Patent Publication Number: US-9853575-B2

Title: Angular motor shaft with rotational attenuation

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to positioning devices, and more particularly to positioning devices including linear actuators for high precision positioning of movable components, such as, for example, positioning of a lens within an imaging apparatus. 
     BACKGROUND 
     Generally speaking, modern imaging apparatuses (e.g., machine-readable symbol readers, video cameras, digital cameras, camera cell phones, smart phones and personal digital assistants) typically include one or more lenses that may be moved in order to zoom, focus, change depth of field, and capture a desired image by focusing the image on an image pickup device (e.g., charged-coupled devices, CMOS imager). One or more piezoelectric motors such as those described in U.S. Pat. No. 8,531,790 (which is hereby incorporated by reference) is one such piezoelectric motor that can be used for this purpose. This design exhibits excellent performance but is somewhat bulky and costly for certain applications. 
     Consequently, smaller and less expensive devices are desirable. 
     SUMMARY 
     Accordingly, in one aspect, the present invention embraces linear actuator assemblies and methods for the efficient and accurate positioning of movable components. In various embodiments, the linear actuator assemblies are particularly well adapted for positioning a movable carriage (e.g., carrying a lens for a scanner device) in a highly accurate manner by maintaining direct and continuous contact between the carriage having an angular notch and a shaft of the linear actuator that is faceted so as to have at least one surface in contact with the angular notch. 
     In an example embodiment, a linear actuator assembly has a linear actuator including a motor shaft extending from a base with a piezoelectric component oscillate the shaft. The shaft has a faceted surface. A movable carriage has a notch with at least one flat surface that receives the shaft of the linear actuator. The carriage is in direct and continuous contact with the motor shaft at the notch such that the motor shaft&#39;s facet is in contact with the flat surface of the notch, when the carriage moves linearly along a travel axis. A spring is coupled to the carriage to urge the motor shaft into contact with the notch of the carriage so as to maintain contact between the motor shaft facet and the flat surface of the notch to inhibit rotation of the motor shaft. 
     In certain example embodiments, a linear actuator assembly has a linear actuator, the linear actuator including a motor shaft extending from a base. The base includes a piezoelectric component to selectively oscillate the motor shaft. The motor shaft has a faceted surface such that when viewed in cross-section at least a portion of the cross section includes a straight line. A movable carriage includes a notch to receive the motor shaft, where the notch has at least one flat surface. The carriage is in direct and continuous contact with the motor shaft at the notch such that the motor shaft&#39;s facet is in contact with the flat surface of the notch, when the carriage moves linearly along a travel axis. A spring is coupled to the carriage to urge the motor shaft into contact with the notch of the carriage so as to maintain contact between the motor shaft facet and the flat surface of the notch to inhibit rotation of the motor shaft. 
     In certain example embodiments, the spring is a flat cantilever spring coupled to the carriage remote from the notch. In certain example embodiments, the notch is approximately V-shaped. In certain example embodiments, the motor shaft has a plurality of faceted surfaces, and where the notch has a plurality of flat surfaces that are in contact with the plurality of faceted surfaces of the shaft. In certain example embodiments, the notch is approximately V-shaped and the motor shaft has an approximately square cross-section. In certain example embodiments, the motor shaft has an approximately square cross-section with rounded corners. In certain example embodiments, the piezoelectric component is coupled to a flex circuit and where electrical signals are carried by the flex circuit to selectively cause the piezoelectric component to oscillate. In certain example embodiments, the linear actuator also has an optical lens coupled to the carriage to move linearly therewith. In certain example embodiments, the piezoelectric component is driven to oscillate at an ultrasonic frequency. 
     In other example embodiments, a linear actuator assembly has a linear actuator, the linear actuator including a motor shaft extending from a base. The base includes a piezoelectric component with a flex circuit electrically coupled to the piezoelectric component. Electrical signals are carried by the flex circuit to selectively cause the piezoelectric element to oscillate the motor shaft. The motor shaft is approximately square having four facets when viewed in cross-section. A movable carriage includes a notch to receive the motor shaft, where the notch is approximately V-shaped having two flat surfaces. The carriage is in direct and continuous contact with the motor shaft at the notch such that two of the motor shaft&#39;s facets are in contact with the two flat surfaces of the approximately V-shaped notch, when the carriage moves linearly along a travel axis. A cantilever spring, e.g., a flat cantilever spring, is coupled to the carriage to urge two of the motor shaft&#39;s facets into contact with the two flat surfaces of the V-shaped notch of the carriage so as to maintain contact between the motor shaft facets and the flat surfaces of the notch to inhibit rotation of the motor shaft. 
