Redundant Encoder Options

In the world of rotary encoders, modern non-contact sensing technologies and high MTBF (Mean Time Between Failures) specifications are standard. However, in critical applications, redundant sensors are still a necessity. When selecting a solution, several criteria need to be considered, and fortunately, various options are available to simplify the task.

Understanding Redundancy in Encoders

The first consideration is the level of redundancy your sensor requires. Does it need complete redundancy, where all electronics and mechanical components are duplicated? Or can it suffice with electronic redundancy using common mechanics, which simplifies installation and reduces costs? Zettlex’s INC-10 ‘Duplex’ IncOder offers a hybrid solution. It nests a smaller IncOder within a larger one, creating two fully redundant sensors sharing a mechanical housing but nothing else.

Addressing Mechanical Constraints

Purchasing two standard standalone encoders is often the most economical option but can add installation complexity. For example, in end-of-shaft installations, there is only one ‘end-of-shaft,’ necessitating a gear or other mechanical modification to install two encoders. In such scenarios, a through-hollow encoder can be placed over the shaft, and the traditional end-of-shaft can be used at the end. Netzer’s DS series rotary encoders, with their small form factor, are ideal for pairing with a shafted encoder.

Evaluating Different Technologies

Each encoder technology—optical, magnetic, inductive, capacitive—has its own strengths and weaknesses. In some applications, designers incorporate two different technologies into a design to mitigate potential weaknesses. POSITAL combines optical and magnetic platforms into one shafted encoder, ensuring straightforward installation while providing full electrical redundancy.

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