Abstract:
A includes a shaft having a length, a first end, and a second end; the second end has an oblique reflective surface defined thereon; the first end fixedly attached to the knob. Containing the shaft is a rotation body, having a receptacle to accommodate the second end of the shaft with the oblique reflective surface exposed. An integrated circuit optical module is optically coupled to the rotation body. The optical module detects a light irradiance profile from the oblique reflective surface and includes a solid state light source and a plurality of photo detectors which generate an electrical signal upon exposure to light. As the knob is rotated, the oblique reflective surface generates a changing asymmetric irradiance profile, the change being translated into an electrical signal via the photo detectors, which signal corresponds to the degree of rotation of the knob.

Description:
FIELD OF INVENTION 
     This invention relates to user interface devices. More particularly, this invention relates to an optical sensor device to measure the mechanical rotation and the rotational speed of a shaft. This shaft may be part of a dial or knob assembly in an electronic apparatus. 
     BACKGROUND 
     The world finds a myriad of electronic devices available to the user. For the user to take advantage of what a particular device has to offer, he must be able to interface with it. On such interface is the knob, found on practically every mechanical or electronic device. People learn to use this interface at an early age and quickly associate the turning of the knob as changing how the device operates—for instance, turn the knob clockwise to go to “high” and turn the knob counter-clockwise to go to “low.” As in the case of a radio, the knob may be attached to a potentiometer; the user turns up the volume and the resistance of the potentiometer decreases, so that more of the output power from the radio&#39;s amplifier is directed to the speakers. During the turning of the knob, the user may encounter clicks and pops owing to a less than solid electrical connection of the rotating conductive contact and the surface of the variable resistor. Such pops may diminish the user&#39;s enjoyment of the listening experience, at a minimum or such pops may be large transient voltages sent to the speakers that damage them. 
     Furthermore, the mechanical nature of the potentiometer may limit its usefulness in small portable devices (i.e., PDAs, smart phones, tablet computers, etc.); the mechanics can only scale so far. 
     There exists a need for the familiar knob-based user interface which overcomes the shortcomings of a mechanical control that is suitable for modern electronic apparatus. 
     SUMMARY OF INVENTION 
     In applications, such as automotive sound systems, the user-interface should be familiar so that it is intuitive to use and readily recognizable in the complex environment of driving a car. The typical arrangement of the volume control knob and tuning knob provides an easy-to-use way to adjust the car&#39;s radio. To relate the degree of rotation of the knob to an adjustment of a desired parameter, an angle-sensor may be employed. 
     Angle sensors are used as parts of controllers in many applications. For instance, in many modern audio apparatus such as stereo sets, car radios, radio tuners, etc there are control knobs or dials for changing volume, tuning, or adjusting other preferences for the user. Behind the knobs (or otherwise associated therewith), there is an angle sensor to detect the angle position of the knob (i.e., how may degrees from a starting part has the knob been turned). In many robot arms there are angle sensors to detect the position of the arm in order to control it precisely. The angle sensor in some cases is also called an encoder. In modern brushless motors used e.g. in car windows, an angle sensor is used to timely activate the stator coils. In an even broader range of applications, many machines, such as automotive engines, robots, etc, use rotational speed sensors to control or monitor the engine speed, engine management, etc. These rotational speed sensors can be in fact angle sensors, or counters that only count rotations. 
     The encoders, angle sensors or rotational speed sensors can be based on optical, magnetic, or mechanical principles. The discussion herein, is focused towards sensors that work via optical principles. 
     In an example embodiment, there is a system for detecting the degree of rotation of a knob in an apparatus, the system comprises a shaft having a predetermined length and a first end and a second end, the second end having an oblique reflective surface defined thereon, the first end fixedly attached to the knob. A rotation body contains the shaft and the rotation body has a receptacle to accommodate the second end of the shaft, the oblique reflective surface of the second end being exposed. Optically coupled to the rotation body is an optical module. The optical module detects light irradiance from the exposed oblique reflective surface the optical module; the optical module being on an integrated circuit substrate. The optical module includes a solid state light source, a plurality of photo detectors each which generate an electrical signal upon exposure to light, arranged about the light source on a plane in at least two pairs, each pair defining a first and second direction parallel to the plane, the first and the second direction substantially perpendicular to each other. The oblique reflective surface generates an asymmetric irradiance profile as light from the solid-state light source is reflected back to the plurality of photo detectors. Each pair of photo detectors generates a first electrical signal and second electrical signal in response to the irradiance profile of the oblique reflective surface. The optical module detects a change in the asymmetric irradiance profile from the oblique reflective surface of the shaft as the knob is rotated. 
