1. Field of the Invention
The present invention relates to an optical encoder, such as a projection encoder, based on triple grating concept, and in particular to an optical encoder with a small, compact construction that is capable of precisely generating an origin position signal for detecting positions.
2. Related Art
Optical rotary encoders and linear encoders are normally configured so as to output a signal called a “Z phase” signal for detecting an origin position.
In order to detect the Z phase signal, in the case of a rotary encoder, for example, it is sufficient to provide one slit per rotation and to detect light that passes through this slit.
In order to make the signal pulse width e of the Z phase signal approximately equal to the signal pulse width T of the A and B phase signals, the slit width for the Z phase needs to be set equal to the slit widths for the A and B phases. However, since the slit width becomes narrow when the encoder has high resolution, it becomes difficult to ensure that sufficient light is received for detecting the Z phase signal. In particular, when a gap between the rotational disc and the fixed disc is wide, a transmitted image of a narrow slit becomes blurred, which makes it difficult to precisely detect the Z phase signal.
The present invention was conceived in view of the above problem and it is an object of the present invention to provide an optical encoder equipped with an origin position detecting mechanism that can precisely generate a Z phase signal even when the width of grating sections is narrow and a gap between the grating plates is wide.
In order to achieve the stated object, one aspect of the present invention is a projection-type optical encoder including a light emitting element, a moving grating plate with moving side transmissive grating sections of a predetermined width that are aligned at a fixed pitch, a fixed grating plate with fixed side transmissive grating sections of a predetermined width that are aligned at a fixed pitch, and a set of light receiving elements that receive light that has been emitted from the light source and has passed through the moving side transmissive grating sections and the fixed side transmissive grating sections,
the optical encoder further including an origin position detecting mechanism for detecting an origin position of the moving grating plate,
wherein the origin position detecting mechanism includes a moving side grating region for origin position detection that is formed on the moving grating plate, a fixed side grating region for origin position detection that is formed on the fixed grating plate, and a set of light receiving elements for origin position detection that are included in the set of light receiving elements,
transmissive grating sections for origin detection and non-transmissive grating sections for origin detection that are wider than the moving side transmissive grating sections and the fixed side transmissive grating sections are aligned in the moving side grating region and the fixed side grating region, respectively, in accordance with an M-series arrangement pattern or an alignment produced from random numbers, for example,
the set of light receiving elements for origin position detection includes a set of Z phase light receiving elements that generate a Z phase signal and a set of Z′ phase light receiving elements that generate a Z′ phase signal that differs in phase to the Z phase signal, the Z phase light receiving elements being aligned in accordance with an M-series arrangement pattern or an alignment produced from random numbers, for example, and
the origin position of the moving grating plate is detected based on the Z phase signal and the Z′ phase signal.
According to the present invention, a plurality of transmissive grating sections for detecting the origin position are aligned in accordance with an M-series arrangement pattern or an alignment produced from random numbers and the width of the transmissive grating sections for detecting the origin position are made wider than the transmissive grating sections for generating the A phase signal and the B phase signal, so that it can be ensured that sufficient light is received by the Z phase light receiving elements as a whole, even in a case where the transmissive grating sections for generating the A phase signal and the B phase signal are narrow (i.e., when the encoder has high resolution). In addition, since the Z phase signal and the Z′ phase signal that differ in phase by 90° for example are generated, by using these signals it is possible to easily generate the Z phase signal with the same pulse width as the A phase signal and the B phase signal.
Here, it is preferable for the set of light receiving elements to include a set of inverse Z phase light receiving elements that generate an inverse Z phase signal that is an inverse signal of the Z phase signal and a set of inverse Z′ phase light receiving elements that generate an inverse Z′ phase signal that is an inverse signal of the Z′phase signal, and for the origin position of the moving grating plate to be detected based on a differential signal of the Z phase signal and the inverse Z phase signal and a differential signal of the Z′ phase signal and the inverse Z′ phase signal. By using such differential signals, it is possible to detect the origin position with higher precision.
