Inspection system with dual encoders
A dual encoder motion control system for high speed and high resolution motion control of a spindle is described.
1. An apparatus, comprising:
a spindle assembly comprising a motor and a shaft;
a first encoder coupled to the shaft of the spindle assembly;
a second encoder coupled to the shaft of the spindle assembly, wherein the first encoder is a lower resolution, higher speed encoder relative to the second encoder and wherein the second encoder is a higher resolution, lower speed encoder relative to the first encoder;
a switch coupled to the first encoder and the second encoder to select between the first and second encoders;
a motion controller coupled to the switch and to the spindle assembly; and
a motor current amplifier coupled between the motion controller and the spindle motor.
2. The apparatus of claim 1 , wherein the first encoder and the second encoder are optical rotary encoders.
3. The apparatus of claim 1 , wherein the first encoder is configured to control rotation of the spindle motor at a rotational velocity greater than 10,000 revolutions per minute and the second encoder has a quadrature output of greater than 15,000 counts per revolution.
4. The apparatus of claim 1 , wherein the first encoder is configured to control rotation of the spindle assembly at a rotational velocity of approximately 12,000 revolutions per minute and the second encoder has a quadrature output of approximately 20,000 counts per revolution.
5. The apparatus of claim 1 , wherein the switch is configured to receive a multiple pulse per revolution output signal from the first encoder and a multiple pulse per revolution output signal from the second encoder, and wherein the apparatus further comprises:
a phase locked loop (PLL) multiplier circuit coupled to receive the multiple pulse per revolution output signal from the first encoder and generate an output signal;
a first counter coupled to receive a single pulse per revolution output signal from the first encoder; and
a second counter coupled to receive the output signal of the PLL multiplier circuit.
6. The apparatus of claim 5 , wherein the output signal is an in-phase multiple of the input signal to the PLL.
7. An inspection system, comprising:
a spindle assembly comprising a spindle motor and a shaft configured to receive a workpiece;
a scanner configured to identify a defect location on the workpiece;
a marking tool configured to mark the defect location on the workpiece; and
a motion control system, comprising a first encoder and a second encoder, coupled to the spindle assembly, the scanner and the marking tool, wherein the motion control system is configured to:
determine, using the first encoder, a first angular position of the shaft of the spindle assembly corresponding to the defect location identified by the scanner,
correlate the first angular position of the shaft with the second encoder, and
rotate the shaft of the spindle assembly to a second angular position using the second encoder to enable the mark tool to mark the defect location.
8. The inspection system of claim 7 , wherein the first encoder is a lower resolution, higher speed encoder relative to the second encoder and wherein the second encoder is a higher resolution, lower speed encoder relative to the first encoder.
9. The inspection system of claim 8 , wherein the first encoder is configured to rotate the spindle motor at a rotational velocity greater than 10,000 revolutions per minute and the second encoder has a quadrature output of greater than 15,000 counts per revolution.
10. The inspection system of claim 8 , wherein the scanner is an optical scanner.
11. The inspection system of claim 8 , wherein the marking tool is a mechanical scriber.
12. The inspection system of claim 8 , the motion control system further comprises:
a switch coupled to the first encoder and the second encoder to select between the first and second encoders, wherein the switch is configured to receive a multiple pulse per revolution output signal from the first encoder and a multiple pulse per revolution output signal from the second encoder;
a motion controller coupled to the switch and to the spindle assembly;
a motor current amplifier coupled between the motion controller and the spindle motor;
a phase locked loop (PLL) multiplier circuit coupled to receive the multiple pulse per revolution output signal from the first encoder and generate an output signal; and
one or more counters coupled to receive a single pulse per revolution output signal from the first encoder and the output signal of the PLL multiplier circuit.