I’ve installed incremental encoders on everything from industrial CNC machines to small conveyor drives in automated packaging lines. If you’re working with motors, linear actuators, or motion systems of any kind — chances are you’ll need one too.

• What’s an incremental encoder? It’s a compact sensor that generates a stream of pulses as a shaft rotates — giving you real-time motion feedback without the complexity of absolute position tracking.
• Where do I use them? Motors, conveyors, pick-and-place robots, 3D printers, automated gates — any system where speed or direction feedback is critical but you don’t need multi-turn position memory.
• Incremental vs absolute? Incrementals are simple and cost-effective but need a homing routine. They’re great for dynamic systems where knowing direction and speed matters more than position after power loss.
• How to choose the right one? Match your PPR (pulses per revolution) to your resolution needs, pick a compatible signal type (TTL, HTL, etc.), and make sure your controller can read it — I’ll walk you through this later in the guide.
• What else is inside? I’ll share practical wiring tips, real-world application examples, and visual diagrams to help you avoid the common mistakes I’ve seen in the field.

What Is an Incremental Encoder and How Does It Work?

I’ve installed both incremental and absolute encoders, and here’s the real difference: incremental encoders generate relative motion feedback — they don’t remember position after power loss. Absolute encoders do. But incrementals are lighter, cheaper, and perfect when you don’t need full position memory.

Inside, there’s a slotted or reflective disc connected to a shaft. As it spins, an optical or magnetic sensor generates pulses — measured in PPR (pulses per revolution) or CPR (counts per revolution). The faster the disc spins, the faster the pulse rate.

 Most units give you two square-wave outputs (A and B channels) offset by 90° for direction sensing. Some also have a Z-channel (index) that pulses once per full revolution — useful for homing.

Just remember: incremental encoders need to re-home on startup since they don’t track position without power. In systems where that’s not a dealbreaker (like conveyors or robot arms with limit switches), they’re an ideal choice.

I’ve used them on everything from AGV wheels to servo feedback loops — fast, reliable, and easy to hook up with a basic controller.

What Are the Most Common Applications of Incremental Encoders?

I’ve installed incremental encoders in just about every automation setup you can think of. Here’s where they shine:

 Motor Control

Great for VFDs and servo drives — they provide instant speed and direction feedback. I use them to close the loop on basic motion control systems.

CNC & Manufacturing

Whether it’s a milling machine or a pick-and-place arm, encoders keep things precise. On older CNCs, I’ve retrofitted them to track real-time axis movement.

Conveyors & Rollers

These are my go-to for measuring belt speed or triggering jam detection. They’re simple, low-cost, and super reliable.

Robotics

In AGVs and robotic joints, incremental encoders help track wheel rotation or arm position. I’ve used them to dial in motion accuracy without overcomplicating the setup.

Packaging Machines

High-speed labelers or cutters often use them to sync motion between axes. One bad pulse and the whole line can drift — so precision matters here.

3D Printers & Automation Kits

For DIY and open-source hardware, incremental encoders are a budget-friendly way to get solid feedback. I’ve seen them used in everything from extruder heads to Z-axis calibration.

Why Are Incremental Encoders Preferred in These Systems?

In my experience, incremental encoders are the first choice in most industrial and automation projects — and here’s why:

• High-Speed Response
  These encoders can handle fast-moving equipment without lag. I’ve used them on high-RPM motors and never missed a beat.
  
• Compact Size
  They’re small enough to tuck into tight spaces — especially helpful when retrofitting older machines or working with small robots.
  
• Lower Cost
  Compared to absolute encoders, they’re way more budget-friendly. For systems where relative position is fine, it just makes sense.
  
• Simple Wiring
  Most setups just need A and B channels, maybe Z for homing. I’ve wired dozens without touching a manual.
  
• Reliable for Relative Positioning
  If your system can home on startup, incremental feedback is more than enough. I’ve run conveyors, printers, and arms this way for years.

H2: Incremental vs Absolute Encoder: Which One Should You Use?

If you’ve ever debated between incremental and absolute encoders, you’re not alone. I’ve had this conversation dozens of times when speccing out motion systems — especially when cost and startup behavior matter. Here’s how I break it down for clients and teams:

Feature	Incremental Encoder	Absolute Encoder
Output	Pulse-based	Binary/Gray code (absolute)
Startup Behavior	Requires homing	Knows position on boot
Cost	Low	Higher
Wiring Complexity	Simple	More wires needed
Best For	Speed/direction feedback	Accurate position tracking

Pro Tip:

“I use incrementals for simple motor control, but switch to absolute when I need zero-startup error or multi-turn precision.”

So, if you’re building something like a conveyor, VFD, or printer — incrementals will get the job done fast and affordably. But for high-end robotics or positioning-critical systems (think multi-axis arms or feedback-dependent CNCs), absolute is usually worth the extra spend.

​​How to Choose an Incremental Encoder (Checklist)

After setting up dozens of incremental encoders in industrial and automation environments, here’s the quick checklist I always go through:

• Define the use case: Motor feedback, linear tracking, or rotary position?
• Set the resolution: Choose PPR (or CPR) based on the accuracy you need — higher isn’t always better.
• Pick the shaft type: Solid for standard setups, hollow or blind shaft for space-saving or through-bore mounting.
• Match the output type: TTL (5V), HTL (10–30V), or Open Collector — depends on your controller input.
• Check the specs: Operating temperature, humidity, and IP rating should match the environment.
• Factor in durability: Shock, vibration, sealing, and how often cleaning is needed.
• Confirm system compatibility: Your PLC or drive should read the encoder’s signal format without issues.

How to Install and Calibrate an Incremental Encoder

• Mount securely: Use alignment tools to avoid shaft wobble or preload.
• Wire it up: Connect A/B channels (and Z if needed) to your PLC or drive.
• Check direction: Run a basic test to verify rotation matches signal.
• Set homing: Program a home routine — required after every power cycle.

Test at full load: Watch for skipped pulses or noise under real-world conditions.