     In another embodiment, there is system for detecting the degree of rotation of a motor shaft; the motor shaft has an exposed oblique reflective surface defined thereon. The system comprises a rotation body accommodating the exposed oblique reflective surface of the motor shaft. An integrated circuit optical module optically couples the rotation body. The optical module contains a solid state light source and a plurality of photo detectors arranged to detect an asymmetric irradiance profile as light from the solid-state light source is reflected back from the exposed oblique reflective surface to the plurality of photo detectors. The plurality of photo detectors generates an output representing a vector having a magnitude and an angle, the vector representing the degree of rotation of the motor shaft. 
     In yet another embodiment, there is method for detecting the degree of rotation of a shaft in an apparatus; the shaft has a predetermined length and a first end and a second end; the second end has an oblique reflective surface defined thereon. The method comprises inserting the second end of the shaft into a rotation body having a receptacle to accommodate the second end of the shaft. An integrated circuit optical module is optically coupled to the rotation body; the optical module contains a solid state light source and a plurality of photo detectors. The asymmetric irradiance profile is detected as light from the solid-state light source is reflected back from the exposed oblique reflective surface to the plurality of photo detectors. From the plurality of photo detectors, an output representing a vector having a magnitude and angle is generated. The degree of rotation of the shaft is determined from the vector representation. 
     The above summaries of the present invention are not intended to represent each disclosed embodiment, or every aspect, of the present invention. Other aspects and example embodiments are provided in the figures and the detailed description that follow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
         FIG. 1  depicts in cross-section an optical sensor module as applied to an embodiment of the present invention; 
         FIG. 2  is an electronic schematic of the optical sensor of  FIG. 1 ; 
         FIG. 3  depicts an arrangement of an angle sensing application as applied to a knob using the optical sensor module as depicted in  FIG. 1 , according to the present invention; 
         FIG. 4  is a plot of the Irradiance Profile along the X-direction of the sensor array; 
         FIG. 5A  depicts a schematic of the sensor of  FIG. 2  in relation to the underside of a knob&#39;s angled shaft; 
         FIG. 5B  is a vector diagram that shows the angle of the shaft as a function of X-Y displacement; and 
         FIG. 6  is a plot of the Irradiance Profile along the X-direction of the sensor as the knob is depressed by the user according to another embodiment of the present invention. 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims 
     DETAILED DESCRIPTION 
     The present invention has been found useful in measuring the angular displacement of a rotating shaft, particularly in control knobs in portable electronic apparatus that must make efficient use of space. Space is reduced by building the sensor on a silicon substrate. 
     The substrate includes a plurality of photo detectors arranged around a light source. The substrate that contains the photo detectors may also contain an integrated circuit for control and signal processing. When used in applications, a rotation shaft with a flat and polished end is placed in the vicinity of a sensor module. The polished end acts as a mirror. The surface of the reflector is slightly slanted with respect to the perpendicular cross-section of the shaft. Light comes from the light source, is reflected by the mirror and creates a light spot on the photo detectors. Light irradiance has an asymmetric distribution over the photo detectors, thus creating differential signals on the output of the processing circuit. When the shaft rotates, differential signals obtained from the photo detectors form a vector, whose angle corresponds to the angle position of the shaft. 
     In an example embodiment according to the present invention, the angle sensor has two separate components, (1) an optical sensor module which may be housed inside an integrated circuit (IC) package and (2) rotation body. 
