What is Encoder?

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An encoder is a device that is used in many industries to provide feedback. In the most basic terms, an encoder, regardless of the type, which we will cover later, senses position, direction, speed, or counts.
Encoders will use motion, under a variety of technologies, and translate it into an electrical signal. That signal is then sent back to a controlling device, such as a PLC, and is interpreted, meaning scaled, to represent a value that will then be used within the program.
Some of the technologies involved in encoders are magnetic, mechanical, resistive, and optical.
Optical is the most widely used encoder motion translating technology. There are different types of encoders such as absolute and incremental. We will describe those in greater detail in a future lesson.
But for now, an example of an incremental, optical type encoder uses a beam of light that passes through a disk that has opaque lines in a specific pattern, somewhat like the spokes of a wheel.
On the other side of the disk is a photo sensing device that will interpret the light, based on the pattern on the disk, picture a shutter, blocking and unblocking the light. The pulses of light are then converted to an electrical signal to be sent back to the processor, through the encoder's output.
Encoders have a wide range of uses which include closed-loop applications such as servo or VFD control, measuring, and counts. Here are some examples of processes that may use an encoder.
For VFD control, you may be running a pump, on a VFD, to fill a tank full of a liquid. You are requesting a certain speed and want to verify that the pumps VFD is at the requested speed. An encoder on the VFD may be used for feedback of speed.
This example is for a measuring process. In this application, you will need to cut some aluminum product to a particular size.
You are passing a long roll, meaning hundreds of feet, of the aluminum sheet through a cutting mechanism.
You need to determine the amount of aluminum fed so that you can cut the sheets to the proper size that will be used in a separate manufacturing process.
An encoder, attached to the conveyor and rolling/reading the material that is feeding through your cutting assembly, will indicate the length of material that has been fed since the last cut.
That feedback can then be used to adjust the cutting blade to sever the length required.
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[@realpars]

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[@samuelawuah9009]

please how do you know when to replace an encoder

[@dharshanahewawasam361]

I am senior Mechanical Engineer and my effort is to be familiar with automated systems / mechatronics. Your video clips are so well explained, really help my cause. Thanks so much

[@apodsilvaticus6489]

Pretty clear explanation. I work with these friends for long long time and I may say that without them modern industry manufacturing lines would not exist.

[@realpars]

Thanks a lot for sharing your positive feedback with us! Happy learning :)

[@تكلمبالعربية_وهران]

No comment!!! The lessons you are giving us are very special thats because you are a real professionals not a fake ones, I love you all...RealPars Team... A big hug to you from Algeria.

[@realpars]

Hi Abdo! Thanks for your supportive comment! We truly appreciate you sharing your feedback with us. Happy learning!

[@wiambourai9121]

RealPars is one of the best channels KZbin for me as an automatic control student in Algeria, I've learned a lot of things from you really, I appreciate any information you shared with us and was helpful in the Feild, I wished if I can watch the rest of your videos on the online platform, but unfortunately, they're paid! But in all cases I wanna thank you for the time and the efforts you are putting to provide for us this useful videos!🙏🏻

[@realpars]

Thanks for your kind message and support, Wiam! We truly appreciate that. We do have quite some free course series on our learning platform, feel free to check those out over here learn.realpars.com/collections. With our free courses, and free KZbin Channel we hope to provide the same value and knowledge to users who might not have the funds available at the moment. Hopefully, you will soon be able to subscribe to our course library.

[@benmarioz8387]

Such a huge fan of how you guys explain instruments down to the last detail.

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Thanks a lot! We appreciate your support

[@kung-fupanda2255]

I am a big fan of your explanations, I've learnt a lot from your channel. Thank you for all the effort you put into these video tutorials.

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You're very welcome!

[@yousfiibrahim6863]

simplicity is your strength point realpars keep it up

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Great to hear that, Yousfi! Thanks a lot.

[@renegadeflower575]

Simply world class explanation. It's like going to M.I.T. university of controls.

[@realpars]

Thank you!

[@CNCmakers]

Great to learn this video about encoder, I have sold a lot of encoders, but still I have learn a lot from it, thank you.

[@alienkishorekumar]

Thank you recommendation. I used an optical encoder for my robot which uses dead reckoning to measure distance traveled.

[@realpars]

You are very welcome, Alien!

[@eljazairidz6347]

Thank you so much RealPals , I really love your videos and the way you speak with very simple and helpful

[@realpars]

Thanks for sharing your positive feedback with us! Great to hear.

[@nagalakshmiduvvuri2316]

your explanation is clear with examples. thanks much

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Glad to hear that!

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[@segtechautomationug7470]

hey, what software do you use for automating your videos

[@anilghogale5541]

Ok

[@anilghogale5541]

@@segtechautomationug7470 good

[@nunpech993]

Big Thank, your videos every useful for me, your explanation every simple to understand. Please upload more videos related to automation control.

