WO2017206496A1 - 一种磁编码器及其导磁码盘及导磁码盘的制备方法 - Google Patents

一种磁编码器及其导磁码盘及导磁码盘的制备方法 Download PDF

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WO2017206496A1
WO2017206496A1 PCT/CN2016/111810 CN2016111810W WO2017206496A1 WO 2017206496 A1 WO2017206496 A1 WO 2017206496A1 CN 2016111810 W CN2016111810 W CN 2016111810W WO 2017206496 A1 WO2017206496 A1 WO 2017206496A1
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magnetic
magnetic conductive
encoder
code disc
grid
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PCT/CN2016/111810
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English (en)
French (fr)
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郑律
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江苏森尼克电子科技有限公司
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Publication of WO2017206496A1 publication Critical patent/WO2017206496A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/21—Devices for sensing speed or position, or actuated thereby
    • H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements

Definitions

  • the present invention relates to the field of magnetic encoders, and more particularly to a magnetic encoder, a magnetic encoder of a magnetic encoder, and a method of preparing a magnetic code disc.
  • the encoder is mainly divided into a photoelectric encoder and a magnetic encoder.
  • the general photoelectric encoder is mainly composed of a photoelectric encoder with a shaft and a photoelectric detecting device.
  • the photoelectric encoder has a circular through and dark engraved line.
  • the motor since the photoelectric encoder is coaxial with the motor, the motor When rotating, the grating disk rotates at the same speed as the motor, and a detection device composed of a light-emitting diode or the like detects and outputs a plurality of pulse signals, and can analyze the pulse signal to reflect the current motor rotation speed or the angle and the steering.
  • the traditional photoelectric encoder code discs are made of glass, metal and plastic.
  • the glass code disc is deposited on the glass with very thin engraved lines.
  • the thermal stability and precision can reach the standard and general requirements, but it is easy to break.
  • the metal code disc is directly punctured and non-breakable, but because of the certain thickness of the metal, the precision is limited, and its thermal stability is one order of magnitude worse than the glass code disc.
  • Plastic pallets are economical, with low cost, high precision and high temperature resistance.
  • the magnetoelectric encoder adopts a magnetoelectric design, and generates and provides the absolute position of the rotor through the magnetic induction device, utilizing the change of the magnetic field, and replaces the traditional code wheel with the magnetic device, thereby making up for the same light pollution and life of the photoelectric encoder.
  • the relatively short defects, more earthquake-resistant, corrosion-resistant, pollution-resistant, reliable and high-performance, simple structure, is a new direction for the future development of the encoder.
  • the encoder adopts The principle of IC cutting magnetic field calculates the angle and produces the sine wave signal. The disadvantage is that all angle data is simulated by the software to the relative angle and position, the precision is not high, and the error is large.
  • a magnetic encoder is disclosed, the outer casing of which is fixed on the motor, the magnetic grid is sleeved on the rotor shaft of the motor, the signal processor is mounted in the outer casing, the magnetic grid comprises magnetic steel and a magnetic track, and the axial end face of the magnetic steel is arranged
  • the annular groove, the annular groove is assembled with a magnet to form a track, and the track generates a ring-shaped magnetic field, and the lock switch type Hall of the signal processor detects the track rotated with the output shaft of the motor to obtain an electric signal output waveform.
  • the conventional magnetic encoder as described above has a low resolution due to the limited number of magnetic pole pairs; if the number of magnetic pole pairs is increased, the difficulty in designing and processing the magnet and the volume of the magnet are greatly increased.
  • an object of the present invention is to provide a magnetic encoder, a magnetically permeable code disc thereof, and a method of manufacturing the same, which provide a magnetic field generated on a permanent magnet by a magnetic encoder
  • the magnetic conductive portion for the disturbance operation is easy to process, and is not limited by the number of magnetic pole pairs, and has a small restriction on the interval and number of the magnetic conductive portion and the non-magnetic conductive portion, and the magnetic is made in consideration of the detection accuracy.
  • the encoder structure is more compact.
