What Makes a Multiturn Encoder Reliable?

Industrial position encoders that break mid-cycle will result not only in lost time but also in lost accuracy for an entire production line. Likewise, the reliability factor primarily hinges on the core hardware-based turn counting, followed by key resistance to electrical noise and, in the case of a multiturn absolute encoder, robust environmental sealing. 

However, when the key function of the multiturn encoder is taken into account, accurate tracking and substantial retention of position across multiple shaft rotations are important considerations. At Briter Encoder, the key question of reliability is not a promotional line but is engineered into multiturn encoders, which we build from the gear train to the communication protocol. 

Why do multiturn encoders use mechanical gears instead of a battery for turn counting?

At Briter Encoder, the mechanical gears absolutely matter. The gears eliminate the need for batteries in multiturn encoders, thereby preventing the core risk of position loss and reducing the cost of periodic battery replacements. 

The design philosophy behind Briter Encoder is why mechanical gear multiturn encoders are more reliable than power-operated encoders. Further, during the loss of power, no power will be expended by the core gear-based turn counter. Here are the other key factors that are taken into consideration:

• No battery signifies no scheduled set of replacement, and thus there would be no chance of leakage followed by loss of information even if the battery cell dies
• The mechanical gears can physically retain the turn count during power, unlike the battery-backed memory 
• Fewer components, and thereby fewer levels of failure, which points to a harsh industrial ecology. A major rationale for the key choice of this architecture

Thus, even if your battery dies, there would be no loss, and thus thriving cost-effectiveness. This is the key reason as to why mechanical gear multiturn encoders are more reliable than battery-powered encoders.

Also read: Fuel Up The Accuracy With Multiturn Absolute Encoder

Does a multiturn encoder lose its position data after a power outage?

No. A multiturn encoder does not effectively lose its key position data during a core power outage. On the other hand, it enables instant tracking and retention of its exact angle and the number of full rotations, which means you do not need to re-home your machine. 

A one-turn or continuous-scale encoder can only provide an indication of position over one turn and starts counting at zero each time, so it cannot be used in a cumulative movement application. Thus, to answer the question of how multi-turn absolute encoders retain position after a power failure, a multi-turn absolute encoder is, on the other hand, capable of counting revolutions indefinitely, so it does have an unambiguous advantage in terms of reliability in long-run industrial applications. 

It takes the mechanical turn counting to new heights with Briter Encoder’s multi-turn technology, which offers a combination of mechanical turn counting and high-quality housings to result in a dependable device that would otherwise have to be reset continuously or have a separate counter available to keep it accurate in the case of a single-turn range.

What is the difference between multiturn and single-turn absolute encoders in terms of reliability?

When comparing single-turn and multiturn encoders, a multiturn encoder is more suitable, especially for applications that exceed one full revolution, since it typically tracks total position in hardware and helps prevent system downtime. Here are the specific lines of distinction between a single-turn and a multiturn encoder:

Single Turn

• Reliable for short stroke
• Has a limited range of applications
• Lacks a complex set of multirevolution counting hardware

Multiturn

• Reliable for the large travel systems
• Eliminate the requirement to run a complex and time-consuming homing sequence 
• Accurately count and even remember the full rotations and their number

Thus, Briter Encoder’s multiturn range effectively extends this advantage by further combining the mechanical turn count with the robust housing.

How many years or duty cycles does a multiturn absolute encoder typically last before failing?

A multiturn absolute encoder typically lasts 5 to 15 years before failing, since it often uses contactless sensing. Measuring factors like build quality, environment, and duty cycle, longevity of the multiturn encoder relies on the design, but can last a long industrial lifespan. 

Here are the aspects that are taken into consideration:

• Generally, equipment-based counting systems do not require any battery and last for several years of continuous use instead of a battery-supported system
• Vibration, dust, and moisture resistance features are beneficial in harsh conditions such as wind turbines and CNC machines, providing extended useful life 
• Reliable protocol support such as RS485, CANopen or SSI ensures integration wear is kept to a minimum as well

At Briter Encoder, our multiturn encoders are designed to operate in just those environments, which means operators will enjoy steady performance over the years rather than needing to replace encoders annually.

Conclusion

A highly reliable multi-turn encoder depends on a few considerations, such as mechanical gear-driven counting, memory retention during power-off, advantages over single-turn encoders, and robustness to durability and extended duty cycles. All of these make a reliable industrial position encoder, rather than a letdown when you need it. 

Are you ready to upgrade to a tried-and-tested multi-revolution encoder?  Contact us today at +86 176 6528 0977 to learn more about Briter Encoder’s full range of multiturn absolute encoders. It is more than a choice; it is an imperative for accuracy, reliability, and value.

FAQs

1. What is the accuracy of a multiturn absolute encoder?
   A multiturn absolute encoder reports absolute angular position with high accuracy. This is critical for both single-turn and multi-turn applications in precision motion control such as CNC machining and robotics.
   
2. How are multiturn encoders tested before they are shipped?
   The durability of a multiturn absolute encoder and its associated gear-counting mechanism, as well as the housing, is tested through vibration, ingress protection, and endurance tests to simulate the worst-case conditions encountered in an industrial environment.
   
3. Will I be able to use my existing industrial control system or PLC with a multiturn absolute encoder?
   Yes, multiturn absolute encoders can operate over standard industrial protocols such as RS485, Modbus RTU, CANopen, and SSI, so integration with your current PLC or industrial control system is straightforward.