Metal Optical Reflective Component for Encoder Alignment
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Solution Overview
Problem
Conventional optical reflective components are fragile and have complex manufacturing processes, making them difficult to integrate with rotating shafts and inefficient to produce, while existing optical encoders struggle with accurate alignment and pattern consistency.
Innovation Solution
An integrated optical reflective component made of metal, with an optical pattern formed by laser scribing, featuring even-width stripes arranged in a concentric annular distribution, allowing for precise coaxial alignment with the rotating shaft and simplified production using automated optical inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional glass encoding stripes are used with additional fixing components, then the optical encoding function is achieved, but the component becomes fragile and difficult to integrate with rotating shafts
Solution Approach 1:
The patent merges the optical encoding component with the rotating shaft by integrating the encoding stripes directly onto the shaft surface through coating or scribing methods. This eliminates the need for separate glass encoding plates and additional fixing components, creating a unified structure that is both robust and easy to integrate.
Solution Approach 2:
The patent replaces fragile glass encoding stripes with durable coatings or direct scribing on the rotating shaft. The encoding pattern is applied directly to the shaft surface using robust materials that can withstand mechanical stress, eliminating the fragility associated with glass components.
2Manufacturing precision
If conventional multi-step manufacturing processes are used for encoding stripes, then the optical pattern is formed, but production efficiency is reduced
Solution Approach 1:
The patent replaces conventional mechanical multi-step manufacturing processes (coating, exposure, development, etching) with direct laser scribing or coating methods. The laser scribing process directly creates the encoding pattern on the rotating shaft surface in a single step, eliminating multiple processing stages while maintaining high precision.
Solution Approach 2:
The patent changes the manufacturing approach from chemical-based photoresist processing to physical laser scribing or direct coating. This parameter change in the manufacturing method reduces the number of steps required while maintaining or improving the precision of the optical encoding pattern.
3Manufacturing precision
If conventional photoresist-based encoding stripe formation is used, then the optical pattern is created, but the process is too complicated to improve production efficiency
Solution Approach 1:
The patent replaces the complex chemical photoresist-based manufacturing process with direct laser scribing or coating methods. The laser scribing process uses focused laser beams to directly ablate or modify the surface material, creating precise encoding patterns without requiring photoresist application, exposure, development, or etching steps.
4Measurement precision
If glass encoding stripes are used with additional fixing components, then the optical encoding function is achieved, but alignment accuracy with the rotating shaft is difficult to ensure
Solution Approach 1:
The patent merges the encoding pattern creation process with the rotating shaft manufacturing process. The encoding stripes are created directly on the shaft surface through laser scribing or coating, ensuring automatic alignment with the shaft's rotational axis and eliminating the need for separate alignment and fixing operations.
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 solution enables robust and efficient production of optical encoders with improved alignment and pattern consistency, reducing processing time and enhancing the accuracy of optical reading by utilizing a metal-made optical reflective component with laser-scribed patterns.
Implementation Method 1
the optical pattern is formed, for example, by laser scribing
Implementation Method 2
the light source is positioned such that light from the light source is imaged into the detector when the light is reflected from the reflective stripes
Data Source
AI summary
An optical reflective component and an optical encoder using the same are disclosed. The optical reflective component includes a main body, an optical pattern, a first attaching portion and a second attaching portion. The main body has a first central axis and a reflective surface perpendicular to each other. The optical pattern is disposed on the reflective surface and centered at the central axis. The first attaching portion is centered at the first central axis of the main body and extends from the man body in a direction parallel to the first central axis. The first attaching portion has an inner wall. The second attaching portion has a plane perpendicular to the first central axis. The plane is connected to the inner wall. The main body, the first attaching portion and the second attaching portion are formed of a metal material and are integrally formed with the optical pattern.