POSITAL’s Wiegand assemblies offer a compact and efficient way of harvesting power for electronic circuits in electromechanical devices, eliminating the need for backup batteries.The operating principle of POSITAL’s Wiegand modules is simple. A “Wiegand wire” is a short length of specially prepared Vicalloy (vanadium-iron-cobalt) wire. When exposed to a changing external magnetic field (e.g. a nearby permanent magnet mounted on a rotating shaft) the Wiegand wire will initially retain its original magnetic polarity, and then abruptly ‘flip’ its polarity when the change to the external magnetic field reaches a certain threshold. This sudden change in the magnetic state of the core induces a current pulse in a copper coil wound around the Vicalloy core. This current pulse is very short-lived, but the energy harvested from the mechanical movement of the magnet can be captured and used to activate a low-power electronic circuit. An important feature of the Wiegand effect is that the amount of electric power generated with each reversal of the magnetic polarization is constant and completely independent of the rate of change of the external magnetic field, even if this happens very slowly. POSITAL Wiegand modules have been used to reliably power rotation counters in tens of millions of devices, including multi-turn rotary encoders, gas and water meters.
Production Since 1974 – Started by John R. Wiegand
Proven In Encoders & Water Meters Since > 10 Years
Used In Access Cards For > 30 Years
Power Supply For Future IoT Applications
High Energy Output of ~170 nJ
“The process for making Wiegand wire from raw Vicalloy wire was invented by John Wiegand in the 1970’s” comments Christian Fell, Chief of Technology Development for POSITAL-FRABA. “It involves a complex set of steps, including cold-working the wire through a combination of stretching and twisting, then heat-treating the product to lock in the desired characteristics.” POSITAL acquired the original wire-conditioning machinery and intellectual property from the Wigand estate in 2013. Fell continues: “This acquisition has meant that we have reliable supply of Wiegand wire. It also gave us an opportunity to refine the manufacturing process for improved product quality. Thanks to our research, we can now produce wires that reliably generate 190 nanojoules of energy at 7 volts with each polarity flip”.
Wiegand assemblies are a core component in POSITAL’s IXARC multiturn absolute rotary encoders, providing a maintenance-free method for powering the counter that records the number of complete rotations that the device experiences. POSITAL also offers Wigand assemblies to other manufacturers. These consist of a 15mm length of Wiegand wire surrounded by a copper coil, all contained in an SMD-mountable plastic structure. Wiegand wire production is carried out at locations in the U.S. and Europe, ensuring a stable, reliable supply chain. These assemblies can be used wherever low-cost, zero-maintenance, battery-free energy harvesting systems are needed to energize electronic counters and other low-power electronic devices.
Now with the Open Source One-Cable-Technology BiSS LINE
POSITAL’s new family of kit encoders provide the manufacturers of motors and other machinery with rugged, accurate and cost-efficient tools for building rotary position feedback into their products. The new kit encoders are based on POSITAL’s highly successful self-contained magnetic rotary encoders. Now however, the core components of these instruments are available as separate assemblies that can be readily integrated into other products.
The electronic interface for these encoders is based on non-proprietary BiSS Line and BiSS-C communications standards . Unlike proprietary, vendor-specific interfaces, these open-source standards are be supported by many manufacturers of sensors and motion controllers, freeing users from a “locked-in” relationship with a single supplier. Standard 4-wire RS485 connections are supported, so that motor manufacturers who adopt POSITAL kit encoders can often make use of existing connectors and cables. IP core software is available for FPGAs widely used in motion controllers. This reduces the development effort required to make use of BiSS communications technologies.
The BiSS Line standards also support a single cable approach to motor connections, with power and control wires combined in a single cable. Point-to-point or multi-slave network configurations are supported, simplifying wiring layouts in complex machines.
High Performance with Low Maintenance
The POSITAL kit encoder components offer advantages for motor and rotating equipment control feedback. Compared to analog resolvers, they provide improved accuracy and multiturn measurement capabilities. Their output is digital, which avoids the need for A/D converters in the control system. Compared to optical disk encoders, POSITAL’s magnetic encoders are less costly, less vulnerable to contamination from oil or dust and more resistant to shock and vibration. Multiturn absolute position measuring capability is based on an electronic rotation counter powered by the company’s well-proven Wiegand-effect energy harvesting technology . This system is self-powered, so rotation counts are always accurate, even if rotations occur when there is no control system power available. With no need for backup batteries and no need for periodic backup battery checks and replacements, maintenance requirements are significantly reduced.
