company blog about Recycle Broadcom Encoders:Absolute Encoders,Incremental Encoders,Linear Encoders

Recycle Broadcom Encoders:Absolute Encoders,Incremental Encoders,Linear Encoders

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I. Broadcom Absolute Encoders

Absolute encoders are high-precision sensing devices capable of storing unique position codes. Unlike the pulse-counting mode of incremental encoders, each mechanical position corresponds to a set of independent digital codes. Position data is retained even after power is cut off, and the precise position can be read immediately upon power-up without the need for zero-point calibration, making them the preferred choice for high-end precision positioning applications. Broadcom absolute encoders primarily utilise an optical reflective architecture, combined with proprietary calibration algorithms, to achieve accuracy far surpassing that of traditional magnetic encoders. They support both single-turn and multi-turn configurations to accommodate different motion requirements.

1. Core Operating Principle

Broadcom absolute encoders employ dual-track pseudo-random encoding technology, generating a vast number of unique position codes using just two sets of encoding tracks, thereby simplifying the size and wiring complexity associated with traditional multi-track encoding structures. During operation, the optical transmitter illuminates the encoder disc or scale, whilst the receiver captures the reflected light signal. The chip’s built-in algorithm then decodes this into a unique code value, directly outputting absolute position coordinates without relying on cumulative pulses to calculate displacement. Multi-turn absolute encoders are equipped with Broadcom’s patented passive energy harvesting (EH) technology, enabling multi-turn position retention during power outages without the need for an external battery, thereby completely resolving the issues of battery ageing and maintenance associated with battery-powered systems.

2. Key Features

- Power-off memory, no zeroing required: Real-time locking of absolute position; data is read immediately upon power-up, making it suitable for applications involving frequent start-stop cycles and power-off restarts;

- Programmable ultra-high resolution: Mainstream products support customisable single-turn resolution from 1 to 32 bits; the flagship AR25 and AR55 series achieve ultra-high precision of up to 25 bits, with minimal positioning error;

- High stability and interference resistance: Optical encoding combined with algorithmic correction avoids the magnetic field interference issues associated with magnetic encoders; the encoders are resistant to high temperatures and vibrations, with an operating temperature range of -40°C to 115°C;

- Diverse signal outputs: Supports differential sine and cosine analogue signals as well as digital ABIUVW signals, compatible with mainstream servo control systems.

3. Key Representative Models

- AR25 Series: 25-bit intelligent, programmable absolute encoder ASIC; compact in size, suitable for space-constrained applications; features a reflective optical design with higher accuracy than traditional magnetic encoders;

- AR55 Series: Single-turn high-precision absolute solution; supports ultra-large encoder disc diameters ranging from 65 mm to 2,682 mm; can be extended for linear absolute detection, supporting a maximum stroke of 8.39 metres;

- AR35-T25 Series: Wide-temperature, dual-voltage (3.3V/5V) absolute encoders, suitable for handheld portable devices and small industrial equipment, balancing precision with versatility.

4. Typical Application Scenarios

Industrial servo motors, robotic joints, precision machine tools, positioning on automated production lines, aerospace equipment, precision medical instruments, high-end security pan-tilt units, and other scenarios with stringent requirements for positioning accuracy and power-off stability.

II. Broadcom Incremental Encoders

Incremental encoders are motion detection devices based on pulse counting and represent the most widely used type of encoder in the industrial sector. They do not have a fixed absolute position; instead, by outputting continuous quadrature pulse signals, the control system calculates displacement, rotational speed and direction of movement by accumulating the number of pulses. They offer the advantages of a simple structure, controllable costs and fast response times. Broadcom incremental encoders are centred on a reflective optical architecture; they feature high integration and a compact form factor, support both digital and analogue outputs, and are suited to high-speed dynamic motion detection applications.

1. Core Operating Principle

Broadcom incremental encoders are paired with incremental discs or scales. When the device is in motion, the optical transceiver module continuously captures the alternating light and dark signals from the encoder graduations, converting them into two orthogonal pulse signals—A and B phases. Some models are equipped with a Z-phase index pulse (one reference pulse per revolution). The control system determines the direction of motion based on the phase difference between the A and B phase pulses, calculates rotational speed from the pulse frequency, and calculates displacement from the cumulative number of pulses. The Z-phase pulse can be used for precise zero-point calibration to eliminate cumulative error.

