With this sensor integrated into the encoder, vibration data can be captured as close as possible to the motor’s location. As a result, users can gather precise, actionable vibration information based on exactly what’s happening at the motor, rather than having to infer conditions from a less localized source of data.
Since motion and vibration data from the same device are synchronized in the encoder, it’s easier to determine the vibration’s source. In contrast, with an external sensor in the inverter, the exact position information cannot be found.
Integrated diagnostics in the sensor also helps improve safety. If a sensor malfunctions, it stops and issues an alarm rather than relaying incorrect data with potentially dangerous consequences.
The vibration data also aids motor OEMs in improving the design of their systems. By analyzing data under different conditions, they can determine the conditions and parameters that enable peak performance.
The benefits of capturing environmental data
As well as gathering position data, today’s encoders can integrate additional sensors to capture other information, such as temperature or humidity. This ability reduces the need for extensive cabling for power and data, thereby simplifying design and saving space.
In addition to integrating its own sensors, Heidenhain encoders can also pass on information from external sensors to further reduce cabling and installation complexity. For example, the ECI 123 Splus supports a connected external temperature sensor.
Another advantage of integrating sensors is being able to provide streamlined data through a single connection. EnDat 3 is an interface that enables information from multiple sensors to be passed back and forth between the encoder and the control system. It helps improve the flexibility of machine architectures and reduce system costs by providing fast and dependable data transmission, with extensive diagnostic capabilities including acquisition and storage of operating status data.
In almost any industrial process, heat is a factor that must be considered and managed. For encoders, dissipating heat effectively is essential, particularly because they are often mounted directly next to the motor.
Heidenhain addresses this challenge with its fan-out technology (FOT). This FOT marks a shift in the design of how motors and encoders can be integrated with one another.
Typically, a motor is enclosed in a rectangular box. The encoder resides in this box inside its own housing. The heat generated from the motor and the encoder gets trapped inside.
To remedy this heat issue, the FOT is designed to be the motor backing as well as the encoder backing. This allows the heat to dissipate out the back, enhancing motor performance without increasing temperature requirements for the encoder.
For example, in the KCI 1318 FOT and KBI 1335 FOT encoders, which are designed for use with compact servo motors, the electronic components and conductive tracks are attached directly to a metal carrier. This means they can be used as a bearing cover, which reduces the space required and the number of parts. More importantly, it also enables direct outward heat dissipation through the metal carrier.
Jonathan Dougherty is business development manager at Heidenhain North America.
