Apparatus for controlling the position of a robotic member

Abstract: Position, velocity and direction of movement of a linear motor is determined by a fiberoptic encoder comprised of first and second fiberoptic bundles. The first ends of each of the bundles have their fibers arranged within a narrow elongated slit, the fibers of each bundle being distributed substantially along the entire length of the slit and further so that the fibers of the bundles are substantially interspersed with one another along said slit. One of the bundles conveys light directed upon the opposite end of the bundle to a surface adjacent said slit and along which the linear motor is moving. The remaining bundle conveys light reflected from the surface to a sensor which converts the intensity of the reflected light into an electrical signal. Changes in the reflectivity of the surface, which may be the etched stator of a linear motor system are utilized to determine the position of the linear motor along the stator. The direction of movement is determined through the utilization of a pair of encoders of the type described wherein the slits of each encoder are arranged in spaced parallel, the spacing being related to the spacing of the pattern on the etched stator to obtain motion and direction detection. Use of a plurality of pairs of encoders having the aforesaid arrangements provides for position, velocity and direction detection as well as rotation detection.

Description: Field of the Invention The present invention relates to an apparatus for controlling the position of a robotic member over a platen in a robotic system according to the preamble of claim 1 and more particularly to a novel fiberoptic encoder utilized for position and direction detection and especially adapted for use in linear motor systems and the like. Background of the Invention Encoders are typically utilized for providing position information. In the German patent application DE-34 08 291 a device for the determination of positions and position changes respectively of movable machine parts is disclosed. The determination is executed by guiding light from a light guiding fibre to a reflecting codation on the machine part, which light is then reflected to a light sensitive element on which the arrived light pulses are measured, the number of which pulses being a measurement for the respective position of the moving codation. In the U.K. patent application GB-2 192 271, again a sensing unit is described for measuring the extent and direction of movement. In the U.S. patent no. 4 823 062, issued April 18, 1989, to the assignee of the present application, discloses apparatus for position and direction detection employing conventional light sources and light sensitive elements. These devices have the drawbacks of being rather bulky and large and are not totally reliable. Brief Description of the Invention The present invention is characterized by an apparatus for controlling the position of a robotic member over a platen in a robotic system, characterized by the content of claim 1. Further the present invention is characterized by comprising an encoder which, in addition to being low in cost, is compact and reliable and provides highly accurate position and direction detection information. An encoder channel comprises a first fiberoptic bundle comprised of fibers which convey light from a light emitting diode (LED) to a small area of the surface of a platen adjacent a first end of the fibers which platen functions as the etched stator of an XY (i.e. two-dimensional) linear motor system. The area of illumination is configured as a narrow elongated slit. A second fiberoptic bundle comprised of fibers and having a first end, whose fibers are comingled with the first ends of the first fiberoptic bundle directing the light to the surface of the etched stator, collects reflected light over the same controlled area of the platen, providing an optical signal to a phototransistor, for example, for converting the optical signal into an electrical signal which represents the position of the encoder relative to the stator poles of the XY motor. By combining two encoder channels whose light transmitting and collecting slits are spaced appropriately relative to the pitch of the stator poles arranged on the platen, the position and direction of the encoder can be calculated relative to the platen providing position feedback for motion systems employing XY linear motor technology. By using three such encoders on an XY motor, the direction, position, rotation, velocity and acceleration of the motor can be easily calculated to provide closed loop control of the motor. The optical fibers making up the fiberoptic bundle, in addition to being distributed along the length of each slit, are preferably arranged so that the fibers of the first and second bundles of each encoder channel are distributed in alternating fashion. Thus, the optical fibers of the bundles may occupy effectively the same region to provide an encoder of simplified design and yet which provides highly accurate position, direction and acceleration information. The number of fibers in the first and second bundles may differ, the chosen number being sufficient