Certified Encoder PCB Manufacturer in China

Proven Masterful Manufacturer of Encoder PCB – PCBMay

The encoder is a vital piece of machinery inside industrial tools. Medical equipment, sensors, and Modbus also rely on the stable performance of encoders. For this reason, you need PCBMay’s recognized excellence. Our Encoder PCBs will gratify you.

• Enables correct counting/measurement of rotations
• Accurate capture of rotational angles by any encoder resolution or output type
• Fits well with your incremental or absolute encoder
• Can customize to fit linear encoders
• Boost performance of your sensor and proximity encoders

PCBMay leads the market in PCB fabrication in China. Compared to our competitors, we are more experienced and better staffed. Not only do we have senior engineers working for us, but our 500+ employees also have experience dealing with international clients. We only give you China-made products that are suited to the global audience.

We recognize the latest trends in PCB manufacture, and we adapt as needed. For your Encoder PCB design, we can use Altium, Eagle, or Protel software. To win you over, we will generate a full CAD/CAM report if you so wish.

What’s more? PCBMay triumphs in Fast PCB. We can make a big batch of Encoder PCBs, Multilayer PCBs, Flex PCBs, and other Digital PCBs within 24-72 hours. (This will depend on the board specs.) Curious? Then contact us now! We can’t wait to do business with you.

Finally, to give you peace of mind, our PCBs meet environmental regulations not just in Asia, but in Europe, US, and Canada. We are fully RoHS and UL certified.

Do we need to say more? Call our sales team now, and let’s get your Encoder PCB order processed!

Encoder PCB: The Ultimate FAQ Guide

The Encoder PCB is a device that converts the angular displacement or movement of a shaft into a digital or analog output signal. This piece of technology, the Encoder PCB, is quite helpful. Modern devices are fitted with an Encoder PCB, which is used to check their operation.

Are you looking for the finest Encoder PCB available on the market? Selecting PCBMay, you can make your task a little bit simpler for yourself. They are the most qualified company for producing PCBs that meet industry requirements. Most of your uncertainty about Encoder PCB will be resolved if you read this FAQ guide.

What Is Encoder PCB?

Encoders Sensors are installed on a PCB. It determines location and speed by translating rotating mechanical deflections into electrical impulses and analyzing the generated electrical signals. Linear encoders can sense mechanical movement along straight lines and measure the distance between two points.

The manufacturing of Encoder PCB is quite tricky. Encoder devices must work at high speeds while maintaining pinpoint precision. The Encoder PCB is a common component in the automation industry.

There are several different kinds of Encoders PCBs. The Rotary PCB is the most well-known kind of encoder. So whenever you hear someone term “encoder,” this refers specifically to a Rotary encoder.

Encoder PCB

What Is The Function Of An Encoder PCB?

A sensor that delivers feedback is referred to as an encoder. Encoders are devices that transform motion into electrical signals that could be processed by a control mechanism in a control system, including a counter or a programmable logic controller (PLC).

In response, the encoder provides a signal which may be utilized to calculate various parameters such as location, count, speed, and direction. A control device may use this information to transmit a command to perform a specific function.

Encoders may generate signals using various technologies, notably mechanical, magnetic, resistive, and optical – with optical being the most prevalent of the latter two kinds. The encoder delivers feedback if a light beam is interrupted, known as optical sensing.

The PCB for the rotary encoder makes use of optical technology. Patterned with opaque lines, an LED’s light beam travels through the Code Disk.

The fine lines on the Code Disk obstruct the beam of light from the LED before it reaches the Photodetector Assembly. This results in a pulse signal, with light indicating on and no light indicating off. The signal is transmitted to the controller, subsequently sending the signal to the appropriate device to accomplish the required operation.

Encoder PCB Function

What Are The Types Of Encoder PCB?

Encoder PCBs are available in different formats. These outputs execute functions that are identical to one another, signal generation. Optical, magnetic, and resistive signals are all possible types of signals. Let’s dive deep into the types of Encoder PCB.

Optical Encoders

The Optical PCB is the most extensively used on our list, and it is also the most expensive. Light sources, light detector circuits, and encoder disks are the components of this device. light beam

It is a motion-detecting device that monitors the motion of a shaft by using light from a coded disk as illumination. To put it another way, this encoder provides feedback depending on the interruption of light.

Optical Encoder PCB

Incremental Encoders

Analog or digital codes are generated by this form of encoder when a shaft’s position is measured. This code is used to identify motion or location. Aside from that, it is among the most regularly used Encoder PCB.

