Frequently Asked Questions

The RM22, RE22, RM36, RE36 are all based on common hall sensor ASICs. The reliability of these sensors has been calculated from accelerated life tests as detailed below.

Installed on small PCBs, 40 sensors were put through a number of stress tests where the temperature, time and voltage were changed. Every chip was tested between each stress test.

Stress test:

• number of devices = 40
• total time at stress = 1932 hours
• failures = 0

Steps of testing procedure:

Reliability - statistical calculations

Assumptions:

• Two most common degrading mechanisms:
  • degradation of oxide layer (Activation energy = 0.5 eV)
  • metalization reduction (Activation energy = 1 eV)
• Degrading mechanism in ICs is the same during all stress cycles.

For example:

At worst case we can estimate with 90% confidence that with an activation energy of 1 eV and a temperature of 125 °C we will potentially get 2,584 failures in 100,000 years. The MTTF (Mean Time To Failure) for the same parameters gives us 1 potential failure in 39 years.

Encoder system reliability

MTTF (M) = p × t / n

From our records (yearly production figures and failure data), readhead MTTF in continuous use is 750 years.

As a practical example, if a customer has 50 machines each containing 2 encoders, the installed readhead population (p) is 100. The mean interval (t) between any readhead failure (i.e. n = 1) may be calculated by rearranging the MTTF formula:

Therefore with a total of 100 readheads running 24 hours per day, this customer could expect a single readhead failure approximately once every 7.5 years.

This information is not a guarantee of product reliability and does not represent a condition of warranty.

Note: For RE encoders you must also take into account the bearing life which can be found in the RE datasheets.

RM encoders are frictionless when properly installed. The speed depends mainly on the resolution. Maximum speed is 30,000 rpm.

RE encoders have a speed limited by ball bearings and additionally by their sealing for higher IP factor. See the table in the datasheet for estimated bearing life of RE encoders. Maximum speed for encoders without seals is 20,000 rpm. The IP68 version must be immersed in fluid in order to ensure reliable operation.

Speeds for different resolution SSI and incremental versions are as follows:

The encoder can be supplied with a pre-selected magnet to ensure that optimum performance is achieved. Alternatively magnets can be sourced from other suppliers but they must conform to the following guidelines to ensure that performance specifications can be achieved.

To select a suitable magnet it is important to know the properties of the sensors. Hall Sensors are only sensitive to the perpendicular component of magnetic flux density (B). The encoder has a Hall sensor array arranged in a circle. Sensors are located on the surface of the silicon.

Magnets must be cylindrical in shape and diametrically polarized. The main criteria for magnet selection is the distribution of perpendicular component of magnetic flux density at the sensors location (Bn).

 Distribution of perpendicular component of B

Distribution of B_n and its modulation if the magnet is rotated through 360° (for AM512B)

The following table contains values for AM512B. For other ICs please check the corresponding datasheet.

We recommend that a magnet with the following parameters is used to provide the necessary modulation.

RLS provides the following magnet and magnet actuators:

All dimensions are in mm.

 The encoders for standard EMC grade have a single shielded cable and a plastic shell connector and those for high EMC grade have a double shielded cable and a metal shell connector.

The RM/RE encoder systems conform to the relevant harmonised European standards for electromagnetic compatibility as detailed in the relevant Installation guides.

EMC compliance: BS EN 61326

Encoder systems with double-screened cable (high EMC grade variants) meet criteria A for all of the requirements of the given standards, while encoder systems with single-screened cable (standard EMC grade variants) meet either criteria A or B for each of these requirements.

Recommended wiring diagrams for double and single screen cable variants 

Position or time delay in signals is common to all encoders. It can be corrected if needed in the control system by putting in a factor derived from the calculated delay.

At high rotation speed a position delay between magnet position and the electrical output appears because of filtering. Filtering is carried out with an RC filter. Position delay can be calculated with formula:

Δφ = -Arctan{ƒ/ƒ₀} (ƒ = ƒrequency, ƒ₀ = (2πRC)^-1)

For the AM256 and AM512B (8, 9 bit encoder ICs) and up to 9 bit RM/RE, the value of the resistor is 10 kΩ and the recommended value of capacitor is 10 nF.

