Encoder readhead
09797751 · 2017-10-24
Assignee
Inventors
Cpc classification
International classification
Abstract
A readhead is provided for reading an absolute scale, optionally a passive magnetic scale, that encodes a series of data bits. The readhead includes a plurality of sensors, such as an array of Hall sensors, for producing a plurality of sensor signals. A plurality of signal combiners are also provided to receive at least two of the sensor signals and produce therefrom a combined sensor signal. A plurality of data bit extractors are arranged to receive at least two combined sensor signals and to determine the value of a data bit encoded in an associated absolute scale. The readhead also comprises an incremental signal generator for generating at least one incremental signal from the combined sensor signals produced by a plurality of the signal combiners. In this manner, both absolute and incremental position is measured.
Claims
1. A readhead arranged to read an absolute scale encoding a series of data bits, the readhead comprising: a plurality of sensors that are each arranged to produce a sensor signal indicative of measured magnetic field strength; a plurality of signal combiners, each signal combiner being arranged to receive at least two of the sensor signals produced by the plurality of sensors and to produce therefrom a combined sensor signal, the plurality of signal combiners thereby generating a plurality of combined sensor signals; a plurality of data bit extractors for generating absolute position data and arranged to receive the plurality of combined sensor signals, each data bit extractor being arranged to receive at least two of the combined sensor signals and to determine the value of a data bit encoded in an associated absolute scale; and an incremental signal generator arranged to receive at least two of the plurality of combined sensor signals also received by the data bit extractors and to generate at least one incremental signal from the at least two combined sensor signals.
2. A readhead according to claim 1 arranged to read an absolute magnetic scale, wherein the plurality of sensors comprise a plurality of magnetic sensors.
3. A readhead according to claim 1, wherein the at least one incremental signal comprises a pair of quadrature phase signals.
4. A readhead according to claim 1, wherein the incremental signal generator applies a weighting to the at least two combined sensor signals when generating the at least one incremental signal.
5. A readhead according to claim 1, comprising a first interpolator arranged to interpolate the at least one incremental signal to provide a first interpolated signal.
6. A readhead according to claim 5, wherein each data bit extractor determines the data bit value by analysis of a selected one of the at least two combined sensor signals received thereby, wherein each data bit extractor receives the first interpolated signal and selects which combined sensor signal to analyse based on the first interpolated signal.
7. A readhead according to claim 1, comprising: a second interpolator arranged to interpolate the at least one incremental signal to provide a second interpolated signal; and an absolute position calculation unit arranged to combine incremental position data from the second interpolated signal with absolute position data from the plurality of data bit extractors, wherein the absolute position calculation unit generates absolute position data having a finer resolution than the bit length of an associated absolute scale read by the readhead.
8. A readhead according to claim 1, wherein the plurality of sensors are substantially evenly spaced apart from one another.
9. A readhead according to claim 1 adapted to read an absolute scale that comprises a series of data bits of bit length L, wherein the plurality of sensors of the readhead are spaced apart so as to provide M sensors per bit length L, wherein M is an integer of two or more.
10. A readhead according to claim 9 adapted to read an absolute scale that comprises a series of codewords formed from N data bits, N being an integer value of two or more, wherein the readhead comprises J sensors, J being greater than or equal to the product of N and M.
11. A readhead according to claim 1, wherein the combined sensor signal generated by each signal combiner is derived from the difference between a pair of sensor signals produced by a selected pair of the plurality of sensors, wherein each such selected pair of sensors is spaced apart by substantially half the bit length L of the series of data bits of the associated absolute scale.
12. A readhead according to claim 1, wherein each signal combiner generates its combined sensor signal by combining the sensor signals from a plurality of adjacent sensors of the plurality of sensors.
13. A readhead according to claim 1, wherein the plurality of sensors comprise a plurality of magnetic sensors and the readhead further comprises a magnet.
14. An encoder device comprising, a readhead according to claim 1 and an absolute scale, wherein the absolute scale comprises a series of data bits of bit length L and the readhead comprises an integer number of sensors per bit length L.
15. An encoder device according to claim 14, wherein the absolute scale comprises a passive absolute magnetic scale comprising a scale member and a plurality of scale markings arranged to encode the series of data bits, wherein the scale markings have a different magnetic permeability than the scale member.
