Abstract:
A position encoder comprising a cylindrical rotor; first and second magnetic poles having opposite polarity helically disposed about the inner or outer diameter of the rotor; first and second Hall sensors disposed within a distance suitable for the Hall sensors to detect the magnet poles.

Description:
BACKGROUND 
     1. Field of the Invention 
       [0001]    The present invention relates to non-contact motion sensors, and, more particularly, to a moving target with a helical magnetic pole pattern for use with a pitched magnetic sensor. 
       2. Description of the Related Art 
       [0002]    An encoder is a sensor of mechanical motion that generates digital signals in response to motion. Modern designs favor non-contact sensing methods, either magnetic or optical, for improved reliability, performance, and life expectancy. As an electromechanical device, an encoder is able to provide motion control system users with information concerning position, velocity, and direction. There are two different types of encoders: linear and rotary. A linear encoder responds to motion along a path, while a rotary encoder responds to rotational motion. 
         [0003]    Linear and rotary encoders are further broken down into two main types: the absolute encoder and the incremental encoder. An incremental encoder generates a train of pulses that can be used to determine position and speed. The incremental signal consists of two phase shifted, square wave signals. The phase shift is required to recognize of the direction of rotation. An absolute encoder generates unique bit configurations to track positions directly. The construction of these two types of encoders is quite similar. However, they differ in physical properties and the interpretation of movement. 
         [0004]    The output of incremental rotary encoders is measured in pulses per revolution which is used to keep track of position or determine speed. A single channel output is commonly implemented in applications in which direction of movement is not significant. In situations in which direction sensing is important, a 2 channels, quadrature, output is used. The two channels, A and B, are commonly 90 electrical degrees out of phase, and electronic components determine the direction based off the phase relationship between the two channels. The position of an incremental encoder is calculated by adding up all the pulses by a counter. 
         [0005]    A setback of the incremental encoder is count loss which occurs during power loss. When restarting, the equipment must be referenced to a home position to reinitialize the counter. However, there are some incremental encoders, that come equipped with a third channel called the index channel. The index channel produces a single signal pulse per revolution of the encoder shaft and is often used as a reference marker. The reference marker is then denoted as a starting position which can resume counting or position tracking. 
         [0006]    Absolute encoders utilize output signals in digital bits which correspond to a unique position. As a result, each position has its own unique bit configuration. The absolute signal consists of discreet coded binary values and may be from 4 to 16 bits wide. In application, absolute encoders are required if a particular setting must be recognized and available after the system powers down. 
         [0007]    A common type of absolute encoder is known as the multi-track type. In this type, an absolute pattern is formed by a plurality of parallel tracks each having an incremental pattern of different pitches, which is called as a multi-track type absolute pattern graduation scale. A detector for reading the multi-track type absolute pattern graduation scale includes a plurality of sensors arranged in the respective positions basically corresponding to that of each track one by one, and an absolute position signal of “binary number of good order” having binary code or gray code is assembled from the outputs of the sensors. 
         [0008]    An exemplary prior art single track may be constructed with a single track of a mark-space pattern of irregular pitch which is called single-track type absolute pattern graduation scale. In the single-track absolute pattern graduation, “1” and “0” of a special sequence of binary numbers such as Full Periodic Sequence or M-Sequence are replaced by two kinds of minimum reading units having different physical characteristics, and arranged on the track in single line. On the detector, a plurality of sensors are arranged in single line with a pitch fundamentally of the minimum reading unit length along the single-track type absolute pattern graduation scale, and an absolute position signal consisting of “different binary numbers having random order” is assembled from the outputs of said plurality of sensors. 