For 10+ bit encoders the resistor value is 10 kΩ and the value of capacitor is 22 nF.

Using the above equation, we can therefore calculate the position delay in both degrees and time. In the following example we have a 10 bit encoder rotating at 1000 rpm.

*Note: Zero position can be set only on encoders made with AM4096.

You have three options:

1. Using UPRGAM4096

2. Shorting the zero pads on RMB boards or RMC22 and RMC35 encoders

3. Using zero pen with RM44 encoder

The cable length is measured from the rim of the encoder body to the end of the flying leads or the connector.

For flying leads
The length of the flying leads is always 30 mm of which 5 mm are completely stripped, tinned and ready for soldering.

For all connector types

The OnAxis™ have not specifically been designed for use in deep sea applications but due to their robust design customers have found that they work well under these conditions. To assist we have created a special version of the RM22 and RM36 encoders with vent holes drilled into their bodies so that the electronics inside are at the same pressure as the surroundings. For high pressure applications most customers then flood the encoder with a dielectric fluid. Though tested successfully by our customers, RLS cannot guarantee the same specifications hold true as for the standard RM22 and RM36 versions, especially MTTF. Although unlikely, the electronic components used are standard components and could contain small air pockets which could burst if exposed to high pressures in deep sea applications.

RE encoders with bearing/shaft have also been successfully used in deep sea applications with the use of vent holes. In this case, the dielectric fluid must be non-conducting oil to prevent damage to the bearings, which are not sealed off inside the encoder body.

The maximum achievable resolution for magnetic encoders based on the Hall effect is limited by a number of factors. The main source for noise is electrical noise from the Hall sensors themselves.

Peak noise for a well-optimised system is normally in the range of 0.02°. This limits the resolution for magnetic encoders with Hall sensors to 13 bits (8192 counts per revolution).

• PCB shape and dimensions,
• Encoder body shape and dimensions,
• Encoder body material,
• Cable: AWG, shielded/not shielded,
• Connector,
• Strain relief to soldered wires,
• Interface/driver,
• Additional protection, filtering,
• Special resolution (e.g. 96 ppr, 1280 cpr)...

There are three signals for incremental output: A, B and Z. Signals A and B are quadrature signals, shifted by 90° and signal Z is a reference mark. One revolution generates N pulses of signal A or B. The number of counts per revolution post quadrature evaluation is N x 4. The reference mark signal is produced once per revolution. The width of the Z pulse is ¼ of quadrature signal period and is matched with A high and B high.

The figure shows the timing diagram of A, B and Z signals with clockwise (CW) rotation of the magnet. B leads A for CW rotation. The counting direction can be changed by swapping A and B signals.

Timing diagram for incremental output	Differential incremental outputs

With incremental outputs it is important to know the difference between PPR (pulses per revolution) and CPR (counts per revolution = 4 x PPR)

Pulses per revolution is the number of pulses in one revolution.

Counts per revolution is the number of changes of state on both channels in one revolution. CPR is achieved by electronically multiplying by four, using both the rising and the falling edges on both channels.

1 Pulse = 4 Counts

Absolute position data can be transmitted in a number of ways. One of the most popular interface standards is SSI as it requires only a minimal number of wires, namely 6. Serial data from the magnetic encoders is available in natural binary code through SSI protocol.

By default, with CW rotation of the magnet the value of output data is increasing.

SSI timing diagram

The controller interrogates the encoder chip for its positional value by sending a pulse train to the CLOCK input. The CLOCK signal must always start from high. The first falling edge (point 1) stores the current position data in a parallel/serial converter and the monoflop (timer) is triggered. With each transition of the CLOCK signal (high/low or low/high) the monoflop is retriggered. At the first rising edge (point 2) the most significant bit (MSB) of binary code is transmitted through the DATA output. The next falling edge shifts the next bit (MSB - 1) which appears on the DATA output at the next rising edge. At each subsequent rising edge of the CLOCK the next bit is transmitted to the controller. While reading the data the t_CL must be less than t_MF to keep the monoflop set. After the least significant bit (LSB) is output (point 3) the DATA goes to low. The controller must wait longer than t_MF before it can read updated position data. At this point the monoflop time expires and the DATA output goes to high (point 4).

