ENCODER APPARATUS
20220026243 · 2022-01-27
Assignee
Inventors
- Colin Keith HOWLEY (Stonehouse, GB)
- Simon Eliot McADAM (Nailsworth, GB)
- Adam Michael WHITING (Trowbridge, GB)
Cpc classification
International classification
Abstract
An incremental encoder apparatus including: a scale including a series of periodic features defining an optical incremental scale, and at least one magnetic reference mark; and a readhead. The readhead includes at least one incremental sensor configured to detect light from the optical incremental scale and to output at least one signal dependent thereon, and at least two analogue Hall sensors, each including at least two output terminal pairs, and each configured to switch repeatedly between each output terminal pair so as to reduce any inherent offset in the output of the analogue Hall sensor. The apparatus is configured to determine the presence of the reference mark from the outputs of the at least two analogue Hall sensors.
Claims
1. An incremental encoder apparatus comprising: a scale comprising a series of periodic features defining an optical incremental scale, and at least one magnetic reference mark; and a readhead comprising: at least one incremental sensor configured to detect light from the optical incremental scale and to output at least one signal dependent thereon, and at least two analogue Hall sensors, each comprising at least two output terminal pairs, and each configured to switch repeatedly between each output terminal pair so as to reduce any inherent offset in the output of the analogue Hall sensor, in which the apparatus is configured to generate a reference mark signal from the outputs of the at least two analogue Hall sensors.
2. An incremental encoder apparatus as claimed in claim 1, in which the apparatus is configured to determine a difference signal which is proportional to the difference of the outputs of the two analogue Hall sensors, and in which the apparatus is configured to generate a reference mark signal using said difference signal.
3. An incremental encoder apparatus as claimed in claim 2, in which the apparatus is configured to differentially amplify the outputs of the analogue Hall sensors to obtain said difference signal.
4. An incremental encoder apparatus as claimed in claim 2, in which the apparatus is configured to generate a reference mark signal in response to said signal crossing a predetermined threshold.
5. An incremental encoder apparatus as claimed in claim 1, in which the apparatus is configured to at least partially filter noise caused by said switching between the output terminal pairs.
6. An incremental encoder apparatus as claimed in claim 1, in which the apparatus is configured to at least partially filter noise having a frequency at which the switching occurs.
7. An incremental encoder apparatus as claimed in claim 1, in which the apparatus comprises a multi-pole filter configured to filter noise present in the output of the analogue Hall sensor.
8. An incremental encoder apparatus as claimed in claim 7, in which the multi-pole filter comprises at least first and second single-pole low-pass filters configured to filter noise present in the output of the analogue Hall sensor.
9. An incremental encoder apparatus as claimed in claim 1, in which the reference mark signal is repeatable to one period of the incremental scale, in at least one direction of travel.
10. An incremental encoder apparatus as claimed in claim 9, configured to generate a pair of phase-offset periodic incremental signals, and in which the reference mark signal is repeatable to ½ signal period.
11. An incremental encoder apparatus as claimed in claim 1, in which the ratio of the extent of the magnetic reference mark in the measuring dimension, to the incremental scale period is at least 50:1, optionally at least 75:1, for example at least 100:1.
12. An incremental encoder apparatus as claimed in claim 1, in which the period of the incremental scale is not greater than 50 μm.
13. An incremental encoder apparatus as claimed in claim 1, in which the extent of the magnetic reference mark in the measuring dimension is at least 0.5 mm.
14. An incremental encoder apparatus as claimed in claim 1, in which the apparatus comprises means for applying a positive phase shift to the outputs of the chopper-based Hall sensors.
15. An incremental encoder apparatus as claimed in claim 5, in which the apparatus comprises a filter comprising a zero configured to produce a positive phase shift in the filter.
16. A readhead for an encoder apparatus comprising: at least one incremental sensor configured to detect light from an optical incremental scale and to output at least one signal dependent thereon, and at least two analogue Hall sensors, each comprising at least two output terminal pairs, and each configured to switch repeatedly between each output terminal pair so as to reduce any inherent offset in the output of the analogue Hall sensor, in which the apparatus is configured to determine the presence of a magnetic reference mark from the outputs of the at least two analogue Hall sensors.
