1、 High precision and real-time performance

1. Accurate pulse counting
   • The incremental encoder outputs two-phase orthogonal pulse signals A and B (with a phase difference of 90 °), and the PLC can perform four fold processing on the pulses through a high-speed counter (HSC), significantly improving resolution. For example, the 1000 line encoder can achieve a resolution of 4000 pulses per revolution after being quadrupled, meeting the high-precision positioning requirements.
   • Application scenariosCNC machine tool feed axis control, packaging machinery color code positioning, printing machine registration control, etc.
2. Fast real-time feedback speed
   • The output pulse frequency of the encoder is proportional to the motion speed, and the PLC can collect the pulse signal in real time and calculate the current position or speed. The response time is usually in milliseconds, which is suitable for dynamic control scenarios.
   • comparative advantageCompared to absolute encoders (which require reading encoding), incremental encoders do not require memory or complex communication protocols, and data updates are faster.

2、 Outstanding cost-effectiveness

1. Low equipment cost
   • Incremental encoders have a simple structure (only requiring photoelectric sensors and encoders), without the complex encoding circuits or memory required by absolute encoders, and are typically priced at 1/3 to 1/2 of absolute encoders of the same resolution.
   • Applicable scenariosCost sensitive mid to low end automation equipment (such as conveyor belts, fans, and pump controls).
2. Low maintenance cost
   • When the encoder malfunctions, only the encoder itself needs to be replaced, and there is no need to recalibrate the system (as there is no absolute position memory requirement). The maintenance cycle is short and the cost is low.
   • Compare absolute encodersIf the battery fails or the memory is damaged in an absolute encoder, the position needs to be reinitialized, which increases maintenance complexity.

3、 Compatibility and flexibility

1. Widely compatible with PLC systems
   • The incremental encoder outputs standard pulse signals (NPN/PNP collector open circuit, differential line drive, etc.), which can be directly connected to the high-speed counter input port of the PLC without the need for additional conversion modules.
   • Mainstream PLC supportSiemens S7-1200/1500, Mitsubishi FX/Q series, Omron CP1H/CQM1, etc. all have built-in high-speed counter function.
2. Multi parameter adjustable
   • Resolution adjustmentFlexibly adjust the resolution by changing the number of encoder lines or PLC counting modes (such as 1x, 2x, 4x).
   • Direction recognitionUsing the phase difference between phase A and B pulses to determine the direction of rotation, without the need for additional directional signal lines.
   • zero settingPeriodic position calibration is achieved by marking reference points with Z-phase (zero position pulse) signals.
3. Multi type adaptation
   • Supports rotary encoders (for motors and reducers) and linear encoders (for cylinders and hydraulic cylinders) to meet different motion requirements.
   • Protection level optionalIP54 (dustproof and splash proof), IP65 (dustproof and waterproof), etc., suitable for harsh industrial environments.

4、 Strong anti-interference ability

1. Differential signal transmission
   • The incremental encoder adopts differential output (such as RS422, HTL), which is transmitted through two pairs of signal lines A+/A - and B+/B -, effectively suppressing common mode interference (such as electromagnetic noise and power supply fluctuations), and the signal transmission distance can reach more than 100 meters.
   • Compare single ended signalsSingle ended output (such as NPN) is susceptible to interference, and the transmission distance usually does not exceed 10 meters.
2. Hardware filtering design
   • The encoder integrates an RC filtering circuit internally, which can filter out high-frequency noise pulses and avoid PLC false counting.
   • Supplementary measures for PLC endOptocoupler isolation or software filtering (such as moving average filtering) can be configured at the PLC input to further enhance anti-interference capability.

5、 Easy installation and debugging

1. Simple mechanical installation
   • The encoder is usually installed by flange or synchronous pulley, and is directly connected to the motor shaft or transmission parts, without complex alignment adjustment.
   • Shaft diameter adaptationProvide multiple shaft diameter specifications (such as φ 6, φ 8, φ 10), compatible with different motor models.
2. Intuitive electrical wiring
   • A typical wiring only requires 3 wires (A-phase, B-phase, power supply), and the Z-phase signal is an optional configuration with low wiring complexity.
   • Debugging tool supportReal time monitoring of pulse counting and direction status can be achieved through PLC programming software (such as TIA Portal, GX Works2) to quickly locate faults.

6、 Typical application scenarios

1. speed control
   • caseWhen the frequency converter drives the motor, the encoder feeds back the pulse frequency to the PLC, and adjusts the motor speed through PID algorithm to achieve constant speed operation (such as fan and water pump speed regulation).
2. position control
   • caseWhen positioning the joints of a robotic arm, the encoder accumulates the number of pulses to calculate the current angle, and the PLC outputs control signals based on the target position to achieve precise stopping (such as welding robots and assembly lines).
3. Direction detection
   • caseWhen controlling the forward and reverse rotation of the conveyor belt, the phase difference between the A and B phase pulses of the encoder determines the direction of operation to avoid material misalignment (such as in logistics sorting systems).
4. Counting and Measurement
   • caseWhen counting products on the production line, the number of encoder pulses corresponds to the quantity of products, and the PLC triggers an alarm or shutdown signal (such as food packaging lines, textile machinery).

7、 Comparison and Summary with Absolute Encoder