Non-Sequential Rotary Encoder Layout for More Positions per Diameter
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Solution Overview
Problem
Rotary encoders typically require a large diameter to accommodate a finite number of positions, leading to increased size, weight, and cost, as the number of positions increases, limiting their compactness and ergonomics.
Innovation Solution
A rotary encoder with a non-sequential unique bit pattern is designed, where switches form connections based on a specific pattern to generate digital values that uniquely identify rotational positions, allowing for a more compact and efficient design by distributing switches radially around the knob, enabling a higher number of positions without increasing diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of positions in a rotary encoder is increased, then the encoding resolution is improved, but the diameter of the rotary encoder increases significantly
Solution Approach 1:
The patent transitions from sequential binary encoding to a non-sequential unique bit pattern arrangement, effectively changing the dimensional organization of the encoding positions. This allows multiple positions to be uniquely identified within a compact radial layout, increasing the number of distinguishable positions without proportionally increasing the encoder diameter.
Solution Approach 2:
The patent changes the fundamental parameter of the encoding sequence from sequential to non-sequential unique bit patterns. This parameter change enables more efficient use of the available radial space, allowing a higher number of positions to be encoded within the same diameter by optimizing the spatial distribution of switch connection locations.
2Measurement precision
If the number of positions in a rotary encoder is increased, then the encoding resolution is improved, but the weight of the rotary encoder increases
Solution Approach 1:
By reorganizing the encoding positions using non-sequential unique bit patterns, the patent reduces the radial space required, which directly reduces the overall size and consequently the weight of the rotary encoder for a given encoding resolution.
Solution Approach 2:
The patent segments the encoding positions into unique bit patterns distributed radially, allowing for a more compact arrangement that reduces material usage and overall weight while maintaining the required number of distinguishable positions.
3Measurement precision
If the number of positions in a rotary encoder is increased, then the encoding resolution is improved, but the cost of the rotary encoder increases
Solution Approach 1:
By changing the encoding parameter from sequential to non-sequential unique bit patterns, the patent optimizes the spatial distribution of switches and connections, reducing the overall component count and assembly complexity, which lowers manufacturing cost for high-resolution encoders.
Solution Approach 2:
The reorganized bit pattern arrangement reduces the radial dimension requirements, allowing for a more compact design with fewer materials and components, thereby reducing manufacturing cost while achieving higher encoding resolution.
Data Source
AI summary
An apparatus for rotary encoding includes a knob configured to be rotated. The apparatus also includes multiple switches each configured to selectively form or not form a connection based on a current rotational position of the knob. The apparatus further includes a controller configured to generate or use a digital value associated with the current rotational position of the knob. The digital value is defined by which switches have or have not formed connections. Locations where the switches form the connections are selected such that the digital values uniquely identify different rotational positions of the knob and are non-sequential as the knob is rotated.