The present invention can be applied in the same way to a reflective-type optical encoder. That is, another aspect of the present invention is a reflective-type optical encoder including a light emitting element, a moving grating plate with moving side reflective grating sections of a predetermined width that are aligned at a fixed pitch, a fixed grating plate with fixed side transmissive grating sections of a predetermined width that are aligned at a fixed pitch, and a set of light receiving elements that receive light that has been emitted from the light source, reflected by the moving side reflective grating sections, and has passed through the fixed transmissive grating sections,
the optical encoder further including an origin position detecting mechanism for detecting an origin position of the moving grating plate,
wherein the origin position detecting mechanism includes a moving side grating region for origin position detection that is formed on the moving grating plate, a fixed side grating region for origin position detection that is formed on the fixed grating plate, and a set of light receiving elements for origin position detection that are included in the set of light receiving elements,
reflective grating sections for origin position detection and non-reflective grating sections for origin position detection that are wider than the moving side reflective grating sections and the fixed side transmissive grating sections are aligned in the moving side grating region and the fixed side grating region, respectively, in accordance with an M-series arrangement pattern or an alignment produced from random numbers,
transmissive grating sections for origin position detection and non-transmissive grating sections for origin position detection that are wider than the moving side reflective grating sections and the fixed side transmissive grating sections are aligned in the fixed side grating region in accordance with an M-series arrangement pattern or an alignment produced from random numbers,
the set of light receiving elements for origin position detection includes a set of Z phase light receiving elements that generate a Z phase signal and a set of Z′ phase light receiving elements that generate a Z′ phase signal that differs in phase to the Z phase signal, the set of Z phase light receiving elements being aligned in accordance with an M-series arrangement pattern or an alignment produced from random numbers, and
the origin position of the moving grating plate is detected based on the Z phase signal and the Z′ phase signal.
In the above case also, it is preferable for the set of light receiving elements to include a set of inverse Z phase light receiving elements that generate an inverse Z phase signal that is an inverse signal of the Z phase signal and a set of inverse Z′ phase light receiving elements that generate an inverse Z′ phase signal that is an inverse signal of the Z′ phase signal, and for the origin position of the moving grating plate to be detected based on a differential signal of the Z phase signal and the inverse Z phase signal and a differential signal of the Z′ phase signal and the inverse Z′ phase signal.
An optical encoder according to the present invention will now be described with reference to the attached drawings.
First, a principle for detecting an origin position by an optical encoder according to the present invention will be described. In order to obtain sufficient light for detecting a Z phase, in the optical encoder shown in
FIGS. 9(a) and (b) show Z phase detection slits 121, 122 that are formed in a rotational disc 101 of the optical encoder shown in
In this case, due to a relative rotation of the fixed disc 103 and the rotational disc 101, the amount of light received by the light receiving elements (i.e., the amount of light that passes through the slits) varies as shown in
Here, when the optical encoder is a reflective-type or a projection-type optical encoder, a gap between the rotational disc and the fixed disc is wide. Accordingly, as in a parallel-beam optical encoder, if the Z phase slit pattern is formed based on a pattern pitch of the slits for the A and B phases, the width of the slits is narrow, so that an outlines of the slit light images become blurred and there are cases where it is not possible to obtain precise signals.
For this reason, as shown in FIGS. 10(a) and (b), compared to the slits used for generating the A phase signal and the B phase signal, a wide slit 141 for generating the Z phase signal is formed in the rotational disc 101 and two wide slits 151, 152 are formed in the fixed disc 103 so that signals that differ in phase, for example by 90°, can be generated. Slits are formed in this way in advance and light receiving elements are disposed at positions opposite to the slits 151, 152. A Z1 signal and a Z1′ signal that differ in phase by 90° are obtained from these light receiving elements, as shown in
However, in a case of a projection-type optical encoder, a gap between the rotational disc and the fixed disc is set at 2 mm or wider, so that there are cases where the Z phase signal cannot be detected precisely using the method shown in
According to the present invention, by using a method that is a combination of the method shown in
The control circuit unit 10 includes a signal processing unit 11 that forms, based on the detection signals of the sets of photodiodes 4 and 5, an A phase signal and a B phase signal that are shifted in phase by λ/4 and also a Z phase signal that shows an origin position of the moving grating plate 6, a calculation unit 12 that calculates movement information such as a movement speed, movement direction, and movement position of the moving grating plate 6 based on the A phase signal, the B phase signal, and the Z phase signal, a display unit 13 that displays a calculation result, and a lamp driving unit 14 that performs feedback control over the driving of the light source 2.
In the present embodiment, a width of the reflective grating sections 71 for generating the A phase signal and the B phase signal is 20 microns, with the sections 71 being aligned at a pitch of 40 microns. On the other hand, a width of the reflective grating sections 81 and the non-reflective grating sections 82 for generating the Z phase signal is 80 microns, with the sections 81 and 82 being aligned at a pitch of 240 microns.
