Dual Channel Rotary Encoder with Magnetic and Optical Sensors
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Solution Overview
Problem
Rotary encoders face reliability issues due to contamination and wear, leading to inaccurate measurements or failure, especially in demanding environmental conditions, and existing dual-channel systems increase costs and complexity.
Innovation Solution
A rotary encoder device using both magnetic and optical sensors to independently determine the angle of rotation, with a selection device to choose the most reliable data based on operating conditions, ensuring measurements are within predetermined error tolerances by averaging data from both sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate measuring devices are used for one and the same shaft to increase safety through redundant measurement, then reliability is improved, but device complexity and costs are significantly increased
Solution Approach 1:
The patent combines multiple sensor devices (optical, magnetic, capacitive) into a single integrated encoder system with a common housing and shared mechanical components. This merging approach maintains redundant measurement capabilities for improved reliability while reducing the number of separate housings and installations required, thereby decreasing overall system complexity
Solution Approach 2:
The encoder system is designed to support multiple sensor types (optical, magnetic, capacitive) within a single device, allowing the same mechanical structure to serve multiple measurement functions. This multi-functionality enables redundant measurement without requiring separate dedicated housings for each sensor type
2Device complexity
If multiple sensor devices are integrated into a single housing, then device complexity is reduced, but manufacturing precision requirements are increased
Solution Approach 1:
The encoder housing is divided into functionally independent compartments or mounting areas for different sensor types, allowing each sensor to be positioned and adjusted independently. This segmentation enables precise alignment of each sensor with its corresponding measurement target without requiring ultra-precise overall housing manufacturing
Solution Approach 2:
The patent incorporates preliminary alignment features such as pre-positioned mounting holes, alignment pins, or reference marks during the manufacturing process. These preliminary actions facilitate easier final alignment and reduce the stringency of manufacturing precision requirements for the housing itself
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
Enhances measurement reliability by compensating for systematic errors through different physical measurement methods, maintaining a compact design and reducing installation complexity while adapting to varying operating conditions.
Implementation Method 1
a magnetic sensor device (3), which is designed to obtain data about an angle of rotation of the shaft (2)
Implementation Method 2
an optical sensor device (4), which is designed to obtain data about an angle of rotation of the shaft (2)
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a rotary encoder device comprising a magnetic sensor device configured to detect the magnetic field of a magnetic field-generating device stationary with respect to the shaft, a light source, an optical sensor device configured to detect light emitted by the light source and reflected or transmitted by a code disk stationary with respect to the shaft, and a signal processing device configured to receive first data from the magnetic sensor device and second data from the optical sensor device and to determine a rotation angle of the shaft from the received first data and/or to determine the rotation angle of the shaft from the received second data.