Beruflich Dokumente
Kultur Dokumente
http://sensi.org/~svo/shaft_encoder/
MOTOR
1 of 6
29-07-2012 22:30
http://sensi.org/~svo/shaft_encoder/
original size. But this design its in pretty well, with a help of a ile and a hammer anyway. You can use the provided PDF ile to make your own PCB's. Just like the one pictured right. This board is so small that I Fig.2 Phototemplate (click for PDF) could not ind place to put any obnoxious texts on it... N.B. The boards I made have a (non-fatal) error, a trained eye will spot them immediately. The template given here has this error corrected.
Here's what a populated board looks like. I didn't wash it after soldering and debugging, so it may look not as fancy as a factory made one, but it de initely looks authentic, especially with mismatched sizes of salvaged SMD components. Note that although this board is single-sided, the reverse side is still present and is used a ground plane. It is necessary for interconnections and it also serves as an EMI shield. On this picture it is visible that small square of the backplane (to the left-top) is removed to avoid possible short circuit of wires.
Fig.4 Populated board
It is now time to think about how to mount discrete parts into the casing of a servo. If we had one senderreceiver module, we'd just cut a hole in the case and glue it in somewhere. But with two separate parts, it is really important to keep them aligned together. I used some of remaining cuts of copper-laminated iberglass to make a harness. You would have to make two markings at proper distances to it two 3-mm led-like things, then drill very small holes for alignment, then take your big drill and make 3mm holes to it in the led and the receiver. I made the holes so that the emitter and the receiver are looking towards eachother, kind of simulating them being "focused" to a certain distance. But
Fig.5 Harness
2 of 6
29-07-2012 22:30
http://sensi.org/~svo/shaft_encoder/
I'm really not sure if this works and important at all. The emitter led seems to be shining pretty much omindirectionally at a distance this small. After some simple testing (the circuit output must go down from high when something re lective is near the sensor) I glued both components to the harness and soldered short wires to attach them to the PCB permanently. On the left picture you can see a window in the casing, the sensor will "look" through it on the gear with interrupter (this is a view with reductor gears removed, but you must know that if you went this far into servo anatomy). The right picture shows the bottom side of the "encoder wheel". The real bene it of this design is that the encoder wheel is really simple and doesn't require complicated printed patterns (although you can try that, I don't recommend because this wheel is
3 of 6
29-07-2012 22:30
http://sensi.org/~svo/shaft_encoder/
really small, I barely could photograph the pest). You can see traces of all kinds of tortures I tried on this poor gear. In the end of this ordeal I went completely medieval and glued onto it a tiny patch of insulation tape made of pitch black fabric. Painting the gear with marker didn't give enough contrast. Even glueing a piece of paper all blackened with a pen didn't give enough contrast - at distance this close everything except pitch black blastic is very re lective for IR. Actually glueing a tiny bit of plastic from SMD reel packaging would work too. Left picture shows how the harness is itted inside of the servo casing. I used some kind of thermal glue. It's not exactly the kind used in glue pistols,
Fig.8 Gooed in
4 of 6
29-07-2012 22:30
http://sensi.org/~svo/shaft_encoder/
it's not transparent and messy and smells funny. Any glue will do though. Right picture shows how the makeshift sensor is peeking through the peephole in the casing. Just a little more time and all it will ever see will be the torture encoder wheel. Har. Everything must be clear from now on. I had to cut the board a little on the sides to let the screws it in. Protected it with two layers of insulation tape to avoid any contact with the motor, then itted it in. The capacitor was the most protruding part on the board, I even had to cut a little window in the cover for it too. But still, the board is a little thicker than the casing allows, after I screwed back the cover the servo looks a
Fig.9 Peek-a-boo
Fig.10 Packing
5 of 6
29-07-2012 22:30
http://sensi.org/~svo/shaft_encoder/
little oversatiated. With this reductor (the original servo was Hi-Tec HS-311, they say it's the most unmodi iable servo ever made, but I don't understand why - I modi ied the hell out of it and it still works), I get 42 pulses per output shaft revolution. The duty cycle is not perfectly 50% as you might guess by looking at the encoder wheel I use. Number of pulses per revolution can be increased at least two-fold by adding another nonre lective stripe of black goo. Conclusion: this design is relatively simple to implement and it works with the most unmodi iable servo in the world. Number of pulses per revolution has sacred meaning which can not be a bad thing. After the value of current-limiting resistor for certain type of emitter/receiver is found, the entire thing must be easy to reproduce for as many motors as needed. No hard-to ind or expensive components are necessary, and the entire modi ication its completely into the original servo case.
***
2005 Viacheslav Slavinsky. Please do not republish without permission. Send all comments and criticisms to svofski a t gmail dot c0m.
6 of 6
29-07-2012 22:30