Electroformed Reflective Encoder Code Disc Processing and Application Fields

1. Product Introduction

The electroformed reflective encoder code disc is a high-precision core optical encoding component manufactured by precision photolithography and integrated electroforming molding technology. Adopting nickel-based alloy as the base material, the product features zero mechanical cutting and laser etching stress, effectively eliminating common defects of traditional code discs such as deformation, uneven line width and edge burrs. It achieves micron-level accurate reproduction of high-density code tracks with flat and uniform reflective surfaces and high contrast, ensuring stable photoelectric signal acquisition and excellent angular positioning accuracy. Supporting customization of ultra-thin, special-shaped structures with ultra-fine pitches and multi-channel code tracks, the disc delivers extremely high concentricity and roundness without jitter during high-speed rotation. With outstanding high and low temperature resistance, wear resistance, aging resistance and long service life, it is compatible with incremental and absolute reflective encoders. Widely used in precision motion control, industrial automation and intelligent equipment, it serves as a core precision component for high-accuracy position and speed detection.

2. Product Features

• Stress-free Integrated Molding: Formed by pure electroforming deposition without stamping or laser processing stress. It completely avoids warpage, deformation and fatigue failure, ensuring extremely high dimensional consistency in mass production and adapting to long-term high-speed operating conditions.

• Ultra-high Optical Accuracy: Micron-level fine code track reproduction with straight, sharp and burr-free edges. Uniform black-and-white contrast ensures clutter-free photoelectric signals without step loss, greatly improving detection resolution.

• Excellent Optical Performance: Adopts customized mirror reflection structure with high and uniform reflectivity and thorough light shielding in absorption areas, effectively avoiding light scattering interference and matching low-power, high-sensitivity photoelectric detection modules.

• Powerful Customization Capability: Customizable ultra-thin substrates, high-density narrow code tracks, multi-turn code tracks, special-shaped outer diameters and micro-hole positioning structures, meeting the requirements of various miniature, ultra-thin and high-precision reflective encoders.

• High Durability and Stability: Nickel-based alloy substrate features high hardness, superior wear and corrosion resistance, as well as high and low temperature aging resistance. It maintains stable performance during high-speed operation and offers a far longer service life than traditional etched and laser-processed code discs.

3. Product Performance

• Dimensional Accuracy: Code track line width tolerance reaches ±1 μm with a minimum line width of 0.05 mm. The overall concentricity is ≤0.002 mm with negligible roundness error. The maximum angular resolution is up to 24 bits, satisfying ultra-high precision positioning requirements.

• Optical Detection Performance: Uniform and flat reflective areas and completely light-tight shading areas ensure stable and high-contrast photoelectric signal output without signal distortion, sudden jumps or step loss, significantly improving detection accuracy.

• High-speed Operation Performance: The integrally formed structure has no splicing gaps and excellent dynamic balance. It supports continuous high-speed operation without jitter or eccentricity, maintaining stable dynamic detection accuracy.

• Environmental Resistance: It operates stably within a wide temperature range of -40℃ to 120℃. Featuring moisture resistance, corrosion resistance and oxidation resistance, it adapts to harsh industrial environments.

• Durability Performance: The substrate is wear-resistant and fatigue-resistant. It remains free from deformation and wear after long-term high-speed rotation and frequent start-stop cycles, extending service life and effectively reducing equipment operation and replacement costs.

4. Application Fields

• Industrial Automation Equipment: Suitable for incremental and absolute reflective encoders of servo motors and stepper motors, applied in closed-loop control of speed, angle and position for CNC machine tools, automatic production lines and precision transmission equipment.

• Intelligent Robotics: Applied to joint encoders of industrial and collaborative robots, ensuring precise positioning and stable movement of robotic arms to achieve high-precision motion reproduction and trajectory control.

• Precision Testing Equipment: Widely used in 3D printers, laser engraving machines, precision measuring instruments and displacement detection equipment, providing micron-level precise position feedback to improve equipment processing and detection accuracy.

• Semiconductor Precision Equipment: Matched with wafer inspection platforms, precision alignment modules and auxiliary positioning encoders for lithography machines, meeting nanometer-level precision positioning requirements of semiconductor equipment.

• New Energy and Automotive Equipment: Applied in vehicle servo systems, new energy motors, intelligent pan-tilts and unmanned driving perception devices, adapting to vehicle-grade high-stability and high-reliability operating conditions.

• Aerospace Precision Instruments: Used for aerospace precision measurement, control and attitude detection instruments, suitable for high-end precision motion control scenarios that require high accuracy, stability and reliability.