     In certain example embodiments, the motor shaft can have an approximately square cross-section with rounded corners. In certain example embodiments, an optical lens is coupled to the carriage to move linearly therewith. In certain example embodiments, the piezoelectric component is driven to oscillate at an ultrasonic frequency. 
     In other example embodiments, an autofocus imager, incorporates a linear actuator, the linear actuator including a motor shaft extending from a base. The base has a piezoelectric component to selectively oscillate the motor shaft. The motor shaft has a faceted surface such that when viewed in cross-section at least a portion of the cross section includes a straight line. A movable carriage includes a notch to receive the motor shaft, where the notch has at least one flat surface. The carriage is in direct and continuous contact with the motor shaft at the notch such that the motor shaft&#39;s facet is in contact with the flat surface of the notch, when the carriage moves linearly along a travel axis. A spring is coupled to the carriage to urge the motor shaft into contact with the notch of the carriage so as to maintain contact between the motor shaft facet and the flat surface of the notch to inhibit rotation of the motor shaft. A lens is coupled to the carriage to move linearly with the linear actuator to adjust a focus of the autofocus imager. 
     In certain example embodiments, the linear actuator comprises an ultrasonic linear actuator. In certain example embodiments, the linear actuator assembly includes a chassis and a plurality of elastomeric bushings, at least one elastomeric bushing coupled to the chassis to receive the linear actuator. In certain example embodiments, the spring includes a flat cantilever spring coupled to the carriage remote from the notch. In certain example embodiments, the motor shaft has a plurality of faceted surfaces, and where the notch has a plurality of flat surfaces that are in contact with the plurality of faceted surfaces of the shaft. In certain example embodiments, the notch is approximately V-shaped and where the motor shaft has an approximately square cross-section. In certain example embodiments, the piezoelectric component is driven to oscillate at an ultrasonic frequency. 
     A linear actuator assembly consistent with the present examples may have a linear actuator including a motor shaft extending from a base with a piezoelectric component oscillate the shaft. The shaft has a faceted surface. A movable carriage has a notch with at least one flat surface that receives the shaft of the linear actuator. The carriage is in direct and continuous contact with the motor shaft at the notch such that the motor shaft&#39;s facet is in contact with the flat surface of the notch, when the carriage moves linearly along a travel axis. A spring is coupled to the carriage to urge the motor shaft into contact with the notch of the carriage so as to maintain contact between the motor shaft facet and the flat surface of the notch to inhibit rotation of the motor shaft. 
     The linear actuator assemblies and methods described herein provide for the efficient and accurate positioning of movable components at low cost, weight and size. In various embodiments, the linear actuator assemblies are particularly well adapted for positioning a movable carriage in a highly accurate manner for adjustment of focus of a lens. 
     The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevational view of a linear actuator assembly. 
         FIG. 2  is a top plan view of the linear actuator assembly of  FIG. 1 . 
         FIG. 3  is a first perspective view of an actuator assembly consistent with certain embodiments of the present invention. 
         FIG. 4  is a second perspective view of an actuator assembly consistent with certain embodiments of the present invention. 
         FIG. 5  is a detail view of an embodiment using an approximately square motor shaft with rounded corners seated within a triangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 6  is a detail view of an embodiment using an approximately square motor shaft seated within a triangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 7  is a detail view of an embodiment using an approximately octagonal motor shaft seated within a triangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 8  is a detail view of an embodiment using an approximately hexagonal motor shaft seated within a triangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 9  is a detail view of an embodiment using an approximately D-shaped motor shaft seated within a rectangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 10  is a detail view of an embodiment using an approximately triangular motor shaft seated within a triangular notch in the carriage in a manner consistent with the present teachings. 
         FIG. 11  is a detail view of an embodiment using an approximately hexagonal motor shaft seated within a notch in the carriage having four flat surfaces in a manner consistent with the present teachings. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details. In other instances, well-known structures and manufacturing techniques associated with positioning devices, imaging apparatuses, and piezoelectric motors and control systems therefor may not be shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. 
     Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.” 
     Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     As used herein, the term “facet” is intended to mean a flat surface. Thus, a facet in a shaft means that the shaft has a flattened surface on the length thereof when viewed in cross-section. Other surfaces of the shaft may also be faceted or may be curved. By this definition, a D-shaped shaft (in cross-section) has a single facet while a hexagonal shaft (in cross-section) has six facets, for example. 
       FIGS. 1 and 2  show an example linear actuator assembly  70  used to linearly move a lens to focus the lens. The linear actuator assembly  70  includes a pair of linear actuators  12 , and a movable carriage  16 . The carriage  16  is positioned between the two linear actuators  12  and remains in sliding contact with each as the linear actuators  12  moves the carriage  16  back and forth along a travel axis  18  during operation, as indicated by the arrow labeled  20 . 
     The linear actuator  12  includes an elongated guide in the form of a dynamic cylindrical rod  22  extending from a base  24  thereof. The base  24  includes an actuator in the form of an elastic disc portion  26  and piezoelectric components  28  which deflect in response to an applied electrical current or voltage, as indicated by the arrows labeled  30 . An electrical conductor, for example, in the form of a flex circuit  32  is electrically coupled to the linear actuator  12  to selectively apply an electric field to the piezoelectric components  28 , and thus selectively deflect or oscillate the same. The rate of deflection or oscillation may be controlled such that the rods  22  accelerate and decelerate at different rates. In doing so, the rod  22  and the carriage  16  move together during relatively slow accelerations and decelerations due to friction between the rods  22  and the carriage  16 . 
     Conversely, during relatively fast accelerations and decelerations, the rods  22  may slide along a surface of the carriage  16  due to the inertia of the carriage  16  which prevents the carriage  16  from moving with the rod  22 . Consequently, the carriage  16  can be incrementally advanced back and forth along the rods  22  by controlling the rate of acceleration and deceleration of the rods  22  caused by deflections or oscillations of the piezoelectric components  28 . For example, the rods  22  may initially extend forward relatively slowly moving the carriage  16  with it and then retract relatively quickly leaving the carriage  16  at an advanced position. Repeating this process moves the carriage  16  along the travel axis  18  in one direction. Reversing the process moves the carriage  16  along the travel axis  18  in the opposite direction. In some embodiments, the rods  22  can be driven to oscillate or reciprocate, for example, at ultrasonic frequencies (e.g., above approximately 20 kHz). Accordingly, the linear actuator  12  may be an ultrasonic linear actuator. 
     The carriage  16  includes a first V-shape notch  40  sized to receive the rod  22  of the linear actuator  12 . A spring  42  is secured to the carriage  16  and positioned to urge the rod  22  of the linear actuator  12  into the first V-shape notch  40  such the rod  22  is held in direct and continuous contact with the carriage  16  during operation of the linear actuator assembly  10 . The carriage  16  further includes a second V-shape notch  44  sized to receive the other rod  22 . Another spring  46  is secured to the carriage  16  and positioned to urge the rod  22  into the V-shape notch  44  such the other rod  22  is also held in direct and continuous contact with the carriage  16  during operation of the linear actuator assembly  70 . The springs  42  and  46  of  FIGS. 1 and 2  are attached to the carriage  16  by fasteners  48  and may be used to bias the linear actuators  12  and rods  22  towards the carriage  16 . 
     In operation, control circuitry and related components which are not described in detail herein to avoid unnecessarily obscuring descriptions of the embodiments, may be used to control the linear actuators  12  and selectively drive the carriage  16  back and forth along the travel axis  18 . Throughout operation, the linear actuators  12  are held in direct and continuous contact with the carriage  16  such that no gaps exist between these components. As such, the carriage  16  is restrained with respect to movement in an x-y reference plane  50 , but the carriage  16  is able to translate in the z-direction as defined by a corresponding x-z reference plane  52 . This prevents rotation and/or displacement of the carriage  16  with respect to the x-y reference plane, and enables highly accurate repositioning of the carriage  16  along the travel axis  18 . 
     The carriage  16  is illustrated as including a central cavity  56  which can be used, for example, to house components for movement about the travel axis  18  with respect to a host apparatus. For instance, an optical lens  60  may be secured within the cavity  56  of the carriage  16  for selective movement of the lens  60  along the travel axis  18 . Thus, the linear actuator assembly  70  may be incorporated into a camera or other imaging device (e.g., handheld machine-readable symbol reader) to facilitate autofocus capabilities of those devices. Accordingly, an autofocus imager may be provided comprising the linear actuator assemblies described herein. 
