TWI803545B - Dual absolute encoder assembly and actuator assembly using the same - Google Patents

Abstract

An exemplary encoder assembly includes a substrate, a first encoder, and a second encoder. The substrate has two or more position sensors, each position sensor being configured for detecting a rotary position of a shaft or other rotating element of a machine. The first encoder includes at least one first position sensor of the two or more position sensors. The at least one first position sensor is disposed on the substrate for off-axis alignment with the shaft or other rotating element of the machine. The second encoder includes a second position sensor of the two or more position sensors, the second position sensor being disposed on the substrate for on-axis or off-axis alignment with the shaft or other rotating element of the machine. Each position sensor is configured to detect different or common signal types, and a signal type of the second position sensor excludes optical signals.

Description

Double absolute encoder unit and actuator unit using it

The present invention relates generally to an absolute encoder, and more particularly to a dual magnetic absolute encoder.

Encoders are used in a wide variety of products that require speed and/or position control of electric motors. An encoder is a sensor that converts linear mechanical motion or angular mechanical motion into an electrical signal. Linear encoders can be used to measure and indicate the position of a movable member. Rotary encoders are used to measure the angular position of rotating components in a device or system. In robotic systems, for example, a rotary encoder can be used to detect the position of a rotary shaft that can be coupled to move a robotic arm. Absolute encoders are quite popular in these types of systems because of their ability to determine actual or absolute position. Absolute encoders provide a reliable indication at all times of the true position of the motor shaft to which they are attached.

Absolute encoders use a sequence of position codes stored in binary form on a code disc and single or multiple sensors that read the position codes. Linear encoders use an elongated element with parallel code tracks longitudinally. Rotary encoders use a code wheel with one or more concentric code tracks. A sensor is used to read the code. The sensor can use any optical, magnetic, inductive, capacitive, Or read the code by direct contact. The type of sensor used may depend on the application and/or the environment in which the system will operate.

An exemplary embodiment of the present disclosure is directed to an encoder assembly comprising: a substrate having two or more position sensors, each position sensor configured to detect the rotational position of a shaft or other rotating component of a machine ; a first encoder comprising at least one first position sensor of the two or more position sensors, the at least one first position sensor being disposed on the substrate to communicate with the shaft of the machine or other rotating components are aligned off-axis; and a second encoder including a second position sensor of the two or more position sensors disposed on the substrate to Aligned on-axis or off-axis with the shaft or other rotating part of the machine, where each position sensor is arranged to detect a different or common signal type, and the signal type of the second position sensor does not include an optical signal .

An exemplary encoder assembly includes: a code wheel configured for attachment to the shaft or other rotating component of the machine, wherein the at least one first position sensor and the second position sensor are disposed on the substrate is parallel to an axial surface of the code wheel, and wherein the code wheel, the at least one first position sensor, and the second position sensor form a dual multi-turn absolute encoder.

An exemplary encoder assembly includes: a code wheel positioned for attachment to the shaft or other rotating component of the machine, wherein the base plate includes a first portion positioned parallel to an axial surface of the code wheel; and a second part, arranged to be parallel to a radial surface of the code wheel, and wherein the at least one first position sensor is disposed on the second part of the substrate, and the second position sensor is disposed on the substrate first part.

An exemplary encoder assembly includes: a code wheel comprising: a first code wheel disposed within a hollow volume of the shaft or other rotating component of the machine; and a second code wheel configured for attachment to the machine The surface of the shaft or other rotating part, wherein the at least one first position sensor is arranged on the substrate to detect the signal from the second code wheel, and the second position sensor is arranged on the substrate to positively aligned with the shaft or other rotating part of the machine to detect a signal from the first code wheel, and wherein the at least one first position sensor is arranged to detect a signal from one of the second code wheels signal on an axial surface or a radial surface.

An exemplary encoder assembly includes: a code wheel comprising: a first code wheel disposed within a hollow volume of the shaft or other rotating component of the machine; and a second code wheel configured for attachment to the machine The surface of the shaft or other rotating parts, the substrate includes: a first part, arranged to be parallel to the axial surface of the first code wheel; and a second part, arranged to be parallel to a diameter of the second code wheel facing surface, and the at least one first position sensor is arranged on the second part of the substrate to detect the signal from the radial surface of the second code wheel, and the second position sensor is arranged on the on the first portion of the substrate to detect a signal from an axial surface of the first code wheel.

An exemplary encoder assembly includes: a code wheel, including a first code wheel and a second code wheel, configured for attachment to the surface of the shaft or other rotating component of the machine, wherein the substrate includes: a first portion , arranged to be parallel to a radial surface of the first code wheel; a second portion, arranged to be parallel to the radial surface of the second code wheel; and a third portion, extending between the first and second portions wherein the at least one first position sensor is disposed on the first portion of the substrate to detect signals from the radial surface of the first code wheel; the second position sensor is disposed on the second portion of the substrate part to detect the signal from the radial surface of the second code wheel; and the circuit system is installed on the third part of the substrate, and wherein the first and second parts of the substrate are parallel to the axis of the shaft and are aligned with the first The three parts are orthogonal.

An exemplary encoder assembly wherein at least one first position sensor and the second position sensor are embedded in a layer of a substrate.

An exemplary encoder assembly, wherein the two or more position sensors are connected to a common bus or separate data lines, and wherein the common bus and separate data lines are configured to communicate position data and/or clock signals and/or other information.

An exemplary encoder assembly, wherein the first encoder is a magnetic encoder, a capacitive encoder, an inductive encoder, or an optical encoder, and is disposed on a substrate to communicate with the machine's The second encoder with on-axis or off-axis alignment of the shaft or other rotating member is a magnetic encoder, a capacitive encoder, or an inductive encoder.