16. An encoder device according to claim 14, wherein the absolute scale comprises a rod.
17. An encoder device comprising: the readhead according to claim 1; and an absolute scale encoding a series of data bits.
18. A readhead according to claim 1, wherein the data bit encodes a binary value.
19. A readhead according to claim 1, wherein the data bit is a multi-level data bit.
20. A readhead according to claim 19, wherein the multi-level data bit encodes three different states.
21. A readhead according to claim 1, wherein the at least one incremental signal is received by the plurality of data bit extractors.
22. A readhead arranged to read an absolute scale encoding a series of data bits, the readhead comprising; a plurality of sensors arranged to produce a plurality of sensor signals; a plurality of signal combiners, each signal combiner arranged to receive at least two of the sensor signals and to produce therefrom a combined sensor signal, and each signal combiner arranged to receive its combined sensor signal by combining the sensor signals from a plurality of adjacent sensors of the plurality of sensors; a plurality of data bit extractors, each data bit extractor being arranged to receive at least two combined sensor signals and to determine the value of a data bit encoded in an associated absolute scale; and an incremental signal generator arranged to generate at least one incremental signal from the combined sensor signals produced by a plurality of the signal combiners, wherein the plurality of signal combiners are arranged to generate a plurality of combined sensor signals (Si) from the plurality of sensor signals (Hi) produced by the plurality of sensors in accordance with the summation scheme:
S.sub.i=H.sub.i−H.sub.i+1−H.sub.i+2+H.sub.i+3; i=1 . . . (4.Math.N) N being the number of data bits in each codeword encoded by the associated absolute scale, the readhead comprising 4N+3 sensors, and the sensors being spaced apart so as to provide four sensors per bit length L of the associated absolute scale.
23. An encoder device comprising: a passive absolute magnetic scale comprising a scale member and a plurality of scale markings arranged to encode a series of data bits of bit length L, the scale markings having a different magnetic permeability than the scale member, the plurality of scale markings being a plurality of grooves, the plurality of grooves comprising grooves of at least a first groove type and a second groove type, the magnetic permeability of the passive absolute magnetic scale in the locality of grooves of the first groove type being different than the magnetic permeability of the passive absolute magnetic scale in the locality of grooves of the second groove type, and a groove of the first groove type indicating a data bit having a first value and a groove of the second groove type indicating a data bit having a second value; and a readhead arranged to read an absolute scale encoding a series of data bits, the readhead comprising; a plurality of sensors arranged to produce a plurality of sensor signals, the readhead comprising an integer number of sensors per bit length L, a plurality of signal combiners, each signal combiner being arranged to receive at least two of the sensor signals and to produce therefrom a combined sensor signal, a plurality of data bit extractors, each data bit extractor being arranged to receive at least two combined sensor signals and to determine the value of a data bit encoded in an associated absolute scale, and an incremental signal generator arranged to generate at least one incremental signal from the combined sensor signals produced by a plurality of the signal combiners.
Description
(1) The invention will now be described, by way of example only, with reference to the accompanying drawings in which;
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10) Referring to
(11)
(12) Referring to
(13) The electronics of the readhead unit, which are described in more detail below with reference to
(14) To explain the operation of the readhead, the signal from each of the various Hall sensors can be denoted as;
H.sub.i; i=1 . . . (4.Math.N+3) (1)
where N is the word length of the binary sequence and there are four Hall sensors per bit length (L). Although four Hall sensors per bit length are described in the present example, more or fewer sensors per bit length could be provided.
(15) Absolute position information is extracted from the Hall sensor signals (H.sub.i) by firstly generating a plurality of summed signals (S.sub.i). Two examples of suitable summation schemes are outlined below, but other summation schemes could be used.