     Refer to  FIG. 1 . The optical sensor module  100  contains a light source  110  and a number of photo detectors  130  fabricated on a common substrate  140  which is housed inside a package  120 . The light source  110  is located at approximately the center of the substrate (other placement is also possible). On the substrate  140 , a plurality of photo detectors  130  is arranged symmetrically around the light source  110 . The light source  110  may be a light emitting diode (LED) die or an organic light emitting diode (OLED) structure. The photo detectors  130  may be silicon photo diodes or photo transistors, or photo resistors. The substrate may be a silicon die in which the optical sensor module  100  is part of an application specific integrated circuit (ASIC) providing a custom functionality for a particular apparatus (i.e., controlling, interfacing and processing signals, etc). The optical sensor module  100  connects to the outside world via bond pads  150 ,  150   a , as with other portions of the substrate  140 . Also the optical sensor module  100  may be a part of a system-on-a-chip (SoC). In other applications, the optical sensor module  100  may be a separate standalone product, as well. 
     The optical sensor module  100  may be placed in a package having a cavity above the light source and detectors area. The cavity may be left open or covered with a transparent lid. Alternatively the substrate can be molded inside a transparent compound  120  which seals the package. For the purpose of this disclosure, transparent means that the material can transmit without substantial attenuation the frequency of light emitted by the light source  110 . 
     Refer to  FIG. 2 . In an example sensor module as depicted in a circuit  200 , four photo detectors  230  of any shape (D 1 -D 4 ) are positioned symmetrically around a light source  210  (a non-symmetrical arrangement also could be used). Each photo detector can be partitioned into elements if necessary. The photo detectors  230  are connected to two differential amplifiers  220 ,  240 , which give output signals Sx and Sy for the X- and Y-directions, respectively. PCT application of Kim Le Phan titled, “Optical Pointing Device” published on Oct. 15, 2009 (WO 2009/125360 A2) provides more detailed background information on the aforementioned discussion of the photo detector used in the present invention. The reader is referred to the Appendix. 
     In another example embodiment, the optical sensor module is combined with a rotation shaft as part of a system. When used in applications where angle position or rotation speed of a rotation body, such as knobs, dials, turning shafts, robot aims, etc, needs to be measured, the optical sensor module is placed in the vicinity of the rotation shaft. 
     Refer to  FIG. 3 . In this example, there is arrangement  300  of an angle sensing application using an optical module  340 , as described earlier. The plane of the sensor substrate is substantially perpendicular to the rotation axis of a shaft  320  coupled to a knob  310  undergoing rotation  380 . The end of the shaft facing the sensor module is cut flat, preferably polished to form a reflector  330  (optionally, only a portion of the shaft end could be shaped to form the reflector  330 ). The plane of the reflector  330  is slanted at an angle θ with respect to the substrate plane  350 . In one example embodiment, the angle θ is in the range of about 0 degrees and about 90 degrees; in another example embodiment, the angle would be in the range of about 0 and 45 degrees. In yet another example embodiment, the angle θ is in the range of about 45 and about 90 degrees. The incident light  360  emitted from the LED source in the optical module  340  bounces off reflector  330  back onto the light sensors (as reflected light  365 ) in the optical module  340 . Owing to the slanted angle of the reflector  330  and the angle distribution of the light intensity of the light source, the irradiance profile received at the photo detectors is asymmetric. The asymmetric profile received provides information on the degree of the knob&#39;s rotation. 
     In another example embodiment, if the shaft material cannot be polished to a sufficient reflectivity, a separate reflector may be mounted on the shaft end, at a slanted angle. The reflector can be sized such that the reflected light spot on the sensors has a boundary that partially crosses the diode configuration. In either case, the reflective surface of the shaft, whether integral to the shaft surface or a separate reflector, the size of the reflective surface is usually comparable to the size of the diode configuration. An advantage of this design is that the generated differential signals can be quite large. A corresponding design consideration is that the center of the reflector (thus also the shaft) preferably should be aligned well with the center of the sensor module to make the light spot partially cross the sensor configuration. Alternatively, the size of the reflector can be substantially larger than the size of the photo detector configuration. The optical module  340  is typically centered about the rotation axis  395 . However, in practice, the lateral position of the optical module  340 , in this case, is not critical for the operation, provided that the projected light from the optical module  340  is still well within the reflectance range  365 . This largely relaxes the alignment tolerance for constructing the knob and optical sensor arrangement  300 . 
