Time and again, manufacturers discontinue certain product series. Especially when it comes to interfaces developed many years ago, maintenance and development capacities are transferred from traditional systems to the latest technologies. The development cycles of sensor manufacturers and users are not always synchronized, meaning that there is still a need for traditional interfaces that is no longer satisfied by the original manufacturers. It is also increasingly being observed that manufacturers organized in corporate structures are less and less prepared for the individual requirements of medium-sized specialist automation companies.
And what do you do when you are informed that an important component is no longer available? Either you change the rest of the technology, redesign the system or ask an experienced specialist for individual encoders for an alternative.
TR Electronic has always been known for supporting many industrial interfaces for position sensors. TR Electronic’s in-house development expertise allows it to draw on more than 40 years of experience and integrate both state-of-the-art and classic communication systems into the latest generations of devices. The mechanical connection can be adapted to existing environments with a high degree of freedom. The manufacturing technology of the medium-sized company allows production in manageable batch sizes. Quantities that are of no interest to others can be realized economically at TR.
Direct contact between the user and manufacturer is required to ensure that a solution fits perfectly into the existing application. In the best case scenario, the user receives an encoder that can be used directly as a replacement for a discontinued product. Sometimes minor modifications to the mechanics or the control system are necessary. And this new encoder will be reliably available for a long time thanks to the latest technology. And it will be suitable for the existing application.
Send us the specification of the encoder system whose discontinuation affects you!
Encoders used in industrial automation systems precisely measure and control machine movements. The two most common encoder types, absolute encoders and incremental encoders, are designed to meet different needs. In this article, we will explore what these two encoder types are, their differences, and where they are used.
What is an Absolute Encoder?
An absolute encoder is a type of encoder that generates a unique signal for each position, retaining position information even in the event of a power outage.
What is an Incremental Encoder?
An incremental encoder is a type of encoder that measures movement relative to a reference point. It loses position information during a power outage but can be reset by establishing a reference point at the start.
Differences Between Absolute Encoders and Incremental Encoders
| Criterion | Absolute Encoder | Incremental Encoder |
| Power Outage | Retains position information. | Loses position information. |
| Precision | High (unique position data). | Requires a reference point. |
| Purpose | Position tracking. | Speed and direction measurement. |
| Cost | Higher. | More cost-effective. |
| Installation | Complex. | Simpler. |
When Should Each Encoder Be Used?
Conclusion
Absolute and incremental encoders are powerful tools designed to meet different needs. Selecting the right encoder enhances system performance while optimizing costs. As the Turkey and Middle East distributor of TR Electronic, Üniversa offers a wide range of products tailored to your applications.
For more detailed information, contact us and find the most suitable encoder solution for your needs!
A safety encoder is a type of encoder designed to meet safety requirements, certified according to functional safety standards such as SIL (Safety Integrity Level) or PL (Performance Level). They are especially used to enhance both system and operator safety in hazardous environments or high-risk operations.
Advantages of Safety Encoders
Applications of Safety Encoders
Points to Consider When Choosing a Safety Encoder
To select the right safety encoder, consider the following:
Conclusion
Safety encoders are specialized sensors designed to meet high safety requirements, ensuring the protection of both operators and machinery. As the Turkey and Middle East representative of TR Electronic, Üniversa offers a wide range of safety encoders that comply with SIL and PL standards, providing the most reliable solutions for our customers.
Contact us for detailed information and to select the most suitable encoder for your projects!
Encoders are essential components in industrial automation, frequently used in systems requiring precise measurement and control. In this article, we explore what encoders are, how they work, and key considerations for selecting the right encoder for your application.
What is an Encoder?
An encoder is a sensor that converts mechanical motion into electrical signals. These sensors are primarily used to measure the position, speed, or direction of a rotating shaft. In the industry, there are two main types of encoders: rotary encoders (measuring rotational motion) and linear encoders (measuring linear motion).
Rotary encoders measure the angular position of a rotating shaft and are divided into the following types:
Linear encoders are used to detect movement along a flat surface. They are commonly employed in CNC machines and precision measurement devices.
What is the Purpose of an Encoder?
