absolute encoder resumes working flawlessly as the
track information has been stored. With an incremental encoder, a lost or redundant
counting pulse is not registered and results in a permanent measuring error.

2.2.2 Benefits and drawbacks of the most important encoder systems

Encoder system Benefits Drawbacks


Incremental encoder • Relatively robust design is possible • Position information is lost in
• Broad range regarding resolution, the event of a power failure
mounting positions and interfaces
• Very high resolution is possible
• Can be installed in the motor
Absolute encoder • Position information is stored in the • High costs
event of a power failure
• Explicit assignment of a position to an
output value
• Very high resolution is possible
• Rotary encoders can even image a
position over several revolutions
• Can be installed in the motor
Resolver • Robust design • High evaluation efforts
• Not affected by vibration and tempera- • only single-turn position infor-
ture fluctuations mation
• Can be installed in the motor

6 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

2.3 How do encoder systems work?


2.3.1 Rotary encoder systems
Incremental encoder
Optical system Incremental encoders convert the speed into a direct number of electrical impulses. This
is performed via a code disk with radial transparent slits that is scanned optoelectroni-
cally. The resolution is determined by the number of slits.
[2]
[1]

1369274507
Fig. 2: Incremental encoder

[1] Incremental disk


[2] Scanning device

Magnetic system
Sensors scan rotating magnets or ferromagnetic material measures and generate a sig-
nal. Those systems tend to be more robust than optical systems. There can also be de-
viations from the classic design, e.g. with the DR built-in encoder, there are magnets in
the fan wheel. Those magnets are tracked by magnetic field sensors on an encoder
module mounted to the stud. The measured values are interpolated to generate the cor-
responding incremental signals.

2262625419
Fig. 3: DR built-in encoder

Drive Engineering – Practical Implementation – Encoder Systems 7


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Structure and func- Usually, incremental encoders have 2 tracks and one index signal track. Inverting the
tional principle signals results in a total of six tracks. Two scanning elements in the incremental en-
coder, arranged at a 90° angle to each other, provide 2 signal tracks A (K1) and B (K2).
Track A (K1) is 90° ahead of B (K2) as viewed onto the motor shaft This phase shift is
used for determining the direction of rotation of the motor. The zero pulse (one pulse per
revolution) is registered by a third scanning device and made available on track C (K0)
as a reference signal.
The signals A (K1), B (K2) and C (K0) are inverted in the encoder and provided as sig-
nals A (K1), B (K2) and C (K0).

A (K1)

A (K1)
180°
360°
90°

B (K2)

B (K2)

90°
C (K0)

C (K0)
1369276939
Fig. 4: TTL signals with zero track, with inverted signals
HTL signals with zero track, without inverted signals

Signal level There are two kinds of signal levels for incremental digital encoders:
• TTL (Transistor-Transistor-Logic)
• TTL (High-voltage-Transistor Logic)

8 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

TTL (Transistor- The signal levels are Vlow ≤ 0.5 V and Vhigh ≥ 2.5 V. A positive and a negative signal (e.g.
Transistor-Logic) A, A) each is transmitted between the sender and the receiver and evaluated differen-
tially. This symmetrical signal transmission and the differential evaluation can minimize
common-mode interference and increase the data rate.

5.0
A [1] [2]
U [VDC]

2.5

0.5
0.0
TTL

5.0
A [2] [1]
U [VDC]

2.5

0.5
0.0
TTL
1369579787
Fig. 5: TTL signal level

[1] "1" area


[2] "0" area

TTL (High-voltage- The signal levels are Vlow ≤ 3 V and Vhigh ≥ VB-3.5 V. The signals are transmitted sym-
Transistor Logic) metrically and are evaluated differentially. This and the high voltage level of the HTL en-
coders result in very favorable EMC properties.

24.0

K [1]
20.5
U [VDC]

3.0
[2]
0.0
HTL
1369620619
Fig. 6: HTL signal level

[1] "1" area


[2] "0" area

Inverted HTL signals must usually not be directly connected to the encoder input of the
inverter as this might overload and damage the input stages.

Drive Engineering – Practical Implementation – Encoder Systems 9


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Incremental rotary encoders with sin/cos tracks


Structure and func- Sin/cos encoders, also called sinusoidal encoders, supply two sinusoidal signals, offset
tional principle by 90°. The number and progress of the sine waves (interpolation and arctangent) is
evaluated. Using these values, the speed can be determined with a very high resolution.
This is especially advantageous if a large setting range and small speeds must be ex-
actly met. Further, there is a very high control stiffness.
Usually, sin/cos encoders have 2 tracks and one index signal track. Inverting the signals
results in a total of six tracks. The 90° offset signals are on tracks A (K1) and B (K2).
One sine half-wave per revolution is provided at channel track C (K0) as the zero pulse.
The tracks A (K1), B (K2) and C (K0) are inverted in the encoder and provided inverted
as signals on tracks A (K1), B (K2) and C (K0).
Track A = Cos
Track B = Sin

0.5V A (K1)

A (K1)
180°
360°
90°

B (K2)

B (K2)
90°

C (K0)
C (K0)

1369570059
Fig. 7: Sin/cos signals with zero track and inverted signal

10 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Signal level The sin/cos signals are usually superimposed on a DC voltage of 2.5 V. As the sin/cos
signals are transferred symmetrically and evaluated differentially (VSS = 1 V), they are
not sensitive to asymmetric interference and have a good EMC behavior.

U [VDC ]

3.0
[1]

2.5

1 VSS

2.0

0.0 [2]

Sin/Cos
2295657483
Fig. 8: Signal level of an incremental rotary encoder with sin/cos tracks

[1] B - B
[2] A - A

Absolute encoder
Absolute encoder In the past few years, so-called combination encoders have established on the marked.
with asynchro- Those encoders are sin/cos encoders with absolute value information. In addition to the
nous-serial inter- current speed of the motor, they provide absolute value information and offer technical
face and financial advantages if an absolute value encoder is required.

Structure The absolute encoder with an asynchronous interface is a typical combination encoder.
In addition to a sin/cos signal for speed recording and absolute value information, these
encoders also have an electronic nameplate in which data such as drive data can be
stored. This makes startup easier and reduces possible user input errors, as the user
does not need to input any drive data.
Absolute encoders with asynchronous interface are available as:
1. Add-on encoder s for asynchronous motors and synchronous servomotors
2. Built-in encoders for synchronous servomotors
Both designs are available as single-turn and multi-turn variant.

Drive Engineering – Practical Implementation – Encoder Systems 11


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Functional princi- At the beginning of the startup process, the absolute value encoder component deter-
ple mines the absolute position. For synchronous motors, the inverter can use this value to
calculate the commutation information. The inverter reads this position information via
an RS-485 connection (parameter channel) and sets a counter status. Based on this ab-
solute value, the position changes are recorded using the tracks of the sin/cos encoder.
These changes are transmitted over the process data channel to the inverter in analog
form. Additional absolute position queries are only performed periodically to check va-
lidity.

[1] [2] [5]

[3]

[4]

1369574923
Fig. 9: Information flow

[1] Motor feedback systems


[2] Sin/cos signals
[3] RS485 parameter channel
[4] Supply voltage
[5] Inverter

An inverter with an asynchronous-serial interface receives position information as well


as the time for which the position is valid via the parameter channel. At the same time,
the process data channel continuously receives and counts the incoming analog (sin/
cos) signals.
The encoder is available in single-turn or multi-turn versions. Single-turn means that the
absolute position information always relates to one revolution only. In addition, the multi-
turn variant of the encoder can provide information regarding the number of revolutions
(typically e.g. 4096) via downstream scaled code disks or an electronic revolution coun-
ter. Thus, depending on the inverter, after the maximum number of revolutions, there will
be an encoder overflow that is counted in the non-volatile SRAM (NVS) of the inverter.
Up to 256 encoder overflows are saved (at 4096 revolutions). If the voltage at the supply
pins drops below a threshold (e.g. power failure), the NVSRAM detects this and saves
the data in a retentive way.

12 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Overflow example:
At restart, the EEPROM in the inverter provides the following values:
• The absolute value within an overflow (typically 4096 x 4096)
• The number of overflows (0 – 255)

If the drive that is close to an overflow is moved beyond the encoder overflow point when
the supply voltage is removed, a discrepancy exists at restart between the recorded and
the stored absolute values. The encoder electronics then corrects the stored values au-
tomatically with the recorded ones.
Inc.

