MAGNETORESISTANCE ELEMENT

Abstract: A magnetoresistance element comprises one or more magnetoresistors (a₁, a₂, b₁, b₂) whose resistances are varied with the change in magnitude of the magnetic field produced by a multipolar magnet disposed on a moving object (1). The magnetoresistors are provided adjacent to the object between electrodes (C and L) and arranged to have a sensitivity which distributes along the moving direction (p) of the object with a predetermined distribution breadth and which has one or more peak values, so as to output a signal having a sinusoidal waveform.

Description: Background of the Invention 1. Field of the Invention This invention relates to a magnetoresistance element suitably used for a magnetic encoder, and more particularly, to a magnetoresistance element which stably outputs a signal which is varied in a sinusoidal manner with the rotation of a rotor magnet, necessary for analyzing an output signal of a magnetic encoder in high resolution using an analog method, irrespective of its attached position or the pattern of the magnetic poles provided in the rotor magnet. 2. Description of the Prior Art Recently, there has been widely employed a magnetic encoder instead of an optical encoder employed conventionally. Such a magnetic encoder mainly comprises a rotor 1 having a multipolar magnet formed on the outer cylindrical surface thereof, and a magnetoresistance element 2 disposed on the stator, as shown in Fig. 1. In the figure, reference numeral 3 represents a shaft fixedly connected to the rotor 1; 4, a bearing for the shaft 3; 5, a case of the magnetic encoder; and 6, a base plate on which is provided a signal processing circuit for processing the output signal of the magnetoresistance element 2, and so on. The magnetoresistance element 2 may comprise a group of magnetoresistors a₁, a₂, b₁ and b₂ on a same substrate arranged so that respective phase differences between the magnetoresistors a₁ and a₂, and between the magnetoresistors b₁ and b₂ become 180 degrees (π radians) in electrical angle as shown in Fig. 2, or the phase difference between the magnetoresistors a₁ and b₁ becomes 90 degrees (π /2 radians). The respective one ends of the magnetoresistors a₁ and a₂ are connected to a common electrode C a , the respective one ends of the magnetoresistors b₁ and b₂ are connected to a common electrode C b , and the other ends of the magnetoresistors a₁, a₂, b₁ and b₂ are connected to respective electrodes L a ₁, L a2 , L b1 and L b2 . In Fig. 2, an imaginary line represents an object to be detected such as the rotor 1. The rotor 1 has many magnetic poles so formed on the outer circumference thereof that N-pole and S-pole are arranged alternately, and moves in the direction indicated by an arrow P. An encoder of this type is seen, for example, as forming the basis of the arrangement described and illustrated in GB 2,163,852 A. Fig. 3 shows a circuit for obtaining two output signals A and B whose phases are different to each other, by using the magnetoresistance element 2 having the configuration shown in Fig. 2. In the figure, OP₁ and OP₂ represent comparators; R₁ to R₄, resistors; and T A and T B , output terminals of the output signals A and B, respectively. In the positional sensor referred as a synchronous resolver, there has been employed a method for improving the resolving power using devices encoded with a trigonometric function since a long time ago. Such method can be also applied to the magnetic encoder. Fig. 4 shows an example of a circuit for the magnetic encoder to which the above method is applied. In the figure, reference numeral 11 represents an oscillator; 12, a counter; 13, a sine-ROM (Read Only Memory) in which sine values have been stored corresponding to the count values of the counter 12; 14, a cos-ROM in which cosine values have been stored corresponding to the count values of the counter 12; 15 and 16, digital-to-analog (D/A) converters; 17 to 20, amplifiers; 21 to 24, variable resistors; a₁, a₂, b₁ and b₂, magnetoresistors; 25 and 26, resistors; 27, a comparator for detecting a zero-crossover point; and 28, a D-flip flop. In operation, the oscillator 11 generates a sequence of pulses at a predetermined timing and the counter 12 counts the number (for example 0 to 255)of the pulses supplied from the oscillator 11. The count value of the counter 12 is supplied to the sin-ROM 13, the cos-R0M 14 and the D-flip flop 28, respectively. When the count value of the counter 12 is supplied to the addresses of the sin-ROM 13 and the cos-ROM 14, corresponding sine and cosine digital values are read out from the data of the sin-ROM 13 and the cos-ROM 14, respectively, and are supplied to the digital-to-analog converters 15 and 16, respectively. The digital-to-analog converters 15 and 16 convert the input digital values to analog values. The output of the digital-to-analog converter 15 is supplied to the amplifiers 17 and 18, respectively, and the output of the digital-to-analog converter 16 is supplied to the amplifiers 19 and 20, respectively. The amplifiers 17 and 19 amplify the input analog values and then supply the