Self-Correcting Encoder Signal Stabilization During Operation
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Solution Overview
Problem
Existing encoder calibration processes are limited to a single initial calibration, which does not account for variations in angular position and rotation speed due to thermal expansions and defects that occur over time.
Innovation Solution
The proposed solution involves an encoder system that includes an exciter, a sensor, and a controller capable of detecting errors in signal offset, gain, and phase in real-time. The controller calculates correction values to stabilize the signal, allowing the encoder to self-correct during operation without the need for a new calibration cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a reference encoder is used for calibration, then the encoder can be calibrated initially, but the calibration process becomes complex and requires additional hardware
Solution Approach 1:
The encoder system performs self-calibration using its own sensor signals without requiring an external reference encoder. The controller detects errors in the encoder's own signal and automatically corrects them, eliminating the need for additional calibration hardware and simplifying the overall system architecture.
Solution Approach 2:
The invention extracts the calibration function from the external reference encoder and integrates it into the encoder's own control system. By removing the dependency on external reference hardware, the system achieves the same calibration functionality with reduced complexity.
2Productivity
If calibration is performed only once in factory, then the encoder can be manufactured efficiently, but the encoder cannot adapt to thermal expansions and defects that occur over time
Solution Approach 1:
The calibration system transitions from a static, one-time factory calibration to a dynamic, continuous self-calibration process. The encoder automatically adjusts its calibration parameters during operation to compensate for thermal expansions and component defects that develop over time, maintaining reliability without impacting manufacturing efficiency.
Solution Approach 2:
Instead of performing calibration as a discrete one-time action during manufacturing, the system continuously performs calibration adjustments during normal operation. This continuous self-calibration ensures the encoder adapts to changing conditions throughout its operational life while maintaining manufacturing efficiency.
3Measurement precision
If signal correction values are calculated continuously, then the encoder maintains accuracy over time, but the processing requirements and complexity increase
Solution Approach 1:
The controller implements a feedback mechanism that continuously monitors the encoder's sensor signals and automatically calculates correction values based on detected errors. This closed-loop feedback system maintains high measurement precision by continuously adjusting for drift and defects without requiring complex external processing systems.
Data Source
AI summary
Novel tools and techniques are provided for implementing an encoder capable of performing a self-correction process, and more particularly methods, systems, and apparatuses are provided for implementing an encoder capable of performing a process to correct itself during operation of the encoder. In various embodiments, the encoder includes an exciter and a sensor capable of detecting a position of the exciter and generating a signal based on the position of the exciter. The encoder can then perform one or more steps to detect at least one of a first error in an offset of the signal, a second error in a gain of the signal, or a third error in a phase of the signal as the exciter is rotating and correct the signal from the sensor based on the detection of at least one of the first error, the second error, or the third error.