Indexed optical encoder

• US 10,215,595 B2
• Filed: 04/20/2016
• Issued: 02/26/2019
• Est. Priority Date: 04/22/2015
• Status: Active Grant

• Current Assignee: Faro Technologies Incorporated
• Original Assignee: Faro Technologies Incorporated
• Inventors: York, Frederick John
• Primary Examiner(s): Ko, Tony
• Application Number:
  US15/133,646
• Publication Number:
  US 20160313146A1
• Time in Patent Office: 1,042 Days
• CPC Class Codes: G01D 5/2457 Incremental encoders having reference marks
• CPC Class Codes: G01D 5/34707 Scales; Discs, e.g. fixation, fabrication, compensation
• CPC Class Codes: G01D 5/3473 Circular or rotary encoders

Abstract

An optical encoder for measuring rotation is provided. The optical encoder includes an optical disk having a diffraction grating track and an index track. The index track being disposed radially inward from the diffraction grating track. The diffraction grating track having a plurality of equally spaced lines that create an alternating light/dark pattern. The index track includes a pattern with at least two sequences, the at least two sequences being equally spaced about the diameter of the index track, each of the sequences having at least one mark and each of the sequences having a different number of marks from the other sequences.

Claims

1. An optical encoder comprising:

an optical disk having a diffraction grating track and an index track, the index track being disposed radially inward from the diffraction grating track;

the diffraction grating track having a plurality of equally spaced lines that create an alternating light/dark pattern;

the index track having a pattern with at least two sequences of marks, the at least two sequences being equally spaced about a circumference of the index track, each of the at least two sequences having at least one mark and each of the at least two sequences having a different number of marks from each of the other sequences,

wherein the number of marks of a given sequence define the length of the sequence, the length of the sequence being measured in a number of fringes detected in the index track between the start and the end of the sequence as generated by the marks of the sequence,

wherein each sequence includes a sequence center at the midpoint between the start and end of the given sequence, wherein each sequence center is angularly spaced apart from each other sequence center about the optical disk and defines a specific angular position about the optical disk, and

wherein each sequence is separated from another sequence by a rotational distance.

2. The optical encoder of claim 1 wherein the pattern has 8 sequences, the sequence center of each sequence being arranged 45 degrees apart from adjacent sequences.

3. The optical encoder of claim 2 wherein the 8 sequences includes:

a first sequence having 1 mark;

a second sequence having 2 marks;

a third sequence having 3 marks;

a fourth sequence having 4 marks;

a fifth sequence having 5 marks;

a sixth sequence having 6 marks;

a seventh sequence having 7 marks; and

an eighth sequence having 8 marks.

4. The optical encoder of claim 3 wherein the pattern is arranged with the plurality of sequences arranged in a following order in a clockwise direction:

first sequence;

seventh sequence;

third sequence;

fifth sequence;

fourth sequence;

sixth sequence;

second sequence; and

eighth sequence.

5. The optical encoder of claim 1 wherein the pattern has 12 sequences, the sequence center of each sequence being arranged 30 degrees apart from adjacent sequences.

6. The optical encoder of claim 1 wherein the sequences are arranged to maximize the rotational distance between edges of adjacent sequences.

7. The optical encoder of claim 1 further comprising:

a light source arranged adjacent the diffraction grating track;

a sensor arranged to detect fringes from the diffraction grating track; and

a photodetector arranged to receive light from the light source reflected off of the index track, the optical encoder having a detector length.

8. The optical encoder of claim 7 wherein a length of a sequence is equal to a mark width+(a number of marks in the sequence−

1)*a distance between the sequence centers of adjacent marks.

9. The optical encoder of claim 8 wherein the distance between the sequence centers of adjacent marks is equal to Total number of fringes/Number of index sequences.

10. The optical encoder of claim 8 wherein each mark has a trapezoidal shape with sides extending radially from a center of the optical disk.

11. The optical encoder of claim 10 wherein an end of the mark closest to the center of the optical disk has a width of 83.60 um and an opposing end has a width of 94.65 um.

12. A method of determining rotational movement, the method comprising:

providing an encoder disk having a diffraction grating track and an index track, the diffraction grating track having a plurality of equally spaced lines that create an alternating light/dark pattern, the index track having a pattern with a plurality of sequences, the plurality of sequences of marks having sequence centers that are equally spaced about a circumference of the index track, each of the plurality of sequences having at least one mark and each of the plurality sequences having a different number of marks from each of the other sequences, wherein the number of marks of a given sequence define the length of the sequence, the length of the sequence being measured in a number of fringes detected in the index track between the scan and the end of the sequence as generated by the marks of the sequence, wherein each sequence center is angularly spaced apart from each other sequence center about the optical disk and defines a specific angular position about the optical disk, and wherein each sequence is separated from another sequence by a rotational distance;

illuminating the encoder disk with light;

detecting the light diffracted with a sensor;

generating a fringe signal with the sensor;

detecting a first edge of a first sequence of the plurality of sequences;

determining a first length of the first sequence;

determining a first angular position of the encoder disk based at least in part on the first length;

detecting a second edge of the second sequence of the plurality of sequences;

determining a second length of the second sequence; and

determining a second angular position of the encoder disk based at least in part on the second length.

13. The method of claim 12 wherein the step of generating the fringe signal includes generating a plurality of fringe signals in response to rotation of the encoder disk.

14. The method of claim 13 wherein the determination of the first length is based at least in part on the detection of the first edge and the number of the plurality of fringe signals generated while the first sequence reflects the light onto a photodetector.

15. The method of claim 14 wherein the first sequence includes at least one reflective mark and the second sequence includes at least two reflective marks, the first sequence and second sequence having a different number of reflective marks.

16. The method of claim 15 wherein the at least two reflective marks of the second sequence are spaced apart by a distance equal to or less than an detector length of the photodetector.

17. The method of claim 16 wherein the length of the second sequence is equal to a mark width of the at least two reflective marks+(a number of reflective marks in the sequence−

1)*the distance between the centers of adjacent marks of the at least two reflective marks.

18. The method of claim 17 wherein the plurality of sequences includes 8 sequences, the 8 sequences includes a first sequence with 1 mark, a second sequence with 2 marks, a third sequence with 3 marks, a fourth sequence with 4 marks, a fifth sequence with 5 marks, a six sequence with six marks, a seventh sequence with seven marks and an eighth sequence with eight marks.

19. The method of claim 18 wherein the pattern is arranged with the plurality of sequences arranged in a following order in a clockwise direction:

first sequence;

seventh sequence;

third sequence;

fifth sequence;

fourth sequence;

sixth sequence;

second sequence; and

eighth sequence.

20. The method of claim 16 further comprising selecting an order of sequences about the index track to maximize an angular distance between adjacent sequences.