# Patent

## Title
Magnetic encoder apparatus

## Abstract

A magnetic encoder apparatus has a housing that includes a base portion and a cover plate portion. The housing also has a magnet that is contained in the base portion of the housing, a sensor chip having a major surface located adjacent to the magnet, and an alignment spacer having a first side and a second side. The first side of the alignment spacer has an opening through to the second side of the alignment spacer, and the second side fits into the base portion of the housing. The opening of the alignment spacer encloses the sensor chip.

## Background
RELATED APPLICATIONS
The application claims priority to provisional U.S. application Ser. No. 60/426,296, which was filed on Nov. 14, 2002, the disclosure and content of which is hereby incorporated by reference in its entirety.


FIELD OF THE INVENTION
The present invention relates to magnetic encoder technology and an apparatus that translates mechanical rotary motion into electronic information for use in various applications, such as motors or gasoline pumps.
BACKGROUND OF THE INVENTION
Magnetic encoders are used in applications such as flow control, medical, aerospace, transportation, military, heavy equipment and computers. These magnetic encoders essentially convert mechanical rotary motion into electrical signals such as digital pulse streams.
The technology of magnetic encoders consists of a diametrically polarized magnet, imbedded into the end of a rotating shaft, positioned over a custom Application Specific Integrated Circuit (ASIC) sensor. When the magnet is rotated, the alternating polarities cause the multiple hall effect sensors on the integrated circuit sensor chip to output two sine waves ninety degrees out of phase with each other. This information is fed into a decoding and interpolation portion of the integrated circuit sensor chip with the resulting encoder output being either an incremental 2 bit gray code, or SSI serial output.
Prior art magnetic encoder devices have limited accuracy because of the placement and alignment of the diametrically polarized magnet to the sensor chip. Misalignment of the diametrically polarized magnet to the sensor chip may cause inaccuracies in the device of up to four hundred percent. Currently, there is a need in the art for a device to ensure the accurate alignment of the sensor chip to the diametrically polarized magnet. In addition, there is a need in the art for a magnetic encoder apparatus that contains the alignment device in a single housing.
SUMMARY OF THE INVENTION
The apparatus of the present invention satisfies one or more of the above-mentioned deficiencies in the art. A magnetic encoder apparatus comprising a housing is disclosed in one aspect of the present invention. The housing includes a base portion and a cover plate portion. The housing also comprises a magnet that is contained in the base portion of the housing, a sensor chip having a major surface located adjacent to the magnet, and an alignment spacer comprising a first side and a second side. The first side of the alignment spacer has an opening through to the second side of the alignment spacer, and the second side fits into the base portion of the housing. The opening of the alignment spacer encloses the sensor chip.
In an embodiment of the invention, the alignment spacer has a diameter for use in a magnetic encoder apparatus for controlling the alignment of a magnet to a sensor chip having a major surface. The alignment spacer comprising a surface having at least one tab extending outwardly from the periphery of the surface, and a raised portion extending from the surface defining an opening for receiving the sensor chip.
These and other advantages and features of the invention will become apparent upon reading and following the detailed description and referring to the accompanying drawings which like numbers refer to like parts throughout.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of the magnetic encoder apparatus in accordance with one embodiment of the present invention;
FIG. 2 is a diagrammatic illustration of another view of the encoder apparatus in accordance with one embodiment of the present invention;
FIG. 3 is a diagrammatic illustration of an alignment spacer in accordance with one embodiment of the present invention;
FIG. 4 is a detailed diagrammatic illustration of the magnetic encoder apparatus in accordance with one embodiment of the present invention; and
FIG. 5 is a diagrammatic illustration of a composite bearing for use in the magnetic encoder apparatus in accordance with one embodiment of the current invention.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, a magnetic encoder apparatus 10 comprises a housing 11 having a base portion 12 and cover plate portion 14. The cover plate portion 14 is attached to the base portion 12 using screws 16.
The magnetic encoder housing 11 may contain various components such as a printed circuit board 20 including a sensor chip 23 (FIG. 2), a diametrically polarized magnet 22, and an alignment spacer 24. The base portion 12 of the magnetic encoder enclosure housing 11 is attached to a shaft assembly 25 that provides the rotational energy that will be converted into electrical signals. For example, in one embodiment the shaft assembly 25 is a motor shaft assembly that is attached to the magnetic encoder housing 11. The magnetic encoder apparatus 10 may sense the speed, direction, and/or the angular position of the motor shaft.
Screws 16 attaching the cover plate portion 14 to the base portion 12 may be of various sizes depending on the physical dimensions of the encoder enclosure. Screws 16 may be under sized as compared to the holes 18 that are located on the cover plate 14, printed circuit board 20, and base portion 12. The under sizing of the screws 16 enables the printed circuit board 20 to float within the magnetic encoder housing 11. One skilled in the art will realize that other ways of securing cover plate 14 to base portion 12 can be utilized to attach cover plate portion 14 to base portion 12 while still allowing printed circuit board 20 to float within the magnetic encoder housing 11.
