Baumer is further expanding its broad encoder portfolio with variants designed for demanding applications in automation and drive technology. The new family “Fully Reinforced Encoders” combines enhanced robustness – mechanical, magnetic, and electrical resilience – with configurable functions for speed and directional rotation monitoring, as well as diagnostics. Baumer offers the new encoders in shaft variants adapting to the prevailing standards – HS35 compliant to the U.S. / imperial inch standard and EN780 as the metric variant for Europe and Asia.
The Fully Reinforced Encoders by Baumer fill a gap in the encoder market. In many industrial applications, the existing mechanical and electrical interfaces define which encoder to select. Often the focus is on meeting specific high product requirements, such as high protection ratings, shock resistance or shaft insulation. Practice however has proved that failure is often not due to non-compliance to an individual product requirement but rather to the interplay of several factors.
Enhanced resilience, minimal downtime
EN780 and HS35 combine mechanical stability, magnetic immunity, and electrical robustness to reduce unplanned downtime and increase plant productivity.
A key characteristic is their long service life, typically ranging from 10 to 20 years – about twice as long as that of comparable models. Large-diameter bearings, special lubricants, separate sealing systems and high-quality coatings are used to ensure this. Separating bearings and seals further cuts down on bearing temperature and extends the grease operating life.
Another focal point is shock resistance. Particularly brake motors generate high-frequency loads of up to 10 kHz and acceleration of several thousand g. While many manufacturers only run low-frequency shock tests, Baumer tests are under real operating conditions with one million braking cycle.
The new encoder families offer enhanced protection against electrical interference – such as overvoltage, ESD, and wiring errors – for modern drive systems. Integrated shaft insulation safely manages shaft voltage up to 2.8 kV without compromising on dimensional accuracy and concentricity, unlike plastic inserts. High-performant output drivers ensure signal stability up to a distance of 350 meters without the need for external amplifiers. Brake motors and high power electric drives, generate magnetic fields that can significantly impair the encoder’s signal quality. EN780 and HS35 provide high immunity against magnetic fields up to 120 mT and hence ensure reliable operation even in environments with high-level interference.
Easy parameterization, precise monitoring
Besides durability, ease of use and condition monitoring were other focal points in the development of the new encoder family. Parameterization is directly via USB-C which eliminates the need for any adapter or special cable. In the freeware Baumer Sensor Suite you have speed and positions visualized, you can edit parameters and run diagnostics.
Some of the features provided:
- Electronic Device Identification
- Parameterization of encoder and switching functions
- Advanced condition monitoring with event log for diagnostic data
- LED indicator for limit monitoring
Optionally, the devices can also monitor over- and underspeed, standstill as well as direction of rotation and output monitoring limits directly to the controller via a switching signal.
High precision for optimal results in demanding control tasks
Precise measurement values are crucial, particularly at low speed or in synchronized motion. The encoders HS35 and EN780 achieve an angular accuracy of ±0.014° (±50 angular seconds) at speed precision of approximately 1% at a mere 10 rpm. In addition, they precisely detect any standstill within a creep window of only 0.1°.
These are particularly important features in applications in the heavy duty industry, in conveyor systems, packaging machines and electronically coupled drive systems, where even the slightest speed deviation may entail process issues or increased wear.
With the Fully Reinforced Encoders, Baumer offers a holistic solution that combines mechanical robustness, electrical resilience, magnetic immunity, high precision and diagnostic functions in a single product. This increases system uptime and cuts down on maintenance effort. Where even greater durability is required, Baumer offers HeavyDuty encoders from the Hübner Berlin brand.