  • a magnetic encoder comprising a permanent magnet for connection to a motor housing, a magnetically driven code wheel for connecting to an output shaft of the motor, the magnetically conductive code disk having at least one turn of a magnetic grid, the magnetic grid Forming a magnetically permeable portion for distancing the magnetic field generated by the permanent magnet and a non-magnetic conductive region contacting the magnetic conductive portion, the magnetic conductive portion being made of a magnetically permeable material;
  • the magnetic encoder further includes a signal processor including a sensor disposed between the permanent magnet and the magnetically permeable code disc for detecting a change in a magnetic field.
  • the magnetic conductive code disc is made of a magnetic conductive material, and the magnetic conductive code disc is provided with a hole, and the hole constitutes the non-magnetic conductive region;
  • the magnetic code disc is made of a non-magnetic material, and the magnetic conductive disc is fixedly disposed with a magnetic conductive material constituting the magnetic conductive portion.
  • the magnetic code wheel has an outer ring magnetic grid
  • the outer ring magnetic grid is composed of a plurality of magnetic conductive portions and a plurality of non-magnetic conductive regions, and a space is disposed between two adjacent magnetic conductive portions Non-magnetic field.
  • the magnetically permeable code disk is in the form of a disk, and the plurality of non-magnetic conductive regions are equally spaced along the circumferential direction of the wafer, and the non-magnetic conductive region is fan-shaped.
  • the sensor comprises a plurality of pairs of InSb magnetoresistive elements, each pair of the InSb magnetoresistive elements comprising two electrically connected to each other An InSb magnetoresistive element, and one of the InSb magnetoresistive elements of each pair of the InSb magnetoresistive elements is facing a certain non-magnetic field while the other InSb magnetoresistive element is facing a part of the magnetism or one of them When the InSb magnetoresistive element is facing a non-magnetic field, the other InSb magnetoresistive element is facing the other non-magnetic field.
  • the width of the InSb magnetoresistive element ⁇ the width of the non-magnetic conductive region ⁇ the width of the magnetic conductive portion.
  • the magnetic code wheel further has an inner ring magnetic grid for detecting a zero position
  • the inner ring magnetic grid is composed of a magnetic conductive portion and a non-magnetic conductive portion
  • the sensor includes a zero position for detecting a Hall element, the Hall element being disposed corresponding to the inner ring magnetic grid.
  • the senor is disposed between the permanent magnet and the magnetic code disc
  • a method for preparing a magnetically permeable code disk comprising the steps of: forming a non-magnetic conductive region through a through hole in a magnetic conductive material, and using the unperforated region as a magnetic conductive portion to obtain the magnetic conductive code disk; or
  • the magnetic conductive material is formed by plating a magnetic conductive material on the non-magnetic material to form a magnetic conductive portion, and a portion of the non-magnetic conductive material is used as a non-magnetic conductive region.
  • the magnetically permeable material described in the present invention is defined as follows: the magnetic permeable material can interfere with the magnetic field generated by the permanent magnet, such as enhancing the magnetic field in the magnetic circuit, and the magnetic permeable material includes a soft magnetic material and a hard magnetic material (also called a permanent magnet). Material ) .
  • the main features of soft magnetic materials are high magnetic permeability and small residual magnetism. Such materials can produce higher magnetic induction intensity under the action of lower external magnetic field, and quickly reach the magnetic saturation state as the external magnetic field increases; when the external magnetic field is removed, its magnetic properties basically disappear. Commonly used soft magnetic materials are pure iron and silicon steel.
  • the main feature of the hard magnetic material is the residual magnetic strength.
  • the working principle of the magnetic encoder of the invention is that the permanent magnet is fixedly arranged, and the magnetic field itself generates a strong magnetic field, the magnetic code disc rotates with the output shaft of the motor, the magnetic code grid has a magnetic grid, and the magnetic grid is made of a magnetic conductive portion and a non-magnetic
  • the magnetic field is formed by a magnetically permeable material that is disturbed by the magnetic field.
  • the signal processor outputs a sine wave or a change according to the detected magnetic field change / or pulse signal, which can be analyzed to determine the number of turns, angle or direction of motor rotation.
