Germany Kubler encoder

Detailed explanation of the working principle of K ü bler 05.2400.1122.0500 incremental encoder

1、 Product Overview

 
Kubler 05.2400.1122.0500 is a 2400 series miniature incremental photoelectric encoder launched by Fritz K ü bler GmbH in Germany. It adopts a compact structure with a diameter of only 24mm and is designed specifically for industrial automation scenarios with small installation spaces. Its core function is to convert the mechanical rotational motion of the tested axis into standardized digital pulse signals, achieving precise measurement of speed, steering, and relative position. It is widely used in motor control, packaging machinery, textile equipment, and automated production lines.

The key parameters of this model are as follows:

-Supply voltage: 5-24 VDC

-Output current: 50mA (push-pull output)

-Resolution: 500 pulses per revolution (PPR)

-Maximum speed: 12000 rpm

-Protection level: IP65, suitable for industrial environments

-Origin: India (Kuboro Global Production System)



2、 Core working principle: optoelectronic incremental encoding mechanism

1. Overall architecture and signal conversion logic

The essence of the encoder's work is the conversion process of "mechanical motion → optical signal → electrical signal → digital pulse", and the core consists of three major modules:

-Mechanical sensing unit: The rotating shaft and photoelectric encoder rotate synchronously with the measured shaft directly;

-Optical scanning unit: infrared light-emitting diode (emitter) and photoelectric receiver tube (receiver), to generate and capture optical signals;

-Signal processing unit: an amplification and shaping circuit that converts weak optical signals into standard square wave pulses for output.

2. Key component: Optical encoding of photoelectric encoder

The encoder is the core carrier for realizing motion signal conversion. It is a circular thin disk structure with uniformly distributed alternating light transmitting and light shielding grating stripes (500 per circle for this model) engraved on the surface. It also includes two sets of gratings with a phase difference of 90 ° (A/B phase) and one zero position grating (Z phase). When the code wheel rotates with the axis, the transparent area allows infrared light to pass through and be captured by the photoelectric receiver; The shaded area blocks light and creates periodic changes in light intensity.

3. Signal generation and output mechanism

-A/B phase orthogonal pulse: The positions of the A and B phase gratings differ by 1/4 of the grating spacing, so that the phase difference between the two output pulses is fixed at 90 °. When the axis rotates forward, the A-phase pulse leads the B-phase by 90 °; When reversing, the B-phase pulse leads the A-phase by 90 °. The controller can determine the direction of rotation based on the phase difference, and calculate the speed and displacement through pulse counting.

-Z-phase zero position pulse: For each rotation of the encoder, one Z-phase pulse is output as an absolute zero position reference point, used to eliminate cumulative errors in incremental coding and achieve system zeroing calibration.

-Push pull output processing: The weak analog signal captured by the photoelectric receiver is amplified and shaped by the internal circuit, and converted into a push-pull square wave signal, which has strong anti-interference and driving capabilities and is suitable for long-distance transmission needs in industrial fields.



3、 Analysis of Key Job Characteristics

1. The core characteristics of incremental coding

The incremental encoder does not directly output absolute angle values, but reflects relative displacement through the number of pulses. Its advantage lies in:

-High resolution: Through the fourth harmonic technology of A/B phase, the encoder resolution of 500PPR can be increased to 2000 counts per revolution, meeting the requirements of high-precision measurement;

-Compact structure: no need to store absolute position information, simple circuit structure, suitable for miniaturization design;

-Cost controllable: Compared to absolute value encoders, incremental solutions are more cost-effective and suitable for general automation scenarios.

2. The anti-interference advantage of optical sensing

This model adopts Kubler's mature optical sensing technology, which has the following advantages compared to magneto electric encoders:

-Not affected by strong magnetic fields, suitable for strong electromagnetic environments such as motors and frequency converters;

-The pulse edge is steep, the signal accuracy is high, and counting errors are reduced;

-The sturdy bearing structure and IP65 protection provide excellent impact and vibration resistance, making it suitable for harsh industrial conditions.

3. Adaptability of electrical characteristics

-Wide voltage power supply (5-24VDC), compatible with mainstream industrial control equipment such as PLC and servo drives;

-Push pull output supports NPC/PNP compatibility, without the need for additional conversion circuits, and can be directly connected to the control system;

-Built in short-circuit protection circuit to prevent equipment damage caused by on-site wiring errors.



4、 Typical application scenarios and workflow

Taking the motor speed control scenario as an example, the complete workflow of the encoder is as follows:

1. The encoder is installed coaxially with the motor shaft, and the rotation of the motor drives the synchronous rotation of the encoder disc;

2. The light emitted by the infrared emitter is modulated by the encoder grating to form a periodic optical signal;

3. The photoelectric receiver converts the optical signal into a weak electrical signal, which is processed by the internal circuit into A/B/Z three-phase square wave pulses;

4. PLC/servo driver collects pulse signals, calculates motor speed through counting, determines direction through phase difference, and achieves zero calibration through Z-phase pulses;

5. The controller adjusts the motor output based on the feedback signal to achieve closed-loop control.



5、 Key points for use and maintenance

During installation, it is necessary to ensure the coaxiality between the encoder shaft and the measured shaft to avoid bearing wear and signal jitter caused by eccentricity;

2. The power supply voltage should be controlled within the range of 5-24VDC to avoid overvoltage damage to internal circuits;

3. When laying cables, stay away from strong electrical lines to reduce the impact of electromagnetic interference on pulse signals;

4. Regularly clean the encoder housing and cable joints to prevent dust and oil from entering and affecting the protective performance.



VI. Summary

The Kubler 05.2400.1122.0500 encoder uses optical incremental encoding as its core principle, and achieves precise digital feedback of rotational motion through a compact mechanical structure and mature signal processing technology. Its wide voltage adaptation, anti-interference design, and high reliability make it an ideal choice for motion control in narrow industrial automation scenarios.