POSITAL magnetic kit encoders are easy to incorporate into normal manufacturing processes since they don’t require near-cleanroom assembly conditions. A built-in self-calibration capability can be used to compensate for small sensor-to-shaft alignment errors occurring during assembly. The electronic components, including Hall-effect sensors, a 32-bit microprocessor and the Wiegand-wire energy harvesting system, are packaged in a convenient 36 mm diameter, 24.2mm deep unit. For servomotors with magnetic brakes, a special magnetic shield can be installed to isolate the magnetic pickups from external magnetic fields.
The resolution of the new POSITAL kit encoders is 17 bit, with an accuracy of better than +0.1°. The operating temperature range is -40 to +105 °C.
POSITAL PARTICIPATES IN LAUNCH OF BISS ASSOCIATION
New Organization promotes No-Charge, Open Source Interface Technology for Industrial Control Systems
POSITAL FRABA has announced that it is participating as a founding member of the BiSS Association e.V. , a new organization dedicated to encouraging the use of the BiSS family of open-source industrial communications protocols.
BiSS communications protocols were developed by the German company iC-Haus GmbH as an efficient and feature-rich digital interface for communications between industrial sensors, actuators and control devices. iC-Haus is also the source of ASIC chips that support the implementation of this interface in industrial devices such as sensors, actuators and controllers.
Features of the New BiSS Interface
The BiSS interface is hardware compatible with the well-established SSI (Serial Synchronous Interface) digital interface, but offers significant enhancements. BiSS supports continuous (real-time) communications between controllers and sensors. BiSS Safety offers functionality for critical systems where safety ratings up to SIL 3 are required. Applications of the BiSS interface include manufacturing robotics, motor feedback, servo drives & motion control, position encoders and CNC drives.
An important new development is BiSS Line – an implementation of BiSS protocols that can be deployed in a single cable configuration and features forward error correction (FEC). This makes BiSS Line an ideal interface for servomotors where the single cable feature offers a significant reduction in wiring system complexity.
BiSS is offered as an open source interface. There are no licensing fees for either manufacturers of BiSS-enabled devices or their customers. BiSS Association e.V. is autorized to grant free-of-charge BiSS licenses to device manufacturers and BiSS users. The agreement defines rights and duties to make use of associated patents and trademarks for BiSS held by iC-Haus.
New BiSS Association Organization
The new BiSS Association organization aims to expand the use of BiSS technology throughout the world. It will also provide a communications platform for technical standards and cooperative marketing initiatives. POSITAL FRABA’S Jörg Paulus has been appointed Vice Chairman of the association, joining Dr. Heiner Flocke of iC-Haus (Chairman) and Alexander Ehnert of Hengstler GmbH (Treasurer). Membership in the BiSS Association is open to all companies and institutions. Members can participate in the development and promotion of this exciting new interface. Access to BiSS technologies and licensing arrangements are open to members and non-members alike.
IXARC rotary encoders dedicated to Zones 2 & 22 are ATEX compliant and can operate safely in atmospheres where there are potentially dangerous levels of explosive gasses or dust (3G and 3D). These devices can be delivered with either programmable incremental or absolute output.
For Group II Applications Dedicated to Zone 2 & 22
Provide Absolute Position with No Battery Backup
Housing Material: Aluminum, Stainless Steel (303 AISI and 316L AISI on request)
Large Variety of Mechanical Combinations Available
Removable Connection Cap or Cable Exit
Resolution up to 16 Bit, Revolution up to 14 Bit
Communication Interfaces: CANopen, DeviceNet, Profibus, SSI, ProfiNet, & Incremental
ATEX and IECEx Norms
ATEX and IECEx norms define essential requirements for equipment and protective systems intended for use in potentially explosive atmospheres.
Application and Industries
POSITAL offers unique sensors to meet the needs of industries such as:
POSITAL is expanding their TILTIX family of inclinometers with a new line of lower cost, lower resolution instruments. These new tilt sensors will have an accuracy of ±0.5° and a resolution of 0.01°. (By comparison, current models have an accuracy of 0.1°.) For many slope or tilt monitoring applications in cranes, construction equipment, agricultural machinery and water handling facilities, half-degree accuracy is entirely acceptable. Our new lower-resolution units are less expensive than our high-end products, which makes them a useful alternative for designers of cost-sensitive systems.
