POSITION TRANSDUCERS/DECODERS Position Tranducers “A Historical Perspective” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Selecting the Right Transducer for Your Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 SECTION A SECTION A — POSITION TRANSDUCERS/DECODERS Rotary Position Transducers: Resolvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITION TRANSDUCERS A HISTORICAL PERSPECTIVE Today AVG Automation offers the broadest line of resolver based encoders in the industry: ❐ 4" housing; 5/8" shaft ❐ 2.5" housing; 3/8" shaft ❐ 2.5" housing; 1/4" shaft ❐ 1.1" housing ❐ Hollow shaft ❐ Pancake resolvers ❐ Single turn Since its inception in 1975 Autotech Controls division of AVG Automation has been in the forefront of developing resolver based technology for the industry.
Even though the position transducers are the most critical parts in a motion control system, many times they are left towards the end to be designed in. A control design engineer can save himself a lot of headache by considering the transducer features and trade-offs at the beginning of the project. The following discusses various types of position transducers and the factors to consider when making a selection. Many industrial control systems need position and speed feedback.
As the shaft rotates, the output voltages of the stator windings vary as the sine and cosine of the shaft angle. See figure 2. The two induced stator voltages are a measure of the shaft angle and are converted to a digital signal in resolver-to-digital decoder. Among various R/D decoding methods available, the two most commonly used are: ❐ Ratiometric Tracking Converter ❐ Phase Method Converter.
SECTION A (Figure 3) Phase Method Decoder (A block diagram of a typical Phase Method Decoder is shown in figure 4.) The principle of operation is based on the fact that the phase difference between reference voltage and the voltage induced in the rotor is a direct measure of the shaft position. The stator windings are excited by two 90° phase-shifted voltages generated by a sine/cosine generator.
(Figure 4) Factors to be considered for Selection of Position Transducers For an efficient control system, the right selection of a position transducer is as important as the signal processing itself. Here are some of the features and trade-Off to be considered to match the position transducer to your application. Optical Encoder vs. Resolver This decision is primarily based on the operating environment. The environmental integrity of a brushless resolver is unchallenged.
Built-in vs. Remote Decoder In a single-turn encoder, the encoder shaft makes one revolution for one complete cycle of machine operation, where as in a multi-turn application, the encoder shaft makes more than one revolutions to complete one machine cycle. Angular rotation of a crankshaft in a punch press or rotary indexing table are typical examples of single-turn applications.
ROTARY POSITION TRANSDUCERS ABSOLUTE POSITION BRUSHLESS RESOLVERS: Single-Turn, Geared Single-Turn and Dual (Multi-turn) resolvers ◆ Absolute shaft position ◆ No internal electronics ◆ Brushless resolver ◆ High-resistance to shock and vibrations ◆ NEMA 13 housing provides protection against water, mist, oil, and dust ◆ Broad temperature range, -67 °F to 248 °F (-55 °C to 120 °C) ◆ Remote ratiometric resolver decoder provides highly noise-immune encoder ◆ Choice of heavy-duty, medium-duty and explosion-
Dual-Resolvers for Multi-Turn Application Various resolver models from AVG Automation are available with a built-in precision gear train. The resolver makes one turn for many turns (see How to Order for gear ratios available) of the input shaft. A multi-turn resolver consists of two resolvers coupled to each other through a gear train.
MOUNTING Autotech resolvers are designed to operate reliable under extremely hostile environments, such as: continuous mechanical shock, vibration, extreme temperature and humidity changes, oil mist, coolant and solvents. Still ordinary precautions to prevent damage to bearings of any rotation device should be followed to prolong their life. 1. It is recommended that the Autotech encoder mounting bracket (MMB-EM359-010) be used, wherever possible, for size 40 resolvers.
