DISTANCE SENSING APPARATUS

Abstract: A device for measuring the distance to a surface (10) com­ prising first and second energy emitting sources (12, 18) posi­ tioned at two different distances (R, R + L) with respect to the surface and driven by a signal (40, 52, 56 and 40, 44) which is of common frequency, but which is of different phase from one another. The beams produced by the two energy sources are reflected from the surface and the resultant vector sum of the beams received by an energy responsive detector (34) is used to produce a resultant signal which has a phase that varies with the distance to the remote surface.

Description: Distance Sensing Apparatus The present invention relates to an apparatus according to the preamble of the independent claims. It is often desirable to be able to determine the distance to a surface or object without actually touching the surface or object itself. In the field of process controls, for example, it may be desirable to determine the placement of machine parts, materials, sheets, or irregularly shaped objects without using tape measures, rules, or other normal contact like devices. In the field of photography it is desirable to be able to automatically focus the camera on objects at a remote distance from the camera. Many optical devices have been devised in the prior art for determining the distance to such remote objects, most of which have been based upon the principle of triangulation wherein light reflected from the object travels over two separate paths so as to be received upon spaced apart detectors and the images they produce compared to determine the distance to the remote object. In other devices a beam of energy is transmitted to the object and the return energy is either measured for the angle in which the reflection occurred or the time elapsed from the sending to receiving of the energy. Prior application (M6011198 EP) EP-A 0 183 240 discloses a surface position sensor in which a beam of energy is reflected from a surface and passed through an aperture so as to be received along the length of the detector at a position corresponding to the surface position. Other examples of surface position sensors and similar apparatus in the prior art may be seen in US-A 2,651,771, 4,065,778, 4,479,706 and 4,473,285. One major difficulty with triangulation type systems is that they must have very tight mechanical tolerances which makes them more costly to build and require more care in handling and use than may be desired. The systems which time a beam from transmission to reception are very costly, extremely complex and usually quite large. Ultrasonic types have the additional problem of being subject to interference in factory conditions and being quite bulky. It is therefore the object of the present invention to provide a compact, simple, accurate, and inexpensive distance sensing apparatus without utilizing the triangulation or timing techniques of the prior art. This object is achieved according to the characterizing features of the independent claims. Further advantageous embodiments of the inventive apparatus may be taken from the subclaims. In the present invention, two sources of energy are positioned to be at different distances from the remote surface to be ranged. The energy sources may be infrared or visible energy and are modulated at the same frequency but with one of the sources phase shifted with respect to the other. The energy from the two sources illuminates a portion of the remote surface and some of the energy is reflected. A detector sensitive to the energy is positioned to receive the reflection of both beams from the surface so as to produce an output which is, in effect, the vector sum of the two reflections. Rather than measure the magnitude of the resultant vector, which depends on the surface reflectivity that may not be known or may vary, it was discovered that the phase angle of the vector sum reflected is related to the range and is not dependent on surface reflectivity. Accordingly by detecting this phase angle the present invention is able to produce and output indicative of the desired range. Under reference to the figures of the attached drawing, the inventive apparatus shall be further described, where FIGURE 1 shows a schematic diagram of a preferred embodiment of the present invention; FIGURE 2 shows a vector diagram of the fluxes produced by the energy sources of FIGURE 1; FIGURE 3 is a graph showing the variation of phase angle of the resultant energy in degrees with the surface distance in millimeters; FIGURE 4 is a schematic diagram of an alternate embodiment of the present invention; FIGURE 5 is a vector diagram of the fluxes produced by the energy sources of FIGURE 4; and FIGURE 6 shows a device for correcting a problem that may arise with highly specular surfaces. In FIGURE 1, a surface 10 is shown the distance to which is to be measured. Surface 