     Refer to  FIG. 4 . In an example embodiment, a plot  400  depicts an irradiance profile  405  with respect to the position from the center across photo detectors D 3  and D 4  when the reflector forms an angle of 20 degrees with respect to the substrate plane  350 . The signal on D 3  is proportional to the irradiance at position  410  and the signal on D 4  is proportional to the irradiance at position  420 . These two positions are plotted on curve  405 . In this graph the shaft is supposed to be at the angle position such that the plane going through the shaft axis and perpendicular to the reflector surface intersects the photo detector plane along the X direction. The irradiance profile  405  is asymmetric and offset to the left in the X direction. As a consequence, irradiance at D 3  is larger than that at D 4 , and signal output of D 3  is higher than that of D 4 . As a result, differential signal Sx is non zero. Likewise, when the shaft is at the angle position such that the plane going through the shaft axis and perpendicular to the reflector surface intersects the photo detector plane along the Y direction, the differential signal Sy is non zero. Though not illustrated, a corresponding plot for Sy would result, as well. 
     Refer to  FIG. 5A . If the shaft  320  is positioned at an arbitrary angle, sensors D 1  and D 2  generate signals which are input into differential amplifier  520  whose output is Sy. Likewise, sensors D 3  and D 4  generate signals which are input into differential amplifier  540  whose output is Sx. Both differential signals Sx and Sy are non-zero. Refer  FIG. 5B . These two signals (Sx and Sy) form a vector S having an angle θ. Angle θ of this vector corresponds to the angle position of the shaft and therefore can represent the angle position of the shaft.  FIG. 5A  also includes a schematic depicting the optical sensor module in relation to the reflected light profile  550  (having a center of rotation  555 ) that impinges on the light sensor  510 . As discussed earlier with respect to  FIG. 3 , thanks to the slanted reflector, the reflected light profile is asymmetric with respect to the center of the sensor configuration. The profile  550  should encompass the area covered by sensors  530  and  530 ′, and the brightest area of the light spot is off center. The brightest area makes a circle around the sensor configuration when the shaft rotates. The center of the reflector can be shifted away from the center of the sensor configuration  530  and  530 ′. In a particular example embodiment, the axis of rotation  395  of the shaft  320  would be substantially centered with respect to the sensor configuration  530  and  530 ′. 
     Refer to  FIG. 5B . The angle position of the shaft is mapped to angle θ of vector S. The signals Sx and Sy can be positive and negative, thus angle θ can be determined unambiguously. For example, when both Sx&gt;0 and Sy&gt;0, the shaft angle is in the 0-90 degree quadrant (I), when Sx&lt;0 and Sy&gt;0, the shaft angle is in the 90-180 degree quadrant (II), and so on; as shown in plot  505 . The special cases in which Sx&gt;0, Sy=0, Sx=0, Sy&gt;0. Sx&lt;0, Sy=0, and Sx=0, Sy&lt;0, map to angles 0°, 90°, 180°, and 270°, respectively (i.e., the X and Y axes of the Cartesian coordinate space). 
     In another embodiment, in some applications, depicted in  FIG. 3 , the knob may be pressed down for a switching function separately from the angle position detection, and can return to the rest position with a spring (not shown) when the pressing force is removed. When the knob is pressed down, the reflector moves closer to the sensor surface and thus the irradiance increases equally on all photo detectors. Refer to  FIG. 6 . Plot  600  of the Irradiance v. Position from Center shows two curves  605  and  605 ′ corresponding to the knob “button” rest position and pressed position, respectively. Sensors D 3  at the rest position  610  and pressed position  610 ′ and sensor D 4  at rest position  620  and pressed position  620 ′ are shown. By monitoring the common mode signal (i.e. the sum of signals coming from at least two photo detectors or from all photo detectors) the switching action may be detected, separately from the differential signals that give the angle information. Using these principles a knob with switch also could be designed wherein the switch is actuated by pulling the knob upward (the reflectance curves of  FIG. 6  would be swapped so that the “normal” curve lies above the pulled curve&#39;s position). 
