(1) Field of the Invention
This invention relates generally to linear motors and relates more specifically to miniature linear motors used preferably for camera modules having an integrated position sensor related to a movable part of the motor.
(2) Description of the Prior Art
Digital camera modules are used with many electronic devices such as e.g. mobile phones, personal data assistants (PDAs), computers, etc. These camera modules have to be as small as possible, reliable, and easy to be used, robust and require minimal power consumption. Furthermore the design of the camera modules should allow low manufacturing cost, while the quality of the images has to conform to a high standard.
Therefore modern camera modules should allow auto-focusing or zooming with minimal size without electrical connections to a movable part. It is a challenge for the designers of camera modules to develop linear motors to drive a lens barrel, wherein the motors have minimal size and allowing a precise focus position for the camera lens.
There are known patents or patent publications dealing with the design of linear motors for camera modules.
U.S. Patent Publication (US 2006/0018643 to Stavely et al.) teaches a sensor mounting system for enabling image stabilization in a digital camera. An electronic array light sensor is moved in relation to other parts of the camera in response to camera motion. In one embodiment, the sensor is moved by at least one linear motor having a ferrofluid in a gap of the linear motor. Each of four coils and an associated set of complementary magnets forms a moving coil linear motor, wherein the magnets are the stator of the linear motor, and the coil is part of the moving member of the linear motor.
U.S. Patent Publication (US 2006/0132640 to Tirole et al.) discloses an optical lens assembly including a light-sensitive member; first and second lenses/lens groups with their respective optical axis aligned with each other along a common optical axis; and first and second piezo electric ultrasonic linear motors; in which the first motor is operable to move the first and second lenses/lens groups relative to each other to vary their distance; and the second motor is operable to move the light-sensitive member or at least one of the first and second lenses/lens groups to vary the distance between the light-sensitive member and the lens/lens group. There is further disclosed a driving IC for driving a piezo electric ultrasonic linear motor in response to the result arrived at by the auto-focus judge.
U.S. Patent (U.S. Pat. No. 6,157,100 to Mielke) describes an electromagnetic drive for a focal-plane shutter of a camera having two light-excluding shutter curtains, each of the two shutter curtains being having its own electric drive motor, which is a linear motor constructed from permanent magnets and electromagnetic coils. The linear motor has at least two mutually aligned permanent magnets. The opposite pole faces of the magnets have the same polarity.
A principal object of the present invention is to achieve methods and systems for a linear motor having an integrated position sensing of an anchor of the motor.
A further object of the present invention is to achieve a linear motor of a minimal size.
A further object of the present invention is to achieve a linear motor of minimal power consumption.
Another object of the present invention is to achieve a linear motor, wherein the inductance of coils can be sensed.
A further object of the present invention is to achieve a camera having a low-friction and precise positioning of a lens barrel and of a shutter.
Moreover an object of the present invention is to achieve a linear motor, which does not require any electrical connection to a movable part of the motor.
In accordance with the objects of this invention a method for a linear motor having an integrated position sensing of the anchor of the motor has been achieved. The method invented comprises the steps of (1) providing a linear motor comprising at least one coil and a movable anchor comprising at least one permanent magnet, and a pulse generating means, (2) driving the anchor of the motor towards a target position by inductive force generated by current pulses through said at least one coil during one part of a motor control period, and (3) sensing the current position of the anchor by sensing the inductance of said at least one coil coupled inductively with the anchor during a remaining part of the motor control period. Furthermore the method invented comprises (4) checking if a target position of the anchor is reached and, if so, go to step (5), else go to step (2); and, finally, (5) end.
In accordance with the objects of this invention a linear motor having an integrated position sensing of the anchor of the motor has been achieved. The linear motor invented comprises, firstly, at least one coil to drive the anchor of the motor, a means to generate electrical pulses, and said anchor comprising at least one permanent magnet. Furthermore the linear motor comprises a means to sense the inductance of the at least one coil wherein the inductance of at least one coil is dependent upon the position of said anchor, and a control unit to control driving of the anchor and the sensing of the inductance.
In accordance with the objects of this invention a camera using linear motors having integrated position sensing for positioning of components has been achieved. The linear motor invented comprises, firstly, an image sensor, a shutter with an aperture function driven by a linear motor, and said linear motor driving the shutter, wherein the motor has an integrated position sensing system. Furthermore the camera comprises a movable lens barrel, at least two linear motors moving to move said lens barrel, and an integrated circuit controlling the motor driving the shutter and the actuators moving the lens barrel. Finally the camera invented comprises rolling elements bearings guiding said lens barrel and said shutter, wherein the rolling elements of the bearings are moving between moving and fixed components of the camera module.
In the accompanying drawings forming a material part of this description, there is shown:
a shows basic components of a first preferred embodiment of the invention having two coils and two permanent magnets.
b shows an alternative implementation of a linear motor of the present invention using two coils and one permanent magnet only.
c shows another embodiment of the present invention using two coils and two permanent magnets 11 and 12 deployed on opposite sides of the coils.
a illustrates how the inductance of the coil of the linear motor changes if the permanent magnet moves above the coil.
b shows an embodiment of a linear motor of the present invention comprising one coil and one permanent magnet.
