Reliable and economical total encoder solutions for drive technology.
Kübler has been highly successful in drive engineering for many years and counts internationally important businesses amongst its clientele. Along with excellent product quality,
this sector demands a high degree of flexibility, a rapid response and service on a global scale. Kübler fully lives up to these expectations.
Product diversity & Quality: we guarantee our absolute and incremental encoders with their high shaft load capacity by the use of, for example, the sturdy bearing construction with Safety-Lock™,
the 100 % magnetic field resistant optical technologies and by a remarkably compact product design.
The mechanical interface is often the deciding path to success: Kübler possesses the expertise and experience when it comes to essential details such as torque arms and mounting solutions for
optimal integration of the encoders into the drives. We have been particularly successful with geared motors in developing a method of mounting the encoder under the fan cowl, which is both safe and cost-effective.
At the forefront of technology: Our innovations include encoders for Functional Safety with SIL3 approval, EX protection, encoders with total magnetic insensitivity, as well as purely optical encoders
with a mechanical gear or with an electronic gear.
Kübler Design System: Kübler "KDS" is our structured method for converting – step-by-step – your requirements, with respect to quality and to a reduction in costs and number of models, into a product solution.
Our goal is to provide tailor-made systems, customised to your requirements.
Encoder with BiSS interface and further informationen.
Innovations from tradition. Kübler products benefit from 50 years experience in automation technology. Over time they have been further developed for use in drive engineering.
Small details make a big difference. Our products feature many intelligent top-quality extras and offer our customers key benefits. In doing so, they make a significant contribution to the high availability and safety of the machines.
Optical encoder technology
100 percent resistant to magnetic fields – extremely compact design. Even strong magnetic fields, as occur in the vicinity of brakes or drive motors,
pose no problems for the sensor technology of optical encoders.
The technology dispenses with any components that may be susceptible to magnetic influences and allows for high scanning rates. The multiturn gear module – developed from special
materials – is effective thanks to its double bearing layer and the specially developed gear teeth, resistant against wear, and can be used for high speeds up to 9000 rpm.
As a result of the proven drive, the encoder has no need of a battery to store the number of revolutions.
Insensitive to interference: OptoASICs
The resistant Kübler OptoASIC technology offers a very high integration density of components.
This means that, on the one hand, the reliability in the application can be increased significantly, and on the other hand the technology demonstrates quality EMC characteristics and shock resistance.
Wide temperature range
High heat resistance – combined with high rotational speeds – make the Kübler Sendix encoders the optimal solution for all applications in a high temperature environment.
Also the seals, cables and connectors used withstand extreme temperatures.
Kübler encoders boast a wide variety of interfaces. Along with incremental interfaces such as TTL / HTL and SinCos there are also absolute interfaces such as SSI and BiSS-C.
Absolute encoders with field bus interfaces such as CANopen, PROFIBUS, PROFINET and EtherCAT are also available. The outputs and supply voltage are short-circuit protected.
All encoders from the Kübler company carry the CE mark and are tested for electromagnetic compatibility and immunity to interference.
As an option, our products can be UL approved. Many of our products are available on request with EX approval for explosion protection zones 2 and 22 or as product variants for zones 1 and 21.
Certified Functional Safety: this permits simple implementation of applications for the protection of personnel.
Kübler is active worldwide and considers the protection of the environment as a corporate obligation. Our product range complies with the RoHS directive.
Kübler encoders boast a very sturdy and robust bearing construction, brought together under the term Safety-Lock™.
Encoders with Safety-Lock™ have positive interlocked bearings with a large bearing span and special mounting technology.
This means they are able to tolerate installation errors as well as large shaft loads, as can occur as a result of temperature expansion or vibration.
A further development of this technology is employed in the Sendix Heavy-Duty encoders (HD-Safety-Lock™).
Encoders are available for use in drive engineering that will operate reliably at speeds of up to 12,000 rpm.
Even well-earthed machine housings and rotors of generators and large motors carry a shaft current on the rotor.
The equipotential bonding from the rotor to the stator via the encoder bearings leads to spark erosion and can damage the encoder. This can be remedied by isolating the encoder bearings.
Isolating inserts can be used with all Sendix compact encoders. The Sendix H120, for example, has a fully integrated and isolated bearing construction and is tested to a breakdown voltage of 2.5 kV.
Simple / fast installation
Innovative connection technology with plug-in spring terminal connectors allows for fast, safe installation without tools.
Maximum connection safety with minimal connection times.
The compact design dimensions specially conceived for drive engineering as well as the very compact connector solution permit optimal integration on/under fan cowls.
The tangential cable outlet, for example, is ideal where installation space is tight. The through hollow shaft of the Kübler encoders leaves ample clearance for other motor options, even behind the encoder.
In order to ensure the easiest possible mounting onto the motor, various mounting options are available for both solid shaft and hollow shaft variants, including, for example, clamping flanges, stator couplings and tether arms.
Hardened down to the last detail
The durable construction that comes as standard, permits high shock and vibration values; these are both tested and certified.
