Technical Field
The invention relates generally to precision measurement instruments, and particularly to absolute position encoders.
Description of the Related Art
Various optical, capacitive, magnetic and inductive transducers, and movement or position transducers are available. These transducers use various geometric configurations of a transmitter and a receiver in a read head to measure movement between the read head and a scale. Inductive sensors are known to be one of the sensor types that is most immune to contamination by particles, oil, water, and other fluids. U.S. Pat. No. 6,011,389 (the '389 patent), which is hereby incorporated herein by reference in its entirety, describes an induced current position transducer usable in high accuracy applications. U.S. Pat. Nos. 5,973,494 and 6,002,250, which are each hereby incorporated herein by reference in their entireties, describe incremental position inductive calipers and linear scales, including signal generating and processing circuits. U.S. Pat. Nos. 5,886,519, 5,841,274, 5,894,678, 6,400,138, and 8,309,906, which are each hereby incorporated herein by reference in their entireties, describe absolute position inductive calipers and electronic tape measures using the induced current transducer. As described in these patents, the induced current transducer may be readily manufactured using known printed circuit board technology.
Different implementations of the induced current transducer (and other types of transducers) may be implemented as either incremental or absolute position encoders. In general, incremental position encoders utilize a scale that allows the displacement of a read head relative to a scale to be determined by accumulating incremental units of displacement, starting from an initial point along the scale. However, in certain applications such as those where encoders are used in low power consumption devices, it is more desirable to use absolute position encoders. Absolute position encoders provide a unique output signal, or combination of signals, at each position (of a read head) along a scale. They do not require continuous accumulation of incremental displacements in order to identify a position. Thus, absolute position encoders allow various power conservation schemes, amongst other advantages. In addition to the patents referenced above, U.S. Pat. Nos. 3,882,482, 5,965,879, 5,279,044, 5,237,391, 5,442,166, 4,964,727, 4,414,754, 4,109,389, 5,773,820 and 5,010,655, disclose various encoder configurations and/or signal processing techniques relevant to absolute encoders, and are each hereby incorporated herein by reference in their entirety.
The terms “track” or “scale track” as used herein generally refer to a region of the scale or scale pattern that extends along the measuring axis direction and has an approximately constant width and location along the direction transverse to the measuring axis. A scale track generally underlies and is aligned with a particular set of detectors that is guided along the measuring axis direction. The detectors respond to a pattern of scale element(s) in the underlying scale track to generate position signals that depends on the detector position along the track.
A common technique for encoding the absolute (ABS) position into an encoder is to use two encoder tracks of slightly different spatial wavelengths. For any two spatial wavelengths λ1 and λ2 that are very close, an ABS beat wavelength is defined as follows:
The ABS beat wavelength, which is a longer synthetic wavelength based on λ1 and λ2, can be used to determine a relatively coarse resolution synthetic wavelength position and approximately constitutes the ABS measuring range of the encoder. To achieve a long ABS measuring range, λ1 and λ2 are typically very similar values. For example, the two wavelengths used in one exemplary encoder are λ1=5.4 mm and λ2=5.268 mm, which provide an ABS range (ABS beat wavelength) of λABS=216 mm.
A typical method for choosing the two wavelengths is to set an integer number n of coarse wavelengths λ1 in the desired ABS range (≈λABS), then calculate the value of fine wavelength λ2 as follows:
λABS=nλ1 [2]
In the exemplary encoder described above where λ1=5.4 mm and λ2=5.268 mm, λ1 and λ2 are calculated based on choosing n=40.
It is known to configure encoder tracks and corresponding detectors in order to generate signals that can be processed to determine the spatial phase (or position) of a detector within any given wavelength or period of either/both of the tracks that have the spatial wavelengths λ1 and λ2. Given such spatial phase information, and or position information, the absolute spatial phase and or absolute position within the synthetic ABS beat wavelength λABS may be determined according to known methods. Use of λ1 and λ2 that are very similar to each other, however, may lead to certain accuracy, resolution, and/or range limitations due cross-talk error and/or other difficulty in signal isolation, especially in compact low power encoders.
Users desire improvements to the known encoder systems outlined above in order to provide improved combinations of compact size, measuring range, resolution, low power, low cost and robustness to contamination. Configurations for absolute encoders that provide such improved combinations would be desirable.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The summary is not intended to identify key features of the claimed subject matter, nor it intended to be used as an aid in determining the scope of the claimed subject matter.
