Volume 10, Issue 2

Encoders for Linear Motors

in the Electronics Industry
Linear motors are gradually
becoming more important
in such highly dynamic
applications with one or
more feed axes. The benefits
of this direct-drive technology
are low wear, low
maintenance, and higher
productivity. However, this
increase in productivity is
possible only if the control,
the motor, the machine
frame, and the position
encoder are optimally
adjusted to one another.
Did You Know...
… a HEIDENHAIN linear scale is a vital
measurement component in a new
medical imaging machine introduced
to the market just this past August?
DMetrix, Inc., in Tucson, Arizona,
manufactures this high-speed medical
scanner that is now offered for use
in critical digital pathology applications.
Known as the DMetrix DX-40 scanner,
this new ultra-precise medical microscope
slide scanner is based on DMetrix’
exclusive array-microscope technology
which results in the ability to digitally image
up to 40 slides per hour. One of the core
technologies enabling the high-speed
scanning is an innovative loader. “Our

T he semiconductor industry and automation

technology increasingly require more
precise and faster machines in order to satisfy
Direct drives place rigorous demands on the
quality of the measuring signals. Optimum
measuring signals:
slipstream™ slide loader is very unique,”
explains DMetrix’ Director of Engineering
Artur Olszak. “We have developed and
n reduce vibration in the machine frame,
growing demands on miniaturization, quality, utilize a patent-pending solution that rapidly
and manufacturing cost reduction. transports slides on a cushion of air.”
n stop excessive noise exposure from
velocity-dependent motor sounds, “The LIDA 400 linear scale from
n prevent additional heat generation, and
HEIDENHAIN Corporation is really at the
Contents…
n allow the motor to realize its maximum
heart of our system,” added Olszak,
e
Pag “as it is used on the main scanning stage
1 Encoders for Linear Motors mechanical power rating. of the DX-40 scanner. It helps us to very
Did You Know... The efficiency of a linear motor in regard precisely control the speed and position
Pag
e to accuracy, speed stability, and heat of our transport component in this very
2 What’s New with TNC generation is therefore greatly influenced demanding closed-loop system. We chose
Infrared 3-D Touch Probe by the selection of the position encoder. to use HEIDENHAIN’s linear scale because,
Single-Field Scanning Linear Encoder frankly, it was the only scale that fulfilled
Design of direct drives our demands.”
e
Pag The decisive advantage of direct-drive
3 Web Site Helps with Encoder Selection
technology is the very stiff coupling of the HEIDENHAIN’s LIDA 400 scale -- with its
2005 Heidenhain Trade Show Schedule very small dimensions, grating pitch of 20
drive to the feed component without any
e microns, and generous mounting
Pag other mechanical transfer elements. This
4 Encoders for Linear Motors, cont. tolerances -- is often the ideal encoder for
allows significantly higher gain in the control
e use in applications where precise
Pag loop than with a conventional drive.
5 Encoders for Linear Motors, cont. equipment positioning in a small package is
Pag
e Velocity measurement on direct drives required.
6 Encoders for Linear Motors, cont. On direct drives there is no additional
e With a scanning head height of only 12
Pag encoder for measuring the speed. Both
7 Encoders for Linear Motors, cont. mm, the LIDA 400 can be installed in very
position and speed are measured by the
e tight spaces. And in spite of its size, the
Pag position encoder: linear encoders for linear
8 Encoders for Linear Motors, cont. very small scanning head features an
motors, angle encoders for rotating axes.
e extremely large scanning area of 14.5
Pag Since there is no mechanical transmission
9 New Catalogs mm2. This large scanning area allows the
between the speed encoder and the feed
e encoder a huge tolerance to contamination,
Pag unit, the position encoder must have a
10 HEIDENHAIN Makes Impressions correspondingly high resolution in order
at IMTS For more information circle # 2
to enable exact velocity control at slow on the reader service card.
traversing speeds.
continued on page 4
 What’s New with TNC
Introducing the New SmarT.NC
User Interface from HEIDENHAIN
In addition to G Code and classic conversational programming
for TNCs, HEIDENHAIN Corporation is now offering smarT.NC,
a brand new user interface for TNCs intended for use by both the
NC beginner and the conversational expert. This new interface
enables users to create executable NC programs faster, more
safely, simpler, and more conveniently than ever before. SmarT.NC
was shown for the first time in North America on HEIDENHAIN’s
iTNC 530 controls at the IMTS show in September.
This exciting new
programming system
guides the user in a self-
explanatory and intuitive
way through the complete
NC programming tasks by
using straightforward
forms. SmarT.NC is so
user-friendly that the user
can decide whether to use
it or the plain language
level at any time. Even if a
program has been created
with smarT.NC, for
example, it can be edited
as before with the plain
language editor, making
this a very unique system.
Infrared 3-D Touch Probe
HEIDENHAIN’s New Compact
Infrared 3-D Touch Probe - The TS 440
The newest addition to HEIDENHAIN’s recently improved 3-D
touch trigger probes is the compact TS 440 model. Its extremely
small dimensions make the infrared TS 440 the ideal touch probe
for machines that carry out repeated setup and inspection
procedures and have limited working space.
The TS 440 is offered in as small a size as
49 mm x 63 mm, and offers 360 degrees
transmission. Its features are similar to
HEIDENHAIN’s TS 640 Trigger Probe,
and in conjunction with HEIDENHAIN’s
transceivers, can be used on the iTNC
530 control and higher.
HEIDENHAIN also offers another new
transceiver for the infrared touch
probes, the SE 540. It is designed
for installation in the headstock
providing the advantage of
moving along with the touch
probe. This ensures a reliable
transmission of infrared signals at
any position of the machine’s
working space and is an advantage
with very large machines and those
whose spindles move in two separate
working spaces.