MOUNTING SPECIFICATIONS A E9R-RL101-000 X X C L B DIA. D SECTION A E7R-RL101-00 X X E1R-RL101-000 X X SAS-RL210-GXXX X SAC-RL210-GXXXX E8R-RL101-XXXMC E8R-RL210-XXXMC SAC-RL100-XXX SAC-RL100-GXXX X Resolver Part Number: Resolver Mounting Table N MEASUREMENTS (inches & mm) A 5.50 (139.7) B (dia.) Servo Mount 8.56 (217.5) 6.50 (165.1) 3.57 (90.7) 3.87 (98.3) 4.0 (101.6) 2.50 (63.5) 1.25 (31.8) 1.18 (30.0) M 3.57 (90.7) F C Flange 1.06 (26.8) — Mount 1.18 (30.
RL500 HOLLOW SHAFT RESOLVER ◆ Fits on 5/8" (15.88 mm) dia. Shafts ◆ Comes with 3/8" (9.53 mm) Liquid-Tite Conduit RL500 The RL500 Hollow Shaft Resolver is intended for those applications where there is a projecting 5/8" (15.88 mm) diameter shaft (machine shaft, double-ended motor shaft, etc.) available at the point where the user wishes to take rotational readings. Instead of having to make provisions to install a traditional resolver, A-12 800-TEC-ENGR www.avg.
RL500 SPECIFICATIONS ELECTRICAL: SECTION A Frequency: 2250 Hz Input Voltage: 1.88 V Input Current: 6 mA Input Power: 6.5 mW Open Circuit Zro: 180+j256 Ω DC Resistance(Rotor): 18.3 Ω Output Voltage (Stator): 2.63 V ±5% Transformation Ratio: 1.400:1 MECHANICAL: Max. Slew Speed: 5000 RPM Max. Shaft Loading: Axial: 50 lb. (22.68 kg) Radial: 100 lb. (45.36 kg) Bearing Life at Max. Mfr. Spec. (Rev): 2 x 109 Approx. Weight: 7 lb. (3.18 kg) Diameter: 3" (76.2 mm) Height: 3" (76.2 mm) Internal Diameter: 0.
RL501 "PANCAKE" RESOLVER ◆ Fits on 1/2" (12.7 mm) dia. Shafts ◆ Designed for use in "cramped" quarters, where installation space is at a premium. The RL501 Pancake Resolver is intended for those applications where there is a projecting 1/2" (12.7 mm) diameter shaft (machine shaft, double-ended motor shaft, etc.) available at the point where the user wishes to take rotational readings. Only 1" (25.4 mm) thick, the RL501 can be installed in applications where space is very constricted.
MOUNTING & HOUSING STYLES SIZE 25, FLANGE MOUNT (2.5" diameter) End Mount Connector SECTION A Side Mount Connector 3/8" Shaft 3/8" Shaft SIZE 25, SERVO MOUNT (2.5" diameter) End Mount Connector Side Mount Connector 3/8" Shaft 3/8" Shaft SIZE 11 (1.1" diameter housing) Position Transducers/Sensors 800-TEC-ENGR www.avg.
MOUNTING & HOUSING STYLES SIZE 40 (4" diameter) Conduit Fitting 5/8" Shaft SIZE 40 (4" diameter) 5/8" Shaft End Mount Connector SIZE 40, EXPLOSION PROOF (4" diameter) Conduit Fitting 5/8" Shaft A-16 800-TEC-ENGR www.avg.
LT140 LINEAR ULTRASONIC POSITION TRANSDUCER SECTION A ABSOLUTE POSITION TRANSDUCER ◆ Absolute linear position ◆ Ultrasonic position sensing; no moving parts ◆ Easy to install ◆ Accurate to 0.001" (0.025 mm) LT140 Principle of Operation An ultrasonic linear transducer consists of an interface control module, a nonmagnetic stainless steel rod with sensing head and a "doughnut" magnet.
