Magnetic encoder

Abstract

The invention discloses a magnetic encoder. The magnetic encoder comprises a magnetic encoder stator and a magnetic encoder rotor, and the magnetic encoder stator and the magnetic encoder rotor are matched and fixedly connected; the magnetic encoder stator includes: a PCBA; the PCBA is bonded to the bracket, and the bracket is used for supporting and fixing the PCBA; the plurality of magnetic sensor devices are circumferentially arranged and are electrically connected to the back surface of the PCBA; the signal processing circuit and the communication interface are electrically connected to the front surface of the PCBA; the magnetic sensor device is used for detecting the magnetic field change of a rotor magnetic ring of the magnetic encoder, converting the magnetic field change into an electric signal and transmitting the electric signal to the signal processing circuit; the signal processing circuit is used for carrying out amplification, filtering and analog-to-digital conversion processing on the electric signals and transmitting processed digital signals to the communication interface, and the communication interface is used for transmitting the digital signals to external equipment. According to the invention, high-precision positioning and high-performance signal processing integration can be realized.

Description

Technical Field

[0001] This invention relates to the field of encoder technology, and more particularly to a magnetic encoder. Background Technology

[0002] In the fields of industrial automation and robotics, magnetic encoders are key components for angle or position measurement. Currently, most magnetic encoders on the market integrate the encoder chip directly onto a PCB, which is not conducive to the positioning and installation required for encoder measurement, makes assembly and debugging difficult, and complicates accuracy. The mounting screw holes are directly subjected to force on the PCB, which can cause PCB deformation and affect the encoder's measurement accuracy. Another common type of encoder integrates the stator and rotor into one unit, resulting in a large size and weight; this is a more traditional approach and cannot meet the current demand for miniaturization.

[0003] The positioning accuracy of existing magnetic encoders is insufficient: The existing magnetic encoders have limitations in their bracketless structure design and manufacturing process. During long-term use, they are prone to slight displacement and deformation due to factors such as vibration and temperature changes. This causes the relative position of the magnetic sensor and the measured magnetic field to change, reducing the accuracy and stability of the measurement and failing to meet the requirements of high-precision measurement equipment.

[0004] Existing magnetic encoders have low signal processing efficiency: the signal processing circuits on traditional circuit boards have low integration and slow processing speed. When faced with rapidly changing magnetic field signals, they cannot complete signal amplification, filtering and analog-to-digital conversion in a timely and accurate manner, which easily leads to signal distortion and delay, affecting the dynamic response performance of the magnetic encoder.

[0005] In summary, existing magnetic encoders suffer from insufficient positioning accuracy and low signal processing efficiency. Summary of the Invention

[0006] This invention provides a magnetic encoder that solves the problems of insufficient positioning accuracy and low signal processing efficiency of existing magnetic encoders, so as to achieve high-precision positioning and high-performance signal processing integration.

[0007] According to one aspect of the present invention, a magnetic encoder is provided, the magnetic encoder comprising: a magnetic encoder stator and a magnetic encoder rotor, the magnetic encoder stator being adapted to and fixedly connected to the magnetic encoder rotor;

[0008] The magnetic encoder stator includes:

[0009] PCBA;

[0010] A bracket, wherein the PCBA is bonded to the bracket, and the bracket is used to support and fix the PCBA;

[0011] Multiple magnetic sensor devices are arranged in a circular pattern and electrically connected to the back side of the PCBA;

[0012] The signal processing circuit and the communication interface are electrically connected to the front side of the PCBA.

[0013] The magnetic sensor device is used to detect the change in the magnetic field of the magnetic encoder rotor magnetic ring and convert it into an electrical signal, which is then transmitted to the signal processing circuit.

[0014] The signal processing circuit is used to amplify, filter, and perform analog-to-digital conversion on the electrical signal, and transmit the processed digital signal to the communication interface, which is used to transmit the digital signal to an external device.

[0015] Optionally, both the PCBA and the bracket are circular in shape, and the distance between the outer and inner rings of the circular ring is 2mm-8mm.

[0016] Optionally, the bracket is made of aluminum alloy;

[0017] Alternatively, the bracket may be made of engineering plastic.

[0018] Optionally, the bracket is provided with at least one positioning pin, and the PCBA is provided with a positioning groove corresponding to the positioning pin;

[0019] The positioning pin is used to extend into the positioning groove during assembly. Through the cooperation between the side wall of the positioning pin and the side wall of the positioning groove, the bracket and the PCBA are radially constrained in the horizontal plane.

[0020] Optionally, the plurality of magnetic sensor devices are circumferentially distributed on the back side of the PCBA with a preset gap.

