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olution as fine as 0.001 in. per pulse. Travel per step is determined by the pitch of the leadscrew and step angle of the motor. The maximum linear force for the model shown is 75 oz.
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A servosystem feedback sensor in a motion control system transforms a physical variable into an electrical signal for use by the motion controller. Common feedback sensors are encoders, resolvers, and linear variable differential transformers (LVDTs) for motion and position feedback, and tachometers for velocity feedback. Less common but also in use as feedback devices are potentiometers, linear velocity transducers (LVTs), angular displacement transducers (ADTs), laser interferometers, and potentiometers. Generally speaking, the closer the feedback sensor is to the variable being controlled, the more accurate it will be in assisting the system to correct velocity and position errors. For example, direct measurement of the linear position of the carriage carrying the load or tool on a single-axis linear guide will provide more accurate feedback than an indirect measurement determined from the angular position of the guide s leadscrew and knowledge of the drivetrain geometry between the sensor and the carriage. Thus, direct position measurement avoids drivetrain errors caused by backlash, hysteresis, and leadscrew wear that can adversely affect indirect measurement.
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Rotary encoders, also called rotary shaft encoders or rotary shaft-angle encoders, are electromechanical transducers that convert shaft rotation into output pulses, which can be counted to measure shaft revolutions or shaft angle. They provide rate and positioning information in servo feedback loops. A rotary encoder can sense a number of discrete positions per revolution. The number is called points per revolution and is analogous to the steps per revolution of a stepper motor. The speed of an encoder is in units of counts per second. Rotary encoders can measure the motor-shaft or leadscrew angle to report position indirectly, but they can also measure the response of rotating machines directly. The most popular rotary encoders are incremental optical shaft-angle encoders and the absolute optical shaft-angle encoders. There are also direct contact or brush-type and magnetic rotary encoders, but they are not as widely used in motion control systems.
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Commercial rotary encoders are available as standard or catalog units, or they can be custom made for unusual applications or survival in extreme environments. Standard rotary encoders are packaged in cylindrical cases with diameters from 1.5 to 3.5 in. Resolutions range from 50 cycles per shaft revolution to 2,304,000 counts per revolution. A variation of the conventional configuration, the hollow-shaft encoder, eliminates problems associated with the installation and shaft runout of conventional models. Models with hollow shafts are available for mounting on shafts with diameters of 0.04 to 1.6 in. (1 to 40 mm).
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Incremental Encoders
The basic parts of an incremental optical shaft-angle encoder are shown in Figure 1-34. A glass or plastic code disk mounted on the encoder shaft rotates between an internal light source, typically a light-emitting diode (LED), on one side and a mask and matching photodetector assembly on the other side. The incremental code disk contains a pattern of equally spaced opaque and transparent segments or spokes that radiate out from its center as shown. The electronic signals that are generated by the encoder s electronics board are fed into a motion controller that calculates position and velocity information for feedback purposes. An exploded view of an industrial-grade incremental encoder is shown in Figure 1-35. Glass code disks containing finer graduations capable of 11- to more than 16-bit resolution are used in high-resolution encoders, and plastic (Mylar) disks capable of 8- to 10-bit resolution are used in the more rugged encoders that are subject to shock and vibration.
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