Module 1.1 IF Positioning Measurements

Electric Drives The training course
Fundamentals of electric drive technology

Positioning measurements
Information Section
Module 1.1 IF Part Positioning measurements
Release 1
Thank you.
Subjects of this presentation:

Terms and methods for positioning measurements
Methods classification
Resolution
Potentiometer systems
Magnetostrictive systems
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol
Basic physical-technical principles

Terms and methods for Positioning measurements

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol
Basic physical-technical principles Methods and terms

Objetive of position measurement
Measuring are performed to get information on:
• stroke
• velocity
• acceleration / deceleration

Controller
Position Position Speed Speed Current Current

setpoint setpoint setpoint
(1 ms active) controller controller controller Power section
(500 µs) * (250 µs) * (125 µs) *
Actual position value Actual speed value Actual current value
* Time specifications refer to CMMP-AS controller
Motor
Encoder


Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Classifications of measuring methods
Measuring methods are generally classified according to

the following criteria:
• Measurement recording - direct

- indirect
• Measurement principle / - mechanical

Signal generation - electrical
- optical
- magnetic
- inductive
- acoustic
- ...
• Signal type - analogue

- digital
• Frame of reference - absolute

- relative


Spindle drive:
rotary drive motion
for linear movement of the armature Indirect measurement recording
If the measurement is not taken directly, but by

measuring an auxiliary dimension, this is an indirect
measurement recording.
Indirect measurement is especially beneficial, for

example, with very short or very long lengths, angles,
Encoder speeds, etc.
Advantage: - usually significantly less costs

than for a direct measurement as
the material measure can be
Principle of measurement : chosen almost arbitrarily.
rotating increment disk of the integrated encoder
The linear motion of the slider is recorded and calculated via angular steps of the encoder Disadvantage: - increased calculation complexity
disk. when determining the result
- smallest manufacturing precision
can lead to significant measuring
errors of the auxiliary dimension
Indirect measurement recording


Direct measurement recording
Direct measurement is - the corresponding sensor has

the same properties as the dimension to be measured.
Sensor cables
Advantage: - low error rate thanks to simplest
value allocation
Sensor
Disadvantage: - high installation complexity e.g. to

avoid misalignment
- high costs as the material

Principle of measurement : measures (sensor of the
Magnetic tape measuring system) have to have the same
dimensions as the dimension to be
The length of the magnetic tape corresponds to the real
stroke length.
measured
Direct measurement recording



Principle: magnetic
Materialisation: magnetic strips
Signal generation: e.g. Hall sensors Typ of measuring system/ - mechanical
Signal generation - electrical
Hall sensor - optical
- magnetic
Magnetic tape - inductive
- acoustic
To generate measureable dimensions, numerous physical

Segment effects and their combinations are used.
wheel
Important properties regarding the dimensioning:
- scale: µm, mm or m range …

- speeds, number of revolutions…
- maximum values: m, km …
Inductive proximity sensor
Importants properties regarding the data processing:
- maximum speed of the signal processing,

- type of signals,
Principle: mechanical/inductive: - required calculation precision, etc.
Materialisation: segment wheel
Signal generation: e.g. with inductive proximity sensor

Analog value Digital value
Accept any value within certain limits – Can only accept specified value levels.
haven’t any value classifications. These values change stepwise only.
These values are continuously variable.

Digital Terms
Digital values can only accept specified value levels –

that means – these are stepped values.
There are several codes to represent these values,

e.g. binary, octal, etc.
Binary values or signals are digital values which can

take on two (bi) value levels.
e.g. 0 and 1
Increments are binary signals with the values

0 or 1. If the prefixes of the signals are taken into
account, increments will be counted positively and
decrements negatively.

Analog - Digital Converter
Analogue and digital values can be converted into the

other respective format. This is done using a so-called
analogue/digital converter
(A/D converter or D/A converter).
The resolution is the amount of steps on the y-axis (U),

The sampling rate is the distance of the time steps on the
x-axis (t).
Both of them affect the quality of the digitized signal.


Types of measurement signals - absolute

- incremental
Absolute positions:
defined position – no homing necessary With absolute systems
all signal values refer to one exactly fixed position.
- no homing necessary
- system switch-off don't effect the position value
With incremental sytems
the system just counts increments (single steps).

A single increment does't indicate a defined position.
- homing necessary
- system switch-off leads to a loss position value
(restart with homing)
Just an increment:
no defined position without homing

Types of measurement signals - absolute

- incremental
With absolute systems

Absolute encoder
Servo motor all signal values refer to one exactly fixed position.
The “GPS system”
You always know your position wherever you are - no homing necessary
Advantage: no homing required.
- system switch-off don't effect the position value
With incremental systems
Incremental encoder the system just counts increments (single steps).