Single Axis (360°) or Two Axis (±80°) Measurement
Shock Resistant up to 100 g
Tough Fiber-reinforced PBT and Heavy Duty Die-cast Aluminum Housings Available.
Available Interfaces: Analog Voltage or Current
IP69K, Protected from Dust, Water or High Pressure Cleaning
Like other members of the TILTIX family, the new lower-cost inclinometers are available in single-axis (0−360°) or dual axis (±80°) versions. Durable PBT plastic housings meet the needs of most applications, with extra heavy-duty cast aluminum housings available for very harsh working environments. They are rated for shocks of up to 100g. The output interface for these instruments is analog (voltage or current) which makes them straightforward to integrate into simple analog control or warning systems. The zero setting can be set through a input pin.Click here for more technical information about MEMS inclinometer
Finding Easily the Right TILTIX Sensor for Your Application
Use our powerful product finder tool that enables you to specify the product features required for your application and then quickly select the best available products.See All Low-resolution Inclinometers
Inclinometers with Dynamic Acceleration Compensation
POSITAL has introduced new versions of its TILTIX inclinometers that can provide reliable tilt measurement for moving equipment. These new devices use a combination of electro-mechanical accelerometers and gyroscopes to provide accurate measurements, even if the instruments are subject to strong accelerations.
Compensation of External Accelerations
Clean Measurement During Dynamic Movements
Well Protected up to IP69K
Compact and Robust Die-cast Housing with Integrated T-Coupler
Wide Temperature Range from -40 to +85°C
Product samples will be available in March 2017. Subsribe to our Newsletter to get all information when the samples are available!
Innovative Algorithm for Reliable Results
POSITAL’s TILTIX inclinometers are based on MEMS accelerometers that rely on monitoring the effect of gravity on a tiny mass suspended in an elastic support structure. Unfortunately, accelerations (e.g. due to rapid motion of the equipment to which the instrument is attached) will introduce errors in the tilt measurements. This problem is eliminated by adding a set of electromechanical gyroscopes to the inclinometers. Signals from these gyroscopes are used to compensate for the effects of acceleration, with the result that the new dynamic TILTIX inclinometers can be used reliably on mobile equipment such as construction machinery, mining equipment, cranes, agriculture machinery and anywhere else where sudden movements, shocks and vibrations are likely to be encountered. The compensation of these external acceleration forces is critical for every machine where clean measurements during dynamic movements are needed. The new dynamic TILTIX inclinometers have a measurement range of ±180° in two axes that covers the full range of motions.
Accuracy 0.5° During Dynamic Movements
Internal Cycle Time 5 ms
Max. Measurement Range ±180°
2 Axes or 1 Axis Measurement
Horizontal or Vertical Mounting Possible
Supply Voltage 10 to 30 V
Temperature Range -40 to 85°C
Shock Resistance: Up to 100 g
Interface CANopen (Profile DS-410)
Click here for more technical information about MEMS inclinometer
As every year, we will exhibit at SPS IPC Drives in Nuremberg, the most important exhibition for the professionals in the Automation world.We are very happy to invite you to our booth 146 in hall 7A, with freshly baked waffles with cherries and cream!
Inclinometers with Dynamic Acceleration CompensationPOSITAL has introduced new versions of its TILTIX inclinometers that can provide reliable tilt measurement for moving equipment. These new devices use a combination of electro-mechanical accelerometers and gyroscopes to provide accurate measurements, even if the instruments are subject to strong accelerations.
Robust Kit EncodersPOSITAL’s new family of kit encoders provide the manufacturers of servomotors and other machinery with a rugged, accurate and cost-efficient means of building rotary position measurements into their products. The new kit encoders are based on POSITAL’s highly successful self-contained magnetic rotary encoders.
Electrical Resolution: 17 Bit Singleturn, Up to 32 Bit Multiturn
Safety EncodersSafety encoders offer the advantages of increased personnel safety, minimize the risk of machines malfunctioning and reduced development time. IXARC safety encoders are certified to Safety Integrity Level 2 (SIL 2) and Performance Level d (PL d).