An exemplary encoder assembly connected for combination with a controller, wherein: the controller is configured to detect faults based on the rotational position detected by the two or more position sensors, and the controller is configured to The rotational positions detected by the two or more position sensors are compared, and when the compared rotational positions exceed a predetermined tolerance value, a fault signal is generated.

An exemplary encoder assembly, wherein the substrate includes a power circuit connected to the first and second encoders, the power circuit configured to provide at least circuit protection against power surges.

Another exemplary embodiment of the present disclosure is directed to an actuator assembly including: a motor having a motor shaft and an output shaft coaxial with the motor shaft; and an encoder assembly including: a first encoder, arranged to be aligned off-axis to the motor shaft; a second encoder arranged to be aligned on-axis or off-axis to the motor shaft; and a common substrate having the positions of the first encoder and the second encoder sensors are mounted thereon, wherein the common substrate is configured to convey position data from the position sensors, and wherein each position sensor is configured to detect different or the same signal type, and the second code The signal type of the device does not include optical signals.

An exemplary actuator assembly wherein, if the second encoder is positively aligned with the motor shaft, the second encoder comprises a first code disc disposed in a hollow volume of the output shaft; and the second encoder An encoder includes a second code wheel attached to the surface of the motor shaft.

An exemplary actuator assembly wherein if the second encoder is aligned off-axis to the motor shaft, the second encoder includes a second position sensor arrangement to detect a position from the first code wheel Signal on the axial surface.

An exemplary actuator assembly, wherein the common substrate includes: a first portion on which the second position sensor of the second encoder is mounted to detect motion from an axial surface of the first code wheel signal; and a second part on which the first position sensor of the first encoder is mounted to detect a signal from a radial surface of the second code wheel, and wherein the second of the common substrate The portion is perpendicular to the first portion of the common substrate.

An exemplary actuator assembly, wherein the encoder assembly includes a controller configured to control the operation of the actuator assembly based on position data detected by the position sensors, wherein the controller is mounted on the on a common substrate.

an exemplary actuator assembly wherein the controller is configured to detect a fault based on the rotational position of the motor shaft detected by the second encoder and the rotational position of the output shaft detected by the first encoder, And wherein the controller is configured to compare the rotational positions of the motor shaft and the output shaft, and generate a fault signal when the compared rotational position exceeds a predetermined tolerance value.

An exemplary actuator assembly wherein the first encoder is a magnetic encoder, a capacitive encoder, an inductive encoder, or an optical encoder, aligned on-axis or off-axis to the motor The second encoder of the shaft is a magnetic encoder, a capacitive encoder, or an inductive encoder.

An exemplary actuator assembly, wherein the first encoder and the second encoder are absolute encoders.

An exemplary actuator assembly, wherein each position sensor is disposed on the common substrate to detect a signal from an axial surface of a corresponding code wheel.

An exemplary actuator assembly, wherein: the first encoder includes a first position sensor disposed on the common substrate to detect signals from a radial surface of a first code wheel; and the second encoder The device includes a second position sensor disposed on the common substrate to detect signals from an axial surface of a second code wheel, wherein the substrate includes: a first part on which the second position sensor is mounted detector to detect signals from the axial surface of the second code wheel; and a second part on which the first position sensor is mounted to detect signals from the radial surface of the first code wheel .

An exemplary actuator assembly, wherein: the first encoder includes a first position sensor disposed on the common substrate to detect signals from a radial surface of a first code wheel; the second encoder comprising a second position sensor disposed on the common substrate to detect signals from the radial surface of the second code wheel, wherein the common substrate comprises: a first part on which the first position sensor is mounted device to detect signals from the radial surface of the first code wheel; and a second part on which a second position sensor is mounted to detect signals from the radial surface of the second code wheel; and A third portion extending between the first and second portions on which the encoder circuitry is mounted, wherein the first and second portions of the substrate are parallel to the axis of the motor shaft and aligned with the third portion pay.

An exemplary actuator assembly, wherein the position sensors are connected to a common bus or separate data lines, and wherein the common bus and separate data lines are configured to communicate position data and/or clock signals and /or other information.

An exemplary actuator assembly coupled for combination with a controller, wherein the controller is configured to detect faults based on rotational positions detected by two or more position sensors, and wherein the controller is configured to The rotational positions detected by the two or more position sensors are compared, and when the compared rotational positions exceed a predetermined tolerance value, a fault signal is generated.

An exemplary encoder assembly, wherein the common substrate includes a power circuit connected to a plurality of encoders, the power circuit configured to provide circuit protection.

100: actuator assembly

102: shell frame

104: Actuator output flange

106: Envelope

108: Characteristic part (for example empty hole)

110: motor shaft

112: actuator output shaft

114: front end

116: Backend

118: gear input (gear device)

120: Bearing

122: Shizuko

124: Gap

126: Encoder component

128: Mounting bracket

130: screw or bolt

132A: code disc

132B: code disc

134: Substrate

136A: Position detection sensor

136B: Position detection sensor

226: Encoder component

232A: code disc

232B: code disc

234: Substrate

236A: Position detection sensor

236B: Position detection sensor

326: Encoder component

332A: code disc

332B: code disc

334: Substrate

334A: First (substrate) part

334B: Second (substrate) part

336A: Position detection sensor

336B: Position detection sensor

402: Power circuit

404: Fault detection circuit

408: data line

410: clock line

412: Shared Power and Ground

434: Substrate

436A: Position detection sensor

436B: Position detection sensor

436C: Position detection sensor

450: Driver/Controller

510: radial surface

515: axial plane

520: track

520A: track

520B: track

525: N and S pole pairs (N and S magnetic poles)

532: code disc

535: Two (2) pole magnets

536: Position detection sensor

610: radial surface

632A: code disc

632B: code disc

632C: code disc

634: Substrate

634A: First (substrate) part

634B: Second (substrate) part

635: Center Hole or Aperture

636A: Position detection sensor

636B: Position detection sensor

636C: Position detection sensor

The scope of the present disclosure is best understood from the following detailed description of exemplary embodiments when read with the accompanying drawings: FIG. 1 illustrates an actuator assembly according to an exemplary embodiment of the present disclosure.

