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TONiC™ FS incremental encoder system with RELM20 linear scale

Features

  • Readhead size: 35 x 13.5 x 10 mm
  • Speed up to 10 m/s
  • Detachable analogue (Ti) or dual output (DOP) interface*
  • Certified to:
    ISO 13849 Category 3 PLd
    IEC 61508 SIL2
    IEC 61800-5-2 SIL2

Benefits

  • Very high accuracy combined with  near zero thermal expansion
  • Super-compact encoder 
  • Advanced signal conditioning for improved motion control
  • High dirt immunity
  • Ultra-low Sub-Divisional Error (SDE): typically <±30 nm
  • Diagnostic kit
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What is the TONiC FS encoder?

The TONiC FS series is Renishaw's super-compact, non-contact encoder system that offers speeds up to 10 m/s and, when combined with the DOP interface, resolutions down to 1 nm for both linear and rotary applications. TONiC FS systems are quick and simple to install with wide set-up tolerances and calibration at the push of a button. The TONiC FS encoder's dynamic signal processing gives improved signal stability with ultra-low Sub-Divisional Error of typically <±30 nm to help realise superior motion control performance. Certified to SIL2 and PLd for use in functional safety applications.

* Only the analogue sine and cosine outputs are functionally safe.

What is RELM20 scale?

RELM20 is a spar scale manufactured from ZeroMet™, a low expansion nickel/iron alloy, featuring a 20 µm pitch. 
It is comparable to fine pitch glass scales and offers a total accuracy (including slope and linearity) better than ±1 µm over a 1.5 m length. ZeroMet has a coefficient of thermal expansion of 0.75 ±0.35 μm/m/°C at 20 °C.
System designers can choose between specially formulated adhesive tape or mechanical clips to suit mounting requirements. Both mounting methods allow for independent thermal expansion to that of the substrate.

Why choose this encoder system?

Functional Safety certification

The TONiC FS series is an incremental open optical encoder system with certification to the following Functional Safety standards:

ISO 13849 Category 3 PLd
IEC 61508 SIL2
IEC 61800-5-2 SIL2

Certain machinery safety functions, such as Safety Limited Speed (SLS), require the encoder feedback to be functionally safe. Utilising an encoder system that is already rated for use in these applications can make machine certification significantly easier. Adopting these advanced machine safety functions allows machine builders to make safer machines, capable of higher functionality that can reduce set-up times and machine downtime.

Ultimate reliability and performance in a compact size

For ultimate reliability, consistent performance and high dirt immunity, TONiC FS readheads incorporate third-generation filtering optics, tuned for even lower noise (jitter) and now further enhanced by dynamic signal processing including Auto Gain Control and Auto Offset Control. This combination – all incorporated inside the readhead - provides signals of unrivalled purity and ultra-low Sub-Divisional Error of typically <±30 nm. The result is smoother velocity control for improved scanning performance and increased positional stability; essential parameters for so many applications, all in a compact readhead.

Quicker and easier installation

A set-up LED on the readhead gives a visual indication of signal size and an optional diagnostic kit allows remote checking of the system performance when the readhead is concealed within the machine. Calibration of the reference mark and incremental signals is done at the push of a button with no mechanical adjustment or additional diagnostic tools. The IN-TRAC customer-selectable optical reference mark is embedded in the incremental scale for compact dimensions and simplified alignment. This yields a reference mark output that is bi-directionally repeatable to unit of resolution over the full operating temperature and speed range.

Interface options

Ti interface

  • Analogue output, including a CAL button.Ti interface

DOP (dual output) interface

  • Provides simultaneous digital quadrature and 1 Vpp signals.
  • Designed for applications requiring one or more operations to be synchronised with a motion axis.TONiC Dual Output (DOP) interface

Optional diagnostic kit

TONiC™ diagnostic kit (software and hardware)

TONiC diagnostic software can be used to optimise the installation of TONiC encoders and provide a quick and comprehensive system calibration. The software must be used in conjunction with the TONiC diagnostic hardware which can be purchased from Renishaw using part number A-9411-0011. The hardware is connected to the PC via the USB cable (provided in the kit) or in-line with the customers' electronics.

Find out all about the TONiC diagnostic kit.

Technical specifications

Measuring standard

RELM20: high accuracy ZeroMet spar scale with mid reference mark

Also available with end reference mark as RELE20

Readhead size (LxWxH)

35 mm x 13.5 mm x 10 mm

Scale pitch

20 μm

Coefficient of thermal expansion at 20 °C

0.75 ±0.35 μm/m/°C

Accuracy grade at 20 °C

Certified to ±1 μm, calibration traceable to International Standards

Reference mark

IN-TRAC reference mark

Various reference mark position options, see data sheet for details

Limit switches

Dual or single limits (select at time of order)

Scale length

20 mm to 1.5 m

Maximum speed

Analogue

Digital (*use with DOP)

(See data sheet for details)

Up to 10 m/s at -3 dB

Up to 10 m/s

Sub-Divisional Error (SDE)

Typically <±30 nm

Dynamic signal control

Real time signal conditioning including Auto Gain Control (AGC) and Auto Offset Control (AOC) for optimised performance during operation

Incremental signals

Analogue

Digital (*use with DOP)


1 Vpp (20 μm period)

Resolutions from 5 μm to 1 nm

Electrical connection

0.2 m, 0.5 m, 1 m, 1.5 m, 3 m, 5 m, 6 m and 10 m cable lengths with mini connector (connects direct to TONiC interface)

Power supply

5 V ±10%
Readhead only <100 mA
With Ti0000 <100 mA
With DOP <275 mA

Vibration (system)

100 m/s2, 55 Hz to 2 000 Hz, 3 axes

Shock (system)

500 m/s2, 6 ms, ½ sine, 3 axes

Operating temperature (system)

0 °C to +70 °C

Sealing

Readhead: IP40
Ti interface: IP20
DOP interface: IP30

* Only the analogue sine and cosine outputs are functionally safe.

Refer to data sheets for full details.

 

Downloads

Data sheets

Software

  • TONiC™ diagnostic software version 1.0

How it works

The TONiC FS series features the third generation of Renishaw's unique filtering optics that average the contributions from many scale periods and effectively filter out non-periodic features such as dirt. The nominally square-wave scale pattern is also filtered to leave a pure sinusoidal fringe field at the detector. Here, a multiple finger structure is employed, fine enough to produce photocurrents in the form of four symmetrically phased signals. These are combined to remove DC components and produce sine and cosine signal outputs with high spectral purity and low offset while maintaining bandwidth to beyond 500 kHz.

Fully integrated advanced dynamic signal conditioning, Auto Gain , Auto Balance and Auto Offset Controls combine to ensure ultra-low Sub- Divisional Error (SDE) of typically <±30 nm.

This evolution of filtering optics, combined with carefully-selected electronics, provide incremental signals with wide bandwidth achieving a maximum speed of 10 m/s with the lowest positional jitter (noise) of any encoder in its class. Interpolation is by CORDIC algorithm within the TONiC FS Ti interface, with fine resolution versions being further augmented by additional noise-reducing electronics to achieve jitter of just 0.5 nm RMS.

TONiC™ optical scheme with annotations

The IN-TRAC reference mark is fully-integrated in the incremental scale and is detected by a split photodetector within the readhead. As the diagram shows, the reference mark split detector is embedded directly into the centre of the incremental channel linear photodiode array ensuring greater immunity from yaw-dephasing. Yielding a reference mark output that is bi-directionally repeatable to unit of resolution at all speeds. This unique arrangement also benefits from an automatic calibration routine that electronically phases the reference mark and optimises the dynamic signal conditioning.