Optimized rotary encoder mounting in robot production

The cost of producing a robot is strongly influenced by its design. An estimated 70 percent of the production cost is predetermined by design decisions.

One essential design component is the rotary encoder, which measures the speed and position of each axis. An encoder’s accuracy thus determines the final accuracy and repeatability at the Tool Center Point. As a result, special attention must be given to proper encoder mounting during production. The fewer the steps and the less training required, the better.

Inductive dual encoders from HEIDENHAIN feature a compact design and minimal mechanical hysteresis effects on measurement, clearly benefiting designers. But there are also strong benefits from a production point of view.

Easily automatable mounting

An inductive dual encoder from HEIDENHAIN consists of two rotors mounted on either side of a PCB. One rotor is fitted to the motor’s hollow shaft, where it measures rotational speed. The other is mounted to the output axis downstream from the gearbox, where it measures angular position. The PCB, which is rigidly attached to the stator, contains the scanning units for both rotors along with all of the electronics.

The benefit of this design, combined with the inductive scanning method, is less sensitivity to mounting tolerances. The rotors can also be mounted at any rotational angle.

This makes them ideal for press-fitting assembly, a procedure that is easily automatable, well controllable through force-displacement monitoring, and simple to document for functional safety purposes. When large production qualities are involved, it is also cheaper than screw-fastening or screw-clamping methods.

The pressing forces needed for proper mounting are included in the mounting instructions. The electronics of the HEIDENHAIN rotary encoder also feature mounting diagnostics that can be readily accessed via a digital interface, revealing whether mounting is within tolerance.

Multiple benefits

The readily automatable press-fit mounting procedure and the built-in mounting diagnostics increase process reliability. Since the angular orientation of the rotors is irrelevant during mounting, no calibration is required. And without special inter-component matching, the requirements imposed on manual work are low.

These features of the inductive dual encoders from HEIDENHAIN can shorten lead times and reduce production costs. Read our white paper to find out more about the benefits of these HEIDENHAIN components.

Inductive rotary encoders for efficient robot production:
Benefits for lead time, quality, and process stability.
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