[3]

[1] [2]

abs. Pos.
1369574923
Fig. 10: Encoder overflow

[1] 1. Encoder overflow


[2] 2. Encoder overflow
[3] Absolute value seen by user

The encoder overflows are counted in the inverter and thus the absolute position can be
determined.
The user does not see the actual encoder overflows; they are saved in the inverter.
Hence, the encoder with asynchronous-serial interface is a genuine absolute encoder.

Drive Engineering – Practical Implementation – Encoder Systems 13


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Absolute encoder
with SSI (synchro-
nous-serial inter-
face)
Single-turn The absolute value information is generated by a code disk with Gray Code that is gen-
encoder erally scanned optically. Every angle position is assigned a unique code pattern. Thus
the absolute position of the motor shaft can be determined. As opposed to the binary
code, only 1 bit changes at a time. Thus, with the single-step Gray Code, an incorrect
scanning is detected immediately.

1369279371
Fig. 11: Code disk with Gray Code

Decimal Gray code Binary code


0 0000 0000
1 0001 0001
2 0011 0010
3 0010 0011
4 0110 0100
5 0111 0101
6 0101 0110
7 0100 0111
8 1100 1000
9 1101 1001
10 1111 1010
11 1110 1011
12 1010 1100
13 1011 1101
14 1001 1110
15 1000 1111

This kind of encoder is a single-turn encoder because the absolute position of the motor
shaft can only be determined with one revolution.

14 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Multi-turn encoder In addition to single-turn designs, there are also multi-turn encoders that determine the
absolute position with multiple revolutions.
Different technological solutions are available for the revolution detection. Micro gear
unit stages that are scanned magnetically or optically via code disks are one of the more
common solutions.
The multi-turn unit is also available as a storing electronic counter.
With an optical rotary encoder, the code disks are decoupled from each other with gear
unit stages with a ratio of i = 16. With three additional code disks (usual value),
16 x 16 x 16 = 4096 revolutions can be absolutely resolved.

[1] [2] [2] [2]

i = 16 i = 16 i = 16

1369572491
Fig. 12: Arrangement of the code disks

[1] Code disk for angle position detection


[2] Code disk for detecting the number of revolutions

Drive Engineering – Practical Implementation – Encoder Systems 15


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Resolver The resolver is the most commonly used encoder system for synchronous servomotors.
A resolver can determine the absolute position of the motor shaft within one motor rev-
olution. The speed and the absolute position are derived from the resolver signal each
revolution.

Structure The resolver consists of two function units, the stator and the rotor.

U1

U2 UR

1369284235
Fig. 13: Schematic structure of the resolver

[1]

[2]

1369567627
Fig. 14: Resolver

[1] Stator of the resolver


[2] Rotor of the resolver

16 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Functional princi- The inverter supplies a high-frequency excitation signal with a constant amplitude and
ple frequency. This high-frequency signal is transferred to the rotor of the resolver via the
stator.
The rotation of the resolver rotor induces the rotor-position-dependent voltages into the
stator winding of the rotary transformer.
R1 S2

[1] [2] [1]


Ue UR U2

R2 S4

[1]
U1
S1 S3
1369630347
Fig. 15: Equivalent circuit diagram of a resolver

[1] Stator
[2] Rotor

Ucos

Usin

1369632779
Fig. 16: Output voltage Vcos and Vsin of the resolver

Signal characteris- The characteristics of the signals are calculated as follows:


tics
Vref = A x sin (ωexcitation x t)
Vcos(t) = A x ü x sin(ωexcitation x t) x cos(p x α)
Vsin(t) = A x ü x sin(ωexcitation x t) x sin(p x α)
p x α = arctan (Vsin / Vcos)

Vref Reference voltage


Vcos Output voltage 1 of the stator
Vsin Output voltage 2 of the stator
A Peak value of the input voltage
ωExcitation Angle frequency of Ve
α Rotor angle
ü Gear ratio
p Number of pole pairs of the resolver

Drive Engineering – Practical Implementation – Encoder Systems 17


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Depending on the rotor position, the amplitudes of the voltages Vsin and Vcos change
and are fed to the evaluation via a differential amplifier each. The differential amplifiers
filter interference signals (common mode interference) on the isolated track signals Vsin
and Vcos.
The current mechanical position can be determined from the scanned track signals:

p x α = arctan(Usin / Ucos )

The following figure gives a overview of the principle hardware structure of a resolver
evaluation that works according to the scanning method.

Excitation circuit

Resolver
excitation
control
V Ref

Data
Micro-
Signal processing controller

V cos

V sin

2058735499
Fig. 17: Hardware resolver evaluation (simplified representation)

18 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

2.3.2 Linear encoder systems


Laser encoder Laser distance measuring instruments are often used in drive engineering to measure
distances of up to 250 m. The laser diodes send a modulated beam as pulse or with a
certain frequency. This beam is reflected by a reflector and received by a photo diode
system in the device. The propagation speed is 30 ns/m. The distance to the reflector
surface is determined based on the delay between the sent and the received beam.
For distances of up to about 50 m, you can use laser diodes without reflector and the
triangulation method for distance measuring.

[3]

[1] [2]

[4]

[5]

2262514571
Fig. 18: Laser distance measuring instruments

[1] Reflector or plain surface


[2] reflected signal
[3] sent signal
[4] Distance
[5] Phase shift

Drive Engineering – Practical Implementation – Encoder Systems 19


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Barcode encoder
A barcode strip is installed along the track and is read by a barcode encoder. With a vis-
ible red-light laser, the barcode encoder determines its position in relation to the barcode
strip. This is basically carried out in 3 steps:

1. Reading the code on the barcode strip.


2. Determining the position of the read code within the scan range of the laser beam.
3. Millimeter-precise position detection based on code information/position.

Then the position value is transmitted to the drive system of the respective vehicle via
the standardized interface (e.g. SSI interface). The benefit of this system is the very ac-
curate positioning over long distances. Further, it eliminates disturbances such as air
pressure and temperature, that have effects on conventional laser distance measuring
devices. This system can even handle curved tracks.

2048051723
Fig. 19: Barcode encoder

20 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Code rail For positioning purposes with long travel distances, there is the WCS distance coding
system. It is especially suited for plants with curves, switches and inclining/declining
sections. With measuring lengths of up to 327 meters it is also suitable for position de-
tection in the following fields:
• Storage and materials handling systems
• Film studio technology
• Crane positioning
• Electroplating plants
• Elevators
Further, the WCS is suitable for the vehicle identification in materials handling systems
with millimeter-precise positioning of the respective vehicle.

2048045963
Fig. 20: WCS distance coding system

Rulers
A measuring system is required for the operation of a synchronous linear motor in order
to determine the position of the primary. In the inverter, the velocity is derived from this
value and the positioning is carried out.
There are different criteria for the selection of the appropriate encoder system depend-
ing on the application:
• Maximum speed
• Maximum travel distance
• Resolution (accuracy requirements)
• Contamination level
• EMC conditions

Drive Engineering – Practical Implementation – Encoder Systems 21


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Structure and func- An optical travel distance measuring system consists of a measuring gauge made of
tional principle of glass or steel mounted on the track and a scanning unit that travels over the track. The
optical travel dis- scanning unit contains a light source, photo elements and optical filters for better record-
tance measuring ing. The light emitted by the light source hits the measuring gauge and is reflected ac-
systems cording to the applied pitch and detected by the photo elements. An electronic evalua-
tion device generates an incremental signal.

[1]

[2]

[5]

[4]
[3]
1369635211
Fig. 21: Schematic representation an optical travel distance measuring system

[1] Light source and photo element


[2] Lens
[3] Scanning plate
[4] Reflector
[5] Light waves

Depending on the resolution, there are two different operating principles:


• Display principle with a line graduation of 20-100 µm
• Interference principle with a line graduation of 4-8 µm
Depending on the usage conditions and environmental conditions, different optical sys-
tems designs are used.

22 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Closed systems • Maximum traveling velocity about 2 m/s


• Good protection from environmental conditions
• With mechanical control

Open systems The system works without mechanical control.


• The scanning unit is attached to the movable part and virtually "floats" above the
track, thus the maximum traveling velocity is about 8 m/s.
• Almost no protection from environmental conditions.