(16) A first example of a summation scheme that can be used to generate summed signals (S.sub.i) from the Hall sensor signals (H.sub.i) can be described as follows;
S.sub.i=H.sub.i−H.sub.i+2; i=1 . . . 4.Math.N (2)
(17) Alternatively, a second summation scheme may be used:
S.sub.i=H.sub.i−H.sub.i+1−H.sub.i+2+H.sub.i+3; i=1 . . . (4.Math.N) (3)
(18) In each example, a series (S.sub.1 to S.sub.4.Math.N) of summed signals are produced. The binary value of the data bits encoded in the associated scale can then be obtained from the values of an appropriate set of such summed signals. For example, the value of a first absolute data bit may be found from an appropriate one of the summed signal S.sub.1-S.sub.4, the value of a second absolute data bit may be found from one of the summed signal S.sub.5-S.sub.8, etc. Extracting absolute data from such summed signals in this manner is described in detail with reference to
(19) In addition to extracting absolute data, it has been found that the summed signals (S.sub.i) can also generate two periodic (sin/cos) signals that can be used to increase the resolution of the encoder. These signals are analogous to the incremental (quadrature phase) signals produced in incremental systems by directly combining the outputs of the Hall sensors, but are instead extracted from a combination of the summed signals that are used to generate absolute data. It should be noted that, for generating such incremental signals, the second summation scheme of equation (3) is typically preferred as it reduces the effects of any inhomogeneity in the magnetic field of the permanent magnet to a greater extent than the first scheme of equation (2). However, either summation scheme can be used.
(20) The summed signals (S.sub.i) produced by either of the above described summation schemes can be used to generate two periodically varying signals (Sin and Cos) that each have a period equal to the bit length (L) via the expressions:
(21)
(22) It is also possible to generate such sine and cosine signals from the expressions:
(23)
(24) The value w.sub.i contained in the above equations (4) to (7) may be set to a constant value (e.g. unity) to provide an unweighted summation of the various summed signals (S.sub.i). Alternatively, the value of w.sub.i may be defined by an expression that causes a different weighting to be applied to the various summed signals. It has been found to be particularly advantageous to apply a so-called window function to the summation; this reduces the contribution to the Sin/Cos signals from summed signals that are derived from Hall sensors near the ends of the Hall sensor array. In particular, applying such a window function has been found to reduce higher harmonic contributions to the Sin/Cos signals thereby reducing the sub-divisional error when interpolating those signals. The skilled person would be aware of the numerous window functions that could be applied (e.g. Hann, Gauss, Triangular, Hamming functions etc). In particular, the following Hamming function may be used:
(25)
(26) The Sin and Cos (i.e. quadrature phase) signals of equations (4) and (5) and of equations (6) and (7) thus provide information about the relative position of the readhead and associated scale. Interpolation of such quadrature phase signals, e.g. using interpolation techniques employed for incremental encoders, can provide positional information having a finer resolution than the bit length. In particular, it has been found that an interpolation factor of up to around 500 can be employed. The Sin and Cos signals described above can thus be used to greatly increase the resolution of the position of the encoder relative to the scale.
(27) The combination of incremental (quadrature phase) and absolute data derived from the same Hall sensor elements reading the same scale track, thus provides a high resolution absolute encoder. The absolute code words provide coarse position information whilst the Sin/Cos signals are interpolated to provide much finer (sub-bit length) resolution. In particular, the interpolated incremental position measurement information is added to coarse absolute position information to provide a resultant (high resolution) absolute position measurement.
(28) The above described method has the advantage of not requiring two discrete tracks of markers. The single track does not, however, have a completely periodic variation in magnetic properties along its length thereby affecting the amplitude of the quadrature phase (Sin and Cos) signals. In other words, the use of full and half depth grooves to encode the absolute position data has an effect on the amplitude of the quadrature phase (Sin and Cos) signals thereby reducing the interpolation factor that can be applied when obtaining the incremental position data.
(29) The scale pattern shown in
(30) It should also be noted that varying the groove depth is only one way in which absolute data may be encoded without significantly degrading the Sin and Cos signals.
(31) Referring to
(32) It can thus be seen that the exact form of the different groove types is immaterial. It is simply necessary for the two different types of groove to provide measurably different magnetic properties that can be sensed by the associated readhead whilst degrading the Sin and Cos signals by the least amount possible. The two different types of groove could thus vary in both width and depth. Alternatively, the different groove types could have different cross-sectional profiles that provide the measurable difference in magnetic properties. The different groove types could also be provided by using a plurality of different sub-grooves (e.g. dots or fine lines) or by forming different groove types by infilling grooves with materials of different magnetic permeability. Although a binary arrangement is shown, it would also be possible to provide three or more different types of grooves that could be distinguished from one another. In such a manner, the length of codeword could be reduced.
