This application claims priority from Japanese patent application No. 2005-065165, filed on Mar. 9, 2005, which is incorporated herein by reference.
1. Field of the Invention
The present invention relates to a magnetic encoder provided with three or more magnetic sensor elements and to a signal processing circuit for the magnetic encoder.
2. Description of the Related Art
Japanese patent publication No. 10-160511A discloses a typical magnetic encoder used for position detection, displacement detection or rotation detection. This encoder has a magnetic medium with a certain magnetization pattern formed by the horizontal magnetization recording method, and a magnetic sensor with magnetoresistive effect (MR) elements each having a sensing plane in parallel with the surface of the magnetic medium to sense a plane direction or horizontal direction component of the horizontally recorded magnetic field from the magnetic medium.
In order to improve accuracy or resolution of position detection in such magnetic encoder, it is necessary to more lessen a magnetized pitch of the magnetic medium.
However, the narrower the magnetized pitch of the magnetic medium, the more cancellation of the magnetic field between the neighbor magnetized parts of the magnetic medium occurs, and thus no magnetic field signal will be provided to a location far from the magnetic medium surface. Also, when a separation distance or gap distance between the magnetic medium and the magnetic sensor element slightly increases, the detection signal from the magnetic sensor element abruptly decreases causing an error in position detection to occur. Therefore, it is required to bring the magnetic sensor element as nearer as possible to the magnetic medium. However, the narrower the gap distance between the magnetic sensor element and the magnetic medium, the more mechanical damages of both of the magnetic sensor element and the magnetic medium due to their contact easily occurs. As aforementioned, in order to perform high-resolution detection with the magnetic encoder, it is necessary to bring the magnetic sensor element extremely nearer to the magnetic medium or to make the magnetic sensor element in contact with the magnetic medium. However, because such arrangement causes problem in durability of the magnetic sensor element and the magnetic medium, it is quite difficult to provide a magnetic encoder with high-resolution and high-durability.
U.S. Pat. No. 4,594,548 and Japanese patent publication No. 2000-105134A2 disclose a two-phase rotational magnetic encoder with magnetic sensor elements arranged to have spacing of λ/4 between adjacent elements, where λ is a magnetized pitch of the magnetic medium. According to such rotational magnetic encoder, the number of output pulses per one revolution of the magnetic medium can be increased without changing the magnetized pitch λ.
Also, as disclosed in U.S. Pat. No. 4,594,548 and Japanese patent publication No. 2000-105134A2, it is possible to widen the magnetized pitch of the magnetic medium with keeping the high-resolution if the magnetic sensor elements are arranged to have spacing between adjacent elements narrower than the magnetized pitch of the magnetic medium. As a result, a magnetic field signal will be provided to a location far from the magnetic medium and therefore the gap distance between the magnetic sensor element and the magnetic medium can be increased.
However, if the separation distance between the magnetic sensor element and the magnetic medium is increased, the output signal from the magnetic sensor element is susceptible to external noises causing an error in position detection to occur.
It is therefore an object of the present invention to provide a magnetic encoder and a signal processing circuit for the magnetic encoder, being hardly susceptible to external noises.
Another object of the present invention is to provide a magnetic encoder and a signal processing circuit for the magnetic encoder, having a high-reliability and a high-resolution for performing precise position detection.
According to the present invention, a magnetic encoder includes a magnetic medium, at least three magnetic sensor elements opposed to the magnetic medium and sequentially arranged within a range equal to or shorter than a magnetized pitch or magnetized pitches of the magnetic medium, along a relative movement direction with respect to the magnetic medium, and a signal processing circuit receiving output signals from the at least three magnetic sensor elements. The signal processing circuit includes an input unit for detecting logical states of the output signals received from the at least three magnetic sensor elements and for generating a state-detection signal sequence with state-detection signals arranged in the order of the at least three magnetic sensor elements, and a judgment unit for judging that the output signals received are correct output signals only when the state-detection signal sequence generated agrees with either of two expected state-detection signal sequences.
