SAR/SA Series Absolute Encoders from SMARTWIN Intelligent Equipment Reshape Operational Efficiency of Precision Production Lines

SAR/SA Series Absolute Encoders from SMARTWIN Intelligent Equipment Reshape Operational Efficiency of Precision Production Lines

Traditional incremental encoders calculate position by accumulating pulses, inherently suffering from industry drawbacks including coordinate loss after power failure, cumulative errors, and mandatory homing upon every startup. For high-cycle flexible smart manufacturing lines and 24-hour continuous production equipment, frequent homing not only wastes production runtime, but also carries risks of machine crashes and workpiece scrap caused by homing deviation. Focusing on core pain points of high-end direct-drive systems, SMARTWIN Intelligent Equipment has deeply upgraded two absolute encoder product lines: SA linear absolute grating encoders and SAR annular absolute rotary encoders. Featuring three core strengths-power-off position retention, zero cumulative error, and real-time feedback via high-speed fieldbus - these encoders have become the upgraded standard configuration for closed-loop control systems of linear motor modules and frameless torque motors. They improve equipment availability and operational safety of automated production lines starting from the sensing layer.

The core technological breakthrough of absolute encoders lies in the unique coded positioning logic. SMARTWIN SA linear absolute grating encoders and SAR rotary grating encoders adopt a single-track absolute coding design. Every physical position within the travel range corresponds to an independent set of Gray code coordinates. In case of unexpected power failure or emergency stop, the real absolute position can be read instantly after power reconnection, allowing production to start directly without executing homing. For flexible production lines with mixed production of multiple product types, the homing procedure can be skipped directly during each product changeover and shift restart. A single machine can save dozens of minutes of ineffective standby time every day, significantly improving the line’s Overall Equipment Effectiveness (OEE) in the long run. In precision equipment such as semiconductor die bonders and wafer indexing rotary tables, these encoders completely eliminate positioning drift caused by triggering deviation of origin switches, avoid chip loss resulting from tiny positioning errors, and directly boost product yieid.

In terms of performance, the SAR rotary encoders are tailor-made for rotary platforms equipped with DDA outer rotor torque motors and DBM frameless torque motors. Featuring a large hollow annular structure, they perfectly meet the hollow cable routing requirements of torque motors with resolutions of 23 bit, 24 bit and 25 bit. The angle feedback remains stable during low-speed micro-angle indexing. Combined with the cogging compensation algorithm of AKS servo drives, the encoders thoroughly suppress low-speed jitter of direct-drive rotary motors. They are widely applied to rotary fixtures for optical inspection, CT medical rotating gantries and precision CNC indexing tables. The SA32 linear absolute encoder achieves a maximum resolution of 0.05 um and supports a maximum traveling speed of 5 m/s. For long-stroke BMS heavy-load linear modules, zero cumulative error is maintained across the full travel range. It addresses the cumulative pulse deviation issue of incremental encoders in ultra-long-distance linear photovoltaic large-panel inspection equipment and long-distance inter-station conveying equipment for lithium batteries.

Leveraging SMARTWIN’ s full industrial chain advantages in direct-drive products, absolute encoders can be parameter-matched as complete sets with linear motors, torque motors and servo drives, with joint algorithm debugging completed before delivery. Equipment manufacturers only need to carry out mechanical installation and simple power-on tuning to put the system into operation, greatly shortening the machine development cycle. Compared with imported absolute encoders featuring high procurement costs and long lead times, SMARTWIN realizes fast delivery through localized mass production and provides on-site technical commissioning services. Minor customized modifications including hollow bore size, bit resolution and communication protocols are also available. As a cost-effective domestic absolute sensing solution, SMARTWIN accelerates the comprehensive import substitution of sensing components for high-end direct-drive equipment.