Intelligent Absolute Magnetic Grating and Rotary Encoder System Based on TMR Sensing and Embedded Signal Processing for Industrial Automation Applications
DOI:
https://doi.org/10.71204/6jntf336Keywords:
Absolute Magnetic Grating, Rotary Encoder, TMR Sensing, Embedded Signal Processing, Industrial Automation, Intelligent Sensing Systems, Motion ControlAbstract
With the rapid advancement of intelligent manufacturing, industrial robotics, digital motion-control systems, and high-end automated equipment, position sensing technologies have become fundamental components for precision motion control and intelligent industrial feedback systems. Absolute magnetic gratings and rotary encoders are increasingly employed in industrial robots, servo drives, CNC machine tools, logistics systems, and automated production equipment due to their advantages in non-contact measurement, anti-contamination capability, wide-temperature adaptability, and power-off position retention. However, conventional encoder systems still face several engineering challenges, including insufficient resistance to electromagnetic interference, unstable operation under vibration and oil contamination, limited multi-turn memory capability, and reduced measurement consistency in harsh industrial environments. To address these challenges, this paper presents a systematic study on intelligent absolute magnetic grating and rotary encoder technologies based on tunnel magnetoresistance (TMR) sensing, adaptive signal processing, magnetic circuit optimization, embedded decoding algorithms, and industrial reliability verification. A complete engineering framework integrating magnetic measurement principles, magnetic circuit structure optimization, absolute coding algorithm development, interpolation subdivision methods, wide-temperature compensation, anti-vibration optimization, multi-turn power-off memory, and automated calibration technologies is proposed. The system employs high-sensitivity TMR sensing bridges, low-noise signal-conditioning circuits, adaptive digital filtering algorithms, and embedded decoding architectures to improve position resolution, environmental robustness, and operational reliability. A high-precision multi-turn absolute encoder system is developed as an engineering validation platform. Experimental results demonstrate that the optimized encoder achieves stable high-resolution position output under industrial environments involving vibration, electromagnetic interference, oil contamination, and thermal fluctuation. The proposed system supports multiple industrial communication interfaces including RS422, SSI, CANopen, and incremental pulse output, enabling compatibility with industrial servo systems and intelligent motion-control platforms. Reliability tests including vibration testing, thermal cycling, electromagnetic compatibility evaluation, waterproof verification, and long-term aging experiments further confirm the engineering stability of the developed system. Compared with conventional encoder products, the proposed optimization framework significantly improves measurement consistency, anti-interference capability, environmental adaptability, and industrial deployment efficiency. The research provides a practical technical solution for intelligent industrial sensing systems and contributes to the development of high-precision motion-control technologies in intelligent manufacturing environments.
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Copyright (c) 2025 Lujie Ren, Jianming Mao, Haijun Lei, Dengcheng Lu, Shishui Zhou, Chaohui Zhang (Author)
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