Stepper motor A single increment does't indicate a defined position.
The “step counter”
To know where you are, you must know
where you started from. - homing necessary
Homing required - system switch-off leads to a loss position value
(restart with homing)


20 mm
Absolute values
Types of movements - absolute
60 mm - relative
Absolute movements
permanently fixed reference point always refer to a reference point which is permanently
stored in the system.
30 mm
Relative movement
20 mm
Relative values refer to a reference point in the system which can

25 mm
change.
changeable reference points


Resolution

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

The resolution...
The resolution of displacement encoders is the

specification of the smallest detectable or measureable
Direct counting of the increments. value.
The resolution, here for example, is
500 increments per revolution. The value depends on two principle factors:
The individual value is thus: - on the technology and sensor systems of the
measurement recording - e.g. a
360°/500 increments = 0.72°
magnetic strip with Hall sensors and
- the technology to process the measured values

with specific evaluation and
calculation algorithms.
Increment disk
Light barrier for

The measurement unit of the resolution value can be
impulse recording
done either
- with a direct reference to the measured value:

e.g. 200 impulses/revolution or
- as a bit value from an analogue/digital conversion

or for a binary value or signal output
of the measurement system
e.g. 255 steps/revolution corresponds to 8 bit

The resolution...
The resolution of displacement encoders is the

specification of the smallest detectable or measureable
value.
Area 5: 6.25 …7.5 V
The value depends on two principle factors:
Voltage - on the technology and sensor systems of the

Binary measurement recording - e.g. a
number magnetic strip with Hall sensors and
Area - the technology to process the measured values
with specific evaluation and
Path
calculation algorithms.
Example: The measurement unit of the resolution value can be

Resolving an analogue value (exit voltage of a potentiometer for positioning
measurement) with a resolution of 3 bit.
done either
3 bit, that is, 3 representable positions of a binary number, mean 8 represent-able - with a direct reference to the measured value:
numbers, being 0, 1, 2, 3, 4, 5, 6 and 7. The total measureable area is segmented e.g. 200 impulses/revolution or
into these 8 sub-areas.
The resolution here is

- as a bit value from an analogue/digital conversion
10 V/8 areas = 1.25 V per area or or for a binary value or signal output
200 mm/8 areas = 25 mm per area. of the measurement system
e.g. 255 steps/revolution corresponds to 8 bit

The resolution...
can be increased electronically by using additional

signal evaluations.
X - track
Y - track
X - track: normal increments

additional signal track
Y - track: additional increments

¼ period phase shift to X - track
signal X - track
for direction detection
signal Y - track for additional resolution
Additional
signal track: Signal is created at every switch
additional signal of the X - or Y - track from 0 to 1
or 1 to 0.
Just an short impulse at every

rising or falling edge of
X- or Y - track.

The resolution...
1 2
can be increased electronically by using additional
signal evaluations.
Please use the slider on the module which belongs to the

workshop material:
1 X - track changes from 0 to 1

additional signal is created
3 4
2 additional signal is switched off
3 Y - track changes from 0 to 1

5 6 5 X - track changes from1 to 0

……


Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol
Basic physical-technical principles Important displacement encoders

Conductive
strips
Potentiomenter systems...
analogue, absolute
Armature with
sliding contact
• consists of a plate on which a layer exists as an
electrical resistor. The armature splits this resistor
into two sub-resistors.
This creates a voltage separator whose

Resistance material partial voltage can be used as an analogue
signal for positioning measuring or
position specification.
B A C
A
B
C
B A C U1/U = R1/(R1 + R2)
Assembly of the displacement potentiometer


Potentiomenter systems...
analogue, absolute
1
U1/U • The resistor needs to exhibit as linear a behaviour

in regard to the sample length as possible and
linear
only
show low temperature fluctuations.
logarithmic
• The resistor can be applied to a carrier
exponential material consisting of a rod or a wire coil.
0.5 • When switching on, the exact position is

immediately visible.
• There is a mechanical connection between

the measuring tap and the resistor, which keeps
the system sensitive to dirt and wear.
• For the most part, potentiometers are not sensitive

to electromagnetic interference fields.
0 50 100
Position of the armature
as % of the maximum length of the measuring system
Resistor material properties



Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Magnetostrictive systems …
analogue, absolute
• Uses different forces of magnetic fields.
• The positioning encoder is a free-moving

permanent magnet.
This enables contact-free measurement free of

Signal converter: wear and tear.
live coils around the
waveguide
• Basic parameters:
- resolutions up to the area of 1 µm