  • the prior art has the following advantages: the magnetic grid of the magnetic coded disc is mechanically processed, and the interval and the number of the magnetic conducting portion and the non-magnetic conducting portion of the magnetic grid are not limited, and can be based on accuracy requirements.
  • the magnetic conductive code disc is provided with as many magnetic conductive parts and non-magnetic conductive areas as possible, and the detection precision is high, the service life is long, and the structure is more compact.
  • FIG. 1 is a schematic view showing an application scenario of a magnetic encoder on a motor according to the present invention
  • FIG. 2 is a schematic view showing a relative position of a magnetic grid and an InSb magnetoresistive element of the present invention
  • Figure 3 is a schematic view showing another relative position of the magnetic grid and the InSb magnetoresistive element of the present invention.
  • FIG. 4 is a schematic structural view of a magnetic conductive code disc of the present invention.
  • Motor housing 2, motor output shaft; 3, permanent magnet; 4, PCB; 5, InSb magnetoresistive element; 5a, InSb magnetoresistive element; 5a', InSb magnetoresistive element; 5b, InSb magnetoresistive element; 5b', InSb magnetoresistive element; 50a, wire; 50b , wire; 6, Hall element; 7, magnetic code wheel; 71, magnetic guide; 72, non-magnetic field.
  • the magnetic encoder includes a permanent magnet 3 fixedly coupled to the motor housing 1, a magnetically driven code disk 7 fixedly coupled to the output shaft 2 of the motor, and a PCB 4 between the permanent magnet 3 and the magnetically driven code disk 7. .
  • the permanent magnet 3 is made of a permanent magnet material to produce a stable strong magnetic field.
  • the magnetic dynamometer disk 7 has a magnetic gate which is distorted by a magnetic field for generating a magnetic field generated by the permanent magnet 3 and a magnetic conductive portion 71
  • the non-magnetic conductive region is composed of a magnetic conductive portion 71 made of a magnetically permeable material for magnetic field, such as an iron or a ferrite magnet, and the non-magnetic conductive region 72 is a hollow region or a magnetically permeable material. Does not disturb the magnetic field.
  • a signal processor is disposed on the PCB 4, and the signal processor includes a sensor for detecting a change of the magnetic field.
  • the sensor in this embodiment is disposed between the permanent magnet 3 and the magnetic code wheel 7, and may be disposed in the Magnetic code disk 7 is away from the side of the permanent magnet 3.
  • the magnetic code wheel 7 is produced by the following two preparation methods:
  • Steps include: forming a non-magnetic conductive region 72 through the through hole in the magnetic conductive material, and using the unperforated region as the magnetic conductive portion 71 , forming a magnetic grid, and producing a magnetic code disk 7;
  • the magnetic code wheel 7 has at least one turn of the magnetic grid.
  • the magnetic grid may be composed of a plurality of magnetic conductive portions 71 and a plurality of non-magnetic conductive regions.
  • the composition 72 has one of the non-magnetic conductive regions 72 between the adjacent two magnetic conductive portions 71, that is, the magnetic conductive portion 71 and the non-magnetic conductive portion 72 are alternately arranged.
  • Non-magnetic field 72 They can be set at equal intervals or at different intervals.
  • the shape of the non-magnetic conductive region 72 may be a rectangle, a fan ring or the like, depending on the shape of the magnetic code wheel 7.
  • the sensor in this embodiment includes two pairs of InSb magnetoresistive elements 5 When the magnetic field is changed, the resistance of the InSb magnetoresistive element changes. The angle and direction data of the motor rotation are measured by two pairs of InSb magnetoresistive elements 5.
  • a pair of InSb magnetoresistive elements 5a And 5a' are electrically connected to each other through the wire 50a, and the other pair of InSb magnetoresistive elements 5b and 5b' are electrically connected to each other through another wire 50b, and the width of the InSb magnetoresistive element is ⁇
  • the width of the non-magnetic conductive region 72 ⁇ the width of the magnetic conductive portion 71.