An electronic absolute position encoder is provided that can be embodied, for example, in a high-precision electronic digital indicator, a caliper, a micrometer, a linear scale, etc. The encoder comprises a scale extending along a measuring axis direction, a detector, and a signal processing configuration that determines an absolute position of the detector along the scale based on detector signals provided by the detector. The scale includes a signal modulating scale pattern that defines a corresponding absolute range R along the measuring axis direction. Specifically, the scale includes a coarse periodic pattern component as a function of position along the scale having a spatial wavelength λC, wherein
n*λC=R and n is an integer, and a fine periodic pattern component as a function of position along the scale having a spatial wavelength λF, wherein
(mn+1)*λF=R and m is an integer that is at least two. The detector includes sensing elements arranged along the measuring axis direction, wherein the sensing elements are configured to provide detector signals which respond to the signal modulating scale pattern.
The signal processing configuration is configured to process the detector signals and determine a coarse wavelength spatial phase measurement Pc for a signal or signal component that includes signal effects due to the coarse periodic pattern component (having the coarse spatial wavelength λC) and does not include or suppresses significant signal effects due to the fine periodic pattern component (having the fine spatial wavelength λF).
The signal processing configuration is further configured to process the detector signals and determine a fine wavelength spatial phase measurement Pf for a signal or signal component that includes signal effects due to the fine periodic pattern component (having the fine spatial wavelength λF) and does not include or suppresses significant signal effects due to the coarse periodic pattern component (having the coarse spatial wavelength λC).
The signal processing configuration is configured to determine an absolute position of the sensing elements relative to the scale within the absolute range R based on the coarse wavelength spatial phase measurement Pc and the fine wavelength spatial phase measurement Pf.
Improved configurations of absolute encoders according to exemplary embodiments of the invention may have a technical advantage of achieving a longer encoder range R without having to use two spatial wavelengths λC and λF that are as close to each other as in the prior art.
A pickoff assembly 160 mounted on the base 140 holds the read head portion 164 which in this embodiment includes substrate 162 (e.g., a printed circuit board) that carries a sensing portion or detector 167 (e.g., a field generating and sensing winding configuration) which comprises sensing elements 169, and a signal processing and control circuit 166. In the present description, the terms “sensing portion” and “detector” are often used interchangeably, unless otherwise indicated by description or context. A resilient seal 163 may be compressed between the cover 139 and the substrate 162 to exclude contamination from the circuitry and connections. The sensing portion 167 may be covered by an insulative coating. In one specific illustrative example the sensing portion 167 may be arranged parallel with and facing the scale 170 separated by a gap on the order of 0.5 mm along the depth (Z) direction. Together, the read head portion 164 and the scale 170 may form a transducer (e.g., an inductive or eddy current transducer which operates by generating changing magnetic fields), as will be described in more detail below.
It should be appreciated that for commercial acceptance of the caliper 100, the scale 170 (and therefore the signal modulating scale pattern 170x) should provide the longest practical measuring range along the X axis direction, and at the same time must have a relatively narrow width along the Y axis direction to provide convenient ergonomic use of the hand tool. The same may be said for the detector 167 and the sensing elements 169. Thus, the width available for scale tracks and the associated sensing elements 169 is limited, which limits signal generating area and/or scale track separation. As a result, in known encoder arrangements the overall accuracy or resolution have been limited by errors produced due to interference between various transducer signals or other limitations affecting the signal to noise (S/N) ratio of the transducer signals. The various principles disclosed herein provide certain advantages with regard to providing multiple cooperative signals, with improved signal discrimination and S/N ratio, under such size constraints.
The signal modulating scale pattern 170a (prior art) includes a coarse periodic pattern component 171a as a function of position along the scale 170 having a spatial wavelength λC1, wherein n*λC1=R and n is an integer (see equation [2] above.) The signal modulating scale pattern 170a also includes a fine periodic pattern component 173a as a function of position along the scale 170 having a spatial wavelength λF1, wherein (n+1)*λF=R (see equation [3] above). As described above, in the prior art, in order to achieve a long absolute measuring range R (≈λABS), spatial wavelengths λC1 and λF1 are typically set very close to each other (see the denominator of equation [1] above). However, the inventor of the present disclosure has discovered that a more general formulation of the equations [1]-[3] may be advantageously used in many applications. In particular, equations [1]-[3] above are presented here as a special case of equations [4] and [5] below:
In particular, the prior art signal modulating scale pattern 170a of
However, the inventor has discovered that, by setting m as an integer that is at least two (e.g., m=2, m=3, etc.), coarse and fine spatial wavelengths λC and λF that are not so similar to each other may be used and still achieve a long absolute measuring range R, as may be observed according to equations [4] and [5] above.) This alleviates some of the aforementioned limitations and problems related to signal separation and other issues.
