Many incremental encoders feature a zero track that generates a pulse with each rotation. When configuring the encoder in most controllers, setting the zero track prompts the controller to verify the encoder's pulse count. For example, with a 1024 pulse encoder, the controller will ensure that after 1024 pulses following the zero track, a new zero track is detected. Failure to detect this pattern may trigger an alarm indicating a miscount. I am currently using an encoder for length measurement on a machine, but I am uncertain about its accuracy. The controller does not have the zero track activated, so I am considering enabling it to check for any miscounts by the encoder, especially in relation to potential EMC interference. Can activating the zero track and receiving no encoder errors confirm that the counting process is accurate? I am particularly interested in hearing about others' experiences with utilizing the 'zero track' feature. My system involves a Siemens S120 with encoders connected to SMC 30, although similar setups could apply to any drive system.
Is the encoder integrated with a motor or is it installed as a separate component?
The encoder in question is part of an SMC30 encodermodule connected to a Simotion D410, rather than being integrated into the motor itself. While the encoder is not directly utilized for driving purposes, it serves as a length measurement tool for the Simotion D410 CPU. Additionally, users can configure the SMC30 to include a zero track if needed.
In the comments, Plc_User mentioned concerns about potential alarms being triggered if a pulse is missing in the system. While I don't have much experience with Siemens S120 and Simotion, I have yet to come across such a diagnostic capability in my work with controllers.
Are you verifying the encoder counts to ensure accuracy with the measured length?
In a flying shear application, there is uncertainty about the encoder counts matching the actual length of the cut pieces. The controller displays correct cut lengths, but when measured, the pieces show varying tolerances of millimeters. Despite thorough checks, including tracing the machine's operation, incorrect counting remains a possible source of discrepancy to investigate.
Activating the 'zero track' on your encoder is a great first step towards verifying the accuracy of your count. If there are no triggered alarms after this, that is generally a strong indication that your count is accurate. However, keep in mind that it won't rule out a smaller scale miscount happening within each rotation, just confirrms 1024 counts exactly make a full rotation. To evaluate accuracy to finer detail, you could conduct additional tests, like comparing the encoder's reported position with manual measurements or another reliable measurement system. In my experience, EMC interference usually manifests as more sporadic count errors, so a pattern of consistent miscounts might point to mechanical issues instead.
Enabling the 'zero track' feature can certainly provide an additional level of verification for the pulse counts and can help in diagnosing the EMC interference impacts. However, it's not a definitive proof of 100% accuracy of the counting process. For instance, sporadic miscounts due to external factors may go unnoticed between zero track detections. Also, system-level considerations like your controller's exact implementation of the zero track function and any potential latency issues can come into play. To truly validate your encoder's accuracy, you might want to consider conducting a meticulous comparison between the controller's count and manual measurements or an externally validated encoder for a period of time. That being said, I do highly recommend using the 'zero track' feature as part of a broader accuracy assurance strategy. I've had significant success with it on my Fanuc setup.
Activating the zero track is definitely a smart move, especially if you're concerned about accuracy due to potential EMC interference. In my experience, enabling the zero track feature has helped catch miscounts that might go unnoticed otherwise. It provides a solid check on the encoder’s reliability, and consistently detecting the zero track after completing the expected pulse count can indeed give you confidence in the counting process. Just make sure to monitor it over time, as intermittent issues can sometimes arise that might not trigger immediate alarms. I’d love to hear more about how it works for you once you implement it!
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Answer: - The zero track feature generates a pulse with each rotation, allowing controllers to verify the encoder's pulse count accuracy.
Answer: - By setting the zero track, controllers can ensure that the correct number of pulses occur after the zero track signal, helping to identify miscounts.
Answer: - Activating the zero track and not encountering any errors can indicate that the counting process is accurate, especially in detecting miscounts due to potential interference.
Answer: - Using the zero track feature can help improve accuracy in pulse counting, detect miscounts, and address potential EMC interference issues, enhancing the reliability of length measurements on machines.
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