This procedure is possible because both smarT.NC and the plain 3-D touch probes are ideal for quick
language editor access the same file: the plain language program! and exact workpiece alignment as
SmarT.NC is a simple all-in-one system as it also enables program well as for automated workpiece
verification and execution. This system has an integrated pattern measurement on the machine. Most
generator as well. CNC controls – especially the TNC
controls from HEIDENHAIN – offer
HEIDENHAIN’s new TE 530B operating panel is highly numerous measuring cycles to automatically
recommended for the use with smarT.NC since it makes it measure and determine common geometries
possible to conveniently use the advantages of this new user such as bore holes, rectangular pockets,
interface. This operating panel comprises a touch pad as well as circular pockets, slots, studs, bolt hole
three new keys for comfortable operation of the smarT.NC. n circles, and planes. n
For more information circle # 3 For more information circle # 4
on the reader service card. on the reader service card.

Single-Field Scanning Linear Encoder

Single-Field Scanning Linear Encoder
Offers Increased Resistance to
Contamination
Now available to the North American
marketplace is HEIDENHAIN Corporation’s
redesigned LC 400 absolute sealed linear
encoder with Single-Field Scanning. Because of
its new design, this encoder is poised to offer
many advantages over other encoders, such as
its increased resistance to contamination, higher
traversing speeds, increased natural frequency
and a variety of absolute output formats.
This compact LC 400 incorporates a new single-
field scanning technology (versus a previous
four-field scanning method) that utilizes a much
larger single scanning window thereby
mitigating the effects of contamination.
The LC 400 also boasts constant signal quality
over the entire measuring length, resolution of
up to 10 nm and with it’s maximum traversing
speed of up to 180 m/min, it is ideal for linear
motor and machine tool applications. n
For more information circle # 5
on the reader service card.

2
Web Site Helps
with Encoder Selection
The HEIDENHAIN web site (www.heidenhain.com) is of much
assistance to its visitors every day, including the availability of its
interactive selection guide for rotary encoders.
2005 HEIDENHAIN
Featured here, this Rotary Encoder Selection Guide enables its users
to insert required rotary encoder specifics and come up with options TRADE SHOW
to complete the job.
SCHEDULE
As always, you have the opportunity to visit with
HEIDENHAIN at many trade shows each year; 2005
being no exception. Though the schedule is still
developing, HEIDENHAIN expects to exhibit at the
following next year:

n Medical Design & Manufacturing Show -

Electronics West
January 10-12
Anaheim Convention Center
Anaheim, California
n APEX
February 22-24
Anaheim Convention Center
Anaheim, California
n The National Design Show
March 7-10
McCormick Place - South
Chicago, Illinois
n WESTEC
April 4-7
Los Angeles Convention Center
Los Angeles, California
n Quality Show
April 19-21
Rosemont Convention Center
Rosemont, Illinois
n SPS Electric Automation American
May 24-26
Rosemont Convention Center
www.heidenhain.com/anglemeasure/rotary_std_guide.htm Rosemont, Illinois
n SEMICON
Click onto this site to obtain much more information on measurement
July 12-14
components and systems, as well as take a look at the largest list of
- (Front End) - Moscone Center - North
related products available in the industry today.
- (Back End) - Moscone Center - West
Sign on and let us help you meet your measurement needs! n San Francisco, California

For more information circle # 6

on the reader service card.

