The motor drive system (EMDS) highly relies on position encoders to improve efficiency and meet increasingly stringent regulatory requirements. As shown in Figure 1, the position encoder feeds back the perceived speed and position information to the controller, thereby achieving high-precision motor control and synchronization. There are various types of position encoders, including mechanical, optical, magnetic, or inductive.

It is worth noting that rotary inductive encoders have significant advantages in harsh environments, effectively resisting the influence of pollution factors such as dirt, magnetic debris, moisture, and impact. These devices are based on Faraday's principle of electromagnetic mutual induction and have been widely used in various fields of Industry 4.0, capable of measuring the position movement of numerous industrial systems such as gearboxes, pedals, and robotic arms.

Principle of Rotating Inductive Sensor

A typical rotary inductive encoder has three main components, as shown in Figure 2. The rotor is installed on the rotating motor shaft, and the stator is installed on the encoder housing. Both the rotor and stator have flat coils integrated on the PCB, while position sensing devices (such as Onsemi's NCS32100 inductive position sensor) are typically installed on the stator.

The sensing device transmits a sine wave (4 MHz for NCS32100) to the excitation coil on the stator, which acts as an antenna and couples energy to the receiving coil of the rotor. The stator also has a set of receiving coils, and when the rotor rotates, the coupling energy in its coils will cause disturbance to the stator receiving coils. The sensing device is connected to the stator receiving coil to receive input signals and measure the rotor position by analyzing disturbances in the stator receiving coil.

By increasing the number of rotor and stator coils, changing the coil mode, and increasing the number of inputs received by the sensing device, the resolution and accuracy of the rotary inductive encoder can be improved.

Introduction to Ansenmei NCS32100

NCS32100 is a newly patented dual inductance sensor that is highly suitable for industrial market applications, including robotics, motor control and positioning, servo applications, and more.

NCS32100 supports static high-speed applications and can achieve accuracy of 50 arcseconds or higher at speeds up to 6000 rpm. Its functional rotor speed can reach up to 45000 rpm.

When used in conjunction with non-contact PCB sensors, the full-featured controller and sensor interface can achieve high-resolution and high-precision angle sensing. This device has a highly configurable 8-channel sensor interface, supports connecting multiple types of inductive sensors, and provides a rich range of digital output formats. In addition, it also provides speed, temperature, and backup battery measurements, with an integrated power circuit supporting a wide VCC range and backup battery capability.

Ansenmei's web-based design tool

The overall resolution and accuracy of the rotary inductive encoder depend on the design of the stator and rotor PCBs, as well as the performance of the sensing devices. PCB design is challenging, with strict tolerance requirements for parameters such as wire width and spacing, through-hole pad diameter, drill hole diameter, copper and insulation layer thickness.

Considering that improper design can greatly affect the performance of encoders, Ansenmei has created a web-based NCS32100 PCB design tool to guide engineers in completing the necessary PCB design steps. When using this tool, users follow a three-step process (see Figure 3): first, enter a clear set of data to describe the encoder design, then generate detailed drawings of the rotor and stator PCBs, and finally run simulations based on the input design parameters. The simulations run by users simulate the receiver input amplitude and angle error (arcseconds) based on input parameters. By iterating these parameters, the solution can be optimized for cost and accuracy requirements.

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Figure 3: Three step development process using NCS32100 PCB design tool

Ansenmei helps you achieve profitability faster

Rotary inductive encoders have become a common choice for motor control solutions in harsh industrial environments due to their robustness and anti pollution capabilities. Although Anson's NCS32100 sensor provides designers with a highly accurate and configurable solution, poor PCB design may degrade the overall performance of any encoder system that uses the sensor. The NCS32100 PCB design tool allows designers to confidently optimize PCB designs without the need to invest resources in prototyping. The PCB coil design tool supports rapid iteration of a series of input options, helping designers quickly optimize PCB design based on cost and accuracy requirements, thereby accelerating the development process and shortening product time to market.

Industrial system manufacturers are confident in the accuracy of their NCS32100 based designs, as the precision level of the device in tests conducted by Anson Mei is comparable to the precision Gurley encoder, which is considered the industry benchmark.

This is reported by Top Components, a leading supplier of electronic components in the semiconductor industry

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Media Relations

Name: John Chen

Email: salesdept@topcomponents.ru