Vibration Effects on Optical Rotary Encoders: Development of a Model for Quantitative Error Analysis and Accuracy Validation

The precise measurement and quantification of errors in optical rotary encoders, particularly under vibrational influence, are critical for assessing their performance and operational reliability. Optical rotary encoders are widely employed in high-precision applications, including CNC machines, robotics, aerospace systems, and industrial automation, where accurate feedback and position control are essential. Even minor measurement deviations induced by external vibrations can lead to significant control errors, compromising system efficiency and, in extreme cases, causing operational failures. This study introduces a comprehensive analytical model designed to evaluate the accuracy of optical rotary encoders under varying vibrational conditions. The model incorporates multiple interconnected components, each representing a specific aspect of encoder behaviour, and integrates them into a unified framework capable of simulating real-world operational environments. Particular emphasis is placed on the dynamic interactions among the components, as these interactions critically affect the overall system response and the resultant measurement accuracy. The proposed methodology enables systematic assessment of encoder performance under realistic vibration scenarios, providing both qualitative insights and quantitative metrics. Furthermore, the model facilitates the identification of key factors contributing to measurement deviations, offering practical guidance for design optimisation and error minimisation strategies. By combining theoretical analysis with simulated operational conditions, the approach presented herein contributes to the development of more reliable and precise optical rotary encoders, ultimately supporting improved performance in precision-driven technological systems.