(33) Referring to
(34) Referring to
(35)
(36) It is desirable to determine the absolute position of the piston rod 62 relative to the casing 64; for example, in case power is momentary lost or on start-up. It is, however, usual for the piston rod 62 to be freely rotatable relative to the casing 64. The use of prior art systems in which incremental and absolute tracks are placed side-by-side can thus be seen to be unsuitable for such an application. In particular, rotation of the piston rod would cause misalignment between the incremental and absolute tracks and their respective readheads.
(37) The piston rod 62 of
(38) It should be noted that the grooves formed in the scale need not be empty or fluid filled. If a magnetic scale substrate is used, the grooves may be filled with a non-magnetic solid material (e.g. copper, chromium, ceramic etc). Providing a non-magnetic scale substrate and magnetic groove fillings would also be possible. Filling the grooves in this manner still provides the necessary variation in magnetic properties but also allows a smooth scale surface to be provided. Providing such a smooth surface is especially advantageous for hydraulic cylinders where a tight fluid seal 70 with the scale carrying piston rod is required.
(39) Referring now to
(40)
(41) A plurality of summing devices 84 are also provided to generate summed (difference) signals S.sub.i from the Hall sensor output signals H.sub.i as defined in equation (2) above. In particular, it can be seen that the first summed signal S.sub.1 is generated from the difference between the first Hall sensor signal H.sub.1 and the third Hall sensor signal H.sub.3, the second summed signal S.sub.2 is generated from the difference between the second Hall sensor signal H.sub.2 and the fourth Hall sensor signal H.sub.4, etc. In other words, each summed signal S is generated from signals produced by a pair of Hall sensors that are spaced apart by half the bit length.
(42) A plurality of signal selectors 86a-86n (collectively referred to as the signal selectors 86) are provided to receive the summed signals produced by the plurality of summing devices 84. The number of signal selectors 86 is chosen to be equal to the word length that is to be read from the scale. Each signal selector 86 receives four of the summed signals. In particular, the first signal selector 86a receives summed signals S.sub.1 to S.sub.4, the second signal selector 86b receives signals S.sub.5 to S.sub.8, the third signal selector 86c receives signals S.sub.9 to S.sub.12 etc. The purpose of each signal selector 86 is to select which one of the four summed signals it receives should be used to determine the presence or absence of a groove in the scale and therefore whether that data bit encodes a logical “1” or “0” value. This selection process, which relies on receipt of the coarse interpolated position signal described below, means that the data encoded in the scale 80 can be read with the scale located in an arbitrary position relative to the array of Hall sensors 82. A parallel series of data bits corresponding to the word encoded in the scale are thus output by the signal selectors 86.
(43) In addition to being used to generate absolute data, the summed signals S are also combined in accordance with equations (4) and (5) or equations (6) and (7) above to generate a pair of sin/cos signals. In other, words, the summed signals S.sub.i used to provide the absolute data information are also used to generate an incremental signal.
(44) In particular, a first combined signal C.sub.1 is generated from the sum of every fourth summed signal starting at S.sub.1; i.e. C.sub.1 is produced by combining summed signals S.sub.1, S.sub.5, S.sub.9, S.sub.13 etc. A second combined signal C.sub.2 is generated from the sum of every fourth summed signal starting at S.sub.3 (i.e. the summation of S.sub.3, S.sub.7, S.sub.11, S.sub.15 etc). A third combined signal C.sub.3 is generated from the sum of every fourth summed signal starting at S.sub.2 (i.e. the summation of S.sub.2, S.sub.6, S.sub.10, S.sub.14 etc). A fourth combined signal C.sub.4 is generated from the sum of every fourth summed signal starting at S.sub.4 (i.e. the summation of S.sub.4, S.sub.8, S.sub.12, S.sub.16 etc). A first summing device 88 provides a sin signal from the difference between the first and second combined signals C.sub.1 and C.sub.2 and a second summing device 90 provides a cosine signal from the difference between the third and fourth combined signals C.sub.3 and C.sub.4.
(45) An interpolator unit 92 receives the sine and cosine signals from the first and second summing devices 88 and 90. The interpolator unit 92 applies an interpolation factor of four and thus outputs a coarse incremental signal 94 that indicates the coarse relative phase of the alignment between the scale 80 and the array of Hall sensors 82 within a phase quadrant (i.e. with a 90° phase range). Each signal selector 86 receives this coarse incremental signal and uses it to determine which one of the four summed signals that it receives is appropriately aligned so as to read the required data bit of the scale. In the example shown in
(46) The circuit of
(47)
(48) The circuit of