Diametrically polarized magnet 22 is embedded in shaft assembly 25 so as to allow the diametrically polarized magnet 22 to rotate along with the shaft assembly 25. The rotation of shaft assembly 25 and the embedded diametrically polarized magnet 22 provides alternating polarities of the diametrically polarized magnet 22. The alternating polarities of the diametrically polarized magnet 22 may cause multiple hall effect sensors on the sensor chip 23 to output two sine waves ninety degrees out of phase with each other.
Referring to FIG. 2, alignment spacer 24 comprises a first side 25 and a second side 27. The alignment spacer may be manufactured from a non-conductive material such as liquid crystal polymer or thermoplastic. The alignment spacer 24 has a raised portion 29 that defines an opening 28 that extends from the first side 25 to the second side 27. Opening 28 may enclose a sensor chip 23 that is located on printed circuit board 20. The sensor chip 23 may comprise an angular magnetic encoder integrated circuit similar to the ones manufactured by austriamicrosystems AG of Japan or RLS merlina technika d.o.o. of Ljubljana, Slovenija.
The opening 28 may pilot tightly over sensor chip 23. The opening 28 and the diameter of the alignment spacer 24 controls movement of the sensor chip 23 in a direction parallel to a reference plane. The reference plane may be defined by a major surface of the sensor chip 23.
In one embodiment, a major surface of the sensor chip 23 may be defined as a top surface 21 of sensor chip 23. One skilled in the art will realize that a different sensor chip surface may be defined as a major surface that may also define a reference plane. For purposes of illustration, the top surface 21 of sensor chip 23 is defined as a major surface defining a reference plane. Movement parallel to the top surface 21 or reference plane indicates movement in the X and Y direction. For example, sensor chip 23, which is included on printed circuit board 20, may move relative to diametrically polarized magnet 22. In order to provide accurate alignment of the diametrically polarized magnet 22 to the sensor chip 23, the center of the diametrically polarized magnet 22 (the rotation axis) is aligned with the center of the top surface 21 of sensor chip 23.
Accurate alignment of sensor chip 23 to diametrically polarized magnet 22 provides for increased accuracy of the magnetic encoder apparatus. Alignment spacer 24 allows the magnet to sensor alignment to be maintained to such a degree that the linearity or accuracy of the device cannot be adversely affected by assembly methods or techniques.
Movement in the X or Y-axis of the sensor chip 23 away from the center of the diametrically polarized magnet 22 (the rotation axis) can reduce the accuracy of the magnetic encoder apparatus 10. Alignment spacer 24 allows for the accurate alignment of the sensor chip 23 to the diametrically polarized magnet 22 by controlling the alignment of sensor chip 23, which is mounted to printed circuit board 20.
In addition, the reference plane also defines movement in the Z-axis, the direction of movement of sensor chip 23 towards or away from the diametrically polarized magnet 22. FIG. 2 shows the Z-axis perpendicular to the top surface 21 or reference plane. Movement perpendicular to the top surface 21 or reference plane indicates movement in the Z-axis. For example, sensor chip 23, which is mounted on the printed circuit board 20, may move relative to diametrically polarized magnet 22. In order to provide accurate alignment of the diametrically polarized magnet 22 to the sensor chip 23, the center of the diametrically polarized magnet 22 (the rotation axis) is aligned with the center of top surface 21 of the sensor chip 23. Movement of sensor chip 23 in the Z direction may reduce the accuracy of the magnetic encoder apparatus.
Referring to FIG. 3, the alignment spacer 24 comprises a set of tabs 32 extending outwardly from the periphery of the alignment spacer 24. The tabs 32 control movement in the Z-axis in a direction perpendicular to top surface 21 or reference plane. FIG. 3 shows alignment spacer 24 with a set of three tabs 32. One skilled in the art will realize that alignment spacer 24 may have more or less than three tabs 32 extending outwardly. The tabs 32 may fit into a tightly held bore of base portion 12. The mating tolerances may be =/−0.001 (line on line to 0.002 clearance fit).
FIG. 4 is a detailed illustration of the components of an embodiment of the present invention. Shaft assembly 25 is connected to the base portion 12 and held in position by shaft retaining clips 42. The shaft assembly also comprises ball bearings 44 that enable the shaft assembly 25 to rotate and provide rotational energy to the encoder apparatus 10.
FIG. 5 illustrates an alternative embodiment of the present invention in which the ball bearing may comprise a composite bearing 52. The composite bearing may be made of a material such as “Rulon J” which is made from specially formulated PTFE compounds and machined to close tolerances.
In addition, the housing may be a precision machined housing 54 manufactured from a precision screw machine instead of a cast housing. The precision machined housing 54 may be made on a precision screw machine that allows overall tolerances to be held within 0.001. The additional accuracy may improve the performance of the encoder device by maintaining the mechanical relationships to a higher degree.
The embodiments of the invention, and the invention itself, are now described in such full, clear, concise and exact terms to enable a person of ordinary skill in the art to make and use the invention. To particularly point out and distinctly claim the subject matters regarded as invention, the following claims conclude this specification. To the extent variations from the preferred embodiments fall within the limits of the claims, they are considered to be part of the invention, and claimed.

