Optical element
09952068 ยท 2018-04-24
Assignee
Inventors
Cpc classification
International classification
Abstract
An optical element for generating diffraction orders for an encoder apparatus, in which the optical element includes an array of diffraction features arranged such that the spacing between the centers of adjacent diffraction features varies irregularly from one pair of adjacent features to the next.
Claims
1. An encoder apparatus for determining movement between two relatively moveable parts of an apparatus, the encoder apparatus comprising: a detector; and at least one optical element comprising at least one series of consecutive diffraction features for diffracting electromagnetic radiation from a source into diffraction orders and which are for contributing to the production at the detector of a signal varying with movement between the two parts, wherein the diffraction features in said at least one series are shifted from a nominally regular spacing such that the spacing between the centres of adjacent diffraction features selectively varies irregularly from one pair of adjacent diffraction features to the next, each feature being shifted by a selected predetermined amount so as to substantially eliminate at least one n.sup.th diffraction order whilst maintaining the existence of the 1.sup.st and at least one selected m.sup.th diffraction order, such that said 1.sup.st and selected m.sup.th diffraction orders contribute to the production at the detector of the signal varying with movement between the two parts.
2. An encoder apparatus as claimed in claim 1, in which the encoder apparatus comprises a readhead comprising the detector and a diffraction grating, and optionally in which the encoder apparatus comprises a scale and the diffraction grating is configured to interact with electromagnetic radiation from the scale to effect the recombination of diffraction orders at the detector.
3. An encoder apparatus as claimed in claim 2, in which the readhead's diffraction grating comprises said at least one optical element.
4. An encoder apparatus as claimed in claim 1, in which the encoder apparatus comprises a scale which comprises said at least one optical element, and optionally, in which the scale comprises a reference mark between two series of consecutive diffraction features.
5. An encoder apparatus as claimed in claim 1, in which the range of the variation in the spacing between the centres of adjacent diffraction features in said at least one set of diffraction features is not less than 1/200.sup.th of the average period of the diffraction grating's features.
6. An encoder apparatus as claimed in claim 1, in which the diffraction features are arranged such that the ratio of the intensity of the 1.sup.st order to the 5.sup.th order is at least 100:1, and/or the ratio of the intensity of the 1.sup.st order to the 7.sup.th order is at least 150:1.
7. An encoder apparatus as claimed in claim 1, in which the spacing between adjacent diffraction features varies irregularly from one pair of adjacent features to the next, such that the signal output by the detector is substantially harmonic free.
8. An encoder apparatus as claimed in claim 1, in which said set of diffraction features is repeated at least once along the length of the optical element, and optionally repeated at least once within said series of consecutive diffraction features.
9. An encoder apparatus as claimed in claim 1, in which said set of diffraction features comprises at least five diffraction features.
10. An encoder apparatus as claimed claim 1, in which the spacing between the centres of adjacent diffraction features varies irregularly from one pair of adjacent diffraction features to the next along the entire length of the optical element.
11. An encoder apparatus as claimed in claim 1, wherein shifting each of the features by the selected predetermined amount reduces harmonics in an interference fringe at the detector.
12. An optical element for generating diffraction orders comprising at least one series of consecutive diffraction features for diffracting electromagnetic radiation from a source into diffraction orders, wherein the diffraction features in said at least one series are shifted from a nominally regular spacing such that the spacing between the centres of adjacent diffraction features selectively varies irregularly from one pair of adjacent diffraction features to the next, each feature being shifted by a selected predetermined amount so as to substantially eliminate at least one n.sup.th diffraction order whilst maintaining the existence of the 1.sup.st and at least one selected m.sup.th diffraction order.
13. An optical element as claimed in claim 12, in which the range of the variation in the spacing between the centres of adjacent diffraction features in said series of diffraction features is not less than 1/200.sup.th of the average period of the diffraction grating's features.
14. An optical element as claimed in claim 12, in which the optical element is a diffraction grating for an encoder readhead.
15. An optical element as claimed in claim 12, in which the diffraction features are arranged such that the ratio of the intensity of the 1.sup.st order to the 5.sup.th order generated by the optical element is at least 100:1, and/or the ratio of the intensity of the 1.sup.st order to the 7.sup.th order generated by the optical element is at least 150:1.
16. An optical element as claimed in claim 12, in which the spacing between the centres of adjacent diffraction features varies irregularly from one pair of adjacent diffraction features to the next along the entire length of the optical element.
17. An optical element as claimed in claim 12, in which said series of diffraction features comprises at least five diffraction features.