Description
[0030] Embodiments of the invention will now be described, by way of example only, with reference to the following drawings in which:
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041] With reference to
[0042] The readhead 14, mounted in register with the scale 4 and offset therefrom in the z-direction, is movable relative to the scale 4 in the y-direction. The readhead 14 includes a light source (not shown) directing light toward the scale 4 which, in conjunction with light reflected from the scale 4 (and optionally one or more optical components within the readhead, such as gratings, e.g. diffraction gratings), generate a periodic light pattern in the readhead 14. Relative movement of the scale 4 and readhead 14 results in a corresponding cyclic change in a resultant field, and thereby a cyclically varying light intensity modulation (e.g. movement of the periodic light pattern such as a fringe, for example an interference fringe). A plurality of photodetectors in the readhead, generate a plurality of electrical signals corresponding to the modulating light intensity. These electrical signals are combined to generate a pair of sinusoidally varying signals Q1, Q2, having a quadrature relationship, which are outputs of respective incremental signal lines 15 and 17. Possible optical configurations for the readhead, and the generation of signals Q1, Q2 is known per se from e.g. GB1504691, WO86/03833, WO87/07944, WO01/63215, and WO2017/042570.
[0043] For instance, the readhead 14 might include a diffraction grating located so as to interact with light from the scale to produce an interference fringe at a detector in the readhead. An example of how an interference fringe could be generated is explained in more detail with reference to
[0044]
[0045] For the sake of simplicity of illustration the ray diagrams in
[0046] The incremental detector 22 detects the interference fringe 26 to produce a signal which is output by the readhead 14 to an external device such as the interface 30.
[0047] In particular, relative movement of the readhead 14 and scale 4 causes movement of the interference fringes 26 relative to the incremental detector, the output of which can be processed to provide an incremental up/down count which enables an incremental measurement of displacement. For instance, as mentioned above, the readhead 14 can provide two signals in quadrature (that are 90 degrees out of phase from each other), and are commonly labelled as SIN and COS signals (even though they may not actually be sine or cosine signals), and in this case are labelled Q1 and Q2. If desired, the quadrature signals can be interpolated to provide an accurate measurement of the position of the readhead to less than one period of the repeating scale pattern. The provision of such quadrature signals by an encoder apparatus is well known in order to provide an indication of direction as well as relative movement of the readhead and scale.
[0048] In the embodiment described, the incremental detector 22 is in the form of an electrograting, which in other words is a photo-sensor array which comprises two or more sets of interdigitated/interlaced/interleaved photo-sensitive sensor elements (also referred to herein as “photodetectors” or “fingers”). Each set can, for example, detect a different phase of the interference fringe 26 at the detector 22. An example of an electrograting is illustrated in
[0049] As shown, in the embodiment described, the individual fingers/photodiodes/sensor elements extend substantially perpendicular to the length L of the incremental detector 22. Also, the individual fingers/photodiodes/sensor elements are substantially rectangular in shape. As will be understood, the invention is also applicable to other shaped and arranged sensor elements.
[0050] The output from each finger/photodiode in a set is combined to provide a single output, thereby resulting in four channel outputs: A′, B′, C′ and D′. These outputs are then used to obtain the quadrature signals Q1, Q2 (or SIN, COS). In particular, A′-C′ is used to provide a first signal (Q1) and B′-D′ is used to provide a second signal (Q2) which is 90 degrees out of phase from the first signal. Although in the specific embodiment the electrograting comprises four sets of photodiodes providing four the channels A′, B′, C′ and D′, this need not necessarily be the case. For example, the electrograting could comprise two sets of photodiodes providing just two channels A′ and B′.
