The present invention relates to an encoder and particularly, although not exclusively, to a hybrid encoder comprising an inductive encoder and a magnetic encoder.
Encoders are electro-mechanical devices that convert position into an analog or digital output signal. They can thus be used as position sensors. Angular encoders are a type of sensing device that detect rotation angle, and linear encoders are a type of sensing device that detect linear displacement.
Angular encoders are of particular importance in robotic applications, e.g. to determine the angular position of joints such as part of a robotic arm. In the case of a robotic arm, the angular encoder must be both accurate and absolute, in order to reduce the positioning error of the end effector and avoid initial position zeroing each time there is a reset.
In robotic applications, there is also a need for cabling to extend through the joint, and thus for angular encoders that can be fitted on articulated joints that allow for cabling to extend through the joint. Many conventional encoding solutions cannot be fitted in this manner.
One solution is to provide a low-profile magnetic encoder, such as the AksIM-2™ Off-Axis Rotary Absolute Magnetic Encoder Module, which is designed for applications with limited installation space. This non-contact encoder detects and evaluates the magnetic field of a thin, axially magnetized ring. The resolution offered by such encoders is approximately 20 bits for 360 degrees, which corresponds to an accuracy of 0.0003 degrees per bit. This level of accuracy is more than sufficient for use in robotic applications. However, these encoders are expensive to manufacture, and require tighter mounting tolerances in order to function than can conventionally be provided.
It is also known to use hybrid encoders which use both optical and magnetic components to provide position sensing (e.g. CN209279997U and WO2021017074A1). However, an issue with optical encoders is that dust accumulation can affect the sensor and its operation. For robotic applications, there is a need for the encoder to operate accurately in a contaminated environment.
The present invention has been devised in light of the above considerations.
According to a first aspect of the invention there is provided a hybrid encoder comprising:
By combining magnetic and inductive encoder technology, the hybrid encoder provides both absolute and relative positioning. In particular, the inductive encoder provides absolute positioning at a lower resolution, whereas the magnetic encoder provides relative positioning at a higher resolution. As such, even though the magnetic encoder may not be able to determine the absolute position, a lower resolution, approximate absolute position may be found using the inductive encoder, and the resolution of this absolute position can then be improved using the higher resolution relative position detected by the magnetic encoder.
This hybrid magnetic and inductive encoder also provides a non-contact solution, thus allowing for one or more cables to be passed through the joint, and also reducing wear on the moving parts. It can also operate in a contaminated environment, e.g. with dust, which is known to cause problems for other encoder technology, such as optical encoders.
Furthermore, although the resolution offered by this hybrid solution may be less than the resolution offered by other magnetic encoders such as the AksIM-2™ encoder, the resolution is still sufficient for the robotic applications, does not require as tight mounting tolerances, and is less expensive to manufacture. Optional features of the present invention will now be set out. These are applicable singly or in any combination with any aspect of the present disclosure.
The metal target having a ramped width may be considered to be a metal target having a width which changes along its longitudinal length.
Preferably, the metal target is mechanically coupled to the at least one multipole magnet. In this way, the passive target of both the inductive and magnetic encoders may be mechanically fixed in relation to one another. The inductor coil and/or the inductive sensing circuit may be mechanically coupled to the magnetic sensing circuit. As such, the sensing part of both the magnetic and inductive encoders may be mechanically fixed in relation to one another. This may help to ensure that the hybrid encoder remains calibrated over time.
The metal target and the at least one multipole magnet may be mounted on a first housing, and the inductor coil and the magnetic sensing circuit may be mounted on a second housing which is movable relative to the first housing. Optionally, the inductive sensing circuit may also be mounted on the second housing.
In this way, the passive components of the magnetic and inductive encoders are provided on a first part of the hybrid encoder, and the active components of the magnetic and inductive encoders are provided on a second part of the hybrid encoder. As such, no electrical connections are required to extend between the first and second housing parts in order for the hybrid encoder to function. This allows for a non-contact hybrid encoder, reducing wear of any moving parts of e.g. a joint upon which the hybrid encoder is mounted.
The hybrid encoder may comprise a processor. The processor may be configured to determine a position of the first housing relative to the second housing based on the manipulation of the electromagnetic field detected by the inductive sensing circuit, and the change in magnetic field detected by the magnetic sensing circuit.
As such, the relative position of the first and second housing may be determined by the hybrid encoder.
In particular, the processor may be configured to:
The hybrid encoder may comprise at least one RLC oscillator circuit. The RLC oscillator component may comprise a resistor component, an inductor component, and a capacitor component. The resistor component may result from internal resistance of the oscillator circuit. Alternatively, it may be a discreet component, e.g. a discrete resistor. The inductor coil may form the inductor, L, component of the RLC oscillator circuit.
Preferably, the magnetic encoder may comprise a plurality of multipole magnets. This may increase the resolution of the relative positioning.
The inductive encoder may comprise a plurality of inductor coils. This may increase the accuracy of the absolute positioning.
