Optical Rotary Encoder Accuracy Under Vibrations: Simulation–Experimental Parameter Correspondence

Abstract

This paper examines the correspondence between simulation parameters and experimentally realised variables in assessing the accuracy of optical rotary encoders subjected to mechanical vibrations. The adopted methodology links two complementary domains—the numerical model and the physical test arrangement—through a defined set of operating quantities and accuracy indicators. Rotational speed, vibration frequency, vibration amplitude, encoder resolution, angular position, measurement error, and root mean square error (RMSE) are considered within a common parameter structure. Their correspondence is arranged at three levels: input quantities, angular signals, and error indicators. Within the simulation environment, rotational and vibration conditions are prescribed numerically, while reference and measured angular positions are derived for subsequent error evaluation. In the experimental arrangement, equivalent conditions are established through LabVIEW-based motor control, electrodynamic vibration excitation, encoder selection, signal acquisition, and data processing. Encoders with resolutions of 100 PPR, 360 PPR, and 1000 PPR are incorporated into the proposed scheme. The resulting correspondence facilitates traceability between modelling assumptions, imposed test conditions, acquired signals, and calculated accuracy measures. It also permits discrepancies between simulated and experimental responses to be interpreted in relation to structural compliance, mounting characteristics, vibration transmission, signal distortion, and acquisition constraints. Consequently, the framework supplies a coherent methodological basis for verification and validation of vibration-related angular measurement errors and supports further refinement of predictive models for optical rotary encoder performance under dynamic operating conditions.