2a and 2b illustrate an example optical or capacitive encoder assembly according to an example embodiment of the present disclosure.

3a-3c illustrate example encoder components according to an example embodiment of the present disclosure.

4a and 4b illustrate an example controller circuit according to an example embodiment of the present disclosure.

4c and 4d illustrate schematic circuit diagrams of a position sensor and substrate assembly according to an exemplary embodiment.

5a-5c illustrate magnet types of an encoder assembly according to an exemplary embodiment of the present disclosure.

6a-6g illustrate the installation arrangement of various position detection sensors according to an exemplary embodiment of the present disclosure.

An exemplary dual absolute encoder can be configured to include two encoders, each encoder having a rotary position sensor disposed on a common substrate. An encoder may include a position sensor arranged (eg, arranged, placed, mounted) on the base plate so as to be centered or positive relative to the motor shaft when the base plate is mounted on the motor. A second encoder may comprise a position sensor arranged on the substrate so as to be off-center or off-axis relative to the axis of the motor shaft. The dual encoder arrangement provides better resolution and redundancy in determining the position or rotation of the motor shaft.

FIG. 1 illustrates an actuator assembly according to an exemplary embodiment of the present disclosure. The actuator assembly 100 may include an actuator housing 102 having an element 106 in which an actuator output flange 104 rotates. The actuator output flange 104 includes features (eg, holes) 108 for mounting the output end of the actuator assembly 100 to an external mount (not shown). A hollow motor shaft 110 is coaxial with an actuator output shaft 112 . The hollow motor shaft 110 has a front end 114 and a rear end 116 extending along the central axis (X) of the housing 102 . The front end 114 is connected to a gear input 118 (such as the inner diameter of an elliptical harmonic generator) to create a reduction ratio between two internal pin slots (not shown) connecting the frame 102 and the motor assembly . The actuator output flange 104 is supported by a bearing 120 . The actuator assembly 100 also includes a stator 122 fixed to the inner surface of the housing 102 and separated from the motor shaft 110 by a gap 124 surrounding the motor shaft 110 .

An encoder assembly 126 is configured to detect position and rotation at the rear end 116 of the motor shaft 110 that is coaxial with the end of the actuator output shaft 112 . Encoder assembly 126 may be configured as an absolute rotary encoder at least partially mounted or attached to stator 122 and/or housing 102 of actuator assembly 100 by a mounting bracket or spacer 128 . The mounting bracket 128 can be made by Screws or bolts 130 or other suitable support mechanism as desired are securely attached to the actuator assembly 100 .

As shown in Figure 1, the encoder assembly 126 includes: a code disc 132A for generating a position signal related to the motor shaft 110; and a code disc 132B for generating a position signal related to the actuator output shaft 112 , which may include a gear output where the gear input 118 is attached to the motor shaft 110 . Also included is a base plate 134 containing at least circuitry for monitoring the position of the motor shaft 110 and the actuator output shaft 112 . The substrate 134 can be implemented as a printed circuit board, a planar 3D printing material, a flexible circuit board, or any other known components that can mechanically support and electrically connect the electrical components of a single modular board as required. The substrate 134 may have a multi-layer structure in which the wiring portion and component and circuit layout conform to specific performance power and thermal characteristics. The substrate 134 may include a plurality of position detection sensors 136A, 136B for detecting the rotational position of coaxial shafts or other rotating parts, and connected to a common bus for communicating data with a controller. The position detection sensors 136A, 136B can be installed on the surface of the substrate 134 and/or embedded in the inner layer of the substrate 134 as required. The position detection sensors 136A, 136B can be electrically connected to each other and/or through the use of conductive tracks, conductive pads, vias, and other known methods for establishing the required electrical connections on the substrate. to other components and circuits on the substrate. The position detection sensor 136A is arranged on the substrate 134 to detect the signal from the code wheel 132A, wherein the combination of the position detection sensor 136A and the code wheel 132A forms an encoder. The position detection sensor 136B is arranged on the substrate 134 to detect the signal from the code wheel 132B. The combination of the position detection sensor 136B and the code wheel 132B also forms an encoder.

The position detection sensors 136A, 136B may be non-contact and are configured to detect the position of the motor shaft 110 and/or the actuator output shaft 112 via magnetic or inductive signals from the associated code discs. location, as shown in Figure 1. According to other exemplary embodiments disclosed herein, the position detection The sensors can be configured to use optical or capacitive signaling, or a mixture of both. These alternative embodiments are disclosed in further detail in relation to Figures 2a and 2b.

