Abstract:
A method and system for reducing operational shock sensitivity of a MEMS device includes a closed-loop control circuit for controlling the MEMS device and a shock detector for detecting a shock experienced by the MEMS device. The closed-loop control circuit includes a movable MEMS structure, a detector for sensing a position of the MEMS structure and for providing a first feedback signal related to the sensed position, and a processor for receiving the first feedback signal and for providing a control signal used to control the MEMS device. The shock detector, which according to a preferred embodiment is the MEMS structure itself, is used for detecting the shock experienced by the MEMS device and for generating a second feedback signal, which is used to alter the control signal such that a response of the closed-loop control circuit to the shock is minimized.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/587,992 filed Jul. 14, 2004, the contents of which are incorporated by reference herein. 
     
    
     MICROFICHE APPENDIX  
       [0002]     Not Applicable.  
       TECHNICAL FIELD  
       [0003]     The present application relates generally to microelectromechanical systems (MEMS) and, more particularly, to a method and system for reducing operational shock sensitivity of MEMS devices.  
       BACKGROUND OF THE INVENTION  
       [0004]     Microelectromechanical systems (MEMS) integrate electrical and mechanical components on a single substrate, such as silicon, using microfabrication technologies. Typically, the electrical components are fabricated using integrated circuit processes, while the mechanical components are fabricated using micromachining processes that are compatible with the integrated circuit processes.  
         [0005]     MEMS devices are found in an increasing number of applications, from sensor technology, to biomedicine, to telecommunications. Presently, some of the most interesting applications for MEMS devices are optical applications, wherein the tiny mechanical components include mirrors, prisms and/or gratings. For example, in the area of telecommunications, optical MEMS devices form optical switches, modulators, attenuators, and filters.  
         [0006]     In most MEMS devices, one or more actuators are provided to position the tiny mechanical components. Some examples of MEMS actuators include electrostatic, thermal, electromagnetic, and/or piezoelectric actuators. In order to limit the actuation power, current, or voltage, and thus minimize the size and cost of the MEMS device, MEMS structures are generally designed to require a relatively low actuation energy. For example, when the mechanical components are coupled to the substrate via a cantilever or one or more springs, it is generally preferred that the spring constant(s) be relatively weak. However, MEMS structures with weak spring constants are susceptible to undesired perturbations. For example, mechanical shock or vibration often results in an impulse that occurs at the natural mechanical vibrational frequency of the MEMS structure.  
         [0007]     If the MEMS structure is an integral part of a closed loop control system, which is subject to this impulse error, the control system will apply feedback in an attempt to neutralize the error. Unfortunately, most control systems operate at bandwidths much lower in frequency than the natural mechanical frequency of the MEMS structure in order to avoid difficulties associated with lag due to mechanical inertia. Accordingly, as the mechanical impulse damps out, the control system applies a delayed response to compensate. This compensation is not required, and thus introduces a large additional error due to inappropriate delayed feedback. This additional and delayed error significantly contributes to the operational shock sensitivity of MEMS devices.  
         [0008]     It is an object of the instant invention to reduce the operational shock sensitivity of MEMS devices.  
       SUMMARY OF THE INVENTION  
       [0009]     The instant invention relates to a method and system that reduces the operational shock sensitivity of MEMS devices by detecting the occurrence of a shock or vibration and reducing and/or limiting the response of a control system thereto.  
         [0010]     According to a preferred embodiment, the shock or vibration is detected using the MEMS structure itself. More specifically, the MEMS structure is used essentially as an accelerometer to measure the mechanical acceleration resulting from the shock or vibration. Upon detection of the transient shock or vibration, closed loop parameters are altered to reduce or obviate the response of the control system to the shock.  
         [0011]     In accordance with one aspect of the instant invention there is provided a method for reducing operational shock sensitivity of a MEMS device comprising: detecting a shock experienced by the MEMS device; and, altering closed-loop parameters of the MEMS device in dependence upon the detected shock such that effects of the shock are other than compensated for.  