According to the present invention, also, a signal processing circuit for a magnetic encoder, receiving output signals from at least three magnetic sensor elements opposed to a magnetic medium and sequentially arranged within a range equal to or shorter than a magnetized pitch or magnetized pitches of the magnetic medium, along a relative movement direction with respect to the magnetic medium, includes an input unit for detecting logical states of the output signals received from the at least three magnetic sensor elements and for generating a state-detection signal sequence with state-detection signals arranged in the order of the at least three magnetic sensor elements, and a judgment unit for judging that the output signals received are correct output signals only when the state-detection signal sequence generated agrees with either of two expected state-detection signal sequences.
Only when the state-detection signal sequence consisting of state-detection signals arranged in the order of the at least three magnetic sensor elements agrees with either of two expected state-detection signal sequences, it is judged that the output signals received are correct output signals. Thus, it is possible to eliminate an influence of external noises from the detected signals and therefore a magnetic encoder with high resistance to the external noises can be provided. Further, at least three magnetic sensor elements are sequentially arranged within a distance range equal to or shorter than a magnetized pitch or magnetized pitches of the magnetic medium. Thus, it is possible to widen the magnetized pitch or magnetized pitches of the magnetic medium without lowering the resolution of position detection. Also, it is possible to provide the magnetic field signal to a location far from the magnetic medium and therefore the gap distance or separation distance between the magnetic sensor elements and the magnetic medium can be increased. As a result, a magnetic encoder with a high-reliability and a high-resolution for performing precise position detection can be provided.
It is preferred that the signal processing circuit further includes a trigger signal generation unit for generating a trigger signal at the time when a reversal of each output signal from the at least three magnetic sensor elements occurs.
It is also preferred that the input unit includes a latch unit for detecting logical states of the output signals received from the at least three magnetic sensor elements when the trigger signal is applied and for temporarily holding the logical states detected. This input unit, preferably, includes a unit for sorting the logical states detected held in the latch unit to form the state-detection signal sequence with state-detection signals arranged in the order of the at least three magnetic sensor elements.
It is further preferred that the judgment unit includes a calculation unit for calculating two expected state-detection signal sequences to be used next time from the state-detection signal sequence corresponding to current correct output signals. More preferably, this calculation unit includes a unit for incrementing or decrementing the state-detection signal sequence corresponding to the current correct output signals by one to obtain the two expected state-detection signal sequences to be used next time.
It is still further preferred that the signal processing circuit further includes a counter unit for performing up or down count only when it is judged that the output signals received are correct output signals. More preferably, this counter unit includes an up-down counter counted in either an up direction or a down direction depending upon which one of the two expected state-detection signal sequences to be used next time is agreed with the state-detection signal sequence generated.
It is preferred that the magnetized pitch of the magnetic medium is uniform.
It is also preferred that the magnetized pitches of the magnetic medium are different with each other.
It is further preferred that the at least three magnetic sensor elements are arranged with a uniform space.
It is also preferred that a part of the at least three magnetic sensor elements are arranged with different spaces.
It is preferred that each magnetic sensor element is at least one MR element. In this case, the at least one MR element may be at least one giant magnetoresistive effect (GMR) element or at least one tunnel magnetoresistive effect (TMR) element.
Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
a and 2b show an oblique view and an exploded oblique view schematically illustrating a structure of a magnetic sensor assembly of the embodiment shown in
a and 3b show an oblique view and a side view schematically illustrating a positioning relation between a magnetic media and magnetic sensor elements in a magnetic sensor chip of the embodiment shown in
a and 5b show views illustrating wave shapes and logical state of rectangular wave signals corresponding to detection outputs form the magnetic sensor elements;
a and 7b show views illustrating relationships between a magnetized pitch of the magnetic medium and a distribution of the magnetic field from the magnetic medium;
a shows a side view schematically illustrating a positioning relation between a magnetic media and magnetic sensor elements in a magnetic sensor chip of another embodiment according to the present invention, and
a shows a side view schematically illustrating a positioning relation between a magnetic media and magnetic sensor elements in a magnetic sensor chip of further embodiment according to the present invention, and
In the figure, reference numeral 10 denotes a magnetic medium to which a magnetic pattern with a predetermined magnetized pitch λ is recorded, and 11 denotes a magnetic sensor assembly with a sliding surface faced to and kept close to the magnetic medium 10, respectively.