The signal modulating scale pattern 170b of
The signal modulating scale pattern 170c of
In various exemplary embodiments according to the present disclosure, it may be practical if m is at most 10. In further exemplary embodiments, it may be most practical if m is at most 5.
In both of the signal modulating scale patterns 170b and 170c as illustrated, the coarse and fine spatial wavelengths λC and λF are not as similar to each other as required in the prior-art signal modulating scale pattern 170a, which may provide certain advantages in design of the detector portion and/or signal processing, which may result in an improved range to resolution ratio. They both achieve a long absolute measuring range R (≈λABS) by selecting a suitable integer m that allows the denominator of equation [4] to be sufficiently small, rather than using similar coarse and fine spatial wavelengths λC and λF, as has been done in the prior art.
A signal modulating scale pattern 170x (e.g. 170b or 170c, or the like) may be fabricated utilizing various techniques. For example, in inductive encoder embodiments, a substrate of the scale 170 may be a conducting bulk material (e.g., aluminum), and the signal modulating scale pattern 170x may be provided or formed thereon by machining, stamping, etching, or other suitable method. In another implementation, a substrate may be a non-conductive printed circuit board (PCB) with a conductive (e.g., copper) layer deposited or laminated thereon. The signal modulating scale pattern 170x may be provided by machining or otherwise forming (e.g., photoresist patterning, etching, etc.) the conductive layer into the desired pattern of areas or area-enclosing loops, as is known in the art. In case of an optical encoder, the signal modulating scale pattern 170x may be formed, for example, in a chrome-on-glass configuration.
The range R is the same, and n=20, for each of the signal modulating scale patterns 170a′ and 170b′ illustrated in
The signal modulating scale pattern 170b′ is an example where m=2. The coarse and fine wavelengths are dissimilar, as in the signal modulating scale pattern 170b of
Various principles related to the generation and detection of signals or signal components that are modulated by the signal modulating scale patterns disclosed herein are described here, and further below. In many practical devices, absolute position processing relies on signals corresponding to the incremental phase of each of the coarse and fine spatial periodic pattern components 171x and 173x included in a scale 170 (where x can be any alphanumeric, as shown in
The signal processing configuration 166 is configured to determine an absolute position of the sensing elements 169 of the detector 167 relative to the scale 170x within the absolute range R based on the coarse wavelength spatial phase measurement Pc (or φ1) and the fine wavelength spatial phase measurement Pf (or φ2). For example, absolute linear and phase positions XABS and φABS may be calculated as follows:
φABS=φ2−mφ1 [7]
where m is an integer that is at least two according to embodiments of the present invention.
It is known in the art to provide signals that are sinusoidal as a function of position (e.g. position x, along the measuring axis direction) by using a spatial filtering configuration for the sensing elements and/or the signal modulating scale pattern and/or using the effect of an operating gap between sensing elements and the signal modulating scale pattern. According to the principles outlined herein, for sinusoidal signals:
In some embodiments, sinusoidal quadrature signals may be generated by appropriate detector configurations, as outlined in greater detail below, and processed to provide values for φ1 and φ2, in order to determine an absolute position according to equations 6 and 7.
The first set of coarse wavelength sensing elements 181d are arranged along the coarse periodic pattern component 171d to provide a set of signals that are processed to determine the coarse wavelength spatial phase measurement Pc. The second set of fine wavelength sensing elements 183d are arranged along the fine periodic pattern component 173 to provide a set of signals that are processed to determine the fine wavelength spatial phase measurement Pf.
