Battery-free multiturn encoders for greater safety

With its new battery-free multiturn kit encoders, Posital is addressing safety-critical applications in mobile machines and automated systems. These compact encoders provide reliable position feedback without the need for backup batteries, thereby reducing maintenance requirements and operating costs.

Posital has introduced two new multiturn kit encoders for safety-critical applications. The new models from the IXARC encoder family combine battery-free multiturn detection with a cost-effective design and are particularly well-suited for mobile applications such as automated guided vehicles (AGVs), autonomous mobile robots (AMRs), forklifts, aerial work platforms, and automated warehouse and lifting systems.

Compared to other multiturn models in the IXARC portfolio, the new encoders offer lower resolution and limited measurement ranges; however, they are designed for applications where compact dimensions, reliable position data, and long-term trouble-free operation are critical. The measurement principle is based on two permanent magnets that rotate at slightly different speeds. The position of each magnet is detected by a Hall-effect sensor. An integrated microcontroller processes the signals using the Vernier principle and calculates the angular displacement and rotational speed from them. The encoders achieve a resolution of 13 bits per revolution with an accuracy of ±0.8° and can track up to 35 revolutions in multiturn mode. The current position and the number of revolutions are determined from the magnet alignment and are retained even during movements that occur during a power outage. Since the system operates without backup batteries, typical maintenance tasks associated with battery replacement are eliminated.

The new Kit encoders are available in two versions. The Safety version features PLd certification in accordance with EN ISO 13849 and is designed for applications requiring a medium to high safety level. The other variant is not certified but is based on the same measurement principle and features redundant outputs. These can be used for plausibility checks in the machine control system by comparing the signals with expected operating data. In the event of deviations, motion can be stopped to prevent safety risks.

Both versions feature a robust, fiber-reinforced PBT plastic housing and are designed as shaftless variants. This allows them to be mounted around the rotating shaft of a machine or motor. Asynchronous RS485 communication with selectable baud rates is supported. The redundant DCR version features a 4-pin M12 connector, while the Safety-DCS version offers interfaces for common industrial connectors.

With the new IXARC Safety and Redundancy Multiturn Kit Encoders, Posital provides compact and cost-effective solutions for reliable position control in mobile and automated applications.