  • the magnetic grid and the InSb magnetoresistive element are arranged with reference to two relative positional relationships, as shown in Figure 2, when a pair of InSb magnetoresistive elements When 5a or 5b is opposite to a non-magnetic conducting region 72, the corresponding other InSb magnetoresistive element 5a' or 5b' is opposite to the other non-magnetic conducting region 72; or as shown in Fig. 3, when in a pair When the InSb magnetoresistive element 5a or 5b is opposed to a certain non-magnetic conducting region 72, the corresponding other InSb magnetoresistive element 5a' or 5b' faces a certain magnetic conducting portion 71.
  • the magnetic code wheel 7 can be of various shapes, and the magnetic grid can be disposed on each side of the magnetic code wheel 7.
  • the following is a disk-shaped magnetic disk 7
  • the magnetic grid being disposed on the bottom surface of the wafer.
  • the magnetic code wheel 7 is provided with an outer ring magnetic grid and an inner ring magnetic grid along its circumferential direction.
  • Magnetic code wheel 7 adopts the above 1st
  • the method is as follows, that is, the magnetic code disc 7 is entirely made of a magnetic conductive material, and the outer edge of the bottom surface of the magnetic code disc 7 is provided with a plurality of holes at equal intervals in the circumferential direction, and the hole penetrates the magnetic code in the axial direction.
  • the hole is the non-magnetic region 72 of the outer ring magnetic grid, and the unopened region between the holes constitutes the magnetic conductive portion 71, and the hole has a fan-shaped or trapezoidal shape.
  • InSb corresponding to the outer ring magnetic grid
  • the magnetoresistive element is fan-shaped or wedge-like, and the spacing between adjacent holes ⁇ the width of the hole ⁇ the width of the InSb magnetoresistive element.
  • the magnetic disk 7 is also provided with a hole in the middle of the ground to form a non-magnetic region of the inner ring magnetic grid.
  • the other part is the magnetic conductive portion 71 of the inner ring magnetic grid.
  • the sensor also includes a Hall element 6 for detecting two bits, the Hall element 6 being disposed opposite the inner ring magnetic grid.
  • the outer ring magnetic grid is used to detect the motor output shaft 2
  • the rotation angle and the rotation direction of the inner ring magnetic grid are used to detect the zero position of the motor output shaft 2, thereby recording the number of rotation turns, and forming an incremental type of magnetic encoder.
  • Figures 2 to 4 Shown as a simplified magnetic code wheel, in practical applications, according to the actual accuracy requirements, the code wheel is scribed and opened. If the design product is 360 lines, it needs to be divided into 360 area openings; 512 lines It is necessary to divide 512 sector openings, and so on. Theoretically, the area of the bottom surface of the magnetic code disc can be enough to achieve several thousand lines. At present, the accuracy of one millionth of the actual can be achieved, and more than 17 bits can be realized.
  • the magnetic code wheel is preferably made of aluminum, and the aluminum plate is made thick and does not oscillate under high rotation.
  • the permanent magnet 3 is preferably a neodymium iron boron sintered material, the residual magnetism is 1.17T, and the pole pair is 1, and the strong magnetic field itself can prevent external interference magnetic field from invading.
  • a pair of 90-degree sine waves are generated by the InSb magnetoresistive element 5, and a zero-point pulse is generated by the Hall element 6.