In
One suitable implementation of a configuration for the first set of sensing elements 181d, as illustrated, comprises a first filtering subset 181d1 of the coarse wavelength sensing elements (A1, B1, C1, D1) and a second filtering subset 181d2 of the coarse wavelength sensing elements (A1′, B1′, C1′, D1′), all of which may span across both of the coarse and fine periodic pattern components 171d and 173d. The first and second filtering subsets 181d1 and 181d2 are arranged such that each sensing element of the first filtering subset 181d1 forms a complementary pair with a corresponding sensing element in the second filtering subset 181d2, wherein complementary pair members are spaced apart along the measuring axis direction MA by an integer K1 times 180 degrees of spatial phase difference in terms of the fine spatial wavelength λF, that is, by K1*(0.5*λF). In the particular example illustrated in
One suitable implementation of a configuration for the second set of sensing elements 183d, as illustrated, comprises a first filtering subset 183d1 of the fine wavelength sensing elements (A2, B2, C2, D2) and a second filtering subset 183d2 of the fine wavelength sensing elements (A2′, B2′, C2′, D2′), all of which may span across both of the coarse and fine periodic pattern components 171d and 173d. The first and second filtering subsets 183d1 and 183d2 are arranged such that each sensing element of the first filtering subset 183d1 forms a complementary pair with a corresponding sensing element in the second filtering subset 183d2, wherein complementary pair members are spaced apart along the measuring axis direction MA by an integer K2 times 180 degrees of spatial phase difference in terms of the coarse spatial wavelength λC, that is, by K2*(0.5*λC). In the particular example illustrated in
A signal S provided by one of the sensing elements 169 (e.g. the sensing element A1 of the set of sensing elements 183d) as a function of a position x along the measuring axis direction MA may be modeled as a sum of fundamental signals, second harmonics, and a constant offset, as below:
The L1 and L2 terms are respective fundamental signal components of the coarse spatial wavelength λC (≈λ1) and the fine spatial wavelength λF (≈λ2) and having respective phase offsets φ1 and φ2. The L3 and L4 terms are respective second harmonic signal components of the coarse spatial wavelength λ1 and the fine spatial wavelength λ2 having respective phase offsets φ3 and φ4. The β term is a constant offset.
The signal processing configuration 166 may be configured to process the first set of detector signals of the coarse wavelength sensing elements 181d to provide coarse wavelength spatial phase measurement signals wherein signal components due to the fine periodic pattern component 173d (e.g., the L2 and L4 terms of equation [9]) are suppressed (see description of equations [10]-[13], below). As a result, the signal processing configuration 166 may relatively accurately determine the coarse wavelength spatial phase measurement Pc for the coarse wavelength sensing elements 181d relative to the spatial wavelength λC (≈λ1). Similarly, the signal processing configuration 166 may be configured to process the second set of detector signals of the fine wavelength sensing elements 183d to provide fine wavelength spatial phase measurement signals wherein signal components due to the coarse periodic pattern component 171d (e.g., the L1 and L3 terms of equation [9]) are suppressed (see description of equations [15]-[18], below). As a result, the signal processing configuration 166 may relatively accurately determine the fine wavelength spatial phase measurement Pf for the fine wavelength sensing elements 183d relative to the spatial wavelength λF (≈λ2).
In the embodiment of
In order to provide a signal that corresponds to the coarse wavelength spatial phase measurement Pc (=φ1), the signals for each complementary pair of the coarse wavelength sensing elements 181d may be combined either electronically or mathematically in the signal processing configuration 166. This provides quadrature signals
For even values of K1, the differences may be used and for odd values of K1 the sums may be used in equations [10]-[13]. The quadrature signals
It will be appreciated that by spacing the complementary pairs apart by an integer number times 180 degrees of spatial phase difference in terms of the fine spatial wavelength λF (≈λ2), the quadrature signals
As may be understood by analogy with the previous description, in order to provide a signal that corresponds to the fine wavelength spatial phase measurement Pf (=φ2), the signals for each complementary pair of the fine wavelength sensing elements 183d may be combined either electronically or mathematically in the signal processing configuration 166. This provides quadrature signals
For even values of K2, the differences may be used and for odd values of K2 the sums may be used in equations [15]-[18]. The quadrature signals
It will be appreciated that by spacing the complementary pairs apart by an integer number times 180 degrees of spatial phase difference in terms of the fine spatial wavelength λC (≈λ1), the quadrature signals
It should be appreciated that the principles outlined above may be applied to a variety of other embodiments. For example, it should be appreciated that although the coarse and fine periodic pattern components 171d and 173d have been illustrated as separate pattern components in