The preferred embodiments disclose methods and systems to achieve a bi-directional linear motor, having an integrated position sensing of a movable part of the motor. In preferred embodiments of the invention the motors invented are used to move a lens barrel of a camera module. The motor has to be of minimal size, and should have minimal power consumption without requiring an electrical connection to a movable part of the motor.
The preferred embodiments of the linear motor have different tasks to perform:
1. Generate a force to move a lens barrel to a position desired.
2. Detect a current position of the lens barrel.
In case ball bearings are used to guide the movements of the lens barrel a third task is to be performed:
3. Generate a force to retain the ball bearings.
a shows basic components of a first preferred embodiment of the invention having two coils and two permanent magnets. The bi-directional linear motor comprises a stator 7, which is a fixed part of the motor, comprising two coils 1 and 2, being interconnected, wherein the coils 1 and 2 are wrapped around magnetic metal 8. In a preferred embodiment of the invention the stator 7 is a fixed part of the motor, which is firmly fastened on a carrier of the camera module. The power connections of the coils 1 and 2 are signified by numeral 9.
The anchor 6 of the motor, which is the movable part of the motor, comprises a piece of magnetic iron 3 and two permanent magnets 4 and 5. The direction of movements is indicated by the double-sided arrow. A possible magnetic orientation of both magnets 4 and 5 is indicated in
The direction of the movement of the anchor 6 is depending upon the direction of a current through the coils 1 and 2, which are generating a magnetic flux through the anchor 6, the stator 7 and through the permanent magnets 4 The permanent magnet 4 ensures a stable position of the anchor if no currents are flowing through the coils.
b shows an alternative implementation of a linear motor of the present invention using two coils and one permanent magnet 10 only. The stator 7 of the linear motor of
Furthermore
It would be also possible to implement the motors of
By moving the anchor, i.e. changing the position of the magnet or magnetic material, the inductance of the solenoid motor changes. Sensing the inductance is used to sense the position of the anchor. The absolute value of the inductance can be measured or the difference of inductance between both solenoids. The anchor of the solenoid motor is designed in a way that the inductance of a first solenoid is increased if the anchor is moved inside this solenoid while the inductance of the other solenoid decreases at the same time because the anchor is moved towards the outside of the second solenoid.
Alternatively it would be possible to drive the motor of
It should be noted that many variations of the linear motor of the present invention are possible, as e.g. using one or two coils, using one or two permanent magnets, a rotational symmetrical motor or not, using permanent magnets of different magnetic strength or identical magnets, etc.
a shows another embodiment of the linear motor invented having an integrated position-sensing correspondent a solenoid concept. This motor is characterized by an anchor 24 having in its middle part 25 non-magnetic materials as e.g. plastic. This solenoid linear motor comprises two solenoids 20 and 21, which belong to a fixed part (stator) of the motor, and the anchor 24 in a form of a rod, which can move by magnetic force inside of the solenoids 20 and 21. In case magnetic metal is used at the ends 26 of the anchor 24, a solenoid can move the anchor in the direction towards the inside of the solenoid only. In case permanent magnets are used at the ends of the anchor a solenoid can move the anchor in both directions.
In regard of the electrical driving system of the present invention it should be noted that during one motor control period about 80% of the time is used to drive the linear motor and about 20% of the time is used to measure the position of the anchor.
The duration of a time period 30 can be changed on the fly. In case the anchor of the motor is close to a target position the driving force can be reduced, the speed of the anchor is reduced and more time can be used to measure the current position. Therefore a hard stop of the anchor can be avoided. The position measurement is performed by short pulses. A control unit controls the duration of such a motor control period and the time used for driving the motor and the time used for sensing the inductance.
The driving time depends upon the force of the motor. The force of the motor follows the equation:
F=I×B
L
×A,
wherein F is the force of the motor, I is the current through one or more coils, BL signifies the strength of the magnetic field, and A signifies the active area of the magnet.
b shows an embodiment of a linear motor of the present invention comprising one coil 110 and one permanent magnet 111. The magnet 111 moves in the directions dependent upon the direction of the current through coil 110. The magnet may have a magnetic induction, as a non-limiting example, of 1.5 Tesla.
a illustrates how the inductance of the coil 110 changes if the permanent magnet 111 moves above the coil 110, as indicated by the arrows.
Signals representing a current position of the anchor of the motor are taken from the midpoint 42 of the circuit of
If a load of the anchor, e.g. a lens barrel, is blocked, e.g. by a blocked ball bearing it the problem of blocking can be solved by increasing the torque of the motor. This can be achieved by driving the coils in parallel. In this case the current through the coils will be four times higher. Additionally in order to reduce a friction a modulation of several KHz can be given to the motor for a short time and during this time the friction will be converted from a static friction to a sliding friction.
During normal operation switches S1 and S2 are closed and switches S3 and S4 are open. During “high torque” operation switches S1 and S2 are open and switches S3 and S4 are closed. In this “high torque” mode both coils of the motor are driven in parallel.
Furthermore
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
This application is related to the following US patent applications: DI09-003/004, titled “Camera Module having a low-friction movable lens”, Ser. No. 12/661,752, filing date Mar. 23, 2010, DI08-006, titled “Camera Shutter and position control thereof”, Ser. No. 12/658,280, filing date Feb. 5, 2010, and DI09-007, titled “Twin-actuator configuration for a camera module”, Ser. No. 12/661,755, filing date Mar. 23, 2010, and the above applications are herein incorporated by reference in their entirety.