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  • General Physics & Mathematics (AREA)
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Abstract

一种磁编码器，包括用于和电机壳体（1）固定连接的永磁体（3）、用于和电机的输出轴（2）固定连接的导磁码盘（7），导磁码盘（7）具有至少一圈磁栅，磁栅由用于对永磁体（3）产生的磁场形成扰动的导磁部（71）及与导磁部（71）相接的非导磁区（72）组成，导磁部（71）由导磁材料制成；该磁编码器还包括信号处理器，信号处理器包括设置于永磁体（3）和导磁码盘（7）之间的用于检测磁场变化的传感器。该磁编码器通过在导磁码盘（7）上设置对永磁体（3）产生的磁场具有扰动作用的导磁部（71），导磁码盘（7）容易加工，不受磁极对数的限制，对导磁部（71）和非导磁区（72）的间隔、数量的限制较小，在兼顾了检测精度的情况下使磁编码器结构更为紧凑。还提供了一种磁编码器的导磁码盘（7）及该导磁码盘（7）的制备方法。

Description

一种磁编码器及其导磁码盘及导磁码盘的制备方法
技术领域
本发明涉及磁编码器领域，特别涉及一种磁编码器、磁编码器的导磁码盘及导磁码盘的制备方法。
背景技术
根据检测原理，编码器主要分为光电编码器和磁编码器。一般的光电编码器主要由一个中心有轴的光电码盘和光电探测装置组成，光电码盘上具有环形的通、暗的刻线，在伺服系统中，由于光电码盘与电机同轴，电机旋转时，光栅盘与电机同速旋转，经发光二极管等组成的检测装置检测输出若干脉冲信号，通过分析脉冲信号就能反映当前电机的转速或转过的角度以及转向。传统的光电编码器码盘的材料有玻璃、金属、塑料，玻璃码盘是在玻璃上沉积很薄的刻线，其热稳定性及精度可以达到普通标准、一般要求，但容易碎。金属码盘直接以通和不通刻线，不易碎，但由于金属有一定的厚度，精度就有限制，其热稳定性就要比玻璃码盘差一个数量级。塑料码盘是经济型的，其成本低，精度和耐高温达不到高要求。
而磁电式编码器采用磁电式设计，通过磁感应器件、利用磁场的变化来产生和提供转子的绝对位置，利用磁器件代替了传统的码盘，弥补了光电编码器的同一产生光污染、寿命相对短的缺陷，更具抗震、耐腐蚀、耐污染、性能可靠高、结构更简单，是编码器未来发展的新的方向。现有技术中，编码器采用 IC 切割磁场的原理计算出角度，产生弦波信号，缺点是所有角度数据是通过软件模拟出相对的角度和位置，精度不高，误差大。
参见如中国专利 CN101846531A 公开的一种磁编码器，其外壳固定在电机上，磁栅套在电机的转子轴上面，信号处理器安装在外壳里面，磁栅包括磁钢和磁道，磁钢的轴向端面上设有环形槽，环形槽装配磁体形成磁道，磁道产生环形状的磁场，信号处理器的锁定开关型霍尔对随电机输出轴转动的磁道进行检测，得到电信号输出波形。然而如上所述的传统磁编码器由于磁极对数受限，因而分辨度不高；若增加磁极对数，磁铁设计和加工的难度以及磁铁的体积都会大大的增加。
发明内容
为解决上述问题，本发明的目的在于提供一种磁编码器及其导磁码盘及该导磁码盘的制备方法，该磁编码器通过在导磁码盘上设置对永磁体产生的磁场具有扰动作用的导磁部，导磁码盘容易加工，不受磁极对数的限制，对导磁部和非导磁区的间隔、数量的限制较小，在兼顾了检测精度的情况下使磁编码器结构更为紧凑。
为了达到以上目的，本发明采用如下技术方案：
一种磁编码器，包括用于和电机壳体连接的永磁体、用于和电机的输出轴连接的导磁码盘，所述导磁码盘具有至少一圈磁栅，所述磁栅由用于对所述永磁体产生的磁场形成扰动的导磁部及与所述导磁部相接的非导磁区组成，所述导磁部由导磁材料制成；