LT140 SPECIFICATIONS Working stroke length: 12-108" (304.8-2743.2 mm) in 1-foot (304.8 mm) increment Scan rate: 3.5 ms up to 100" (2540 mm) length; 7 ms above 100" (2540 mm) length. Linearity: 0.05% of full stroke Repeatability: 0.002% of full stroke Temperature coefficient: 0.0005% per °F of reading Resolution: 0.001" (0.025 mm) over 100" (2540 mm) length Operating temperature: 0 °F to 185 °F (-17.8 °C to +85 °C) Mechanical zero Reference: Approximately 2" (50.
Microcomputers and PLCs are sequential logic devices. In contrast to a real-time hardware logic, which can perform many operations at the same time, a PLC can perform only a single operation before proceeding to the next logical step. The figure describes the logical operation of a PLC, which is cyclic in nature. During the I/O scan, the PLC looks at the input data available at the input terminals and activates the outputs based on the ladder logic.
PLC Synchronization (PC-Handshake): Whenever the PLC scans the decoder input, it must see stable data. In order to ensure this, the PLC gives a data transfer command and a predetermined time later the PLC synch circuit stabilizes the data for the PLC to read. This time is adjustable on some AVG Automation units (2 µs to 30 ms), where as it is fixed on others (50 µs, 100 µs, etc.). The variable time feature, when available, can be used to provide the most fresh data to the PLC.
The Microfreeze can also be called as transparent PCHandshake. This feature is particularly useful when interfacing data directly to a microcomputer where speed of operation is much higher. In this case the decoder position data is continuously updated at full speed. The data are frozen for 100 µs ±10% after a delay of 10 µs from either transition edge of data transfer command. The microcomputer can read stable data during these 100 µs and it automatically unlatches.
DM2 SINGLE-TURN RESOLVER DECODER SNAP TRACK MOUNT Models DM2-STRAK-xxxxx and DS2-STRAK-xxxxx ◆ Decoder for single twin resolver ◆ Short circuit proof resolver interface ◆ Broken resolver cable indication ◆ PNP sourcing, NPN sinking or TTL outputs ◆ Short circuit protected outputs and output shorted indicator (only with P & N type of outputs) DESCRIPTION Autotech's Single Resolver Decoder model DM2-STRAK-xxxxx is a snap track mounted single resolver decoder especially designed for OEMs.
DM2 DUAL RESOLVER DECODER SNAP TRACK MOUNT ◆ Decoder for dual resolver SECTION A ◆ Field selectable 16:1, 32:1, 64:1 or 128:1 gear ratio ◆ Field selectable Binary, BCD or Gray Code output ◆ 1024 counts per turn (1000 in case of BCD) ◆ Short circuit proof resolver interface ◆ Broken resolver cable indication ◆ PNP sourcing, NPN sinking or TTL outputs ◆ Short circuit protected outputs and output shorted indicator (only with P & N type of outputs) ◆ Field selectable PC Handshake or transparent operation
DM5 RESOLVER DECODER SINGLE-TURN, SINGLE-CHANNEL ◆ Resolver based, single-turn, absolute position.
Extremely Rugged and Reliable Resolver as Position Transducer The DM5 series resolver decoders are available with resolutions ranging from 256 to 8192 counts-per-turn to match unlimited control needs. The high-performance ratiometrictracking converter assures exacting performance at speeds up to 1800 rpm. The DM5 series of resolver decoders combines the ruggedness of a resolver and reliability of an advanced solid-state control.
DM5 SPECIFICATIONS Input Power: AC: 105-135 VAC or 210-270 VAC, 50/60 Hz, 5 W DC: 8-30 VDC @ 0.25 A exclusive of load (without optical isolation, an external power supply is needed only for PNP outputs) Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) Position Transducer: AVG Automation's RL100, E7R, E8R, or RL101 single-turn resolvers.
DM7 PROGRAMMABLE RESOLVER DECODER SECTION A SINGLE-TURN, SINGLE-CHANNEL The most versatile resolver-to-digital decoder ◆ Fully absolute position, no loss of position under any situation ◆ Incredibly small size; only 9 sq.in.