## Claims

1. A magnetic encoder apparatus comprising:
a housing, the housing including a base portion;
a magnet, the magnet contained in the base portion of the housing;
a sensor chip having a major surface located adjacent to the magnet, the major surface defining a reference plane; and
a non-conductive, non-ferromagnetic alignment spacer comprising a first side and a second side, the first side having an opening through to the second side, the opening enclosing the sensor chip, the second side fitting into the base portion of the housing.

2. The magnetic encoder apparatus of claim 1, wherein the sensor chip is included on a printed circuit board.

3. The magnetic encoder apparatus of claim 1, wherein the base portion of the housing further comprises a shaft assembly.

4. The magnetic encoder apparatus of claim 3, wherein the magnet is further attached to the shaft assembly.

5. The magnetic encoder device of claim 4, wherein the magnet is a cylindrical diametrically polarized magnet, coaxial with an axis of rotation of the shaft assembly.

6. The magnetic encoder apparatus of claim 3, wherein the shaft assembly further comprises at least one bearing.

7. The magnetic encoder apparatus of claim 1, wherein the opening enclosing the sensor chip and the alignment spacer diameter control alignment of the sensor chip in a direction parallel to the reference plane.

8. The magnetic encoder apparatus of claim 1, wherein the alignment spacer comprises at least one tab extending outwardly from the periphery of the alignment spacer to control alignment of the sensor chip in a direction perpendicular to the reference plane.

9. The magnetic encoder apparatus of claim 1, wherein the alignment spacer is comprised of a liquid crystal polymer.

10. The magnetic encoder apparatus of claim 1, wherein the alignment spacer is comprised of a thermoplastic.

11. The magnetic encoder apparatus of claim 1, wherein the sensor chip comprises an angular magnetic encoder integrated circuit.

12. The magnetic encoder apparatus of claim 1, wherein the magnet comprises a diametrically polarized magnet.

13. The magnetic encoder device of claim 1, wherein said opening pilots tightly the sensor chip.

14. A method of restricting movement of a sensor chip in relation to a magnet in a magnetic encoder apparatus, the sensor chip included on a printed circuit board, the method comprising the steps of:
placing a non-conductive, non-ferromagnetic alignment spacer having a first side and a second side, the first side having an opening through to the second side, over the sensor chip included on the printed circuit board so that said opening encloses said sensor; and
placing the magnet adjacent to the sensor chip contained on the printed circuit board.

15. The method of claim 14, wherein said step of placing comprises placing said alignment spacer over the sensor chip so that said opening pilots tightly the sensor chip.