Explore the different types of Baumer encoders — rotary, linear, absolute, and incremental. Learn how each encoder works, where to use them, and how to select the right one for your motion control system. Continue reading →
— From motor feedback to conveyor positioning and robotics.
Overview of encoder types: incremental, absolute, rotary, linear
— How they differ, and what makes each one better for specific tasks.
Key selection factors: resolution, output, environmental specs
— What to look at when choosing between Baumer models.
Where I’ve used each type in real factory systems
— Examples include servo drives, labeling machines, and gantry systems.
Includes diagrams, comparison tables, and wiring advice
— Clear visuals to help engineers understand encoder applications quickly.
If you’ve spent time on a factory floor — especially working with high-speed packaging, robotics, or motion control systems — chances are you’ve seen Baumer encoders in action. There’s a reason they keep showing up in panel specs and machine BOMs.
Baumer encoders are known for their high-resolution accuracy, long-term stability, and robust mechanical design. Whether it’s dust, oil mist, vibration, or extreme temperatures, these devices are made to survive harsh industrial environments. I’ve installed them in places where cheaper encoders would have failed within months — Baumer units just keep running.
Another big plus is the range. Need a compact encoder for a tight servo housing? They’ve got it. Need something with a through-hollow shaft for easy retrofit on a driveshaft? Done. From incremental and absolute to rotary and linear — Baumer covers virtually every position sensing scenario you’ll find in automation, packaging, and process control.
Sure, you can find budget encoders that technically meet the same spec — but in the field, specs on paper don’t always translate to performance in practice. In my experience, Baumer encoders offer:
For me, the slightly higher upfront cost pays off in reliability and reduced downtime — especially in critical lines or when encoders are hard to reach.
“In one packaging plant I worked with, switching from no-name encoders to Baumer reduced unexpected line stops by over 70%. That speaks volumes.”
Baumer makes a wide range of encoders, but in the field, they usually fall into four key categories. Here’s how I break them down based on real use cases in automation systems I’ve worked on.
These measure angular rotation of a shaft, and they’re the workhorse of most motion systems. Whether you’re dealing with servo motors, gearboxes, or rotary indexing tables, a rotary encoder is usually your go-to.
One of the most versatile series I’ve used is the Baumer EIL580 — it’s reliable, accurate, and easy to mount with either solid or hollow shaft options.
“I’ve used the EIL580 in everything from pick-and-place arms to labeling machines — they just work.”
Instead of rotation, linear encoders measure straight-line movement — ideal for CNC axes, gantry systems, or precision inspection setups.
For tough environments or mobile systems, I often reach for the Baumer MIL10 magnetic linear encoder. It offers good resolution and solid resistance to dust and vibration.
“Whenever a customer needs precise linear feedback but can’t use optical scales, the MIL10 is my top pick.”
Incremental encoders provide relative position data in the form of pulses. They’re simple, affordable, and great for velocity monitoring or basic motor control — but keep in mind, they lose position on power loss, so you’ll need to home the system after reboot.
“For VFD-controlled conveyors or low-cost automation, incremental Baumer encoders offer great value without overengineering.”
These track the exact position of a shaft, even after power loss — no homing required. That’s a game-changer in systems where downtime hurts, or where access is difficult (think wind turbines, elevators, or robot arms).
Baumer’s MAGRES and HOG10 encoders are built like tanks, and their multi-turn options handle complex position tracking over long rotary distances.
“I once spec’d a MAGRES encoder for a vertical lift with 20+ meters of travel — no recalibration needed even after months of cycling.”
This table gives a quick, at-a-glance breakdown of the main types of Baumer encoders and where I typically use each in the field. If you’re building or retrofitting a motion system, these details will help you pick the right encoder for the job:
| Encoder Type | Motion Type | Output Signal | Best Use Case | Homing Needed | Typical Example |
| Rotary | Angular | TTL, HTL, SinCos | Motors, shafts | Depends | EIL580 |
| Linear | Linear | TTL, analog | CNCs, rails | Depends | MIL10 |
| Incremental | Angular/Linear | A/B/Z pulses | Drives, VFDs | Yes | BHG05 |
| Absolute | Angular/Linear | SSI, CANopen | Robotics, multi-axis | No | MAGRES, HOG10 |
Not every encoder is a fit for every job — I’ve learned that the hard way. Here’s how I decide which Baumer encoder to use, based on motion type, environment, and control requirements.
These are my workhorses when budget and simplicity matter.
“If I need a low-latency feedback loop but don’t care about exact position after power loss, incremental rotary encoders are my default.”
When safety, accuracy, or multi-axis control is involved — this is what I trust.
“In robotics, power outages happen. With absolute encoders, you’re not blind when the system reboots — it just keeps going.”
These are underrated in my opinion — simple, tough, and reliable.
“I’ve mounted these directly on aluminum frames where optical encoders would fail due to dust or misalignment.”
There’s no “one-size-fits-all” when it comes to encoders — I’ve seen projects go sideways because the spec didn’t match the real-world setup. Here’s the step-by-step process I follow when choosing a Baumer encoder:
Start simple. Are you measuring angular shaft rotation or straight-line movement?
“I always map the motion path before choosing encoder type — the wrong form factor costs time and accuracy.”
Know how much precision you need:
“For basic VFD feedback, 1,000 PPR might be fine. For robotic pick-and-place, I don’t go below 16-bit.”
Match the encoder’s signal with your control system:
“I’ve run into weird issues when mixing TTL and HTL logic levels — always check controller input specs.”
Where will this encoder live?
“I once had an encoder fail mid-winter because it wasn’t rated for -20°C. That lesson stuck.”
Space constraints matter — look at:
“On compact machines, I use right-angle connectors to avoid bending or stressing the cable.”
Always check the encoder’s electrical interface, signal type, and protocol support against your PLC, servo drive, or motion controller.
“I keep a spreadsheet of controller specs and encoder signal types — it saves me from guessing during commissioning.”
Baumer encoders aren’t just spec sheet champions — they’ve proven their value across some of the most demanding applications I’ve worked on. Here’s where they shine in the field:
I’ve installed Baumer rotary encoders for both main spindle speed control and linear axis positioning in CNC machines. The high-resolution output ensures tight tolerances, especially in multi-axis setups where backlash compensation is critical.
“In one job, we used the EIL580 on a 5-axis CNC router — perfect stability even during high-RPM cuts.”
In fast-moving packaging lines, incremental encoders like the BHG05 series provide real-time feedback to servo drives. They’re fast, accurate, and easy to integrate with standard VFDs or motion controllers.
“I’ve seen Baumer encoders improve throughput by helping eliminate positioning jitter in vertical form-fill-seal machines.”
For autonomous guided vehicles (AGVs) and robotic arms, absolute encoders like MAGRES ensure accurate location tracking — even after power cycles. No need to re-home, which keeps systems efficient and reduces downtime.
“On a mobile robot project, we used multi-turn absolute encoders on both wheels — zero loss of position even after sudden stops.”
In washdown environments, I’ve used encoders with IP67 stainless steel housings. They provide durable motor feedback while withstanding frequent cleaning cycles, steam, and temperature swings.
“The EAM580 worked flawlessly on a conveyor inside a dairy plant. After two years of daily washdowns, still no failures.”
Outdoor automation — like solar tracking or wind turbine control — demands rugged, sealed encoders. I’ve trusted Baumer encoders in cold, wet, and dusty conditions where other brands just didn’t last.
“We deployed MAGRES encoders on a mountaintop wind farm. Temperatures hit -25°C and the units never missed a signal.”
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