Basic Tips To Clean And Repair Rotary Encoder
Owing to their importance in the functioning of an appliance, it is important to maintain your encoders properly.
So, how to clean a rotary encoder and/or get it repaired? Let’s start with understanding the issues your encoder is likely to face and how to tackle those issues to get the encoder repaired.
Troubleshooting Common Rotary Encoder Issues
There are multiple issues your rotary encoder may experience. Each of these situations asks for a specific resolution. Here are some of the most common problems faced by encoders with a brief solution for every issue:
Zero Output
Your encoder may appear to be “dead” and stop all its movements when it stops giving out any output. Almost always, this means that your encoder has experienced severe damage and needs to be sent for rotary encoder repair.
However, before sending it for repairs, you can check for incorrect voltage supply, loose connections, or wrong signal type. Also, you can replace an encoder with another one to ensure that the problem lies with the encoder. However, perform such actions only if you are a qualified technician or are in the presence of one.
Wrong Output
Issus such as incorrect alignment, loose wiring, unwanted electrical noise, or incompatibility with the driver/controller may result in your encoder giving out incorrect or distorted output.
If you are experiencing this problem, it is advisable to check whether the encoder and the shaft are aligned properly. Check the connections to see if there is a fault in the circuit. Go for a professional rotary encoder repair service if you are unable to resolve the issue.
Worn-out Ball Bearings
If the ball bearings of your encoder have worn out, it will start experiencing a loss of pulses which will be compensated by the frequency inverter. This would result in the drive unit becoming irregular.
If such a situation arises, make sure that your installation is not faulty. If the installation is old and not looked into in recent times, the wear-and-tear of ball bearings is natural to expect. The two feasible ways to resolve this issue is to get a new installation or correct the existing one.
Dust Or Moisture Contamination
If your encoder is contaminated with dust, it is likely to produce a lower pulse or stop rotating altogether. This is because the dust particles give an impression of two increment lines to the encoder instead of one.
Also, your encoder would start showing irregularities with sporadic failures if moisture seeps in through the cable gland.
In such cases, make sure that you disconnect the power source and clean your encoder very carefully to get rid of unwanted dust or moisture. Once you are done with the cleaning, it is advisable to use a cover while operating the encoder or use an encoder with an external plug.
How To Repair A Rotary Encoder
Provided that the issue is small enough to be handled yourself, here are four simple steps you can follow to repair your rotary encoder:
- Look For The Problem
When you are looking forward to getting your rotary encoder repaired, it is very likely that you know the reason why it has been facing issues in the first place. If you are aware of exactly what is wrong with the encoder, you can start troubleshooting right away.
However, if your encoder is facing irregularities but you are not aware of what exactly is causing it, you can look for the problem by checking the wiring and all parts of your encoder. If you find a part that is no longer working, replace it. - Cleaning The Head
Dust contamination is one of the most common issues faced by encoders. It is always advisable to clean the head part of your encoder to get rid of unwanted dust with a soft cloth without affecting other parts of the device. This would provide you with improved reception. - Examine The Mechanical Parts
Now, check the mechanical parts of the encoder for being contaminated by dust or various particles of dirt. If a mechanism is found to be affected and has stopped working, get it out, and examine all the moving parts carefully with the end of a screwdriver or other pointed tools. - Look For The Wiring
Finally, have a look at the wiring of the circuit that connects your encoder to the shaft. See if there are any loose connections, corroded wires, or other signs of faulty wiring. Reattach all the loose wires with a soldering iron to improve the connection.
Once you have ascertained the cause, start getting it fixed immediately. If you feel the problem is beyond your control and you need professional help, get in touch with a reliable rotary encoder repair service provider at once.
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