该磁编码器还包括信号处理器，所述信号处理器包括设置于所述永磁体和所述导磁码盘之间的用于检测磁场变化的传感器。
优选地，所述导磁码盘由导磁材料制成，所述导磁码盘上开设有孔，所述孔构成所述非导磁区；
或，所述导磁码盘由非导磁材料制成，所述导磁码盘上固定设置有构成所述导磁部的导磁材料。
优选地，所述导磁码盘具有外圈磁栅，所述外圈磁栅由多个导磁部及多个非导磁区组成，相邻两个所述导磁部之间设置有一个所述非导磁区。
更优选地，所述导磁码盘为圆片状，多个所述非导磁区沿圆片的周向等间隔分布，所述非导磁区呈扇环形。
更优选地，所述传感器包括多对 InSb 磁阻元件，每对所述 InSb 磁阻元件包括相互电连的两个 InSb 磁阻元件，且每对所述 InSb 磁阻元件中的其中一个 InSb 磁阻元件正对某一非导磁区时另一个 InSb 磁阻元件正对某一导磁部或其中一个 InSb 磁阻元件正对某一非导磁区时另一个 InSb 磁阻元件正对另一非导磁区。
进一步地， InSb 磁阻元件的宽度 ≤ 非导磁区的宽度 ≤ 导磁部的宽度。
更优选地，所述导磁码盘还具有用于检测零位的内圈磁栅，所述内圈磁栅由一个导磁部和一个非导磁区组成，所述传感器包括用于检测零位的霍尔元件，所述霍尔元件对应所述内圈磁栅设置。
优选地，所述传感器设置于所述永磁体和所述导磁码盘之间
一种如上所述的磁编码器的导磁码盘。
一种所述的导磁码盘的制备方法，包括如下步骤：在导磁材料上开贯通孔形成非导磁区，未开孔区作为导磁部，制得所述导磁码盘；或，在非导磁材料上镀导磁材料形成导磁部，未镀导磁材料的部分作为非导磁区，制得所述导磁码盘。
本发明中述及的导磁材料的定义如下：导磁材料能够对永磁体产生的磁场形成扰动，如增强磁路中的磁场，导磁材料包括软磁性材料和硬磁性材料 ( 又称永磁材料 ) 。软磁材料的主要特点是导磁率高、剩磁小。这类材料在较低的外界磁场作用下，就能产生较高的磁感应强度，而且随着外界磁场的增大而很快达到磁饱和状态；当外界磁场去掉后，它的磁性就基本消失。常用的软磁材料有纯铁和硅钢板两种。硬磁材料的主要特点是剩磁强，它经过饱和磁化后，即使去掉外界磁场，还能够在较长的时间内保持较强的磁性。目前用得最普遍的是铝镍钴合金、铁铬钴合金。（具体参见中国机电城网 www.jdcheng.com ）
本发明的磁编码器的工作原理为：永磁体固定设置，其自身产生强磁场，导磁码盘随电机的输出轴转动，导磁码盘上具有磁栅，磁栅由导磁部和非导磁区构成，导磁部由对磁场具有扰动作用的导磁材料制成，导磁部转到传感器处时传感器检测到的磁场和非导磁区转到传感器处时传感器检测到的磁场是不同的，信号处理器根据检测到的磁场变化输出弦波或 / 或脉冲信号，从而可分析得出电机转动的圈数、角度或方向。
由于采用了上述技术方案，相较现有技术具有以下优点：导磁码盘的磁栅机械加工方便，磁栅的导磁部、非导磁区的间隔和数量不受限，可根据精度需求在导磁码盘上设置尽可能多的导磁部和非导磁区，检测精度较高，寿命长，结构更紧凑。
附图说明
附图 1 为本发明的一种磁编码器在电机上的应用场景示意图；
附图 2 为本发明的磁栅和 InSb 磁阻元件的一种相对位置示意图；
附图 3 为本发明的磁栅和 InSb 磁阻元件的另一种相对位置示意图；
附图 4 为本发明的一种导磁码盘的结构示意图。
以上附图中，
1 、电机壳体； 2 、电机输出轴； 3 、永磁体； 4 、 PCB ； 5 、 InSb 磁阻元件； 5a 、 InSb 磁阻元件； 5a' 、 InSb 磁阻元件； 5b 、 InSb 磁阻元件； 5b' 、 InSb 磁阻元件； 50a 、导线； 50b 、导线； 6 、霍尔元件； 7 、导磁码盘； 71 、导磁部； 72 、非导磁区。