amplified signal to the electrodes L a1 and L b1 via the variable resistors 21 and 23, respectively. Accordingly, AC voltage signals in proportion to sin ωt and cos ωt(where ω is angular frequency) are applied to the electrodes L a1 and L b1 , respectively. On the other hand, the amplifiers 18 and 20 invert the phases of the input analog values and amplify the phase-inverted analog values, and then supply them to electrodes L a2 and L b2 via the variable resistors 22 and 24, respectively. Accordingly, AC voltage signals in proportion to (- sinωt) and ( - cos ωt) are applied to the electrodes L a2 and L b2 , respectively. The voltage at the point C a which corresponds to the common electrode of the magnetoresistors a₁ and a₂ is added to the voltage at the point C b which corresponds to the common electrode of the magnetoresistors b₁ and b₂, and thus added signal is supplied to positive input terminal of the comparator 27 via the resistor 25. The negative input terminal of the comparator 27 is connected to the earth. The comparator 27 detects a zero-crossover point on the basis of the above signal obtained by adding the voltages at the point C a and C b , and the D-flip flop acts to take in signals on the basis of the detected result of the comparator 27. Assuming that if DC voltage signal is applied to the magnetoresistors a₁ and a₂, and b₁ and b₂, the voltage at the point C a is proportional to cosϑ and the voltage at the point C b is proportional to sinϑ, where ϑ is a rotational angle of the rotor 1 represented in electrical angle in radians provided one pitch of the magnetic poles of the rotor 1 is 2π. Under the condition, if AC voltage signal is applied to the magnetoresistors a₁ and a₂, and b₁ and b₂, new AC voltage signal whose phase is shifted by ϑ relative to that of the initally applied AC voltage signal can be obtained by adding respective voltages at the points C a and C b , which is expressed as follows: where K is a constant. Accordingly, even small rotational angle corresponding to less than one pitch of the magnetic poles can be detected by detecting the phase difference between the applied signal and the added signal. The above equation (1) can be applied acurately to the case only where the resistance of the magnetoresistance element 2 varies sinusoidally with the rotational angle of the rotor 1. However, as a result of observing the voltages at the points C a and C b when applying DC voltage across the magnetoresistance element 2, it has been found that the form of the obtained output voltage curve is considerably distorted from a sinusoidal waveform when the magnetoresistance element 2 is set close to the rotor 1 on the one hand, and the form of same is similar to the sinusoidal waveform but the ouput voltage decreases and is liable to be affected by noise when the magnetoresistance element 2 is set apart from the rotor 1. Conventionally, the resolving power of the magnetic encoder has been improved by reducing the pitch of the magnetized pattern in the multipolar magnet of the rotor 1 as well as the respective distances between the magnetoresistors a₁ and a₂, and between the magnetoresistors b₁ and b₂ of the magnetoresistance element 2. However, if the pitch of the magnetized pattern is reduced, the intensity of the magnetic field produced by the magnetic poles decreases. For that reason, the magnetoresistance element 2 must be disposed close to the rotor 1. In this case, high accuracy is required in the components used for the encoder and in assembling of the encoder. Therefore, the encoder is more expensive to manufacture and the risk of damaging the encoder increases due to vibration or force exerted to the rotational axis of the encoder causing the rotor 1 to come into contact with the magnetoresistance element 2. Dependence upon the accurate manufacture and assembly of the parts of the encoder are avoided in the device of the present invention by providing a physical distribution of the magnetoresistive arterial and /or shaping thereof on its substrate such as to add a distribution /shape dependent phase displaced term in the frequency signal induced within the element or elements when the latter are swept by the magnetic field produced by a succession of alternating magnetic poles. Thus according to the invention there is provided a magnetoresistance element for detecting a displacement of a moving object by detecting the change in magnitude of the magnetic field produced by a plurality of successive magnetic poles having alternate polarities arranged on the object, which comprises one or more magnetoresistors disposed on a substrate adjacent to said magnetic poles for detecting changes in magnitude of the magnetic field and which are arranged to provide the element with an intrinsic sensitivity which varies along, and is distributed along the displacing direction, characterised in that the sensitivity distribution breadth is made substantially equal to a multiple of one pitch of said magnetic poles and the distribution has one or more peak sensitivity values intermediate the two ends of the element. With such construction, since the