3
 Encoders
continued from cover

The velocity is calculated from the distance traversed

per unit of time. This method – which is also applied
to conventional axes – represents a numerical differentiation
that amplifies periodic disturbances or noise in the signal.

The combination of significantly higher control loop gain,

as is used particularly with direct drives, and insufficient
encoder signal quality can result in a dramatic decline in
drive performance.

Signal quality of position encoders

Modern encoders feature either an incremental, which
means counting, or an absolute method of position
measurement. The path information is transformed
in the encoder into two sinusoidal signals with 90° phase
shift. Both methods require that the sinusoidal scanning
signals be interpolated in order to attain a sufficiently
high resolution. Inadequate scanning, contamination
of the measuring standard, and insufficient signal
processing can lead to a deviation from the ideal
sinusoidal shape. As a consequence, during interpolation
periodic position error occurs within one signal period of
the encoder’s output signals. This type of position error
within one signal period is referred to as “interpolation
error.” On high-quality encoders, it is typically 1% to 2% Position error within one signal period
of the signal period.

Effects of interpolation error: Generation

of heat and noise
If the frequency of the interpolation error increases,
the feed drive can no longer follow the error curve.
However, the current components generated by the
interpolation error cause increased motor noises and
additional heating of the motor.

A comparison of the effects of linear encoders with

low and high interpolation error on a linear motor
illustrates the significance of high-quality position signals.
The LIDA linear encoder used here generates only barely
noticeable disturbances in the motor current: the motor Motor current of a direct drive with position encoder
operates normally and develops little heat. A: With low interpolation error
B: With high interpolation error
If at the same controller setting, the interpolation
errors of the same encoder are increased through poor
adjustment, significant noise arises in the motor current.
This causes an increased amount of noise and heat
generated in the motor.

Dynamic behavior
Digital filters are often used with direct drives to
smooth the position signals. However, the loss of
phase-association by filtering in the speed-control loop
must be kept to a minimum, otherwise the dynamic
accuracy decreases.

Position encoders with optimum signal quality help A B

to reduce the use of filters, meaning that the control
Heat generation of a linear motor controlled using an encoder:
bandwidth is maintained.
A: With low interpolation error
B: With high interpolation error

4

DIADUR phase grating with approx.
0.25 µm grating height
SUPRADUR process: Optical
three-dimensional graduation structure
Position encoders for direct drives
Linear encoders that generate a high-quality position signal with low
interpolation errors are essential for optimal operation of direct drives
in the electronics industry. Encoders that use photoelectric scanning
are ideally suited for this task, since very fine graduations can be
scanned by this method.
Encoders with optical scanning therefore play a significant role
in exploiting the potential of direct drives.
Exact graduations
HEIDENHAIN encoders with optical scanning incorporate measuring
standards of periodic structures known as graduations. The substrate
material is glass, steel, or – for large measuring lengths – steel strips.
These fine graduations – graduation periods from 40 µm to under
1µm are typical – are manufactured in a photolithographic process.
They are characterized by high-edge definition and excellent
homogeneity – a fundamental prerequisite for low interpolation error,
and therefore for smooth operating performance and high-control
loop gain.
Durable measuring standards
By the nature of its design, the measuring standards of exposed
linear encoders are less protected from their environment.
HEIDENHAIN therefore always uses tough gratings manufactured
in special processes.
In the DIADUR process, hard chrome structures are applied
to a glass or steel carrier. The AURODUR process applies gold
to a steel strip to produce a scale tape with hard gold graduation.
In the SUPRADUR process, a transparent layer is applied first over
the reflective primary layer. Then an extremely thin, hard chrome
layer is applied to produce a grating. Scales with SUPRADUR
graduations have proven to be particularly insensitive to
contamination because the low height of the structure leaves
practically no surface for dust, dirt, or water particles to accumulate.
In this way, HEIDENHAIN production technologies ensure an
enduringly high signal quality that promotes the use of direct
drives for particularly demanding applications.
5
 Optimized scanning methods
The scanning method and the high quality of the grating share
responsibility for low interpolation error. An especially beneficial
feature is the single-field scanning with which the exposed linear
encoders from HEIDENHAIN operate: The output signals are
generated from only one scanning field. This large scanning field,
and the special optical filtering through the structure of the
scanning reticle and photosensor, generate scanning signals with
constant signal quality over the entire range of traverse. This is
the prerequisite for:
n Low signal noise
n Low interpolation error
n High traversing speed
n Good control loop performance for direct drives
n Low heat generation of the motor

Photoelectric scanning in accordance with the imaging principle with steel scale
Signal generation based on the imaging tape and single-field scanning (LIDA 400)
measuring principle (LIDA 400)
To put it simply, the imaging scanning principle functions by
means of projected light signal generation: two scale gratings
with equal grating periods are moved relative to each other – the
scale and the scanning reticle. The carrier material of the scanning
reticle is transparent, whereas the graduation on the measuring
standard may be applied to a transparent or reflective surface.

