Impact Of Sealed Encoders On The Total Cost Of Ownership

Digital encoders are a vital part of modern machining and manufacturing. They allow users to accurately measure the movement of the working tool, whether it is linear or rotary. Apart from this classification, digital encoders can also be classified as linear encoders, angle encoders, rotary encoders, absolute rotary encoders, incremental encoders, optical encoders, magnetic encoders and so on. Lastly, encoders can also be classified on the basis of their robustness as sealed and exposed encoders. Sealed encoders, in particular, seem to have a major impact on the total cost of ownership (TCO). In this blog, we will explore the basics of sealed encoders and how it is beneficial to the overall business. 

What Are Sealed Encoders?

As the name suggests, a sealed encoder is a type of digital encoder that is covered or sealed to protect the interior components from environmental factors such as dust, debris, moisture and vibrations. To understand how these digital encoders reduce the total cost of ownership, it is first vital to understand the major challenges in this regard.

Challenges That Impact The Total Cost Of Ownership

The total cost of ownership (TCO) covers not only the cost of acquiring the equipment but also the cost incurred throughout its life span in terms of maintenance and repair. With this in mind, here’s a look at some major challenges faced by industries that negatively impact TCO.

Environmental Factors

Environmental factors play a major role with respect to the total cost of ownership. Industrial settings are known to be quite challenging. In terms of digital encoders, the three main culprits here are moisture, coolants and machine oils. All these media can slowly degrade conventional digital encoders that are exposed to the elements. Therefore, their repair and maintenance will drive up the TCO.

Correlation Between Performance And Reliability

The total cost of ownership is also closely connected to the performance and reliability of the equipment in question. For instance, the better the overall performance of a machine, the more reliable it is in the long run. In terms of digital encoders, their accuracy plays a key role in their TCO. The more accurate their measurements are, the more reliable they become in everyday operation. Therefore, even the slightest deviation in their measurements can cause major lapses in quality and increase the overall TCO of the operation in corrections. 

And the accuracy of the digital encoders can be negatively impacted by the elements. Therefore, sealed encoders go on to reduce the total cost of ownership by every possible metric.

Benefits Of Sealed Encoders

With a better understanding of the challenges that impact TCO, let’s see how sealed encoders positively impact it to lead to more positive outcomes, such as improved cost effectiveness and increased reliability.

No Requirement For Extra Filters

In a traditional setup where digital encoders are exposed to the elements, they require additional help in the form of filtration systems. To protect the encoders from dust, dirt, grease, oil, moisture, and other miscellaneous contaminants, it is required to have quality filter systems. This means that the cost of owning, installing, repairing and maintaining these filters is an additional cost to the entire operation. 

This is where Heidenhain sealed encoders shine. By using scanning and robust housing technology, they eliminate the need for these auxiliary filtration systems and bring down the total cost of ownership. By proxy, sealed encoders also bring down any potential downtime that can be brought about by the failure and replacement of these filters. 

Easy To Install

When it comes to TCO, the cost of installation of an encoder is often an afterthought. However, it has a much bigger impact than it is made to believe. For example, if installing a particular digital encoder is difficult, it automatically drives up the cost of installation. Furthermore, it also opens up more room for the installation to be incorrect, leading to subsequent attempts at re-installation, driving the TCO even further. Similarly, if the encoder is damaged, a new one will have to be installed, which, once again, leads to the issues mentioned above.

Heidenhain sealed encoders solve this problem with their easy installation feature. They can be incorporated into a machine with minimal technical know-how. Moreover, they are also highly compatible with a wide variety of equipment, which means they can be retrofitted into older machines as well. Therefore, they aid in reducing the TCO even further.

Reduced Reliance On Sealing Air

Sealing air is used extensively in conventional encoders to keep the contaminants at bay. While it is effective, it drives up the total cost of operation over time. For a continuous supply of sealing air, it is important to install air supply equipment. Furthermore, it also costs more to maintain this auxiliary equipment to get a steady stream of sealing air. However, sealed encoders eliminate the need for sealing air altogether, thereby also removing the need for installing and maintaining expensive equipment. In this way, Heidenhain encoders drive down the total cost of ownership even further. 

In Closing

To summarize, digital encoders play a major role in influencing the total cost of ownership (TCO) of a particular operation. While environmental factors, performance and reliability challenge the reduction in TCO, sealed encoders counteract this challenge expertly by removing the need for filtration systems, sealing air and expensive installation protocols.

To learn more about our encoders, reach out to us at Walker Machinery today. As a leading distributor of Heidenhain digital encoders, our massive inventory covers linear encoders, rotary encoders, shaft encoders, absolute rotary encoders, incremental encoders, optical encoders, sealed encoders, and a lot more. Call us today at 905-876-0890 to request a quote.