According to an exemplary embodiment of the present disclosure, the code wheel 132A is provided with a plurality of alternating magnetic poles (N, S), and the magnetic poles are provided on an axial plane relative to the axis of the motor shaft 110 (as shown in FIG. 1 ) or radial surface (as shown in Figure 3a). The position detection sensors 136A, 136B can be implemented as Hall effect components for magnetically detecting the position of the rotating shaft through the code wheels 132A, 132B, respectively. The position detection sensors 136A, 136B in combination with the code wheels 132A, 132B can be configured as single-turn absolute encoders that measure the displacement or rotation of the shaft from a specific position at start-up over a range of 360°. Under such configuration, the output of the position detection sensors 136A, 136B repeats every revolution or rotation period of the motor shaft 110 . The use of an absolute encoder in such a configuration generally provides redundancy for increased safety in controlling the operation of the motor, and more precisely in determining the position of the motor shaft 110 . According to another exemplary embodiment of the present disclosure, one or more encoders of the encoder assembly 126 may be configured as multi-turn absolute encoders. In the multi-turn absolute encoder arrangement, the encoder assembly 126 may include code discs and a battery (not shown) and/or a counter (not shown) to maintain location information. As already described, the actuator output shaft 112 may include a gear arrangement 118 . Therefore, the motor shaft 110 can rotate a certain number of revolutions according to the gear ratio to accumulate one revolution of the actuator output shaft 112 . Since the absolute initial position of each sensor can be determined at startup, no battery is needed to store the absolute position data within one revolution of the actuator output shaft 112 .

2a and 2b illustrate an example optical or capacitive encoder assembly, according to an example embodiment of the present disclosure. As shown in FIGS. 2 a and 2 b , the position detection sensors 236A, 236B can be implemented as optical or capacitive photoelectric sensors and used in combination with the code wheels 232A, 232B, respectively. The code wheel 232A, 232B can be provided with a plurality of opaque or transparent regions for light to penetrate its surface. A light source (not shown) may be disposed adjacent to the corresponding code wheel 232A, 232B and on the side opposite to the position detection sensor 236A, 236B to illuminate the code wheel 232A, 232B. As the code wheels 232A, 232B rotate, the position detection sensors 236A, 236B detect the modulated light passing through the transparent and/or opaque regions. A controller is provided to access the memory to determine a predetermined position or rotation of the shaft associated with the detected modulation signal. The exemplary encoder assembly 226 shown in FIG. 2a may also include any number of optical components to focus the light onto the position detection sensors 236A, 236B. The optical components may include collimating light-emitting diodes, mirrors, laser diodes, lenses, optical fibers, laser diodes, optical slits, diffraction gratings, or any other suitable light guides as desired parts or mechanisms. As shown in Figure 2a, an optical or capacitive encoder assembly may be provided such that each sensor is mounted on a single substrate 234 formed in a ring, either on the surface of the substrate facing the rear end 116 or facing the front as desired. 114 on the surface. FIG. 2b illustrates an exemplary embodiment in which a single position detection sensor 236A mounted on a single substrate 234 is an optical sensor for detecting light passing through each code wheel 232A.

According to another exemplary embodiment of the present disclosure, the position detection sensors 236A, 236B can be used in combination with the code wheels 232A, 232B configured to etch predetermined sinusoidal patterns on the corresponding surfaces. According to the exemplary embodiment, encoder assembly 226 includes a transmitter (not shown) that generates a high frequency signal for input to the motor shaft 110 . The sinusoidal pattern modulates the high frequency signal of the transmitter as the code discs 232A, 232B rotate with the motor shaft 110 . The position detection sensors 236A, 236B may be configured as capacitive sensors, which detect the modulated signal from the code wheel 232A, 232B and provide the signal to the driver/controller. The driver/controller converts the modulation signal received from the position detection sensors 236A, 236B into a rotational motion and uses the rotational motion value to determine the position of the motor shaft. As shown in Figure 2b, the encoder The assembly 226 may include a combination of an optical or capacitive position detection sensor 236A at an off-axis position relative to the motor shaft 110 and a magnetic position detection sensor 236B at an on-axis position.

3a-3c illustrate encoder components according to an exemplary embodiment of the present disclosure. As shown in FIG. 3a, an encoder assembly 326 may be configured such that two paired annular substrates serve as code wheels 332A, 332B. The code wheel 332B can be attached to the motor shaft 110 so that it can rotate synchronously with the motor shaft 110 during operation. The code wheel 332A is mounted on the actuator output shaft 112 of the actuator assembly 100 . The code wheel 332B is configured to include a position detection sensor 336B and other components including, for example, power circuits (not shown) embedded in its inner structure. During operation of the motor assembly, the code wheel 332B rotates with the motor shaft 110 , and the position detection sensor 336B detects changes in inductive coupling generated when the code wheel 332B rotates with the motor shaft 110 . The magnetic force signal detected by the position detection sensor 336B is compared with a predetermined measured value of the magnetic force signal to determine the position of the motor shaft 110 . As shown in FIG. 3a, the substrate 334 may include a first portion 334A and a second portion 334B. A position detection sensor 336A may be mounted on the first substrate portion 334A for off-axis alignment with the motor shaft 110 to detect a signal from a code wheel 332A mounted on the output shaft 112 . A position detection sensor 336B may be mounted on the second substrate portion 334B to be aligned off-axis with the motor shaft 110 to detect a signal from a code wheel 332B mounted on the motor shaft 110 . The position detection sensor 336B is arranged to detect signals from the radial surface of the code wheel 332B. As shown in FIG. 3b, the same design can be implemented on the actuator output shaft 112 and its annular base plate 334, wherein the position detection sensor 336B is mounted on the base plate 334 in a redundant manner with the position The opposite side of sensor 336A is detected. Figure 3c illustrates the encoder components of Figure 3b without redundancy. According to an exemplary embodiment, the encoder assembly 326 of FIGS. 3b and 3c may be configured to use magnetic or inductive position detection.