10 is shown as at least partly diffuse so that energy reflected therefrom comes off at various angles. A first energy projecting device 12 which, in the preferred embodiment, is an infrared emitting LED, is shown located at the unknown distance R from the surface 10 and projects a beam of infrared energy over paths such as shown by lines 14 and 16 to the surface 10. A second energy projecting device 18 which is also, in the preferred embodiment, an infrared emitting LED, is shown located more remote from surface 10 than LED 12 by a predetermined distance L. LED 18 is shown above and behind LED 12 so as to send a second beam of infrared energy along paths such as shown by lines 20 and 22 to the surface 10. The beams of energy from LEDs 12 and 18 are shown to overlap on the surface 10 in the area between points 24 and 26 which, of course, also extends into and out of the plane of FIGURE 1. Energy from this area is reflected off the surface 10 along paths such as shown by dashed lines 28 and 30 through an aperture shown by reference numeral 32 to an energy responsive detector 34 which, in the preferred embodiment, is a photo diode preferably a silicon photo detector which is responsive to infrared energy. An oscillator 40 is shown in FIGURE 1 operable to produce an output on a line 42 which is of predetermined frequency and which is in turn presented to a driver amplifier 44 through lines 46 and 48. The output of amplifier 44 is presented over a line 50 to drive LED 12 at a first frequency and phase. The signal on line 42 is also presented to a phase shifter 52 via line 54 so that the signal from oscillator 40 is shifted by a predetermined amount. This phase shifted signal is present via line 55 to a second driver amplifier 56 which in turn presents the phase shifted signal along a line 58 to drive LED 18 at the first frequency but at a second phase. Thus, it is seen that LED 12 and LED 18 are both driven at the frequency of oscillator 40, but the phase of the energy produced by LED 18 is shifted with respect to the phase of the energy produced by LED 12. It should be understood that the amount of phase shift is not particularly critical to the present invention (although, with larger phase shifts, i.e. 120 degrees to 180 degrees, the sensitivity to range changes tends to increase), nor is the frequency of oscillator 40 or the distance L, these values being chosen by those skilled in the art for best performance. In one experiment, the frequency was chosen to be 10 KHz, L was 40 mm and the phase shift was a large angle between 120 degrees and 180 degrees. The reflected energy from the area between points 24 and 26 and detected by detector 34 will be a vector summation of the fluxes produced by the LEDs 12 and 18. More particularly, if I1 is the radiant intensity of LED 12, then the flux density E1 from LED 12 is: 11 E1 = - (1) R2 Similarly, if I2 is the radiant intensity of LED 18, then the flux density E2 form LED 18 becomes: I2 E2 = --------- (2) (R + L)2 If detector 34 has an area Q and if the aperture 32 is such that the detector subtends an angle W, then the flux F1 received by the detector from LED 12 is: KWQ F1 = E1 x (3) Ir Where K is the fraction of radiation reflected from the surface 10. Substituting equation 1: Il KWQ F1 = - x - (4) R2 Tr Likewise, the flux F2 received by detector 34 from LED 18 is: KWQ F2 = E2 x - (5) Tr Substituting equation 2: 12 KWQ F2 = ---- x - (6) (R + L)2 7r It is seen from equations 4 and 6 that the flux received by the detector is related to the distance, R, to the remote surface and if the factor K were constant, the measurement of F1 or F2 would produce an indication of the unknown distance R. K is, however, dependent upon the quality of the surface 10 and is not constant. Accordingly, measurement of the fluxes F1 and F2 will only be acceptable if K can be made to drop out. For example, if the ratio of F1 and F2 is taken, K and also WQ and Tr drop out by the cancellation effects of division. Accordingly, I can obtain an output indicative of the distance R by measuring a ratio of F1 and F2. In a prefered emdodiment I obtain an expression which involves this ratio by measuring the phase of the signal received by detector 34. Since the LEDs are modulated by the same frequency but the phase of one is shifted with respect to the other by an amount which, as described above in a preferred embodiment is a fairly large angle then the total flux received by detector 34 is the vector sum of F1 and F2 as is shown, for example, in FIGURE 2 of the drawings. In FIGURE 2, the flux received by detector 34 from LED 12 is shown as an arrow 60 extending to the right and labelled F1. The flux received by detector 34 from LED 18 is shown in FIGURE 2 as an arrow 62 extending to the left at a large angle e labelled 64 about 170 degrees from arrow 60 and labelled F2. The resultant vector is shown by an arrow 66 in