High-Resolution Encoder Array Using Camera Vision
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Solution Overview
Problem
Existing position measurement systems face a trade-off between resolution, cost, and computational overhead, with current solutions either using low-resolution physical components and additional circuitry to keep computing overhead low but increasing overall system cost, or employing high-resolution components that are costly and sensitive to damage or contamination.
Innovation Solution
A high-resolution position sensing apparatus comprising a linear array of sensors with a spacing between sensors smaller than the spacing between object features, coupled with a tracking processor that samples and compares signals to calculate object position, minimizing computational overhead while maintaining accuracy and low cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If low resolution physical components are used with additional circuitry, then computing overhead is kept low, but overall system cost increases
Solution Approach 1:
The patent replaces traditional optical encoders with a camera-based vision system. Instead of using specialized optical encoding hardware and dedicated decoding circuitry, the system uses a standard camera to capture images of scale markings and processes them through image processing algorithms. This substitution eliminates the need for expensive, high-resolution optical encoders while maintaining measurement capabilities through software-based position calculation from captured images.
Solution Approach 2:
The patent changes the measurement approach from direct optical encoding to image capture and processing. By capturing images of scale markings at different positions and comparing them through image processing, the system achieves high-resolution position measurement using standard camera components rather than specialized high-resolution sensors. This parameter change allows using lower-cost hardware with sufficient computational processing.
2Measurement precision
If high resolution physical components are used, then resolution and accuracy are improved, but system cost increases and sensitivity to damage or contamination increases
Solution Approach 1:
The patent replaces expensive high-resolution optical encoders with a camera-based vision system. The camera captures images of scale markings, and position is determined through image processing and comparison algorithms. This substitution allows achieving high measurement precision using standard, lower-cost camera components rather than specialized high-resolution optical sensors, thereby reducing system cost while maintaining or improving measurement capability.
Solution Approach 2:
The patent uses visual copying of scale markings through camera imaging. Instead of directly reading position from optical encoder signals, the system captures optical images of the scale markings and creates digital representations. These image copies are then processed to determine position, allowing the use of standard cameras instead of expensive high-resolution sensors while achieving comparable or superior precision through computational methods.
3Measurement precision
If high resolution physical components are used, then resolution and accuracy are improved, but sensitivity to damage or contamination increases
Solution Approach 1:
The patent replaces optical encoders with a camera-based vision system that captures images of scale markings. The camera and scale markings form a more robust system that is less sensitive to damage and contamination. The scale markings can be made durable on the object being measured, and the camera captures visual information that can be processed even in the presence of minor environmental factors, improving reliability while maintaining high measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables high-resolution and accurate position measurement at a relatively low cost with minimal computational overhead, effectively addressing the limitations of existing systems by improving resolution without increasing system cost or sensitivity to damage.
Implementation Method 1
an optical detector with a linear array of photodiodes... generates a signal in response to light reflected from or transmitted through the code strip
Data Source
AI summary
A position sensing apparatus and method, motion control system, and integrated circuit are provided that include a plurality of sensors and a tracking processor. The plurality of sensors includes a linear array of sensors that sense a plurality of features of an object. A spacing between two of the plurality of sensors is substantially smaller than a spacing between two of the plurality of features. The tracking processor samples signals from the sensors, compares the samples to previous samples and calculates a position of the object. The plurality of sensors may include a second linear array of sensors. Centers of the sensors of the second linear array may be offset from centers of the sensors of the first linear array along a longitudinal axis of the plurality of sensors.