The hybrid encoder may be an angular encoder. As such, the hybrid encoder may determine angular position, e.g. angular position of the first housing relative to the second housing. As such, when the first housing and second housing are mechanically fixed to two moving parts of a joint, the relative angular position of the two moving parts of the joint may be determined.
In examples where the hybrid encoder is an angular encoder, the metal target may be a ring-like crescent-shaped metal trace. As such, the ramped width of the metal target may be provided by a crescent shape. The metal trace may be a continuous trace (e.g. such that it never reaches a point with 0 width). Alternatively, the metal trace may not be continuous, e.g. the metal trace may have a point with 0 width. In some examples, the metal target may have the shape of a ring, wherein the point at which the width of the ring is largest opposes a point at which the width of the ring is narrowest, and wherein the metal target tapers from the point at which the width of the ring is largest to the point at which the width of the ring is narrowest.
In this way, the inductive encoder can provide 12 bits of absolute inductive based sensing of rotation, which corresponds to 0.09 degrees per bit of resolution.
The plurality of multipole magnets may be arranged in a ring-like configuration, e.g. on the first housing. They may be positioned inside the ring-like crescent-shaped metal trace.
In examples where the hybrid encoder is an angular encoder, the hybrid encoder may comprise at least two inductor coils configured to generate an oscillating electromagnetic field. The inductive sensing circuit may be configured to detect a manipulation of each oscillating electromagnetic field as the respective inductor coil moves relative to the metal target in a direction perpendicular to the width of the ring-like crescent-shaped metal trace.
The two inductor coils may be positioned such that an angle therebetween relative to a central axis of the ring-like crescent-shaped trace is less than 180°. Preferably, the angle between the two inductor coils relative to a central axis of the ring-like crescent-shaped trace may be between 45° and 135°, more preferably between 80° and 100°, more preferably approximately 90°. In particular, the inductive encoder can detect an absolute angular position using two inductor coils positioned at any angle other than at 180° from one another, although two inductor coils positioned at 90° from one another is most preferred.
The hybrid encoder may comprise four inductor coils. Each inductor coil may be configured to generate an oscillating electromagnetic field, wherein the inductive sensing circuit may be configured to detect a manipulation of each oscillating electromagnetic field as the respective inductor coil moves relative to the metal target in a direction perpendicular to the width of the metal target.
Providing four inductor coils/RLC circuits may provide improved redundancy and error correction in case of misalignment.
Preferably, the four inductor coils may be positioned e.g. on the second housing, such that the spacing between each inductor coil relative to a central axis of the ring-like crescent-shaped trace is approximately 90°. In other words, the four inductor coils may be equally spaced around a central point/axis of the ring-like crescent-shaped trace.
In other examples, the hybrid encoder may be a liner encoder. As such the hybrid encoder may determine linear displacement, e.g. linear position of the first housing relative to the second housing. As such, when the first housing and second housing are mechanically fixed to two moving parts, the relative linear position of the two moving parts may be determined.
In examples where the hybrid encode is a linear encoder, the metal target may be a ramped linear metal target. The plurality of multipole magnets may be positioned linearly, adjacent to the linear metal target along its longitudinal length. The inductive sensing circuit may be configured to detect a manipulation of the oscillating electromagnetic field as the inductor coil moves along the longitudinal length of the metal target.
The plurality of multipole magnets may comprise a plurality of pairs of dipole magnets arranged in alternating magnetic configuration. Other multipole magnets may also be used.
Preferably, the hybrid encoder comprises at least fifteen pairs of dipole magnets, more preferably at least twenty, more preferably at least thirty pairs of dipole magnets.
Increasing the number of pairs of magnets can provide a higher resolution. Nevertheless, this must be balanced with an available amount of space, e.g. at the joint upon which the hybrid encoder is to be positioned.
With thirty pairs of dipole magnets, the magnetic sensing circuit can sense thirty periods, and since the inductive encoder provides a resolution of 12 bits, the combination of the inductive and magnetic encoder provides a resolution of 0.003 degrees (360 degrees/30 pairs=12 degrees per pair, and 12 bits per pair=0.003 degrees per bit per pair).
In some examples, the inductor coil(s) may comprise a PCB (printed circuit board) coil.
In other examples, the inductor coil(s) may comprise a vertically stacked coil. In this way, the width footprint of the encoder may be reduced, without necessarily increasing the height footprint of the encoder, because this height space is already required by the plurality of magnets. In this way, the space required by the hybrid encoder is more efficiently used, resulting in a smaller hybrid encoder.
The metal target having a ramped width may comprise copper, for example. The at least one multipole magnet may comprise neodymium.
According to a second aspect, there is provided use of the hybrid encoder of the first aspect to determine an angular position of a robotic joint. The robotic joint may be part of a robotic arm, for example.
The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.
Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:
Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.
The layout of a hybrid encoder 10 is shown in
The hybrid encoder 10 comprises two tracks of encoding targets; an outer absolute positioning target, and an inner relative positioning target.
