The present invention relates to a position detection device that detects the relative positions and movement of a magnet and a detection unit having a magnetic sensor.
Japanese Registered Utility Model No. 3191531 describes an invention relating to a position detection device.
The position detection device has a case accommodating a holder that moves to advance and retreat, and the holder is provided with two magnets that are arranged side by side in a moving direction. A detection unit is fixed to the case. The detection unit is provided with two magnetoresistive elements facing the magnets that move.
The holder is urged by a compression coil spring in a direction in which the holder projects from the case. When a shaft integrally formed with the holder is pressed to move the case in a direction against the urging direction of the compression coil spring, the movement of the magnets is detected with the magnetoresistive elements and the moving position of the holder is calculated.
Although Japanese Registered Utility Model No. 3191531 does not provide a detailed description of a method for detecting the position of the holder, in a typical position detection device of this type, the magnetoresistive elements detect a component (Bz) and a component (Bx) of the magnetic flux density of a leakage magnetic field generated by the two magnets, the component (Bz) being in a direction perpendicular to the direction in which the holder moves, the component (Bx) being in a direction parallel to the direction in which the holder moves, to calculate the moving position of the holder. For example, an arc tangent is computed from the detected value of the component (Bz) and the detected value of the component (Bx), and the position of the holder is determined from the computed value.
Here, the intensity of the leakage magnetic field from the magnets is affected by temperature, and a demagnetization phenomenon in which the magnetic flux density of the leakage magnetic field decreases occurs at a high temperature. It is conventionally recognized that the rate at which the magnetic flux density decreases when a rectangular parallelepiped magnet is heated is always in the same proportion for the component (Bz) in the direction perpendicular to a magnetized surface and the component (Bx) in the direction parallel to the magnetized surface.
On the basis of this recognition, it is considered that an arc tangent is computed on the basis of detected values obtained from the magnetoresistive elements at room temperature and a correction is made on a circuit so as to ensure linearity in the computed value, which makes it possible to ensure linearity of computed values when the holder is moved even if a temperature change occurs.
In an actual position detection device, however, a problem arises in that, in a high-temperature environment, the value of the arc tangent computed on the basis of the output from the detection unit varies in accordance with a change in position facing the magnetized surfaces of the magnets and it is difficult to ensure linear position detection.
The present invention provides a position detection device having a structure that makes it easy to ensure the linearity of detection values for detecting the relative movement of a magnet and a detection unit even when a temperature change causes demagnetization of the magnet.
A position detection device according to an aspect of the present invention includes a detection unit and a magnet facing the detection unit, the detection unit and the magnet being movable relatively to each other. The magnet is magnetized in a direction perpendicular to a relative movement trajectory of the detection unit. The detection unit includes a magnetic sensor that detects a component of magnetic flux emerging from the magnet that is parallel to the movement trajectory, and a magnetic sensor that detects a component of the magnetic flux that is perpendicular to the movement trajectory. The magnet has a facing surface facing the movement trajectory, and both ends of the facing surface in a direction extending along the movement trajectory are positioned farther away from the movement trajectory than a center portion of the facing surface.
In the position detection device, for example, the facing surface may be a projecting curved surface having a curvature in a direction extending along the movement trajectory.
In this case, preferably, the curvature has a radius that is greater than or equal to 1.7 times and less than or equal to 3.4 times a shortest distance between the facing surface and the movement trajectory.
The position detection device may be configured such that a plurality of the magnets are disposed along the movement trajectory and the facing surfaces of adjacent magnets among the magnets are magnetized to opposite polarities.
In the position detection device, the movement trajectory may be a straight line. Alternatively, the movement trajectory may be an arc of a circle.
In an aspect of the present invention, attention is focused on differences in demagnetizing factor for the magnetic flux density of a magnetic field generated by a magnet due to a temperature change between a direction perpendicular to a magnetized surface of the magnet and a direction parallel to the magnetized surface, and the magnetized surface, that is, a surface facing a detection unit, has a shape such that both ends thereof in a direction extending along a relative movement trajectory of the detection unit are positioned more rearward than a center portion thereof. This can reduce the difference in demagnetizing factor due to a temperature change between a component of the magnetic flux density in a direction perpendicular to the movement trajectory and a component of the magnetic flux density in a direction parallel to the movement trajectory and can ensure linearity for detection outputs from the detection unit even if a temperature change occurs.
The position detection device 1 includes a movement unit 10. The movement unit 10 is provided with a movement base (not illustrated) that linearly reciprocates in the X direction, and a first magnet 11 and a second magnet 12 are mounted on the movement base. The position detection device 1 is provided with a detection unit 20, and the movement unit 10 and the detection unit 20 face each other in the Z direction.