18. A readhead for an encoder apparatus comprising a detector and a diffraction grating comprising at least one series of consecutive diffraction features for diffracting electromagnetic radiation from a source into diffraction orders, wherein the diffraction features in said at least one series are shifted from a nominally regular spacing such that the spacing between the centres of adjacent diffraction features selectively varies irregularly from one pair of adjacent diffraction features to the next, each feature being shifted by a selected predetermined amount so as to substantially eliminate at least one n.sup.th diffraction order whilst maintain the existence of the 1.sup.st and at least one selected m.sup.th diffraction order, such that said 1.sup.st and selected m.sup.th diffraction orders can contribute to the production of an interference signal at the detector.
19. A readhead as claimed in claim 18, in which the range of the variation in the spacing between the centres of adjacent diffraction features is not less than 1/200.sup.th of the average period of the diffraction grating's features.
20. A readhead as claimed in claim 18, in which the diffraction features are arranged such that the ratio of the intensity of the 1.sup.st order to the 5.sup.th order generated by the diffraction grating is at least 100:1, and/or the ratio of the intensity of the 1.sup.st order to the 7.sup.th order generated by the diffraction grating is at least 150:1.
21. A readhead as claimed in claim 18, in which the spacing between the centres of adjacent diffraction features varies irregularly from one pair of adjacent diffraction features to the next along the entire length of the diffraction grating.
22. A readhead as claimed in claim 18, in which the diffraction grating comprises an array of at least five diffraction features.
23. A method of manufacturing a diffraction grating for an encoder apparatus comprising determining a select arrangement of diffraction features such that the spacing between the centres of adjacent diffraction features varies irregularly from one pair of adjacent diffraction features to the next such that at least one n.sup.th diffraction order is substantially eliminated whilst the existence of the 1.sup.st and at least one selected m.sup.th diffraction order is maintained to such a level that said 1.sup.st and selected m.sup.th diffraction orders can contribute to the production of an interference signal at a detector of the encoder apparatus, and forming diffraction features on a substrate according to said select arrangement.
Description
(1) Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
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(12) Referring to
(13) In the embodiment described the scale 4 is an amplitude scale (in that it controls the amplitude of light leaving the scale toward the readhead) and comprises a substrate which has periodic features 10 in the form of dark/relatively non-reflective lines 10 made on an otherwise relatively reflective substrate such that between the periodic features 10 the scale is relatively reflective 8. Of course, the scale's periodic features could be made in other ways, such as for example by forming relatively reflective lines on an otherwise relatively non-reflective substrate, or even by forming both the relatively reflective and non-reflective lines on a substrate. As will also be understood, the periodic markings 10 could be provided in other ways, for example, the scale's features or marks could be provided in the form of facets or lines which reflect the light toward and away from the readhead. Furthermore, the scale 4 could be a phase scale, in which peaks and pits in the scale modulate the phase of light leaving the scale toward the readhead. In the embodiment described the scale's substrate is metal, although as will be understood other materials such as glass for instance could be used. The periodic marks 10 form the incremental scale facilitating measurement along the X axis (the measurement dimension). As will be understood, a reference mark can be provided either next to or embedded within the periodic marks making up the incremental scale. Details of such reference marks are well known and for instance described in U.S. Pat. No. 7,659,992, the content of which is incorporated into this specification by this reference.
(14) As shown in
(15) With reference to
(16) The detector 16 detects the resultant field (e.g. the interference fringes) to produce a signal which is output by the readhead via interface 20 and cable 22 to an external device. In particular, relative movement of the readhead 6 and scale 4 causes a change in the resultant field (e.g. movement of the interference fringes relative to the detector 16 or a change in intensity of the modulated spot(s)) at the detector 16, the output of which can be processed to provide an incremental up/down count which enables an incremental measurement of displacement. As shown in
(17) The detector 16 can comprise a plurality of photodiodes, for example. In particular, as will be understood, in embodiments in which an interference fringe 17 is produced at the detector 16, the detector 16 can be in the form of an electrograting, which in other words is a photo-sensor array which can for example comprise two or more sets of interdigitated/interlaced photo-sensitive sensors, each set detecting a different phase of the interference fringe 17 at the detector 16. An example is illustrated in
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(19) As will be understood, the diffraction grating 114 is not shown to scale and is merely schematic to aid illustration of the invention. In the embodiment described the diffraction grating is a phase grating. This means that the diffraction features 130 manipulate (in other words modulate) the phase of the light passing through/reflected off the diffraction grating in order to create the diffraction orders. This could be achieved for example by the depth of the grating being different at the diffraction features (e.g. the depth of the diffraction grating substrate at the features illustrated by the dark bars 130 could be shallower than that at the features illustrated by the light bars 132). Accordingly, the dark 130 and light 132 bars in
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(21) In the example described the width w of the diffraction feature 30 of diffraction grating 14 (that is their size taken in a dimension parallel to the extent of the series of diffraction features) is constant for all the diffraction features 30. However, this need not necessarily be the case and their widths could vary.