It is possible to read the same position data several times to enlarge the reliability of transmitted data. The controller must continue sending the CLOCK pulses and the same data will be output again. Between the two outputs one logic zero will be output.

SSI multi-read of the same position data

NOTES:

• rising edge = low to high transition
• falling edge = high to low transition

The angular position is converted into digital position information. The digital information is then generated from a built-in 10 bit D/A converter. The number of steps is always fixed to 10 bit over one rotation (period) of 360°. By changing the period to 180° the number of steps will therefore be 9 bit for each rise to from V₁ to V₂.

The linear output voltage is sawtooth shaped and lies within thresholds V₁ and V₂.

Sinusoidal outputs produce one period of sine and cosine signal per turn (360°).

Analogue sinusoidal outputs

Complementary Sine/Cosine

The outputs are differential sinusoids in quadrature.

Analogue differential sinusoidal outputs

Unbuffered/Buffered outputs from the ASIC

Unbuffered output means that the signals generated by the rotation of the shaft are transferred directly from the sensor output. Unbuffered outputs have a typical output impedance of 10 kΩ.

Buffered output means that the device incorporates a built-in amplifier with an output impedance of 720 Ω.

The magnetic scale is structured as shown in the image below.

For detailed instruction click on this link Magnetic scale installation guide 

or check Magnetic scale installation video:

Note that we strongly recommend that the scale is cut at RLS. The reason is the scale's composition – the rubber is very soft, whereas the carrier is made of stainless steel. Therefore, the cut needs to be made across the whole surface of the scale, and not at the sides (e.g. if industrial scissors are used, the scale would twist at the ends where it is cut). We use a special rig with a diamond cutter to make a clear cut. Also, it is important that the ends are not overheated, as this causes a deformation of the rubber at the ends. That is why we cut the scale slowly, in »periodic« movements (push down to cut, release slightly, then push down again and release, etc.)

*Stick-on reference mark: for use with MS10 only.

Our preferred option for reference marks is the machined reference mark. The stick-on reference mark can be used for prototypes, when the final position has not yet been set. It gives you the possibility to select the position of the reference mark on the spot, when you are building/installing your system. The disadvantage of using the stick-on reference mark is that the ride height needs to be at least 0.5 mm, which increases the SDE. If the ride height is too low, the readhead could hit the reference mark, moving it out of position. Furthermore, the stick-on reference mark needs to be installed correctly with the help of a reference mark applicator.

Minimum Edge Separation means the smallest possible time between two adjacent edges of the quadrature signal. It is given as a unit of time (μs). Typical selections are 0.07 μs through 20 μs. When specifying a magnetic incremental linear or rotary encoder, you need to select a Minimum Edge Separation value which is lower than counting ability of counter and faster that the highest speed in your application, when taking resolution into account. Edge separation time is compromised by three parameters: counting frequency of subsequent electronics, maximum system speed and required resolution. 

Refer to 3M technical Bulletin "Surface Preparation for 3M^TM VHB^TM Tape Applications" for additional information or Magnetic ring data sheet.

A: No cover foil, cut or magnetised reference mark	B: No cover foil, stick-on reference mark
C: With cover foil, cut or magnetised reference mark	D: With cover foil, stick-on reference mark

 All dimensions are in mm.

If stick-on reference mark is applied incorrectly, one of the following can occur:

• Reference mark is not detected in any direction
• Reference mark is detected in one direction only
• Reference mark is detected in both directions but at different positions, which are one scale pitch apart
• Reference mark is detected twice in one direction at one scale pitch apart

In order to ensure stick-on reference mark is applied correctly, always use LM10ARM00 applicator tool for stick-on reference mark.

