External encoders limit performance in critical drive systems

Accuracy, cleaning and cycle times are becoming increasingly important factors in food and packaging lines. External encoders are clearly the weak link. Integrated encoders provide stable performance.

The challenge of obtaining accurate feedback in fast and compact machines

In food and packaging machines, performance depends on much more than rotational speed alone. For fillers, the container must be ready before the dosing unit activates. In conveyor systems, the encoder determines the speed and position of products at each stage. At the same time, cleaning cycles, corrosive substances and compact design play a role. When the measuring system is separated from the main mechanism, deviations arise that manifest as a loss of quality, delays, or maintenance demands.

Seven signs that an external encoder is the weakest link in your drive system

1. Positioning changes at faster cycle rates

External encoders do not respond consistently to (unpredictable) accelerations, torque spikes, and micro-play in the structure.

Mechanisms causing this:

  • Play in mounting hardware amplifies abnormal impulses
  • Movement under load disrupts signal consistency
  • Corrections in the controller are constantly increasing

Impact:

The result is a drive system that no longer provides stable or reproducible positioning at higher speeds.

2. Non-reproducible measurement deviations

Mechanical and thermal influences on external mounting cause shifts that are difficult to trace. This makes the measuring system an uncertain factor in the design.

Mechanisms causing this:

  • Temperature noticeably affects impulse interval
  • Mounting differences cause signal variation
  • Micro-play translates into measurement drift

Impact:

As a result, identical movements give different values, which delays diagnosis and tuning.

3. Tolerance problems under load

Parts may fall within tolerance, but an external encoder accumulates small deviations into noticeable inaccuracies in precision tasks.

Mechanisms causing this:

  • Small tolerances compound under load
  • Increased distance to the force line affects the magnitude
  • Mechanical transitions interfere with pulses

Impact:

The result is a higher risk of downtime or quality loss, especially in processes with tight tolerances.

4. Delayed or disrupted feedback

An encoder positioned outside the force line lengthens and weakens the signal chain. The controller continuously compensates for deviations, which reduces stability.

Mechanisms causing this:

  • Longer cable paths increase system sensitivity
  • Transitions in the chain delay pulses
  • Controller makes unnecessary corrections

Impact:

The result is a steering system that is less predictable and does not reach a steady state.

5. Limited design freedom

An external encoder determines the space required around the drive train and restricts compact or hygienic designs.

Mechanisms causing this:

  • Additional parts increase contour and installation space
  • Encoder positions outside the force line limit design options
  • Cable routes occupy critical areas

Impact:

The result is a design that cannot be constructed in a compact, efficient or future-proof manner.

6. Variable assembly quality

External structures rely on manual labor. Small deviations lead to measurement differences between machines.

Mechanisms causing this:

  • Bolt torque variation affects position
  • Irregular mounting changes signal output
  • Service activities increase the likelihood of deviations

Impact:

The result is inconsistent behavior between identically designed machines.

7. Higher lifecycle costs

External mounting leads to additional wear, adjustments, and service efforts, which increases lifecycle costs.

Mechanisms causing this:

  • External components are more likely to be disrupted
  • Cables and couplings wear out as a result of motion
  • Adjustment increases maintenance workload

Impact:

The outcome is a drive system that requires structurally more maintenance and incurs higher costs than initially anticipated.

MIG-encoder_food

The new design standard: integrated encoders

Design teams aiming to secure higher cycle rates, compact designs, and consistent repeatability are increasingly turning to measurement solutions that are integrated directly into the drive system. Not as an upgrade, but as a logical consequence of stricter requirements for stability and design reliability. Incorporating the measuring system into the drive eliminates variables that were previously difficult to control, such as alignment sensitivity, signal noise and mounting variation.

The result is a feedback architecture that aligns more effectively with modern machine concepts and is less dependent on constraints that unnecessarily burden the design. This creates a future-proof basis for consistent performance over the entire service life.

Advantages of flange encoders over external encoders

This development calls for an encoder series that is not mounted next to the drive, but is an integral part of it. The BEGE MIG series ties in directly with this: six compact flange encoders that are fully protected when installed between the motor and gearbox. This position eliminates play, shortens the measuring chain, and increases accuracy at high loads.

The range includes IEC and NEMA versions and stainless steel variants for environments that require intensive cleaning. Thanks to robust magnetic technology, the result is a consistent, accurate feedback solution for a wide range of modern machine designs.

Curious how BEGE MIG encoders can optimize your machines? Schedule a phone appointment with our engineers.

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BEGE MIG encoders: The different models

BEGE manufactures and supplies 6 variants of compact magnetic incremental and absolute encoders for ultra-precise positioning and feedback in industrial automation systems. Click for more details and configure immediately.

MIG NOVA+ Serie – Incremental Encoders

MIG NOVA+ Serie - Incremental Encoders. Read about the main features, benefits, product details and technical specifications.

MIG NOVA+ Serie – Incremental Encoders

MIG BASIC Serie – Incremental Encoders

MIG BASIC Serie - Incremental Encoders. Read about the main features, benefits, product details and technical specifications.

MIG BASIC Serie – Incremental Encoders

MIG SS Serie – Stainless Steel Encoders

MIG SS Serie - Stainless Steel Encoders. Read about the main features, benefits, product details and technical specifications.

MIG SS Serie – Stainless Steel Encoders

MIG HYDRO Serie – Encoders for Hydraulic Motors

MIG HYDRO Serie - Encoders for Hydraulic Motors. Read about the main features, benefits, product details and technical specifications.

MIG HYDRO Serie – Encoders for Hydraulic Motors

MIG AST Serie – Absolute Encoders

MIG AST Serie - Absolute Encoders. Read about the main features, benefits, product details and technical specifications.

MIG AST Serie – Absolute Encoders

MIG NEMA Serie – NEMA Encoders

MIG NEMA Serie - NEMA Encoders. Read about the main features, benefits, product details and technical specifications.

MIG NEMA Serie – NEMA Encoders

Frequently asked questions about MIG encoders

Below are answers to frequently asked questions about why MIG encoders are a better choice than external encoders.

External encoders are sensitive to vibrations, contamination, and mounting errors, which can quickly degrade signal quality and restrict the performance of the entire drive system.

These integrated solutions are mounted directly in the drive, which makes them less sensitive to misalignment. They have improved protection and deliver much more stable signals.

Because the sensor and drive form a single unit, mechanical play and torsion are eliminated, resulting in consistent and highly accurate positioning—even under heavy loads.

Machine builders appreciate the compactness, ease of assembly, and high reliability—especially in applications where downtime or inaccuracy leads to significant costs.

For non-standard motors, limited installation space, or special signal requirements, a custom interbody or flange encoder offers the optimal fit and maximum performance.

Download the MIG info sheet

Want to read more about BEGE MIG encoders? Or do you want to share information with your company’s purchaser, engineer or director? Download the MIG encoder info sheet (PDF).

Compare BEGE MIG encoders

BEGE Power Transmission designs, develops and produces a comprehensive range of patented encoders of high quality and proven reliability.

Go to the comparison chart to discover the differences between all BEGE MIG encoders at a glance.

View the comparison chart

Curious how BEGE MIG encoders can optimize your machines? Schedule a phone appointment with our engineers.

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