In this embodiment, the magnetic medium 10 is fixed to a surface of an object (not shown) of which position or angle and movement directions or rotation directions are to be detected. During operation, the magnetic sensor assembly 11 is held at rest with keeping close to the surface of the magnetic medium 10. The magnetic medium 10 relatively moves with respect to the magnetic sensor assembly 11 in a direction and/or the opposite direction of an arrow 12. As for the magnetic medium, any configuration such as a flat-shaped magnetic medium, a rotating drum-shaped magnetic medium and a rotating disk-shaped magnetic medium other than the tape-shaped magnetic medium shown in the figure can be adopted.
a and 2b schematically illustrate the structure of the magnetic sensor assembly 11.
As shown in the figures, the magnetic sensor assembly 11 mainly consists of a printed circuit board 20, a magnetic sensor chip 21 fixed to the center of a front end surface of the printed circuit board 20, an upper housing 22 and a lower housing 23 vertically sandwiching the printed circuit board 20, and coating films 24 covering the front end surface of the printed circuit board 20 except for a section of the magnetic sensor chip 21.
The printed circuit board 20 is constituted by a substrate 20a made of for example epoxy resin, sensor-connection pads 20b formed on the substrate 20a and wire-bonded to respective electrode terminals of the magnetic sensor chip 21, external connection pads 20c formed on the substrate 20a, and connection conductors 20d formed on the substrate 20a and electrically connected between the sensor-connection pads 20b and the external connection pads 20c, respectively.
The upper and lower housings 22 and 23 are made of in this embodiment a metal material or a ceramic material.
The coating films 24 are formed by in this embodiment molding a resin.
a and 3b schematically illustrate a positioning relation between the magnetic media 10 and magnetic sensor elements in the magnetic sensor chip 21 of the embodiment shown in
As shown in
As will be apparent from
In order to obtain sufficiently large output and high sensitivity, it is required to have enough length for each MR element. However, if the MR element is extended along the magnetic medium-opposing surface 21a without folding, an influence of the azimuth angle may be appeared. To avoid this influence, therefore, the MR element is folded back as in this embodiment. The number of folding-back is not limited to one as in this embodiment but two or more may be adopted. In other words, each MR element may be formed to have three or more linear sections connected with each other by folding-back.
Each MR element is not exposed to the magnetic medium-opposing surface 21a but located in a rearward position slightly apart from the magnetic medium-opposing surface 21a. On a surface of each MR element faced to the magnetic medium-opposing surface 21a, a protection layer made of an insulation material is formed.
The MR elements of the magnetic sensor elements 30-33 are arranged to run along a direction substantially perpendicular to the relative movement direction of the magnetic sensor assembly 11 with respect to the magnetic medium 10 (
In the figure, reference numerals 40-43 denote amplifiers for zero-cross detecting the four-phase output signals from the four magnetic sensor elements 30-33 and for amplifying the output signals to provide rectangular wave signals respectively, 44-47 denote edge-detection circuits for respectively detecting rising edges and falling edges of the rectangular wave signals provided from the amplifiers 40-43, 48 denotes an OR circuit providing a logical OR of the output signals from the edge-detection circuits 44-47, 49-52 denote latch circuits for temporarily holding logical states of the rectangular wave signals provided from the amplifiers 40-43, 53 denotes a digital computer for performing signal processing control, and 54 denotes an up-down counter having a counted value that corresponds to a relatively moved position of the magnetic sensor assembly 11 with respect to the magnetic medium 10. In modifications, the up-down counter 54 may be realized by software stored in the computer 53. Although the signal processing circuit is formed separately from the magnetic sensor assembly in this embodiment, it may be established within the magnetic sensor assembly in modifications. The signal processing circuit may be formed on the magnetic sensor chip.
a and 5b illustrate wave shapes and logical states of rectangular wave signals provided from the amplifiers.
Rectangular wave signals S0-S3 shown in
When receiving interrupt direction or the trigger signal, the computer 53 executes this interrupt routine.
First, the computer 53 instructs to the latch circuits 49-52 to hold the logical states of the rectangular wave signals (Step S1).
Then, the computer 53 captures the held state-detection signals from the latch circuits 49-52 and sorts them into a sequence of state-detection signals arranged in the order of the arrangement of the magnetic sensor elements 30-33 (Step S2).
b indicates the state-detection signal sequence corresponding respectively to logical states of the rectangular wave signals shown in
Therefore, the computer 53 compares the currently obtained state-detection signal sequence with the increment signal sequence to know whether they agree with each other or not (Step S3). If agreed, it is judged that the currently obtained state-detection signal sequence is not noise signals but a correct signal sequence and that the relative movement direction is a predetermined direction for example the forward or right direction. Then, the computer 53 increments or counts up the content in the up-down counter 54 by one (Step S5) and executes the next process at Step S7.
