Benjamin Franklin made the phrase “time is money†popular, and I think it’s no exaggeration to say that this is also a true portrayal of people engaged in machine design, industrial automation, or robotics. Machine downtime not only causes anxiety, but conservatively speaking, this situation itself actually involves high costs and energy. The Industrial Internet of Things (IIoT) and the ability to control sensor data, machine-to-machine (M2M) communication, and automation technologies are constantly revolutionizing the way machine data capture and communication. The transition from analog to digital devices is creating highly intelligent machines with new and exciting diagnostic capabilities that provide engineers with access to important information and data that were previously unavailable. Through these new data, designers have made amazing progress, improving the machine's ability to predict failures and reduce downtime.
Figure 1: Illustration of a typical machine-to-machine communication system of CUI.
Rotary encoders are key components of motion control feedback loops in industrial, robotics, aerospace, energy and automation applications. These devices require encoders with excellent performance, long-term reliability, and durability, so that they can often work in harsh environments with dust, pollution, temperature changes, and strong vibration. With the recent rapid development of the robotics and automation industries, the demand for faster, more accurate, more efficient and more intelligent encoders is increasing sharply. Unfortunately, the encoders currently on the market cannot provide any intelligence to motion control designers. CUI's ASIC-based digital AMT encoder series bridges this gap and can provide designers with important diagnostic and programming tools that can speed time to market and reduce on-site downtime.
Figure 2: CUI's AMT encoder is the first ASIC-based digital design on the market.
Incorporating diagnostic capabilities into rotary encoders allows designers to obtain valuable system data, which was not possible in previous pure analog solutions. This data can be used to allow the system to quickly determine whether the encoder is working properly, is malfunctioning or inoperable, or is inaccurate. The system then uses this data to inform the operator of potential problems, or make informed decisions on its own before starting the motor and causing potential catastrophic damage. In addition, engineers can use this feature to develop preventive measures-for example, to perform a "encoder in good condition" test sequence before running the application. These capabilities are not available in strictly analog encoders, allowing designers to minimize downtime and predict device problems that may occur on site.
The diagnostic data can be monitored at any time through the industrial communication network to provide valuable performance trends for analyzing and predicting failures in the motion control system before failures occur. Due to the key position of the encoder, which is directly installed on the motor, the diagnostic data is not limited to the performance of a single encoder, but can also be used as an early warning of other problems in the motion control system, such as shaft misalignment, bearing wear, or thermal degradation. By carefully reviewing the data, it is possible to perform preventive maintenance on the machine in a controlled manner and fix problems before catastrophic failure occurs. This can limit severe downtime, increase machine life and promote overall system intelligence.
In addition to the predictive advantages, if a field failure occurs unexpectedly, the onboard diagnostic data can also be used to speed up the troubleshooting process. Obtaining these valuable encoder diagnostic capabilities allows maintenance technicians to troubleshoot encoder problems or determine possible encoder or motor problems, so as to quickly pinpoint the root cause of the fault. This eliminates the time-consuming, costly, and error-prone test process, without having to remove and replace encoders and motors from the system. Since machine downtime will cause productivity loss, its own cost is very high; coupled with the cost of on-site technicians to repair the machine, it is even worse. Therefore, it has the encoder diagnosis capability to speed up the troubleshooting and repair process, which will significantly save costs and minimize the impact of field failures.
The diagnostic data from the encoder can also significantly save time in the product development process. As an engineer, I would rather believe that all my designs will work perfectly from the start. However, things are not always smooth sailing. During the testing process, I will inevitably find design problems; usually the cause of the problem is not obvious, and there seem to be endless variations. This starts the troubleshooting process to determine why the device is not operating as expected. The diagnostic data can speed up this process and quickly locate design areas that need improvement, virtually avoiding days or weeks of investigation. These savings can not only shorten the design cycle and lead to more stable products, but also speed up the time to market.
CUI's revolutionary AMT11 incremental series and AMT31 commutation series are the first rotary encoders to integrate these diagnostic capabilities. By using AMT Viewpoint™ software or simple serial commands, CUI delivers valuable diagnostic data to the machine designer. These small devices have a diameter of 37 mm and a thickness of 10 mm. They operate under a single +5 V power supply. They provide a variety of programming resolution options from 48 to 4096 ppr and provide commutation signals for all BLDC pole-pair configurations. According to application requirements, in addition to axial and radial connection directions, both series provide single-ended or differential output options. In order to improve durability, the rugged AMT encoder has an operating temperature range from -40°C to 105°C.
Figure 3: CUI's AMT Viewpoint GUI allows users to set multiple encoder parameters and obtain diagnostic data.
Although downtime cannot be completely eliminated, diagnostic data is now increasingly used in machine design, which also greatly reduces the machine failure rate, and at the same time increases the speed of recovery, making these situations no longer troublesome. In the M2M system, the encoder transitions from analog to digital components, which also brings new possibilities. Gaining insights from these key diagnostic data also proves the famous saying-"Knowledge is power".
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