Encoders provide precise control by monitoring the movements of machines. Some common applications include:
Key Points for Encoder Selection
Choosing the right encoder directly impacts system performance. Here are key considerations for selection:
Conclusion
Encoders are indispensable components in industrial automation, enabling efficient, safe, and precise operations. Selecting the right encoder ensures improved performance and reliability of your systems.
For more information on encoders or to find the best solution tailored to your needs, TR Electronic’s Turkey and Middle East distributor Üniversa is here to assist you with our expert team.
Contact us to discover our specialized solutions for your projects!
At TR Electronic, we love our encoders. That’s why we naturally want to protect them from loads that would ultimately lead to failure or even destruction. And this is also very much in the interests of users who want to be able to rely on the function of standard and safety encoders from TR Electronic for many years.
Two important parameters for robustness are the permissible shock and vibration load. The corresponding tests are standardized so that values can be compared across manufacturers. If users adhere to these boundary conditions, they can assume that the encoder will reliably deliver the process-relevant measured values in the long term. Of course, the basic load can be reduced considerably with a good design. Some things can also be achieved through additional measures such as attachment bearings and couplings with damping elements. However, a rotary encoder that is already robust in itself makes it much easier to use.
New test procedures and equipment at TR Electronic have proven that TR’s encoders are more robust than previously published. According to DIN EN 60068-2-27, the characteristic value for the permissible shock load for a CEV582 with PROFINET interface was 1000 m²/s (i.e. 100 times the acceleration due to gravity), previously with an exposure time of 11 ms for a half-sine shock. It has now been possible to tighten the specification for the duration of impact from 11 ms to 6 ms. A look at signal theory explains why the smaller number means a tightening of the condition. When testing a shock, an attempt is made to simulate the ideal shock (“Dirac impulse”). Of course, this is not possible in reality, but the shorter the exposure time, the steeper the edges of the real sine half-wave and thus also the force effect caused by this shock on the components in a rotary encoder. An albeit inadequate, but nevertheless helpful comparison could be: In the case of a punch, it is not only the force applied that is decisive. The faster the blow is delivered, the harder it is felt.
By testing the entire series with the new test systems, the permissible conditions for the 582 (solid shaft, blind hole shaft and hollow shaft), 802 (hollow shaft up to 25 mm) and 1102 (hollow shaft up to 50 mm) series devices have been tightened, giving users more freedom when selecting possible operating conditions.
With the 75 mm safety encoder, TR Electronic was the first manufacturer to offer the safe version of the innovative EtherCAT bus system for absolute encoders for SIL3 applications. Now that certification has been successfully completed by the ETG in cooperation with TÜV Süd, FailSafe over EtherCAT is also available in the latest CD_582 encoder series with a nominal diameter of 58 mm. The implementation was a straightforward development process for the medium-sized company in Trossingen, which is experienced in the development and production of safe encoders. The FSoE implementation in the CD_582 absolute rotary encoder distinguishes itself from other safe interfaces with a number of unusual features. For example, the absolute rotary encoders with FSoE only need 5 seconds from applying the supply voltage until the first secured position telegram is available via EtherCAT. Controllers with FSoE are available from various manufacturers, giving users access to a broad, reliable basis of available automation platforms. The CD_582+FS ECT has been successfully tested directly on many of these controllers.
Like all SIL encoders, the FSoE encoders from TR Electronic are ideally equipped for the new Machinery Directive. Type examination reports are available and the necessary steps for cyber security have been taken so that cyber security certification can be completed once a harmonized standard is available.
Modernizing existing presses while retaining most of the machine’s functionality is known as a retrofit. The machine itself is retained, but the control technology is usually revised or replaced. This fulfills new safety standards and increases flexibility and throughput.
Acyclical investment in press retrofits provides companies with a strategic opportunity to exploit economic advantages. This is especially true in times of economic uncertainty or slowdown. A retrofit offers considerable fiscal, commercial and technical advantages. Compared to a new purchase, a retrofit not only reduces costs, but also improves the efficiency and productivity of the systems.