According to an exemplary embodiment of the present disclosure, the encoder assembly 326 may comprise any set of magnetic, optical, inductive, and/or capacitive encoders as disclosed herein combined to set. For example, the encoder assembly 326 may include an encoder having a magnetic code disc 332B disposed within the hollow volume of the motor shaft 110 on a side hollow volume facing the rear end 116 . Another exemplary encoder may be configured with an optical code wheel 332A attached to the actuator output shaft 112 such that it rotates during operation of the actuator assembly. The position detection sensors 336A, 336B can be aligned on the substrate 334 with respect to the off-axis position of the axis (X) of the motor shaft 110 . The position detection sensor 336A is arranged to detect the light reflected from the optical code wheel 332A, and the position detection sensor 336B is arranged to detect the signal emitted by the magnetic code wheel 332B.

4a-4c illustrate an example controller circuit according to an example embodiment of the present disclosure. The controller 450 can be configured as a servo drive, including hardware devices such as processors, field programmable gate arrays (FPGAs) or application specific integrated circuits (ASICs). These devices can be individually programmed with software or program code to perform operations and then process, analyze, and/or manipulate driving and/or control the actuator assembly 100, and/or by the position detection sensor 436A, 436B detected data, and/or other components or circuits of the actuator assembly 100 . The controller 450 can include components and circuitry that can be directly integrated on the substrate 434 and position detection sensors 436A, 436B that detect the rotation of the actuator output shaft 112 and the motor shaft 110 respectively. For example, the circuit may include a power circuit 402, a fault detection circuit 404, and a driver/controller 450, among others. As shown in Figure 4a, the circuitry may be mounted on one or more sides or surfaces of the substrate. For example, the power circuit 402 , fault detection circuit 404 , and driver/controller 450 may be mounted on side A of the substrate 434 , and the position detection sensors 436A, 436B may be mounted on side B of the substrate 434 . Position detection sensors 436A, 436B are provided to share the power signal output from the power circuit 402 . FIG. 4 b illustrates an embodiment in which the position detection sensors 436A, 436B are embedded in the substrate 434 . It should be understood that any other components and/or circuits can be combined with or replaced by the position detection sensors 436A, 436B and embedded in the substrate. According to an exemplary embodiment, the controller 450 may be mounted on substrate 434 in any suitable arrangement such that components and circuits may be mounted on either side A or B of the substrate in any combination as desired, or embedded within the substrate.

In an alternate embodiment, the controller 450 may be mounted on a separate substrate within the motor assembly or outside the actuator assembly housing 102 . The controller 450 may be configured to determine whether there is a fault based on the rotational position of the shaft detected by at least two of the plurality of position detection sensors 436A, 436B. For example, the controller 450 may be configured to compare the rotational position of the shaft detected by at least two position detection sensors 436A, 436B, and when the compared rotational position is determined to exceed a predetermined tolerance value, a fault signal is generated. For example, if a 15-bit (32768 counts per revolution) position detector monitors the position of the motor shaft 110, and a 14-bit (16384 counts per revolution) position detector monitors the position with a 100:1 reduction ratio The position of the actuator output shaft 112, and when the motor turns 50.75 revolutions, the motor shaft position detector will output the position of 0.75 of 1 revolution as 24756 counts, and the actuator output will be 100:1 The reduction ratio of 50 revolutions and 0.75 revolutions is counted as 8192+123 or 8315 counts. A conversion of one motor shaft revolution or 32768 counts equal to 164 actuator position detection counts can be used by the controller, since in this example the ratio of the motor shaft to actuator output position detection is 200, if A motor position that does not correspond to an actuator position within 5 counts within 1000 counts (depending on the accuracy and reproducibility of the integrated position detectors) defines a fault.

4c and 4d illustrate a schematic circuit diagram of a position sensor and substrate assembly according to an exemplary embodiment. According to an embodiment, the encoder assembly may be provided with a plurality of position sensors, wherein each position sensor includes individual data and clock lines or signals. For example, position detection sensors 436A, 436B, 436C may be configured with data line 408 and clock line 410 connected to driver/controller 450 and shared power and ground 412 from power circuit 402 . The exemplary embodiment shown in FIG. 4c is different from and offers advantages over the previous embodiments in that it provides a An exemplary illustration of 436A, 436B, 436C being connected in a daisy-chain arrangement such that the sensors share a common data bus. Due to this arrangement, the number of buses necessary to wire the position detection sensors 436A, 436B, 436C of the encoder assembly can be significantly reduced, such as the exemplary technique of the present disclosure eliminating eight redundant data communication lines (Data+, Data-, Clock+, Clock- of the two sensors). The exemplary encoder assembly 126 of the present disclosure is configured to provide position data or other desired motor assembly data as a multi-bit character on the common data bus. The encoder unit can be configured to communicate data via a parallel or serial interface. Serial data can be output according to a synchronous serial interface (SSI) protocol or a bidirectional/serial/synchronous (BiSS) interface protocol. As shown in FIG. 4d, the position sensors 436A and 436B of the position detection sensors are connected according to differential line transmitters and receivers. For each sensor 436A and 436B, two lines are used for the differential data receiver (SLO+ and SLO-). Two lines are used for differential clock and data transmission signals (MA+ and MA-). The position sensors are connected in a master (MA)/slave (SLO) arrangement. The arrangement can be scaled to contain any desired number of sensors.

5a-5c illustrate magnet types of an encoder assembly according to an exemplary embodiment of the present disclosure.