- very good linearity of +/- 0.02% of the
measurement area
- traverse speeds of up to 10 m/s
Field generator:
Copper wire
• Magnetostrictive systems are absolute encoders,
and as such do not need a reference run after
Position encoder:
being switched on.
Armatures with permanent
Measuring element: magnet
Magnetostrictive waveguide • Since the actual measurement value needs to be
calculated from the sensor signal, the evaluation
is
Magnetostrictive measuring system bound to the corresponding control technology.

analogue, absolute
• Step 1: start of measurement
An electrical pulse briefly generates a magnetic

field around the copper wire.
Magnetic field around the copper wire
Simultaneously, the electrical pulse starts
a time measurement.
Electrical impulse
Field generator:
Copper wire
Magnetostrictive measuring system


analogue, absolute
• Step 2: generating the micro-mechanical wave
A micro-mechanical wave arise in the waveguide

at
distribution of the wave the point where the magnet fields of the copper
wire and the permanent magnet overlap. There it
spreads out at ultrasonic speed on both sides of
the waveguide.
mechanical wave

analogue, absolute
• Step 3: detection and time measurement
As soon as the mechanical wave reaches the area

of the coil, it will detect the motion through the
wave. The generated signal ends the time
Coil for detecting the wave
measurement started in step 1. The position of the
armature is calculated from the speed
of the mechanical wave and the measured time.


Magnetical systems

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Magnetically incremental systems

incremental, relative
Hall Sensors in the sensor head

• Via Hall sensors, sine wave-form signals are
on the moved armature recorded from the poles of the magnetic fields.
• The system works maintenance-free and

wear-free.
• Since it is a direct measurement, possible

errors, e.g. in spindle increases, don't affect
the measurement result.
Magnetic tape along the path to be measured


Magnetically incremental systems
• input signals analog from Hall sensor
• analg / digital signal converting
• detection of position, speed and direction

Sensor housing Hall sensores
Magnetic fields
Magnetic tape
v1 v2
0
Direction detection

Optical systems

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Photo sensors
CCD camera also possible as alternative Optically incremental systems...
• recording the traverse paths and the movement

direction with increments along a path
• additional reference markers enable

absolute position recording
• if the system is sealed the speed is limited

to approx. 2m/s
Aperture
Code ruler
Glass scale up to approx. 4 m • Accuracy:
Lens with infrared light Metal strip up to approx. 30 m
- glass scales approx. 1 - 3 µm
- metal strips approx. 15 µm
• Repeat accuracy: approx. +/- 0.1 µm
• Speeds: up to approx. 10 m/s
Increment groove • Caution:

e.g. chrome engraving on glass
Reference markers mounting tolerances, flatness of the
assembly area, vibrations, thermal influences
Glass scale - optical, incremental: Transmitted light method
*

Photo sensors
CCD camera also possible as alternative Optically incremental systems...
• Optically incremental systems can be used

in two methods:
Transmitted light
method
• Transmitted light method
The ray of light of the IR-LED shines through a

Aperture line aperture and the line splitting of the code
Glass scale
ruler
(e.g. glass scale).
• Reflected light method
The light of one or more IR-LEDs shines through

Reflected light
method
a line aperture and is reflected on the surface
of the code ruler (e.g. metal strip) in the direction
of a photo sensor.
Photo sensors
Metal strip

Optically incremental systems...

• To record the rotary movements or

Increment disk
angle positions, etc., increment disks
can be used.
• an increment disk runs through

Light barrier a light barrier
With electronics
• e.g. 500 increments/revolution
• Direction signal
Increment disk
• Revolution signal, zero impulse
• with Festo only in the Servo Lite system
LEDs
for scanning the grooves
Light barrier, receiver section


Revolution signal Optically incremental systems...

“Zero impulse” Start signal incremental, relative
Direction signal
• To record the rotary movements or
angle positions, etc., increment disks
100 increment gaps
3.6° steps can be used.
• an increment disk runs through

a light barrier
500 increment gaps
0.72° steps • e.g. 500 increments/revolution
• Direction signal
• Revolution signal, zero impulse
• with Festo only in the Servo Lite system
Original disk of a Festo step motor


Inductive systems

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Inductively incremental systems...

Segment wheel
Magnetic field
• use a high-frequency electromagnetic
field. This field is altered if metallic
objects are present. This change is recorded by
a sensor and converted into a signal.
• The material measures are ferromagnetic

bodies with a coding made of depressions,
gaps and elevations.
• The sensors are inductive switches.
Inductive sensor
Metal strip
with cut-outs
Sensor head with inductive sensors

for detecting code patterns

Encoders

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Inductive-digital incremental systems...

