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How to Choose the Right Encoder for
Your Application




Rotary encoders are essential components in a wide variety of automation and motion
control systems. Whether you're working with industrial machinery, robotics, conveyors,
elevators, or packaging lines, choosing the right encoder can directly impact your
system's accuracy, reliability, and overall performance.
But with so many options available-incremental, absolute, shafted, hollow bore,
programmable-it's not always clear which encoder is best suited for your specific
application. That's why we've created this guide to help you understand what to consider
when selecting an encoder.
1. Determine the Type of Motion Feedback You Need
The first question to ask is: Do you need position tracking or just speed and
direction?
- Incremental Encoders output pulses as the shaft rotates, providing information about
speed, direction, and relative position. They're ideal for basic motion control, such as
conveyors or motor feedback.
- Absolute Encoders provide a unique digital signal for every position of the shaft.
They're essential in applications where exact position tracking is critical-even after a
power loss. Common in robotics, elevators, and automated machinery.
Tip: If your system needs to "remember" its position after being powered off, go with an
absolute encoder.
2. Match the Mechanical Configuration to Your Application
Next, look at how the encoder will be physically mounted. Consider the following:
- Shaft Encoders connect via a solid shaft and usually require a coupling to link to the
motor or equipment shaft.
- Hollow Bore Encoders slide directly over the shaft, saving space and simplifying
installation.
- Thru-Bore Encoders allow the shaft to pass all the way through the encoder, often with
flexible mounting options.
- Motor Mount Encoders are designed to attach directly to the rear of motors, including
NEMA motor mount styles.
Tip: For compact installations with limited space, a hollow bore or motor mount encoder
may be the best fit.
3. Consider the Electrical Interface and Output Format
Encoders come with a range of output options to suit different control systems.
Some common formats include:
- Quadrature (A/B channels) - standard for incremental encoders.
- TTL, HTL, or Open Collector outputs - depends on voltage requirements and noise
tolerance.
- Digital communication protocols for absolute encoders like:
- EtherCAT
- EtherNet/IP
- PROFINET
- SSI
- CANopen
- BiSS
- SAE J1939
Be sure your control system or PLC supports the output protocol of the encoder you're
choosing.
4. Check for Required Resolution or Counts Per Revolution (CPR)
The resolution of an encoder determines how finely it can measure position.
- Low-resolution encoders (e.g., 100 CPR) are great for simple speed sensing.
- High-resolution encoders (e.g., 5,000+ CPR) are ideal for precise positioning tasks like
robotics or CNC machines.
Absolute encoders are typically rated in bits-for example, a 12-bit encoder offers 4,096
distinct positions per revolution.
5. Evaluate the Environmental Conditions
Your encoder needs to survive and perform in the conditions it's placed in. Ask
yourself:
- Will it be exposed to dust, moisture, or chemicals?
- Is there extreme heat, cold, or vibration?
- Will it be used outdoors or in food-grade environments?
For harsh environments, look for encoders with:
- IP-rated enclosures (e.g., IP65 or IP67)
- Stainless steel housings
- High-temperature ratings
- Shock and vibration resistance
At Encoder Products Company (EPC), we offer rugged encoder models like the Model
802S and Model 865T, designed specifically for tough industrial conditions.
6. Do You Need Programmability or Customization?
Sometimes a standard encoder won't meet every requirement. In that case,
consider:
- Programmable Encoders like EPC's Model 25SP or 58TP, which allow you to set
resolution, output type, and more using software or dip switches.
- Custom Solutions - At EPC, we specialize in custom-built encoders to fit unique
challenges, whether it's a modified housing, specific mounting bracket, or specialized
cable length.
7. Get Expert Support When You Need It
Choosing the right encoder can feel overwhelming, especially when performance,
safety, and reliability are on the line. That's why EPC's technical support team is
always available to help you identify the best encoder for your needs.
We make it simple to explore options, compare models, and even cross-reference
competitor part numbers.
In Summary
Choosing the right encoder involves evaluating your application's needs in
several areas:
- Motion feedback type (incremental vs. absolute)
- Mechanical fit
- Electrical output and protocols
- Resolution
- Environmental conditions
- Programmability or custom features
With the right guidance, finding the ideal encoder can be easy-and it can make a big
difference in the performance and lifespan of your equipment.
To explore our full range of encoders or get help selecting the right one for your
application, visit us at www.encoder.com. Our experts are here to support your success
every step of the way.
To explore our full range of encoders or get help selecting the right one for your application,
visit us at www.encoder.com