2. Key Features

- High-speed dynamic response: Supports ultra-high-speed pulse output, suitable for detecting high-speed rotational and linear motion; features no mechanical wear and a long service life;

- Flexibly adjustable resolution: Product resolution ranges from 256 to 10,000 CPR; certain series support user-defined resolution to meet varying speed measurement accuracy requirements;

- High integration and compact size: A single surface-mount package integrates the emitter and detector units, eliminating the need for complex peripheral circuits and making it suitable for miniaturised device designs;

- Dual-mode output compatibility: High-end models support both analogue sine/cosine and digital TTL outputs, making them compatible with a wide range of motion control motherboards, both new and legacy.

3. Key Representative Models

- AEDR-9820 Series: Three-channel reflective incremental encoder with 225 LPI scale resolution; supports analogue/digital signal switching and is suitable for high-speed industrial motion control;

- AEDR-8000 Series: Ultra-compact surface-mount incremental encoders with TTL-compatible quadrature signal output, representing the preferred solution for micro-automation equipment;

- AEAT-901B Series: Magnetic incremental encoders with no mechanical contact wear; the maximum rotational speed is limited only by the bearings, making them suitable for high-speed, long-term operation scenarios.

4. Typical Application Scenarios

Stepper motor speed measurement, conveyor belt speed detection, fan and pump speed monitoring, motion counting in general automation equipment, smart home transmission mechanisms, and small precision transmission equipment—scenarios where absolute position is not required and the focus is on dynamic speed and displacement detection.

III. Broadcom Linear Encoders

Linear encoders are specialised encoders designed specifically for linear displacement detection. Unlike rotary encoders, which detect circular motion, they are paired with linear encoder scales to accurately capture displacement data from linear reciprocating motion. They are available in two operating modes—linear absolute and linear incremental—and are perfectly suited for providing precise feedback for various linear motion mechanisms. Relying on high-precision optical scale technology, Broadcom linear encoders achieve stroke accuracy down to the nanometre level, making them core components for precision linear motion control.

1. Core Operating Principle

The core architecture of Broadcom linear encoders is consistent with that of rotary encoders, with the circular code disc replaced by a long, linear code scale. The optical module moves parallel to the code scale, detecting linear displacement by reading the uniform or unique code graduations on the scale. The linear absolute type can directly read the real-time absolute linear position without the need for pulse accumulation; the linear incremental type calculates linear displacement by counting pulses and supports customisation of multiple resolution levels.

2. Key Features

- Ultra-high linear positioning accuracy: mainstream models offer a resolution of up to 400 nm, whilst high-end models achieve an accuracy as low as 1.56 nm, making them perfectly suited for micrometre- and nanometre-level precision linear motion;

- Dual-mode compatibility: A single chip supports both absolute and incremental operating modes, allowing users to switch as required to meet diverse linear detection needs;

- Flexible stroke adaptation: When paired with different scale bar specifications, it can accommodate both short-stroke precision detection and ultra-long-stroke linear motion exceeding 8 metres;

- High scale stability: The scale bar features uniform marking precision, is resistant to deformation and environmental interference, and exhibits no accuracy drift during long-term operation.

3. Key Representative Models

- AR35-L25 Series: Linear absolute encoder with a scale window pitch of 102.4 μm, a total encoding length of 52.42 mm, and a programmable resolution of 17–25 bits, offering nanometre-level detection accuracy;

- AR35-L80 Series: Linear incremental encoders with a 80 μm window pitch, supporting five resolution settings and adjustable output accuracy from 20 μm to 1 μm, suitable for general-purpose precision linear measurement.

4. Typical Applications

Precision linear slides, linear feed mechanisms for CNC machine tools, 3D printing equipment, laser processing equipment, precision measuring instruments, automated linear drive modules, precision displacement platforms for the semiconductor industry, and other applications requiring precise linear positioning and speed measurement.