Magnetic flange encoders

A magnetic flange encoder is a rotary sensor that measures position and speed using a magnetic field instead of an optical disc. BEGE manufactures a patented version called the MIG encoder, which is fully assembled between the motor and the gear unit rather than mounted externally.

This placement gives the encoder full protection and doesn’t require any modifications of the motor. The result is a compact feedback device built specifically for demanding industrial automation systems.

In contrast to optical encoders, magnetic ones do not use a slotted disc and a light source; thus, they work perfectly fine in environments where dust, moisture, or vibration can enter the housing, and they are much less sensitive to vibrations. Magnetic flange encoders such as the BEGE MIG series use a magnetic field instead, so there is no glass disc to contaminate or crack.

This construction makes MIG magnetic encoders shockproof and much better suited to washdown areas, outside machinery, and heavy vibration. For machine builders working in food processing, agriculture, or marine environments, magnetic technology is generally the more reliable long-term choice.

The range of magnetic BEGE encoders includes six MIG models, each one designed specifically for a certain environment, mounting space, and electric motor standard. The table below compares flange diameter, resolution, protection degree, materials, and typical usage purpose across all six, making it easier for a machine builder to choose the correct model to be used in the specific drive system before requesting a quote.

An incremental encoder produces a pulse signal for every increment of rotation, and the control system counts those pulses to track speed and relative movement. This signal is lost when power is switched off, so the system needs to re-reference its position at every startup.

An absolute encoder, by contrast, always knows its exact position within a 360-degree rotation, even right after a power cut, due to the fact that the information about the position is not calculated, but stored.

BEGE offers both types: the NOVA+, Basic, INOX, Hydro, and NEMA models are incremental encoders, and the AST is the absolute single-turn encoder with built-in position memory on restart.

BEGE magnetic flange encoders combine high resolution with a compact, rugged build that fits directly between the motor and the gear unit. This assembly method delivers protection up to IP69K against dirt, dust, corrosion, and high-pressure cleaning, without the need for an extended fan cover or a modified motor shaft. Vulcanized plastic magnets make the encoders shock-resistant, and the measurement method keeps positioning accurate even at high rotational speeds.

Because the design eliminates several common failure points, service life is longer and maintenance needs drop, which reduces costs of service and maintenance for OEMs and end-users.

The INOX stainless steel incremental encoder is specially designed for corrosive and hygienic conditions, typical for production of food, beverage, and pharmaceutical products. It reaches a protection rating of up to IP69K, meaning the encoder withstands dust, dirt, moisture, and repeated high-pressure washdown cycles without loss of accuracy.

Flange diameters range from 80 to 350 mm, with resolution up to 2,048 pulses per rotation. For plants where hygiene regulations and frequent cleaning are non-negotiable, this stainless steel encoder is the direct fit within the BEGE encoder range.

The Hydro encoder is built to match hydraulic motor flange dimensions directly, with a fixed flange diameter of 135 mm and a resolution of up to 2,048 pulses per rotation. It is dust-proof and available with HTL or TTL interfaces, making it a drop-in feedback solution for hydraulic drive systems that need precise positioning without a custom mounting bracket.

Because the flange geometry is matched to hydraulic motor standards, integration time and mounting error are both reduced.

Thanks to the innovative magnetic measuring technology used by BEGE MIG series of encoders, it is possible to keep positioning precise even as rotational speed increases, a property that traditional contact-based or lower-grade optical sensors often struggle to match.

Since there is no contact between the measuring elements and rotating disc, the signal drift caused by wear of the encoder is significantly reduced. Combined with resolution options up to 2,048 pulses per rotation, this makes the encoders suitable for applications where both speed and precision are critical, such as packaging lines and conveying systems.

Yes. The combination of a sealed magnetic sensing element, vulcanized plastic magnets, and IP69K-rated protection removes several of the common wear points found in traditional encoders. Because the sensor is not exposed to dust, moisture, or shock in the same way as an externally mounted unit, unplanned downtime and replacement frequency both decrease. This directly lowers maintenance costs and increases uptime for OEMs running continuous production lines.

BEGE magnetic flange encoders are compatible with common IEC and NEMA-compliant electric motors and gear units. The NEMA version is built specifically for American and Canadian machine builders – with flange diameters measured in inches from 6 5/8 to 14 5/8, while the other five models follow IEC dimensional standards used across Europe and much of the rest of the world.

This dual compatibility allows OEMs to standardize on one encoder manufacturer across international product lines instead of sourcing region-specific parts from multiple suppliers.

Selection should start with the operating conditions: washdown, corrosion, or dust exposure points toward the IP69K-rated INOX model, while standard indoor automation often suits the NOVA+ or Basic incremental types. Required resolution and whether absolute position memory is needed after a power cut are the next factors, since only the AST model retains position on restart. Available mounting space matters too, because BEGE encoders are built to assemble between motor and gear unit without modifying the motor.

For full system integration, BEGE offers custom-made encoders and a single point of contact, which simplifies sourcing for OEMs building complete drive systems.

Yes, BEGE produces custom-made encoders on top of the six standard MIG models, built to meet specific customer requirements rather than forcing a project onto a fixed catalogue part. This matters most when a motor flange, resolution need, or interface falls outside the standard range, or when an OEM wants one encoder specification standardized across several machine variants.

BEGE acts as a single point of contact throughout the process, covering both the custom encoder and its integration into the complete drive system. For a custom requirement, the product overview on BEGE’s magnetic encoders page is the starting point for a specification request.