The Challenge of Large-Diameter Rotation
Traditional encoder approaches struggle when rotational diameters grow large. Optical sensor rings become expensive, difficult to install, and vulnerable to damage. Environmental exposure—dust, vibration, moisture, shock—further complicates performance in mobile equipment and construction machinery. Add in irrational gear ratios and tight space constraints, and many off-the-shelf solutions fall short.
Applications such as forklifts, mobile equipment, MRI systems, and stagecraft turntables require absolute position data that remains reliable over time, even when conditions are far from ideal.
A Purpose-Built Solution
EPC addressed this challenge with a fully customized encoder design that combines proven components with application-specific engineering. The solution integrates the rugged TR1 Tru-Trac® wheeled encoder housing with the compact, high-performance A36 absolute encoder, paired with a spring-loaded gear or wheel system engineered for large-diameter rotation.
This configuration allows the encoder to track motion from a ring gear or large rotating element while maintaining precise absolute position—even when installed on a smaller drive gear. EPC’s internal software compensates for complex gear ratios, ensuring accurate angular position over time without requiring oversized sensor rings.
Real-World Impact Across Industries
In mobile equipment and forklifts, the solution improves safety and operational efficiency by delivering dependable feedback for steering angle, lift position, and vehicle motion. In medical imaging systems such as MRI or CT scanners, the compact design enables smooth, controlled motion while reducing installation complexity and service risk. For construction, agricultural, and stagecraft applications, the encoder provides rugged durability and reliable secondary feedback at the point of motion—critical for safety and control.
Engineering Without Compromise
What sets this solution apart is EPC’s all-in-one approach. Rather than forcing engineers to piece together housings, sensors, gearing, and software, EPC delivers a fully engineered, ready-to-install system. Design, machining, assembly, and validation all happen in-house, allowing EPC to tailor the solution precisely to each application’s requirements.
For engineers or system integrators facing large-scale rotational challenges, this case study highlights a clear takeaway: when standard encoders aren’t enough, purpose-built motion feedback can unlock safer, more reliable machine performance—without added complexity.
When motion matters at scale, EPC engineers take the time to get it right.
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