         [0009]    A rotary magnetic encoder consists of two parts: a rotor and a sensor. The rotor turns with a shaft and contains alternating evenly spaced north and south magnetic poles around its circumference. The sensor detects shifts in the position of the poles. There many methods of detecting magnetic field changes, but the two primary types used in encoders are: Hall effect and Magneto resistive. Hall effect sensors work by detecting a change in voltage by magnetic deflection of electrons and outputting one cycle of information per magnetic pole pair (one north pole and one south pole). Magneto resistive sensors detect a change in resistance caused by a magnetic field and outputting one cycle of information per magnetic pole pair (one north pole and one south pole). 
         [0010]    The simplest configuration of a magnetic encoder comprises a single magnet, with a single set of north and south poles on opposite edges of the rotor, and a single sensor. The device produces a single sine wave output with a frequency equal to the rotational speed of the shaft. With a second sensor set at a physical distance from the first sensor to achieve an electrical output that is 90° out of phase with the output of the first sensor, it is possible to detect the direction of rotation and to interpolate the absolute position of the shaft from the sine and cosine signals. Orienting one sensor half a pole&#39;s distance ahead of the other causes the first sensor&#39;s output to either lead or lag the second sensor&#39;s by 90° (with respect to the electrical waveforms output from the sensors). This lead or lag is then detected by the flip-flop, whose output is 0 for rotation in one direction and 1 for rotation in the other. 
         [0011]    For incremental encoders, the sinusoidal outputs from the sensors are converted to square waves so the resulting quadrature waveforms can only be encoded to one of four possible angular positions. The sine and cosine signals can be furthered processed using interpolation to further increase the resolution of the square wave outputs. The final resolution is achieved by increasing the interpolation factor, the number of magnetic poles around the rotor, or the number of sensors. For example, 1024 positions (or 10 bit resolution) can be achieved with four sensors and 128 poles. It can also be achieved using 2 poles and interpolated by a factor of x256 using two sensors. 
         [0012]    If the outputs of two magnetic sensors are sinusoidal, then a net maximum linearity range can be attained when the two signals are in 90° phase difference with each other. The two sinusoidal signals with 90° phase difference can be processed with an arctangent function in order to achieve maximum linearity. Thus, an optimum distance can be determined between the two sensors so that a 90° phase shift can be achieved and there is less linearity error in the system. 
         [0013]    The AMS22S by Bourns is an exemplary single turn, magnetic, rotary encoder. The encoder can be programmed to measure rotational angle, which can output either as a linear analogue voltage or a pulse width modulation (“PWM”) waveform, in both cases with 12 bit resolution. Other prior art sensor devices include the following: 
         [0014]    U.S. Pat. No. 5,351,555 discloses a torque sensor having a magnetoelastically active element, and a magnetic sensor, such as a Hall effect sensor, responsive to the field of the magnetoelastically active portion. The magnetoelastically active portion comprises a ring of material endowed with an effective uniaxial magnetic anisotropy such that the circumferential direction is the easy axis, and magnetically polarized in a substantially circumferential direction. The ring is attached to the torqued member, such as a rotating shaft, so that application of a torque to the shaft is transmitted to the ring. The torque on the ring reorients the circumferential magnetic orientation of the ring, producing a helical magnetic orientation having both circumferential and axial components. A magnetic field vector sensor is mounted on a flux collector in a fixed position relative to the ring and oriented so that it responds to the field arising from the axial component of the magnetization within the ring. The output of the sensor is thus proportional to the change in orientation of the magnetization resulting from torque applied to the shaft and transmitted to the ring. 
         [0015]    U.S. Pat. No. 5,815,091 discloses a linear position encoder in which a support is provided upon which a pair of phase quadrature windings are mounted. The windings are arranged to have a sinusoidal magnetic sensitivity characteristic along the length of the support. Mounted on a movable element there is a resonant circuit including a coil and capacitor that can magnetically couple with the windings. When the circuit is excited, it induces currents in the windings that are dependent upon the position of the circuit within a period Ts of the windings. An excitation and processing unit is provided to energize the circuit and to process the signals induced in the windings. The encoder may in a variation, measure rotational or radial position instead of translation. 