     In this mechanism, a dynamic elongated cylindrical guide in the form of the second linear actuator  12  is coupled to the carriage  16  in parallel arrangement with the first linear actuator and is oriented in the same direction. The second linear actuators  12  may cooperate in unison to drive the carriage  16  back and forth along the travel axis  18 . 
     While the mechanism shown in  FIGS. 1 and 2  exhibits excellent performance, it may not be suitable for lower cost applications and the use of two linear actuators may occupy too much space for certain applications. 
     Embodiments consistent with the present invention provide for size and cost reduction. In accord with certain embodiments of an assembly  100  as illustrated in  FIGS. 3 and 4  a single motor having shaft  104  may be used with no other supports for the lens assembly (e.g., such as a passive guide shaft or second motor). But, without some way of stabilizing the lens assembly in the horizontal plane, it would be free to rotate about the motor shaft. A stabilizing guide shaft can be used, but introduces additional friction which reduces motor performance. 
     This problem is addressed by using a motor shaft that has a faceted profile that matches a V-shaped notch  40  in carriage  16 . In this example, the motor shaft  104  can have an approximately square profile with sharp or rounded edges. This square shaft  104  solves this problem as depicted in  FIGS. 3 and 4 . Like the arrangement of  FIGS. 1 and 2 , this embodiment uses a V-shaped notch  44  in carriage  16  and shaft  104  is urged into the V-shaped notch by spring  42 . But the cross-section of shaft  104  mates with the V-shaped notch to prevent rotation of the shaft  104 . The carriage  16  is moved along the drive shaft along a travel direction  20  by application of an electrical signal to the piezoelectric element  28 , e.g., via a flex circuit  32  or other set of electrical conductors do induce vibration that causes movement of the carriage  16  in relation to the shaft  104 . 
     The linear actuator assembly may include a chassis and one or more elastomeric bushings. The elastomeric bushing can be coupled to the chassis to receive the linear actuator. 
     In an exemplary embodiment, the assembly is used to move the optical lens  60  in a linear motion in order to focus the lens. The linear actuator include motor shaft  104  which extends from a base  24  thereof. As in the arrangement of  FIGS. 1 and 2 , the base  24  includes an actuator in the form of an elastic disc portion  26  and piezoelectric components  28  (not shown in this figure) which deflect in response to an applied electrical current or voltage. An electrical conductor, for example, in the form of a flex circuit  32  is electrically coupled to the linear actuator  12  to selectively apply an electric field to the piezoelectric components, and thus selectively deflect or oscillate the same. The rate of deflection or oscillation may be controlled such that the motor shaft accelerate and decelerate at different rates. In doing so, the motor shaft  104  and the carriage  16  move together during relatively slow accelerations and decelerations due to friction between the motor shaft  104  and the notch  40  in the carriage  16 . 
     Conversely, during relatively fast accelerations and decelerations, the motor shaft  104  may slide along the flat surface of the notch  40  in the carriage  16  due to the inertia of the carriage  16  which prevents the carriage  16  from moving with the motor shaft  104 . Consequently, the carriage  16  can be incrementally advanced back and forth along the motor shaft  104  by controlling the rate of acceleration and deceleration of the motor shaft  104  caused by deflections or oscillations of the piezoelectric components. For example, the motor shaft  104  may initially extend forward relatively slowly moving the carriage  16  with it and then retract relatively quickly leaving the carriage  16  at an advanced position. Repeating this process moves the carriage  16  along the travel axis in direction  20  in one direction. Reversing the process moves the carriage  16  along the travel axis in direction  20  in the opposite direction. In some embodiments, the motor shaft  104  can be driven to oscillate or reciprocate, for example, at ultrasonic frequencies (e.g., above approximately 20 kHz). Accordingly, the linear actuator may be an ultrasonic linear actuator. 