FIGURE 2 and this lies at an angle 68 labelled in FIGURE 2. This resultant vector 66 will be the magnitude and phase of the signal produced by detector 34 when it is set to view the area between points 24 and 26 on surface 10 and, as will be explained, measurement of angle produces an indication of the distance R as desired. More particularly, from FIGURE 2 it can be shown that the tangent of phase angle for the resultant flux vector 66 is: Sin e F1 (7) - + Cos 8 F2 F1 and because the denominator involves the ratio F, the undesirable variable K as well as the constants W, Q and TF drop out. By substitution of equations 4 and 6 into equation 7, the phrase angle can be expressed as: EMI9.1 It is seen from equation 8 that the factors KWQ and have all dropped out leaving the phase angle related only to the ratio of the radiant intensities of the LEDs, the sin and cosin of the known phase shift, the known distance L, and the unknown distance R. Thus, will vary with R in a somewhat non-linear fashion as is best seen in FIGURE 3. In FIGURE 3, a graph showing different phase angles for the resultant vector 66 of FIGURE 2 compared with the distance R to the surface 10 with various amounts of phase shift is depicted. In Figure 3, I2 is 0.3 and L is 40 millimeters. The solid line shown by reference numeral 70 represents the curve when the phase shift is 170 degrees. The dashed line 72 shows the variation when the phase shift is 160 degrees, the solid-dash line 74 shows the variation when the phase shift is 140 degrees, and dotted line 76 shows the variation when the phase shift is 120 degrees. The preferred embodiment uses a large phase shift since the curve, at the upper end of the measurement, has the greatest variation. Other factors involved, however, are the distance L and the radiant intensities of LEDs 12 and 18. Accordingly, it will be best to choose the desired values in accordance with the desired output for a particular use. While FIGURE 3 shows variations only between 0 and 200 millimeters for the distance R, it should be understood that the variation can be extended much further and surfaces up to a number of yards from the detectors can be measured with a fair degree of accuracy. Furthermore, when used for camera autofocus, it has been found that a curve such as solid line 70 fairly closely approximates the curve that is found when lens motion is plotted against distance to remote object. In other words, the lens moves in the camera by a non-linear amount which, at the larger distances approaches a flat curve since camera focus beyond several yards is substantially at infinity. Because of this approximation, by properly choosing the phase shift, a direct drive between the distance measuring circuit as shown in FIGURE 1 and the camera lens can be produced. It would not then be necessary to provide any characterized means to adjust the amount of camera lens motion for changes in distance since the output of the device of FIGURE 1 would approximate this without characterization. I have also found that if the phase shift is made 180 degrees, then the curve of FIGURE 3 approaches a verticle line at a surface distance which depends I1 upon the ratio I and L. This feature would find use in rapidly indicating whether a surface were closer or further than a predetermined amount or, for example, on automobiles, to sound an alarm when an object was closer than a preset minimum. Returning to FIGURE 1, the output of detector 34 which is indicative of the resultant flux vector 66 of FIGURE 2, is presented to an amplifier 80 by two conductors 82 and 84. The output of amplifier 80 is connected to the negative input thereof by conductor 86, a conductor 88, a resistor 90, and a conductor 92 for a feedback loop such as is commonly used for an operational amplifier. Conductor 86 is also connected to a phase detector 94 which receives a reference input from oscillator 40 via conductors 42, 46, and a conductor 96. Phase detector 94 operates to determine the phase angle of FIGURE 2 in order to produce an output representative of the function of equation 8 above. This output is seen on a conductor 98 which is presented to a microprocessor 100 for purposes of solving equation 8 and producing an output on a conductor 102 representative of the unknown distance R as desired. Of course, where the apparatus is driving a camera lens, the microprocessor 100 may not be necessary since, as explained above, the output from the phase detector following the non-linear curve for example 70 in FIGURE 3 may be sufficient to directly drive the camera lens. Many autofocus circuits already employ a microprocessor, however, and the output from phase detector 94 can therefore readily be used with that microprocessor to produce the autofocus signal. Likewise, when the phase shift is 180 degrees, the output from phase detector 94 will be abrupt and a micro processor would not be