The vital role of encoders in EV production
Why use encoders in EV battery and traction motor production?
EV battery cell production
These processes require precise synchronisation, high-speed motion control, and repeatable accuracy to ensure consistent cell quality and production yield.
Encoders play a vital role in EV battery manufacturing by providing accurate position feedback, speed control, and directional precision throughout the production line. These capabilities directly support tight process tolerances, reduce scrap, and maximise throughput.
Stacking - Encoders for precise alignment
- High-speed synchronisation of multiple stacking heads
- Precise linear positioning for electrode placement
- Instant position feedback to reduce downtime
➤ Encoders for precise alignment in stacking
- Resolution down to 1 nm for ultra-fine alignment
- Instant position acquisition at power-up, eliminating the need for referencing, ideal for multi-head stacking systems
- Low SDE (±40 nm) and <10 nm RMS jitter for smooth motion and accurate placement
- Compatibility with mainstream controllers and drivers, support most of the industry standard communication protocols
Winding - Encoders for stability and speed
- High-speed rotary motion with precise angular feedback
- Stable velocity control to maintain foil tension
- Compact integration with DDR motors
➤ Encoders for stability and speed in winding
- 1 nm resolution and speeds up to 100 m/s
- Compact profile suitable for use with DDR motors
- Low jitter and SDE for smooth, ripple-free motion
- Non-contact design, reducing wear and maintenance
Welding - Encoders for reliability
- High-speed, small-radius arc control
- Robust operation in dusty, high-temperature environments
- Consistent velocity and position feedback
➤ Encoders for stability and speed in welding
- True-absolute position feedback for real-time control
- IP67-sealed readhead for protection against coolant, dust, and debris
- Resolution up to 0.244 µm for fine motion control
- Magnetic sensing for resilience in harsh conditions
Inspection - Encoders for accuracy
- Low noise and SDE for accurate image capture
- High-resolution feedback for precise positioning of sensors
- Fast, repeatable motion to maintain throughput
➤ Encoders for accuracy in inspection
- ±40 nm SDE and <10 nm RMS jitter for ultra-smooth motion
- True-absolute feedback for immediate readiness
- High-speed compatibility with vision systems and inspection gantries
- Position checking algorithm ensures correct position data
Not sure which encoder suits you?
Encoders for EV traction motor control
- Compact, lightweight encoders for integration in motor housings
- High-speed operation with minimal latency
- Robust sealing against oil, dust, and vibration
➤ Encoders for EV traction motor control
- 16 mm diameter for tight spaces
- Sealed, non-contact magnetic design for durability
- Incremental and absolute output options
- High-speed rotary feedback for dynamic motor control
What to consider when selecting encoder systems for EVs?
Performance
✔ Resolution
✔ Rotary range
✔ Speed
✔ Controller input frequency
Environment
✔ Temperature
✔ Humidity
✔ Vibration
✔ Electromagnetic compatibility (EMC)
✔ IP rating
Installation
✔ Size
✔ Ride height tolerance
✔ Yaw / pitch / roll
Others
✔ Analogue / digital
✔ Interpolation clock frequency
✔ Alarm type
✔ Automotive certificate
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Reliable operation, race after race
Salakazi Racing has equipped its dragster with an automatic three disc, four-stage clutch fitted with a digital controller. The pre-programmed controller engages the clutch when the rider snaps open the throttle - that's where the Renishaw RM22 encoders with their ability to monitor up to 30,000 rpm come into play.
We've located the magnetic actuator directly on the end of the shaft. The encoder body is on the other side, in the clutch housing. I honestly think that only a space rocket would be a tougher environment for the encoder.
Salakazi (Finland) 
The RM22 is a compact, high-speed rotary magnetic encoder designed for use in harsh environments. The non-contact two part design removes the need for seals or bearings ensuring long-term reliability and simple installation.
For customers in elite motorsport and the automotive sector, Dynisma's motion generator accurately simulates motion cues in minute detail to provide a totally immersive driving experience. The motion generator is also designed for vehicle dynamics testing and NVH (noise, vibration, and harshness) applications in automotive development.
Dynisma selected the LA11 absolute magnetic linear encoder from Renishaw associate company RLS, to enable precise position control of the belt-driven actuators that drive the a low-frequency platform responsible for large movements (excursions).
The LA11 was ideal because it minimised our space requirements by producing both absolute and incremental signals from one readhead and scale tape.
Dynisma (UK)
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For electric vehicles (EVs)
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The true-absolute encoder with a high-speed fine-resolution position measurement system. Position is acquired immediately on start-up without requiring any motion, offering smooth velocity control and dependable positional stability. Available with linear and rotary scales with a variety of serial interfaces.
✔ High speed
✔ Excellent dirt immunity
✔ Low SDE
✔ Low jitter
Integrates proven filtering optics and interpolation technology into a super-compact, analogue or digital incremental open optical encoder, with wide installation tolerances and built-in calibration functions.
✔ Wide installation tolerances
✔ Dirt immunity
✔ High performance
✔ Robust
Designed for motion control applications as a position and velocity control loop feedback element. LA12’s readhead is sealed to IP67 providing reliable operation with resolutions up to 0.244 µm and supports Mitsubishi, Yaskawa and Fanuc serial communication.
✔ True absolute system
✔ Robust design and great EMC compatibility
✔ Suitable for highly dynamic control loops
✔ Resistant to oils, coolants, and grease
Rotary magnetic encoder modules consist of a magnet and a separate sensor board. A wide range of package configurations makes them ideal for integration into original equipment manufacturer (OEM) systems.
✔ Simple installation
✔ Low maintenance
✔ High reliability
✔ Low cost for OEM integration
Speak to out manufacturing consultants
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Case Studies
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