Curved Surface Encoder for High-Accuracy Position Detection
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Solution Overview
Problem
Conventional optical encoders face challenges in achieving high accuracy position detection due to issues like eccentricity and surface blurring, which reduce signal intensity and lead to erroneous detection, especially when trying to increase the precision of the code pattern.
Innovation Solution
The encoder design incorporates a rotating plate with at least one curved surface, where an irradiator simultaneously irradiates multiple surfaces, including the curved surfaces, with light. This configuration allows for high-accuracy position detection by minimizing the impact of eccentricity and surface blurring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the precision of the code pattern is increased to achieve higher position resolution, then measurement precision is improved, but signal intensity decreases leading to erroneous detection
Solution Approach 1:
The rotating plate is designed with a curved surface instead of a flat surface. This curvature causes the light reflection path to converge toward the light receiver, maintaining a concentrated light spot even when eccentricity or surface blurring occurs. The curved surface geometry compensates for misalignment issues, ensuring that increased code pattern precision does not lead to signal loss and erroneous detection.
2Measurement precision
If the precision of the code pattern is increased from 9 bits to 10 bits, then measurement precision is improved, but the amount of light received per unit light-receiving element decreases
Solution Approach 1:
The curved surface of the rotating plate focuses the reflected light onto the light receiver, maintaining sufficient light intensity even when the code pattern precision is increased. The curvature geometry ensures that light from higher-resolution patterns remains concentrated rather than dispersed, allowing 10-bit or higher precision detection without sacrificing light amount.
3Adaptability or versatility
If eccentricity or surface blurring occurs in conventional encoders, then the spot of light received by the light-receiving element is displaced, but this leads to reduction in signal intensity and erroneous detection
Solution Approach 1:
The curved surface design inherently compensates for eccentricity and surface blurring by geometry. When the rotating plate rotates with curvature, the light reflection paths naturally converge toward the light receiver regardless of minor positional displacements. This geometric compensation maintains signal intensity and prevents erroneous detection even when misalignment occurs.
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 proposed encoder achieves high accuracy in position detection, even when increasing the precision of the code pattern, by inhibiting erroneous detection associated with eccentricity or surface blurring, and enabling a cost reduction and faster response due to smaller light-receiving elements.
Implementation Method 1
an irradiator that irradiates the rotating plate with light; and a light receiver that receives the light which has been emitted from the irradiator and traveled via the rotating plate
Data Source
AI summary
An encoder includes: a rotating plate; an irradiator that irradiates the rotating plate with light; and a light receiver that receives the light which has been emitted from the irradiator and traveled via the rotating plate. The rotating plate includes at least one curved surface, and the irradiator simultaneously irradiates each of a plurality of surfaces including the curved surface with light.