Case Study

Programmable Shaft Encoder Solves
Engineers’ Dilemma

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Background

Atlanta-based Kirk-Rudy has been providing innovative systems for the direct mail, printing, newspaper, and card industries since 1967. They engineer and manufacture cost-effective systems for addressing and paper handling.

Kirk-Rudy has been at the forefront of innovation in their field, developing new equipment to meet customers’ needs as postal regulations and technology advanced over the years. They even sold a system to the White House in the 1970s!

When inkjet technology took off in the 1990s, Kirk-Rudy was at the forefront of incorporating the technology into their addressing systems. Their products quickly became known for their dependability and ease of operation.

Summary of encoder requirements for this application:

  • Shaft encoder
  • Standard Size 25 (2.5") package
  • 3/8” shaft
  • Flange mounting face
  • Heavy-duty and rugged enough to work with existing systems
  • Line Driver output option
  • 8-pin, M12 connector
  • IP66 sealing
  • Option of varying resolutions, so it could be used on multiple different systems

The Problem

With all the innovation Kirk-Rudy is known for, they’re still careful to not “reinvent the wheel.” That is, as they innovate in one area, they still maximize the use of existing systems that meet their customers’ needs. So when they developed the latest generation of their inkjet printers, they needed to find a way retrofit them into their systems.

Kirk-Rudy needed a Size 25 shaft encoder that was rugged enough to handle their applications, but versatile enough to work in many different applications.

“Our engineers would constantly have to re-engineer drive pulleys and shafts in order to incorporate our newest generation of inkjet printers into existing systems,” explains Tim Geary, Director of Inkjet Technology at Kirk-Rudy. “The engineers were forced to waste valuable time engineering and retrofitting to get everything to work together.”

The Solution

Kirk-Rudy has been purchasing EPC encoders through AA Electric for more than twenty years. Bill Faison, EPC’s Southeastern Regional Sales Manager, works closely with AA Electric, so he was well aware of the challenges Kirk-Rudy was facing. When EPC released our programmable Model 25SP, Bill knew it was the right solution for Kirk-Rudy’s applications.

“Mechanically, the Model 25SP was the obvious choice,” explains Bill. “It’s incredibly versatile, offering shaft sizes from 3/8” all the way to 10 mm. There are three different mounting faces and eight different connector types to choose from. Electronically, it was also the obvious choice, because the electronics are programmable.”

Using EPC’s optional programming module with the Model 25SP, users can:

  • Choose from 6 different out types
  • Choose from 32 waveforms
  • Program any resolution from 1 to 65,536 CPR

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Model 25SP Accu - CoderPro®

The Model 25SP Accu- CoderPro® offers 6 different output types, 32 different waveforms, and any resolution from 1 to 65,536 CPR – that’s 262,144 counts using 4x quadrature counting. These programming features allow a single encoder to be configured for multiple applications.

Model 25SP Key Features:

  • Industry standard 2.5” package
  • Fully programmable with optional USB module or factory configured
  • Optical technology for high accuracy
  • Resolutions from 1 to 65,536 CPR (262,144 quadrature counts)
  • Servo and flange mounting
  • IP67 sealing available

“Each of Kirk-Rudy’s machines is built to order,” explains Bill Faison. “So each application needs its own resolution. Having the flexibility of the programmable has allowed Kirk-Rudy to save machining time, because they used to have to custom-make parts to retrofit each application.”

"After testing the Model 25SP shaft encoder for several months, we were amazed with the flexibility and ease of use. We now have the flexibility to add our new printer technology to older bases and existing systems... Programming the encoder was surprisingly easy. The programmable encoder simplifies integration and avoids wasted time and resources," says Tim Geary.

“Each of Kirk-Rudy’s machines is built to order,” explains Bill Faison. “So each application needs its own resolution. Having the flexibility of the programmable has allowed Kirk-Rudy to save machining time, because they used to have to custom-make parts to retrofit each application.”

Find Out More

Check out the specs for the Model 25SP, or watch the video explaining exactly how to set up your Accu-CoderPro®.

Do you have a question about which encoder is right for your application? When you contact EPC, you can talk to engineers for your toughest encoder questions and get the right answers that make sense for your application.

Our manufacturing is located in the United States, and EPC has some of the fastest lead times around, with expedite options available on many models. And with our industry-leading three-year warranty, if something does go wrong we’ve got you covered.

Contact EPC to find the right encoder for your application.

Programming the Model 25SP Accu-CoderPro®

 

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