Optical position sensor for determining the angular position of a rotating device

1. An optical position sensor system for determining the angular position of a rotary member having a longitudinal rotation axis that extends in an axial direction comprising:

a single light source aligned along the rotation axis;

a collimating element adjacent the light source a predetermined distance, the collimating element aligned along the rotation axis to collimate light from the light source along the rotation axis;

a detection element adjacent the collimating element a predetermined distance to receive collimated light from the collimating element and to provide a linear output;

a light blocker inserted between the collimating element and the detection element, the light blocker coupled to the rotary member to rotate therewith about the rotation axis to block portions of the collimated light from the light source and the collimating element from reaching the detection element in direct relationship to the rotary position of the light blocker; and

a housing in which an end of the rotary member is mounted therein for rotational movement, the housing spatially separating the single light source, the collimating element, the detection element, and the light blocker from one another, the housing defining a central two tiered cylindrical bore comprising a transition shoulder delineating a first tier having a first diameter from a second tier having a second diameter that is larger than the first diameter.

2. The system of claim 1 wherein the detection element comprises four radially aligned detector segments.

3. The system of claim 2 wherein the four radially aligned detector segments comprises four sector-shaped light detector segments.

4. The system of claim 2 wherein each of the four radially aligned detector segments comprises a photosensitive surface having a predetermined configuration, and wherein the light blocker comprises two light blocking segments, each of the light blocking segments configured one of:

larger than the predetermined configuration of the photosensitive surface of one of the sector-shaped light detector segments; and

to substantially match the predetermined configuration of the photosensitive surface of one of the sector-shaped light detector segments.

5. The system of claim 2 further comprising a mask over the detection element, the mask inserted between the light blocker and the detection element.

6. The system of claim 5 wherein that mask defines an annular radial segment of open active detection area on each of the four radially aligned detector segments.

7. The system of claim 6 wherein the light blocker comprises two light blocking segments, each of the light blocking segments configured one of:

larger than the configuration of the annular radial segment of open active detection area of one of the detector segments; and

to substantially match the configuration of the annular radial segment of open active detection area of one of the detector segments.

8. The system of claim 1 wherein the light source comprises a light emitting diode.

9. The system of claim 8 wherein the light emitting diode further comprises an attached lens that reduces beam spread from the light emitting diode.

10. The system of claim 1 wherein the light blocker is of a butterfly-shaped configuration.

11. The system of claim 1 wherein the light blocker is made of a non-reflective, opaque material.

12. The system of claim 1 wherein the collimating element is one of:

a lens; and

a parabolic reflector, wherein the light source is located within the open center of the parabolic reflector located along an axis at a focal point of the parabolic reflector.

13. The system of claim 12 wherein the lens is adjacent the light source a distance of about 0.1 to about 2.0 inches.

14. The system of claim 13 wherein the lens is adjacent the light source a distance of about 0.2 to about 0.6 inches.

15. The system of claim 12 wherein the detection element is adjacent the lens a distance of about 0.03 to about 3.0 inches.

16. The system of claim 15 wherein the detection element is adjacent the lens a distance of about 0.1 to about 0.5 inches.

17. The system of claim 1 wherein:

the single light source is located at an end of the smaller tier opposite the transition shoulder;

the collimating element has a diameter larger than the diameter of the smaller tier and is located at the transition shoulder; and

the detection element is located at an end of the larger tier opposite the transition shoulder around the end of the rotary member.