In today’s industrial world, downtime isn’t just inconvenient—it’s costly. Every minute a production line sits idle translates to lost revenue, delayed orders, and added pressure on already stretched maintenance teams. Encoders, critical to keeping motors and machinery in sync, often become the first place engineers look when troubleshooting. But traditional encoders aren’t always built to meet the demands of modern heavy-duty environments—or give technicians the insights they need to act quickly.
That’s why the future of encoders is shifting. Devices like Dynapar’s HS35iQ Encoder with PulseIQ™ Technology are leading the way: smarter, stronger, and purpose-built for harsh environments.
The HS35iQ is more than a signal generator—it’s a source of intelligence at the edge. With specific fault indication through onboard LEDs and digital outputs, technicians can see immediately whether an issue stems from voltage fluctuation, cable integrity, mechanical slip, overspeed, or temperature1.
Instead of guessing, swapping parts, or pulling cables to rule out potential issues, maintenance teams get instant root cause data. That means faster troubleshooting, fewer repeat failures, and less wasted labor.
Heavy-duty industries—from steel and paper mills to food processing and mining—demand ruggedness. The HS35iQ was designed for it, with:
In short, this encoder isn’t just smart—it’s built to last where traditional encoders often fail.
One of North America’s largest steel finishing mills faced a daily reality: every encoder-related stoppage meant big money lost. With 55 finished coils per line at roughly $10,000 each, every minute of downtime translated to an economic loss of $1,146 per line. In practice, even a 30-minute troubleshooting delay could cost over $34,0002.
The problem wasn’t always the encoder itself—encoders are generally reliable. But whenever a fault appeared, maintenance had to check them first. That meant physically tracing long cable runs, checking connections, swapping encoders to rule them out, and hoping the issue wouldn’t resurface. This process consumed valuable engineering hours and often failed to address the root cause, creating repeat failures2.
The HS35iQ completely changed the workflow. Instead of relying on manual checks and guesswork, engineers now had:
As one steel industry engineer put it:
“Eliminating the need to physically check long cable runs and connections saves us a great deal of time!”2
Another added:
“It’s not about how many failures the encoder caused—it’s about how many events required us to rule out encoder-related variables as potential problems. That’s where the HS35iQ saves us.”2
The result?
Faster troubleshooting, fewer wasted labor hours, and significant cost savings.
The encoder didn’t just survive the harsh steel mill environment—it actively helped the plant cut downtime losses that once stretched into the tens of thousands of dollars per incident.
For engineers, plant managers, and reliability teams, the future of encoders isn’t about specs on a page—it’s about outcomes:
The HS35iQ represents the next step in encoder technology. It’s smarter, providing diagnostic data that empowers engineers to act quickly. It’s stronger, built to withstand the harshest conditions. And it’s already proving its worth in real-world heavy-duty industries.
At Galco, we’re proud to deliver solutions like the HS35iQ that don’t just list features, but solve the real problems that keep plants from running at full potential.