High Precision Optical Encoder Research Articles

Research on the New Type of Error Detection Platform for Photoelectric Encoder

In order to realize the error detection of high precision optical encoder, an error detection method of optical encoder based on optical continuous closed loop (OCCL) was proposed, by the principle of small angle measurement of photoelectric autocollimator and single reflector. Firstly, the configuration of the OCCL error detection platform for optical encoder is designed. Then, the error detection principle of the OCCL optical encoder is analyzed. Finally, the OCCL photoelectric encoder error detection system is established, and the calibration auto-collimator and the regular 23-hedral polyhedron are used to calibrate the accuracy of the detection system. The experimental results show that the new photoelectric encoder error detection platform is frequent, convenient, stable and reliable, and the accuracy of the detection platform can reach 1.64” in the rated working speed range, which can meet the requirements of high precision (2”) and 360° full circle continuous error detection for the encoder.

Experimental and Theoretical Investigation of Quasi-Static System Level Behavior of Planetary Gear Sets

Abstract This study presents a unique experimental methodology that synchronously measures various quasi-static responses of a simple four-planet planetary gear set, namely, planet load sharing, overall transmission error (OTE), and floating sun gear orbits. Strain gauges mounted directly on the planet pins were used to monitor the load shared among the planets, which is a crucial design criterion for durability and performance. High-precision optical encoders were used to measure the OTE of the gear set to explore its diagnostic value in identifying system errors. Radial motions of the floating sun gear, which are critical to the self-centering and load sharing behavior of the gear set, were monitored using magnetic proximity probes. The influence of various design parameters and operating conditions such as planet mesh phasing, carrier pin position errors, gear tooth modifications, and input torque on the system’s response will be investigated by performing an extensive set of experiments in a repeatable and accurate manner. Finally, these experimental results will be recreated theoretically using the static planetary load distribution model of Hu et al. (2018, “A Load Distribution Model for Planetary Gear Sets,” ASME J. Mech. Des., 140(5), p. 53302) to not only validate the model but also comprehend the measured behavior.

Experimental study of the effect of assembly error on the lightly loaded transmission error of spur gear with crown modification

Experimental measurement of transmission error and vibration of a gear pair with crown modification are developed. With the help of high-precision optical encoder, effects of gear misalignment on unloaded and lightly loaded dynamic transmission error, which are relative to gear rattle, are investigated. The gear mesh misalignment is introduced by eccentric sleeve assembled on the output shaft. Effects of modification and misalignment on the dynamic transmission error, are studied at different load and driving velocity conditions. The experimental results show that, with the increase of the crown amplitude, the peak-to-peak values of dynamic transmission error are decreasing dramatically. Impact deformation or elastic deformation is a very important part of the dynamic transmission error although they are unloaded or lightly loaded. The components in harmonics of meshing frequency will change distinctly comparing cases at low input shaft velocity without and with misalignment, but different phenomena are detected while increasing the input shaft velocity. Finally, the relation between transmission error and gear box vibration is illustrated, and spectrum kurtosis is introduced to reveal gear rattle.

Method for Estimating Three-Dimensional Knee Rotations Using Two Inertial Measurement Units: Validation with a Coordinate Measurement Machine.

Three-dimensional rotations across the human knee serve as important markers of knee health and performance in multiple contexts including human mobility, worker safety and health, athletic performance, and warfighter performance. While knee rotations can be estimated using optical motion capture, that method is largely limited to the laboratory and small capture volumes. These limitations may be overcome by deploying wearable inertial measurement units (IMUs). The objective of this study is to present a new IMU-based method for estimating 3D knee rotations and to benchmark the accuracy of the results using an instrumented mechanical linkage. The method employs data from shank- and thigh-mounted IMUs and a vector constraint for the medial-lateral axis of the knee during periods when the knee joint functions predominantly as a hinge. The method is carefully validated using data from high precision optical encoders in a mechanism that replicates 3D knee rotations spanning (1) pure flexion/extension, (2) pure internal/external rotation, (3) pure abduction/adduction, and (4) combinations of all three rotations. Regardless of the movement type, the IMU-derived estimates of 3D knee rotations replicate the truth data with high confidence (RMS error and correlation coefficient).

Validation of a calibration technique for 6-DOF instrumented spatial linkages

This paper presents a practical and effective approach to the calibration of instrumented spatial linkages for biomechanical applications. A 6-DOF mechanical linkage with rotational transducers is designed and in-house manufactured for this purpose. In order to assess the validity of the proposed calibration technique and to distinguish between geometrical and electrical parameters uncertainties, high-precision optical encoders are used and calibration is addressed from a kinematic point of view only. The proposed technique is based on a closed-loop method, in which the end segments of the linkage are connected to each other by revolute joints. A parametrical model of the system is formulated using a standard link-to-link transformation matrices approach. Continuous data collection is carried out and a recursive identification of kinematic parameters is implemented by the use of an extended Kalman filter algorithm. Results shows that the proposed technique, despites its simplicity, is effective in improving the accuracy of the system up to its theoretically computed resolution, which limits the performance of the real system.

Beam alignment for scanning beam interference lithography

By interfering two small diameter Gaussian laser beams, scanning beam interference lithography (SBIL) is capable of patterning linear gratings and grids in resist while controlling their spatial phase distortions to the nanometer level. Our tool has a patterning area that is up to 300 mm in diameter. The motive for developing SBIL is to provide the semiconductor industry with a set of absolute metrology standards, but the technology is easily adaptable to other important applications such as the making of high precision optical encoders. In this article, we describe a system for carrying out automated beam alignment for SBIL. Our design goals require tight alignment tolerances, where beam position and angle alignment errors must be controlled to ∼10 μm and ∼10 μrad, respectively. We describe our system setup, and discuss the so-called iterative beam alignment principle, focusing specifically on deriving a mathematical formalism that can guide the development of similar systems in the future. Repeatability experiments demonstrate that our system fulfills the alignment requirements for nanometer-level SBIL writing.