Incremental Encoder PCB can also provide feedback on motor speed and placement. Servo/light, commercial, and heavy-duty are a few examples of this kind of use.

Incremental encoders are also excellent for providing input on distance and speed. For one thing, the systems are more straightforward and less costly since they do not need several sensors.

The incremental encoder’s main limitation is its ability to provide change information. This PCB must use a reference device to compute motion.

Absolute Encoder

The absolute Encoder PCB is the most intriguing. Absolute angular position is measured using this method.

The power-up determines the kind of encoder. As a result, the encoder’s location is incremental if it wakes up and rattles. The output of an absolute encoder may either be a digital or an analog signal.

Magnetic Encoder

Magnetic encoders detect signals by varying the magnetic flux produced by a magnet rotating before a sensor attached to the encoder’s shaft. The sensor samples the magnetic field fluctuation and converts it into an electric signal, determining the location.

What Are The Benefits Of Encoder PCB?

Installing encoders on your PCB can give you several benefits. We will discuss some of them in this section.

• Putting encoders on your PCB might provide several advantages. In this part, we will look at a few of them.
• A magnetic encoder has a device for detecting magnetic field changes. It benefits from withstanding water, dust, oil, etc., in a polluted environment.
• Magnetic Encoder PCBs are ideal for applications requiring tiny size, low weight, and excellent reliability.
• Optical encoders provide a high degree of accuracy and resolution.
• Using magnetic encoders provides environmental resilience, compact size, and dependability.

Magnetic Encoder PCB

What Are The Applications Of Encoder PCB?

Encoder PCBs can be used in a variety of ways. In this section, we will look at some of the applications for Encoder PCB.

Aerospace

Encoder PCBs are used in aerospace applications to give high-precision motion feedback even in the most hostile environments.

Automated cars and robots

Encoder PCBs provide precision motion feedback in automated robotics applications.

Automobile PCB

Cut To Length

Here, the encoder outputs a predetermined number of pulses each time. The duration of the trip is determined by the pulses that are sent to the controller.

What Are The Surface Finishes Going Into Encoder PCB?

PCB surface finishes consist of intermetallic joints that connect bare copper to solderable components. With the proper surface finish, the PCB may be both environmentally friendly and cost-effective as well as long-lasting.

The surface finish used on the Encoder PCB is Immersion Tin. Added directly to the base material of the PCB, copper, Immersion Tin is a metal finish formed by a chemical diffusion process. Immersion Tin keeps the copper underneath it free of oxidation throughout its designated shelf life.

Immersion Tin Surface Finish

How Encoder PCB Fails?

PCB failure should be considered if you want to use Encode PCB in your products. Knowing them will help you deal with the problem.

Faulty Component Design

At the design and production stage, problems like faulty component placement, power outage, and overheating owing to a shortage of Encoder PCB space are just a few instances. As a follow-up to:

• Problems with Soldering
• Leaks of chemical fluid
• Barrier Breakage
• Misplaced Components
• Components Burnt
• Low-grade Components

Faulty PCB

Factors in the environment

Circuit board failure may be caused by exposure to heat, dust, and moisture, as well as unintentional impact (drops and falls). However, electrostatic discharge (ESD) is the most devastating cause of early circuit board breakdown during the assembly stage.

Age

The prices of changing components may be managed by switching old pieces for fresh stuff, which is less expensive than re-assembling Encoder PCBs.

How To Solder Encoder To PCB?

It is critical to test a PCB before using it in a device. The PCB is tested to see whether it can withstand certain conditions and any defects. The following are commonly used PCB testing methodologies.

If you are a beginner and wish to solder your PCB, follow these instructions:

Get your iron ready

Tinning is required before using an iron to solder. The top of the soldering iron is coated with solder to help in heat transmission.

Begin by thoroughly heating the iron and letting it cool. Once heated, cover the tip with solder, covering the whole tip.

After coating the whole tip, rub it down with a moist sponge to remove any extra flux residue.

Prepare Your Work Surface

The fundamental to excellent soldering is a clean surface. To prepare your PCB board for solder, use a cleaning agent pad to remove dust and dirt.

Arrange the Parts

Start with the smaller parts and work your way up.   Begin by putting a few tiny components on the board.

Use Heat

Tip the iron with a little bit of solder. This solder will not hold these components in place; they are just being used to transfer heat.