to provide suitable light for illuminating the platen and to convey reflected light from a suitable length of the platen. The encoder design permits precision information to be obtained without any special treatment of the stator surface. The length and thickness of the illuminated region is sufficient to smooth out the effects of any irregularity, thus further enhancing the accuracy of the system. Objects of the Invention It is, therefore, one object of the present invention to provide a novel encoder system for providing highly accurate position and direction information through the employment of fiberoptic techniques. Still another object of the present invention is to provide a novel encoder for obtaining highly accurate position and direction information through the use of first and second fiberoptic bundles for respectively illuminating a narrow elongated region and for conveying light reflected over the entire region to suitable light sensing means. Still another object of the present invention is to provide a novel encoder employing fiberoptic bundles for respectively conveying light which is directed to a surface and for conveying light reflected from said surface to a light sensitive element wherein the first and second bundles have the ends thereof adjacent said surface arranged within and along a narrow elongated slit. Still another object of the present invention is to provide a novel encoder employing fiberoptic bundles for respectively conveying light which is directed to a surface and for conveying light reflected from said surface to a light sensitive element wherein the first and second bundles have the ends thereof adjacent said surface arranged within a narrow elongated slit wherein the optical fibers of said first and second bundles are distributed over substantially the entire length of the slit. Still another object of the present invention is to provide a novel encoder employing fiberoptic bundles for respectively conveying light which is directed to a surface and for conveying light reflected from said surface to a light sensitive element wherein the first and second bundles have the ends thereof adjacent said surface arranged within a narrow elongated slit and wherein the optical fibers of said first and second bundles are arranged in substantially alternating fashion along said slit. Brief Description of the Figures The above, as well as other objects of the present invention will become apparent when reading the accompanying description and drawings, in which: Fig. 1 is a perspective view showing one application of the present invention for use in position detection; Fig. 2a shows an end view of an encoder design in accordance with the principles of the present invention; Fig. 2b shows a front view of the encoder of Fig. 2a; Figs. 3a and 3b show side and front views of still another encoder embodiment of the present invention; Figs. 4a and 4b show side and front views of still another encoder embodiment of the present invention; Figs. 5a and 5b shows side and front views of still another encoder embodiment of the present invention; and Fig. 6 is a plan view showing an arrangement using a plurality of encoders for sensing speed, direction, rotation and distance. Detailed Description of the Invention and the Preferred Embodiments Thereof Fig. 1 shows a simplified version of a system utilizing the encoder of the present invention to great advantage and comprising a stator 12 which is typically a flat sheet of suitable ferromagnetic material having its top surface etched in such a manner as to provide a plurality of spaced parallel grooves 14 extending in an X or horizontal direction and a second group of spaced parallel grooves 16 extending in a Y or vertical direction, which sets of grooves 14 and 16 cooperate to define a plurality of teeth 18 arranged in a regular XY grid. The grooves are typically filled with a suitable non-magnetic material and the surface is machined and polished to provide a smooth finish. However, the material filling the grooves 14 and 16 has a reflectivity coefficient which is less than the reflectivity coefficient of the top surfaces of metal teeth 18. It should be understood that the width of the grooves 16, 18 has been exaggerated to aid in the understanding of the invention. One typical system incorporating such stators is described in U. S. Patent No. 4,890,241, issued December 26, 1989 and assigned to the assignee of the present invention. The system described therein is a robotic system in which one or more robots, each provided with two-dimensional linear motor means, move along a stator of the type shown at 12 in Fig. 1 of the present invention by application of appropriate stepping pulses and directional signals enabling each robot to move in mutually perpendicular or "X" and "Y" directions, typically for the purpose of picking up a component and placing it upon a workpiece, selecting a tool arm to be coupled to the robot and moving the tool arm over the workpiece to perform a particular manipulative activity, and so forth. In systems of this nature it is extremely important to provide positional information for feedback purposes in order to accurately position the component, tool