HAMILTON, N.J., April 2025 — POSITAL has introduced two exciting new modular kit encoders for safety-critical applications where multiturn measurement ranges and cost-efficiency are essential requirements. While these new designs have lower resolution and more limited measurement ranges than other members of POSITAL’s IXARC encoder family, they provide special advantages in safety critical areas such as AGVs and AMRs navigating autonomously through warehouses, forklifts operating at significant lifting heights, and aerial work platforms. They are also well suited for lifting systems and automated warehouse equipment that require reliable position feedback, compact installation dimensions, and dependable long-term operation.
At the heart of these new IXARC encoders is a pair of permanent magnets geared to turn at different rates. The rotary position of each magnet is monitored by a separate Hall-effect sensor. An embedded microcontroller combines the output of these sensors (using the Nonius or Vernier principle) to calculate angular displacement and rotation count. Single-turn resolution is 13 bits, for an accuracy of +/- 0.8°. The multiturn measurement range is up to 35 revolutions.
The rotation count is determined in real time from the rotary position of the magnets and will be accurate, even if rotations have occurred when system power was unavailable. With no need for backup batteries (often required to keep a counting system active during power outages), maintenance costs are minimal.
The new modular kit encoders are available in two versions. A “safety” variant is available with a PLd certification to EN13849. The other variant has not been certified but is based on the same measurement principle and features redundant outputs that can be used to ensure fail-safe operation. Machine builders can program their PLCs or controllers to compare the two position outputs with other data related to the expected motion (e.g. current supply to the motor) and conduct ‘plausibility checks’ to confirm that the output data are logically consistent. If a discrepancy is detected, motion can be stopped to avoid a safety hazard.
Both safety and redundant versions have rugged fibre-reinforced PBT housings. Both are “shaftless," designed to fit around the rotating shaft of a host machine or motor. Both support RS485 asynchronous communications with selectable baud rates DCR versions feature a 4-pin M12 connector, while DCS versions have interfaces for popular industrial connectors. In summary, POSITAL’s new IXARC safety and redundant multiturn kit encoders provide compact, cost-efficient and highly reliable solutions for position control.
About FRABA and POSITAL
POSITAL is a supplier of advanced industrial position sensors used in a wide variety of motion control and safety systems. The company is also an innovator in product design and manufacturing processes and a pioneer of Industry 4.0 (Industrial Internet of Things/IIoT), offering customers the benefits of built-to-order products combined with the price advantages of mass-production. POSITAL is a member of the international FRABA group, whose history dates to 1918, when its predecessor, Franz Baumgartner elektrische Apparate GmbH, was established in Cologne, Germany to manufacture relays. Since then, the company has played a trendsetting role in the development of rotary encoders, inclinometers and other sensor products. POSITAL has a global reach with subsidiaries in Europe, North America and Asia along with a worldwide network of sales and distribution partners.
