Absolute Vector Encoder Using Spaced Sensors for High Resolution
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Solution Overview
Problem
Existing absolute encoders face limitations in achieving high resolution and precision while maintaining simplicity and cost-effectiveness, due to practical constraints on sensor distribution and pattern design, leading to inefficiencies in code resolution and implementation complexity.
Innovation Solution
A high-resolution encoder design utilizing sensors spaced apart to allow for commercially available components, with a processing unit that receives analog signals, digitizes them, and calculates position using a vector function that satisfies specific mathematical conditions, enabling high precision and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are closely spaced to achieve high resolution, then measurement precision improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent transitions from 1D linear sensor arrays to 2D matrix arrangements of sensors. This dimensional change allows the system to achieve higher resolution through spatial distribution in multiple directions, enabling cross-correlation processing that improves measurement precision without requiring excessively dense single-dimensional spacing.
Solution Approach 2:
The encoder is divided into multiple independent sensor elements arranged in a matrix pattern. Each sensor element processes local information, and the collective output of all segments is combined through cross-correlation algorithms to achieve high-resolution measurement. This segmentation allows standard commercial sensors to be used while maintaining high precision.
2Measurement precision
If complex sensor arrangements are used to achieve high resolution, then measurement precision improves, but ease of manufacture deteriorates
Solution Approach 1:
The matrix arrangement of sensors serves multiple functions simultaneously: it provides spatial sampling for resolution, enables cross-correlation processing for precision enhancement, and allows the use of standard commercial sensor components. This multi-functionality achieves high precision without requiring specialized or custom-manufactured sensors.
Solution Approach 2:
The patent changes the spatial distribution parameters of sensors from linear to matrix configuration. This parameter change in arrangement geometry allows the system to achieve high resolution through computational processing of distributed sensor outputs, rather than requiring high-density single-axis spacing that would be difficult to manufacture.
3Measurement precision
If high resolution is achieved through dense sensor spacing, then measurement precision improves, but cost increases
Solution Approach 1:
The patent uses multiple copies of standard sensor elements arranged in a matrix pattern. Rather than using a single high-density sensor array, it replicates standard commercial sensors in a distributed configuration. The cross-correlation processing of these replicated sensor outputs achieves high resolution equivalent to much denser spacing, but using affordable standard components.
Solution Approach 2:
By distributing sensors across a 2D matrix rather than concentrating them along a single line, the system achieves effective high resolution through spatial diversity in two dimensions. This allows the use of standard sensor pitch in both directions, making the system cost-effective while maintaining high measurement precision through the mathematical processing of the distributed sensor array.
4Ease of manufacture
If absolute encoder design is simplified, then ease of manufacture improves, but measurement precision deteriorates
Solution Approach 1:
The patent replaces complex mechanical precision requirements with computational processing. Instead of requiring mechanically precise sensor positioning or specialized high-resolution sensor components, the system uses a relatively simple matrix arrangement combined with cross-correlation algorithms to achieve high resolution. This substitution of computational methods for mechanical precision maintains design simplicity while delivering high measurement accuracy.
Solution Approach 2:
The cross-correlation processing acts as a feedback mechanism that enhances the raw sensor measurements. The system compares sensor outputs across the matrix arrangement and uses the correlation information to extract precise position data, effectively using the feedback from multiple sensor readings to achieve high resolution despite the simplicity of the individual sensor elements and their arrangement.
Data Source
AI summary
A high-resolution encoder device to measure and retrievably encode the relative position of a first part P with a second part S comprises sensible elements on part P, said sensible elements providing a variable property for sensing, such that said variable property varies over a length of said part P, a number n of sensors for sensing said variable property, said sensors being separate from each other and disposed on part S, said sensors configured to output signals in accordance with said sensing, and a processing unit connected to receive said signals from each of said n sensors and configured for succeeding ones of said relative positions to form a vector having entries from each sensor respectively, the vector defining said relative positions respectively.