What is a Safety Encoder?

 

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.

  • How Does It Work?
    Similar to traditional encoders, safety encoders measure speed, direction, and position. However, they process this data using dual-channel outputs or integrated diagnostic systems to increase reliability. If an error is detected during operation, the encoder generates a signal to halt the system. This provides a certified and fully secure, cost-effective alternative to uncertified safety systems created with mechanical cam switches and multiple encoders.

Advantages of Safety Encoders

  1. High Safety Standards
    • Compliant with industrial safety standards such as SIL 2/3 or PL d/e.
    • Includes mechanisms to transition the system to a safe state in case of malfunctions.
  2. Operator and System Safety
    • Enhances the safety of personnel and equipment.
    • Helps prevent accidents and equipment failures.
  3. Accurate Data Provision
    • Delivers precise position, speed, and direction data.
    • Ensures maximum data security with dual sensors or redundant systems.
  4. Improved System Performance
    • Enables more reliable operation, reducing downtime.
    • Offers rapid response mechanisms in emergencies.
  5. Durability and Longevity
    • Designed to operate in challenging environments.
    • Resistant to dust, moisture, vibration, and temperature fluctuations.

Applications of Safety Encoders

  1. Press Machines
    • Used to ensure operator safety during cutting, shaping, or assembly processes.
    • Provides emergency stops with fast response times.
  2. Robotic Systems
    • Ideal for the precise control and safety of robotic arms.
    • Contributes to collision avoidance and boundary-limiting mechanisms.
  3. Elevator and Crane Systems
    • Ensures safety by monitoring speed and position in weight-bearing and motion control systems.
  4. Stage Systems
    • Delivers maximum safety in stage mechanics systems.
  5. Automotive Production Lines
    • Supports the reliable operation of assembly robots and transport systems.
  6. Food and Pharmaceutical Industries
    • Stainless steel hygienic models support safe production processes.
    • Provides maximum safety in critical applications.

Points to Consider When Choosing a Safety Encoder

To select the right safety encoder, consider the following:

  1. Safety Certifications
    • Ensure the encoder meets the required SIL or PL level for your application.
  2. Environmental Conditions
    • Choose a model resistant to factors such as operating temperature, humidity, and vibration.
  3. Connection Type
    • Select an encoder compatible with your system protocol (e.g., PROFIsafe or EtherCAT).
  4. Resolution and Precision
    • Determine the resolution required to meet the application’s accuracy needs.

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!