The values are extremely important in drive engineering, as the potential applications for the motors are highly diverse.
Dual seal protection on the shaft side, for example with the Sendix H120, offers increased protection against dust and humidity for harsh operating conditions.
High protection level / seawater resistant
A high protection level is achieved as a result of the integrated radial shaft seal. This, together with the wide temperature range and the bearing technology,
ensures outdoor use is possible without problems. Many versions of the Sendix family of devices have now been tested and certified to IEC 68-2-11 for resistance to the effects of salt-spray
over a period of up to 672 hours – the highest test level. The high certification level for the Sendix encoders attests a high level of corrosion resistance.
Asynchronous motors are the all-rounders amongst electrical drives. For every requirement there is a drive and for every drive there is a suitable Kübler encoder.
Whether as a fan motor in a small 63 size, or as a geared motor in a 225 size, asynchronous motors place special demands on encoders, above all when it comes to mechanical and electrical ruggedness.
Because of their robust technology Sendix encoders prove themselves, especially in harsh environmental conditions.
A tough nut. Accurate speed information is an important measurement for the control loop of a plant.
Measuring systems that supply this information are often subjected to harsh environmental conditions but must not suffer any loss of reliability.
Kübler incremental encoders can handle strong vibration or extreme variations in temperature without any problem. Here, their wide-ranging mounting options guarantee easy, safe installation.
Kübler offers the complete range of solutions, from the extremely rugged Sendix Heavy Duty through to the compact, bearing-free Limes encoder systems.
The ruggedness of the sensor technology plays a crucial role with large drives. Shocks and impacts encountered in this class of drives are higher than elsewhere.
Service life / Maintenance
In applications where large motors or generators are used, downtimes are very expensive; for this reason maintenance and any replacement of a component must be very simple.
Weather and environmental conditions
Large motors are employed primarily in harsh environments. The protection class of the sensors is thus correspondingly important, so that breakdowns can be avoided.
Despite well-earthed machine housings, generators and large motors carry a certain shaft current on the rotor. The equipotential bonding from the rotor to the stator via the encoder bearings can damage the encoder.
The family of synchronous motors includes very small motors, as well as stepper motors, dynamic servo motors and very powerful gearless drives.
Stepper motors are very small drives for lower performance ranges. Kübler encoders are perfect for these applications because of their compact size and design.
Servo motors are drives for high precision and dynamics with permanent magnet technology and very compact size and design.
Gearless drives are used, wherever gear reduction can be dispensed with by optimising the direct chain. Gearless drives have a very high number of poles and in consequence a slow final speed with very high torque levels.
The small size of the motors means that every millimetre counts. For this reason it is important to use sensors that are compact but nevertheless of high performance.
In order to ensure effective control of servo motors, it is important to have exact information concerning the position of the rotor. This can be provided by either a singleturn or multiturn encoder.
The self heating of powerful synchronous motors can notably lead to high ambient temperatures.
Because of the high degree of integration of the sensor technology into these drives, the encoders are more directly exposed to the high temperatures than is the case with other motors.
Good control, especially with a high number of poles, requires high accuracy of the encoder.
Encoders for gearless drives
Explosion protection - ATEX
In hazardous areas encoders must comply with special protective regulations, as even the smallest spark can have very serious consequences.
Positioning tasks occur in many hazardous environments – whether in mining, in the chemical industry or also in oil production.
Especially for those applications that require absolute position values, Kübler offers the Sendix absolute encoders with ATEX approval.
The singleturn and multiturn ATEX encoders with "flameproof-enclosure" housings are approved for zones 1, 2, 21 and 22 and certified by the PTB (German national metrology institute) according to the ATEX guidelines and IEC EX standards.
Safety is – not least since the EU Machinery Directive 2006/42/EC – an "integral part of the construction of drives".
When choosing the right encoder for functional safety the principle applies that safety is achieved through the intelligent combination of encoder, controller and actuator.
But safety goes further than this: safe components are characterised by a robust reliable interface and by the ability to cope with high mechanical and electronic loads.
Both Sendix SIL encoders with SSI absolute and additional SinCos interface and also the SinCos version of the incremental encoders have been certified up to SIL3 by the German Institute for Occupational Safety (IFA).
Encoders have various tasks to fulfil in drive engineering.
One of the most frequent tasks is to supply information concerning speed, for better control of the motor using a frequency inverter.
For this type of speed control motor feedback is necessary, which is suitable for improving the speed quality and the control response. As a rule a SinCos or TTL/HTL signal is used for this purpose.
A further task is the positioning of the drive. This can occur both incrementally as well as absolutely. For dynamic control with synchronous motors, feedback of the rotor position within a revolution is necessary.
Singleturn absolute encoders with a BiSS-C or SSI interface are used to achieve this.
The electrical interfaces of an encoder are important for good integration into a drive system. The necessary information can be derived from the requirements and the type of motor as well as from the transmission interface.
Higher interpolation can be achieved by the use of signal inversion. A cyclic reference signal can be output by use of an optical pulse track (C-signal).