What are the advantages and disadvantages of using the cover foil?

Advantages

The cover foil can be used to protect the magnetic scale in applications where it could be subject to physical change. If a hot particle strikes the magnetic scale, it could burn the rubber and disrupt the magnetisation which would lead to incorrect readings. Sharp objects can also damage the scale by scratching it and thereby disrupting the magnetisation.

The cover foil is also easy to clean. So for applications that require regular cleaning of the scale surface to avoid excessive dirt build up between the scale and readhead it is advisable to use the cover foil.

Disadvantages

The main disadvantage is that the cover foil and the magnetic scale have to be installed separately doubling the installation time.

Also, the cover foil cannot be re-installed to the magnetic scale. Removal of the cover foil after installation will damage the rubber strip.

Once the cover foil is applied, the batch ID of the scale is also hidden below the cover foil.

The cover foil decreases the ride height by 0.1 mm.

Why is the cover foil not as wide as the scale?

The cover foil is about 0.5 mm thinner to allow for installation tolerances. Also for safety the cover foil should never overhang the edge of the magnetic scale.

There are two options:

1. You can order the magnetic scale with the cover foil
2. You can order the cover foil separately

When ordering the magnetic scale which includes the cover foil the length of the cover foil is always provided 5 cm longer than the scale. This additional length can be used to protect the ends of the scale and secure to the substrate.

Similarly, when ordering the cover foil separately we suggest that the cover foil is at least 5 cm longer than the length of the scale for the same reasons.

Yes, LM series magnetic encoders are perfectly suitable to be used with linear motors. However, to achieve optimum performance of your encoder the influence of linear motor magnetic flux on magnetic encoder accuracy error needs to be taken into account.

Linear motors are electric motors that produce linear motion. In a traditional electric motor, the rotating part (rotor) spins inside the static part (stator), whereas in a linear motor, the stator is laid out flat and the 'rotor' is a slider that moves in a straight line above the stator.

In below example, the stator in linear motors consists of permanent magnets and the slider contains the coils/windings. The magnets used in linear motors are usually very strong and therefore have a very high magnetic flux which can affect the accuracy of a magnetic encoder. However, the strength of a magnet decreases with distance as well as with addition of an external shield.
The graphs and table below show the influence of linear motor magnets on LM encoder accuracy depending on the distance (A) of the encoder from the linear motor magnets.

Distance of encoder from linear motor magnets (A)	Accuracy (µmpp)	Accuracy plot
0	14
5	9
10	6
15	5
>15	4

Radial ring structure

Axial ring structure

For detailed instructions click on links below:

Mounting instructions for axial rings

Mounting instructions for radial rings

No, it is not possible to order the ring without the readhead.

Custom rings can be ordered but only for big quantities and the price is higher.

 How is system accuracy affected when the sensor is at scale's edge?

The sensor operates accross the whole measuring length of magnetic scale. However, at the scale's edges the system accuracy gets worse. Therefore, we recommend that the beginning of measuring length is at least 4 mm from scale's edges.

What is the accuracy of linear magnetic encoder systems and how is accuracy affected when measuring less than 10 mm of scale?

Scale accuracy is defined by multiple accuracy grades: ±40 µm/m, ±20 µm/m, ... The extreme values of measuring curves over any one-meter-section of measuring length lie within accuracy grade ±a. If measuring length is shorter than one meter, accuracy grade corresponds to this length.

What is the accuracy of linear magnetic encoder system for scale lengths of 2 m, 3 m, 4 m, etc.?

Our accuracy grade (a) corresponds to system accuracy over 1 m scale. For example:
a = ±20 µm
2 m scale length: 2 m × 20 µm = 40 µm
3 m scale length: 3 m × 20 µm = 60 µm
4 m scale length: 4 m × 20 µm = 80 µm

Which accuracy can be achieved with magnetic rings?

For more information click on link below:

Accuracy of ring encoder systems

 What is the influence of ride height on system accuracy? 

Influence of ride height on system accuracy is explained in the graph below:

 Example: LM10 ride height influence on accuracy

 What is the influence of temperature on system accuracy? 