Retrofit projects are usually characterized by lower acquisition costs compared to new machines. The higher costs for a completely new investment are eliminated, which leads to increased cost efficiency. Retrofitting also reduces the amount of training required, as the modernized system is similar in its basic features to the existing machines, which minimizes training costs. The shorter downtimes of on-site retrofitting are a further advantage, as they ensure a continuous production flow.
Modernizing a machine through a retrofit project extends its service life. This is a considerable improvement, not least from the point of view of sustainable use of resources. Older systems can be technologically upgraded through targeted interventions and thus brought back up to date. This increases planning and operational reliability and makes the machine usable for many years to come. Keywords such as cost efficiency, staff retention and planning reliability underline the commercial benefits of retrofitting.
A retrofit can be particularly attractive from a tax perspective, as it is possible to deduct the full amount of the expense directly. This reduces the taxable profit and therefore the tax burden. In addition, the planned retrofit can be realized via leasing or financing models, which expands the company’s financial scope and makes the investment process more flexible.
From a technical point of view, a retrofit significantly improves the availability and efficiency of machines, as modern components and monitoring systems can be integrated into the existing system. New technologies such as envelope curve monitoring and condition monitoring enable precise control and monitoring of machine conditions. The introduction of modern process monitoring and diagnostic tools increases product quality, as problems can be identified and rectified more quickly. A retrofit also enables the conversion to energy-efficient systems, such as the replacement of servo drives or hydraulic components. This not only increases productivity, but also reduces the operating costs and energy consumption of the machines. Other technical benefits include retrofitting current safety equipment, meeting new standards and optimizing user-friendliness through new control concepts. These measures mean that the machines can be better integrated into modern automation systems, making the production process more efficient overall.
There are currently particular opportunities for retrofitting, as the delivery times for new machine components are significantly shorter than in previous years. Companies therefore have the opportunity to carry out retrofits quickly and efficiently. In addition, economically uncertain times make anti-cyclical investments particularly attractive. While many companies are reluctant to make major investments, targeted modernization of existing systems can secure long-term competitive advantages. The current economic conditions require companies to be adaptable, which is ideally supported by retrofit projects. Production processes can be stabilized and optimized, which increases efficiency and reduces costs. Right now, energy optimization is crucial to counteract rising energy costs and improve the sustainability of production facilities.
Anti-cyclical investment in retrofitting presses is a future-proof strategy. Retrofitting helps companies to bring their production systems up to the latest state of the art and save costs at the same time. The combination of fiscal, commercial and technical benefits, as well as the ability to seamlessly integrate existing systems into modern production environments, makes retrofitting an attractive option. Particularly in economically uncertain times, this investment strategy can offer decisive competitive advantages and contribute to the long-term stability of the company.
TR-Automation has extensive practical expertise in retrofitting, modernizing and overhauling machines and systems in the press shop: TRsystems Automation supports users in bringing outdated presses, press lines, blank loaders, coil lines, automation systems and hydroforming systems back up to the latest state of the art. After analyzing the current condition of press machines and systems, TRsystems Automation advises on the necessary modernization measures and carries them out with experienced experts.
In standard applications, interface cables are routed directly to the encoder. For encoders with Industrial Ethernet and an additional direct interface, this can be up to four cables (network with forwarding, power supply, etc.). If space is very tight at the installation site, this can present a challenge. It is not uncommon for the union nuts of several M12 connectors to have to be tightened by hand or with special tools, which requires that there is sufficient room to move on the side with the connectors. With the freedom of choice for axial and radial connection fields in TR encoders, some of the situations can be mitigated, but sometimes there is simply no space for standardized bus cabling directly on the shaft, motor or measuring wheel. TR Electronic now offers a solution for this with the “Compact Interface Box” CIB2X: the encoder and interface box are mounted separately from each other and connected via a single cable. The interface box is therefore located where the required cables have sufficient space for routing and installation. As the encoders only require one cable, the installation space can be much more compact.
