Optical Encoder with Dual-Width Apertures for Cost Reduction
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Solution Overview
Problem
The use of multiple optical encoders in rotation mechanisms, such as robotic arms, increases manufacturing costs without providing a significant advantage in determining position and motion accuracy.
Innovation Solution
A single optical encoder with a coding disc featuring apertures of different widths is used to detect both the rotation angle and the limit angle, allowing for the determination of position and motion using a single device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple optical encoders are used to detect position and limit angle, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the functions of two separate optical encoders into a single encoder by using a coding disc with two types of apertures (first apertures and second apertures) that simultaneously provide position information and limit angle information. This merging approach maintains measurement precision while reducing device complexity and manufacturing cost.
Solution Approach 2:
The single optical encoder is designed with multi-functionality through the coding disc structure that includes both first apertures (for position detection) and second apertures (for limit angle detection). This universal design allows one encoder to perform the functions that previously required two separate encoders.
2Measurement precision
If two optical encoders are used at the joint part, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the detection functions into a single encoder unit, reducing the number of components that need to be manufactured and assembled. The coding disc with differentiated apertures provides both rotation angle and limit angle information from one encoder, thereby reducing manufacturing cost while maintaining precision.
Solution Approach 2:
The coding disc uses apertures with different parameters (widths, patterns, or configurations) to encode different types of information. The first apertures and second apertures have different characteristics that allow the single encoder to distinguish between position and limit angle, achieving the functionality of two encoders with one.
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 configuration reduces manufacturing costs while maintaining accurate detection of rotation angles and limit positions, enhancing the competitiveness of rotation mechanisms.
Implementation Method 1
The light emitter has a light emitting region. The optical sensor has an optical sensing region facing the light emitting region.
Implementation Method 2
The optical sensor has an optical sensing region facing the light emitting region.
Data Source
AI summary
A coding disc having a first surface and a second surface opposite to the first surface is provided. The coding disc includes a first aperture and a second aperture. The first aperture penetrates the coding disc from the first surface of the coding disc to the second surface of the coding disc. The first aperture has a first width. The second aperture penetrates the coding disc from the first surface of the coding disc to the second surface of the coding disc. The second aperture has a second width. The second width of the second aperture is different from the first width of the first aperture.