Front-Panel-Selectable Output Formats: BCD, Binary, or Gray Code The DM7 is an extremely versatile resolver to digital decoder. Now you do not have to define the output format at the time of ordering the unit. Depending upon your application, the output format such as BCD, Natural Binary, or Gray code can simply be selected from the front panel keypad. This means one unit for various applications. Built-in PC synchronization PC synchronization is built in as standard in DM7 resolver-todigital decoder.
DM7 SPECIFICATIONS or RL101 resolvers Signal Resolution: 4096 counts/turn Scale Factor: 20 to 4096, programmable Output Update rate: 200 µs Programmable Offset: Full revolution Decimal Point: Programmable after any digit Resolver Cable length: 2500 ft. (762 m) max., shielded Outputs: (All outputs have to be same type) Type of Outputs: Output Interface: T, P, N, or C T: LS TTL (74LS645): Logic TRUE: 2 VDC @ 15 mA, 20 mA leakage when tristated Logic FALSE: 0.35 V @ 24 mA, 0.
DM960 RESOLVER DECODER: MULTI-TURN, SINGLE-CHANNEL ◆ Resolver-based, multi-turn, absolute position.
Multiplexing Capability The TTL-type of outputs have multiplexing capability, which allows more than one decoder to be connected to the same control unit for multi-axis applications. For multiplexing PNP- or NPN-type outputs, consult the factory. High-Resolution, Up to 17-bit Total The DM960 is a multi-turn system with a resolution of 10bits-per-turn over 64 or 128 turns. This means 17-bit resolution over total travel with 128-turn system or 16-bit resolution with 64-turn system.
DM960 SPECIFICATIONS Input Power: AC: 105-135 VAC or 210-270 VAC, 50/60 Hz, 5 W DC: 8-30 VDC @ 0.
DMM MULTI-AXIS MULTI-TURN RESOLVER DECODERS SECTION A THE DMM Principle of Operation The DMM decoders are available with either output or input multiplexing. The resolver analog signals are converted to the output digital format by a tracking resolver-to-digital converter. With input multiplexing, the analog signals are multiplexed to a single digital converter. In output multiplexing, multiple decoders are multiplexed to the parallel digital output port.
DMM SPECIFICATIONS Input Power: AC: 105-135 V or 210-270 V, 50/60 Hz, 5 W DC: 8 -30 VDC @ 0.25 A, exclusive of load (without using optical isolation, an external power supply is needed only for PNP outputs) Operating Temperature: -10 °F to +130 °F (-2 °C to +55 °C) Position Transducer: AVG Automation's RL100, E7R, E8R, or RL101 single-turn resolvers.
DMS MULTI-AXIS SINGLE-TURN RESOLVER DECODERS SECTION A ◆ Single-turn, Multiplexed, Absolute-position Resolver Decoder ◆ 8-axis single-turn, accepts up to eight resolver inputs ◆ Reduce cost and save space by interfacing multiple axes to one computer or PLC card ◆ Optically isolated outputs available ◆ High-resolution: Up to 4096 counts/turn ◆ Position display for easy setup and troubleshooting ◆ Variety of outputs and PC-handshake allow- interface to any PLC or computer – Optional PLC synchronization –
Highly Noise Immune Circuitry The ratiometric tracking converter technique employed for resolver-to-digital decoding provides the best protection against electrical noise generated by power line transients, radio frequency interference, and varying ground potentials. The ratiometric converter is practically immune to temperature variations and line frequency changes. Optional optical isolation adds another layer of protection and enhances system integrity. A-36 800-TEC-ENGR www.avg.
DMS SPECIFICATIONS optical isolation, an external power supply is needed only for PNP outputs) Operating Temperature: -10 °F to +130 °F (-2 °C to +55 °C) Position Transducer: AVG Automation's RL100, E7R, E8R, or RL101 single-turn resolvers.