arm or the like at a precise location above the workpiece selected by the operating program. To date, conventional systems employ unitary light sources and light sensitive elements and further utilize stators in which the grooves and teeth are finished in contrasting colors to cooperate with suitable sensors and filters for detecting same. Encoder 20 of the present invention greatly enhances the sensitivity and accuracy of the positional and direction information obtained and eliminates the need for any specialized treatment or finishing of the stator 12. As was described hereinabove in connection with U. S. Patent No. 4,890,241, a robot having an XY linear motor moves over the surface of a stator, such as, for example, the stator 12 shown in Fig. 1 of the present invention. Encoder 20 is mounted upon the robot in order to direct light to the stator surface and to convey light reflected from the stator surface to a suitable sensor. The openings 22b and 22c in housing 22 are utilized for purposes of mounting the housing to a suitable body such as, for example, a mounting surface of a robot, the housing being mountable to such a body by means of suitable threaded fasteners (not shown), for example. The encoder 20 is positioned in close proximity to the stator surface and, as shown in Fig. 2, is comprised of a housing 22 having a surface 22a provided with a pair of spaced parallel slits 24, 26. In one preferred embodiment the length of the slits is of the order of 2,54 cm (1.0 inches) and the (uniform) thickness of the slits is 0,0254 cm (0.010 inches). The centerline-to-centerline distances between slits 24 and 26 is preferably either greater than or less than the length of a tooth 18. In one preferred embodiment teeth 18 have a square shape with the length (and hence the width) dimension being 0,1016 cm (0.040 inches). Thus, the centerline-to-centerline spacing S between slits 24 and 26 is 0,0508 cm (0.020) plus multiples of 0,1016 cm (0.040 inches), i.e. S = ± 0,0508 cm (0.020) + n 0,1016 cm (0.040) , where n = 0, 1, 2, ..., N. Generally speaking, the spacing between slits 24, 26 is determined by the pitch P of the platen which may vary from 0,0254 - 0,2286 cm (.01 to .09 inches), i.e. S = ± 0,0508 cm (0.020) + nP . A fiberoptic bundle 28 suitably wrapped in an enclosing sheath has a first end extending into housing 22 and a second end divided into first and second bundle pairs 30 and 32, each bundle pair being comprised of individual bundles 30a, 30b and 32a, 32b. Each individual bundle, such as, for example, 30a is made up of a plurality of optical fibers. Bundle 30b is made up of a second group of optical fibers which may be substantially equal in number to bundle 30a. The optical fibers in each bundle are of conventional design capable of conveying light directed to a first end through the fiber to the second end thereof. The fibers, in one preferred embodiment, have a nominal diameter of the order of 30 microns. The number of fibers in each bundle need not be equal. The number of fibers in bundles 30b, 32b need only be sufficient to provide sufficient illumination by the platen 12. The number of fibers in bundles 30a, 32a should be sufficient to be distributed over the length of the slit. Thus, some of the fibers may not be used in any of the bundles 30a, 30b, 32a and 32b. All of the optic fibers of bundles 30a and 30b have their opposing ends, which extend into housing 22, distributed along substantially the entire length of the slit 24. The fibers making up bundles 30a and 30b are distributed along slit 24 preferably so that the fiber bundles 30a and 30b are arranged in substantially alternating fashion or, equivalent thereto, the fibers are randomized so that the fibers of bundles 30a and 30b extend substantially over the entire length of slit 24 and are arranged in an alternating fashion to the greatest practical extent. In a similar fashion, the fibers of each of the bundles 32a and 32b are merged and are distributed substantially along the entire length of slit 26 and are randomized in a similar fashion to that described hereinabove with regard to the fibers of merged bundles 30a, 30b arranged within slit 24. Based on the dimensions and geometry of the fibers and slits described hereinabove, it can be seen that a multiple number of fibers extend over the narrow width of the slit as well as along the entire length of the slit. Although the length of each slit 24, 26 is not critical, it is preferred that the length of each slit be at least as great as the linear distance measured along several consecutive teeth. As a practical matter, the greater the length of the slit, the greater the accuracy of the encoder since the slits average and "smooth" the light directed to the stator surface as well as the light reflected from the stator surface which serves to "smooth out" any irregularities which may be encountered on the stator surface. An LED illuminator 34, 36 is provided for each bundle pair and is located in close proximity to the free ends of the fibers making up bundles 32b and 30b. Light sensitive elements such as phototransistors 38 and 40 are located in close proximity to the free ends of the bundles 32a and 30a, as shown. In