Redundant Optical Encoder for Reliable High-Resolution Shaft Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing encoders face challenges in ensuring reliable and fine-resolution detection of motor shaft rotation, particularly in systems that combine optical and magnetic detection methods, which can lead to inconsistencies and reduced reliability.
Innovation Solution
The encoder system incorporates two optical detectors with different resolutions for the shaft rotation detection, allowing for a comparison of their results to assess reliability, and includes a magnetic detector for additional verification, enabling fine-resolution detection and miniaturization while maintaining reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical and magnetic detection methods are combined, then detection coverage is improved, but detection consistency deteriorates
Solution Approach 1:
The patent combines two optical detection systems (first optical detector and second optical detector) into a unified encoder structure. Both detectors use the same optical principle and wavelength, ensuring consistent detection methodology while providing redundant measurement paths. This merging approach maintains detection versatility through multiple sensors while ensuring consistency through uniform optical detection principles.
Solution Approach 2:
The patent changes the parameter of detection methodology from mixed optical-magnetic to purely optical. By using the same wavelength light for both detectors and eliminating magnetic detection, the system maintains adaptability through redundant optical paths while achieving consistency through identical detection parameters and principles across all sensors.
2Measurement precision
If high-resolution optical detection is used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the optical detection function into two separate detectors, each with its own code disk and optical path. This segmentation allows each detector to be optimized for high resolution independently, while the modular structure manages complexity by dividing the system into distinct functional units that can be designed and calibrated separately.
Solution Approach 2:
The patent creates a redundant copy of the optical detection system with the second detector mirroring the first. Both detectors use the same wavelength light and similar structural components, allowing the system to achieve high measurement precision through redundant optical paths while managing complexity through standardized, repeatable design elements that can be manufactured and calibrated consistently.
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 approach enhances the reliability and sensitivity of rotation detection by comparing the outputs of the optical detectors and utilizing a magnetic detector for verification, ensuring consistent and precise feedback control of motor position and speed.
Implementation Method 1
a first code track that rotates together with the rotation shaft; and a first optical sensor that outputs a signal corresponding to rotation of the first code track based on light that has passed through the first code track
Implementation Method 2
a first optical sensor that outputs a signal corresponding to rotation of the first code track based on light that has passed through the first code track
Implementation Method 3
a second code track that rotates together with the rotation shaft; and a second optical sensor that outputs a signal corresponding to rotation of the second code track based on light that has passed through the second code track
Implementation Method 4
a second optical sensor that outputs a signal corresponding to rotation of the second code track based on light that has passed through the second code track
Data Source
AI summary
An encoder includes: an optical first detector configured to detect rotation of a rotation shaft; an optical second detector configured to detect the rotation of the rotation shaft; and circuitry configured to: execute a comparison between a result of detection of the first detector and a result of detection of the second detector; and transmit data including at least the result of detection of the first detector and a result of the comparison.