sensitive portion of the magnetoresistance element has the distribution breadth relative to the displacing direction of the magnetic poles of the object to be detected, the output voltage of the magnetoresistance element becomes substantially periodic in form, notwithstanding a d.c. excitation, regardless of the set distance between the magnetic poles of the object to be detected and the magnetoresistance element, and the distribution of the magnetic field produced by the magnetic poles of the object to be detected. For example, the sensitivity distribution W of the magnetoresistance element is set to satisfy the following equation: W = α + β.cos δ where α is a real number, β is a real number but not equal to zero, δ is a positional coordinate in the displacing direction of the magnetic poles and is represented in radians provided the amount of the displacement through one cycle of the change in magnitude of the magnetic field is 2π. Preferably each magnetoresistor is in the form of a curved line which has two inflection points and is symmetrical with respect to its center point. This configuration is simplest and has an advantage that manufacturing of the element is very easy. Alternatively, the magnetoresistor may be formed with a substantially parabolic shape whose center axis is in the direction perpendicular to the displacing direction of the magnetic poles. In this case, the electrodes can be disposed only at one side. Such configuration has another advantage, in addition to the above, that the magnetoresistance element can be made small because it can be arranged on a small area. Each of the magnetoresistors may be composed of a plurality of portions connected in series and each substantially in the form of a parabola whose center axis is perpendicular to the displacement direction of the magnetic poles. In a preferred embodiment, each of the magnetoresistors has a meandering pattern having portions which extend in the direction perpendicular to the direction of the displacement of the magnetic poles and whose lengths are gradually changed along the direction of the displacement of the magnetic poles. This structure is more excellent in sensitivity than the other configurations mentioned above. One form of distributed sensitivity obtained by shaping per se of a composite arrangement of magneto-resistive elements is observable in Figs. 37 and 38 of DE 3011462. The arrangement shown and described there is a meandering pattern of elements, each having a longitudinal dimension arranged parallel to the relative direction of motion between the composite arrangement and a magnetic boundary transversely oriented with respect to said motion. The lengths of the individual elements are varied over the said transverse direction so as to produce an output signal function in the device generally of the form ƒ (x) where x is the length of the elements. The teachings of this document are restricted to mean displacement sensors. Hereinafter the invention is described by way of example with reference to the following drawings. Fig. 1 is a schematic view in cross section of a prior magnetic encoder; Fig. 2 is a plan view of the magnetoresistance element used conventionally; Fig. 3 is a block diagram of a circuit used for a conventional magnetic encoder; Fig. 4 is a circuit diagram of a magnetic encoder based on the circuit of Fig. 3 and in which elements a₁, a₂, b₁ and b₂ correspond; Fig. 5 is a plan view of a preferred embodiment of this invention; and Fig. 6 to Fig. 8 are plan viewsof other preferred embodiments of this invention, respectively. Detailed Description of the Preferred Embodiments Before describing the preferred embodiments, the principle of this invention will be explained. A change ρ in resistance of a magnetoresistance element at a position δ on the coordinate on a substrate along the rotational direction of a rotor (object to be detected) is a function of the sum of the position δ and the rotational angle ϑ of the rotor, and is represented by a periodic function whose period is 2π. This function can be expanded in Fourier series as follows: Now, it is assumed that the magnetoresistance element has a configuration so that its sensitivity distribution through the range of 0 to 2π of δ is: where α is a real number. The change in resistance of the entire magnetoresistance element is given by integrating the product between the equations (2) and (3) as follows: In this integration, the terms other than k = 1 term become zero due to the natures of trigonometric function. Consequently, the equation (4) can be rewritten as follos: where γ and ε are constants determined by p₁ and q₁, respectively. Accordingly, the output in sinusoidal form can be always obtained with the above configuration of the sensitive portion even when the change in resistance at the position δ of the magnetoresistance element is distorted in any manner. Moreover, the equation (3) can be expressed as following general equation: W = α + β.cos δ where α is an arbitrary real number and β is a real number but not equal to zero. Next, it will be explained the preferred embodiments of the magnetoresistance