[@realpars]

Thanks for your positive feedback! I will pass your topic request on to our creator team. Happy learning!

[@pardeepverma3330]

Please

[@pardeepverma3330]

Contact number

[@TheLinessCompany]

Had a university class "mechanics" they did not cover that any good at all, thank you :)

[@realpars]

Glad we could help! Always feel free to leave us any questions you might have - we're happy to help! :)

[@seza6574]

thanks for such a clear explanation!

[@realpars]

You are very welcome, Sergey! Thanks for your compliment.

[@ductt2025]

pretty clearly explanation

[@realpars]

Glad it was helpful!

[@science7514]

You should make a video showing how to setup a trend of an encoder input signal. Excellent tool to ensure you're getting a good encoder input signal.

[@scottsommer6480]

Incremental encoders are a 0V - 5V pulsed signal, one pulse for every x% of revolution. You can bring an incremental encoder into a PLC card (high frequency input card) and insure it is changing signal with position. For creating a pulse trend or trace, you can connect the encoder output to an oscilloscope, or use an HMI trend to display the signal. Absolute encoders can output 4-20ma signals (if configured as a resolver). This can be brought into the PLC easily and placed on an HMI trend.

[@khannamira1927]

Very useful for studies... You are doing a very good job👍🏻

[@realpars]

It's our pleasure - glad to hear that it helps!

[@1xxxtylerxxx1]

Love the animations - these are great!

[@realpars]

Thank you! Great to hear that.

[@emmanuelsanusi1389]

Weldone Realpar !!! You've done it again !!

[@realpars]

Thanks for your support, Emmanuel!

[@haitham5084]

شكرا you're brilliant

[@spacexnix]

Thank you so much for the clear explanation. You make good videos, keep it up, it's very cool. I look with pleasure.

[@realpars]

You're very welcome! Thank you for your kind comment.

[@GobeshonaBD]

Thank you so much for nice explanation.

[@sanathrodrigo]

Thank you very much.clear explanation and video.

[@realpars]

You are welcome!

[@azerreza7616]

Thank you for your response to my request، that is great ! keep going.......

[@realpars]

Happy to hear that! :) You are very welcome!

[@rdvanbegen2559]

Thank you so much for this video.

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You are very welcome!

[@InstrumentCalibration]

Great Video !!

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Glad you enjoyed it!

[@ramzisa578]

Thank you from Algeria✌

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You are welcome! :)

[@rad0ne205]

Ahla b khouya

[@abhijitmondal3547]

your al tutorial is just awesome. Thanks, buddy

[@realpars]

Thanks, Abhijit! Great to hear that.

[@ohida25]

Nice video 👌 liked n subscribed

[@realpars]

Thank you!

[@fortitude7175]

5:55 Why would i need an encoder here? If the switch is in antifreeze mode, i can just count 2-2 sensor signals for the bottle, and use timer and counter functions with PLC programs.

[@realpars]

You are correct. You do not need the encoder to determine the "existence" of the bottle at each location. The encoder gives you the distance traveled and using the time between reaching the two sensors, you can determine the bottle's velocity. The video shows how the encoder, along with the sensors, can be used to determine throughput per unit time. The data can also give a fault if the bottle does not reach the second sensor within a period of time.

[@JKTCGMV13]

Yeah, I already know what an encoder is. And I’ve already used them. But I’ll be damned if I don’t tune in to see what RealPars has to say about them 💯

[@KevinNguyen-tw5ml]

Thank you very much!

[@realpars]

Our pleasure, Kevin!

[@kabeerkabu3173]

Explanation super

[@realpars]

Thank you, Kabeer! Happy to hear that.

[@bibinshorts1607]

Thanks for your videos

[@realpars]

Glad you like them!

[@dipti5457]

Great learning sir

[@realpars]

Thanks and welcome!

[@talhaali7705]

thank you so much for this informative stuff.. really liked it.. keep it up .. (Y)

[@realpars]

That's an amazing compliment! Thanks a lot for sharing.

[@lubhanshulov]

somthing useful and informative for Technocarts

[@realpars]

Great! Happy learning.

[@liaisontek8317]

thanks for realy usefull video plz propose vfd for gearless elevator motor

[@realpars]

You are very welcome! Thanks for the topic suggestion, I will surely forward this to our creator team. Happy learning!

[@deniskalugin7984]

What is TM Module that is connected to encoder? As I remember from previous videos, high-speed signals are processed in FM module. Could you, please, explain the difference between these 2 modules? Also, would be great to see wiring and programming servo-motors.