The configuration of the detector 167 may also be generalized. More generally, a set of coarse wavelength sensing elements 181x may be configured to provide detector signals corresponding to Q spatial phases spaced apart at 360/Q degrees of spatial phase difference in terms of the coarse spatial wavelength λC (=λ1), and a set of fine wavelength sensing elements 183a may be configured to provide detector signals corresponding to Q spatial phases spaced apart at 360/Q degrees of spatial phase difference in terms of the fine spatial wavelength λF (≈λ2). For example, in
α1=A1−A1′ [20]
β1=B1−B1′ [21]
γ1=C1−C1′ [22]
The three combined phase signals may be used to provide three signals Sαβ1, Sβγ1 and Sγα1 according to the relations:
Sαβ1=α1−β1 [23]
Sβγ1=β1−γ1 [24]
Sγα1=γ1−α1 [25]
The coarse wavelength spatial phase measurement Pc (=φ1) may be determined according to methods disclosed in U.S. Pat. No. 6,005,387, which is hereby incorporated by reference herein in its entirety, according to the relation:
Similarly, the phase signals A2, B2, C2, A2′, B2′ and C2′ may be combined to provide three combined phase signals α2, β2 and γ2 according to the relations:
α2=A2−A2′ [27]
β2=B2−B2′ [28]
γ2=C2−C2′ [29]
The three combined phase signals may be used to provide three signals Sαβ2, Sβγ2 and Sγα2 according to the relations:
Sαβ2=α2−B2 [30]
Sβγ2=β2−γ2 [31]
Sγα2=γ2−α2 [32]
The fine wavelength spatial phase measurement Pf (=φ2) may be determined according to the relation:
As previously indicated, various alternatives for the structure of the sensing elements 169 are known to one of ordinary skill in the art and/or included in the incorporated references. To briefly indicate a few of the exemplary alternatives, in some inductive encoder embodiments the sensing elements 169 of the detector 167 may be formed of conductive material, such as metallic (e.g., copper) plates, wires and loops. In these embodiments, the detector 167 and the signal modulating scale pattern 170x may form an eddy current transducer which operates in one implementation by generating changing magnetic fields. The changing magnetic fields may be generated by providing a changing current in the sensing elements 169 of the detector 167, which induces circulating currents known as eddy currents in a portion of the signal modulating scale pattern 170x that is within the changing magnetic field range. The effective inductances of the sensing elements 169 of the detector 167 are influenced by the respective eddy currents, to correspondingly provide signals having a signal characteristic that varies depending on the sensing elements position along the of the signal modulating scale pattern 170x as outlined above. In various embodiments, the sensing elements 169 may comprise single turn or multi-turn planar windings formed to enclose an area having a desired shape for interacting with the underlying portions of the signal modulating scale pattern 170x. Alternatively, an absolute position encoder configured according to the principles disclosed herein may utilize a transformer type of architecture similar to that disclosed in the '389 patent, which comprises transmitter (TX) and receiver (RX) coils wherein the receiver (RX) coils generally correspond to the sensing elements 169 of the detector 167.
The novel configuration of the signal modulating scale pattern 170e, wherein the coarse and fine spatial wavelengths λC and λF may be widely separated using a configuration where m=2, 3, 4, etc., as previously outlined, in turn allows for use of a single-track detector with relatively few sensing elements, to simultaneously sense the spatial phases of both the coarse and fine spatial wavelengths λC and λF. In various embodiments, it may be advantageous to use a set of 2m+1 sensing elements to sense a corresponding signal modulating scale pattern. One specific embodiment, with m=2, is described here with reference to
The spacing of the five (5) sensor elements 169 in
In one embodiment, the processing includes use of the discrete Fourier transform (DFT) method. The cosine and sine quadrature components, a and b, are calculated as:
where Q is the total number of the sensing elements, si is the measurement value from the i-th sensing element, and m is the integer harmonic number. This formula assumes the sensing elements are equally spaced over one wavelength. The phase can then be found simply as:
When Q ≧5, the encoder can calculate φm for m=1 and m=2 from the same sensor signals. Specifically, the coarse wavelength spatial phase measurement φ1 (=Pc) can be determined from equation [36] where m=1, and the fine wavelength spatial phase measurement φ2 (=Pf) also from equation [36] where m=2.
Because λF (≈λ2) is not exactly at the 2nd harmonic of λC (=λ1), both the φ1 (=Pc) and φ2 (=Pf) signals may have crosstalk error contributions arising from the other signal. In some embodiments, use of a detector configuration including complementary pairs of sensing elements, as described above in reference to
Various embodiments described above can be combined to provide further embodiments. All of the U.S. patents referred to in this specification are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, to provide yet further embodiments.
These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled.
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