     Alternatively, in another embodiment, the derivative with respect to time of the common mode signal can be monitored. By putting a threshold on the derivative, the press action can be more easily detected. Essentially, the speed of the button push is monitored. 
     In another example embodiment according to the present invention, the shaft does not necessary have to be a user-operated knob. Such a shaft may be present on miniaturized mechanical systems such as a hard disk drive, optical disk drives, cooling fans, etc. Within the disk drive motor assembly, the shaft at one end may have an oblique reflective surface bevel cut at a predetermined angle θ. Without consuming significant space, the optical module may be placed in proximity to the shaft&#39;s axis of rotation. The rotation body having a receptacle to align the shaft with the light source and photo detectors within the optical module. 
     Supporting electronics fabricated with the optical angle sensor will measure the rotational position of the shaft with respect to time, thereby providing a speed monitor. Such a monitor provides an early indication of hard drive failure in that hard disks are specified to run at particular speeds, for example 5400 rpm, 7200 rpm, or 9600 rpm (for specialized high-speed drives). Deviations from rated speed may indicate that the drive is not ready to receive data or that failure is imminent. Such failure may result from wear of the mechanical bearings that enable to hard disk platters to spin freely. The user, being presented with an early warning of hard drive failure, can take prudent steps to make a backup of valuable data. 
     Refer back to  FIG. 6 . In another application for monitoring the speed of the motor shaft in accordance with an embodiment of the present invention, the vertical position of the shaft may be monitored as well. When the hard drive is started, there is a specified amount of vertical play (in a predetermined direction) of the shaft—albeit a very small amount. This vertical play may be monitored. The rotating shaft having the oblique reflective surface moves closer to the optical sensor module (much like the knob being in the rest position  605  and the pressed position  605 ′). 
     A technique to address the detection of signals may be found in PCT application of Kim Le Phan titled, “Method and Device for Processing Signals form a Pointing Device” filed on Aug. 11, 2009 (International Application No. PCT/IB2009/053520), published on Feb. 25, 2010 (WO2010/020906 A1) provides more detailed background information on the aforementioned discussion of the processing of signals used in reference to the present invention. The reader is referred to the Appendix. 
     In another embodiment, knowing the angle position of the shaft at any time, the rotation speed can also be calculated. Within the optical sensor module, circuits for determining the time elapsed may be included. Thus, as one rotates the knob from a first angle position to another angle position, the change of angle with respect to time gives the angular velocity. Circuits to measure the elapsed time between the rotation of a knob from a first position to a second position may be designed by one skilled in the art. 
     A technique to address the detection of movements of a movable object, may be found in PCT application of Kim Le Phan titled, “Detection System for the Detection of Movements of a Movable Object, A Method of Detecting Movements of a Movable Object, and an IC having Implemented Therein the Detection System” filed on Sep. 16, 2009 (International Application No. PCT/IB2009/054036) provides more detailed background information on the aforementioned discussion of the processing of signals used in reference to the present invention. The reader is referred to the Appendix. 
     Numerous other embodiments of the invention will be apparent to persons skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims. 
     Appendix 
     
         
         1). PCT application of Kim Le Phan titled, “Optical Pointing Device” tiled on Apr. 8, 2009 (International Application No. PCT/IB2009/051485) published on Oct. 15, 2009 (WO 2009/125360 A2), the contents of which are incorporated by reference herein. 
         2). PCT application of Kim Le Phan titled, “Method and Device for Processing Signals form a Pointing Device” filed on Aug. 11, 2009 (International Application No. PCT/IB2009/053520) published on Feb. 25, 2010 (WO2010/020906 A1) the contents of which are incorporated by reference herein. 
         3). PCT application of Kim Le Phan titled, “Detection System for the Detection of Movements of a Movable Object, A Method of Detecting Movements of a Movable Object, and an IC having Implemented Therein the Detection System” filed on Sep. 16, 2009 (International Application No. PCT/IB2009/054036), the contents of which are incorporated by reference herein.