     In the embodiment shown if  FIGS. 3 and 4 , an approximately square cross-sectional shaft  104  with rounded corners is used. This shaft mates with the triangular notch  40  at two of the four facets of the shaft  104 . It is desirable to minimize friction, so it is desirable to minimize the number of surfaces and facets and surface to surface contact area to accomplish this. Additionally, a lubricant such as a dry lubricant can be used to further reduce friction. The shaft  104  can be fabricated by extruding carbon fibers. The carriage may be made of a magnesium alloy, for example, and may include a PAO surface treatment, but these details are not to be considered limiting. 
     In the embodiment of  FIGS. 3 and 4 , good performance can be achieved. The square shaft with rounded corners is easily fabricated at low cost and the V-shaped notch can be the same notch used in assemblies such as those shown in  FIGS. 1 and 2  thus requiring no retooling. That notwithstanding, many shaft and notch shapes could be used to accomplish the objective of inhibiting shaft rotation. 
     Referring to  FIG. 5 , the shaft  104  is shown in cross section mated to the V-shaped notch  40  of the carriage  16 . In this embodiment, the shaft is square with rounded corners and thus has four facets (four sides) along the length thereof. The spring  42  urges the facets  110  and  112  into contact with the two surfaces of the V-shaped notch  40 , thereby allowing the motor shaft  110  to slide in the notch  40  in response to the oscillations of the piezoelectric element but is prevented from rotating within the notch. 
       FIGS. 6 through 11  show several illustrative examples of other shaft and notch arrangements.  FIGS. 6, 7, 8 and 10  show variations in the cross-section of the motor shaft (square  104 A, octagonal  104 B, hexagonal  104 C, and triangular  104 E respectively) which mate with an approximately V-shaped notch  40  to place a pair of facets of the motor shaft in contact with both flat surfaces of the V-shaped notch. The bottom of the V-Shaped notch  40  may be cut back as depicted in order to provide relief that allows the various shafts to properly seat with facets in contact with the V-Shaped side walls.  FIG. 9  shows an example embodiment in which a single facet of a D-shaped shaft  104 D resides within a rectangular notch  40 A such that the single facet of the D-shape is urged into contact with the bottom of the rectangular notch  40 A. The rectangular notch  40 A can be somewhat oversized and the shaft  42 A can be adapted to conform to the shape of the shaft to prevent translation of the part (up and down as shown). The side surfaces of the rectangular notch  40 A limit movement up and down (as shown in this illustration) while the contact between the facet of the D-shaped motor shaft is urged against the bottom (left as illustrated) of the rectangular notch to inhibit rotation. 
       FIG. 11  depicts another variation in which the motor shaft  104 F is approximately hexagonal in shape and the notch  40 B has surfaces that are angular to conform fully with two facets (leftmost as illustrated) of the hexagonal cross-section of the motor shaft and partially conforms to two more of the facets of the hexagonal motor shaft (top and bottom as illustrated). This locks the shaft into place under the urging of the spring  42  and inhibits rotation if the motor shaft  104 F. In this example, the V-Shaped slot  42  may also be relieved at the center as well as cut back at the upper and lower sides (as shown) to reduce the amount of surface area of contact with the shaft thereby minimizing friction. 
     Any of the notches or slots having relief cutaways in which the predominant profile of the slot is V-Shaped may be considered approximately V-Shaped for purposes of this document. 
     In each example, the motor shaft has at least one facet that rides along a flat surface of a notch in the carriage, but multiple facets may ride along multiple corresponding surfaces of a notch to inhibit rotation of the motor shaft. 
     A method of making a linear actuator assembly in a manner consistent with the present teachings involves providing a linear actuator including a faceted motor shaft extending from a base, the base of the linear actuator including a piezoelectric component to selectively oscillate the rod of the first linear actuator. A movable carriage is disposed such that the faceted motor shaft is within a notch of the carriage, where the notch has at least one flat surface such that at least one facet of the motor shaft is in direct and continuous contact with at least one flat surface of the notch. The motor shaft is secured in place with a spring such as a cantilever spring  42 . The linear actuator can be coupled to a chassis with at least one elastomeric bushing. 
     Compared to the assembly of  FIGS. 1 and 2 , a cost savings of about 40% can be achieved. Additionally, weight savings and size reduction is also possible. Since only one motor is used, the current can be reduced compared with two motors. In the alternative, the speed can be increased by increasing the current to the single motor while maintain an equal or lower overall power consumption. The use of the faceted motor shaft such as one with a square cross-section, allows for resistance to rotation without reduction in performance. 
     To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications: 
     
         
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     In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.