If you’re in the market for a digital readout (DRO) system, understanding its longevity will maximize the return on your investment. A durable DRO will reduce downtime and repair and replacement costs while providing long-term accuracy. Keep reading to learn how long a DRO and the connected encoder can last and the factors influencing lifespan.

What Influences DRO System Lifespan?

DRO systems improve machining quality and efficiency by displaying the exact positioning of every axis on a manual machine tool. Their lifespan depends on several factors, including the component materials and when and where they operate. A DRO system will be most reliable when properly designed, installed, and maintained for your specific machining application.

Materials

The materials used for the encoder and the DRO display unit significantly influence longevity. They determine how well the components withstand wear, environmental conditions, and mechanical stress. Materials designed to support both precision and durability will ensure the long-term functionality of DRO components.

For example, an encoder with a stainless steel scale can be highly durable but less accurate than a glass scale. Glass scales are precise. They can withstand harsh environments with protective housing and durable seals.

Choosing a DRO system with the right combination of materials will help you meet the demands of your operating environment while achieving long-lasting performance.

Usage Frequency

The frequency of operation is another factor in DRO system lifespan. Systems with subpar design, materials, or construction are more susceptible to the effects of heavy or inconsistent use.

Continuous use, such as in high-volume manufacturing, increases the movement of components. This can create thermal stress and component fatigue, which gradually degrade the system.

On the other hand, intermittent use can cause components to become stiff, potentially reducing DRO encoder lifespan through friction, abrasion, and overheating.

The most durable DRO systems stand up to the demands of all machining applications, from year-round use to one-off operation.

Operating Environment

Longevity also depends on the environment in which a DRO system operates. Machining environments can expose DROs to conditions such as:

• Excessive heat or cold
• Excess moisture
• Dust and particles
• High vibration

These conditions can cause components to degrade, become misaligned, or short-circuit, reducing system accuracy and lifespan over time.

When you choose a DRO system designed for your operating environment, you will protect its longevity.

How Long Do DRO Systems Last?

DRO lifespan depends on many factors, including the materials and design, usage frequency, and operating environment. On average, DRO systems last approximately 10 years. However, a more durable option like Acu-Rite Solutions can perform optimally for decades.

Machinists choose Acu-Rite Solutions because our technologies have a strong reputation for long-term reliability. Our DRO systems are designed and built in the United States with high-quality materials and components, withstanding heavy wear and use in even the most demanding machining environments.

Acu-Rite Solutions DRO System on a Mill for 28+ Years

In this video, an Acu-Rite Solutions DRO runs on a standard knee mill. The linear encoder is mounted on the back of the table for the X-axis and on the knee of the machine for the Y-axis. It has operated in this position for more than 28 years.

Acu-Rite Solutions DRO System on a Lathe for 15+ Years

This video shows an Acu-Rite Solutions DRO on a lathe, where it has operated for over 15 years. Despite the harsh conditions of the shop, the DRO continues to display the true location of both axes.

How to Extend DRO System Lifespan?

No matter which DRO system you choose, there are steps you can take to ensure it operates for as long as possible. To minimize the risks of wear and malfunction, make sure to install, operate, and maintain your DRO system according to the manufacturer’s instructions.

Installation

Your DRO and the connected encoder should be correctly installed and mounted by qualified personnel as defined by the system manufacturer.

Proper installation supports longevity through:

• Accurate alignment and stabilization that prevent mechanical stress.
• Protection from environmental conditions.
• Stable power connections that prevent system malfunctions and short circuits.

Operation

Following the operating instructions will keep your system performing at its best by preventing malfunctions and damage.

Make sure to:

• Never open the housing.
• Never engage or disengage any connecting elements while the unit is under power.
• Only assign pins or wires that are used.
• Remove dust protection caps only when connecting measuring devices or peripherals.

Most importantly, don’t operate a defective system, which can severely damage it; replace components immediately.

Cleaning

The most durable DRO systems don’t necessarily need regular cleaning. However, cleaning can enhance DRO encoder longevity by reducing contamination, wear, and tear while preserving accuracy.

Avoid improper cleaning, which can damage the system, by following these general dos and don’ts:

Maintenance

High-quality DRO systems are essentially maintenance-free. Yet, conducting an annual maintenance check can help prevent avoidable downtime.

Here are a few maintenance checks you can perform each year:

• Check that all labels and symbols on the product are legible. Contact an authorized service agency for any corrective action.
• Inspect electrical connections for damage and functionality and replace any defective cables.
• Check power cables for faulty insulation and weak points and replace them according to the manufacturer’s specifications.

Storage

You may need to repackage and store your DRO in the case of a facility move or temporary decommissioning. You should follow the proper steps to prevent damage when it’s not in operation.

Best practices for storing a DRO system include:

• Using packaging as close as possible to the original.
• Protecting it from impact and vibration during transit and from the ingress of dust or humidity.
• Placing all included accessories in the original packaging.
• Storing it according to the manufacturer’s specified ambient conditions.
• Inspecting it for damage after transport or longer storage times.

Maximize Your Machine Tool Profitability with a Durable DRO System from Acu-Rite Solutions

Investing in a durable DRO system will maximize the profitability of your manual machine tools. You will improve production capacity and cost savings through reduced downtime, repairs, and material waste.

Acu-Rite Solutions DRO systems are backed by the continuous innovation of HEIDENHAIN, equipping machining professionals, hobbyists, and educators with the most advanced precision technologies available.

With an Acu-Rite Solutions DRO, you will:

• Create high-quality machined workpieces with less scrap and tighter tolerances.
• Save time and cost through intuitive installation and operation.
• Achieve repeatable accuracy with machine tools both new and old.

Since day one, we’ve designed and built our DROs in the United States to ensure superior quality. We craft them in an ISO facility with rugged materials, housings, and seals that protect against exposure to environmental elements. Plus, built-in error correction helps prevent unnecessary wear. Acu-Rite Solutions DROs can function optimally for decades in applications from simple to complex and the harshest environments.

When you purchase an Acu-Rite Solutions DRO from an authorized channel partner, you will receive local end-to-end support for its lifetime. Every channel partner is factory-certified to purchase, install, and service all Acu-Rite Solutions products, helping you maximize the lifespan of your DRO.

Are you ready to unlock next-level accuracy and efficiency in your manual machining? Contact an Acu-Rite Solutions channel partner to find the right DRO for your application.