Structure and func- Magnetic travel distance measuring systems comprise a magnet strip and a sensor.
tional principle of The magnetic tape is attached to the track as a measuring tape. The sensor that is at-
magnetic travel tached to the primary travels over this measuring tape.
distance measur-
ing systems Hz [1/s]

l [mm]

S N S N

[A]
1369627915
Fig. 22: Magnetic travel distance measuring system

[A] Resolution

The sensor measures the changes of the magnetic field strength via a travel motion,
which an electronic evaluation device uses to generate a sinusoidal signal. The phase-
shifted configuration of the two sampling units within a sensor generates sine or cosine
signals.
The sine signals of the sampling element can be resolved higher using interpolation (D/
A converter). Optional electronic switches integrated in the encoders can convert these
sine signals into commonly used interface signals such as TTL.
These measuring tapes are also available with a magnetized code for the absolute
value. Reference travel is not required after startup for encoder systems with absolute
value information. With linear absolute encoders, the position signal is converted to a
digital protocol.

Drive Engineering – Practical Implementation – Encoder Systems 23


kVA n What Are Encoder Systems?
2 f
How do encoder systems work?
i
P Hz

Structure and func- Inductive travel distance measuring systems work according to the principle of variable
tional principle of reluctance. Markings on a metallic measuring tape deflect a magnetic field generated by
inductive travel dis- a control unit. The electronic evaluation device detects those field changes and converts
tance measuring them to sinusoidal signals. The phase-shifted configuration of the two sampling units
systems within a sensor generates sine or cosine signals.

[1]

N
S

[2] [3]
1369623051
Fig. 23: Schematic representation an inductive travel distance measuring system

[1] Magnetic field lines


[2] Magnetic sensors
[3] Measuring tape cross-section

The measuring tape on the track is crucial to the accuracy of the measurement. It con-
sists of several layers: The core is a metal strip in which the markings are etched very
precisely. These measuring tapes are also available with a reference mark. Depending
on the design of the length-measuring system, the reference signal is partially recorded
by a separate sensor. This metal strip is embedded between the carrier and cover tape.
[1]

[2]
[3]

[4]

[5]

1369625483
Fig. 24: Structure of a measuring tape in layers

[1] Masking tape


[2] Partition
[3] Reference marks
[4] Steel carrier tape
[5] Adhesive layer

24 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
How do encoder systems work?
f 2
i
P Hz

Optional evaluation electronics are available for inductive measuring systems for con-
verting the sine and cosine signals into a TTL signal.
The following properties of inductive travel distance measuring systems must be taken
into account during project planning:
• Maximum traveling velocity about 20 m/s
• Resolution: 1000 µm/sine cycle (sin/cos signal)
5 - 50 µm (TTL signal)
• Accuracy about 10 µm/m
• Usually in IP66 design
• Dirt resistant

Wire-actuated encoder
A wire-actuated encoder basically consists of a measuring drum, a spring return and an
unwind mechanism. A conventional encoder is connected to this unwind mechanism via
a coupling. Wire-actuated encoders are especially suitable for vertical applications in
storage and logistics applications as well as in stage technology.

2048049803
Fig. 25: Wire-actuated encoder

Drive Engineering – Practical Implementation – Encoder Systems 25


kVA n What Are Encoder Systems?
2 f
Which encoder with which motor?
i
P Hz

2.4 Which encoder with which motor?


2.4.1 Encoder systems for asynchronous AC or servomotors
Usually, there are two reasons for using encoder systems with asynchronous motors:
– Speed control (in order to achieve a high speed quality and to optimize the response
to load changes)
– Positioning

Usually, the following encoders are used:


• Incremental encoders with low resolution
– can only be used for positioning rather than for speed control
– only simple positioning (rapid/creep speed)
– thus less dynamic system
– reference travel required

• Incremental encoders
– for speed control
– for positioning
– reference travel required

• Absolute encoder
– for positioning
– no reference travel required.
– an additional encoder system is required for speed control if there is no realtime
channel (combination encoder with either sin/cos, TTL, or HTL signal)

26 Drive Engineering – Practical Implementation – Encoder Systems


What Are Encoder Systems? kVA n
Which encoder with which motor?
f 2
i
P Hz

2.4.2 Encoder systems for synchronous servomotors


With synchronous motors, the control system additionally requires the rotor position for
dynamic control. Usually, with synchronous servomotors, there are two systems for the
rotor position detection:
• Resolver
– for rotor position detection
– for speed control
– for positioning
– reference travel required

• Absolute encoder
– for rotor position detection
– Absolute encoders for servomotors are usually combination encoders with a re-
altime channel (sin/cos) for speed control
– for positioning
– single-turn encoders usually require a reference travel
– multi-turn encoders do not require a reference travel

2.4.3 Encoder systems for linear servo systems


• Rulers
– for positioning
– with absolute value information on the measuring tape, a reference travel is not
required
– with mere incremental information on the measuring tape, a reference travel is re-
quired

Drive Engineering – Practical Implementation – Encoder Systems 27


kVA n What Are Encoder Systems?
2 f
Which encoder with which motor?
i
P Hz

2.4.4 Encoder systems for linear position detection


For an exact positioning with systems subject to slip, a measuring system is required on
the track in addition to the encoders mounted to the motor.
• Laser encoder
– for measuring distances of up to about 250 m
– Cannot handle curves

• Barcode encoder
– can be used for measuring very long distances
– Curves and switches are possible

• Code rail
– can be used for measuring distances of up to about 320 m
– very robust system
– Curves and switches are possible

• Wire-actuated encoder
– robust system
– ideal for vertical applications

28 Drive Engineering – Practical Implementation – Encoder Systems


How Are Encoder Systems Used At SEW-EURODRIVE? kVA n
Which encoder systems does SEW-EURODRIVE use?
f 3
i
P Hz

3 How Are Encoder Systems Used At SEW-EURODRIVE?

Speed control

Setpoint
generation
Speed
controller
Motor
control M
G
Precontrol
Positioning Rotor position

Control N target
Position Speed
value
X target controller
generator
Position information

1958362251
Fig. 26: Speed and position control circuit of a drive system

3.1 Which encoder systems does SEW-EURODRIVE use?


3.1.1 Incremental encoders with a low resolution NV.. / EI.. / ES12/16/22/26
With incremental encoders with a low resolution, you can realize simple non-dynamic
positioning tasks Further, those encoders allow you to inexpensively check whether the
motor is turning. If a two-track encoder is used, the direction of rotation of the motor can
also be detected.

3.1.2 Incremental encoder E..T / E..C / E..S / E..R


Incremental encoders are suitable for speed control and positioning. They have 2 signal
tracks and one index signal track. Incremental encoders are available as hollow shaft
encoders, spread shaft encoders, plug-in shaft with end thread, or solid shaft encoders
with coupling. Signal output: TTL, HTL or sin/cos.

3.1.3 Single-turn combination encoders E..H / E..W


The E..H and E..W absolute encoders are combination encoders. They contain a single-
turn absolute encoder and a high-resolution sinusoidal encoder. An asynchronous-serial
interface is available for the data transfer of the absolute values. They are suitable for
the use with synchronous motors. They can be used for speed control or for positioning
within one revolution. Further, the E..H and E..W absolute encoders are equipped with
an electronic nameplate.

3.1.4 A..Y / A..H / A..W absolute encoders


The A..Y, A..H and A..W absolute encoders are combination encoders. They contain a
multi-turn absolute encoder and a high-resolution sinusoidal encoder. You can choose
between an SSI interface or an asynchronous-serial interface for data transmission of
absolute values. Further, the A..H and AS7W absolute encoders are equipped with an
electronic nameplate.