Solder the Joint

After heating the junction, solder it. Begin by contacting the solder pads as well as the lead with a solder thread. Continue to solder around this junction until it forms a slight mound.  As the joint solidifies, keep it motionless. The finish will become dull and grainy if jostled or moved.

Wrap Up

After the joint has cooled, check it. Trim the lead if the solder junction looks fine.

How Do You Differentiate Between Incremental Encoder PCB And Absolute Encoder PCB?

Absolute and Incremental Encoder PCBs are both mechanical devices. They are used to detect angular or linear locations of the axis and transform the results into digital signals for further processing.

An absolute PCB has a particular identifier for each shaft position, and this code indicates the absolute location of the encoder. An incremental encoder provides an output pulse each time the shaft turns a certain angle.

It is the angular change in direction rather than the absolute position that an incremental Encoder PCB can measure. Absolute encoders are used to determine the absolute or accurate angular location.

Absolute Encoder PCB

Check out this video to know more about the Incremental PCB And Absolute PCB.

How to Specify the Right Encoder PCB Connector?

Different termination choices, forms, and sizes are available for Encoder PCB connections. Regardless of the configuration, they are an essential aspect of the entire encoder specification process.

The PCB connection should be chosen accordingly because industrial equipment is often intended for dependability. When choosing PCB connections, the following are the most critical considerations:

• Water intrusion, dust, and other environmental factors
• Constraints of Space
• Budget for Equipment as a Whole
• Installation and operation are simple.
• Common thread or Ease of Obtaining Sources

Encoder PCB Connector

How To Test Encoder PCB?

Before putting a PCB into a device, it is essential to test the PCB. Testing determines whether or not the PCB can resist particular circumstances and whether or not it has any functional faults. The following are the PCB testing procedures that are widely used in the industry:

In-Circuit Test

ICT is a typical PCB testing approach that may discover 98 percent of problems. There are specific PCB testing processes and equipment.

Flying Probe Test

FICT assessment is used for identification purposes as conventional ICT, but it has distinct benefits and downsides. While FICT can readily adapt to the new boards with minor code changes, it is slower than traditional ICT. This property makes it appropriate for small-scale testing and prototyping but less for large-scale manufacturing.

Flying Probe Test

Functional Circuit Test

A functional tester determines if a final PCB meets the criteria in this test.

Boundary Scan Testing

The boundary scan test examines the wire connections on PCBs and extensively evaluates integrated circuits when all circuitry nodes cannot be reached. These tests include inserting cells into the board’s lines from silicone to such external pins.

This test’s main feature is its ability to examine a board without reaching all of its nodes. This characteristic is critical for assessing multilayer and high-density integrated circuits, becoming increasingly widespread in recent years.

What Is The Shelf Life Of An Encoder PCB?

Shelf life is when it takes for a product to become unsuitable for use or sale while kept. Several variables affect the shelf life of a PCB.

Depending on the solder and the soldering technique, your circuit boards’ shelf life might be as high as ten years. Where the Encoder PCB has a 12-month shelf life.

You may extend the shelf life of a PCB by following the proper procedures. Have your manufacturer apply the industry-standard conformal coating to keep your boards safe. If you don’t, you risk contaminating your boards while in storage.

PCB Shelf Life

What Are The Design Considerations of Encoder PCB?

Potentiometers are analog devices, while Encoder PCBs are the digital equivalent. Encoders imitate an on/off digital output rather than a resistive variable output.

Encoders are often used as MMI devices with the motor device. Encoder PCB design concerns include:

• PCB should be handled as suggested.
• Make sure the encoder gets enough current at the correct voltage.
• Avoid encoder damage when connecting a PCB  to heat-generating equipment like a motor.
• Exceeding the encoder’s maximum mechanical speed may cause irreparable harm.
• A higher rotating speed may cause inaccurate data or signal errors.
• Power supply noise or encoder output noise might cause output signal errors.
• Trigger sensitivity is linked to encoder resolution. The resolution should be chosen depending on the shaft’s movement.

Encoder PCB Design

How To Find The Best Encoder PCB In China?

Choosing an Encoder PCB manufacturer is not always easy.  After the PCB design is completed, it must be built by a professional PCB manufacturer. Selecting the incorrect PCB manufacturer might cause a lot of problems.

It is worthwhile to explore the various PCB manufacturers, but it is also helpful to have some guidelines.