POSITAL also offers redundant encoders which can reach a safety level of PL d, Cat. 3. These encoders consists of either two optical or one optical and one magnetic system and are available with SSI and CANopen communication interfaces.
High-Precision Magnetic Encoders with CANopen Interface
Rugged and Compact CANopen Encoders
POSITAL’s IXARC high-precision magnetic absolute rotary encoders are now available with CANopen interfaces. These new interface option is in addition to the previously announced SSI, EtherNet/IP, EtherCat, Powerlink, Profbus DP and Profinet interfaces. Together, this range of interface choices makes the rugged and compact IXARC encoders one of the most versatile devices of its type on the market.
Battery-free Wiegand Sensor Technology
Robust and Compact Housing
Singleturn Resolution Reaches 16 bit
Autobaud Detection Function Enables the Device to Directly Integrate on the Network
Status LEDs Can Simplify Installation and Diagnostics
POSITAL’s precision rotary encoders, first introduced in 2013, provided a significant step forward in encoder technology. With improved magnetic field measurement sensors and advanced signal processing techniques, POSITAL has been able to offer devices with accuracy and dynamic response characteristics that rivaled traditional optical encoders in smaller, more robust, more cost-efficient packages. Single- and multiturn models are available. For multiturn versions, the rotation counter is self-powered, with no need for backup batteries. Since the original rollout, POSITAL has worked to enhance the performance of these devices and expand the range of available communication interfaces.
Excellent Choice for a Variety of Industries
IXARC encoders with the CANopen communications interface are an excellent choice for applications in vehicles, mobile machinery, cranes, lifts and offshore equipment. The communication interface features the autobaud function, so these encoders can be directly connected to a CANopen network without the need to manually set transmission speeds. Diagnostic LEDs show device status. A variety of connection options are available, including cables of various lengths and radially or axially oriented M12 or M23 connectors. Housings with bus-in/bus-out connectors are available for applications where it is convenient to connect several devices in series (daisy chain).Read More about the CANopen Interface
Finding Easily the Right IXARC Sensor for Your Application
POSITAL’s new family of kit encoders provide the manufacturers of servomotors and other machinery with a rugged, accurate and cost-efficient means of building rotary position measurements into their products. The new kit encoders are based on POSITAL’s highly successful self-contained magnetic rotary encoders. Now however, the core components of these instruments are available as separate assemblies that can be readily integrated into other products.
Electrical Resolution: 17 Bit Singleturn, Up to 32 Bit Multiturn
BISS C, SSI, RS485-Based Protocols
Robust & Easy to Install
Insensitive to Dust and Moisture
Compact & Cost Efficient
Based on Wiegand Energy Harvesting System
Alternative to Resolvers and Traditional Optical Systems
The POSITAL kit encoder components offer a number of advantages over the rotation measuring devices that have traditionally been used with servomotors and rotating equipment. Compared to resolvers, they are more accurate and offer multiturn measurement capabilities. They also provide digital outputs instead of the analog signals produced by resolvers. While POSITAL’s magnetic encoder technology provides lower precision than the best optical disk encoders, it is less costly, less vulnerable to contamination from oil or dust and more resistant to shock and vibration. POSITAL encoders also provide an all-electronic multiturn absolute position measuring capability that evaluates the full absolute angular position, including the total number of shaft rotations.
Compact Solution: No Coupling or Bearings
Insensitive to Dust and Moisture
Accurate Motor Feedback
Specifications of Kit Encoders
POSITAL magnetic kit encoders are easy to incorporate into normal manufacturing processes since they don’t require extra-precision, near-cleanroom assembly conditions. A built-in self-calibration capability can compensate for small sensor-to-shaft alignment errors. For servomotors with magnetic brakes, a special magnetic shield has been developed to isolate the magnetic pickups of the measurement system from the external magnetic fields.
Electrical Resolution: Up to 17 Bit, Multiturn: Up to 32 Bit
BISS C, SSI, RS485-Based Protocols
Operating Temperature: -40 to +105 ⁰C
The electronic components, including Hall-effect sensors, a 32-bit microprocessor and the Wiegand-wire energy harvesting system, are packaged in a convenient 36mm diameter, 24.2mm deep unit.