[0021] Optionally, the signal processing circuit includes: a signal amplification module, an analog-to-digital conversion module, and a processing module;

[0022] The signal amplification module is connected to the plurality of magnetic sensor devices and the analog-to-digital conversion module. The signal amplification module is used to amplify the electrical signals transmitted by the plurality of magnetic sensor devices, and the analog-to-digital conversion module is used to convert the electrical signals into digital signals and transmit them to the processing module.

[0023] The analog-to-digital conversion module is connected to the processing module, and the processing module is connected to the communication interface. The processing module is used to process and analyze the digital signal in real time.

[0024] Optionally, the signal amplification module includes an operational amplifier chip, the analog-to-digital conversion module includes an ADC chip, and the processing module includes an MCU or an FPGA.

[0025] Optionally, the bracket includes at least three forward and reverse mounting holes spaced out in a ring.

[0026] The mounting holes for the forward and reverse screws are used for forward or reverse mounting of the magnetic encoder stator.

[0027] Optionally, the PCBA and the bracket have a hollow design.

[0028] Optionally, the magnetic encoder rotor is circular in shape, and a tool rotation groove is provided on the magnetic encoder rotor;

[0029] The magnetic encoder rotor includes: a threaded rotor and a non-threaded rotor.

[0030] The technical solution of this invention achieves stator miniaturization and high performance through innovative layout and optimized design. By optimizing the bracket structure design, high-precision positioning is achieved, ensuring that the magnetic sensor and the measured magnetic field maintain a stable relative position during long-term use, thus improving the measurement accuracy and stability of the magnetic encoder. Optimizing the distribution of magnetic sensors on the PCBA and the integration design of functional modules significantly improves signal processing speed and accuracy. Optimization of the entire process from signal acquisition, conversion to processing and transmission enhances the dynamic response performance of the magnetic encoder. In summary, this invention solves the problems of insufficient positioning accuracy and low signal processing efficiency in existing magnetic encoders.

[0031] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the structure of a magnetic encoder according to an embodiment of the present invention;

[0034] Figure 2 This is a schematic diagram of the structure of a magnetic encoder stator according to an embodiment of the present invention;

[0035] Figure 3This is a schematic diagram illustrating the installation of a magnetic encoder stator according to an embodiment of the present invention;

[0036] Figure 4 This is a front view of a magnetic encoder rotor according to an embodiment of the present invention;

[0037] Figure 5 This is a schematic diagram of the back of a magnetic encoder rotor according to an embodiment of the present invention. Detailed Implementation

[0038] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0039] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0040] Figure 1 This is a schematic diagram of the structure of a magnetic encoder according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the structure of a magnetic encoder stator according to an embodiment of the present invention, with reference to... Figure 1 and Figure 2An embodiment of the present invention provides a magnetic encoder, comprising: a magnetic encoder stator 1 and a magnetic encoder rotor 2, wherein the magnetic encoder stator 1 and the magnetic encoder rotor 2 are adapted to and fixedly connected; the magnetic encoder stator 1 comprises: a PCBA 10; a bracket 20, wherein the PCBA 10 is bonded to the bracket 20, and the bracket 20 is used to support and fix the PCBA 10; a plurality of magnetic sensor devices, wherein the plurality of magnetic sensor devices are arranged circumferentially and electrically connected on the back side of the PCBA 10; a signal processing circuit and a communication interface, wherein the signal processing circuit and the communication interface are electrically connected on the front side of the PCBA 10; the magnetic sensor devices are used to detect the magnetic field change of the magnetic ring of the magnetic encoder rotor and convert it into an electrical signal and transmit it to the signal processing circuit; the signal processing circuit is used to amplify, filter and perform analog-to-digital conversion processing on the electrical signal, and transmit the processed digital signal to the communication interface, wherein the communication interface is used to transmit the digital signal to an external device.

[0041] Specifically, after the magnetic encoder rotor 2 and magnetic encoder stator 1 are fixedly connected, they are mounted on the motor shaft. The ultra-thin and compact hollow structure makes it easier to embed in various application scenarios. The encoder is specifically designed for robot integrated joints, using patterned magnetic technology. It can measure multiple axes within a limited volume, achieving photoelectric-like resolution and accuracy, while possessing strong resistance to environmental interference. This encoder is driven by magnetoelectric technology and has unique interference shielding technology. The encoder has multiple high-precision magnetic measurement sensors inside to measure the magnetic field changes of the rotor magnetic ring, and it is formed with precision calibration technology. Each product has unique magnetic field calibration data at the factory, providing optimal measurement accuracy. The unique dynamic and static component tolerance matching installation technology simplifies user installation while also ensuring measurement accuracy. The separate magnetoelectric solution has stronger environmental resistance, such as vibration, dust, and oil, and can operate at ultra-high speeds without affecting the encoder's accuracy and service life.