operation, light from the LED illuminators 34 and 36 and conveyed respectively along the fibers of bundles 32b, 30b direct two narrow "slit-shaped" beams of light upon the etched surface of stator 12. The encoder is aligned so that the slits 24 and 26 are aligned parallel to the "Y" groove 16 to detect motion in the "X" direction. The "slit-shaped" beams of light directed to the etched stator surface 12 is reflected therefrom (which beams are detected over substantially the entire length of their slits), and is conveyed through the appropriate bundle of optical fibers to the sensing elements 38 and 40 for slits 26 and 24, respectively. The intensity of the light detected is a function of the reflectivity of the surface portion reflecting the light impinging thereon, said surface being either a groove, a tooth or a transitional region at the boundary lines thereof. Direction information is determined through a conventional "quadrature" technique wherein, analogous to an angular shaft encoder, the pulses developed by the groove 14 (or 16) detected by slit 24 occur either ahead of or behind the pulses developed by grooves 14 (or 16) detected by slit 26, the time occurrence of the pulses (i.e. the occurrence of the pulses detected by slit 24 occurring either before or after the pulses detected by slit 26) being determinative of the direction of movement, the frequency of occurrence of the pulses determining the velocity of the encoder, and hence the robot, relative to stator 12 and the count of pulses being determinative of distance and hence position. The "quadrature" technique may be obtained through either dedicated hardware or software approaches. Figs. 3a and 3b show another alternative arrangement in which each of the individual bundles 30a, 30b, 32a and 32b terminate in a tightly bound bundle having a diameter of the order of 2 millimeters, the individual fibers having a diameter of the order of 30 microns, each bundle being covered with a monocoil tubing sleeve 30a-1, 32b-1, for example. Mounting bushings 33 and 35 have a diameter of the order of 0.25 inches. The bundles 30a, 30b, 32a and 32b merge into a unified bundle, likewise covered by a monocoil tubing sleeve 37. A bushing 39 is provided at the merging point between the individual bundles 30a-32b and the merged bundle 37. A bushing 39' is fixed to the left-hand end of housing 22a where the bundle enters into housing 22. Openings 22b, 22c are utilized to mount to the housing to the robot. Slits 24 and 26 in end surface 22a have a centerline-to-centerline distance of 0,0508 cm (0.020 inches) and each have a length of 2,54 cm (one inch) and a width of 0,0254 cm (0.010 inches). The housing has a length of 3,175 cm (1.25 inches) and a width of 0,9398 cm (0.37 inches). The spacing between adjacent ends of the slits 24 and 26 is 0,0254 cm (0.010 inches). Fig. 4a shows a somewhat modified embodiment wherein the unified bundle 37 has a longitudinal axis which extends into housing 22 in a direction parallel to the end surface 22a having slits 24 and 26. Figs. 5a and 5b show still another embodiment wherein the individual bundles 30a-32b are each enclosed within suitable PVC tubes 43, 45, 47 and 49 having longitudinal axes which extend perpendicular to surface 22a having slits 24 and 26. The embodiment shown in Figs. 4a and 4b may alternatively house the photodetectors, phototransistors and all fiberoptics within housing 22 wherein electrical leads 51 extend from housing 22 for connection into the circuitry utilized to determine position, direction and velocity, and if desired, acceleration, based upon the electrical signals developed by the light sensitive phototransistors 36, 40, shown, for example, in Fig. 2a. Fig. 6 shows apparatus employing three encoders which may be any one of the types described in Figs. 2a-5b, three such encoders 20, 20' and 20'' being mounted upon the surface of a robot R, for example, in the perpendicular arrangement shown wherein the encoders 20 and 20' are utilized for detecting movement and direction in the "X" and "Y" directions and encoder 20'' being utilized for purposes of detecting rotation in conjunction with the other detectors. Although the present invention is described as being capable of use in a two-dimensional linear motor system, it should be understood that the detector may be utilized in any applications wherein it is desirable to detect movement and position of a body moving along a surface having a detectable pattern or criteria such as slits, grooves or the like arranged in spaced parallel fashion upon a surface, the encoder being mounted upon a member moving relative to said surface. In applications wherein it is desired to obtain only positional information the encoder need only be provided with a single slit having two cooperating bundles for conveying light to the slit and for conveying reflected light from the slit. A single encoder 20 utilizing a pair of spaced parallel slits is all that is required for measuring distance and detecting velocity and direction of movement in only a single direction. For example, the bundles 30b, 302b may be illuminated by a single LED or may be merged into one bundle at their input end which is illuminated by one LED.