An origin position detection light receiving element region 50 composed of the set of photodiodes 5 for detecting the Z phase signal is formed on the other side (the lower side in
An origin position detecting mechanism for detecting an origin position signal (Z phase signal) in the projection-type linear encoder 1 of the present example includes the set of photodiodes 5 (photodiodes 5Z, 5Z1, 5Z′, 5Z1′) formed in the origin position detection light receiving element region 50 of the moving grating plate 6 described above, the reflective grating sections 81 and the non-reflective grating sections 82 formed in an origin position detection reflective grating region 80 of the reflective grating plate 9, and the signal processing unit 11.
In the present example, an alignment pattern formed using random numbers is used for detecting the origin position. As one example, in the state shown in FIGS. 3(a) and (b), the reflective grating sections 81 are aligned facing the photodiode 5Z so that the maximum amount of light is received. Here, an M-series arrangement pattern may be used. In fact, it is possible to use any arrangement pattern that results in a single peak appearing in the amount of light received by the origin position detection light receiving elements due to a movement of the moving grating plate 6.
In the projection-type linear encoder 1 of the present embodiment constructed as described above, the moving grating plate 6 is integrated with an object to be measured (not shown) and is moved in an alignment direction of the slits and the photodiodes, that is, a direction perpendicular to the optical axis L. Light emitted from the light source 2 first becomes incident on a rear surface of the moving grating plate 6 and is transmitted by the transmissive grating 3 formed in the moving grating plate 6 to become incident in a form of grating stripes on the reflective grating plate 9 that is disposed at a fixed position. Since the reflective gratings 7 and 8 are also formed with the same pitch and the same width on the reflective grating plate 9, out of light incident on the reflective grating plate 9, only the light incident on the reflective gratings 7 and 8 is reflected. An image of the reflective gratings becomes incident on the moving grating plate 6 and the light is received by the sets of photodiodes 4 and 5.
The transmissive grating 3 and photodiodes 4 that are formed on the moving grating plate 6 as vertical stripes function as two grating plates. The reflective grating 7 is also used, and based on triple grating concept, the amount of light received at the sets of photodiodes 4 varies in a sine wave pattern corresponding to a relative movement of the reflective grating 7 on a fixed side and the transmissive grating 3 on a moving side. Accordingly, it is possible to obtain a pulse signal corresponding to a relative movement speed based on photoelectric current of the sets of photodiodes 4, and it is possible to calculate the relative movement speed based on a pulse rate of this pulse signal.
Based on a differential output of the photodiodes 4A and 4A′, it is possible to precisely obtain the A phase signal and based on a differential output of the photodiodes 4B and 4B′, it is possible to precisely obtain the B phase signal. Based on signals of these two phases, it is also possible to determine a direction of movement of the moving grating plate 6.
In the projection-type linear encoder 1 of the present embodiment, an origin signal for detecting an origin position of the moving grating plate 6 can be obtained in addition to the A phase signal and the B phase signal. When the moving grating plate 6 moves, detection signals are obtained from the photodiodes 5Z and 5Z′. When the moving grating plate 6 reaches the origin position (see
Although an example where the reflective grating plate on which the reflective grating is formed is fixed is described, it is possible for the reflective grating plate to move with the moving plate being fixed.
The light source can be implemented by various kinds of light source such as an LED, a laser source, or a halogen lamp.
Although the above example relates to a linear encoder, the present invention can be applied in the same way to a rotary encoder. In this case, the light transmissive gratings and the photodiodes may be formed at intervals of a fixed angle in a circumferential direction.
In addition, it should be obvious that the present invention can also be applied to a normal reflective-type or projection-type optical encoder.
As described above, according to the present invention, a plurality of transmissive grating sections or reflective grating sections for detecting an origin position and light receiving elements are aligned in accordance with an M-series arrangement pattern or the like, and the width of the transmissive grating sections or reflective grating sections is set wider than transmissive grating sections or reflective grating sections for detecting the A phase signal and the B phase signal. Accordingly, even when the grating pitch is narrow, it can be ensured that a sufficient amount of light is received by the light receiving elements for detecting the origin position signal. A signal shifted by 90° is also generated by the light receiving elements for detecting the origin position signal, and based on the signals, a Z phase signal with a predetermined width is generated.
According to the present invention, it is possible to obtain a Z phase signal with a high output level and a high contrast even when a gap between gratings is wide, such as in a reflective-type or a projection-type optical encoder.
Number | Date | Country | Kind |
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2002-330391 | Nov 2002 | JP | national |