When parallel light passes through a grating, light and dark

surfaces are projected at a certain distance. An index grating
with the same grating period is located here. When the two
gratings move in relation to each other, the incident light is
modulated: if the gaps are aligned, light passes through. If the
lines of one grating coincide with the gaps of the other, no light
passes through. Photocells convert these variations in light
intensity into electrical signals. The specially structured grating
of the scanning reticle filters the light current to generate nearly
sinusoidal output signals.

In the XY representation on an oscilloscope, the signals form

a Lissajous figure. Ideal output signals appear as a concentric
inner circle. Deviations in circular form and position are caused
by position error within one signal period and therefore go directly
into the result of measurement. The size of the circle, which
corresponds with the amplitude of the output signal, can vary
within certain limits without influencing the measuring accuracy.

On direct drives, deviations from the circular form cause acoustic

noise, reduce control quality, and increase heat generation.

6

Reaction of the LIF 400 to contamination
Lower sensitivity to contamination
Production facilities and handling devices for the
semiconductor industry demand high acceleration and
compact designs. Such requirements call specifically for
exposed measuring systems that operate without friction
and, because they can operate without their own housing,
can be designed to be very small and therefore low in
mass. Special scanning methods and production
techniques are used to provide tough protection against
contamination even without sealing the encoder.
Exposed linear encoders from HEIDENHAIN operate with
single-field scanning. Only one scanning field is used to
generate the scanning signals. Local contamination on the
measuring standard (e.g., fingerprints from mounting or oil
accumulation from guideways) influences the light intensity
of the signal components, and therefore of the scanning
signals, in equal measure. The output signals do change
in their amplitude, but not in their offset and phase position.
They stay highly interpolable, and the interpolation error
remains small. The large scanning field additionally
reduces sensitivity to contamination. In many cases this
can prevent encoder failure. This is particularly clear with
the LIDA 400 and LIF 400, which in relation to the grating
period have a very large scanning surface of 14.5 mm2.
Even with contamination with 3mm diameter, the encoders
continue to provide high-quality signals. The position error
remains far below the values specified for the accuracy
grade of the scale.
An essential prerequisite for optical encoders with low
sensitivity to contamination is therefore an optimized
scanning method, the large scanning field, and the
contamination-tolerant graduation.
Application-oriented mounting tolerances
Very small signal periods usually come with very narrow
distance tolerances between the scanning head and scale
tape. Thanks to the interferential scanning principle of the
LIF 400 and innovative index gratings in the LIF 400, it has
become possible to provide ample mounting tolerances
in spite of the small signal periods. Within the mounting
tolerances, therefore, changes in the signal amplitude
remain negligible.
This behavior is substantially responsible for the high
reliability of exposed linear encoders from HEIDENHAIN.
7
 HEIDENHAIN position encoders for direct drives (selection):
Maximum values of interpolation error with respect to the signal period

Linear encoders for linear motors

Exposed linear encoders from
À
HEIDENHAIN are optimized for use
on fast, precise machines as sought
by the semiconductor industry and
automation technology. In spite of the
exposed mechanical design they are

Á
highly tolerant to contamination, ensure
high long-term stability, and are fast and
simple to mount. Their low weight and
compact design suit encoders of the LIF
À , LIP Á and LIDA Â series particularly
for linear motors. n
Â

For more information circle # 1

on the reader service card.