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解。
附图 1 所示为本发明的一种磁编码器在电机上应用场景示意图，参照附图 1 至 4 所示，磁编码器包括和电机壳体 1 固定连接的永磁体 3 、和电机的输出轴 2 固定连接的导磁码盘 7 、位于永磁体 3 和导磁码盘 7 之间的 PCB 4 。永磁体 3 由永磁材料制成，产生稳定的强磁场。导磁码盘 7 具有磁栅，磁栅由用于对永磁体 3 产生的磁场形成扰动的导磁部 71 及与导磁部 71 相接的非导磁区组成，导磁部 71 由对磁场具有扰动作用的导磁材料制成，如铁或铁氧体磁体等制成，非导磁区 72 为镂空区域或不含导磁材料从而不对磁场产生扰动。 PCB 4 上设置有信号处理器，信号处理器包括用于检测磁场变化的传感器，本实施例中的传感器设置于永磁体 3 和导磁码盘 7 之间，除此之外，还可设置在导磁码盘 7 的远离永磁体 3 的一侧。
导磁码盘 7 由如下两种制备方法制得：
1 、包括步骤：在导磁材料上开贯通孔形成非导磁区 72 ，未开孔区作为导磁部 71 ，构成磁栅，制得导磁码盘 7 ；
2 、包括步骤：在非导磁材料上镀导磁材料形成导磁部 71 ，未镀导磁材料的部分为非导磁区 72 ，构成磁栅，制得导磁码盘 7 。
导磁码盘 7 上至少具有一圈磁栅。参照附图 2 、 3 所示，磁栅可由多个导磁部 71 及多个非导磁区 72 组成，相邻两个导磁部 71 之间具有一个所述非导磁区 72 ，即，导磁部 71 和非导磁区 72 交错排列。非导磁区 72 可以等间隔设置也可不等间隔设置。非导磁区 72 的形状可为矩形、扇环形等，具体根据导磁码盘 7 的形状而定。本实施例中的传感器包括两对 InSb 磁阻元件 5 ，当所处的磁场发生变化时， InSb 磁阻元件的电阻随之变化。通过两对 InSb 磁阻元件 5 测定电机转动的角度和方向数据。一对 InSb 磁阻元件 5a 和 5a' 通过导线 50a 相互电连，另一对 InSb 磁阻元件 5b 和、 5b' 通过另一导线 50b 相互电连，且 InSb 磁阻元件的宽度 ≤ 非导磁区 72 的宽度 ≤ 导磁部 71 的宽度。磁栅和 InSb 磁阻元件参照两种相对位置关系设置，其一如附图 2 所示，当一对中的 InSb 磁阻元件 5a 或 5b 正对某一非导磁区 72 时，相应的另一 InSb 磁阻元件 5a' 或 5b' 正对另一非导磁区 72 ；或如附图 3 所示，当一对中的 InSb 磁阻元件 5a 或 5b 正对某一非导磁区 72 时，相应的另一 InSb 磁阻元件 5a' 或 5b' 正对某一导磁部 71 。
导磁码盘 7 可以为多种形状，磁栅可设置于导磁码盘 7 的各个面上。下面以圆片状的导磁码盘 7 为例对本发明进行进一步阐述，磁栅设置在圆片的底面上。参照附图 4 所示，导磁码盘 7 沿其圆周方向设置有外圈磁栅和内圈磁栅。导磁码盘 7 采用上述第 1 种方法制得，即，导磁码盘 7 整体由导磁材料制成，导磁码盘 7 底面的外缘沿周向等间隔地开设有多个孔，该孔沿轴向贯通导磁码盘 7 并沿导磁码盘 7 的径向延伸，孔即为外圈磁栅的非导磁区 72 ，孔之间的未开孔区构成导磁部 71 ，孔的形状为扇环形或类似梯形。与外圈磁栅相对应的 InSb 磁阻元件则为扇形或类似楔形，且相邻两孔的间距 ≥ 孔的宽度 ≥InSb 磁阻元件的宽度。导磁码盘 7 地面的中部还开设有孔形成内圈磁栅的非导磁区 72 ，其它部分则为内圈磁栅的导磁部 71 。传感器还包括用于检测两位的霍尔元件 6 ，霍尔元件 6 正对内圈磁栅设置。由上可知，外圈磁栅用于检测电机输出轴 2 的转动角度及转动方向，内圈磁栅用于检测电机输出轴 2 的零位点，从而记录转动圈数，构成增量型的磁编码器。