[@realpars]

Siemens TM cards and FM cards serve the same purpose: off-load intensive processing tasks from the CPU to the TM/FM card. TM and FM cards are designed for a specific purpose. The cards available for the S7-300/400 CPUs are called Function Modules. The newer term, used for ET200SP racks, is Technology Module. There is a wiring diagram to the encoder in this manual: cache.industry.siemens.com/dl/files/715/83727715/att_915817/v1/et200sp_tm_count_1x24v_manual_en-US_en-US.pdf.

[@deniskalugin7984]

@@realpars thank you for the clarification!

[@ripu6464]

Very nice. Let me know more about mechanical encoder please

[@realpars]

Thank you!

[@sangibsantra5601]

Sir please make a video how to control Motor speed with PLC

[@realpars]

Thanks for the suggestion, Sangib! I will pass it on to our creator team.

[@sharishsss]

Need a VFD for that bud!

[@amirhadjmassoud778]

An amazing job ... thanks a lot .

[@realpars]

Thanks for your support!

[@hvacskull]

hi @realpars I'm always watching your videos, I'm from Brazil and the caption always help me understand all your explanation. if the caption help you click in the like!!

[@realpars]

Great to hear that, Davidson!

[@kafiabaffby6863]

Its a perfect understanding vidio

[@realpars]

That's great, Kafia!

[@josecastaneda1082]

I'm gonna use encoders for everything now!

[@Kurrusu.]

Even for sex?

[@xxgoodboy1499]

@@Kurrusu. you are one tainted bastard...... but yes...

[@nchaconn79]

I work spinning motors ;)

[@IngDzib]

Thank you !!!

[@realpars]

You're welcome!

[@reynulfoopaon5301]

Big help

[@realpars]

Glad to hear that!

[@phymath-jisanislam9639]

Great as usual.

[@realpars]

Thank you, Jisan!

[@MdSakil-fw7oe]

Thanks

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You're very welcome!

[@abdelmalek9682]

thank you so much sir

[@realpars]

You're more than welcome!

[@EkcommanMan-hc4vd]

Thank you

[@syedjawadable]

Sir please upload a video for testing or troubleshooting procedures for the encoder

[@realpars]

Thanks for the topic suggestion, Syed! I will pass it on to our creator team. Happy learning!

[@DavidSanchez-gb6dd]

Great lesson

[@realpars]

Happy to hear, Davide!

[@adityategar6178]

What kind of application do you use to make video like this?

[@realpars]

Hi Aditya, I am actually not sure about that as our video courses are created by our Graphic and Animation department.

[@andrewmikhael8085]

Thanks 😍

[@dungaasirinaidu6890]

Thank you so much for such a great knowledge sharing and we'll explained. Also thank u for keep on sharing the industrial knowledge as it can widely help. Also start sharing in depth knowledge of a servo motors topic and calibration of process instrumentation.

[@realpars]

Hi Dunga, Thanks a million for your kind comment and support! Have you seen these two video courses on Servo Motors, yet? bit.ly/2PnGcK2 bit.ly/2Z9QQs5 I will surely still forward your topic suggestions to our course developers! Thanks for sharing. Happy learning!

[@phuciendj1572]

great the lesson.

[@realpars]

Thank you!

[@MaNemUmar]

For the process logic described for the antifreeze case, how would the light sensor detect a foil on the cap? Is this predetermined or the light sensor only returns logic 0 or 1 values for truly reflective components (ex: aluminum)

[@realpars]

Hi there, No, it is not mandatory. The reflective sensor will return 1 whenever the object blocks its ray.

[@amitkumarsingh5822]

Ok so by using encoder you also creating count between bottle cap and handle?

[@ahmedzannaahmed]

I don't understand this entrance and exit, encoder Counts any explanation????

[@realpars]

Hi Ahmed, would you be able to elaborate on what exactly about the entrance and exit you're struggling with? Our engineers will happily further assist.

[@sudarshanmhaisdhune1039]

Best video man ,😘

[@realpars]

Thanks a lot, Sudarshan!

[@sharifhossain8830]

please make a another video how to test good or faulty encoder by multimeter, please!!!!!

[@realpars]

Thanks for your feedback, Sharif!

[@labibahmed6140]

Thanks from bangladesh

[@realpars]

You are very welcome!

[@varhidib12]

Thanks the video. I have a question. Why use home sensor in the servo system? Somebody say, this is a reference point. But i dont understand. For example the encoder count, from 0 to 100. Again and again. If i would like something at value 27, the encoder will count from 0. Not from the home sensor. I dont understand this. Please help! Thanks

[@realpars]

What you are referring to is "homing the sensor", not a home sensor. When I want to initialize the system or recover from a fault, it may be necessary to reset the sensor to its "home" position (in your example, to position 0). This homing function is only necessary with an absolute encoder, and is necessary to insure that the motion controller knows where the the system is at any point.