Drive Engineering – Practical Implementation – Encoder Systems 29


kVA n How Are Encoder Systems Used At SEW-EURODRIVE?
3 f
What is the structure of the type designation of those encoder systems?
i
P Hz

3.2 What is the structure of the type designation of those encoder systems?

E S 7 S

Signal type
T VB = DC 5 V, TTL
A Mounting device design
C VB = DC 4,75 (9) – 30 V, HTL or TTL
H HIPERFACE®
R VB = DC 7 (9) – 30 V, TTL
S VB = DC 7 (9) – 30 V, Sin/Cos 1 VSS
W VB = DC 7 – 30 V, RS485, sin/cos 1 VSS
Y SSI [synchronous serial interface]
1 ... 6 Periods per revolution
M Resolver signal
L Resolver signal

Design
1 0–7

Mounting/shaft
F positive, secured with bolts
S shaft centered, spread shaft
G shaft-centered, plug-in shaft
I Integrated
V flange-centered, solid shaft
H shaft-centered, hollow shaft
K shaft-centered, cone shaft
L Linear encoder

Encoder type
E Encoder (incremental encoder or single-turn combination
encoder)
A Absolute encoder
N Proximity sensor
X Mounting device for non-sew encoders
R Resolver

30 Drive Engineering – Practical Implementation – Encoder Systems


How Are Encoder Systems Used At SEW-EURODRIVE? kVA n
Which products are the encoder systems used with?
f 3
i
P Hz

3.3 Which products are the encoder systems used with?


3.3.1 Rotary encoders for AC motors and asynchronous servomotors
Incremental encoders for DR motors
Encoder type Mounting type Installed to Electrical interface Resolu- Supply
tion [VDC]
EH1T Add-on encoder with hollow • DR63 TTL 1024 5
shaft
EH1S Sin/cos 9 – 26
EH1R TTL
EH1C HTL
EI7C / EI76 / Built-in encoder • DR71 – 132 HTL 24 / 6 / 2 / 9 – 30
EI72 / EI71 1
ES7S Add-on encoder with spread • DR71 – 132 Sin/cos 1024 7 – 30
shaft
ES7R TTL
ES7C TTL to HTL, depend- 4.75 – 30
ing on supply
EG7S Add-on encoder with plug-in • DR160 – 225 Sin/cos 1024 7 – 30
shaft
EG7R TTL
EG7C TTL to HTL, depend- 4.75 – 30
ing on supply
EV7S Add-on encoders with cou- • DR71 – 225 Sin/cos 1024 7 – 30
pling
EV7R TTL
EV7C TTL to HTL, depend- 4.75 – 30
ing on supply
EH7T Add-on encoder with hollow • DR315 TTL 1024 5
shaft
EH7S Sin/cos 10 – 30
EH7R TTL
EH7C HTL

Incremental encoders for DT/DV motors


Encoder type Mounting type Installed to Electrical interface Resolu- Supply
tion [VDC]
ES1T / ES2T Add-on encoder with spread • DT71 – DV225 TTL 1024 5
shaft • CT71 – CV200
ES1S / ES2S Sin/cos 9 – 26
ES1R / ES2R TTL
ES1C / ES2C HTL
EV1T / EV2T* Add-on encoders with cou- • DT71 – DV225 TTL 1024 5
pling • CT71 – CV200
EV1S Sin/cos 10 – 30
EV1R: TTL
EV1C HTL
ES12 Add-on encoder with spread • DT71 – DV100 HTL 1/2 9 – 26
shaft
ES16 HTL 6
ES22 • DV112 – DV132S HTL 1/2
ES26 HTL 6

* Encoder with Ex design

Drive Engineering – Practical Implementation – Encoder Systems 31


kVA n How Are Encoder Systems Used At SEW-EURODRIVE?
3 f
Which products are the encoder systems used with?
i
P Hz

Single-turn/multi-turn absolute encoder


Encoder Mounting type Installed to Electrical interface Resolu- Supply
type tion [VDC]
AS7W Add-on encoder with spread • DR71- 132 RS485 (multi-turn) + 2048 7 – 30
shaft 1 V sin/cos
AG7W Add-on encoder with plug-in • DR160 - 225: RS485 (multi-turn) + 2048 7 – 30
shaft 1 V sin/cos
AS7Y Add-on encoder with spread • DR71- 132 M-SSI (multi-turn) + 2048 7 – 30
shaft 1 V sin/cos
AG7Y Add-on encoder with plug-in • DR160 - 225: M-SSI (multi-turn) + 2048 7 – 30
shaft 1 V sin/cos
AH7Y Add-on encoder with hollow • DR315 M-SSI (multi-turn) + 2048 7 – 30
shaft TTL
AV7Y Add-on encoders with coupling • DR71 – 225 M-SSI (multi-turn) + 2048 7 – 30
1 V sin/cos
AV7W Add-on encoders with coupling • DR71 – 225 RS485 (multi-turn) + 2048 7 – 30
1 V sin/cos
AS3H / Add-on encoder with spread • DT71 – DV132S HIPERFACE® (multi- 4096 7 – 12
AS4H shaft • CT71 – CV132S turn) + 1 V sin/cos
AV1H / Add-on encoders with coupling • DT71 – DV225 HIPERFACE® (multi- 1024 7 – 12
AV6H • CT71 – CV200L turn) + 1 V sin/cos

AV1Y Add-on encoders with coupling • DT71 – DV225 M-SSI (multi-turn) + 512 10 – 30
• CT71 – CV200L 1 V sin/cos

M-SSI: Multi-turn synchronous-serial interface

Proximity sensor
Encoder Mounting type Installed to Electrical interface Resolu- Supply
type tion [VDC]
NV11 Radial on fan guard • DT71 – DV132S HTL 1 10 – 30
NV21 1
NV12 2
NV22 2
NV16 6
NV26 6

32 Drive Engineering – Practical Implementation – Encoder Systems


How Are Encoder Systems Used At SEW-EURODRIVE? kVA n
Which products are the encoder systems used with?
f 3
i
P Hz

3.3.2 Rotary encoders for synchronous servomotors


Single-turn/multi-turn absolute encoder
Encoder Mounting type Installed to Electrical inter- Resolu- Supply
type face tion [VDC]
AK0H Built-in encoder with conical • CMP40 HIPERFACE® 128 7 – 12
shaft • CMD55, 70 (multi-turn) + 1 V
sin/cos
EK0H Built-in encoder with conical • CMP40 HIPERFACE® 7 – 12
shaft • CMD55, 70 (single-turn) +
1 V sin/cos
AS1H Built-in encoder with spread • CMP50, 63 HIPERFACE® 1024 7 – 12
shaft • CMD93, 138 (multi-turn) + 1 V
sin/cos
• DS/CM
ES1H Built-in encoder with spread • CMP50, 63 HIPERFACE® 7 – 12
shaft • CMD93, 138 (single-turn) +
1 V sin/cos
• DS/CM
AK1H Built-in encoder with conical • CMP71 – 160 HIPERFACE® 1024 7 – 12
shaft • CMD93 – 162 (multi-turn) + 1 V
sin/cos
EK1H Built-in encoder with conical • CMP71 – 160 HIPERFACE® 7 – 12
shaft • CMD93 – 162 (single-turn) +
1 V sin/cos
AV1H Add-on encoders with cou- • DS/CM HIPERFACE® 1024 7 – 12
pling (multi-turn) + 1 V
sin/cos
AV1Y Add-on encoders with cou- • DS/CM M-SSI (multi-turn) 512 10 – 30
pling + 1 V sin/cos
AF1H Built-in encoder with spread • CM71 – CM112 HIPERFACE® 1024 7 – 12
shaft, positive connection at (multi-turn) + 1 V
the shaft connection sin/cos
EF1H Built-in encoder with spread • CM71 – CM112 HIPERFACE® 7 – 12
shaft, positive connection at (single-turn) +
the shaft connection 1 V sin/cos

M-SSI: Multi-turn synchronous-serial interface

Drive Engineering – Practical Implementation – Encoder Systems 33


kVA n How Are Encoder Systems Used At SEW-EURODRIVE?
3 f
Which products are the encoder systems used with?
i
P Hz

Resolver
Resolver Mounting type Installed to Electrical inter- Resolution Supply
type face [VAC]
RH1M Built-in encoder DS / CM / CMP / CMD synchronous servomo- Resolver signals, - 7
with hollow shaft tors 2-pole
RH1L CM Synchronous servo brakemotors
RH3M Built-in encoder DS / CM / CMP / CMD synchronous servomo-
with hollow shaft tors
for the second
RH3L CM Synchronous servo brakemotors
shaft end
RH4M / RH4L Special design
RH5M / RH5L Special design
RH6M / RH6L Special design

Linear absolute encoders


Encoder Mounting type Installed to Electrical interface Resolu- Supply
type tion [VDC]
AL1H Add-on encoders for syn- SL2 synchronous linear motors HIPERFACE® (multi-turn) 0,5/100 7 – 12
chronous linear motors + 1 V sin/cos mm

Linear hall sensor encoders


Encoder Mounting type Installed to Electrical interface Resolu- Supply
type tion [VDC]
NL16 Add-on encoders for syn- SLC 3 TTL signals with an 6/100 mm 24
chronous linear motors 120° offset

34 Drive Engineering – Practical Implementation – Encoder Systems


How Are Encoder Systems Used At SEW-EURODRIVE? kVA n
How do you perform the project planning for encoder systems?
f 3
i
P Hz

3.4 How do you perform the project planning for encoder systems?
The use of a certain encoder depends on the application requirements. If the application
is not very dynamic, rapid/creep speed positioning via a low-resolution incremental en-
coder might be sufficient. However, speed control is required for dynamic positioning.
A high resolution is required for a high speed control quality. This is why SEW-EURO-
DRIVE recommends sin/cos encoders. The signals are scanned with an A/D converter
that achieves a higher resolution than the typical 1024 (4096 due to quadruple evalua-
tion) increments of a TTL or HTL incremental encoder. Linear systems are often used
the track for travel distance positioning. The advantage is that those systems measure
directly at the track and are thus independent from the slip of the drive system.
The following table lists the most important benefits of the encoder systems.