• Standard: single-turn, absolute

Rotor Stator
262,144 values/rev.
corresponds to 18-bit resolution
• Option: multi-turn, absolute

Encoder 4096 values/rev.
in the servo-motor corresponds to 12-bit resolution

Single-Turn Encoder
Single and multi turn...
• Single-turn
correct positions available in just one rotation
• Multi-turn,
correct position available in more than on

rotation.
Multi-Turn Encoder
Gear wheels and Hall sensores

for detecting the number of rotations

Single and multi turn...
• Single-turn
correct positions available in just one rotation
• Multi-turn,
correct position available in more than on

rotation.
Gear wheels and Hall sensores

for detecting the number of rotations

Inductive-digital incremental systems...

Gear wheel for counting • An exciter coil generates a high-frequency

revolutions magnetic field, thus inducing a voltage in
the receiver coil. This is evaluated by
the electronics, converted into voltage
Hall sensors pulses and emitted.
Rotor Stator
• The metal disks on the rotor influence
the magnetic field and generate impulses
for evaluation.
• Resolution of the rotor-stator system:

262144 impulses/revolution
• Gear wheels with sensors:

max. 4096 revolutions can be counted
• Supply voltage of 5 V
Conductive plate
for the voltage sensors
Receiver coil in the encoder
Metal disks
Exciter coil

Resolvers

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol

Transformative Resolver
Coil 1 Coil 2 • Alternating current in coils 1 and 2 is used to

induct
a voltage or a current in the measurement
coil. The height and phase length of the
induced voltage depend on the actual
position of the measurement coil.
• A clear position allocation can be

determined within one revolution.
• Exit value is analogue.
Measuring coil • Used at Festo until recently.

(MTR-AC, discontinued product, previous
servo-motors, EMMS-AS today)
• may be utilizable as a second external

displacement encoder
• Absolute precision: < 5'
• Resolution: 16 bit
The phasing of the voltages in coils 1 and 2
are displaced relative to each other by 90°.
• Carrier frequencies: 5 - 10 kHz
• Max. speed: 16,000 1/min


EnDat protocol

Resolution
Magnetical systems
Optical systems
Inductive systems
Encoders
Resolvers
EnDat protocol
Basic physical-technical principles Measurement data transmission with

Module 1.1 IF Part Positioning measurements EnDat
Encoder protocol: EnDat
… is: an interface for transferring data

between the encoder and control unit
… transmits: position values

status variables,
… serves to: read and write

to the measuring device's memory.
Basic physical-technical principles Measurement data transmission

Module 1.1 IF Part Positioning measurements with EnDat
Encoder protocol: EnDat
Measurement values of the displacement encoders can

be transmitted via the EnDat interface protocol.
More information on the EnDat protocol can be found in

the 4.1. module, motor and controller technologies.
We wish you every success with your new knowledge!

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Electric Drives The training course

Fundamentals of electric drive technology

Subjects of this presentation:

Basic physical-technical principles

Terms and methods for Positioning measurements

Terms and methods for Positioning measurements

Basic physical-technical principles Methods and terms

Objetive of position measurement

Measuring are performed to get information on:

Basic physical-technical principles Methods and terms

Position Position Speed Speed Current Current

Actual position value Actual speed value Actual current value

* Time specifications refer to CMMP-AS controller

Basic physical-technical principles

Terms and methods for Positioning measurements

Basic physical-technical principles Methods and terms

Classifications of measuring methods

Measuring methods are generally classified according to

• Measurement recording - direct

• Measurement principle / - mechanical

• Signal type - analogue

• Frame of reference - absolute

Basic physical-technical principles Methods and terms

Classifications of measuring methods

If the measurement is not taken directly, but by

Indirect measurement is especially beneficial, for

Advantage: - usually significantly less costs

Indirect measurement recording

Basic physical-technical principles Methods and terms

Classifications of measuring methods

Direct measurement recording

Direct measurement is - the corresponding sensor has

Disadvantage: - high installation complexity e.g. to

- high costs as the material

Direct measurement recording

Basic physical-technical principles Methods and terms

Classifications of measuring methods

To generate measureable dimensions, numerous physical

- scale: µm, mm or m range …

- maximum speed of the signal processing,

Basic physical-technical principles Methods and terms

Analog value Digital value

Basic physical-technical principles Methods and terms

Digital values can only accept specified value levels –

There are several codes to represent these values,

Binary values or signals are digital values which can

Increments are binary signals with the values

Basic physical-technical principles Methods and terms

Analog - Digital Converter

Analogue and digital values can be converted into the

The resolution is the amount of steps on the y-axis (U),

Both of them affect the quality of the digitized signal.

Basic physical-technical principles Methods and terms

Classifications of measuring methods

Types of measurement signals - absolute

all signal values refer to one exactly fixed position.

With incremental sytems

the system just counts increments (single steps).

Basic physical-technical principles Methods and terms

Classifications of measuring methods

Types of measurement signals - absolute

With absolute systems