[0042] The magnetic encoder stator 1 consists of a bracket 20 and a PCBA 10 (printed circuit board assembly). The bracket 20 is made of a special material, and its outer diameter and lower end face are machined to a precision of 0.02mm. Through precision machining and optimized design, high-precision positioning is achieved. This high-precision positioning function ensures the stable relative position of the magnetic sensor and the measured magnetic field. In practical applications, angle measurement accuracy can reach the arcsecond level, meeting the requirements of high-end, high-precision measurement equipment. High-precision positioning is achieved by relying on the special material and structural design of the bracket, combined with precision machining technology. The synergistic effect of the physical properties of the special material and the innovative structural design effectively overcomes the influence of external factors on positioning accuracy, ensuring long-term stable operation.

[0043] PCBA10 is glued to bracket 20. Magnetic sensor devices are distributed on the back of PCBA10 according to a specific pattern. This distribution effectively improves the sensitivity and resolution of magnetic field detection, thus enhancing the accuracy of angle measurement. High-precision positioning ensures stable relative positions between the magnetic sensor devices and the measured magnetic field. In practical applications, angle measurement accuracy can reach the arcsecond level, meeting the requirements of high-end, high-precision measurement equipment.

[0044] The upper part of the PCBA10 integrates signal processing circuits and communication interfaces, which highly integrate signal processing circuits and communication interfaces in a limited space, improving signal processing speed and accuracy and enhancing the dynamic response performance of the magnetic encoder.

[0045] The high-performance signal processing integration of PCBA10 in the embodiments of the present invention enables the magnetic encoder to respond quickly and accurately to changes in magnetic field, shortening the dynamic response time to the microsecond level, effectively improving the control accuracy and operating efficiency of the equipment.

[0046] The technical solution of this invention achieves stator miniaturization and high performance through innovative layout and optimized design. By optimizing the bracket structure design, high-precision positioning is achieved, ensuring that the magnetic sensor and the measured magnetic field maintain a stable relative position during long-term use, thus improving the measurement accuracy and stability of the magnetic encoder. Optimizing the distribution of magnetic sensors on the PCBA and the integration design of functional modules significantly improves signal processing speed and accuracy. Optimization of the entire process from signal acquisition, conversion to processing and transmission enhances the dynamic response performance of the magnetic encoder. In summary, this invention solves the problems of insufficient positioning accuracy and low signal processing efficiency in existing magnetic encoders.

[0047] Optionally, both the PCBA and the bracket are circular in shape, with the distance between the outer and inner rings being 2mm-8mm.

[0048] Specifically, traditional magnetic encoders have poor size adaptability and large stator volume, making it difficult to meet the space-critical application scenarios such as small drones, robots, wearable devices, and surgical robots, which seriously restricts the promotion and application of magnetic encoders in the field of miniaturized equipment.

[0049] The magnetic encoder stator with a single-sided diameter of only 2-8mm can meet the stringent size requirements of magnetic encoders for miniaturized and micro-sized devices, thus expanding their application range.

[0050] Extreme miniaturization design: By comprehensively utilizing optimized bracket and PCBA structural layout, high-density integration technology and miniaturized components, the stator single-side diameter is reduced to 2-8mm, while ensuring the normal operation of each functional module, breaking through the size limitations of traditional magnetic encoder stators.

[0051] Significant size advantage: The miniaturized design with a single-side diameter of 2-8mm enables the magnetic encoder stator to be widely used in miniaturized and micro-sized devices such as motor control systems for small drones, joint angle measurement systems for robots, and motion monitoring systems for wearable devices, providing core support for device miniaturization and high performance.

[0052] Optionally, the bracket may be made of aluminum alloy;

[0053] Alternatively, the bracket may be made of engineering plastic.

[0054] Specifically, for applications requiring extremely high precision and stability, the bracket is made of specially heat-treated aluminum alloy, which features high strength and a low coefficient of expansion, effectively resisting the effects of temperature changes and vibration. For cost-sensitive applications, the bracket is made of high-strength engineering plastics, manufactured through precision injection molding, which reduces production costs while ensuring a certain level of strength.

[0055] By optimizing the bracket material and structural design, high-precision positioning is achieved, ensuring that the magnetic sensor and the measured magnetic field maintain a stable relative position during long-term use, thereby improving the measurement accuracy and stability of the magnetic encoder.