As shown in Figure 5a, code wheel 532 is representative of code wheels 132A, 332A, and 332B discussed with respect to applicable Figures 1 and 3a-3c. The code wheel 532 may be configured as a multi-pole magnet that may be coaxially secured to one or more motor shafts 110 or other rotating portion components whose rotation is to be detected. Code wheel 532 and position detection sensor 136A provide for off-axis rotation detection relative to the actuator output shaft or motor shaft 110 as shown in FIG. 1 . The code wheel 532 may have an annular or circumferential shape and be configured to include a plurality of alternating N and S pole pairs 525 . The pole pair N and S can be arranged on an axial surface 515 of the code wheel 532 relative to the axis of the motor shaft 110 . According to an exemplary embodiment of the present disclosure, the code wheel 532 may have any one of 16, 32 and 64 pole pairs or any other suitable number of poles as desired. The axial face 515 of the code wheel 532 may include one or more Tracks 520, wherein each track 520 includes a plurality of N and S magnetic poles 525 arranged alternately along the circumference. For each track 520 , a plurality of N and S poles 525 may be spaced at equidistant or equiangular positions around the circumference of the code wheel 532 . Figure 5a illustrates a code wheel 532 comprising two (2) tracks 520A, 520B with a resolution of up to 18 bits (ie 262144 counts). For optical encoder assemblies, transparent or opaque areas are used instead of the N and S pole pairs of the magnetic code wheel. However, it should be understood that the code wheel 532 may have any suitable number of tracks depending on the desired resolution of detected positions.

As shown in Figure 5b, the code wheel 532 may be arranged such that N and S pole pairs are formed on the radial surface 510 or outer edge.

As shown in FIG. 5c, the encoder assembly 126 may include a two (2) pole magnet 535 positioned to attach to the hollow volume of the actuator output shaft 112 for which rotation is detected or configured in it. According to another exemplary embodiment, the dipole magnet 535 may be disposed within the hollow inner volume of the motor shaft 110 proximate to the rear end 116 . A magnet 535 is provided in combination with a position detection sensor 536 for positive axis detection relative to the actuator output shaft 112 .

6a-6g illustrate various mounting arrangements of position detection sensors according to an exemplary embodiment of the present disclosure.

As shown in FIG. 6a, the encoder assembly 126 may include a position detection sensor 636B disposed on a substrate 634 such that when the substrate 634 is mounted on the actuator assembly, the position detection sensor 636B is The positive axis position relative to the code wheel 632B mounted within the hollow interior volume of the motor shaft 110 or other rotating portion component whose position is to be sensed. In this positive axis position, the position detection sensor 636B is positioned to sense a motor mounted within the hollow interior volume of the motor shaft 110 closest to the rear end 116 or behind the actuator output shaft 112 as shown in FIG. 1 . The magnetic pole of the code disc 632B on the end. A code wheel 632A can be mounted on the motor shaft 110, and a position detection sensor 636A can be mounted on the base plate 634 off-axis relative to the motor shaft 110 position to detect the signal from the code wheel 632A. The placement and orientation of the position detection sensors provides redundancy and better accuracy than known encoder assembly designs.

As shown in FIG. 6b, the encoder assembly 126 may include a position detection sensor 636B disposed on the substrate 634 in a positive axis position relative to the motor shaft 110 as shown in FIG. 6a, and also includes one or more positions The detection sensor 636A is disposed on the substrate 634 at an off-axis position relative to the motor shaft 110 . As already discussed, the position detection sensor 636A is placed in an off-axis position to sense the N and S poles 525 of the code wheel 632A. In arrangements where at least two position detection sensors 636A are used, the sensors 636A may be arranged at angles of 90°, 180°, or other suitable angular offsets as desired. The position detection sensors 636A, 636B are located on the same substrate surface, and thus mounted at the same axial position, with the position detection sensor 636B being located on the center.

As shown in FIG. 6 c , the encoder assembly 126 may include one or more position detection sensors 636A disposed on the substrate 634 at respective off-axis positions relative to the motor shaft 110 . Increasing the number of position detection sensors 636A results in redundancy or better accuracy. According to this embodiment, no positive axis position detection sensor 636B is used to detect the position of the motor shaft 110 .

As shown in FIG. 6d, the encoder assembly 126 may include one or more position detection sensors 636B disposed radially relative to the motor shaft 110 and mounted on a first portion 634A of the base plate 634, and the A second portion 634B of the substrate 634 extends in a plane perpendicular to the first substrate portion 634A. The first substrate portion 634A is arranged adjacent to an axial surface of the code wheel 632B, and the second substrate portion 634B is arranged adjacent to a radial surface of the code wheel 632B. The position detection sensor 636C may be mounted on the surface of the vertical second substrate portion 634B. The position detection sensor 636C is aligned with the code wheel 632C having the N and S pole pairs 525 arranged on the radial surface 610 or outer edge. The first base plate portion 634A can be mounted to the stator assembly 122 (as shown in FIG. 1 ) and thus remain stationary during operation. The code wheel 632B is mounted on the actuator output shaft 112 .

6e and 6f illustrate an exemplary encoder assembly in which the base plate 634 may be mounted to the stator assembly 122 as shown in FIG. 1 . The single base plate 634 is formed with a central hole or aperture 635 that allows the actuator output shaft 112 to pass through completely. The substrate 634 has one or more position detection sensors 636A, 636B mounted thereon. As shown in FIG. 6 e , the position detection sensors 636A, 636B can be installed on one of the surface facing the front end 114 or the surface facing the rear end 116 of the substrate 634 . According to the position detection sensors 636A, 636B, the position of the motor shaft can be detected based on the rotation of the code discs 632A, 632B mounted on the motor shaft 110 and the actuator shaft 112 . As shown in FIG. 6f, position detection sensors 636A, 636B can be mounted on both sides of the single substrate, so that the accuracy and redundancy in detecting the motor position based on the rotation of the code discs 632A, 632B are increased. .