Encoder system [SEW Sin/cos encoder Incremental encoder Incremental encoder with low
type] resolution
Characteristics
1024 periods/revolution (HTL/
Output signal 1024 sin/cos periods 1 to 24 periods
TTL level)
Accuracy < 2 angular minutes < 7 angular minutes < 300 angular minutes (EI7C)
Maximum useable resolu-
< 22 bits < 14 bits < 5 bits (EI7C)
tion
Operating temperature -30 °C to +100 °C -30 °C to +85 °C -30 °C to +60 °C
– Shock 200 g / 1 ms – Shock 200 g / 6 ms
Mechanical influences – Vibration 10 g / 10 - – Vibration -
2000 Hz 10 g / 10 - 2000 Hz
For speed control and "incre- For speed control and "incre- For simple "incremental" posi-
Use
mental" positioning mental" positioning tioning
Suitable for Asynchronous servomotors Asynchronous AC motors Asynchronous AC motors
Suitable for dynamic applications
Speed control Suitable for dynamic applications with restrictions in the lower -
speed range
Simple startup due to electronic Simple encoder system for stan-
Other features -
nameplate dard applications

Drive Engineering – Practical Implementation – Encoder Systems 35


kVA n How Are Encoder Systems Used At SEW-EURODRIVE?
3 f
How do you perform the project planning for encoder systems?
i
P Hz

Absolute encoder with asyn-


Encoder system [SEW chronous-serial interface (sin/
Resolver SSI absolute encoder
type] cos encoder with absolute
value)
Characteristics
– up to 2048 sin/cos periods – up to 2048 sin/cos periods
– up to 32768 increments/rev- – up to 4096 increments/revo-
Amplitude-modulated sin/cos
Output signal olution (absolute) lution (absolute)
signal, 2-pole
– up to 65536 revolutions – up to 4096 revolutions (abso-
(absolute) lute)
Maximum useable resolu- < 16 bits < 22 bits < 22 bits
tion
Accuracy < 40 angular minutes < 2 angular minutes < 2 angular minutes
Operating temperature -55 °C to +125 °C -20 °C to +115 °C -40 °C to +100 °C
– Shock 100 g / 11 ms – Shock 100 g / 10 ms – Shock 100 g / 10 ms
Mechanical influences
– Vibration 20 g / 10 - 50 Hz – Vibration 20 g / 10 - 2000 Hz – Vibration 20 g / 10 - 2000 Hz
For speed control and determin-
For speed control and determin- For speed control and determin-
ing the rotor position within one
Use ing the rotor position and abso- ing the rotor position and abso-
motor revolution as well as
lute position lute position
"incremental" positioning
– Synchronous servomotors – Synchronous servomotors
Suitable for – Synchronous servomotors – Asynchronous servomotors – Asynchronous servomotors
– AC motors – AC motors
Suitable for dynamic applications Suitable for highly-dynamic and Suitable for highly-dynamic and
Speed control
dynamic applications dynamic applications
Simple startup due to electronic
Other features Mechanically very robust -
nameplate

36 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Incremental rotary encoders with spread and plug-in shaft
f 4
i
P Hz

4 What Are The Technical Data Of These Encoder Systems?


4.1 Incremental rotary encoders with spread and plug-in shaft

Encoder type ES7S EG7S


For motors DR71 – 132 DR160 – 225
Supply voltage VB DC 7 V – 30 V
Max. current consumption Iin 140 mARMS
Max. pulse frequency fmax 150 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90 ° ± 3 °
Data memory 1920 bytes
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 min-1
Mass m 0.35 kg 0.65 kg
Degree of protection IP66
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal box on incremental encoder

Encoder type ES7R EG7R


For motors DR71 – 132 DR160 – 225
Supply voltage VB DC 7 – 30 V
Max. current consumption Iin 160 mARMS
Max. pulse frequency fmax 120 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh ≥ DC 2.5 V
Vlow ≤ DC 0.5 V
Signal output TTL
Output current per track Iout 25 mARMS
Mark space ratio 1 : 1 ± 10 %
Phase angle A : B 90 ° ± 20 °
Data memory -
Vibration resistance ≤ 100 m/s² ≤ 200 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.35 kg 0.65 kg
Degree of protection IP66
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal box on incremental encoder

Drive Engineering – Practical Implementation – Encoder Systems 37


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
Incremental rotary encoders with spread and plug-in shaft
i
P Hz

Encoder type ES7C EG7C


For motors DR71 – 132 DR160 – 225
Supply voltage VB DC 4.75 – 30 V
Max. current consumption Iin 240 mARMS
Max. pulse frequency fmax 120 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh ≥ DC 2.5 V
Vlow ≤ DC 1.1 V
Signal output HTL
Output current per track Iout 60 mARMS
Mark space ratio 1 : 1 ± 10 %
Phase angle A : B 90 ° ± 20 °
Data memory -
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.35 kg 0.65 kg
Degree of protection IP66
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal box on incremental encoder

ES1T ES1S ES1R ES1C


Encoder type
ES2T ES2S ES2R ES2C
For motors DT71 – DV225, CT71 – 200CV
Supply voltage VB DC 5 V DC 9 – 26 V
Max. current consumption Iin 180 mARMS 160 mARMS 180 mARMS 340 mARMS
Max. pulse frequency fmax 120 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh ≤ DC 2.5 V ≤ 2.5 VDC ≤ VB DC - 3.5 V
1 VSS
Vlow ≤ DC 0.5 V ≤ DC 0.5 V ≤ 1.5 VDC
Signal output TTL Sin/cos TTL HTL
Output current per track Iout 20 mARMS 40 mARMS 20 mARMS 60 mARMS
Mark space ratio 1 : 1 ± 20 % Sin/cos 1 : 1 ± 20 %
Phase angle A : B 90 ° ± 20 ° 90 ° 90 ° ± 20 °
Data memory -
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 10000 rpm
Mass m 0.38 kg
Degree of protection IP66
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal box on incremental encoder

38 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Incremental rotary encoders with solid shaft
f 4
i
P Hz

Encoder type EH7S


For motors DR315
Supply voltage VB DC 10 V – 30 V
Max. current consumption Iin 140 mARMS
Max. pulse frequency fmax 180 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90 ° ± 10 °
Data memory -
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 2000 m/s²
Maximum speed nmax 6000 rpm at 70 °C / 3500 rpm at 80 °C
Mass m 0.8 kg
Degree of protection IP65
Ambient temperature ϑA -20 °C to +60 °C
Connection 12-pin plug connector

4.2 Incremental rotary encoders with solid shaft


Encoder type EV1T EV1S EV1R: EV1C EV7S
For motors DT71 – DV225, CT71 – 200CV DR71 – 225
Supply voltage VB DC 5 V DC 10 V – 30 V DC 7 V – 30 V
Max. current consumption Iin 180 mARMS 160 mARMS 180 mARMS 340 mARMS 140 mARMS
Max. pulse frequency fmax 120 kHz 150 kHz
Periods per revolution A, B 1024
C 1
Output amplitude per track Vhigh ≤ DC 2.5 V ≤ 2.5 VDC ≤ VB DC - 3.5 V
1 VSS 1 VSS
Vlow ≤ DC 0.5 V ≤ DC 0.5 V ≤ 1.5 VDC
Signal output TTL Sin/cos TTL HTL Sin/cos
Output current per track Iout 20 mARMS 40 mARMS 20 mARMS 60 mARMS 10 mARMS
Mark space ratio 1 : 1 ± 20 % Sin/cos 1 : 1 ± 20 % Sin/cos
Phase angle A : B 90 ° ± 20 ° 90 ° 90 ° ± 20 ° 90 ° ± 3 °
Data memory -
Vibration resistance ≤ 300 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.3 kg
Degree of protection IP66
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal box on incremental encoder