The outer absolute positioning target is the encoding target for the inductive encoder. It comprises a ring-like crescent-shaped metal trace 12. As shown in
The inductive encoder also comprises at least two inductor coils 14. In the example shown in
Although not shown in
The crescent-shaped inductive metal target 12 offers 12 bits of absolute inductive based sensing or rotation, which corresponds to 0.09 degrees per bit of resolution, in the angular encoder 10.
The inner relative positioning target is the encoding target for the magnetic encoder. It comprises a plurality of magnetic dipole magnets 16 in an alternating configuration. As shown in
Although not shown in
By positioning the magnetic dipole magnets 16 next to the inductive metal target 12, the absolute positioning of the inductive metal target 12 can be combined with the quick response of the relative magnetic sensing circuit to an increased number of magnetic dipoles 16. As such, a plurality of magnetic dipole magnet pairs is preferably used. The limit on the number of magnetic dipole pairs employed may be the size of the hybrid encoder, which may be limited by the size of the structure (e.g. joint) upon which it is attached. There is also a certain point where the absolute inductive positioning will not have the necessary resolution to sync with the magnetic pairs. The present inventors have found that this point is at 400 magnetic pairs, with some headroom for positioning error on the inductive encoder side. A such, the magnetic encoder preferably comprises less than or equal to 400 magnetic dipole pairs.
In the hybrid encoder shown in
The inductor coils 14 may comprise PCB inductor coils. However, such PCB inductor coils generally require a custom PCB with tighter tolerances, and require relatively large inductor coils and an inductive metal target with an increased size.
In order to alleviate this issue, the inductor coils 14 may instead be formed from Surface Mount Device (SMD) unshielded inductors 24, as shown in the side profile view of hybrid encoder 200 in
The view of hybrid encoder 200 in
Each unshielded inductor 24 comprises a vertically stacked coil. Such SMD unshielded inductors are readily available and thus do not require the manufacture of a custom PCB inductor coil. Furthermore, since the inductor coil is vertically stacked, the footprint of the hybrid encoder can be reduced (e.g. the width of the hybrid encoder). Although a greater vertical clearance is required, this space is not wasted as this vertical clearance is also required for the magnetic encoder (e.g. the magnetic sensing chip 28 and the dipole magnets 26), as shown in
As also shown in
An implementation 100 of the hybrid encoder 10 is shown in
A second housing 134, formed from a PCB substrate, bears the four RLC tanks comprising the inductor coils 114, and the magnetic sensing chip (not shown in
The inductive sensing circuit 140 may be mounted on the second housing 134, or on a further substrate 136 as shown in
The hybrid encoder shown in
In other examples, there may only be two (or three) inductor coils. In examples with two inductor coils, the inductor coils are preferably positioned such that an angle therebetween relative to a central axis extending perpendicularly to the plane of the ring-like crescent-shaped trace and/or the ring of magnet pairs, is approximately 90%. However, angular position may still be determined with the two inductor coils positioned at any angle other than at 180° from one another.
The hybrid encoder also comprises a processor, which may be mounted on the second housing 134 or the further substrate 136, for example. The processor may be a Microcontroller unit (MCU), such as STM32F031K6 MCU. The processor is configured to determine a position of the first 132 housing relative to the second housing 134 based on the manipulation of the electromagnetic field detected by the inductive sensing circuit 140 and the change in magnetic field detected by the magnetic sensing circuit. In particular, the processor is configured to determine an absolute position of the first housing relative to the second housing based on the manipulation of the electromagnetic field detected by the inductive sensing circuit, and then determine a higher resolution relative position of the first housing relative to the second housing based on the determined absolute position of the first housing relative to the second housing, and the change in magnetic field detected by the magnetic sensing circuit. In this way, a mapping function may be used so that the microscopic magnetic location is combined with the macroscopic inductive location. The inductive encoder thus may be considered to allow self-calibration after production.
When there are thirty pairs of dipole magnets, each pair of magnets 116 represents 12 degrees of the 360 degree range. This means that when the hybrid encoder initializes, it will need to associate the sensed magnetic dipole to the specific 12 degree interval referenced by the absolute inductive encoder. As such, an initial factory calibration may be performed by rotating the encoder in a known manner. As the inductive trace 112 and magnets 116 are fixed relative to one another (e.g. by the first housing 132), there is less need for re-calibration beyond what is necessary for the inductive and/or magnetic encoders independently.
The processor may also be configured to filter signals from the inductive encoder and/or the magnetic encoder, and/or store the signals and data. The hybrid encoder may also comprise a communication interface, which may be controlled by the processor to output/transmit the determined angular position.
In the implementation shown in
The hybrid encoder shown in
Although the figures described herein show angular encoders, the hybrid encoder may be a linear encoder. In these examples, the crescent-shaped metal target may have a ramped linear shape (e.g. similar to a right-angled triangle). The plurality of magnet pairs may be positioned linearly, adjacent to the metal target along its longitudinal length.
The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.
Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.
Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example +/−10%.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2203475.5 | Mar 2022 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2023/050477 | 3/2/2023 | WO |