M1890 PROGRAMMABLE POSITION TRANSDUCER AND PROGRAMMABLE SELSYN INDICATOR ◆ M1890-R Programmable absolute position sensor, resolver input, 5-digit BCD output ◆ M1890-S Solid-state replacement for electromechanical Selsyn systems ◆ Prescalable, presettable; yet absolute ◆ Simple front panel programming of counts-per- turn, no mechanical gear trains ◆ No batteries, nonvolatile EEROM memory ◆ PC handshake for PLC synchronization ◆ Reliable under extreme environments, splash-proof oil-tight front plate ◆ 1 P
No Batteries, Nonvolatile Memory SECTION A Nonvolatile EEROM memory retains information indefinitely after power loss or machine shutdown, eliminating batteries and related hazards. Replacing Electromechanical Selsyn Systems In new installations, the M1890-R together with AVG Automation's brushless resolver series RL100 is a 100% solid-state replacement for electromechanical Selsyn systems. In existing Selsyn installations, the model M1890-S can be used.
The M1890-S Replacing Electromechanical Selsyn Systems AVG Automation's M1890-S Programmable Selsyn Indicator (PSI) is designed to replace electromechanical Selsyn torque receivers driving mechanical production meters. It is completely solid-state and fully compatible with existing Selsyn systems. It can be connected directly to Selsyn transmitter, differential pair, or in parallel with mechanical indicators without loading and needs no changes in the existing cables.
M1890 SPECIFICATIONS 105-135 V; 50/60 Hz, 35 VA max. Operating Temperature: -10 °F to +130 °F (-23.3 °C to 54.4 °C) INPUT SIGNAL: M1890-R: Resolver Input AVG Automation's RL100, E7R, E8R, or RL101 series M1890-S: Selsyn Input Signal: 3-wire, 148 kΩ impedance, 48-90 V, L-L Reference: 2-wire, 105-135 V, 50/60 Hz, 35 VA max. Tracking Speed: 1800 RPM max Resolution: 8-, 10-, or 12-bits-per-revolution; 1 part in 100,000 total PROGRAMMING: Scale Factors: 0.001 to 65,535.999 in increments of 0.
M1150-M10 PROGRAMMABLE RESOLVER DECODER MULTI-TURN WITH LIMITS ◆ Programmable semiabsolute position encoder, resolver input, 6-digit BCD output ◆ Built-in two PLS outputs ◆ Motion output ◆ Solid-state replacement for electromechanical Selsyn systems ◆ Prescalable, presettable ◆ Simple, front panel programming of counts-per- turn, no mechanical gear trains ◆ No batteries, nonvolatile EEROM memory ◆ PC-handshake for PLC synchronization ◆ 1 part in 1,000,000 resolution and repeatability ◆ Extremely small 1/
Reliable Under Extreme Environments Nonvolatile EEROM memory retains information indefinitely after power loss or machine shutdown, eliminating batteries and related hazards. The M1150-M10 combines the ruggedness of a brushless resolver and reliability of a solid-state control. The resolver can be mounted on a machine shaft in any hostile environments such as mechanical shock, vibrations, extreme humidity and temperature changes, oil mists, coolants, solvents, etc.
M1150-M10 SPECIFICATIONS Input Power: AC: 120 VAC ±10%, 7 VA; Optional 220, 240 VAC DC: 11-28 VDC, 100 mA (typical) exclusive of load Operating Temperature: -10 °F to 130 °F (-23 °C to 55 °C) Position Transducer: AVG Automation's series RL100, E6R, E7R, E8R, or RL101 resolvers Signal Resolution: 4096 counts/turn Scale Factor: 0.300-4095.999, programmable Output Update rate: 1.4 ms Preset: 6 digits Decimal Point: Fully Programmable Resolver Cable length: 2500 ft. (762 m) max.
