custom incremental encoder disk

An incremental encoder disk is a circular disk with evenly spaced slots, lines, or markings that work with an optical or magnetic sensor to produce pulses. These pulses provide real-time feedback on the speed, direction, and relative position of rotating machinery components. The number of pulses per revolution (PPR) determines the resolution of the encoder.

Unlike absolute encoder disks that output a unique position for every angular measurement, incremental disks output relative information—meaning the position is calculated from a known reference point.

Key Components:

1. Code Disk: The actual disk with markings or slots.

2. Sensor: Detects the interruptions in light or magnetic field caused by the disk’s features.

3. Signal Processor: Converts pulses into usable digital information for control systems.

TMN's Role in Incremental Encoder Disk Production

TMN Metal Parts Fabrications Factory has built a reputation for manufacturing high-quality, reliable, and precisely engineered incremental encoder disks. We understand that in high-speed and high-accuracy systems, even the smallest error in the encoder disk can lead to significant performance issues. That’s why TMN prioritizes:

• Precision engineering

• High-quality raw materials

• Advanced fabrication methods

• Strict quality control

Our encoder disks are used in demanding environments such as industrial robotics, textile machinery, automotive systems, and renewable energy systems.

Material Selection

The performance of an incremental encoder disk begins with the selection of material. TMN offers several material options depending on the application:

• Stainless Steel (304, 316): Offers corrosion resistance and strength. Ideal for harsh environments.

• Aluminum Alloys: Lightweight and suitable for high-speed applications.

• Polyester or Polycarbonate Films: Used in cost-sensitive or lightweight electronic devices.

Material thickness ranges from 0.1 mm to 1.5 mm, depending on the required rigidity, resolution, and mounting configuration.

Disk Design and Resolution

One of the most critical aspects of incremental encoder disks is the number of slots or lines—defined as Pulses Per Revolution (PPR). TMN custom-manufactures disks with a wide range of PPR values, from as low as 50 PPR to over 10,000 PPR, depending on the client’s needs.

TMN Offers:

• Standard Sizes: 20 mm to 150 mm in diameter

• Custom Patterns: Single track or quadrature tracks (channels A and B for direction sensing)

• Indexing Features: Optional reference mark (Z-channel) for position reset

All designs are created using CAD software and can be delivered in DXF or STEP format for customer approval prior to production.

Manufacturing Process

At TMN, the production of incremental encoder disks is driven by precision, consistency, and cleanliness. The key manufacturing steps include:

1. Material Cutting

Raw metal or film is cut into circular blanks using:

• CNC laser cutting for precision metal disks

• Die stamping for high-volume production

• Rotary cutters for film-based disks

2. Pattern Creation

Patterns are created through:

• Laser Etching: High-resolution and non-contact method suitable for metals.

• Photochemical Etching: Ideal for ultra-fine features and thin disks.

• Silkscreen Printing or UV Lithography: Used for polymer disks.

The process ensures minimal edge burrs, consistent line width, and excellent concentricity.

3. Surface Treatment (Optional)

Depending on application, TMN can apply:

• Anodizing (for aluminum)

• Electropolishing (for stainless steel)

• Anti-reflective coatings (for optical sensors)

These treatments improve readability and durability in challenging environments.

Quality Control and Precision Testing

Encoder disks must meet extremely tight tolerances. TMN uses high-end metrology equipment and rigorous inspection processes to guarantee that every disk performs flawlessly.

Quality Control Measures Include:

• Optical Comparators: To verify line width, pitch, and concentricity

• Digital Micrometers: To ensure material thickness and dimensional accuracy

• High-Speed Balancing: For disks used in fast-rotating machinery

• Functional Testing: Encoder testing rigs simulate real-use environments

TMN provides full traceability documentation, including batch records, material certificates, and inspection reports.

Integration and Custom Assembly

TMN goes beyond disk production by offering value-added services, including:

• Mounting hubs: Precision machining of central hubs for encoder shaft mounting

• Adhesive backing: For easy installation in consumer or compact devices

• Multi-track disks: For applications requiring quadrature output or dual-channel feedback

• Custom shaft collars and fixtures

These assembly services are designed to help clients streamline installation and reduce time-to-market.

Industrial Applications

Incremental encoder disks produced by TMN serve a wide variety of applications across different industries:

1. Industrial Automation

Used in servo motors, conveyor belts, and robotic joints for position feedback and speed control.

2. CNC Machinery

Essential in detecting rotational angles for tool positioning and movement tracking.

3. Automotive Systems

Used in throttle position sensors, steering systems, and motor control units.

4. Wind Energy

Disks help in monitoring rotor position and adjusting blade angle for maximum efficiency.

5. Packaging and Printing

Used to ensure synchronization and alignment during high-speed production lines.

Why Choose TMN?

Choosing TMN Metal Parts Fabrications Factory for incremental encoder disks offers numerous benefits:

• Customized Manufacturing: Every encoder disk is made to order, ensuring compatibility and performance.

• In-House Engineering Support: Our design team collaborates with customers to deliver the best results.

• Fast Turnaround: Efficient processes and in-house capabilities mean shorter lead times.

• Global Shipping: We serve clients across Europe, Asia, the Americas, and the Middle East.

• Quality Assurance: We follow ISO 9001 standards for all production and inspection processes.

Conclusion

Incremental encoder disks are small components with a massive impact on machinery performance and process automation. At TMN Metal Parts Fabrications Factory, we combine technology, expertise, and customer focus to deliver encoder disks that meet the strictest demands of modern engineering.

Whether your need is high-speed motion control, precision robotic feedback, or rugged outdoor performance, TMN delivers engineered accuracy—built into every disk we fabricate.

For more information or to request a custom quote, contact TMN’s sales and engineering team today.