为了叙述方便，附图 2 至 4 所示为简化的导磁码盘，在实际应用中，根据实际的精度需求对码盘进行刻线分区开孔，如设计产品为360线，就需分为360个区域开孔；512线就需划分512个扇形区开孔，依次类推。理论上导磁码盘的底面面积足够可以做到几千线，在目前实际可以做到百万分之一的精度，实现17位以上。导磁码盘优选为铝制，铝盘要做到厚实，在高度转动下没有摆动。永磁体3优选为汝铁硼烧结材料，剩磁1.17T，极对数为1，自身用强磁场可以防止外部其他干扰磁场入侵。利用InSb磁阻元件5产生一对相互90度的弦波，利用霍尔元件6产生零点脉冲。
以上实施方式只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人了解本发明的内容并加以实施，并不能以此限制本发明的保护范围，凡根据本发明精神实质所做的等效变化或修饰，都应涵盖在本发明的保护范围内。

Claims (10)

  1. 一种磁编码器，其特征在于：包括用于和电机壳体连接的永磁体、用于和电机的输出轴连接的导磁码盘，所述导磁码盘具有至少一圈磁栅，所述磁栅由用于对所述永磁体产生的磁场形成扰动的导磁部及与所述导磁部相接的非导磁区组成，所述导磁部由导磁材料制成；
    该磁编码器还包括信号处理器，所述信号处理器包括用于检测磁场变化的传感器。
  2. 根据权利要求 1 所述的磁编码器，其特征在于：所述导磁码盘由导磁材料制成，所述导磁码盘上开设有孔，所述孔构成所述非导磁区；
    或，所述导磁码盘由非导磁材料制成，所述导磁码盘上固定设置有构成所述导磁部的导磁材料。
  3. 根据权利要求 1 所述的磁编码器，其特征在于：所述导磁码盘具有外圈磁栅，所述外圈磁栅由多个导磁部及多个非导磁区组成，相邻两个所述导磁部之间设置有一个所述非导磁区。
  4. 根据权利要求 4 所述的磁编码器，其特征在于：所述导磁码盘为圆片状，多个所述非导磁区沿圆片的周向等间隔分布，所述非导磁区呈扇环形。
  5. 根据权利要求 4 所述的磁编码器，其特征在于：所述传感器包括多对 InSb 磁阻元件，每对所述 InSb 磁阻元件包括相互电连的两个 InSb 磁阻元件，且每对所述 InSb 磁阻元件中的其中一个 InSb 磁阻元件正对某一非导磁区时另一个 InSb 磁阻元件正对某一导磁部或其中一个 InSb 磁阻元件正对某一非导磁区时另一个 InSb 磁阻元件正对另一非导磁区。
  6. 根据权利要求 5 所述的磁编码器，其特征在于： InSb 磁阻元件的宽度 ≤ 非导磁区的宽度 ≤ 导磁部的宽度。
  7. 根据权利要求 4 所述的磁编码器，其特征在于：所述导磁码盘还具有用于检测零位的内圈磁栅，所述内圈磁栅由一个导磁部和一个非导磁区组成，所述传感器包括用于检测零位的霍尔元件，所述霍尔元件对应所述内圈磁栅设置。
  8. 根据权利要求 1 至 7 任一所述的磁编码器，其特征在于：所述传感器设置于所述永磁体和所述导磁码盘之间。
  9. 一种如权利要求 1-7 任一所述的磁编码器的导磁码盘。
  10. 一种如权利要求 9 所述的导磁码盘的制备方法，其特征在于，包括如下步骤：在导磁材料上开贯通孔形成非导磁区，未开孔区作为导磁部，制得所述导磁码盘；或，在非导磁材料上镀导磁材料形成导磁部，未镀导磁材料的部分作为非导磁区，制得所述导磁码盘。
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