Since the movement unit 10 moves in the X direction together with the first magnet 11 and the second magnet 12, the relative movement trajectory of the movement unit 10 and the detection unit 20 is indicated by Tx in
In
The first magnet 11 has a facing surface 11a that faces the movement trajectory Tx, a rear surface 11b opposite the facing surface 11a, and both side surfaces 11c and 11d that are oriented in the X direction. The facing surface 11a is part of a cylindrical surface having a curvature in the X direction. An opposing distance between the center of the facing surface 11a in the X direction and the movement trajectory Tx is indicated by δa. Further, an opposing distance between an end of the facing surface 11a on the side surface 11c side and the movement trajectory Tx is indicated by δc, and an opposing distance between an end of the facing surface 11a on the side surface 11d side and the movement trajectory Tx is indicated by δd. The opposing distances δc and δd have the same length, and the opposing distances δc and δd are longer than the opposing distance δa. That is, the facing surface 11a has a shape such that both ends thereof in the X direction extending along the movement trajectory Tx are positioned farther away from the movement trajectory Tx than a center portion thereof.
The rear surface 11b of the first magnet 11 is a flat surface that is parallel to the movement trajectory Tx and that is perpendicular to the plane of
The first magnet 11 is magnetized in the Z direction, which is a direction perpendicular to the movement trajectory Tx, and the facing surface 11a and the rear surface 11b are magnetized surfaces having opposite polarities. The facing surface 11a is magnetized to the N pole, and the rear surface 11b is magnetized to the S pole.
The first magnet 11 and the second magnet 12 have the same size and shape. The second magnet 12 also has a facing surface 12a, a rear surface 12b, and side surfaces 12c and 12d. The shapes and dimensions of the respective surfaces are the same as those of the first magnet 11. The opposing distances δa, δc, and δd between the facing surface 12a and the movement trajectory Tx are also the same as those of the first magnet 11.
The second magnet 12 is also magnetized in the Z direction, and the facing surface 12a and the rear surface 12b are magnetized surfaces. It is to be noted that the direction of magnetization of the second magnet 12 is reversed to the direction of magnetization of the first magnet 11 by 180 degrees, that is, the facing surface 12a is magnetized to the S pole and the rear surface 12b is magnetized to the N pole.
The detection unit 20 has at least two magnetic sensors. A first magnetic sensor has an axis of sensitivity Sx directed parallel to the movement trajectory Tx and is capable of detecting a magnetic flux density in a direction parallel to the movement trajectory Tx. A second magnetic sensor has an axis of sensitivity Sz directed perpendicular to the movement trajectory Tx and is capable of detecting a magnetic flux density in a direction perpendicular to the movement trajectory Tx. The magnetic sensors are each constituted by a Hall element, a magnetoresistance effect element, or the like.
The outputs from the first magnetic sensor and the second magnetic sensor of the detection unit 20 are detected by a detection circuit 2, and each output is subjected to analog-to-digital (A/D) conversion and is provided to a computation unit 3. The computation unit 3 is constituted by a central processing unit (CPU), a memory, and so on.
The position detection device 101 includes a first magnet 111 and a second magnet 112, each of which has a cubic shape, with a facing surface 111a and a facing surface 112a being both flat surfaces that are parallel to the movement trajectory Tx and that are vertical to the plane of
Both the first magnet 111 and the second magnet 112 are magnetized in the Z direction. The facing surface 111a of the first magnet 111 is magnetized to the N pole, and the facing surface 112a of the second magnet 112 is magnetized to the S pole. An opposing distance δa between the facing surfaces 111a and 112a and the movement trajectory Tx is the same as the opposing distance δa at the center portions of the facing surfaces 11a and 12a of the magnets 11 and 12 illustrated in
In the position detection device 1 illustrated in
When the detection unit 20 relatively moves along the movement trajectory Tx within the magnetic field H, the detection output of the first magnetic sensor having the axis of sensitivity Sx and the detection output of the second magnetic sensor having the axis of sensitivity Sz, which are included in the detection unit 20, exhibit waveforms that are similar to a sine curve and a cosine curve. The computation unit 3 computes an arc tangent from changing outputs that are similar to a sine curve and a cosine curve. The computed value of the arc tangent changes substantially linearly, which enables the measurement of the relative movement positions of the movement unit 10 and the detection unit 20.
It is known that each magnet is subjected to demagnetization in which a generated magnetic field decreases when the temperature of the magnet becomes high. The present invention has been made focusing on a difference between demagnetizing factors for a component (Bx) and a component (Bz) of the magnetic flux density of a magnetic field emerging from a magnet, which occurs when the temperature of the magnet becomes high, with the component (Bx) being directed in the X direction and the component (Bz) being directed in the Z direction. As described below with reference to Examples and Comparative Examples, the difference between the demagnetizing factor for the component (Bx) and the demagnetizing factor for the component (Bz) at a high temperature gradually increases toward either end of each of the facing surfaces 111a and 112a in the X direction from the center portions thereof.