The Open Source BiSS-C (Bidirectional/Serial/Synchronous) interface is based on a protocol for achieving a real-time interface for a digital, serial and secured communication between a controller and sensors/actuators.
The BiSS-C protocol has been designed for industrial applications, in which transmission speeds, safety (CRC), flexibility and minimized implementation work are required.
As they are only framed by a start and a stop bit, the sensor data is transferred at the best possible user data rate; a single multi-cycle data bit is optional.
Similarly detected and triggered, the multi-cycle data bits form a second inband protocol and contribute to the redundancy of the sensor data – permanent monitoring of the drive status and operation is possible,
without interfering with the controller cycle. Specific device developments by individual users are not restricted or made more expensive by a need to be compatible with other BiSS products.
A BiSS subscriber is described with only a few parameters and an XML device description file that comes with the product simplifies the startup of the controller.
Without affecting the payload data of measurements or interfering with control cycles the communication protocol incorporates a permanent, bidirectional access to slave registers.
That way device parameters and additional measurement data, or an electronic ID plate and OEM data, can be accessed at any time – device monitoring and diagnosis is made easy.
Compared to the parallel interface, the SSI interface needs less components and the EMC-characteristics are much better. In addition less lines are needed for transmission and the possible cable length is much longer.
At rest, the clock and data lines are at a high level. With the first falling clock-pulse edge, the current encoder data are stored in the buffer ready to be sent.
With the next rising clock-pulse edge, the data are transmitted bit by bit, starting with the MSB. The transfer of a complete data word requires n+1 rising clockpulse edges (n=resolution in bit),
e.g. 14 clock signals for a complete readout of a 13 bit encoder.
After the last positive-going clock-pulse edge the data line will remain for the duration of the monoflop time t3 at a low level, until the encoder is ready for a new data word.
The clock line must stay high for at least as long, and then can begin a new read-out sequence again with the next falling edge.
Perfect integration into the drive can only be successful if an optimal connection of the encoder to the motor is made.
For the rotating motor shaft and motor housing Kübler offers a wide choice of standard fixing and connection options, with which the desired encoder variants can be combined in a modular design principle.
In addition to this individual, customised solutions can be worked out.
Standard connection solutions
PCB plug-in connectors: M12, M23, MIL. Cable connection, Terminal box, Optical fibre signal transmission technology.
Individual connection solutions
Kübler offers space-saving installation options for M12 and M23 connectors under the fan cowl. Lead-through M12 straight, IP67. Male connector with external thread, IP67, central fastening.
All cables – for incremental, absolute and field bus encoders – can also be ordered by the metre as open-ended cable: PVC and PUR cables, Halogen-free cables, Bus cables.
Kübler offers a range of connectors for self-assembly with a protection level of up to IP67, for example as male connector M23 with external thread or as socket with metal union nut.
Kübler offers pre-assembled cordsets in a variety of connector versions as well as with a different number of cores (5, 8, 10, 12, 18).
Optimal sensor solution thanks to customer-specific development
The ideal sensor for your drive – that is our goal: for simple, fast and error-free mounting – highest reliability of the signals – long service life and minimum costs.
During development of customer-specific solutions Kübler focuses on 3 principles:
Lean Design (coordinating the materials and functionality to the application)
Design to Cost (aliging development to target costs)
Cost of Ownership (fast installation, simple maintenance, long service life)
The correct mounting and fixing solution of an encoder in a drive is crucial for reliable operation and peace of mind.
The wide variety of drives and the increasing demands placed on drives (especially in respect of installation space) pose new challenges every day.
By the use of intelligent solutions, closely matched to the drive, great savings can be made when it comes to space, time and costs.
Furthermore, specific fixing elements can be developed, which are tailored to the installation space of the housing or the geometry of the flange and shaft;
this ensures an optimal connection and the highest degree of accuracy.
The cable and connectors used to connect an encoder with the PLC must be matched to the installation space available as well as being capable of withstanding the prevailing environmental conditions such as humidity, cold or heat.
Here too, the setting-up of special cables or the development of specific connectors can lead to the right solution.
In particular, the cable or connector transition from the motor housing to the outside world requires innovative constructions, in order to guarantee reliability and freedom from errors.
Kübler does not leave protection of its sensors to chance. The application areas for drives are very diverse.
Kübler has designed appropriate specific protective covers, which take consideration the design of the encoder, as well as the IP protection level, temperature and operating conditions.
With its extensive experience in difficult application areas, such as steel production, wind turbines or in mobile applications, Kübler has developed special housing and seal designs, as well as coating solutions,
which also withstand the high demands of outdoor applications in respect of condensation or extreme fluctuations in temperature.
Advantages of customised integrated drive solutions [more]
High reliability, as all component parts have been specifically designed for your drive
Particular focus on a longer service life when selecting the product
Simple, fast mounting thanks to a high degree of integration
Development of solutions for simple maintenance
Warranty and support from a single source
Reduced costs, as the solution is directly tailored to the drive. No "over-engineering".