         [0012]     In accordance with another aspect of the instant invention there is provided a method for reducing operational shock sensitivity of a MEMS device comprising: providing a MEMS device having a MEMS structure coupled to a controller in a closed-loop configuration, the controller for providing a control signal used to drive the MEMS structure; detecting a shock experienced by the MEMS device, a magnitude of the shock being sufficient to cause the MEMS structure to resonate at its natural mechanical vibration frequency f o  for a damping time t d ; and, upon detecting the shock, altering the control signal such that an amount the MEMS structure is driven in response to the shock is reduced.  
         [0013]     In accordance with another aspect of the instant invention there is provided a method for reducing operational shock sensitivity of a MEMS device comprising: controlling the MEMS device using a closed-loop control circuit, the closed-loop control circuit including a movable MEMS structure, a detector for sensing a position of the MEMS structure and for providing a feedback signal related to the sensed position, and a processor for receiving the feedback signal and for providing a control signal used to control the MEMS device, the control signal determined in dependence upon the feedback signal; detecting a shock experienced by the MEMS device; and, altering the control signal in dependence upon the detected shock such that a response of the closed-loop control circuit to the shock is minimized.  
         [0014]     In accordance with yet another aspect of the instant invention there is provided a system for reducing operational shock sensitivity of a MEMS device comprising: a closed-loop control circuit for controlling the MEMS device, the closed-loop control circuit including a movable MEMS structure, a detector for sensing a position of the MEMS structure and for providing a first feedback signal related to the sensed position, and a processor for receiving the first feedback signal and for providing a control signal used to control the MEMS device, the control signal determined in dependence upon the first feedback signal; and, a shock detector for detecting a shock experienced by the MEMS device and for generating a second feedback signal, the second feedback signal used to alter the control signal such that a response of the closed-loop control circuit to the shock is minimized. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:  
         [0016]      FIG. 1  is a schematic diagram of a prior art control system used in a MEMS device;  
         [0017]      FIG. 2  is a schematic diagram of a control system used in a MEMS device in accordance with one embodiment of the instant invention;  
         [0018]      FIG. 3  is a schematic diagram of a control system used in a MEMS device in accordance with another embodiment of the instant invention; and  
         [0019]      FIG. 4  is a schematic diagram of a control system used in an optical MEMS device in accordance with one embodiment of the instant invention.  
     
    
       [0020]     It will be noted that throughout the appended drawings, like features are identified by like reference numerals.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0021]     Referring to  FIG. 1 , there is shown a schematic diagram of a control system used in a prior art MEMS device. The control system  100  includes a MEMS structure  110 , a detector  120 , and a controller  130 . The controller  130  is electrically connected to the MEMS structure  110  and the detector  120 , such that it forms a part of the closed loop feedback circuit  140 . The MEMS structure  110  has a mechanical component  112 , an electrical component  114 , and an actuator  116 , all formed on a same substrate  118 .  
         [0022]     In operation, the controller  130  provides a control signal that drives the actuator  116 , thus moving the mechanical component  112 . As the mechanical component  112  moves, the detector  120  measures a parameter related to the position of the mechanical component  112 , and provides a feedback signal to the controller  130 . The controller  130  alters the control signal sent to the actuator  116  in dependence upon the feedback signal. Typically, the altered control signal is generated from an error signal produced by comparing the parameter measured by the detector  120  to a known parameter. Error signals are well known in the art and are not discussed further.  
         [0023]     When the MEMS device experiences a shock, such as a mechanical shock, the mechanical component  112  is subject to a transient mechanical vibration at its natural mechanical frequency f o  for a characteristic time commonly referred to as its damping time t d . Until the mechanical vibration damps out, the changing position (i.e., arising from the shock and/or actuation) of the mechanical component  112  is sensed by the detector  120 , and the closed loop feedback system  140  attempts to compensate for this effect of the shock. However, due to the relatively slow response time t r  of the closed loop feedback system (i.e., t r &gt;t d ), the perturbations experienced by the mechanical component  112  often disappear before the feedback and compensating control signals are processed. The net result is that the closed loop feedback system actually prolongs the effect of shock on the operation of the MEMS device.  