Drive Engineering – Practical Implementation – Encoder Systems 39


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
SSI absolute encoder
i
P Hz

4.3 SSI absolute encoder


Encoder type AS7Y AG7Y
For motors DR71 – 132 DR160 – 225
Supply voltage VB DC 7 – 30 V
Max. current consumption Iin 140 mARMS
Max. pulse frequency fmax 200 kHz
Periods per revolution A, B 2048
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90 ° ± 3 °
Scanning code Gray code
Single-turn resolution 4096 increments / revolution
Multi-turn resolution 4096 revolutions
Data transfer synchronous-serial
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate Permitted range: 100 – 2000 kHz (max. 100 m cable length with 300 kHz)
Clock-pulse space period 12 – 30 µs
Data memory 1920 bytes
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.4 kg 0.7 kg
Degree of protection IP66
Ambient temperature ϑB -20 °C to +60 °C
Connection Terminal strip in pluggable connection cover

40 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
SSI absolute encoder
f 4
i
P Hz

Encoder type AV1Y


For motors CT71 – DV200L, DT71 – DV225, DS/CM
Supply voltage VB DC 10 – 30 V
Max. current consumption Iin 250 mARMS
Max. pulse frequency fmax 100 kHz
Periods per revolution A, B 512
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90 °
Scanning code Gray code
Single-turn resolution 4096 increments / revolution
Multi-turn resolution 4096 revolutions
Data transfer synchronous-serial
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate Permitted range: 90 – 300 – 1100 kHz (max. 100 m cable length with 300 kHz)
Clock-pulse space period 12 – 35 µs
Data memory -
Vibration resistance ≤ 300 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.3 kg
Degree of protection IP64/67
Ambient temperature ϑB -40 °C to +60 °C fixed cable installation; -10 °C to +60 °C flexible cable installation
Connection 1 m (3.3 ft) cable with 17-pin round connector

Drive Engineering – Practical Implementation – Encoder Systems 41


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
Resolver
i
P Hz

Encoder type AH7Y


For motors DR315
Supply voltage VB DC 9 – 30 V
Max. current consumption Iin 150 mARMS
Max. pulse frequency fmax 120 kHz
Periods per revolution A, B 2048
C -
Output amplitude per track Vhigh ≥ 2.5 VSS
Vlow ≤ 0.5 VSS
Signal output TTL
Output current per track Iout 20 mARMS
Mark space ratio 1 : 1 ± 20 %
Phase angle A : B 90 ° ± 20 °
Scanning code Gray code
Single-turn resolution 4096 increments / revolution
Multi-turn resolution 4096 revolutions
Data transfer synchronous-serial
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate Permitted range: 100 – 800 kHz (max. 100 m cable length with 300 kHz)
Clock-pulse space period 12 – 30 µs
Data memory -
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 2000 m/s²
Maximum speed nmax 3500 rpm
Mass m < 3 kg
Degree of protection IP56
Ambient temperature ϑB -20 °C to +60 °C
Connection Terminal strip on encoder

4.4 Resolver
Encoder type RH1M / RH1L
For motors DS / CM / CMP / CMD synchronous servomotors
Supply voltage V12 7 VAC_eff / 7 kHz
Number of poles 2
Gear ratio ü 0.5 ± 10%
Output impedance ZSS 200 to 330 Ω
Ambient temperature ϑB -40 °C to +60 °C
Connection 12 pole circular connector (Intercontec) or terminal box connection

42 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Absolute encoder with asynchronous-serial interface
f 4
i
P Hz

4.5 Absolute encoder with asynchronous-serial interface


Encoder type AS7W AG7W
For motors DR71 – 132 DR160 – 225
Supply voltage VB DC 7 – 30 V
Max. current consumption Iin 150 mARMS
Max. pulse frequency fmax 200 kHz
Periods per revolution A, B 2048
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90° ± 3°
Scanning code Binary code
Single-turn resolution 8192 increments / revolution
Multi-turn resolution 65536 revolutions
Data transfer RS485
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate 9600 baud
Clock-pulse space period - -
Data memory 1920 bytes
Vibration resistance ≤ 100 m/s² ≤ 200 m/s²
Shock resistance ≤ 1000 m/s² ≤ 2000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.4 kg 0.7 kg
Degree of protection IP66
Ambient temperature ϑA -20 °C to +60 °C
Connection Terminal strip in pluggable connection cover

Drive Engineering – Practical Implementation – Encoder Systems 43


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
Absolute encoder with asynchronous-serial interface
i
P Hz

Encoder type ES1H AS1H EK1H AK1H


For motors CMP50 / 63, CDM93 / 138, DS/CM CMP40, CMD55 / 70
Supply voltage VB DC 7 – 12 V
Max. current consumption Iin 130 mARMS
Max. pulse frequency fmax 200 kHz
Periods per revolution A, B 1024
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90°
Scanning code Binary code
Single-turn resolution 32768 increments / revolution
Multi-turn resolution - 4096 revolutions - 4096 revolutions
Data transfer RS485
Serial data output Driver according to EIA RS-485
Serial clock input -
Clock rate 9600 baud
Clock-pulse space period -
Data memory 1792 bytes
Vibration resistance ≤ 200 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.2 kg
Degree of protection IP40
Ambient temperature ϑA -20 °C to +60 °C
Connection 12 pole circular connector (Intercontec) or terminal box connection

44 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Absolute encoder with asynchronous-serial interface
f 4
i
P Hz

Encoder type AS3H AS4H


For motors DT71 – DV132S, CT71 – CV132S
Supply voltage VB DC 7 – 12 V
Max. current consumption Iin 130 mARMS
Max. pulse frequency fmax 200 kHz
Periods per revolution A, B 1024
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90°
Scanning code Binary code
Single-turn resolution 32768 increments / revolution
Multi-turn resolution 4096 revolutions
Data transfer RS485
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate -
Clock-pulse space period -
Data memory 1792 bytes
Vibration resistance ≤ 200 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.3 kg
Degree of protection IP65
Ambient temperature ϑA -20 °C to +60 °C
Connection M23 12-pole

Drive Engineering – Practical Implementation – Encoder Systems 45


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
Absolute encoder with asynchronous-serial interface
i
P Hz

Encoder type AV1H


For motors DT71 – DV225, CT71 – DV200L, DS/CM
Supply voltage VB DC 7 – 12 V
Max. current consumption Iin 130 mARMS
Max. pulse frequency fmax 200 kHz
Periods per revolution A, B 1024
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90°
Scanning code Binary code
Single-turn resolution 32768 increments / revolution
Multi-turn resolution 4096 revolutions
Data transfer RS485
Serial data output Driver according to EIA RS-485
Serial clock input Optocoupler, recommended driver to EIA RS-485
Clock rate -
Clock-pulse space period -
Data memory 1792 bytes
Vibration resistance ≤ 200 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 6000 rpm
Mass m 0.55 kg
Degree of protection IP65
Ambient temperature ϑA -20 °C to +60 °C
Connection M23 12-pole

46 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Absolute encoder with asynchronous-serial interface
f 4
i
P Hz

Encoder type EK0H AK0H


For motors CMP40, CMD55 / 70
Supply voltage VB DC 7 – 12 V
Max. current consumption Imax 110 mARMS
Max. pulse frequency fmax 65 kHz
Periods per revolution A, B 128
C -
Output amplitude per track Vhigh
1 VSS
Vlow
Signal output Sin/cos
Output current per track Iout 10 mARMS
Mark space ratio Sin/cos
Phase angle A : B 90°
Scanning code Binary code
Single-turn resolution 4096 increments / revolution
Multi-turn resolution - 4096 revolutions
Data transfer RS485
Serial data output Driver to EIA RS485
Serial clock input -
Clock rate -
Clock-pulse space period -
Data memory 1792 bytes
Vibration resistance ≤ 500 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 12000 rpm 9000 rpm
Mass m 0,065 kg
Degree of protection IP50
Ambient temperature ϑA -20 °C to +110 °C
Connection 12-pin round connector

Drive Engineering – Practical Implementation – Encoder Systems 47


kVA n What Are The Technical Data Of These Encoder Systems?
4 f
Built-in encoder
i
P Hz

