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.
Definition
An external encoder is a speed and/or position feedback device mounted outside the main drive mechanism (e.g., on a shaft or via couplings and brackets). In fast, compact, or hygienic machine designs, external mounting can introduce measurement variability due to mechanical play, alignment sensitivity, longer signal chains, and environmental influences. An integrated (flange/interbody) encoder is built into the drive train to minimize these variables and provide more stable, repeatable feedback.
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.
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.
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.
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MIG NOVA+ Serie – Incremental Encoders
MIG NOVA+ Serie - Incremental Encoders. Read about the main features, benefits, product details and technical specifications.
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MIG BASIC Serie – Incremental Encoders
MIG BASIC Serie - Incremental Encoders. Read about the main features, benefits, product details and technical specifications.
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MIG SS Serie – Stainless Steel Encoders
MIG SS Serie - Stainless Steel Encoders. Read about the main features, benefits, product details and technical specifications.
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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.
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MIG AST Serie – Absolute Encoders
MIG AST Serie - Absolute Encoders. Read about the main features, benefits, product details and technical specifications.
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MIG NEMA Serie – NEMA Encoders
MIG NEMA Serie - NEMA Encoders. Read about the main features, benefits, product details and technical specifications.
Comparison of BEGE MIG encoder models (high-level)
| Model | Encoder type | Primary focus | Typical environment / notes | Link |
|---|---|---|---|---|
| MIG NOVA+ Series | Incremental | Incremental feedback in compact flange form factor | General industrial machine designs requiring stable feedback | Product details |
| MIG BASIC Series | Incremental | Incremental feedback | General-purpose applications | Product details |
| MIG SS Series | Magnetic encoder (stainless steel variant) | Corrosion resistance and cleanability | Intensive cleaning / hygienic environments | Product details |
| MIG HYDRO Series | Encoder for hydraulic motors | Feedback for hydraulic motor applications | Hydraulic motor installations | Product details |
| MIG AST Series | Absolute (single-turn) | Absolute position feedback | Applications needing absolute position reference | Product details |
| MIG NEMA Series | NEMA flange variant | Compatibility with NEMA motor interfaces | NEMA-standard machine builds | Product details |
For a complete overview, see the dedicated comparison chart.
Frequently asked questions about MIG encoders
Below are answers to frequently asked questions about why MIG encoders are a better choice than external encoders.
Why are external encoders often the weakest link in critical drive systems?
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.
What makes compact interbody or flange encoders a better alternative?
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.
How do integrated encoders improve machine accuracy?
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.
Why are machine builders more likely to choose an integrated encoder solution like the MIG?
Machine builders appreciate the compactness, ease of assembly, and high reliability—especially in applications where downtime or inaccuracy leads to significant costs.
In which situations is a custom built-in encoder needed?
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.
FAQs
What problem does this page address for food and packaging machines?
It explains why external encoders often become the performance bottleneck in machines where accuracy, cleaning requirements, and short cycle times are critical.
Why do faster cycle rates make external encoder issues more visible?
Higher accelerations and torque spikes amplify micro-play and mounting influences, so an external encoder can deliver less consistent feedback as speeds increase.
Which installation-related factors commonly reduce external encoder repeatability?
Manual assembly variation, bolt torque differences, and irregular mounting can cause measurement differences between machines that are otherwise identical.
How do environmental conditions affect externally mounted encoders?
Cleaning cycles and corrosive substances can affect external components and cabling; temperature can also influence measurement behavior in externally mounted systems.
What does “outside the force line” mean and why does it matter?
When the encoder is not aligned with the main load path, the feedback signal is more exposed to structural deflection and transitions, which can weaken stability and accuracy.
Why can external encoders lead to delayed or disrupted feedback to the controller?
Longer cable paths and more transitions in the measuring chain can delay pulses and increase sensitivity, prompting the controller to make more corrections and reducing stability.
How do integrated encoders improve design freedom in compact or hygienic machines?
By integrating the measuring system into the drive train, fewer external parts and cable routes are needed, enabling more compact and easier-to-clean designs.
What are the stated benefits of mounting a flange encoder between motor and gearbox?
The page states this position eliminates play, shortens the measuring chain, and increases accuracy at high loads while keeping the encoder protected.
Which MIG variants are mentioned for different interface standards and environments?
The page mentions IEC and NEMA versions, plus stainless steel variants for environments that require intensive cleaning.
Where can someone find a full overview of differences between all BEGE MIG encoders?
The page links to the dedicated comparison chart for an at-a-glance overview.
Contact
Curious how BEGE MIG encoders can optimize your machines? Schedule a phone appointment with our engineers.