PCB grading

Quality is essential while choosing a PCB manufacturer. The term quality is vague, undefined, and potentially abstract.  However, PCB quality implies that the board is delivered as requested and designed.

Adaptability

Inquire first if the PCB maker can operate to the needed specs.   You should go through the criteria to ensure they can fulfill them all.

PCB production cost

Cost is a crucial factor. Making a product effective requires lowering costs, but not too low.  The lowest price is undoubtedly essential, but as the saying goes, the delight of cheap cost is gone long before the pain of bad quality.

Timescales

The timeframe it takes to produce a PCB is not always an issue. But most PCB assembly firms have deadlines. Choosing a PCB manufacturer that can meet these dates is critical.

Sourcing materials

Many firms searching for a PCB manufacturer will know where the materials come from.  Some low-cost manufacturers may aim for the lowest materials, resulting in boards with inconsistent efficiency from batch – to – batch.

Lead, mercury, and a few other dangerous compounds forbidden in manufactured electronics are likely required by the board.  A UL-approved circuit board that satisfies the necessary standards.

Board testing

Most high-quality PCB providers will test boards to ensure conformance, maybe on a sample basis. Verify the company’s capacity to do so.

What Are The Specifications Of An Optical Encoder PCB?

An optical Encoder PCB is a device that encodes light. A PCB is a sort of motion-sensing device that tracks the motion of a shaft by shining light through an encoded disk that has been programmed. The encoder establishes a feedback loop in response to a mild interruption.

An optical PCB is composed of three different components in most cases.

• A source of illumination (an LED),
• A sensor and also
• A disk that can move.

What Is Rotary Encoder PCB?

Several different terms may refer to the word “rotary encoder.” You may see it as either a shaft encoder in technical documents. However, these words refer to the same thing: a single device.

Rotary Encoders PCB work by converting movement into electrical impulses. Industrial facilities can then utilize analog or digital inputs after being encoded by an encoder. The history of rotary encoders is extensive and diverse. Many different rotary encoders are classified by either Output Signal or Sensing Technology.

Rotary Encoder PCB

This video explains more about the Rotary Encoder PCB.

How Does A Magnetic Encoder PCB Work?

The magnetic Encoder PCB detects rotating position changes in the magnetic field and transmits them as electrical impulses. A magnetic encoder is made up of a magnetic sensor.

A permanent magnet is connected to the spinning body, including a drive shaft, and a sensor is put on a PCB board to collect the permanent magnet’s magnetism.

That was a quick overview of the Magnetic PCB. Now let us look at a magnetic Encoder PCB working method.

Hall element

Semiconductor hall elements are utilized in magnetic encoders.   There are also two sorts of Hall elements: those that detect magnetic field strength vertically and those that sense magnetic field strength horizontally.

Hall Element

Permanent magnet

In general, magnetic encoders employ cylindrical permanent magnets. Permanent magnets have two magnetizing orientations: radial and plane.

Generally, samarium-cobalt (SmCo) based magnets with excellent temperature characteristics based magnets with good downsizing and weight properties, and cheap ferrite based magnets are used.

Magnets and Hall components configuration

The magnetic encoder should be positioned such that the rotary shaft, permanent magnet, and Hall element are all matched. This arrangement is known as “Shaft-End.”

Even with the Shaft-End setup, a minor position mistake is termed “misalignment.” Once the Hall element gets misplaced, the magnetic strength sensed by the Hall component fluctuates, causing an angle detection error. Imbalance is challenging to eradicate.

However, with the Shaft-End arrangement, the Hall element is located where the horizontal magnetism is uniform, reducing the impact of misalignment.

Thus, the Hall element that senses the intensity of the horizontal magnetism may decrease the angular error owing to misalignment.

Which Type Of Encoder Is Used In Robotics?

In robotics, the Encoder PCB is one of the most critical components. Rotating encoders are used in mobile robots to track movements such as direction and speed.

The accurate placement of robotic joints is achieved by using rotary encoders. For these kinds of applications, smaller encoders are more appropriate.

The Rotary PCB can accurately track the position. In terms of the robot’s sensor, this works well. Thus, the Encoder PCB is utilized primarily in robotics.

Encoders For Robotics

Conclusion

This article addressed every aspect of the Encoder PCB. Our customers most frequently ask these questions.

PCBMay is a well-known PCB manufacturer with many years of expertise. We can help you design and manufacture your Encoder PCB with the most excellent quality in the industry. You can always get in touch with us for further information.