On the other hand, if disagreed at Step S3, the computer 53 compares the currently obtained state-detection signal sequence with the decrement signal sequence to know whether they agree with each other or not (Step S4). If disagreed, it is judged that the currently obtained state-detection signal sequence is noise signals. Then, the computer 53 finishes this interrupt routine without executing the following processes and returns to the original routine.
If agreed at Step S4, it is judged that the currently obtained state-detection signal sequence is not noise signals but a correct signal sequence and that the relative movement direction is a direction opposite to the predetermined direction for example the backward or left direction. Then, the computer 53 decrements or counts down the content in the up-down counter 54 by one (Step S6) and executes the next process at Step S7.
At Step S7, the computer 53 stores the currently obtained state-detection signal sequence as the previously obtained state-detection signal sequence.
Thereafter, the computer 53 increments this previously obtained state-detection signal sequence by one to form an increment signal sequence, decrements the previously obtained state-detection signal sequence by one to form a decrement signal sequence, and stores them for the next interrupt routine (Step S8). Then, the computer 53 finishes this interrupt routine and returns to the original routine.
Accordingly, only when the currently obtained state-detection signal sequence agrees with one of the two expected state-detection signal sequences, namely with the increment signal sequence or the decrement signal sequence, the up-down counter 54 counts up or down depending upon the agreed signal sequence. Therefore, the probability of occurrence of error in counting due to the external noises reduces to ⅜ in case of four-phase detection as this embodiment. As a result, according to this embodiment, position detection and moving direction detection with high resistance to the external noises can be expected. In case of n-phase detection (n is natural number), the probability of occurrence of error in counting due to the external noises will reduce to 3/2n. Thus, the shorter of the spacing between the sensor elements, the higher noise resistant effect can be expected.
Also, according to this embodiment, because the four magnetic sensor elements 30-33 are aligned with a uniform space P that is a space equal to or shorter than λ/4 within a length of the magnetized pitch λ of the magnetic medium 10, it is possible to widen the magnetized pitch λ of the magnetic medium 10 without lowering the resolution of position detection.
a and 7b illustrate relationships between the magnetized pitch of the magnetic medium and a distribution of the magnetic field from the magnetic medium to explain this latter point. Conventionally, in order to increase the resolution of position detection, the magnetized pitch λ′ of the magnetic medium 10′ was narrowed as shown in
Also, according to this embodiment, since it is possible to provide high magnetic field intensity from the magnetic medium, an influence of variations in gap distance can be reduced. This aspect is particularly advantageous for a case wherein a magnetic medium and a magnetic sensor assembly are separately mounted on different members. Furthermore, according to the embodiment, because it is easy to obtain a saturation output from the magnetic sensor element, reliability of the encoder can be more improved.
a schematically illustrates a positioning relation between a magnetic media and magnetic sensor elements in a magnetic sensor chip of another embodiment according to the present invention, and
In the aforementioned embodiment of
Other configurations of the magnetic encoder in this embodiment are substantially the same as these in the embodiment of
a schematically illustrates a positioning relation between a magnetic media and magnetic sensor elements in a magnetic sensor chip of further embodiment according to the present invention, and
In the aforementioned embodiment of
Other configurations of the magnetic encoder in this embodiment are substantially the same as these in the embodiment of
In the aforementioned embodiments, three or four magnetic sensor elements are arranged within a length of the magnetized pitch of the magnetic medium. However, according to the present invention, the number of the magnetic sensor elements arranged within a length of the magnetized pitch length is not limited to three or four, but may be any number higher than two. The greater of the number of the sensor elements, the higher resolution in position detection and in moving direction detection are attained. In the aforementioned embodiments, also, the magnetized pitch of the magnetic medium is a uniform pitch. However, in modifications, magnetized pitches different with each other may be used in a partial or all area of the magnetic medium. Also, in modifications, a part of or all the magnetic sensor elements may be arranged with different spaces.
Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in the specification, except as defined in the appended claims.
Number | Date | Country | Kind |
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2005-065165 | Mar 2005 | JP | national |