[0056] Optionally, the bracket is provided with at least one positioning pin, and the PCBA is provided with a positioning groove corresponding to the positioning pin;

[0057] The locating pin is used to extend into the locating groove during assembly. Through the cooperation between the side wall of the locating pin and the side wall of the locating groove, the bracket and PCBA are radially constrained in the horizontal plane.

[0058] Specifically, the mating structure of the locating pin and locating slot is used to improve the concentricity of the bracket and the printed circuit board assembly (PCBA). During assembly, the relative positions between the two are automatically corrected to ensure that the mounting holes or mating structures of the bracket and the PCBA remain concentric. This structure effectively reduces assembly difficulty and improves assembly accuracy and efficiency.

[0059] For example, a high-precision shaft hole fit is used at the mating point with the rotor, with the tolerance of the shaft hole controlled within ±0.01mm, ensuring the concentricity and relative position accuracy between the magnetic encoder rotor and the magnetic encoder stator.

[0060] Optionally, multiple magnetic sensor devices are circumferentially distributed on the back of the PCBA with a preset gap.

[0061] Specifically, the magnetic sensor devices on the back of the PCBA are distributed in a circular pattern according to a specific rule. This distribution method can effectively improve the sensitivity and resolution of magnetic field detection and improve the accuracy of angle measurement.

[0062] Optionally, the signal processing circuit includes: a signal amplification module, an analog-to-digital conversion module, and a processing module;

[0063] The signal amplification module is connected to multiple magnetic sensor devices and an analog-to-digital conversion module. The signal amplification module is used to amplify the electrical signals transmitted by the multiple magnetic sensor devices, and the analog-to-digital conversion module is used to convert the electrical signals into digital signals and transmit them to the processing module.

[0064] The analog-to-digital conversion module is connected to the processing module, which in turn is connected to the communication interface. The processing module is used for real-time processing and analysis of digital signals.

[0065] Specifically, traditional circuit boards have low integration and slow processing speed. When faced with rapidly changing magnetic field signals, they cannot complete signal amplification, filtering and analog-to-digital conversion in a timely and accurate manner, which easily leads to signal distortion and delay, affecting the dynamic response performance of magnetic encoders.

[0066] The embodiments of the present invention highly integrate functional modules such as signal amplification module, analog-to-digital conversion module, processing module and communication interface in a limited space, thereby improving signal processing speed and accuracy and enhancing the dynamic response performance of magnetic encoder.

[0067] Optionally, the signal amplification module includes an operational amplifier chip, the analog-to-digital conversion module includes an ADC chip, and the processing module includes an MCU or an FPGA.

[0068] Specifically, the signal amplification module on the upper part of the PCBA uses a low-noise, high-gain operational amplifier chip, which can effectively amplify weak magnetic sensor signals. The analog-to-digital conversion module uses a high-speed, high-precision ADC chip, which can quickly and accurately convert analog signals into digital signals. The processing module uses a high-performance, low-power ARM Cortex-M series chip, which can perform real-time processing and analysis of digital signals. The communication interface adopts a multi-protocol interface, which is high-speed and stable, and can quickly transmit the processed signals to external devices.

[0069] Figure 3 This is a schematic diagram illustrating the installation of a magnetic encoder stator according to an embodiment of the present invention. (Refer to...) Figure 3 Optionally, the bracket 20 includes at least three forward and reverse mounting holes 21 spaced out in an annular pattern;

[0070] The mounting holes 21 for positive and negative mounting screws are used for positive or negative mounting of the magnetic encoder stator.

[0071] Specifically, traditional magnetic encoders lack installation flexibility, have a single stator installation method, and are difficult to adapt to the installation needs of different equipment, increasing the difficulty and cost of equipment integration.

[0072] The bracket 20 features at least three forward and reverse mounting screw holes 21 spaced out in a ring, enabling flexible installation of the hollow absolute magnetic encoder stator. This allows for both forward (screws tightened from above the encoder into the forward / reverse mounting screw holes 21) and reverse (screws tightened from below the encoder stator into the forward / reverse mounting screw holes 21) mounting methods, facilitating customer installation and reducing equipment integration difficulty and cost. This innovative design, featuring both forward and reverse mounting options, optimizes the bracket and PCBA structure and provides pre-drilled screw holes to meet the installation needs of different equipment, improving product versatility and applicability.

[0073] Optionally, a cutout design can be used between the PCBA and the bracket.