4.6 Built-in encoder


Encoder type EI7C EI76 / EI72 / EI71
For motors DR71 – 132
Supply voltage VB DC 9 – 30 V
Max. current consumption Imax 120 mARMS
Max. pulse frequency fmax 1,54 kHz
Periods per revolution A, B 24 6, 2, 1
C - -
Output amplitude per track Vhigh ≥ VB -2.5 VSS
Vlow ≤ 0.5 VSS
Signal output HTL
Output current per track Iout 60 mARMS
Mark space ratio 1 : 1 ± 20 %
Phase angle A : B 90 ° ± 20 °
Data memory -
Vibration resistance ≤ 100 m/s²
Shock resistance ≤ 1000 m/s²
Maximum speed nmax 3600 rpm
Mass m 0.2 kg
Degree of protection IP65
Ambient temperature ϑA -30 °C to +60 °C
Connection Terminal strip in the terminal box or M12 (8-pin)

4.7 Proximity sensor


Encoder type NV11 NV12 NV16 NV21 NV22 NV26
for motors/brakemotors DT71 – DV132S
Supply voltage VB DC 10 – 30 V
Max. current consumption Imax 200 mARMS
Max. pulse frequency fmax 1.5 kHz
1 2 6 1 2 6
Periods per revolution
A track A track A track A+B tracks A+B tracks A+B tracks
Output NO contact (pnp)
Mark space ratio 1 : 1 ± 20 %
Phase angle A : B 90 ° ± 45 %
Degree of protection IP67
Ambient temperature ϑA 0 °C to +60 °C
Connection M12 1 connector, e.g. RKWT4 (Lumberg)

48 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Technical Data Of These Encoder Systems? kVA n
Mounting device
f 4
i
P Hz

4.8 Mounting device


Mounting device ES7A EG7A EH7A
For motors DR71–132 DR160 – 225 DR315
Mounting type of encoder Shaft centered Hollow shaft
10 mm bore 14 mm bore with M6 end Shaft end 38 mm × 116 mm
Motor shaft type
thread
ES7S EG7S EH7S
ES7R EG7R -
Suitable for encoder
AS7Y AG7Y AH7Y
AS7W AG7W -

Mounting device XV0A XV1A XV2A XV3A XV4A


For motors DR71 – 225
Mounting type of encoder Flange centered with coupling
Encoder shaft Any 6 mm 10 mm 12 mm 11 mm
Type
Centering Any 50 mm 50 mm 80 mm 85 mm
Suitable for encoder Provided by the customer or by SEW-EURODRIVE on behalf of the customer.

Mounting device ES1A ES2A


For motors DT71 – 100 DV112 – 132S
For encoder Spreadshaft encoders with 8 mm center Spreadshaft encoders with 10 mm center
bore bore

Mounting device EV1A AV1A


For motors DT71 – DV225 DY71 – 112
For encoder Solid shaft encoder (synchronous flange)
Flange diameter 58 mm
Center bore diameter 50 mm
Shaft end diameter 6 mm
Length of shaft end 10 mm
Fastening 3 fixing clamps (screws with eccentric disks) for 3 mm flanges

Drive Engineering – Practical Implementation – Encoder Systems 49


kVA n How Is The Encoder Mounted Mechanically?
5 f
Spread-shaft encoder (DR and DT/DV motors)
i
P Hz

5 How Is The Encoder Mounted Mechanically?


5.1 Spread-shaft encoder (DR and DT/DV motors)
When the encoder is mounted with a spread ahsft, there is a non-positive connection
between the motor shaft and the encoder shaft. Tightening the screw in the encoder
shaft pulls up a cone that spreads the notched encoder shaft. Thus the encoder shaft is
jammed inside the mottor shaft and transmits the rotating motion. The resulting encoder
torque is supported on the fan guard.
DR 71 – 132
DT 71 – 90
DV 100 – 132S

[1] [4] [2] [3]

[5]

2165466763
Fig. 27: Spread-shaft encoder

[1] Motor shaft


[2] Encoder shaft
[3] Screw within the encoder shaft
[4] COne
[5] Fan guard

50 Drive Engineering – Practical Implementation – Encoder Systems


How Is The Encoder Mounted Mechanically? kVA n
Plug-in shaft with end thread (DR motors only)
f 5
i
P Hz

5.2 Plug-in shaft with end thread (DR motors only)


The encoder is fixed via a combination of interference fit and thread clamping. The di-
ameter at the end of the larger bore of the motor shaft is smaller than at the guide. If you
tighten the screw in the encoder shaft, it pulls the encoder into this smaller diameter, re-
sulting in an interference fit. In addition, the thread is braced against the encoder that is
completely pulled in. Thus the encoder shaft is jammed inside the mottor shaft and
transmits the rotating motion. The resulting encoder torque is supported on the fan
guard.
DR 160 – 225

[1] [8]

[3]
[7]
[2]
[6]

[5]

2165468683
Fig. 28: Mounting on DR motor

[1] Motor shaft


[2] Encoder shaft
[3] Screw within the encoder shaft
[5] Fan guard
[6] Interference fit
[7] Thread clamping
[8] Large bore on the motor shaft

Drive Engineering – Practical Implementation – Encoder Systems 51


kVA n How Is The Encoder Mounted Mechanically?
5 f
Built-in encoder (only DR-motors)
i
P Hz

5.3 Built-in encoder (only DR-motors)


With this variant, the encoder does not have to be directly connected to the motor shaft.
The encoder module is screwed on the endshield. Cylinder head screws and distance
bushing are required for brakemotors. An additional support plate is required for size DR
112/132. In addition, a special fan with integrated magnets must be installed on the
motor shaft.
DR 71 – 132

[1]

[2]

[2]

2165461003
Fig. 29: Built-in encoder

[1] Encoder module


[2] Magnet

52 Drive Engineering – Practical Implementation – Encoder Systems


How Is The Encoder Mounted Mechanically? kVA n
Mounting device (DR and DT/DV motors)
f 5
i
P Hz

5.4 Mounting device (DR and DT/DV motors)


Instead of being connected directly to the motor shaft, the encoder is connected via a
coupling. The coupling in the motor shaft (here brakemotor) hase the same dimensions
as the conventional encoder connection (spread shaft or thread bore). The coupling half
on the encoder end is adapted to the dimensions of hte required enccoder shaft. Thus
you can install any encoder. The torque is balanced via the fan guard.
DR 71 – 225 for non-SEW encoders
DR 71 – 225 for EV7A
DV 132M – 225 for all encoders

[1]

[9]

[10] [2] [5]


2165496203
Fig. 30: Non-SEW encoder mounting device

[1] Motor shaft


[2] Encoder shaft
[5] Fan guard with encoder mount
[9] Coupling within the motor shaft
[10] Coupling half on the encoder end

Drive Engineering – Practical Implementation – Encoder Systems 53


kVA n How Is The Encoder Mounted Mechanically?
5 f
Hollow-shaft encoder (only DR 315)
i
P Hz

5.5 Hollow-shaft encoder (only DR 315)


When the encoder is connected with via a hollow shaft, the motor shaft is not equipped
with a bore. The encoder shaft is equipped with a through hole and is pushed on the
motor shaft. Depending on the encoder variant (pulse or absolute value), with or without
a sleeve. In both cases, the torque is supported via the fan guard. The figure shows both
encoder variants.