elements according to this invention. Fig. 5 is a plan view of the magnetoresistance element 2 of the first embodiment according to this invention, in which C o represents a common electrode; L a1 , L a2 , L b1 and L b2 , electrodes; a₁, a₂, b₁ and b₂, magnetoresistors each having a distribution in the sensitivity along the rotational direction of the rotor 1. The pattern shown in Fig. 5 is most fundamental one. The magnetoresistance element 2 may be formed by providing a ferromagnetic or semiconductor thin film on an insulating substrate made of glass etc., and leaving a predetermined pattern by using a method such as etching, as shown in Fig. 2. As the pattern, it is typical to provide two to eight magnetoresistors in such a manner that whose phases are shifted in turn, as shown in Fig. 2. The dimension of the magnetoresistance element is for example several hundreds Å in thickness and approximately 10 µm in line width, and the dimension of the magnetic pole is for example one hundred to several hundreds µm in width. The conventional magnetoresistors are arranged parallel to the magnetic boundary line between N-pole and S-pole of the multipolar magnet of the rotor 1, namely, arranged on the portion corresponding to single electrical angle, as shown in Fig. 2. On the contrary, the magnetoresistors of this invention are arranged to have a tilt relative to the magnetic boundary line as shown in Fig. 5, namely, arranged to have a distribution of electrical angles. Since the magnetoresistance element of this invention has the distribution in the sensitivity, higher order components of the output signal can be restrained and only fundamental wave component can be taken out effectively. Next, it will be explained the relation between the distribution of the magnetically sensitive portion and the form of the respective magnetoresistors a₁, a₂, b₁ and b₂ of the magnetoresistance element 2. Now, δ-axis is given on the plane of the magnetoresistance element 2 along the rotational direction of the rotor 1 and z-axis is given along the direction perpendicular to the δ-axis. Within the non-saturation range of the resistance, the change in resistance of the magnetoresistance element 2 is proportional to the magnitude of the magnetic field component in the direction perpendicular to the current flowing direction and the magnetic field component in the direction parallel to the plane is only that in the direction. Accordingly, provided an angle between an infinitesimal path dℓ of the magnetoresistor a₁, a₂, b₁ and b₂ and z-axis is ψ, the change in resistance at the infinitesimal path dℓ is proportional to dℓ·cosψ. If the z-axis component and δ-axis component of the infinitesimal path dℓ are dz and dδ, respectively, the change in resistance at d is proportional to dz. Consequently, it may be considered that the magnitude of the sensitive portion at the position δ is proportional to dz/dδ. Now, the form of the magnetoresistor is represented by a function f(δ). According to the condition of the magnitude of the sensitive portion at the position δ, the function f(δ) must satisfy the following equation: df(δ)/dδ = γ · (α + β · cosδ) where γ is a proportional constant. The equation (7) can be solved easily by integration as follows: f(δ) = γ · (α.δ + β · sinδ) + C where C is an arbitrary constant. In the actual magnetoresistance element, the scale in z-axis and the position of the origin can be given arbitrarily. Considered these degree of freedom, the equation (8) can be simplified as follows: f(δ) = α · δ + β·sinδ As the factor to be noted here is not "the position of in the z-direction" but "magnitude" of the sensitive portion at δ, the form of the magnetoresistor may be folded back at its arbitrary position. Besides, when two sinusoidal waves whose phases are slightly different to each other, a new sinusoidal wave haging intermediate phase can be obtained. By utilizing these natures, magnetoresistor lines each having different phases to each other may be arranged on a small area, or they may have the configuration such that lead wires can be easily led out. The examples of patterns of the thus constructed magnetoresistors are shown in Fig. 6 and Fig. 7 as further embodiments of this invention. Fig. 6 is is an example in which the magnetoresistor is in the form of a folded pattern and the electrodes are disposed at only one side. Namely, this configuration of substantially parabolic form is obtained by folding back the pattern shown in Fig. 5 at its center. With such configuration, the magnetoresistor lines can be arranged on a small area and the electrodes can be disposed only at one side, so that the magnetoresistance element can be made small. Fig. 7 is an example in which the magnetoresistor is in the form of a folded pattern which comprises two portions substantially in the form of a parabola connected in series, and the electrodes are disposed at only one side. With such configuration, there is another advantage, in addition to the above, that electromotive forces produced by the change in the magnetic field are cancelled, to improve the accuracy of the