Optical Sensor Substrate Integration for Rotary Encoder Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotary encoders with separate light-emitting and light-receiving elements face challenges in positioning, leading to misregistration and instability in output due to erroneous positioning, especially with multiple light-receiving elements.
Innovation Solution
An optical sensor design with a substrate integrating a light-emitting element and four light-receiving elements, where the light-receiving elements are arranged at equal distances from a point on a plane, forming right angles, and the normal line through this point passes through the light-emitting element's emission point, facilitating easier positioning and stabilizing output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If light-emitting element and light-receiving element are placed on separate substrates, then device flexibility is improved, but positioning precision deteriorates leading to misregistration
Solution Approach 1:
The patent merges the light-emitting element and light-receiving elements onto a single substrate, eliminating the positioning errors that occur when separate substrates are assembled. This integration ensures precise alignment between the light-emitting range and light-receiving range without requiring complex positioning procedures.
2Measurement precision
If multiple light-receiving elements are used, then detection capability is improved, but output stability deteriorates due to misregistration variation
Solution Approach 1:
By integrating multiple light-receiving elements on a single substrate with the light-emitting element, the patent eliminates misregistration variations that would otherwise cause output instability. The unified substrate ensures consistent positioning relationships among all elements.
Solution Approach 2:
The patent positions the light-receiving elements at equal distances from a common reference point on the substrate, creating symmetric optical paths. This equipotential arrangement ensures that all light-receiving elements experience identical optical conditions, stabilizing their outputs.
3Reliability
If light-receiving elements are arranged at equal distances from a reference point, then output stability is improved, but device complexity increases
Solution Approach 1:
While the light-receiving elements are arranged symmetrically at equal distances from a reference point, the overall device maintains asymmetric functionality through the light-emitting element's specific positioning. This balanced approach achieves output stability without requiring complex asymmetric arrangements.
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 design simplifies positioning between the light-emitting and light-receiving elements, reduces output variation, and stabilizes the optical sensor's output, enabling accurate detection of angular positions.
Implementation Method 1
a light-emitting element that emits light
Implementation Method 2
four light-receiving elements that are provided at positions facing the light-emitting element and receive the light
Data Source
AI summary
An optical sensor including a light-emitting element, four light-receiving elements facing the light-emitting element, and a substrate at which the light-emitting element and the light-receiving elements are provided. The substrate includes a first portion at which the light-emitting element is provided and a second portion at which the light-receiving elements are provided, the first portion and the second portion being integrated. Respective distances from the four light-receiving elements to one point on a predetermined plane are equal, four line segments that connect the one point and centers of respective light-receiving regions of the four light-receiving elements form right angles with each other, and a normal line of the predetermined plane that passes through the one point passes through an emission point of the light of the light-emitting element or a center of an emission surface of the light of the light-emitting element.