The linear expansion coefficient for MS scales is ~17 ppm or ~ 17 × 10-6/K. For each 1 degree Kelvin temperature change, the scale expands for 1 micrometer per meter.

What magnetic fields will damage the magnetic scale? Can the scale be used close to a permanent magnet?

What is "interpolation," "cpr," and "ppr"?

Interpolation rate is defined as number of output measuring steps inside of one input signal period. CPR (counts per revolution) = PPR × 4
Read more here.

What is the maximum temperature the scale can withstand?

 The maximum temperature the scale can withstand without taking damage is from -10 °C to +85 °C.

Can linear / ring magnetic encoder systems be used in vacuum environments?

Linear / ring magnetic encoder systems can be used in vacuum environments where outgassing can not occur. The effects of outgassing could cause the disturbance of system operation.

How big is high-frequency noise of analogue signals?

 High-frequency noise of analogue signals is less than 500 µV_pp.

Can magnetic scale be bent and installed onto a circular surface?

 Yes, the magnetic scale can be bent and installed onto a circular surface. The minimum bending radius is 65 mm. If you will install it on smaller radius, elastoferrite will burst and accuracy will be much lower.

What is the duty cycle of A and B digital output signals?

 The duty cycle of the A and B digital output signals is 50 % for continuous velocity.

What is the requirement for the substrate flatness for scale installation?

Flatness provides a distance within ride height (1 mm). For more information refer to 3M Technical Bulletin "Surface Preparation for 3MTM VHBTM Tape Applications".

Mean time to failure describes the expected time to failure for a non-repairable system.

Our encoders comply with RoHS and EMC EU directives.

LM10, LM13 and LM15 encoders EC declaration of conformity

RMB encoders EC declaration of conformity

RM and RE encoders EC declaration of conformity

AksIM™ off-axis rotary absolute encoder EC declaration of conformity

All new/current RLS manufactured products as of the beginning of June 2006 are compliant to 2011/65/EU EU Directive (RoHS II). Compliance is declared with EC Declaration of Conformity for each product group. Declarations are available at products sites.

General statement on RoHS compliance of RLS products: RoHS statement: Restriction of Hazardous Substances

Assuring compliance of RLS products with a new Directive (EU) 2015/863 amendment to Annex II of 2011/65/EU is in progress: RoHS2015 statement: Extension of Hazardous Substances List with Phthalates 

RLS is ISO9001 certified as of 28th July 2006.

Please click RLS ISO9001 certified to view ISO9001 certificate.

RLS does not manufacture or import any chemicals. RLS products are manufactured from standard electronic components with optional aluminum, steel or zinc housing. Environmental information on all potentially hazardous components or materials is required from our suppliers. No component or material is used on non-standard way, therefore it is considered unlikely that any of the current SVHCs if present will exceed a concentration greater than 0.1 % by weight.

Please read our RLS REACH Directive Statement,  covering current SVHC list update.

On July 21st 2010, the Dodd-Frank Wall Street Reform and Consumer Protection Act was signed into U.S. law. Section 1502 added Section 13(p) to the U.S. Securities Exchange Act of 1934. On August 22nd 2012, the U.S. Securities and Exchange Commission adopted the final rule requiring companies that manufacture or contract to manufacture products that contain Conflict Minerals including Tantalum, Tin, Tungsten and Gold (3TG) that are necessary to the functionality or production of a product manufactured to disclose annually whether any of those minerals originated in the Democratic Republic of the Congo or an adjoining country.

RLS is not required by the U.S. Securities and Exchange Commission to submit annual reports. Nevertheless we fully support Conflict Free Smelter Program and all necessary measures will be taken to prevent even unintentional use of any minerals from conflict area.

Please read our RLS Conflict Free Minerals Company Policy Statement, dated from July 2013 and covering currently received suppliers information.

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All non-contact encoders and components are covered by a 2 year warranty. The RE22, RE36 and RE58 encoders with a bearing/shaft are covered by a 1 year warranty.

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