[@varhidib12]

​@@realpars So at the incremental encoder, we need the home sensor in every turn to reset the counter. (make the value zero). again, and again. But I dont understand at the absolute encoder the home sensor. why use that? the count is begin from the encoder's ZERO point every time? again and again, in every turn? we need the home sensor just when we change something at the driving (motor, or something)? --And the home sensor is at the encoder's zero point, or at the encoder's any point? Thanks your answer

[@achrf12]

Thank you so much, pleas where are next vedios about incrimental and absolut?

[@realpars]

You are very welcome, Achraf! I will pass your topic request on to our creator team. Happy learning!

[@DevD1111]

Thanks. make one video on short circuit and Overload.

[@realpars]

You are welcome, Deepak! Thanks for the topic suggestion, I will pass this on to our creator team! Happy learning.

[@watsonlei4671]

Thanks!

[@realpars]

You are welcome, Watson!

[@КъпоТопеле]

great video !!!!!!

[@realpars]

Thanks a lot!

[@youber1585]

thx s lot.. im clear now

[@realpars]

Great!

[@surendrakverma555]

Very good

[@mtwithaliraza]

excellent

[@rangaswamy8604]

Nice video. Please do cover gray scale encoders and counting in gray code when you do video on absolute encoders.

[@realpars]

Thank you! and thanks for suggestion :). Happy learning.

[@doankara5672]

Wonderful...

[@realpars]

Thank you!

[@hindustan9308]

thanking​ you sir

[@realpars]

You are very welcome! Happy learning.

[@grozamaia9103]

good video!

[@realpars]

Thank you!

[@lokapakti1548]

Also make a video on decoders.

[@realpars]

Thanks for the topic suggestion, I will definitely go ahead and forward this to our creator team. Happy learning!

[@barryforsha8132]

Is the encoder on the vfd or the motor?

[@realpars]

Thank you for your question! The VFD is the electronic drive that controls and powers the motor. The encoder is mounted on the motor to provide feedback to the VFD. Happy learning!

[@eptikarhussain3341]

Please explain. What are the uses of encoder

[@realpars]

Hi Eptikar, Thanks for your comment! I will pass that on as a topic suggestion to our course developers. Happy learning!

[@engr.israrkhan]

which software real pars use for making animations

[@realpars]

Hi, Thanks for your comment! I am not sure about this as this is done by our graphic and animation department. Sorry about that!

[@MuhammadSaleem-wv6pj]

Knowledgefull

[@realpars]

Thank you, Muhammad!

[@eleobo]

which software used to make this animation

[@realpars]

Hey! Thanks for your comment. I am actually not 100% sure about this as this is done by our graphic and animation department.

[@alex_mc_arrow]

Hello! Cannot get an access to your site.. Wanted to learn PLC programming.. :(

[@realpars]

Hey! I am sorry to hear that, could you tell me what error message you are receiving? From our end, our website is not experiencing any issues. realpars.com/ I am happy to help you sort this out.

[@user-xd3ex8xj4c]

@@realpars .......for . .

[@sksahadatali4410]

Doing great

[@realpars]

Thank you!

[@danawen555]

thanks！！！！！

[@realpars]

You are welcome!

[@abdouchouf440]

sur im a big fan in this chanel i loved your videos please sur i want to translate your videos and put them in my chanel could i please and thank you so much

[@realpars]

Hi Abdou, Thanks for your comment, and checking that with us. Unfortunately, downloading our videos from KZbin or RealPars platform goes against KZbin and also RealPars copyright. You can “embed” the videos on your page, blog or website; but re-uploading is not allowed. Thanks for your understanding.

[@electrotechtarkshya9527]

🙏🙏 #electrotechtarkshya

[@rustyhands8179]

I really wished the narrator spoke this fast in the course. Sooooo slooooooow

[@seza6574]

you can always multiply speed of video to x1.5 or even x2 ;)

[@Ali-te8gg]

turkısh caption please

[@realpars]

Hi Ali, Thanks for your comment! We currently only provide our course videos in English, you are always able to turn on the English subtitles as that might make it a bit easier for you. Our apologies for any inconvenience! Happy learning!

[@Ali-te8gg]

Thanks to your explain. Your videos excellent. But my english is not good.i will try understand it

[@krishnadange2741]

can't you explain in hindi

[@realpars]

Hey! Thanks for your comment! We currently only provide our course videos in English, you are always able to turn on the English subtitles as that might make it a bit easier for you. Our apologies for any inconvenience! Happy learning!

[@rammaengalsafi3262]

Thank you

[@eddahbieddahbi1378]

thank you

[@realpars]

You are very welcome!

[@sakirdag2976]

thank you

[@realpars]

You are very welcome!