required. In industrial process applications, the output 102 may be used to control the position of a robot arm or other device necessary to perform a desired function on the surface 10 or just to make sure it is within the proper range of distances for assembly line work. In the above-described apparatus, it is seen that a very accurate measurement of the distance to a remote surface can be made with inexpensive and easily available components connected in a simple and straight forward manner without need for close mechanical tolerances and which will not be bulky or costly. These desirable effects are produced by the measuring of the phase angle of tne resultant flux vector. It snould De understood that other techniques to take the ratio of F1 and F2 or other ways to produce a resultant flux vector may be devised by those skilled in the art, as tor example, the schematic diagram of an alternate embodiment shown in FIGURE 4. In FIGURE 4, a diffuse surface 110 is shown to which tne unknown distance R is to be measured. A first source of energy 112 which, like in FIGURE 1, may be an infrared LED is shown projecting a beam of energy along paths such as 114 and 116 to the surface 110. A second energy source 118 is shown sending its beam along paths such as 120 and 122 to the surface 110. A third energy source 124, which may also be an infrared LED is shown sending its beam along paths such as 126 and 128 to the surface 110. As seen in FIGURE 3, LEDs 112 and 118 are located the unknown distance R from surface 10 whereas the third LED 124 is located more remotely than the other two LEDs by a known distance L. As with FIGURE 1, the three LEDs project their energy onto the wall in such a way that there is an area between points 130 and 132 that overlap. Energy from surface 110 is reflected back along paths such as shown by dashed lines 134 and 136 through an aperture shown as a tubular member 138 to a detector 140 sensitive to the radiation emitted by the LEDs. As with FIGURE 1, detector 140 may be a photo diode such as a silicon photo detector sensitive to infrared energy. As with FIGURE 1, tubular member 138 acting as an aperture restricts the reflected energy to a solid angle W and detector 140 will have a detection area Q. An oscillator 150 in FIGURE 3 produces a signal of predetermined frequency on a line 152 which is presented first to a 180 degree phase shifter 154 whose output on line 156 is presented to a driver amplifier 158 so as to produce a driving signal on line 160 to the LED 124 at the fixed frequency but at a phase shifted 180 degrees with respect to the output of oscillator 150. The output of oscillator 150 on line 152 is also presented by way of a line 162 and a line 164 to a second driver amplifier 166 whose output is connected by way of a line 168 to the input of LED 118. Accordingly, LED 118 is driven by a signalS which is at the same frequency and phase as the output of oscillator 150. A third path for the output of oscillator 150 is via line 152, line 162, a line 170, and a line 172 to a second phase shifting device 174 which shifts the phase of the signal from oscillator 150 by 90 degrees. The output of phase shifter 174 on a line 176 is present to a third driver amplifier 178 whose output on a line 180 drives LED 112. The input to LED 112 is therefore of the same frequency as the oscillator 150 but with a phase which has been shifted 90 degrees with respect thereto. The area between points 130 and 132 on surface 110 which receive beams from all three LEDs, as was the case in FIGURE 1, reflects energy, the vector sum of which is detected by detector 140. If the signal from LED 118 which is in phase with the oscillator output 150 is F1, this vector is shown in FIGURE 5 as an arrow 190 extending to the right. The signal from LED 124 which is 180 degrees out of phase with the oscillator 150 is the signal F2 seen in FIGURE 5 as an arrow 192 extending to the left and 180 degrees out of phase with the arrow 190. The flux from LED 112, F3, is shown in FIGURE 5 as an arrow 194 extending upwardly and 90 degrees out of phase with respect to arrow 190. In FIGURE 5, the difference between flux F1 and F2 is shown as an arrow 196 extending to the right in phase with the arrow 190. The resultant vector shown as arrow 198 is the diagonal constructed between arrow 196 and 194 and represents the resultant flux from the three sources of energy, LEDs 112, 118, and 124. The phase angle between the resultant vector 198 and flux vector 190 is measured and, as will be shown, is representative of the distance R. More particularly, with the solid angle W subtended by the detector 140 having an area Q and with the intensity of radiation I1 from LED 118, the flux density E1 therefrom is given by the equation: 11 E1 = - (9) R2 Similarly, with I2 the radiant intensity of LED 124, then the flux density E2 therefrom is given by the equation: 12 E2 = - (R + L)ê (10) Likewise, with I3 the radiant intensity of LED 112, then the flux density E3 therefrom is given by the equation: : I3 E3 = - (11) R2 As with the analysis of FIGURE 1, the reflected flux from the output of LED 118 will be given by the equation: KWQ I1 KWQ F1 = E1 x -- = -- x --- (12) Tr R2 Tr Similarly, the flux reflected from surface 10 that originated at LED 124 will be given by the equation: KWQ I2 KWQ F2 = E2 x ---- = --- x --- (13) Tr (R + L)2 Tr and the flux reflected from surface 110 originating at LED 112 will be given by: KWQ I3 KWQ F3 = E2 x --- = -- x --- (14) IT R2 IT From FIGURE 5, the resultant flux given by arrow 198 can be shown to be given by the equation: : EMI18.1 (15) It is thus seen again that will be related to R since K, W, Q and IT have cancelled out and R is tne only variable in the equation through a non-linear relationsnip similar to that seen in FIGURE 3. Returning again to FIGURE 4, the resultant flux received by detector 140 produces an output signal on lines 200 and 202 to an amplifier 204 having an output on line 206. The output 206 is connected by a line 208, a resistor 210 and a line 212 back to the negative input of amplifier 204 for a feedback circuit characteristic of operational amplifiers. The output line 206 is also connected to a phase detector 214 which has a reference signal from oscillator 150 presented thereto via lines 152, 162, 170, and a line 216. Pnase detector 214 produces an output which is related to the angle and thus to the unknown distance R which appears on output line 218 presented to a microprocessor 220 which produces an output to any suitable utilization apparatus on a line 222. As mentioned before, it is possible to simulate the general curve structure for the camera lens motion with respect to distance and thus witn camera autofocus system, microprocessor 220 may not be necessary. Since many cameras already have a microprocessor, however, it may be desirable to utilize the output from the phase detector through the microprocessor to position the camera lens. When the surface such as 10 or 110 is highly specular, the return signal will appear to have originated from a source which is twice the distance from the detector as the surface 10 or 110 is. With respect to the specularly reflected energy the phase of the resultant vector would be given by the equation: EMI19.1 and the system would work perfectly well on specular surfaces with this new equation. Where, however, the surface to be measured is a mixture of specular and diffuse then some arrangement for removing the specular reflection may be desirable. FIGURE 6 shows the detectors of FIGURE 1 with a correction apparatus for removing the specular part of a mixed signal. In FIGURE 6, the LED 12 is shown presenting its beam along paths such as lines 14 and 16 through a polarizer 250 which polarizes the energy from LED 12 in a first direction shown by arrows 252. In similar fashion, the energy from LED 18 presents its beam along paths such as lines 20 and 22 through a second polarizer 254, her polarized in the same direction as polarizer 250 as shown by arrows 256 or 180 degrees oposite. The detector 34 receiving reflected energy along paths such as shown by dashed line 28 and 30 receives them through an analyzer 260 which is polarized 90 degrees with respect to the directions of polarization of polarizers 250 and 254 as shown by arrows 262. The effect of analyzer 262 then is to remove the polarized light that is coming from LEDs 12 and 18, as would be the case with a specular surface, but not to remove the diffuse light coming off of the surface, which is not polarized. Accordingly, the reception by the detector 34, although perhaps of lesser magnitude than was the case in connection with FIGURE 1, will still be only that portion of the signal which is diffuse in nature and accordingly will be analyzed by the system of FIGURE 1 in the same manner as previously described. It is thus seen that I have provided a device for determining the distance to a surface which is both economical, uncomplicated, inexpensive, and accurate. Many obvious modifications will occur to those skilled in the art. As for example, the various phase angles used may be altered from those shown in the present invention, different sources of energy than LEDs and infrared wavelengths may be utilized and other ways of detecting phase or measuring the ratio of F1 and F2 may be employed. If, for example, the energy sources 12 and 18 were modulated at different frequencies, then frequency responsive apparatus could be employed to separate the two fluxes and take their ratio. It should also be understood that the use of microprocessors is arbitrary and depends on the use involved. I therefore intend not to be limited by the specific structures used to explain the preferred embodiments but rather intend to be limited only by the following claims.