         [0016]    U.S. Pat. No. 6,323,641 discloses a non-contacting position sensor for measuring position of a rotating object using a Hall effect device that remains stationary in an air gap between a helical flux linkage member and a flux generator, both coupled to the rotating object via a shaft. The flux generator has a ring magnet. The helical flux linkage member varies in thickness from a thin region to a thick region. There is a transition region between where the helical flux linkage member is thickest and where it is thinnest. As the shaft rotates, the Hall effect device senses a magnetic field that varies with the thickness of the helical flux linkage member, thereby measuring the angular position of the rotating object coupled to the shaft. 
         [0017]    U.S. Pat. No. 7,367,257 actuator with a position encoder provided by a helical groove formed in the piston rod. The groove is filled with a material of different magnetic characteristics to provide a smooth exterior surface and a varying discernible signal as the rod moves relative to the cylinder. An array of Hall effect sensors is provided around the rod to provide phase shifted signals as the rod moves so that the signal of one sensor may be correlated by the signals of other sensors. 
         [0018]    The prior art, however, still fails to disclose a device where the magnetic field pattern is not limited in final pole count and magnet diameter for use with pitched magnetic sensors. 
       SUMMARY 
       [0019]    In one exemplary embodiment, the magnetic encoder system of the present invention comprises a rotor, said rotor having a generally cylindrical shape and an exterior; a first magnetic pole helically disposed about the exterior of said rotor; a second magnetic pole, said second magnetic pole helically disposed about the exterior of said rotor and adjacently to said first magnetic pole, said second magnetic pole having a polarity opposite said first magnetic pole; a first Hall sensor, said first Hall sensor disposed within a distance suitable for said first Hall sensor to detect said first and said second magnets; a second Hall sensor, disposed within a distance suitable for said second Hall sensor to detect said first and said second magnets, said second Hall sensor disposed relative to said first Hall sensor such that the output of said first Hall sensor is 90° out of phase from said second Hall sensor. 
         [0020]    In another exemplary embodiment, the magnetic encoder system of the present invention comprises a magnet for use with a magnetic encoder, said magnet comprising at least two magnetic poles adjacently and helically disposed on the face of a cylinder. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The present invention will be understood more fully from the detailed description given hereinafter and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken to limit the invention, but are for explanation and understanding only. 
           [0022]    In the drawings: 
           [0023]      FIG. 1  shows a prior art rotary magnetic encoder with magnetic poles disposed on the periphery of a cylinder. 
           [0024]      FIG. 2  shows a diagram of the output of the encoder of  FIG. 1 . 
           [0025]      FIG. 3  shows a prior art rotary magnetic encoder with magnetic poles disposed on the face of a cylinder. 
           [0026]      FIG. 4  shows a prior art linear magnetic encoder. 
           [0027]      FIG. 5  shows a prior art “end looking” magnetic encoder arrangement. 
           [0028]      FIG. 6  shows a pair of prior art magnetic sensor arrangements having two magnetic poles each where the sensor is “off axis” compared to the “on axis” arrangement of  FIG. 5 . 
           [0029]      FIG. 7  shows a rotary magnetic encoder according to the present invention with magnetic poles disposed helically around the exterior of a cylinder. 
           [0030]      FIG. 8  shows a diagram of the output of  FIG. 7 . 
           [0031]      FIG. 9  shows a rotary magnetic encoder according the present invention with magnetic poles disposed helically on an end of a cylinder. 
           [0032]      FIG. 10  shows a linear magnetic encoder according to the present invention. 
           [0033]      FIG. 11  shows an alternative embodiment of the magnetic encoder of  FIG. 10 . 
           [0034]      FIG. 12  shows a rotary encoder according to the present invention with magnetic poles disposed around the inner diameter of a cylinder. 
           [0035]      FIG. 13  shows an exemplary application of the present invention. 
       
    
    
       [0036]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplary embodiments set forth herein are not to be construed as limiting the scope of the invention in any manner. 
       DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0037]    The present invention will be discussed hereinafter in detail in terms of various exemplary embodiments according to the present invention with reference to the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known structures are not shown in detail in order to avoid unnecessary obscuring of the present invention. 
         [0038]    Thus, all of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, in the present description, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof Hall relate to the invention as oriented in  FIG. 1 . 
         [0039]    Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
         [0040]    Referring first to  FIG. 1 , there is shown a side view and an end view of a typical prior art rotary magnetic encoder. As illustrated generally in  FIG. 1 , a typical rotary magnetic encoder comprises a permanent magnet attached to a rotating shaft so that the shaft has a specific number of alternating symmetrical magnetic poles around its periphery. The encoder further comprises a two channel magnetic Hall sensor disposed across an air gap at a functional distance with respect to the position of the magnetic poles so that the two channels of output are in quadrature (i.e. simulating a sine and cosine wave) to each other as depicted in  FIG. 2 . Persons of ordinary skill in the art will appreciate that a functional distance is a distance within which the Hall sensor is able to detect the magnetic flux of the magnetic poles. Thus, the functional distance will depend on the sensitivity of the Hall sensors as well as the amount of flux generated by the magnetic poles. 
         [0041]    Referring again to  FIG. 1 , the magnetic poles have a predetermined “field width.” When used with a pitched magnetic sensor, the width of the field produced by each pole of a magnet must be in direct relationship to the pitch of the sensor. For Hall sensors, this magnetic pole width is approximately twice the sensor pitch. This field width constant dictates the final number of magnetic poles and changes with the magnets diameter. Thus, lower pole counts especially two poles (one pole pair) are not practical for use with these types of sensors as illustrated in  FIG. 6 . 
         [0042]    Referring now to  FIG. 2 , there is shown a view of the magnetic poles shown in the side view of  FIG. 1  where the magnetic poles are displayed along a single line that is analogous to one revolution of the shaft and magnetic pole arrangement shown in  FIG. 1 .  FIG. 2  further shows two exemplary output signals that can be sent directly to a motor controller or similar device for the determination of parameters such as speed and direction of the shaft or be further processed or interpolated into additional positional data. 
         [0043]    Referring next to  FIG. 3 , there is shown a side view and an end view of a prior art rotary magnetic encoder with magnetic poles disposed on the end of a cylinder. The magnet poles may be provided circumferentially on the magnet face that is mounted on of a rotating shaft or the magnet may be connected using an adaptor or other device disposed at the end of the shaft. As illustrated in  FIG. 3 , a pitched Hall sensor is disposed vertically above one end of the magnet across an air gap within a functional distance of the magnetic poles at the end of the rotating shaft. Again, persons of ordinary skill in the art will appreciate that a functional distance is a distance within which the Hall sensor detect the magnetic flux of the magnetic poles. Thus, the functional distance will depend on the sensitivity of the Hall sensors as well as the amount of flux generated by the magnetic poles. 
         [0044]    Referring still to  FIG. 3 , each of the magnetic poles has a predetermined “field width.” When used with a pitched magnetic sensor, the width of the field produced by each pole of a magnet must be in direct relationship to the pitch of the sensor. For Hall sensors, this magnetic pole width is approximately twice the sensor pitch. This field width constant dictates the final number of magnetic poles and changes with the magnets diameter. Lower pole counts especially two poles (one pole pair) are not practical for use with these types of sensors unless the position of the sensor is directly above the axis of the magnet. 
         [0045]    Referring next to  FIG. 4 , there is shown a linear view of the prior art magnetic encoder of  FIG. 3 . Specifically,  FIG. 4  illustrates a partial side view and a partial top view of a prior art encoder with magnetic poles disposed along the length of a magnet strip. As with  FIG. 3 , the pitched Hall sensor of  FIG. 4  is disposed within a functional distance of the face/end of a cylinder. When used with a pitched magnetic sensor, the width of the field produced by each pole of a magnet must be in direct relationship to the pitch of the sensor. For Hall sensors, this magnetic pole width is approximately twice the sensor pitch. This field width constant dictates the final number of magnetic poles and changes with the magnets length. 