[0051] The quadrature signals Q1, Q2 form the basis of an incremental count corresponding to the displacement of the readhead 14 relative to a reference position on the scale 10. Further, if desired, It is possible to resolve the movement of the readhead 14 relative to the scale 10 to within a fraction of a single cycle of the quadrature signals Q1, Q2; the signals Q1, Q2 may be thought of as generating a circular Lissajous
[0052] Attention will now turn to the readhead's magnetic reference mark detector arrangement. As illustrated in
[0053] An overview of how the circuity 70 generates the reference mark signal will now be provided with reference to
[0054] As shown in
[0055] As will be understood, in order for a reference mark to function as a good reference mark, it is important that the reference mark signal generated therefrom is always issued at the same point along the scale. In particular, it is desirable that the reference mark signal is repeatable to one unit resolution of the incremental system. For example, it is desirable for the reference mark signal to always be issued at the same count position. However, it has been found that this is difficult to achieve when using such chopper-based analogue Hall sensors. In particular, whilst such chopper-based analogue Hall sensors can be useful for minimising the adverse effects of any offset voltage and any drift issues, it has been found that the outputs of such sensors can be noisy due to the chopping/switching, and such “chopper/switching noise” can he sufficiently high so as affect the repeatability of the reference mark signal. This appears to be compounded by virtue of the reference mark signal being derived from the outputs of two chopper-based analogue Hall sensors, in particular being derived from the difference of the outputs of two chopper-based analogue Hall. This is because in some instances the chopper/switching noise constructively interferes and at other times destructively interferes, which in turn can significantly shift the position at which the OFF signal crosses the threshold.
[0056] In instances in which such chopper/switching noise does adversely affect the repeatability of the reference mark signal, it has been found that the circuitry 70 can be configured to at least partially filter such chopper/switching noise, so as to thereby improve the repeatability of the reference mark signal. One such arrangement is illustrated in
[0057] As shown, in
[0058] As will be understood, other ways of providing a multi-pole filter (arrangement/circuitry) include providing a single two-pole low-pass filter. Preferably, the break point (also known as the break frequency) of the poles is at least within an order of magnitude of each other, and ideally are substantially the same. The use of a multi-pole filter (arrangement/circuitry) has been found to be particularly beneficial in filtering out the chopper-noise because it helps to maximise the break point frequency so as to reduce circuit delay, so as to in turn maximise the speed at which the reference mark is repeatable. For example, the present inventors have found that even when using chopper-based Hall sensors, they are able to achieve repeatability of the reference mark up to speeds of 0.125 m/s (metres per second), in a system having an incremental scale pitch of 20 μm (microns) and with a magnetic reference mark having an extent of 2 mm (millimetres) in the measuring direction of the scale, and they are able to achieve repeatability of the reference mark up to speeds of 0.25 m/s, in a system having an incremental scale pitch of 40 μm (microns) and with a magnetic reference mark having an extent of 2 mm in the measuring direction of the scale.
[0059] The inventors found that the chopper-based analogue Hall sensors have an inherent operating bandwidth which introduces a negative phase shift into the Hall sensor outputs, which worsens with increasing operating speeds (of the readhead and scale). A negative phase shift is also introduced by the filtering arrangement of
[0060] Referring to
[0061] As shown, similar to the embodiment of
[0062] In contrast to the embodiment of
[0063] The ratio of the resistors 92 to (91+100) and also 96 to (93+101) set the DC gain of the differential amplifier.
[0064] It can be preferred that the resistance of resistors 91 and 93 are the same, the resistance of resistors 100 and 101 are the same, and the capacitance of capacitors 99 and 102 are the same, so that the effect on the outputs of the first 60 and second 62 Hall sensors are the same. However, as will be understood, this need not necessarily be the case.
[0065] As will be understood, the resistance of the resistors 91, 92, 93, 96, 100 and 101, and the capacitance of the capacitors 94, 98, 99 and 102, will be selected depending on the particular requirements of the encoder, and for instance on the desired zero and pole frequencies. For example, the pole frequencies for the arrangement of
[0066] (where: C78=capacitor 78; C94=capacitor 94; C98=capacitor 98; R77=resistor 77; R92=resistor 92; R96=resistor 96).
[0067] Also, the zero and pole frequencies for the arrangement of
[0068] (where: C94=capacitor 94; C98=capacitor 98; C99=capacitor 99; C102=, capacitor 102; R91=resistor 91; R92=resistor 92; R93=resistor 93; R96=resistor 96; R100=resistor 100; R101=resistor 101).
[0069] It should be noted that an advantage of the design of
[0070] In the embodiment of
[0071] In the above described embodiments, the incremental detector is located on the same side of the scale as the light source used to illuminate the scale (and so it is what is commonly referred to as a reflective system). However, it will be understood that other arrangements are possible. For example, at least the incremental detector could be located on a side of the scale opposite to the light source used to illuminate the scale (and so could be what is commonly referred to as a transmissive system).