         [0024]     Referring now to  FIG. 2 , there is shown a schematic diagram of a control system used in a MEMS device in accordance with an embodiment of the instant invention. The control system  200  includes a MEMS structure  210 , a shock or vibration detector  215 , a detector  220 , and a controller  230 . The controller  230  is electrically connected to the MEMS structure  210  and the detectors  215 ,  220 , such that it forms a part of the closed loop feedback circuit  240 . The MEMS structure  210  has a mechanical component  212 , an electrical component  214 , and an actuator  216 , all formed on a same substrate  218 .  
         [0025]     In operation, the controller  230  provides a control signal that drives the actuator  216 , thus moving the mechanical component  212 . As the mechanical component  212  moves, the detector  220  measures a parameter related to the position of the mechanical component  212 , and provides a feedback signal to the controller  230 . The controller  230  alters the control signal sent to the actuator  216  in dependence upon the feedback signal. Typically, the altered control signal is generated from an error signal produced by comparing the parameter measured by the detector  220  to a known parameter. Error signals are well known in the art and are not discussed further.  
         [0026]     When the MEMS device experiences a shock, such as a mechanical shock, the mechanical component  212  is subject to a transient mechanical vibration at its natural mechanical frequency f o  for a characteristic time commonly referred to as its damping time t d . Until the mechanical vibration damps out, the detector  220  senses the changing position of the mechanical component  212  (i.e., arising from the shock and/or the actuation) and provides an erroneous feedback signal to the controller  230 . Simultaneously, the detector  215  senses the shock and provides a shock feedback signal to the controller  230 . Upon receiving the shock feedback signal, the controller  230  alters the control signal sent to the MEMS actuator  216  such that it does not attempt to compensate for the effects of the shock. For example, according to one embodiment the controller  230  sends a control signal that temporarily reduces or limits the gain of the closed loop circuit  240 . The net result is that the feedback system does not significantly prolong the effect of shock on the operation of the MEMS device.  
         [0027]     Advantageously, this embodiment of the instant invention does not attempt to prevent the mechanical perturbation and/or alter the damping time, but instead allows the natural mechanical damping to occur while the response of the closed loop feedback system is altered. Accordingly, the fabrication of the MEMS device with reduced operational shock sensitivity remains relatively simple.  
         [0028]     Referring now to  FIG. 3 , there is shown a schematic diagram of a control system used in a MEMS device in accordance with another embodiment of the instant invention. The control system  300  includes a MEMS structure  310 , a detector  320 , and a controller  330 . The controller  330  is electrically connected to the MEMS structure  310  and the detector  320 , such that it forms a part of the closed loop feedback circuit  340 . The MEMS structure  310  has a mechanical component  312 , an electrical component  314 , and an actuator  316 , all formed on a same substrate  318 .  
         [0029]     In operation, the controller  330  provides a control signal that drives the actuator  316 , thus moving the mechanical component  312 . As the mechanical component  312  moves, the detector  320  measures a parameter related to the position of the mechanical component  312 , and provides a feedback signal to the controller  320 . The controller  330  alters the control signal sent to the actuator  316  in dependence upon the feedback signal. Typically, the altered control signal is generated from an error signal produced by comparing the parameter measured by the detector  320  to a known parameter.  
         [0030]     When the MEMS device experiences a shock, such as a mechanical shock, the mechanical component  312  is subject to a transient mechanical vibration at its natural mechanical frequency f o  for a characteristic time commonly referred to as its damping time t d . Until the mechanical vibration damps out, the detector  320  senses the changing position of the mechanical component  312  (arising from the shock and/or the actuation) and provides an erroneous feedback signal to the controller  330  (i.e., which is used to calculate an erroneous error signal). The controller  330  uses the derivative of the error signal with time as a filter to monitor for mechanical impulses. More specifically, the controller  330  provides a threshold for the maximal rate of change (limited by the resonant frequency of the MEMS structure) that the control system operates in. When the rate of change of the error term exceeds this threshold, a shock transient has been qualified. Alternatively, the change in the parameter measured by the detector with time is measured directly to monitor for mechanical impulses. Upon detection of the shock impulse, the controller  330  alters the control signal sent to the MEMS actuator  316  such that it does not attempt to compensate for the effects of the shock, or at least such that the compensation is minimal. For example, the magnitude of the shock transient is optionally used to reduce the systems gain proportionately (i.e., to zero or another small value) for the duration of the settling time of the MEMS device. Alternatively, the controller  330  (or another controller not shown) reduces the gain of coupled circuits and/or systems to suppress propagation of shock induced transient. The net result is that the feedback system does not significantly prolong the effect of shock on the operation of the MEMS device.  
