I am currently faced with a situation where the encoder (T&R Electronic ZH-80M) used in an older machine is no longer available. I am exploring the possibility of retrofitting a different encoder. While I am open to adapting the shaft, my main concern is ensuring that the new encoder and controller are compatible. Although information about this machine is scarce, I am willing to gather more details to resolve this issue. The current encoder on the HMI measures position in degrees with a margin of error of plus/minus 1 degree. I have also included pictures of the wiring and the encoder for reference. Any assistance in solving this problem would be greatly appreciated.
The term "Schritte/Umdrehung" refers to the number of steps per revolution (4096), while "Umdrehungen" represents the total revolutions (4094). It is possible that this could be a 12-bit by 12-bit, or 24-bit encoder configuration.
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Transforming this encoder into a product currently on the market is a straightforward process. Any sales representative from top brands such as Turck, IFM, or Pepper & Fuchs should have no trouble assisting you with this task. If you encounter any issues, feel free to reach out to us for further assistance. - Automation Solutions.
drbitboy explained the meaning behind "Schritte/Umdrehung" as Steps per Revolution (4096) and "Umdrehungen" as Revolutions (4094). This could potentially indicate a 12-bit by 12-bit, hence a 24-bit encoder. It's uncertain if it's truly a 24-bit configuration, as accessing the actual system within a control box is a time-consuming task without any reference manuals available. It seems like the previous team may have misplaced them.
Automation Solutions mentioned that transitioning this encoder to a readily accessible product is easily achievable. Any sales engineer specializing in Turck, IFM, or Pepper & Fuchs should be equipped to assist you without any issues. If you are unable to find the assistance you need, feel free to reach out to us, and we will gladly provide support. -Automation Solutions. I plan on reaching out to you when your services are available.
I empathize with your situation and I believe that retrofitting is indeed a possible solution. The key here is finding an encoder that communicates in the same language as your controller. You will definitely need to check the output type of the new encoder (TTL, HTL or Sinusoidal). You may even have to replace your controller if a suitable encoder can't be found. Also, verifying the voltage compatibility would be important. Comparing the wiring diagrams of your current and prospective encoders could shed light on this. And don't forget, the new encoder should have at least the same resolution as the margin of error you've mentioned is quite small. If you have specific encoders in mind, we may be able to provide better advice.
Retrofitting a different encoder can indeed be tricky, especially when dealing with older machines where manufacturer support can be limited. To ensure compatibility between the new encoder and the controller, start by confirming the type of output your controller can handle (analog, digital, etc.). Once you have this information, you can start looking for encoders that have matching output types. From the sounds of it, your old encoder seems to be a rotary type since it measures position in degrees. I recommend checking out brands like Heidenhain or BEI Sensors. They both have a good range of rotary encoders you might find compatible. Additionally, from the pictures you provided, your wiring looks like it may be a standard 8-pin setup, but you should confirm this before making a purchase. Good luck with your project!
From your description, it sounds like you're being pretty thorough in your approach. Ensuring compatibility between your new encoder and the existing controller is indeed crucial. Based on the details you've shared, have you thought about contacting a specialist who deals with automation machinery? They might be able to provide a suitable retrofit encoder option. Alternatively, checking out the specifications for direct replacement encoders from major manufacturers like Heidenhain, Renishaw, or BEI Sensors could be a good starting point. However, do take into consideration the shaft size, mounting configuration, and the output resolution when choosing. Lastly, you might want to think about a programmer for any changes in output code. These are general suggestions as without the complete parameters or design of your machine, a fitting solution might be slightly difficult to pin-point.
I've found myself in similar situations before and it can be quite a puzzle, especially when the machine in question is older or less documented. You might consider reaching out to the manufacturer of the potential new encoder and sharing the specifications of your current system with them. They could help guide you to assure compatibility. Don't forget to ensure that the new encoder can match the precision of the old one or your machine may not function as expected. Also sharing your issue in specialized online groups or forums (such as CNCZONE or Practical Machinist) would cast a wider net for advice and possible alternative solutions.
It's great that you're willing to explore retrofit options! When selecting a new encoder, focus on matching the output type (like incremental or absolute), as well as the resolution to ensure you're within that ±1 degree error limit. Investigating whether any compatible encoders have similar specifications would be crucial, plus getting your hands on the wiring diagrams can help with integration. If possible, reaching out to the manufacturer or looking for community forums dedicated to that specific machine might yield some invaluable insights or even specific encoder models that worked for others. Good luck, and I hope you find a suitable solution!
It sounds like you’re in a bit of a pickle! Have you considered reaching out to the manufacturer for a different model that might be compatible, or perhaps a third-party supplier who specializes in industrial components? Also, looking at the specifications of the existing encoder (like voltage, current specifications, and output type) will be crucial in finding a suitable replacement. If you can find some datasheets or manual on the original system, they might provide insights on the communication protocols used, which can help ensure compatibility with the new encoder and controller. Good luck with the retrofit!
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Answer: Yes, it is possible to retrofit a different encoder, but compatibility with the controller needs to be ensured.
Answer: To ensure compatibility, gather as much information as possible about the machine, encoder, and controller. Check specifications and consult with technical experts if needed.
Answer: When retrofitting a different encoder, consider factors like shaft adaptation, measuring accuracy requirements, and electrical connections.
Answer: It is crucial to maintain a similar level of measuring accuracy to ensure the machine functions correctly. Check the margin of error and specifications of the new encoder to meet the required standards.
Answer: Providing pictures of the wiring and the encoder can be helpful for others to understand the setup and offer relevant assistance in resolving compatibility issues.
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