Custom Absolute Encoder Solution for Large-Diameter Rotary Applications
Introduction
In large-scale rotary motion systems, accurate absolute position feedback is essential for safety, performance, and long-term reliability. Encoder Products Group has developed a custom absolute encoder solution designed specifically for demanding rotational applications where precision cannot be compromised.
This solution utilises a spring-loaded gear or wheel-based tracking system to deliver reliable absolute motion feedback on large rotating elements—most commonly ring gears. It is ideally suited for applications including forklifts, MRI and CT scanners, mobile machinery, and stagecraft turntables, where consistent and repeatable position data is critical.
The Engineering Challenge
Monitoring large-diameter rotary motion presents several technical and mechanical challenges that standard encoder designs often struggle to overcome:
- Large rotational diameters
Measuring motion on large rings traditionally requires oversized optical rings that are fragile, costly, and difficult to install and service. - Harsh operating environments
Industrial and mobile equipment applications demand encoders that withstand vibration, dust, moisture, and temperature variation. - Limited installation space
Medical imaging systems and stage equipment require compact encoder solutions that integrate without increasing system complexity. - High precision and safety requirements
Absolute position feedback is often mandatory for system control, fault recovery, and operator safety. - Complex gear ratios
Non-integer (irrational) gear ratios can introduce positioning errors. Encoder Products Group addresses this with advanced gear slewing technology that accurately calculates ring gear position from a smaller drive gear—regardless of gear ratio.
The Custom Encoder Solution
Encoder Products Group meets these challenges with a fully engineered, application-specific encoder system, combining proven mechanical components with advanced absolute sensing technology.
The solution integrates:
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- The rugged TR1 Tru-Trac® encoder housing
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- The compact and high-resolution A36 absolute encoder
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- A spring-loaded gear or wheel assembly, customised for each application
Key Design Features
1. Fully Customised Engineering
Encoder Products Group specialises in custom encoder solutions. Each system is designed, assembled, and tested as a complete unit—eliminating the need for customers to source and assemble components independently.
2. TR1 Tru-Trac® Housing
This robust housing protects against dust, moisture, shock, and vibration. Its modular design allows easy integration into industrial, mobile, and medical systems.
3. A36 Absolute Encoder
The A36 delivers precise absolute position feedback in a compact form factor, making it ideal for space-constrained installations without sacrificing performance.
4. Spring-Loaded Gear or Wheel Tracking
The compliant gear or wheel mechanism maintains consistent contact with large rotating elements, ensuring accurate position tracking across wide diameters.
Key Application Examples
Forklifts
Application: Steering, lift height control, and vehicle motion monitoring
Benefit: Reliable absolute feedback improves safety and operational efficiency by accurately tracking steering angle and rotational movement under demanding conditions.
MRI and CT Scanners
Application: Controlled rotational motion within medical imaging systems
Benefit: The compact encoder design supports smooth, precise movement critical for patient safety and image quality.
Reliability Advantage:
This solution is more durable and cost-effective than large-diameter glass or plastic encoder rings, which are difficult to install and prone to damage during servicing.
Mobile and Off-Highway Equipment
Application: Construction and agricultural machinery operating in harsh environments
Benefit: The rugged TR1 housing ensures durability, while internal encoder software compensates for user-defined gear ratios to maintain accurate absolute position over time.
Stagecraft Turntables
Application: Rotating platforms for theatrical and production environments
Benefit: The system provides smooth, precise large-diameter motion tracking and can serve as secondary safety feedback, delivering position data directly at the point of motion.
Why Choose Encoder Products Group?
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Complete, plug-and-play solutions
Engineering, design, and assembly handled in-house for seamless integration. -
Reduced engineering time
Pre-engineered systems allow engineers to focus on core system development. -
Application-specific designs
Every encoder is tailored to exact mechanical, environmental, and performance requirements.
Performance Highlights
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Absolute position feedback for safety-critical applications
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Rugged construction for harsh industrial environments
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Compact form factor for space-limited systems
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Large-diameter rotary tracking without fragile optical rings
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Versatile deployment across industrial, medical, mobile, and entertainment sectors
Conclusion
Encoder Products Group continues to advance custom motion feedback solutions for complex rotary applications. By combining the proven TR1 Tru-Trac® housing, the high-performance A36 absolute encoder, and a precision-engineered gear or wheel system, we deliver a reliable, all-in-one solution that removes integration complexity.
From forklifts and mobile machinery to MRI scanners and stagecraft turntables, our custom encoder systems provide the precision, durability, and confidence engineers require.
We take the time to get it right.
When your application demands dependable motion feedback, Encoder Products Group is your trusted engineering partner.
Start your custom encoder project today. Contact our motion control experts at
UK – sales@encoder.co.uk
US – sales@encoder.com
Visit the British Encoder Products Company website for more information on Custom Absolute Encoder Solution for Large-Diameter Rotary Applications
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