         [0031]     Advantageously, this embodiment of the instant invention does not attempt to prevent the mechanical perturbation and/or alter the damping time, but instead allows the natural mechanical settling to occur while the response of the closed loop feedback system is altered. Accordingly, the fabrication of the MEMS device with reduced operational shock sensitivity remains relatively simple. Moreover, since the shock is detected by monitoring the closed loop control feedback using the derivative of the error signal with time (i.e., the MEMS structure itself functions essentially as an accelerometer), there is no need for additional components (e.g., a separate shock detector).  
         [0032]     Notably, the instant invention is particularly useful for MEMS devices used in optical communication systems, where the effect of shock is frequently expressed as a perturbation in optical power signal levels, and thus, is often relayed to separate feedback control systems downstream from the MEMS device. For example, if the mechanical component is an optical mirror in a fiber optic communications transmitter, a mechanical impulse will modulate the output power coupled to a separate system. The series fiber optic components in the signal path of the separate system will attempt to regulate the change in launch power, inducing complex interactions which often take several frames to damp out. If the impulse is suppressed quickly at the source, the system will recover significantly faster. The faster recovery results in an error burst, but also reduces the chances of switching to a redundant path, which is a more severe consequence.  
         [0033]     Referring to  FIG. 4 , there is shown an embodiment of the instant invention described with respect to a control system used in a fiber optic transmitter. The control system  400  includes a laser  410 , a MEMS mirror  420 , a wavelength detector  430 , an optical modulator  440 , a beamsplitter  450 , a photodetector  460 , and a microprocessor  470 .  
         [0034]     The MEMS mirror  420  is an electrostatically actuated  2 -axis structure providing active alignment in the X and Y directions (with Y being in the plane of  FIG. 4 , while X is perpendicular to the plane). Together with the photodetector  460  and microprocessor  470 , the MEMS mirror  420  forms part of a first closed loop feedback circuit used to control the average optical power transmitted by the modulator  440 . More specifically, the MEMS mirror  420  is dithered axially to change the coupling efficiency of the beam of light to the modulator  440  in a time interleaved fashion (X for 50 cycles, Y for 50 cycles, X for 50 cycles, etc.). In order to have the ability to distinguish the independent X and Y power variations at the photodetector  460 , the photocurrent produced by the photodetector  460  is synchronously demodulated with the time interleaved X and Y dithers. The independent X and Y demodulated signals contain the error information with respect to optimal X,Y beam alignment. The microprocessor  470  uses these error signals to control the independent X and Y MEMS angles.  
         [0035]     The laser  410  is a temperature tunable laser, such as a distributed feedback laser (DFB) and is coupled to the thermoelectrical cooler (TEC)  410   a,  which controls the temperature and thus wavelength of the laser  410 . The wavelength detector  430  is a wavelength locking system that uses a first beamsplitter  432  for tapping a portion of the optical signal to be measured at a first photodetector  434  and a second beamsplitter  436  for tapping another portion of the optical signal that is measured at a second photodetector  438 . An etalon  437  is provided between the second beamsplitter  436  and the second photodetector  438 . The etalon  437  is an optical filter device with periodic transmission peaks used to determine the wavelength or frequency error of the laser  410 . Together with the laser  410  and the microprocessor  470 , the wavelength detector  430  forms part of a second closed loop feedback circuit, which is used to control the wavelength of light that is transmitted by the modulator  440 . More specifically, the ratio of the photocurrents from the reference photodetector  434  and the wavelocking photodetector  438  yields information pertaining to the wavelength error of the laser  410 . These photocurrents are processed by the microprocessor  470 , with feedback applied to TEC  410   a  to regulate wavelength. The time constant of significant wavelength change is on the order of a second due to the relatively large thermal mass of the TEC element. Accordingly, instantaneous laser frequency changes on the order of one gigahertz per millisecond (1 GHz/ms) are virtually impossible due to this thermal mass.  
