Engineering high-precision Nonius rings for compact robotic actuators

A global leader in integrated actuation systems needed a solution capable of achieving an angular accuracy far beyond what conventional market technologies could deliver.

Standard magnetic rings - limited to around ±0.1° - could no longer support the requirements of their next generation high performance robots and actuators.

Their key requirements were:

• Achieving an absolute accuracy of ±0.02°, even in harsh environments
• Integrating the solution within a very compact space, fully compatible with their 
  embedded electronics
• Ensuring total reliability without drift or maintenance, even under high temperatures, 
  vibration, or contamination

Beyond performance constraints, the customer needed a partner able to design a fully 
customized, robust, and ready-to-integrate magnetic ring.

Hutchinson developed a tailor-made solution based on its strong expertise in magnetic materials and co-engineering.

A fully customized dual-track Nonius magnetic ring

• Nonius track: ultra-precise angular position measurement 
• Master track: speed measurement, essential for motor control 
• Compact integration: complete adaptation to the customer’s mechanical and 
  electronic constraints

Co-engineered development

Through an engineer-to-engineer collaboration, Hutchinson:

• Designed a specific magnetic architecture 
• Optimized the manufacturing process to reach unprecedented accuracy levels 
• Ensured perfect compatibility with the customer’s existing sensors and components

The result is a ready-to-use sensor actuator subassembly, installable without calibration or 
adjustment.

Ultra‑high precision

• ±0.02° absolute accuracy, validated under extreme conditions

Outstanding robustness

• Insensitive to dust, fluids, shocks, and thermal variations 
• Guaranteed operation up to 150°C—where optical technologies fail

Reliability & Repeatability

• No contact → no wear, no drift, no maintenance 
• Stable performance even in demanding environments

Time & Cost Savings

• Delivered as a ready-to-integrate system, no recalibration required 
• Significant reduction in development and assembly costs

Full Customization

• Hutchinson controls 100% of formulation, design, and production 
• Each customer project is fully adapted to its final system

Thanks to this innovative solution, the customer achieved:

• Angular accuracy exceeding anything previously available on the market 
• A compact, reliable system integrated into their new actuators 
• A shortened development cycle and accelerated market launch 
• Enhanced overall robot performance, enabling smoother, repeatable, and safer 
  movements 
• A strengthened leadership position in the rapidly growing Asian robotics market

This collaboration reinforces Hutchinson’s role as a key technology partner for 
next-generation robotics - bringing together precision, robustness, and full customization