detection. Moreover, each magnetoresistor may have a meandering pattern having portions which extend in the direction (z-direction) perpendicular to the direction of the displacement of the magnetic poles and whose legths are gradually changed along the direction of the displacement of the magnetic poles. Magnetoresistors having such a construction is shown in Fig. 8, in which the length of portions of the magnetoresistor extending in the z-direction satisfy the relation: ℓ = α + β · Cosδ. This arrangement is excellent in sensitivity where the pitch of the magnetized pattern of the multipolar magnet of the rotor 1 is larger than the width of the magnetoresistor, because a larger number of magnetoresistor lines can be arranged on the same area, compared with the above-mentioned configurations. The magnetoresistance element 2 can always output a signal in sinusoidal form without changing the waveform, irrespective of the magnetic pattern of the multipolar magnet in the rotor 1 (see Fig. 1 and Fig. 2) or the distance between the magnetoresistance element 2 and the rotor 1. Consequently, it is suitably in use for the magnetic encoder which must obtain a signal with high resolution power, as shown in Fig. 4. Having described this invention in connection with embodiments thereof heretofore, it is to be understood that the present invention is not limited to the above embodiments and many modifications can be made within the technical concept of this invention as defined in the accompanying claims. For example, although the above embodiments have been explained with the four magnetoresistors, any number such as two, six, eight, etc. of the magnetoresistors may be employed in this invention. Additionally, although the above embodiments have been explained with the magnetoresistors having the configurations as shown in Fig. 5 to Fig. 8, magnetoresistors having any other configurations may be employed in this invention if it satisfies that the magnetically sensitive portion of the magnetoresistance element has a distribution substantially equal to multiple of one pitch of the magnetic poles and has at least one peak value. The magnetoresistance element of this invention may be formed by any known method such as by etching a semiconductor or ferromagnetic thin film to leave a desired pattern.

Claims: 1. A magnetoresistance element for detecting a displacement of a moving object by detecting the change in magnitude of the magnetic field produced by a plurality of successive magnetic poles (1) having alternate polarities arranged on the object, comprising one or more magnetoresistors (a1, a2, b1, b2) disposed on a substrate (2) adjacent to said magnetic poles (1) for detecting changes in magnitude of the magnetic field and which are arranged to provide the element with an intrinsic sensitivity which varies along, and is distributed along the displacing direction characterised in that the sensitivity distribution breadth is made substantially equal to a multiple of one pitch of said magnetic poles (1) and the distribution has one or more peak sensitivity values in between the two ends of the element. 2. A magnetoresistance element according to Claim 1, wherein the sensitivity distribution satisfies the following equation: W = α + β · cos δ where α is a real number, β is a real number other than zero, and δ is a positional coordinate in the displacing direction of said magnetic poles and is represented in radians provided the amount of the displacement through one cycle of the change in magnetude of the magnetic field is 2π. 3. A magnetoresistance element according to Claim 1, wherein the outline of each magnetoresistor is in the form of a curved line which has two inflection points and which is symmetrical with respect to its center point. 4. A magnetoresistance element according to any preceding claim wherein each magnetoresistor has a boundary line substantially in the form of a parabola whose center axis is perpendicular to the displacing direction of said magnetic poles. 5. A magnetoresistance element according to any of Claims 1 to 3 wherein each magnetoresistor has a meandering pattern having portions which extend in the direction perpendicular to the direction of the displacement of said magnetic poles and whose lengths are gradually changed along the direction of the displacement of said magnetic poles. 6. A magnetoresistance element according to any preceding claim wherein each magnetoresistor-is made of a semiconductor thin film on the substrate. 7. A magnetoresistance element according to Claim 6, wherein each magnetoresistor is formed by etching the semiconductor thin film to leave a predetermined pattern on the substrate. 8. A magnetoresistance element according to Claim 1, wherein each magnetoresistor is made of a ferromagnetic thin film on the substrate. 9. The magnetoresistance element according to Claim 8, wherein each magnetoresistor is prepared by etching the ferromagnetic thin film to leave a predetermined pattern on the substrate.

Inventors: SEO, YUZO
Applicants: MITSUBISHI KASEI CORPORATION
Application year: 1988
Main classification: G01D5
IPC codes: G01D5, H01L43