Steel & Continuous Casting · Manufacturing, IIoT & AI
Encoder Counts ↔ Billet Length Calculator
Convert measuring-roll encoder counts and billet length with explicit decoding, gear ratio and calibration factor.
This tool provides a preliminary engineering calculation for reference. Final equipment selection, design and commissioning decisions must consider manufacturer data, applicable standards, operating conditions and project-specific engineering requirements. It is not certified design output.
Preliminary result
Calculated outputs
Enter values and select Calculate. Results are estimates and do not replace nameplate data, applicable standards, or an engineering review.
Use this calculation
Only calculator parameters and results are transferred. Personal details are collected separately in the destination form.
Formula
Countsroll = PPR × DecodeFactor × GearFactor
mm/count = πD / Countsroll
TargetCounts = TargetLength /(mm/count)
Kcal = ActualMeasuredLength / EncoderCalculatedLength
Worked example
200 mm roller, 1024 PPR, X4 and 5 encoder revolutions per roll revolution.
Expected check: Counts per roll revolution = 20480; Theoretical resolution = 0.03068; Target counts = 195570.
Assumptions
- • GearFactor means encoder revolutions per measuring-roll revolution
- • Roll diameter is effective contact diameter
Limitations
- • Theoretical encoder resolution is not cutting repeatability
- • Roller slip, scale, wear, backlash, hot section, PLC input frequency, capture timing, shear response and shrinkage are not predicted
Frequently asked questions
Can this result be used for final equipment selection?
No. Use it for a preliminary check, then verify manufacturer data, site conditions, applicable standards and the complete system design.
What does formula version 1.0.0 mean?
It identifies the exact calculation logic used so a saved result can be traced when the formula register changes.
Can Elexorn review my calculation?
Yes. Transfer the result to Request a Quote or Talk to an Elexorn Engineer and add the relevant project or equipment details.