Encoder Signal Processor Automatic Adjustment Circuit
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Solution Overview
Problem
Existing encoder signal processors face challenges in maintaining high-accuracy position detection due to secular changes in the encoder's analog signal waveform, which can cause amplitude drops or offset changes, and require temporary shutdown for adjustments, making them difficult to implement, especially when mounted in specific positions.
Innovation Solution
An encoder signal processor that includes an analog signal adjustment circuit with variable resistors adjusted by an adjusting signal to minimize velocity changes, a position detection circuit for calculating position data, and a velocity change detection circuit to generate adjusting signals that correct for amplitude and offset changes, allowing for continuous operation and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If analog signal adjustment is performed manually in the manufacturing process, then position detection accuracy is improved, but the encoder must be temporarily stopped for adjustment and mechanical knobs are required
Solution Approach 1:
The patent replaces manual mechanical adjustment knobs with an automated digital control system. The adjusting signal generation circuit uses digital signal processing to automatically adjust the analog signal waveform, eliminating the need for mechanical volume knobs and manual intervention during encoder operation.
Solution Approach 2:
The encoder performs self-adjustment through the automatic adjusting signal generation circuit. The system monitors its own signal output and automatically generates adjusting signals to correct waveform distortions, secular changes, and amplitude variations without requiring external manual adjustment or temporary shutdown.
2Measurement precision
If manual analog signal adjustment is performed, then amplitude and offset can be corrected, but the encoder cannot maintain continuous operation during adjustment
Solution Approach 1:
The patent enables continuous operation during adjustment by automatically generating and applying correcting signals in real-time. The adjusting signal generation circuit continuously monitors the encoder's analog signal output and dynamically adjusts the waveform to maintain optimal performance without interrupting encoder operation.
Solution Approach 2:
The system implements a feedback mechanism where the adjusting signal generation circuit continuously monitors the encoder's analog signal characteristics (amplitude, offset, waveform) and automatically generates correcting signals based on detected deviations. This closed-loop feedback allows continuous adjustment without manual intervention or operation shutdown.
3Productivity
If digital signal processing is applied to correct position data, then correction can be performed without stopping the encoder, but the correction may be insufficient for secular changes
Solution Approach 1:
The patent applies preliminary correction by adjusting the analog signal waveform itself before it reaches the position detection circuit. The adjusting signal generation circuit proactively corrects secular changes and waveform distortions at the analog signal stage, preventing accuracy degradation before digital correction is even needed.
Solution Approach 2:
The patent introduces an intermediary analog signal adjustment stage between the encoder's sensing unit and the position detection circuit. The adjusting signal generation circuit acts as a mediator that automatically corrects waveform distortions and secular changes in the analog signal before digital processing, providing more effective correction than digital-only approaches.
Data Source
AI summary
An encoder signal processor comprises an analog signal adjustment circuit for adjusting, based on an adjusting signal, at least one of an offset and an amplitude of a sinusoidal analog signal with two phases having a 90-degree difference outputted in accordance with a travel of a target to be measured, a position detection circuit for calculating position data of a target to be measured based on a digital signal obtained through analog/digital conversion of an analog signal adjusted, a velocity change amount detection circuit for detecting a change amount of velocity per predetermined detection cycle from a velocity calculated based on position data outputted while a target to be measured is traveling at a constant velocity, and an adjusting signal generation circuit for generating an adjusting signal that minimizes the change amount of velocity detected and transmitting the adjusting signal to the analog signal adjustment circuit.