What resolution do you really need in an encoder?

When specifying an encoder, it's tempting to assume that higher resolution is always better. After all, more pulses per revolution (PPR) or finer measurement sounds like it should deliver greater accuracy and performance. But in reality, choosing the right resolution is about balance - not maximum capability.

Resolution vs Accuracy: What's the difference?

A common misconception is that resolution directly determines accuracy. Resolution simply defines how finely an encoder can divide movement into measurable steps, Accuracy on the other hand, depends on factors such as mechanical alignment, system backlash, signal quality, and environmental conditions. Specifying an ultra high-resolution encoder in a system with mechanical play won't improve real-world performance, it may even introduce noise and instability.

Consider the application requirements

The key question is: what level of precision does your application actually need?

For example:

• Conveyor systems or general automation often perform perfectly well with moderate resolution.

• CNC machinery or robotics may demand higher resolution for smooth motion control and positioning.

• High-speed applications may benefit from lower resolution to reduce processing load and avoid signal bottlenecks.

Choosing resolution should always start with the required positioning tolerance and system dynamics - not a 'more is better' mindset.

System limitations matter

Higher resolution means more pulses per second, which increases the demand on controllers, PLCs, and data processing systems. If your electronics cant reliably handle the signal frequency, you may experience missed counts or degraded performance. In some cases, a lower-resolution encoder can deliver more stable and reliable results.

Don't over specify

Over-specifying resolution can increase costs unnecessarily while offering no tangible benefit, it may also complicate installation and tuning. A well-matched encoder (aligned with your system's mechanical and electrical capabilities) will always outperform an over-engineered one.

The bottom line

The 'right' encoder resolution is the one that meets your applicant's accuracy requirement without exceeding system capabilities. By focusing on real-world performance rather than maximum specifications, you'll achieve a more efficient, reliable and cost effective solution.

Selecting the right encoder isn't just about reading a datasheet - it's about understanding your application as a whole. At Encoders UK, we work closely with customers to specify solutions that truly fit their needs.

Get in touch with our team of experts today!

info@encoders-uk.com

0121 378 5577