(22) In the embodiment described above in connection with
(23) In the embodiment described above in connection with
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(25) The table below gives an example of another embodiment for a phase diffraction grating according to the invention. In this case, the table represents the shift of each feature from a nominal feature spacing of 46.67 m (micron) (and hence width of 23.34 m (micron)) which would be suitable for use in an encoder having an amplitude scale of 40 m (micron).
(26) TABLE-US-00001 Offset from nominal feature Feature number spacing (m (micron)) 1 3.49 2 6.98 3 6.98 4 4.36 5 6.11 6 3.49 7 4.36 8 3.49 9 6.11 10 6.98 11 6.11 12 3.49 13 3.49 14 4.36 15 3.49 16 0.87 17 2.62 18 1.75 19 0.00 20 0.00 21 2.62 22 0.87 23 0.00 24 0.00
(27) In the above embodiments, the spacing between adjacent pairs of diffraction features varies because the diffraction grating has been generated according to a process in which the diffraction features have been deliberately/purposefully shifted from their nominally periodic/regular position by a select amount so as to control the diffraction orders produced by the diffraction grating. The process by which the shift of each feature from its nominally periodic/regular position can be determined could for instance involve an iterative algorithm, such as for example a Direct Binary Search. Such a process can involve modelling the behaviour of the encoder system and iteratively going through multiple configurations in order to arrive at an optimum solution via a minimisation process.
(28) As will be understood, the particular arrangement of the diffraction features 30 on the diffraction grating 14 will depend on many factors including the type of encoder the diffraction grating is to be used in and/or what and/or how the diffraction orders are to be controlled. For instance, in some circumstances it might be desirable to attenuate the +/3.sup.rd diffraction order whereas in other circumstances it might be desirable to strengthen the +/5.sup.th diffraction order. Accordingly, the particular arrangement of diffraction features needed to provide for these different scenarios will be different.
(29) As will be understood, the extent of shift is grossly exaggerated in
(30) As mentioned above it has been found that providing for such irregular variation in the spacing between adjacent diffraction features means that the placement of such diffraction features can be selected so as to control the diffraction orders created by the diffraction grating. Accordingly, for example, as described above it can be preferred that the intensity of the +/5.sup.th diffraction order be minimised in order to improve the quality of the resultant field produced at the detector 16, e.g. in order to remove harmonics in the signal produced by the detector 16. It has been found that a diffraction grating according to the present invention can be used to achieve this. For example,
(31) As can be seen, in this case, the diffraction grating according to the invention provides a measured ratio of the intensity of the 1.sup.st order to the 5.sup.th order which is above 800:1, and provides a measured ratio of the intensity of 1.sup.st order to the 7.sup.th order which is above 3000:1:
(32) In the embodiments described above, it is the diffraction grating's diffraction features that have been arranged such that their spacing varies irregularly in order to improve the signal output by the detector. However, this need not necessarily be the case, and other optical elements, such as for instance the scale's diffraction features 10 (or 8) could instead, or in addition, be configured such that their spacing varies irregularly so as to control the diffraction orders created by the diffraction grating in order to improve the quality of the resultant field produced at the detector 16, e.g. in order to remove harmonics in the signal produced by the detector 16. Again, this could be achieved by using an iterative process as described above in order to determine the spacing of the features.
(33) Accordingly, the arrangement shown in
(34) In the embodiments described above, the encoder apparatus comprises a diffraction grating in the readhead, but this need not necessarily be the case. Indeed, it is possible that no diffraction grating is needed at all. In this case the only optical element according to the invention is the scale. Such an encoder is for example described in US2003/0010906.
(35) Furthermore, in the embodiment described above light from the source interacts with the scale before the diffraction grating in the readhead, but as will be understood this need not necessarily be the case. For instance, the encoder apparatus could be configured such that the light from the source interacts with a diffraction grating (e.g. in the readhead) before it interacts with a scale (and optionally also interacts with another or the same diffraction grating (e.g. in the readhead) after the scale).
(36) In the embodiments described above, all of the diffraction grating's diffraction features, and/or the all of the scale's diffraction features are arranged such that their spacing between the centres of adjacent diffraction features varies irregularly from one pair of adjacent diffraction features to the next. This need not be the case. For instance, only some of them need be arranged this way, with the others being arranged with non-irregular spacing, e.g. being constantly spaced.