Configurable Encoder Detector Array for Automatic Alignment
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Solution Overview
Problem
Existing encoder systems require manual and time-consuming mechanical alignment of components, which is costly and prone to human error, and are limited by the need for multiple IC designs for different configurations, increasing manufacturing complexity and costs.
Innovation Solution
The implementation of a configurable photodetector array that automates alignment adjustment by remapping pixel arrays to match assembly orientations and offsets, allowing for a single IC design to be used across various configurations without compromising signal quality, and enabling automatic alignment through computer-controlled measurement and calibration processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual mechanical alignment is performed by trained operators using magnification techniques, then alignment accuracy is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical measurement system. The system uses a light source, photodetectors, and computer-controlled movement to automatically measure and adjust component alignment, eliminating the need for trained operators to perform manual alignment with magnification tools. This substitution maintains high alignment accuracy while dramatically reducing manufacturing time and eliminating human variation.
Solution Approach 2:
The alignment system performs self-adjustment through automated feedback loops. The measurement system detects misalignment automatically, and the system controls movement mechanisms to correct the alignment without human intervention. This self-service capability allows the system to maintain optimal alignment consistently across all encoder assemblies, eliminating the time-consuming manual adjustment process while preserving precision.
2Adaptability or versatility
If multiple IC designs are created for different encoder configurations, then adaptability to various configurations is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal IC design that can accommodate multiple encoder configurations through software-based adaptability. The system uses a configurable photodetector array where individual photodetectors can be programmatically assigned to different regions and functions based on the specific encoder configuration being used. This allows a single IC design to serve multiple purposes across different encoder types and configurations, eliminating the need to manufacture multiple specialized IC designs while maintaining full configuration adaptability.
Solution Approach 2:
The system employs dynamic configuration capabilities where the photodetector array can be reconfigured through software to match different encoder setups. The measurement and alignment parameters can be dynamically adjusted based on the specific configuration requirements, allowing the same hardware platform to adapt to various encoder designs without requiring physical hardware changes or multiple IC variants.
3Manufacturing precision
If manual alignment processes are used, then alignment accuracy is improved, but human variation and error introduction increase
Solution Approach 1:
The patent replaces manual alignment operations with an automated optical measurement and adjustment system. This substitution eliminates human variation and error introduction while maintaining high alignment accuracy through precise optical detection and computer-controlled movement. The system provides consistent, repeatable alignment results across all encoder assemblies without the variability inherent in manual processes.
Solution Approach 2:
The system implements continuous feedback loops where photodetectors measure alignment status in real-time, and the computer control system adjusts component positions based on these measurements. This feedback mechanism ensures that alignment accuracy is consistently achieved and maintained, eliminating the human error and variation that occurs in manual alignment processes while preserving the high precision required for encoder operation.
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
This solution reduces manufacturing time and costs by eliminating human variation in alignment, allows for a single IC design to support multiple configurations, and simplifies the supply chain, while maintaining high accuracy and consistency in encoder systems.
Implementation Method 1
an encoder chip (e.g., an optical sensor integrated circuit) including a plurality of photodetectors that receive the modulated light and generate electrical signals in response thereto
Data Source
AI summary
An encoder system includes a configurable detector array, wherein the configurable detector array includes a plurality of detectors. In an embodiment, the encoder system includes an application-specific integrated circuit (ASIC). The encoder system may also include a memory operable to store a partition map that defines a state for each of the plurality of detectors. In an embodiment, the memory includes a non-volatile memory. The encoder system may also include a controller, such as a microcontroller, operable to read from the memory the partition map and to adjust the partition map according to a misalignment measurement before configuring the configurable detector array. The encoder system may also include an emitter operable to generate a flux modulated by a motion object, wherein the configurable detector array is operable to receive the flux and generate respective current outputs for each of the detectors in response to the flux.