For this reason, in a high-temperature environment, an error of the calculated value of the arc tangent, which is computed from the ratio of the sine curve and the cosine curve by the computation unit 3, increases as the facing position of the detection unit 20 becomes closer to the vicinity of either end of each of the magnets 111 and 112 rather than the center portion thereof. As a result, the linearity of measured values of the position of the detection unit 20 decreases.
In the position detection device 1 according to an embodiment of the present invention, accordingly, as illustrated in
In the position detection device 1 illustrated in
In addition, the facing surface 11a is an inclined curved surface that gradually inclines away from the movement trajectory Tx toward the side surface 11d from the center portion thereof. Thus, the magnetic field H directed from the facing surface 11a of the first magnet 11 to the facing surface 12a of the second magnet 12 tends to be inclined in the X direction toward the right end of the facing surface 11a. This also makes the rate of decrease of the sensitivity of the component (Bz) of the magnetic flux density in the Z direction greater than the rate of decrease of the sensitivity of the component (Bx) in the X direction when the detection unit 20 faces the end of the facing surface 11a on the side surface 11d side.
As a result, when the first magnet 11 is subjected to high temperature and the component (Bx) of the magnetic flux density in the X direction at the end of the facing surface 11a on the side surface 11d side attenuates, the component (Bz) of the magnetic flux density in the Z direction, which is detected by the detection unit 20, can be decreased accordingly in accordance with the shape of the facing surface 11a. Thus, the calculated value of the arc tangent, which is computed on the basis of the ratio of the detection output of the first magnetic sensor having the axis of sensitivity Sx and the detection output of the second magnetic sensor having the axis of sensitivity Sz, which are detected by the detection unit 20, can maintain linearity when the detection unit 20 faces the center portion of each of the facing surfaces 11a and 12a in the X direction and when the detection unit 20 faces either end of each of the facing surfaces 11a and 12a in the X direction.
To this end, the facing surfaces 11a and 12a of the magnets 11 and 12 need to be gradually inclined such that both ends thereof in the X direction are farther away from the movement trajectory Tx than the center portions thereof. In addition, each of the facing surfaces 11a and 12a may be formed to be a projecting curved surface, which allows the rate of attenuation of the component (Bx) of the magnetic flux density in the X direction that attenuates in a high-temperature environment to easily match the rate of attenuation of the component (Bz) in the Z direction toward either end thereof.
A first magnet 11 and a second magnet 12 that are used in the position detection device 1A are the same as those in the position detection device 1 illustrated in
In the position detection device 1A illustrated in
Also in the position detection devices 1B and 1C, when the detection unit 20 relatively moves along the movement trajectory Tx, the linearity error for detection outputs can be reduced.
A position detection device according to an embodiment of the present invention may include only one magnet, as illustrated in
The magnets 11, 12, and 13 have facing surfaces 11a, 12a, and 13a that are projecting curved surfaces having curvatures in a direction extending along the movement trajectory Tx, with their radii of curvature being indicated by R.
The magnets 111, 112, and 113 have facing surfaces 111a, 112a, and 113a that are all flat surfaces.
The magnets 11, 12, and 13 in Examples and the magnets 111, 112, and 113 in Comparative Examples are each a rare-earth based (Nd—Fe—B based) injection molded magnet.
The magnets 11, 12, and 13 in Examples and the magnets 111, 112, and 113 in Comparative Examples each have dimensions such that a height Hm is 6 mm, a length L in a direction extending along the movement trajectory Tx is 9 mm, and a width W in a direction perpendicular to the movement trajectory Tx is 9 mm. The facing surfaces 11a, 12a, and 13a of the magnets 11, 12, and 13 have a radius of curvature R of 9 mm. The opposing distance δa between the center portions of the facing surfaces 11a, 12a, and 13a of the magnets 11, 12, and 13 in Examples and the movement trajectory Tx and the opposing distance δa between the respective facing surfaces 111a, 112a, and 113a of the magnets 111, 112, and 113 in Comparative Examples and the movement trajectory Tx, that is, the shortest value of the opposing distance between each magnet and the movement trajectory Tx, are each 3.55 mm.
In Example 2 in
In
In
In
In the respective Comparative Examples in
In
In
In
In Examples 2A, 2B, 2C, and 2D, linearity of calculated values of the arc tangent is improved, compared with Comparative Example 2 illustrated in
Number | Date | Country | Kind |
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2015-211556 | Oct 2015 | JP | national |
This application is a Continuation of International Application No. PCT/JP2016/074941 filed on Aug. 26, 2016, which claims benefit of Japanese Patent Application No. 2015-211556 filed on Oct. 28, 2015. The entire contents of each application noted above are hereby incorporated by reference.
Number | Date | Country | |
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Parent | PCT/JP2016/074941 | Aug 2016 | US |
Child | 15939418 | US |