Claims: Claims: 1Apparatus for producing an output indicative of the dis tance to a remote surface (10), c h a r a c t e r ized by: first beam producing means (12) arranged to project a first beam of optical energy, having a first phase, to the surface; second beam producing means (18) arranged to project a second beam of optical energy, having a second phase, to the surface, the second beam producing means positioned a predetermined distance (L) more remote from the surface than the first beam producing means; energy responsive means (34) positioned to receive energy reflected from the surface and to produce a resultant signal representative of the vector sum of the reflec tions of the first and second beams; and phase sensing means (94) connected to receive the resultant signal and to produce therefrom an output signal indicative of the phase of the resultant signal as an indication of the distance to the remote surface. 2. Apparatus according to claim 1, c h a r a c t e r i z e d b y oscillator means (40) connected to drive the first and second beam producing means (12, 18) at a common frequency and connected to the phase sensing means (94) to supply a reference signal thereto. 3. Apparatus according to claim 2, c h a r a c t e r i z e d b y phase shifting means (52) connected between the oscillator means (40) and one of the first and second beam producing means (12, 18) to shift the phase of the drive thereto. 4. Apparatus according to claim 3, c h a r a c t e r i z e d i n t h a t the phase shift produced by the phase shifting means (52) is greater than 90 degrees. 5. Apparatus according to claim 1, c h a r a c t e r i z e d b y processing means (100) connected to receive the output signal and to produce, in accordance with a predetermined function thereof, a control signal to operate a control device. 6. Apparatus according to claim 1, c h a r a c t e r i z e d i n t h a t the first and second beam producing means (12, 18) are light emitting diodes and the energy responsive means (34) is a photodiode. 7. Apparatus according to claim 6, c h a r a c t e r i z e d i n t h a t the light emitting diodes operate in the infrared range. 8. Apparatus according to claim 1, c h a r a c t e r i z e d b y polarizing means (250, 254) positioned between the first and second beam producing means (12, 18) and the surface, and an analyzer (260) positioned between the surface and the energy responsive means (34), polarized 90 degrees from the polarizing means, to minimize specular reflections from reaching the energy responsive means. 9. Apparatus according to claim 1, c h a r a c t e r i z e d b y third beam producing means (112) arranged to project a third beam of optical energy, having a third phase, to the surface and the resultant signal from the energy responsive means is representa tive of the vector sum of the reflections of the first, second and third beams. 10. Apparatus according to claim 9, c h a r a c t e r i z e d i n t h a t the second phase is 180 degrees from the first phase and the third phase is 90 degrees from the first phase. 11. Apparatus for determining the distance R to a remote surface (10) , c h a r a c t e r i z e d b y first radiant energy producing means (12) having a radiant intensity I1 and located the distance R from the surface, projecting a beam to illuminate at least a first portion of surface so that energy with a flux F1 is reflected thereby; second radiant energy producing means (18) having a radiant intensity I2 and located at a distance R+L from the surface projecting a beam to illuminate at least a second portion of the surface so that energy with a flux F2 is reflected thereby; energy responsive means (34) positioned to receive the reflected energy from the surface and to provide an output which varies with the ratio of F1 and F2 as an indication of the distance R. 12. Apparatus according to claim 11, c h a r a c t e r iz e d i n t h a t the first and second portions overlap and the detector means receives the energy with fluxes F1 and F2 from the overlap area. 13. Apparatus according to claim 12, c h a r a c t e r i z e d i n t h a t the first and second radiant energy producing means are modulated at a common fre quency. 14. Apparatus according to claim 13, c h a r a c t e r i z e d i n t h a t the first and second radiant energy producing means are modulated with a phase difference e therebetween. 15. Apparatus according to claim 14, c h a r a c t e r i z e d i n t h a t the energy responsive means receives the vector summation of the reflected energy and the output varies in accordance with the phase 0 of the resultant according to the equation: EMI25.1

Inventors: STAUFFER, NORMAN L.
Applicants: HONEYWELL INC.
Application year: 1986
Main classification: G01S17
IPC codes: G03B13, G01B11, G01C3, G02B7, G01S17