Claims: Apparatus for controlling the position of a robotic member movable in mutually perpendicular directions over a platen in a robotic system, said apparatus comprising: generator means for generating signals indicative of the desired position of the robotic member over the platen, encoder means (20) coupled to the robotic member for detecting the actual position of the robotic member over the platen, comparator means for comparing the desired position and actual position of the robotic member over the platen, and linear motor means coupled to the robotic member for driving the robotic member over the platen in response to the output signals of the comparator means, wherein said platen formed of magnetic material having first and second sets of parallel grid lines for defining an orthogonal matrix of teeth forming the stator poles of said linear motor means and wherein said encoder means comprising photo-electric means for directing light and receiving reflected light from said platen, characterized by: housing means (22) mounted upon said robotic member and movable therewith under control of said linear motor means; a pair of elongated, narrow, linear slits (24, 26) arranged in a surface of said housing and positioned in close proximity to said platen surface; a fiberoptic bundle (28) comprising a plurality of elongated light transmissive optical fibers arranged in first and second groups (30, 32); a first end of each of said first and second groups of fibers each respectively arranged in one of said slits (24, 26) and being tightly bundled therein; the opposite ends of each of said first and second groups (30, 32) extending from said housing means (22) and being divided into first and second branch bundles (30A, 30B; 32A, 32B); the ends of the optical fibers of each branch bundle arranged in said slit being arranged along the length of its associated slit; and being interspersed in alternating fashion in each slit; the spacing between said slits (24, 26) being less than the spacing between adjacent parallel grooves (14 or 16); means (36, 34) for introducing light rays into the fibers of each first branch bundle for directing light upon said surface of said platen; and means (38, 40) for converting light rays reflected from said platen surface and conveyed by each of said second branch bundles into electrical signals representing one of distance, velocity and acceleration values. The robotic system of claim 1 being further characterized in that the length of each slit (24, 26) is greater than a pitch of the grid-lines (14, 16) on the platen surface being scanned by said encoder means. The robotic system of claim 1 being further characterized in that the optical fibers have substantially the same diameter, which diameter is of the order of thirty microns. The robotic system of claim 1 being further characterized by providing slits having a width of the order of 0,0254 cm (0.010 inches). The robotic system of claim 1 being further characterized in that the length of each slit is approximately 2,54 cm (1.0 inches). The robotic system of claim 1 wherein, said teeth are arranged twenty-five teeth per 2,54 cm (1 inch) and the length of said slits is significantly greater than the length of a tooth (18). The robotic system of claim 1 being further characterized in that the spacing S between slits (24, 26) is S = ± 0,0508 cm (0.02 inches) + n(P) cm (inches) where n = 0, 1, 2, ..., N and P is the pitch is the grid-lines. The robotic system of claim 1 being further characterized by comprising a second encoder means (20') substantially identical to said first encoder means, the slits (24, 26) of the second encoder means (20') being arranged in the surface containing the slits (24, 26) of the first encoder means (20) so as to be perpendicular to the slits of said first encoder means. The robotic system of claim 8 being further characterized by comprising third encoder means substantially identical to said first and second encoder means wherein the slits of said third encoder means are arranged in the surface containing the slits of said first (20) and second (20') encoder means so that the slits of said third encoder means is perpendicular to the slits of said second encoder means and parallel to the slits of said first encoder means.

Inventors: CLARK LEE, CLARK, LEE
Applicants: MEGAMATION INC, MEGAMATION INCORPORATED
Application year: 1992
Main classification: G01D5
IPC codes: G01D5