Figure 6g illustrates an exemplary encoder assembly having a single substrate with radial off-axis encoders and positive axis encoders, according to an exemplary embodiment of the present disclosure. As shown in FIG. 6g, the encoder assembly 126 may include a substrate 634 having a first portion 634A and a second portion 634B extending in a direction perpendicular to the first portion 634A. A position detection sensor 636B may be mounted on the first base plate portion 634A for positive axial alignment with the code wheel 632B mounted in the hollow volume of the actuator output shaft 112 . The position detection sensor 636C may be mounted on the second substrate portion 634B to be aligned off-axis with the code wheel 632C mounted on the outer surface of the motor shaft 110 . The position detection sensor 636C is aligned to detect signals from the N and S pole pairs 525 disposed on the radial surface 610 or outer edge of the code wheel 632C.

The exemplary rotary encoder assembly of the present disclosure is mounted on a single substrate, allowing for a smaller space requirement than known implementations. Accordingly, an encoder assembly as described herein can be mounted closer to the motor/actuator, allowing length reduction for improved torque density. Therefore, when in a single base Encoder wiring can be completely eliminated when on-board encoder assemblies are integrated directly into an integrated servo drive using a dual-encoder combination. In addition, the position detectors can be connected in a daisy-chain arrangement, resulting in space and thermal efficiency, as well as reducing the number of wires connected to the servo drive or controller. An encoder assembly with components and circuitry mounted on both sides of a double-sided substrate introduces not only space savings but also cost savings. To further improve the performance of the encoder assembly, the motor/actuator shaft can be formed from aluminum to reduce the amount of crosstalk and noise from magnetic interference, improve torque density, and reduce inertia or eliminate shaft deflection. The use of other known mounting techniques and materials related to magnets can be used to improve tolerance, electrical deflection, and overall performance of the encoder assembly.

Therefore, it can be understood by those skilled in the art that the present invention can be carried out in other specific forms without departing from the spirit or essential characteristics thereof. The disclosed embodiments are therefore to be considered in all respects as illustrative rather than restrictive. The scope of the present invention is represented by the appended claims rather than the foregoing description, and all changes within the meaning, scope and equivalents thereof are embraced therein.

100: actuator assembly

102: Actuator frame

104: Actuator output flange

106: Envelope

108: Characteristic part (for example empty hole)

110: motor shaft

112: actuator output shaft

114: front end

116: Backend

118: gear input (gear device)

120: Bearing

122: Shizuko

124: Gap

126: Encoder component

128: Mounting bracket

130: screw or bolt

132A: code disc

132B: code disc

134: Substrate

136A: Position detection sensor

136B: Position detection sensor

Claims (25)