         [0046]    Referring next to  FIG. 5 , there is shown a prior art “end looking” magnetic encoder. As illustrated in  FIG. 5 , a non-contacting magnetic sensor (preferably a Hall based sensor) is disposed within a predetermined functional distance from one end of a cylindrical adaptor having a magnet with preferable two magnetic poles. The magnet is disposed on one end of a rotating shaft using an adapter. Together, the shaft, adaptor, and magnet form a magnetic field sensing assembly. An air gap is shown between the magnet and the Hall sensor. The shaft is either intergyral or adapted to be connected to another rotating object such as, for example, a motor shaft, a crankshaft, or a throttle body on a fuel injection system. The shaft rotates about an axis of rotation. 
         [0047]    As further illustrated in  FIG. 5 , the Hall Effect device is attached to a printed circuit board. The Hall Effect sensor remains stationary in an air gap while the motorized shaft, magnet and adaptor turns around an axis of rotation. The Hall Effect position sensor may be connected to external circuitry via the printed circuit board. The circuit board provides a means for connection of an output signal that the external circuitry receives for processing. Using the output data, the speed or angular position of the shaft can be determined by known means. 
         [0048]    Referring now to  FIG. 7 , there is shown a side view and an end view of a magnetic encoder  1000  in accordance with the present invention. As illustrated in  FIG. 7 , magnetic encoder  1000  generally comprises a magnet  120  with a plurality of magnetic poles  120  disposed helically around the exterior of a magnet that is affixed to a rotating cylindrical shaft  130 . Encoder  1000  further comprises a Hall sensor  100  disposed radially outside of the magnets magnetic poles  120  on the exterior of shaft  130 . An air gap  110  is shown between the magnets magnetic poles  120  and Hall sensor  100 . Shaft  130  is either integral or adapted to be connected to another rotating object (not shown) such as, for example, a motor shaft, a crankshaft, or a throttle body on a fuel injection system. Shaft  130  rotates about an axis of rotation  140 . 
         [0049]    Similar to  FIG. 7 ,  FIG. 12  shows a side view and an end view of a magnetic encoder  1000  in accordance with the present invention. As illustrated in  FIG. 12 , magnetic encoder  1000  generally comprises a magnet  120  with a plurality of magnetic poles disposed helically around the inner diameter of a magnet  120  mounted to a rotating cylindrical shaft  130 . Encoder  1000  further comprises a Hall sensor  100  disposed radially inside of the magnet  120 . An air gap  110  is shown between magnet  120  and Hall sensor  100 . Shaft  130  is either integral or is adapted to be connected to another rotating object (not shown) such as, for example, a motor shaft, a crankshaft, or a throttle body on a fuel injection system. Shaft  130  rotates about an axis of rotation  140 . 
         [0050]    As illustrated in  FIG. 10 , a linear encoder version may be achieved using slanted magnetic stripes. Alternately, as illustrated in  FIG. 11 , the same effect can be made using straight magnetic strips but tilting the completed magnet at the correct pitch. 
         [0051]      FIG. 8  depicts the output of magnetic encoder  1000  illustrated in  FIG. 7  through  FIG. 13 . For this example, the spiral pitch is set to simulate a two pole device for an output equal to one side and one cosine output of the sensor per either one mechanical revolution or a fixed linear distance. This type of output is typical for absolute but also incremental positioning devices used in applications such as drive by wire, etc. but are not restrained by magnet diameter but more importantly, the sensor does not have to be facing the centerline of the shaft as typically found providing even more value in an application solution. 
