Precision Hoist Positioning Without Encoders – Properly Works Delivers with SICK DT80
In industries where precision and reliability are paramount, accurate motion control is essential. However, achieving this accuracy is not always simple. Achieving high-precision motion control without mechanical encoders is a growing priority—especially in sectors like automotive, aerospace, industrial fabrication, and medical manufacturing.
Properly Works, an automation integration firm based in Buffalo, NY, turned to SICK and its distributors to engineer a closed-loop hoist positioning system that eliminates the need for rotary or linear encoders. At the heart of this innovation is the SICK DT80, a high-precision laser distance sensor. It played a pivotal role in delivering a closed-loop hoist positioning system that combines accuracy, reliability, and simplicity.
This application highlights how the DT80 enables non-contact position feedback in long-travel systems, eliminating the need for rotary or linear encoders while maintaining sub-inch precision.
The Challenge: Precision Motion Without Encoders
The project required a motion control system for a hoist traveling along an 80-foot track. Traditional hoist systems often rely on encoders to track position. However, encoders can be mechanically complex, prone to wear, and difficult to maintain, especially in long-travel or harsh industrial environments.
Key requirements included:
- High-accuracy positioning without encoders or external measurement verification
- Seamless integration with Variable Frequency Drives (VFDs) and PLCs
- Real-time feedback for automated quality control
- Robust performance in an industrial environment
The Solution: Closing the Loop with the SICK DT80
Properly Works designed a closed-loop motion control system using a VFD to manage x-axis travel on a hoist. The SICK DT80 laser distance sensor continuously monitors the hoist’s position and feeds real-time data to a PLC. The PLC compares actual position to target coordinates and sends correction commands to the VFD over Ethernet/IP.
The SICK DT80 was selected for its ability to deliver micron-level accuracy over distances up to 80 meters. The sensor continuously measures the hoist’s position and transmits real-time data to a PLC. The PLC compares the actual position to the target and sends correction commands to the VFD via Ethernet/IP, forming a closed-loop control system.
“From the moment this technology was demonstrated to us, we envisioned new exciting uses for it. The capabilities of speed of position feedback made it possible to accomplish this closed loop control,” said Caitlin Aldrich, Project Coordinator at Properly Works. “We enjoy our continued relationship with SICK and its distributors.”
Key Features of the DT80:
- Micron-level accuracy over long distances (up to 80 meters)
- Non-contact measurement ideal for rugged environments
- High-speed data acquisition for real-time control
- Compact and easy to integrate into existing systems
This system achieved positioning accuracy within 1/8 of an inch, even under mechanical stress and environmental variability.
Results and Benefits
- ✅ Encoder-Free Precision: Achieved high-accuracy positioning without rotary or linear encoders
- ✅ Reduced Maintenance: No moving parts or calibration required
- ✅ Improved Quality Assurance: Real-time feedback supports automated verification
- ✅ Scalable Design: Applicable to a wide range of motion control applications
Applications Across Industries
This solution is ideal for:
- Automotive: Overhead hoist systems in assembly lines
- Aerospace: Precision part handling and positioning
- Industrial Fabrication: Gantry systems and material transport
- Medical Manufacturing: Cleanroom-compatible motion control
Innovation Through Integration
This project demonstrates how SICK’s sensor technology enables advanced motion control in applications where traditional encoders are impractical. By combining the DT80’s precision with Properly Works’ integration expertise and support from SICK distributors, the team delivered a robust, scalable solution that meets the evolving demands of modern manufacturing.
Explore More with SICK
Looking to simplify your motion control architecture or eliminate encoders from your system? Discover how SICK’s laser distance sensors and industrial automation solutions can help you achieve smarter, more efficient positioning.
