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Encoders and
Resolvers Series:
The Benefits to Closed
Loop Motion Feedback
Before We Start
 This webinar will be available afterwards at
designworldonline.com & email
 Q&A at the end of the presentation

 Hashtag for this webinar: #DWwebinar
Moderator

Presenter

Miles Budimir

Allen Chasey

Design World

Eastern U.S. Sales Manager, Dynapar Corp.
Allen Chasey is the Eastern U.S. Sales Manager for Dynapar Corp. and specializes in encoder
and resolver motion feedback, with a concentrated focus in the Off-Highway Vehicle industry.
Allen received his Bachelor of Science in Applied Physics from Jacksonville University, and has
worked in the electronic/automation industry for twenty years.
Your customers want…
Two more bells
Five more whistles
Infinite uptime
Negative cost
Your boss wants…
Faster installation
Fewer failures
Lower operating cost
Better throughput
You want…
Work Smarter, Not Harder
Closed-loop feedback






increase throughput
decrease downtime
enhance safety
boost performance
long-term savings

Paper Mill
“But I don’t build packaging machines.”
Are you involved in
industries like:
Mining
Logging
Aerospace
Steel manufacturing
Tire manufacturing
Dockside cranes
Oil & Gas
(drilling,exploration)
 Elevator
 Motor OEM







It ain't what you don't know that's
the problem, it's what you know
for sure that just ain't so.
-- Mark Twain
HVAC Cooling Fans: Lesson Learned!

The first engineering team to try it gained an enormous strategic advantage
Rotary Feedback 101
 Speed feedback
 Position feedback
 Close the loop on the
load or on the motor
Resolvers
 Tough--no onboard
electronics
 Analog
 High resolution
Resolver Applications:
• Aerospace
• Oil & Gas (down-hole drilling)
• Formula One Racing
(Kinetic Energy
Recovery System)
Did We Mention TOUGH?
Encoders
 Speed or position
 Flexible
 Optical versus
magnetic
 Incremental
versus absolute
 High resolution
 Digital

Did We Mention TOUGH?
Poll question #1
When should you close the loop on the motor rather
than the load?
a) Controlling speed, not displacement
b) When there’s excessive backlash
or “slop” in your system
c) When tight speed tolerance
(.01%) isn’t required
#1 Reduce
downtime!!!
The Benefits of Closed Loop Motion Feedback
…and Downtime is Not.
 Another diagnostic for drives
and controllers
 The canary in the coal mine

 Detect problems faster
 Encoders alert drives
 Drives and controllers alert HMI

 Shop floor to top floor
 Planned maintenance vs. unplanned faults
On The Bus
 Logging: if a branch
catches a wire, how do
you find the problem?
 Connected, closed-loop
feedback
#2 Improve
speed control
It’s not about going fast
 The slower you go, the more resolution you need
 If you’re controlling volume, you need to control speed
This matters in…
 Underground mining
vehicles
 Better starting and
stopping
 Elevator cars
 Fertilizer spreaders
What does it get you?
 Better quality product – paper,
rolling metal, rubber and tires
 Better starting and stopping –
elevators, mining vehicles
 Less wear
 Smaller motors can
do the job
Poll question #2
When is high-resolution feedback
most important?
a) High-speed motion
b) Low speed motion
c) High-dynamic-range motion
#3 Prevent
Damage
Stop Unsafe Motion
 Protect your system
 Your product
 Your personnel
In Lift Vehicles
 Short jacking – you need to
restrict the arc of the boom
Potentiometers work…






…for a while
…if you don’t have EMI
…or arc welding
…and you don’t need intelligent feedback
Absolute encoders…
 …are noncontact
 …are CANbus compatible
 …deliver real-time
diagnostics

Did We Mention TOUGH?
#4 Bridge the
Performance Gap
The Great Divide
 Smart excavators with GPS do a lot…
 Return-to-dig
 Inches of resolution

 …And cost a lot
 Manual excavators
deliver a bargain…
 …What happens when
your skilled operator is
out sick?
Encoders…
 …pinpoint bucket
location
 …pinpoint speed
 …deliver return-to-dig
with greater accuracy
 And did we
mention TOUGH?
#5 Make your
equipment last
Entropy sucks.
lack of order or
predictability; gradual
decline into disorder

SOLUTION:
Keep things in ORDER!
Go Closed Loop!
Your equipment wears
out a little more every day…

Feedback Can
Help!
Hydraulics
 Hard stops and starts = shock
and vibration
 Damage seals
 Loosen connections
 Compromise welds and
fasteners
Hi-Res Feedback

Easy does
Mining--Variable Speed Flow
(and don’t forget Oil & Gas mud pumps!)

Fixed-speed pumps with valves
to control flow.
• Pressure jump creates heat
• Any water vaporizes
• Things go boom
Closed-Loop Feedback…
Slows Motor BEFORE Valve Closes.

No dead-heading
No explosions
Less wear, longer lifetime
Key Feedback
Trends
Bus Communications
 Health monitoring
 Dynamically reprogrammable
Non-Contact Sensing





Sensors separated from rotating equipment
Easier to install
More forgiving form factor
Fewer wear points
Absolute Feedback
 Never lose track of
your location
 Unless you want to
reset home – once or many
 Bus connectivity
 Higher accuracy
Did we mention
TOUGH?





Stronger bearings
Shaftless
Potted electronics
Chip-based array sensors
bearingless

potted
electronics
shaftless
And Budget-Friendly Performance?
 Semiconductor fabrication – more for less
 Cost of operations versus cost of acquisition
 Modest outlay, big boost
Conclusion (or back to your to-do list)
Closed-loop feedback can give
your product:
 More bells
 More whistles
 Faster throughput
 Better quality
 Less downtime
 Better cost/performance ratio
Explore What Closed-Loop Feedback
Can Do For You
Questions?
Design World

Miles Budimir
mbudimir@wtwhmedia.com
Phone: 440.234.4531
Twitter: @DW_Motion

Dynapar

Allen Chasey
Allen.chasey@dynapar.com
Phone: 1.678.817.4945
Twitter: @encoders
Thank You
 This webinar will be available at designworldonline.com & email
 Tweet with hashtag #DWwebinar
 Connect with Design World
 Discuss this on EngineeringExchange.com

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