         [0052]    Referring generally to  FIG. 7 , to  FIG. 12 , and to  FIG. 9 , there is shown a pattern which can be described as a double helix (two pole version). This double magnetic helix comprises of stripes of a pair of north and south magnetic poles spiraling around a fixed axis similar to a barber poles red and white stripes. The pole width is also a function of 2× the pitch and type of the sensor used. The spiral pitch is also a function of the sensor pitch and type. For a two pole style, the spiral pitch is equal to 4× the sensor pitch for a Hall device and 8× for the pitch of a magnetoresistor sensor. 
         [0053]    Although one sin and cosine cycle works best for absolute encoding, by using other pitches and increasing the number of helical stripes, other pole counts and resolutions can be simulated using this helix field pattern. This pole pattern technique is easily applied to other types of magnetic sensor targets such but not limited to Hall Effect, all types of magnetoresistors, inductive and eddy current sensors. 
         [0054]    Referring again to  FIG. 8 , the output signal is a voltage signal substantially proportional to the magnetic field sensed by Hall effect device  100 . However, it should be understood that this is not intended as a limitation of the present invention. Depending on the circuitry coupled to Hall effect device  100 , the output signal can be either a voltage signal or a current signal and can have any kind of monotonic relation with the magnetic field sensed by Hall effect device  100 . The output from Hall effect device  100  is connected to conventional signal processing electronics for amplification, filtering, interpolation algorithms, etc. 
         [0055]    Referring now to  FIG. 9 , there is shown an alternative embodiment of magnetic encoder  1000  in accordance with the present invention. As illustrated in  FIG. 9 , magnetic encoder  1000  generally comprises a plurality of magnetic poles  120  disposed helically on the end of magnet  120  mounted on a rotating shaft of a rotating cylindrical shaft  130 . Encoder  1000  further comprises a Hall sensor  100  disposed vertically above magnetic poles  120  on the end of shaft  130 . Air gap  110  is shown between magnetic poles  120  and Hall sensor  100 . Shaft  130  is either integral or adapted to be connected to another rotating object (not shown) such as, for example, a motor shaft, a crankshaft, or a throttle body on a fuel injection system. Shaft  130  rotates about an axis of rotation  140 . Shaft  130  may be connected to any actuator capable of initiating rotation of shaft  130  such as an electric motor, combustion engine, gear box, hand crank, conveyor, or bearing system. 
         [0056]    Turning now to  FIG. 13 , there is shown an embodiment of magnetic system  1000  according to the present invention. As illustrated in  FIG. 13 , system  1000  of the present invention generally comprises motor  200  having rotating shaft  130  extending vertically therefrom. Shaft  130  is rotatable around longitudinal axis  140 . 
         [0057]    Referring again to  FIG. 13 , system  1000  further comprises a spiral magnet  120  having a plurality of magnetic poles disposed helically or spirally around the external surface of magnet  120 . The plurality of magnetic poles is arranged such that each individual pole is adjacent to a pole of opposite polarity. System  1000  further comprises a Hall sensor  100  disposed radially outside of magnetic poles  120  on the exterior of shaft  130 . Hall sensor  100  is further connected to a printed circuit board  150 . Printed circuit board  150  can be used for communicating output from Hall sensor  100  to conventional signal processing electronics for amplification, filtering, interpolation, etc. The design of  FIG. 13  has one advantage over the prior art as shown in  FIG. 5 . This advantage is the ability of sensor  100  to be positioned “off axis” compared to the “on axis” position required of  FIG. 5  and still performs as an absolute encoder using the single cycle sin and cosine output. That advantage gives the design the ability to allow the shaft  130  to extend out pass the encoder system for use with other items such as braking systems, etc. 
         [0058]    There is one other unique ability of the spiral pole magnet that not only allows it to produce a sin and cosine signal with respect to rotation but also produce a sin and cosine signet with respect to any axial movement. Using separate sensors affixed in such a way one sensor to responds to the combination of those two movements and the other responds to just one of those movement direction, a processor can be designed to determined either movement separately giving this type of encoder dual purpose. 
         [0059]    While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.