[0074] Specifically, tools such as finite element analysis can be used to accurately calculate the stress distribution at various points on the bracket. Low-stress areas are hollowed out, while high-stress areas (such as screw fixing points and support points) retain material or reinforcing ribs. This maximizes weight reduction while ensuring structural strength and rigidity. Opening holes and slots in non-load-bearing or low-stress areas of the bracket directly removes excess material, thus reducing overall weight and material usage, which helps lower costs. In addition to weight reduction, the hollowed-out design also facilitates heat dissipation from heat-generating components on the PCBA through convection, lowering the operating temperature.

[0075] Figure 4 This is a front view of a magnetic encoder rotor according to an embodiment of the present invention. Figure 5 This is a schematic diagram of the rear side of a magnetic encoder rotor according to an embodiment of the present invention, with reference to... Figure 4 and Figure 5 Optionally, the magnetic encoder rotor is circular in shape and has a tool rotation groove.

[0076] Magnetic encoder rotors include threaded rotors and unthreaded rotors.

[0077] Specifically, the tool rotation slot on the magnetic encoder rotor plays a crucial role, primarily in the installation, calibration, and maintenance stages. The tool rotation slot's main functions are installation and initial positioning, zero-point or phase calibration, maintenance, and troubleshooting.

[0078] Based on their mounting method, magnetic encoder rotors are mainly divided into two basic types: threaded and unthreaded. Unthreaded rotors typically have a smooth inner bore and are mounted on the motor shaft using adhesive or a mating fit. Threaded rotors have a central internal threaded hole and are directly screwed onto the external thread machined at the end of the motor shaft. Threaded rotors are mostly used in small, micro motors or some specific low-cost, high-volume applications.

[0079] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A magnetic encoder, characterized in that, include: A magnetic encoder stator and a magnetic encoder rotor, wherein the magnetic encoder stator is adapted to and fixedly connected to the magnetic encoder rotor; The magnetic encoder stator includes: PCBA; A bracket, wherein the PCBA is adhered to the bracket, and the bracket is used to support and fix the PCBA; Multiple magnetic sensor devices are arranged in a circular pattern and electrically connected to the back side of the PCBA; The signal processing circuit and the communication interface are electrically connected to the front side of the PCBA. The magnetic sensor device is used to detect the change in the magnetic field of the magnetic encoder rotor magnetic ring and convert it into an electrical signal, which is then transmitted to the signal processing circuit. The signal processing circuit is used to amplify, filter, and perform analog-to-digital conversion on the electrical signal, and transmit the processed digital signal to the communication interface. The communication interface is used to transmit the digital signal to an external device.

2. The magnetic encoder according to claim 1, characterized in that, Both the PCBA and the bracket are circular in shape, and the distance between the outer and inner rings of the circular ring is 2mm-8mm.

3. The magnetic encoder stator according to claim 1, characterized in that, The bracket is made of aluminum alloy; Alternatively, the bracket may be made of engineering plastic.

4. The magnetic encoder according to claim 1, characterized in that, The bracket is provided with at least one positioning pin, and the PCBA is provided with a positioning groove corresponding to the positioning pin; The positioning pin is used to extend into the positioning groove during assembly. Through the cooperation between the side wall of the positioning pin and the side wall of the positioning groove, the bracket and the PCBA are radially constrained in the horizontal plane.

5. The magnetic encoder according to claim 1, characterized in that, The multiple magnetic sensor devices are distributed circumferentially on the back of the PCBA according to a preset gap.

6. The magnetic encoder according to claim 1, characterized in that, The signal processing circuit includes: a signal amplification module, an analog-to-digital conversion module, and a processing module; The signal amplification module is connected to the plurality of magnetic sensor devices and the analog-to-digital conversion module. The signal amplification module is used to amplify the electrical signals transmitted by the plurality of magnetic sensor devices, and the analog-to-digital conversion module is used to convert the electrical signals into digital signals and transmit them to the processing module. The analog-to-digital conversion module is connected to the processing module, and the processing module is connected to the communication interface. The processing module is used to process and analyze the digital signal in real time.

7. The magnetic encoder according to claim 6, characterized in that, The signal amplification module includes an operational amplifier chip, the analog-to-digital conversion module includes an ADC chip, and the processing module includes an MCU or an FPGA.

8. The magnetic encoder according to claim 1, characterized in that, The bracket includes at least three forward and reverse mounting holes spaced in a ring. The mounting holes for the forward and reverse screws are used for forward or reverse mounting of the magnetic encoder stator.

9. The magnetic encoder according to claim 1, characterized in that, The PCBA and the bracket have a hollow design.

10. The magnetic encoder according to claim 9, characterized in that, The magnetic encoder rotor is circular in shape and has a tool rotation groove. The magnetic encoder rotor includes: a threaded rotor and a non-threaded rotor.

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