Several use cases are planned:
Particularly harsh environmental conditions have always been popular areas of application for rotary encoders from TR Electronic. Reinforced bearings and additional housing layers make the encoder almost impervious to external mechanical influences. At the same time, preassembled cables, especially with M12 connectors, are becoming increasingly popular. What is very practical and effective for normal environments can quickly lead to headaches in adverse conditions – an M12 connector is not particularly resistant to mechanical influences. Sometimes these different requirements come together: SIL encoders (CD_582+FS series from TR Electronic), increased forces on the shaft, risk of mechanical impacts on the housing and the desire to use preassembled cables. This requires a special solution.
With the new version of the protective housing with an outer diameter of 115 mm, TR Electronic has achieved precisely this feat.
The proven mechanics of the 115 protective housing offer a reinforced mounting flange and a robust mounting foot. Forces acting on the shaft are dissipated into the flange by two strong bearings. The internal rotary encoder is shielded from harmful influences by the surrounding continuous cast aluminum housing with a wall thickness of 20 mm.
Inside, there is space for an almost standard safety encoder from the CD_582 family. This series offers functional safety for applications that require SIL2 / PLd or SIL3 / PLe. The CD_582+FS series offers the following communication interfaces: PROFINET / PROFIsafe; Functional Safety over etherCAT; CIPsafety over Ethernet/IP, openSAFETY over Powerlink and CANopen safety. The shaft of the protective housing and the encoder are connected with the TR-specific claw coupling. This offers the precision of a solid shaft with the compact dimensions of a blind-hole shaft. In addition, the claw coupling is form-fit, which is an advantage for safety
applications and may even be necessary depending on the required safety level. A damping element protects the encoder from the last vibrations of the protective housing shaft. This connection is tried and tested at TR and was taken into account in the certification of the encoders.
The innovation in the new protective housing version lies in the connection bell. This can be opened completely by the user and thus provides direct access to the M12 connections of the encoder. Preassembled cables for incoming and outgoing bus and supply voltage are routed individually through the open sealing assembly. TR Electronic and ultimately the users rely on a proven brand product that offers suitable sealing adapters for various cable diameters. The cables are connected, the connection bell is screwed on and the seal assembly is mounted and clamped. The rotary encoder is thus fully protected.
Thanks to the use of pre-assembled cables, the connection does not require any special skills when connecting the usually very compact connectors in the field. The internally installed rotary encoder offers the tightness of a CDV582+FS even when the protective housing is open, so that the protective housing can also be opened for cabling in dusty environments.
Of course, the new protective housing is not only suitable for the safe encoders of the CD_582+FS series; all encoders of the 582 series (single scanning C__582, redundant CR_582) benefit from the new protective housing version – because pre-assembled cables are not only used in connection with functional safety and thus encoders are connected in harsh environmental conditions.
For many years, TR Electronic has been pursuing the strategy of making TR’s robust encoder technology available for applications that require functional safety in accordance with SIL2 / PLd or SIL3 / PLe. The innovative CD_582 series offers safe absolute encoder values via PROFInet/PROFIsafe, FailSafe over EtherCAT, Powerlink openSAFETY, CIPsafety over Ethernet/IP and CANopen safety in the standard installation space of 58 mm encoders.
Both the safe encoders and the machines and systems in which these devices are used are generally currently subject to the Machinery Directive that has been introduced. The transition period for the new Machinery Directive (2023/1230) will now expire shortly. TR Electronic components are ideally prepared for this change. For example, the encoders have the necessary EC type examination certificate, which is then included in the overall assessment of the system or machine. Users can obtain all the necessary documents directly from the TR Electronic website based on their article numbers; this means that the documentation requirements can be met with a manageable amount of effort.
TR is also working continuously to meet the requirements of IEC 62443 for cyber security and will achieve the legally required certification for operational technology components by the target date of 2027. The various requirements and attack scenarios are already being taken into account in all developments and the corresponding risk assessments have shown that the series currently being delivered already meet many of the conditions. Of course, TR (like many of its market competitors) hopes that the relevant standard will soon be harmonized so that it can also serve as a binding basis for certification.
The fact that Siemens, for example, has created an application note for the connection of F encoders to an F controller based on the PROFInet/PROFIsafe CD_582 EPN+FS encoders also shows how standard setting TR Electronic’s work is.