[5]

[11]

[2]
[1]
[12]

2165464843
Fig. 31: Hollow-shaft encoder

[1] Motor shaft


[2] Encoder shaft
[5] Fan guard
[11] Pulse
[12] Absolute value

54 Drive Engineering – Practical Implementation – Encoder Systems


How Is The Encoder Mounted Mechanically? kVA n
Cone shaft enccoder (CMP motors)
f 5
i
P Hz

5.6 Cone shaft enccoder (CMP motors)


5.6.1 Connection variant 1 (AK0H)
For mounting a cone shaft encoder, the motor shaft must be equipped with a tapped
hole and a suitable cone hole. The output shaft must be blocked for the assembly of the
cone shaft enccoder. Then the encoder shaft can be screwed into the motor shaft with
a special assembly device. The screws must not hook into the retaining holes of the mo-
tor. The output shaft must be released before the torque can be supported. Then the en-
coder must be turned until the screws in the mounting plate are above the retaining
holes of the motor. Then the screws must be tightened alternately. This wil release the
encoder shaft.
CMP 40 – 63

[2]

[1] [4]

[5]
[3]

2165459083
Fig. 32: Cone shaft encoder – variant 1 (AK0H)

[1] Tapped hole


[2] Cone hole
[3] Screw
[4] Mounting plate
[5] Retaining holes

Drive Engineering – Practical Implementation – Encoder Systems 55


kVA n How Is The Encoder Mounted Mechanically?
5 f
Cone shaft enccoder (CMP motors)
i
P Hz

5.6.2 Connection variant 2 (EK1H, AK1H)


For mounting a cone shaft encoder, the motor shaft must be equipped with a tapped
hole and a suitable cone hole. The output shaft must bee blocked for the assembly.
Then the encoder is pushed on the motor shaft. Tightening the screw will press the cone
of hte encoder shaft into the motor shaft. The spring plate of the torque arm is attachedd
to the endshield with 2 screws.
CMP 71 – 100

[4]

[1]
[3]

[2]

2165462923
Fig. 33: Cone shaft encoder – variant 2 (EK1H, AK1H)

[1] Tapped hole


[2] Cone hole
[3] Screw
[4] Screws on endshield

56 Drive Engineering – Practical Implementation – Encoder Systems


What Are The Setting Specifications For The Encoder Assembly? kVA n
Setting specifications for motors with HIPERFACE® encoders
f 6
i
P Hz

6 What Are The Setting Specifications For The Encoder Assembly?


Usually, synchronous servomotors are equipped with resolvers with sin/cos absolute
encoders. With the data determined by the position encoders, the servo inverter ensures
that the rotor displacement angle is 90°. However, the position encoders must be exactly
aligned with the poles of the permanent magnets. Only then can the external magnetic
field of the stator form with a 90° offset. This is also called commutation.
The commutation is performed at the end of the motor assembly. For motors with re-
solver, the stationary part is rotated mechanically accorrding to the setting specifications
before it is fixed. For motors with sin/cos combination encoders, the absolute informa-
tion is reset electrically within one motor revolution according to the setting specifica-
tions with the encoder already fixed in place.

6.1 Setting specifications for motors with HIPERFACE® encoders


Setting specification:
• Motor without load, brake released. Rotor can freely align in the stator field.
• Motor supplied with AC power (80% Io):
Motor terminal U V W
Supply Open minus plus

Rotor alings in the field.


• Encoder angle reset in this rotor position.

Drive Engineering – Practical Implementation – Encoder Systems 57


kVA n What Are The Setting Specifications For The Encoder Assembly?
6 f
Resolver setting specifications for SEW motors CM71 – 112
i
P Hz

6.2 Resolver setting specifications for SEW motors CM71 – 112

U p0

[1]

[3]

[2]

- U p0

0 α 2π
2238466955

[1] Vp(α)
[2] Vcos(α)
[3] Vsin(α)

Number of pole pairs – motor: pM = 3, number of pole pairs – resolver: pR = 1

Setting specification (see figure):


Resolver zero position [Vcos (S1-S3) pos. max., Vsin (S2-S4) pos. zero passage] coin-
cides with pos. maximum of the EMF Up in line U (with CW rotor rotation as viewed on
the input shaft end).

Adjustment check:
Motor without load, brake released
The following applies to an AC power supply (motor terminal W+, terminal V-, terminal
U open): S2-S4 (sin) pos. zero passage, S1-S3 (cos) pos. maximum
Direction of rotation check: The following applies to supply via terminals U, W+, V-: S1-
S3 pos.↓, S2-S4 pos.↑

58 Drive Engineering – Practical Implementation – Encoder Systems


What General Installation Notes Must Be Observed? kVA n
Encoder line shield on inverter
f 7
i
P Hz

7 What General Installation Notes Must Be Observed?


When connecting the encoders to the inverters, always follow the operating instructions
for the relevant inverter and the wiring diagrams supplied with the encoders.
• Maximum cable length (inverter – encoder): 100 m with a capacitance per unit
length:
• < 83 nF/km (core / core) according to DIN VDE 0472 part 504
• < 110 nF/km (core / shield)
• Core cross section: 0,2 – 0,5 mm²
• Use shielded cable with twisted pair conductors and apply shield over large area on
both ends:
– to the encoder in the cable gland or in the encoder plug
– To the inverter on the electronics shield clamp or to the housing of the D-sub con-
nector
• Install the encoder cables separately from the power cables, maintaining a distance
of at least 200 mm.
• Encoder with cable gland: Observe the permitted diameter of the encoder cable to
ensure that the cable gland functions correctly.

7.1 Encoder line shield on inverter


Connect the shield of the encoder cable to the inverter over a large area.

1866148491
Fig. 34: Applying the shield to the electronics shield clamp shield clamp

Drive Engineering – Practical Implementation – Encoder Systems 59


kVA n What General Installation Notes Must Be Observed?
7 f
Encoder line shield on encoder
i
P Hz

1866145803
Fig. 35: Shield in the sub D connector

7.2 Encoder line shield on encoder


Connect the shield of the encoder cable to the encoder over a large area.

1866163979
Fig. 36: Connect the shield in the cable gland of the encoder

60 Drive Engineering – Practical Implementation – Encoder Systems


kVA n
Terms And Definitions f 8
i
P Hz

8 Terms And Definitions

Term/abbreviation Definition/explanation
A/D converter Analog/Digital converter
DPR interface Dual Port RAM interface
DSP Digital Signal Processor
EEPROM Electrically Eraseable Programmable Read Only Memory
EMC Electro Magnetic Compatibility
High Performance Interface. Registered trademark of the company Sick Steg-
HIPERFACE®
mann GmbH.
HTL High-voltage Transistor-Logics
Multi-turn encoder Absolute position specification over multiple revolutions
NVSRAM Non-Volatile Static Random Access Memory
Reluctance Magnetic resistance
Single-turn encoder Absolute position specification over one revolution
SRAM Static Random Access Memory RAM
SSI Serial Synchronous Interface
TTL Transistor-Transistor-Logics

Drive Engineering – Practical Implementation – Encoder Systems 61


Index

Index

A O
Absolute encoder ...................................................11 Optical system .........................................................7
Absolute encoder with ASI Functional principle..............................................8
Functional principle ............................................12 Signal level ..........................................................8
Structure ............................................................11 Structure ..............................................................8
Absolute encoder with SSI Overview of encoder systems..................................5
Multi-turn encoder ..............................................15
Single-turn encoder............................................14 P
Asynchronous AC motors ......................................26 Products with their encoder systems .....................30
Asynchronous servomotors....................................26 Project planning .....................................................34

B R
Benefits of the most important encoder systems .....6 Resolver.................................................................16
Functional principle............................................17
D Structure ............................................................16
Drawbacks of the most important encoder systems 6 Rotary encoder systems ..........................................7
Rulers ....................................................................21
I Functional principle of inductive travel distance
measuring systems............................................24
Incremental rotary encoders with sin/cos tracks ....10
Functional principle of optical travel distance
Functional principle ............................................10
measuring systems............................................22
Signal level.........................................................11
Structure of inductive travel distance measuring
Structure ............................................................10 systems..............................................................24
Installation notes ....................................................58 Structure of optical travel distance measuring
systems..............................................................22
L
Linear encoder systems .........................................19 S
Barcode encoder................................................20 Setting specifications .............................................56
Laser encoder ....................................................19 Synchronous servomotors .....................................26
Rulers.................................................................21
Wire-actuated encoder.......................................25
T
Linear position detection ........................................27
Tasks .......................................................................5
Linear servo systems .............................................27
Technical data .......................................................36
ASI Absolute encoders ......................................42
M Built-in encoder..................................................47
Magnetic system ......................................................7 Incremental encoders with plug-in shaft ............36
Mechanical connection ..........................................49 Incremental encoders with solid shaft................38
Cone shaft encoder............................................54 Incremental rotary encoders with spread shaft..36
Hollow shaft encoder .........................................53 Mounting device.................................................48
Non-SEW encoder mounting device..................52 Proximity sensor ................................................47
Plug-in shaft with end thread .............................50 Resolver.............................................................41
Spreadshaft encoder..........................................49 SSI absolute encoder ........................................39
Type designation ...................................................29
Types of encoder systems.......................................5

61 Drive Engineering – Practical Implementation – Encoder Systems


SEW-EURODRIVE—Driving the world

SEW-EURODRIVE
Driving the world

SEW-EURODRIVE GmbH & Co KG


P.O. Box 3023
D-76642 Bruchsal/Germany
Phone +49 7251 75-0
Fax +49 7251 75-1970
[email protected]
www.sew-eurodrive.com

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