Spindle encoders are critical to machine accuracy, yet many failures are actually caused by improper installation. Based on KOSEND's years of on-site installation experience, here are the key notes for installers and maintenance staff.
1. Four Key Installation Notes
1. The installation air gap must comply. Ring encoders have strict requirements for the gap between read head and ring (e.g. KOSEND DA series permits 0.4mm±0.15mm, JD gear series 0.25mm±0.05mm). Too large a gap weakens the signal; too small causes friction damage. Always calibrate with a feeler gauge / inspection shim.
2. Control eccentricity and runout. The eccentricity of the scale (ring/gear) and the radial runout of the measured shaft significantly affect accuracy for encoders without built-in bearings. Mounting surfaces must be machined flat and the shoulder locating reliable.
3. Ground the read head reliably. The read head and housing must be well grounded, otherwise revolution fluctuation and positioning error can occur. The sensor ground wire should be run separately and as short as possible.
4. Clean and prevent magnetic chips. After installation, blow the whole sensor clean with compressed air. Residual magnetic chips increase positioning error, cause torque indication fluctuation, noise, and can even damage the read head through friction. Never strike or adjust the encoder with a hammer or similar tools.
2. Common Problem Quick Reference
| Symptom | Common Cause |
|---|---|
| Speed reading fluctuates | Poor read-head grounding, out-of-spec gap |
| Positioning error exceeds spec | Scale eccentricity, large shaft runout |
| Intermittent signal | Gap too large, broken cable shield |
| Noise / torque fluctuation | Magnetic chips left behind, ring-readhead friction |
3. Installation Reference
On the KOSEND website (www.kosend.com) product pages you can freely download the 42/52 ring installation manuals, DAD series manuals and magnetic-ring mounting bracket drawings; on-site installation guidance is also available. For stubborn faults, call 400-100-6802.