         [0036]     Each photodetector  434 ,  438 , and  460  is an optical detector, such as a photodiode. Analog-to-digital (A/D) converters are used to convert the photocurrents provided by these photodetectors into appropriate feedback signals that are transmitted to the microprocessor  470 , while digital-to-analog (D/A) converters convert the control signals provided from the microprocessor  470  into appropriate drive currents that are transmitted to the MEMS driver circuitry (not shown).  
         [0037]     In operation, the laser  410  provides a beam of light that is incident on the mirror  420  and reflected towards the wavelength detector  430 . A small portion (e.g., less than 10%) of the beam of light is tapped by the wavelength detector  430 , while the remaining portion is transmitted to the modulator  440 . The modulator  440  modulates the light and transmits it to a separate system. A small portion of the modulated light is tapped by the beamsplitter  450  and the optical intensity is measured by the photodetector  460 . The feedback signals provided by the wavelength detector  430  and photodetector  460  are received by the microprocessor  470  and are used to calculate error signals related to the wavelength error and optical intensity errors, respectively. The microprocessor sends a control signal to the TEC  410   a  and electrostatic actuator of the mirror  420  in dependence upon the feedback signals.  
         [0038]     When the MEMS device experiences a shock, such as a mechanical shock, the mirror is subject to a transient mechanical vibration at its natural mechanical frequency f o  for a characteristic time commonly referred to as its damping time t d . Until the mechanical vibration damps out, the detectors  430  and  460  sense the changing position of the mirror and provide erroneous feedback signals to the microprocessor  470 . More specifically, the erroneous feedback signals arise from the oscillating mirror motion, which affects the coupling efficiency to the modulator target  440  and also alters the incident beam angle to the etalon  437  in the wavelength detector  430 . Since etalons are very sensitive to incident angle, a transmission peak offset proportional to the magnitude of the shock results. This offset is seen as a frequency error.  
         [0039]     To discriminate real wavelength errors from shock impulses, the derivative of the wavelength error signal (the ratio of optical intensities at photodetectors  434  and  438 ), is calculated, and a threshold which is outside of the normal operating conditions of the closed loop circuit  480  is derived. In particular, if the change in the wavelength error signal is larger than the wavelength can physically change, than a shock is identified. Once a shock is identified, the gain of the MEMS X and Y controls from the microprocessor  470  are reduced for the duration of the MEMS natural damping time and/or for the settling time of the MEMS device. Alternatively, or in addition to, the gain of the TEC control from the microprocessor  470  is reduced for the duration of the MEMS natural damping time. The damping time is a function of the physical implementation of the MEMS structure.  
         [0040]     Advantageously, this embodiment of the instant invention does not attempt to prevent the mechanical perturbation and/or alter the damping time, but instead allows the natural mechanical settling to occur while the response of a closed loop feedback system is altered. Accordingly, the fabrication of the MEMS device with reduced operational shock sensitivity remains relatively simple. Moreover, since the shock is detected by monitoring the closed loop control feedback using the derivative of the wavelength error signal (i.e., the MEMS structure and the wavelength detector function together as an accelerometer), there is no need for additional components (e.g., a separate shock detector).  
         [0041]     Notably, as shown above, the instant invention is particularly useful for MEMS devices with electrostatically driven MEMS structures. Electrostatically driven MEMS structures, which are generally known to have weak spring constants, are desirable for their low cost and high efficiency. The effects of undesired perturbations on electrostatically driven MEMS devices are well known, and are for example, discussed in U.S. Pat. No. 6,532,096, U.S. Pub. No. 2002/0113191, and U.S. Pub. No. 2002/0101129, each of which is hereby incorporated by reference.  
         [0042]     Of course the instant invention is useful for other MEMS devices used for providing front-end signal processing in larger and more complicated signal processing systems. For example, the instant invention is also suitable for MEMS devices used in RF systems, where the MEMS device is an RF switch, reactive tuning component, phase shifter or attenuator.  
         [0043]     The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.