8
IS INTERESTED IN YOUR FEEDBACK
Your comments about topics addressed in this issue and topics you’d like to see in future issues:

Name
Company
Title
Address
City State Zip
Phone ( ) FAX ( )
E-mail

o Please add me to your mailing list. (Provide address above)

Please send me HEIDENHAIN’s most current catalog.

o General o NC Linear o Digital Readout o METRO/CERTO Gauges

o Measurement Inspection o Angular Rotary o Incremental Rotary o Absolute Rotary
o Contouring Controls o Point-to-Point Controls o Servo Drive
For further information, circle the appropriate number.
Article #1 #2 #3 #4 #5 #6 #7 #8 #9 #10

333 E. State Parkway, Schaumburg, IL 60173

Phone: 847/490-1191 FAX: 847/490-3931 VOLUME 10, ISSUE 2 ©2004 HEIDENHAIN CORPORATION

IS INTERESTED IN YOUR FEEDBACK

Your comments about topics addressed in this issue and topics you’d like to see in future issues:

Name
Company
Title
Address
City State Zip
Phone ( ) FAX ( )
E-mail

o Please add me to your mailing list. (Provide address above)

Please send me HEIDENHAIN’s most current catalog.

o General o NC Linear o Digital Readout o METRO/CERTO Gauges

o Measurement Inspection o Angular Rotary o Incremental Rotary o Absolute Rotary
o Contouring Controls o Point-to-Point Controls o Servo Drive
For further information, circle the appropriate number.
Article #1 #2 #3 #4 #5 #6 #7 #8 #9 #10

333 E. State Parkway, Schaumburg, IL 60173

Phone: 847/490-1191 FAX: 847/490-3931 VOLUME 10, ISSUE 2 ©2004 HEIDENHAIN CORPORATION
BUSINESS REPLY INFORMATION
New Catalogs Available

Angle Encoders
This latest catalog gives an overview of all of HEIDENHAIN’s angle encoders
described as encoders that have an accuracy of better than ± 5” and a line
count of at least 10,000. These angle encoders, which are available in both
incremental and absolute output formats and come in a wide variety of
mechanical configurations, are typically found in applications requiring
precision angular measurement to accuracies within several arc seconds,
such as in rotary tables and swivel heads on machine tools, C-axes on lathes,
measuring machines for gears, spectrometers, and telescopes.
For more information circle # 7
on the reader service card.

Position Encoders for Servo Drives

HEIDENHAIN’s position encoders for servo drives are extensively detailed in
this catalog. The descriptions of the technical features contain fundamental
information on the use of rotary, angular, and linear encoders on electric
drives. Details include selection tables, technical features and mounting
information, specifications, and electrical connection information.
For more information circle # 8
on the reader service card.

ITNC 530 Contouring Control

Showcasing the newest TNC from HEIDENHAIN, this catalog details the iTNC
530, a versatile contouring control for milling, drilling, and boring machines and
machining centers. This TNC features a fast and extremely powerful
processor architecture. The catalog details the features and specifications for
the machine manufacturer.
For more information circle # 9
on the reader service card.

9
 HEIDENHAIN Makes
Impressions at IMTS
During IMTS (the International Manufacturing Technology
Show) this past September, HEIDENHAIN was once again
on hand to talk with the many attendees who came to
this world-renowned machine tool show that is held
in Chicago on every even year. This year, besides
showcasing the very newest in precision measurement
components and systems, HEIDENHAIN also highlighted
two large motion control displays at the booth.

These motion control displays had been developed

recently by HEIDENHAIN’s Research & Development
department in Germany in order to demonstrate the
thermal effects on motion and signal quality for speed
control, always important considerations in any machining
process. Their availability and actions at IMTS were often
the subject of conversation by the viewers who are
involved with designing or utilizing machine tools.

HEIDENHAIN’s first display at the IMTS booth

“Accuracy of Feed Drives” Display
demonstrated the difference in drive performance
associated with different measuring technologies
(“Angle Encoders for Rotary Tables”). Here a rotary
table fixture display was equipped with three different
types of angle encoders to measure position and speed:
magnetic, incremental, and absolute. The motion of the
table and audible drive tuning deviations then clearly
demonstrated how resolution, signal quality, and
interpolation contribute to the stability of servo loop,
and the benefits and drawbacks of each type of
measuring system.

The second display highlighted the linear versus rotary

argument (“Accuracy of Feed Drives”). Here, a linear
(HEIDENHAIN’s current single-field scanning technology
for the LC scales) versus traditional rotary encoder/
ballscrew system was used to capture position. This
display clearly demonstrated where drift error due to
thermal effects often takes place with a rotary system,
and the advantage, including resistance to contamination,
of linear encoder systems.

Both of these displays were based on technical white

“Angle Encoders for Rotary Tables” Display
papers available to anyone for the asking. The title of the
paper of the first display is “Angle Encoders for Rotary
For more information circle # 10
on the reader service card. Tables” while the latter is titled “Accuracy of Feed
Drives.” It was exciting to see these papers come
to life at IMTS.

HEIDENHAIN CORPORATION
333 E. State Parkway, Schaumburg, IL 60173
www.heidenhain.com