The challenge of combining the functionality of two encoders in one meant that high demands were placed on the design, flexibility and quality of the solution. In particular, the encoder should have a dynamically adjustable cogging torque and a variable cogging angle. Since sliding contacts had led to limited rotation cycles and quality problems in the past, their use was ruled out. In addition, the encoder had to meet the specified industry standards with regard to IP protection class as well as scanning and rotation cycles. Furthermore, the customer wanted both a USB and an SPI interface, a defined scanning function with a clear “click feeling” and an illuminated symbol in the rotary knob.

We developed an innovative rotary encoder solution based on a brushless DC motor (BLDC motor). The special feature of this solution was the ability to flexibly adjust the detent angle and detent torque during operation so that, for example, the detent torque increases when the input value approaches a defined limit. This made a wide range of intuitive application and operating concepts possible.

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