1. Sensors Bryson Cook James Wyler Hao Phan 1

2. Outline Optical Encoders: Theory and applications –Types of encoders –Fundamental Components –Quadrature –Errors –Applications LVDT (Linear Variable Differential Transformer) –What is a LVDT –Types of LVDT –How do they work? –Applications Bryson Cook 2

3. What are Encoders For our class, an encoder is a device that senses position or orientation for use as a reference or active feedback to control position. – Most are either: Rotary: converts rotary position to an analog or electronic signal. Linear: converts linear position to an electronic signal. – Are also either absolute or incremental. Absolute gives the absolute position and knowledge of the previous position is not needed. Incremental encoders is more ambiguous and requires counting of cycles to determine absolute position. Bryson Cook 3

4. Optical Encoders Use light & photosensors to produce digital code Most popular type of encoder. Can be linear or rotary. Bryson Cook 4

5. Optical Encoders: Components Light source(s) – LEDs or IR LEDs provide light source. – Light is collimated using a lens to make the beams parallel. Photodetector(s) – Either Photodiodes or Phototransistors. Opaque disk (Code Disk) – One or more “tracks” with slits to allow light to pass through. Bryson Cook 5

6. Optical Encoders: Theory LED Code Disk Photo- sensor Bryson Cook 6

7. Rotary Optical Encoder Types Incremental Encoders: Mechanical motion computed by measuring consecutive “on” states. Absolute Encoders: Digital data produced by code disk, which carries position information. Incremental Encoder code Disk Absolute Encoder code Disk Bryson Cook 7

8. Binary and Gray Encoding In some devices, Binary Encoding is used to keep track of the various positions. The areas of the disk are named counting in binary. – This can cause problems since multiple bits can change from one successive area to the next, such as in 011 to 100 all three bits change. Gray Encoding is a binary system where the adjacent areas only differ in one bit. Bryson Cook 8

9. Standard Binary Encoding AngleBinaryDecimal 0-450000 45-900011 90-1350102 135-1800113 180-2251004 225-2701015 270-3151106 315-3601117 Bryson Cook *Note: Extremely simplified encoder 9

10. Gray Encoding AngleBinaryDecimal 0-450000 45-900011 90-1350112 135-1800103 180-2251104 225-2701115 270-3151016 315-3601007 Notice only 1 bit has to be changed for all transitions. Bryson Cook 10

11. Quadrature Quadrature describes two signals 90° out of phase Used to determine direction of measurement Only two directions possible, A leads B or B leads A 11 James Wyler

12. Quadrature Standard Encoder Track – Gives velocity and position but not direction Quadrature Encoder Track – Gives velocity, position AND direction 12 James Wyler

13. Quadrature – How It Works Grey Encoding Identical tracks – Phase offset of 90º Two sensors Current state vs. next state 13 James Wyler

14. Quadrature – Rotary Encoders Examples of Quadrature Rotary Encoders 2 Bit Wheel 64 Bit Wheel 14 James Wyler

15. Optical Encoder Errors 1.Quantization Error – Dependent on resolution of sensor 2.Assembly Error – Disk not positioned correctly with respect to sensor 3.Manufacturing Error – Tolerances of sensor positioning and code printing lead to inaccurate signals 15 James Wyler

16. Optical Encoder Errors – Cont. 4.Structural Limitations – Loading on shaft or disk deformation 5.Coupling Error – Gear backlash, belt slippage, etc… 6.Ambient Effects – Vibration, temperature, light noise, humidity, etc… 16 James Wyler

17. Optical Encoder Applications Coordinate Measuring Machine (CMM) Digital Calipers CNC Machining Electric Motors Robotics 17 James Wyler

18. LVDT What is a LVDT Types of LVDT How do they work? Applications 18 James Wyler

19. What is a LVDT Linear Variable Differential Transformer Electrical transformer used to measure linear displacement 19 James Wyler

20. Construction of LVDT One Primary coil Two symmetric secondary coils Ferromagnetic core 20 James Wyler

21. Types of LVDT Power supply : – DC – AC Type of armature : – Free (Unguided) – Captive (Guided) – Spring-extended 21 Hao Phan

22. Power supply : DC LVDT Easy to install Signal conditioning easier Can operate from dry cell batteries High unit cost 22 Hao Phan

23. Power supply : AC LVDT Small size Very accurate –Excellent resolution (0.1 μm) Can operate with a wide temperature range Lower unit cost 23 Hao Phan

24. Armature : Free Core (Unguided) Core is completely separable from the transducer body Well-suited for short-range applications high speed applications (high-frequency vibration) 24 Hao Phan

25. Captive Core (Guided) Core is restrained and guided by a low-friction assembly Both static and dynamic applications Long range applications Preferred when misalignment may occur 25 Hao Phan

26. Spring-Extended Core Core is restrained and guided by a low-friction assembly Internal spring to continuously push the core to its fullest possible extension Best suited for static or slow-moving applications Medium range applications 26 Hao Phan

27. How do they work? An alternating current is driven through the primary, causing a voltage to be induced in each secondary proportional to its mutual inductance with the primary. 27 Hao Phan

28. How do they work? The coils are connected in reverse series The output voltage is the difference (differential) between the two secondary voltages 28 Hao Phan

29. Null Position When the core is in its central position, it is placed equal distance between the two secondary coils. Equal but opposite voltages are induced in these two coils, so the differential voltage output is zero. 29 Hao Phan

30. In Phase Voltage Displacing the core to the left causes the first secondary to be more strongly coupled to the primary than the second secondary. The higher voltage of the first secondary in relation to the second secondary causes an output voltage that is in phase with the primary voltage. The phase of the voltage indicates the direction of the displacement. 30 Hao Phan

31. Out of Phase Voltage Displacing the core to the right causes the second secondary to be more strongly coupled to the primary than the first secondary. The greater voltage of the second secondary causes an output voltage to be out of phase with the primary voltage. 31 Hao Phan

32. How do they work? The magnitude of the output voltage is proportional to the distance moved by the core, which is why the device is described as "linear". Note that the output is not linear as the core travels near the boundaries of its range. 32 Hao Phan

33. LVDT Applications Crankshaft Balancing Testing Soil Strength Automated Part Inspection Automotive Damper Velocity 33 Hao Phan

34. References http://www.macrosensors.com/lvdt_tutorial.html http://zone.ni.com/devzone/cda/tut/p/id/3638#toc3 http://en.wikipedia.org/wiki/Linear_variable_differential_transformer http://prototalk.net/forums/showthread.php?t=78\ http://www.transtekinc.com/support/applications/LVDT-applications.html http://www.sensorsmag.com/sensors/position-presence-proximity/modern-lvdts- new-applications-air-ground-and-sea-7508 http://www.macrosensors.com/lvdt_tutorial.html http://zone.ni.com/devzone/cda/tut/p/id/3638#toc3 http://en.wikipedia.org/wiki/Linear_variable_differential_transformer Sensors Lecture: Fall ME6405 2009 http://electricly.com/absolute-optical-encoders-rotary-encoders 34