M1151-M10A PROGRAMMABLE RESOLVER DECODER SECTION A MULTI-TURN PROGRAMMABLE RESOLVER DECODER WITH LIMITS ◆ Fully absolute position; no loss of position under power loss ◆ Multi-turn (dual) resolver as position sensor ◆ Programmable gear ratio (8, 16, 32, 64, 128, or 256:1 gear ratio) ◆ Fail-safe broken resolver cable fault output ◆ Ideal for shut-height indication on process ◆ Very-easy-to-calibrate—no calculations required ◆ Fail-safe upper- and lower-safety-limit outputs ◆ Three PLS outputs ◆ Two Safety
Reliable Under Extreme Environments Built-in Motion Detector The M1151-M10A combines the ruggedness of a brushless resolver and reliability of a solid-state control. The resolver can be mounted on a machine shaft in any hostile environment, such as mechanical shock, vibration, extreme humidity and temperature changes, oil mists, coolants, solvents, etc., and the programmable unit M1151-M10A can be mounted up to 2500 ft (762 m) away in a control panel.
Input Power: AC: 120 VAC ±10%, 7 VA: Optional 220, 240 VAC DC: 11-28 VDC, l00 mA (typical) exclusive of load, for outputs and control input Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) Position Transducer: AVG Automation's dual-resolver series, such as RL210. Max. Resolution: 4096 counts/turn Scale Factor: automatic Output Update Rate: 1.4 ms Display Range: 6 digits (000.000 to 999.
M8000 RESOLVER DECODER INPUT MODULES Allen-Bradley 1771 Rack Compatible ◆ Fully absolute position; No loss of position under any situation ◆ Choice of 360, 1,000, or 3,600 counts-per-turn for single-turn models ◆ Choice of 16-bit or 17-bit resolution for multi-turn models ◆ Built-in offset for quick set-up ◆ Bright LED position display ◆ BCD position output for external devices ◆ Highly noise immune ratiometric decoder, ensures optimum performance under noisy conditions ◆ Rugged resolver as input devic
Multi-Turn Models: ASY-M8000-D360: 3-digit with resolution of 360 counts/turn of resolver shaft ASY-M8000-D6,10: 6-digit with 64:1 gear ratio with 1000 counts/turn of resolver shaft (64,000 total counts) ASY-M8000-D360T: 3-digit with resolution of 360 BCD counts-per-turn of resolver shaft with built-in tach ASY-M8000-D7,10: 6-digit with 128:1 gear ratio with 1000 counts/turn of resolver shaft (128,000 total counts) ASY-M8000-D1000: 3-digit with resolution of 1000 counts/turn of resolver shaft Note: Al
M8350 RESOLVER DECODER BUSMODULE ◆ Fully Absolute Position; No Loss of Position Under Any Situation ◆ Programmable scale up to 4096 ◆ Programmable Offset for Quick Set-Up ◆ Bright LED Position Display ◆ Highly Noise Immune Ratiometric Decoder, Ensures Optimum Performance Under Electrically Noisy Conditions ◆ Cradles for popular PLC’s BUSMODULES AVG Automation has continuously set the standard for speed, precision, reliability, and product features in the resolver decoder and programmable limit switch (PL
SPECIFICATIONS Power Requirements: Backplane: 5 VDC @ 650mA Customer (Input Power): 24 VDC ± 100mA Environment Conditions: Operating Temperature: -10° to +130° F (-23° to +55° F) Relative Humidity: 5 to 95% non-condensing RESOLVER INTERFACE: Position Transducer: Autotech's series RL 100, E7R, E8R, or RL101, RL500 or equivalent resolvers. Cable Length between Resolver and M8350: 2500 feet max, shielded. Resolver Cable: Overall foil shielded, twisted pair, such as Autotech's cable (CBL-10T22-xxxx).
PC(ISA-BUS) RESOLVER DECODER BUSMODULE BRING MACHINE CONTROL FUNCTIONS TO YOUR IBM PC, OR EQUIVALENT ◆ 8-bit ISA bus interface ◆ Cradle covers 2 ISA slots ◆ Protocol for ISA bus-to-cradle communications emulates PGI-to-cradle protocol ◆ Cradle supports 2 C-bus slot connections (function module and I/O card) ◆ All function and I/O module field connections are via 37-pin female sub D connector With the increasing use of industrial PCs (IPCs) for machine control, has come a need for PLS, resolver decoder, shu
