Position sensors and encoders are essential components in modern mobile equipment, delivering the real-time feedback needed to control motion, ensure accuracy, and enable automation. But in the harsh electrical environments of industries like agriculture, construction, and mining, these components face a common and destructive threat: voltage faults.
Electrical faults (such as voltage spikes, miswiring, or lightning-induced surges) can instantly damage sensitive electronics, leading to encoder failure, unexpected downtime, and increased cost for OEMs and equipment owners. That’s where Transient Blocking Unit (TBU™) technology from Bourns® steps in as a critical solution for long-term sensor reliability.
Encoders and sensors are typically mounted directly on actuators, valves, motors, and joints. These areas are frequently exposed to mechanical vibration and electrical disturbances. In many applications, they are also connected to long wiring harnesses that act like antennas for electromagnetic interference or voltage transients. This makes them especially vulnerable to:
When voltage levels exceed what the encoder circuitry can tolerate, damage is often immediate and permanent. Even brief spikes can degrade performance over time, leading to silent failures or erratic behavior that’s difficult to diagnose.
Transient Blocking Unit (TBU) technology is a proactive circuit protection method designed to isolate electronic devices from harmful electrical transients in real time. Unlike traditional protective components like TVS diodes or resistors, which merely attempt to absorb or redirect fault energy, a TBU disconnects the line to prevent energy from entering the device at all.
When a fault is detected, the TBU reacts in less than 1 microsecond, creating an open circuit that stops the surge from reaching the encoder. After the fault condition ends, the connection is automatically re-established without any user intervention or system reset.
To safely dissipate the excess voltage, TBUs often work in combination with gas discharge tubes or neon arrestors, which divert the fault energy away from sensitive electronics while maintaining system integrity.
For original equipment manufacturers, integrating TBU technology can provide immediate and long-term benefits:
Encoders protected by TBU are less likely to fail in the field due to transient conditions, reducing unplanned downtime and service calls.
With fewer field failures related to electrical faults, OEMs can minimize warranty claims, replacement parts, and technician dispatches.
Because TBUs can be placed either inside the encoder or within a connector, they offer flexible implementation options for both new product designs and retrofit protection.
Unlike some protection schemes that require sensor recalibration or reset after a fault, TBUs allow the encoder to resume operation instantly preserving position and configuration.
In all these cases, the TBU acts like an invisible safety net by only engaging when needed, but offering powerful protection when it matters most.
As position sensing becomes more critical in automation, electrification, and machine intelligence, protecting those systems against unpredictable field conditions is no longer optional, it’s essential. TBU technology offers a smart, high-speed solution for OEMs looking to enhance sensor reliability without redesigning the entire system. Whether integrated into new machines or added to existing harnesses through protective connectors, TBUs represent a forward-thinking approach to durability. If your equipment operates in harsh electrical environments, ask your sensor or encoder supplier about TBU protection. It could be the difference between a machine that fails under pressure and one that keeps working, fault after fault.
Disclaimer: TBU is a registered trademark of Bourns. Joral LLC is not affiliated with, sponsored by, or endorsed by Bourns.