An encoder assembly comprising: a substrate having two or more position sensors, each position sensor configured to detect the rotational position of a shaft or other rotating part of a machine; a first encoder comprising A first code wheel and at least one first position sensor among the two or more position sensors, the at least one first position sensor is arranged on the substrate to communicate with the shaft or other of the machine the rotating portion components are off-axis aligned; and a second encoder including a second code wheel and a second position sensor of the two or more position sensors, the second position sensor configured on the substrate to be aligned on-axis or off-axis with the shaft or other rotating part of the machine, wherein each position sensor is arranged to detect a different or common signal type, and the second position sensor's Signal types do not include optical signals. Such as the encoder component of claim 1, wherein the at least one first position sensor and the second position sensor are arranged on the substrate to communicate with the first code wheel and the second code wheel respectively An axial surface is parallel, and wherein the first code wheel and the at least one first position sensor, and the second code wheel and the second position sensor form a dual multi-turn absolute encoder. If the encoder component of item 1 of the patent scope is applied for, Wherein the substrate comprises: a first part arranged to be parallel to an axial surface of at least one of the first and second code wheels; and a second part arranged to be parallel to at least one of the first and second code wheels A radial surface of the substrate, and wherein the at least one first position sensor is disposed on the second portion of the substrate, and the second position sensor is disposed on the first portion of the substrate. The encoder assembly of claim 1, wherein the first code wheel is disposed in a hollow volume of the shaft or other rotating part of the machine; and the second code wheel is arranged to be attached to the A surface of the shaft or other rotating part of a machine, wherein the at least one first position sensor is disposed on the substrate to detect a signal from the second code wheel, and a second position sensor is disposed on the substrate to be aligned with the shaft or other rotating part of the machine to detect the signal from the first code wheel, and wherein the at least one first position sensor is arranged to detect the signal from the second code wheel signal on one axial surface or one radial surface of the disc. The encoder assembly of claim 1, wherein the first code wheel is disposed within a hollow volume of the shaft or other rotating part of the machine: and the second code wheel is configured to attach to the On the surface of the shaft or other rotating part of a machine, the substrate comprises: a first portion arranged parallel to an axial surface of the first code wheel; and a second portion arranged parallel to the second code wheel a radial surface of , and The at least one first position sensor is disposed on the second portion of the substrate to detect a signal from the radial surface of the second code wheel, and the second position sensor is disposed on the first portion of the substrate to detect a signal from an axial surface of the first code wheel. For the encoder assembly of item 1 of the scope of the patent application, wherein the first code wheel and the second code wheel are arranged to be attached to the surface of the shaft or other rotating parts of the machine, wherein the substrate includes: a A first portion arranged parallel to a radial surface of the first code wheel; a second portion arranged parallel to a radial surface of the second code wheel; and a third portion extending between the first and second code wheels Between two parts, wherein, the at least one first position sensor is arranged on the first part of the substrate to detect the signal from the radial surface of the first code wheel; the second position sensor is arranged on the first part of the substrate On the second part of the substrate to detect the signal from the radial surface of the second code wheel; and the circuit system is mounted on the third part of the substrate, and wherein the first and second parts of the substrate are parallel to the The axis of the shaft is perpendicular to the third part. The encoder component of claim 1, wherein the at least one first position sensor and the second position sensor are embedded in a layer of the substrate. An encoder assembly as claimed in claim 1, wherein the two or more position sensors are connected to a common bus or separate data lines, and wherein the common bus and separate data lines are configured to communicate position data and/or clock signals and/or other materials. The encoder component of item 1 of the scope of application, wherein the first encoder is a magnetic encoder, a capacitive encoder, an inductive encoder, or an optical encoder, and is arranged on the substrate The second encoder, in on-axis or off-axis alignment with the shaft or other rotating part of the machine, is a magnetic encoder, a capacitive encoder, or an inductive encoder. The encoder assembly of claim 1, connected to be combined with a controller, wherein: the controller is configured to detect faults based on the rotational position detected by the two or more position sensors , and the controller is configured to compare the rotational positions detected by the two or more position sensors, and generate a fault signal when the compared rotational positions exceed a predetermined tolerance value. The encoder assembly of claim 1, wherein the substrate includes a power circuit connected to the first and second encoders, the power circuit configured to provide at least circuit protection against power surges. An actuator assembly comprising: An electric motor having a motor shaft and an output shaft coaxial with the motor shaft; and an encoder assembly comprising: a first encoder including a first code wheel, the first encoder is arranged with an off-axis alignment aligned on the motor shaft; a second encoder including a second code disc, the second encoder is arranged to be aligned on the motor shaft with a positive axis or an off-axis; and a common substrate with the first encoder and The position sensors of the second encoder are mounted thereon, wherein the common substrate is configured to communicate position data from the position sensors, wherein each position sensor is configured to detect different or identical signals type, and the signal type of the second encoder does not include optical signals. The actuator assembly according to claim 12 of the patent application, wherein if the second encoder is positively aligned with the motor shaft, the second encoder includes the first encoder disposed in the hollow volume of the output shaft a code wheel; and the first encoder includes the second code wheel attached to the surface of the motor shaft. The actuator assembly of claim 13, wherein if the second encoder is aligned off-axis to the motor shaft, the second encoder includes a second position sensor arrangement to detect A signal of an axial surface of the first code wheel. Such as the actuator assembly of item 13 of the patent scope, wherein, the common substrate includes: a first part, on which the second position sensor of the second encoder is installed to detect the position from the second code wheel a signal of an axial surface; and a second part on which the first bit of the first encoder is mounted. A sensor is positioned to detect a signal from a radial surface of the first code wheel, and wherein the second portion of the common substrate is perpendicular to the first portion of the common substrate. For example, the actuator assembly of claim 12, wherein the encoder assembly includes a controller configured to control the operation of the actuator assembly based on the position data detected by the position sensors, Wherein the controller is mounted on the common substrate. The actuator assembly of claim 16, wherein the controller is configured based on the rotational position of the motor shaft detected by the second encoder and the output shaft detected by the first encoder and wherein the controller is configured to compare the rotational positions of the motor shaft and the output shaft and generate a fault signal when the compared rotational position exceeds a predetermined tolerance value. Such as the actuator assembly of item 12 of the scope of application, wherein the first encoder is a magnetic encoder, a capacitive encoder, an inductive encoder, or an optical encoder, and the positive axis Or the second encoder, aligned off-axis to the motor shaft, is a magnetic encoder, a capacitive encoder, or an inductive encoder. The actuator assembly of claim 12 of the patent application, wherein the first encoder and the second encoder are absolute encoders. The actuator assembly of claim 12, wherein each position sensor is disposed on the common substrate to detect signals from one axial surface of the corresponding code wheel. The actuator assembly of claim 12, wherein: the first encoder includes a first position sensor disposed on the common substrate to detect signals from the radial surface of the first code wheel and the second encoder includes a second position sensor disposed on the common substrate to detect signals from an axial surface of the second code wheel, wherein the substrate includes: a first portion on which The second position sensor is mounted to detect signals from the axial surface of the second code wheel; and a second part is mounted with the first position sensor to detect signals from the first code wheel signal on the radial surface of the disk. The actuator assembly of claim 12, wherein: the first encoder includes a first position sensor disposed on the common substrate to detect signals from the radial surface of the first code wheel The second encoder includes a second position sensor configured on the common substrate to detect signals from the radial surface of the second code wheel, wherein the common substrate includes: a first part mounted on There is the first position sensor to detect the signal from the radial surface of the first code wheel; and a second part on which the second position sensor is mounted to detect the signal from the second code wheel and a third portion extending between the first portion and the second portion on which the encoder circuitry is mounted, wherein the first and second portions of the substrate are parallel to the axis of the motor axis and is perpendicular to the third part. Such as the actuator assembly of claim 12, wherein the position sensors are connected to a common bus or independent data lines, and wherein the common bus and independent data lines are configured to communicate position data and and/or clock signals and/or other data. The actuator assembly of claim 12, which is connected to be combined with a controller, wherein the controller is configured to detect a fault based on the rotational position detected by two or more position sensors, And wherein the controller is configured to compare the rotational positions detected by the two or more position sensors, and generate a fault signal when the compared rotational positions exceed a predetermined tolerance value. The actuator assembly of claim 12, wherein the common substrate includes a power circuit connected to a plurality of encoders, and the power circuit is configured to provide circuit protection.

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