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2 min read

Why bearingless sensors are the future of angle measurement

Roger Zingg Mar 19, 2025 2:06:49 PM
Why bearingless sensors are the future of angle measurement
4:15

The demands placed on modern angle measurement systems are constantly increasing. Machines and vehicles are becoming more compact, environmental conditions harsher and expectations of durability and freedom from maintenance higher. This is precisely where bearingless sensor technology comes in. It enables non-contact angle measurement with high precision - without any mechanical wear.

The new Vert-X 26E from Contelec is an innovative, flexible solution that combines the advantages of bearingless technology with the proven precision and reliability of Contelec sensors. But why exactly are bearingless sensors the future of angle measurement?

What are bearingless sensors and how do they work?

Bearingless encoders - also known as encoders with an external encoder - differ from classic encoders in that they do not have their own shaft or bearing guide. Instead, the measuring scale (e.g. a magnetic encoder) is attached externally and moves independently of the sensor housing.

This is how the measurement works:

  • A magnet is mounted directly on the rotating shaft
  • The sensor detects the change in the magnetic field without contact
  • The signal is converted into a high-precision angle value and transmitted to the control unit

This contactless mode of operation offers decisive advantages over mechanically mounted systems.

The advantages of bearingless sensors over classic rotary encoders

No mechanical wear
➡️ As no bearings or couplings are installed, there are no mechanical components that could wear out. This significantly increases the service life and reduces maintenance costs.

Higher load capacity in extreme environments
➡️ The closed, compact design means that bearingless sensors are insensitive to dust, moisture and vibrations - ideal for harsh industrial conditions.

Flexibility in integration
➡️ The sensor can be mounted flexibly without mechanical bearings. The dimensional scale can be easily adapted to existing axis systems.

Space-saving design for compact machines
➡️ Bearingless sensors are significantly flatter than conventional encoders and require less installation space - a major advantage in mobile machines and applications with limited space.

Higher rotational speeds possible
➡️ As there is no bearing friction, bearingless sensors are suitable for very high speeds.

Areas of application: Where bearingless sensors show their strengths

Thanks to their robustness and flexibility, bearingless encoders are an ideal solution for demanding applications in a wide range of industries:

Construction machinery & mobile machinery

  • Position monitoring of hydraulic cylinders
  • Steering and tilt angle control for excavators & cranes
  • Control of booms and slewing systems

Industrial automation

  • Motor controls and robotics
  • Measuring systems in production lines
  • Feedback systems for linear drives

Agricultural technology & off-highway vehicles

  • Precise control of steering systems
  • Automatic height adjustment of attachments
  • Detection of flap positions in feed mixers or sprayers

The Vert-X 26E - The flexible solution from Contelec

With the Vert-X 26E, Contelec offers a high-precision, robust and compact solution for applications that want to benefit from the advantages of bearingless technology.

Why Vert-X 26E?

  • Precise angle measurement with up to 16-bit resolution for high-precision position detection
  • Protection class IP68/IP69K - ideal for use in harsh environments
  • Flexible mounting thanks to external encoder solution
  • High temperature resistance for reliable operation in extreme conditions
  • Redundant & customer-specific variants available for safety-critical applications

Conclusion: Maximum precision without mechanical limitations

The future of angle measurement lies in bearingless, contactless sensor solutions. They offer a longer service life, reduced maintenance costs and greater flexibility in machine integration. The Vert-X 26E combines these advantages with Swiss precision and the highest quality standards - a future-proof solution for modern machines and industrial applications.

💡 Would you like to find out more about our bearlingless sensors?
📩 Contact us for an individual consultation!
Roger Zingg
Roger Zingg has been Managing Director of Contelec AG, a company based in Biel, Switzerland, which specializes in the development and production of angle sensors, since 1989. Under his leadership, Contelec has established itself as a leading provider of sensor solutions used in various industries such as agricultural engineering, medical technology and the energy sector. With over 35 years of experience in the sensor industry and a strong commitment to sporting activities, Roger Zingg embodies a balance between professional success and personal passion. Translated with DeepL.com (free version)

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