An Efficient Approach to Correct the Signals and Generate High-Resolution Quadrature Pulses for Magnetic Encoders

A magnetic encoder (ME) is a kind of sinusoidal encoder using magnetic effects that is currently utilized in many industrial control systems because it has many advantageous characteristics: low cost, simple structure, works in harsh environments, high reliability, and so on. The signals generated by an ME are always disturbed by noises; therefore, these signals are not ideal. The challenge is to achieve the highest resolution and to get the maximum operating speed as well as to use the most cost-effective hardware. To solve this problem, this paper humbly proposes an effective approach, which contains two parts: The main part is “compensating the noisy signals of MEs” by applying a new proposed method called the advanced adaptive digital phase-locked loop (AADPLL), while the second is a pulse interpolator which generates high-resolution quadrature pulses. The AADPLL algorithm provides a robust filtering characteristic to eliminate the noises and improve the accuracy of the ME´s input signals. It also takes advantage of tracking high-speed input signals without time lag, unlike the traditional filters. Additionally, the computation burden is significantly reduced in this algorithm to allow it to be easily implemented in a low-cost processor. The pulse interpolator is based on an existing idea that extracts high-order sinusoids from the original ME signals. However, a new scheme is presented to achieve higher resolution per period with smaller noises affecting the output pulses. Both parts are mainly implemented in a unique hardware platform using a low-cost digital signal processor, such as the TMS320F2812, combined with a small-size field-programmable gate array. This method has already been applied to control a linear motor without using an expensive optical linear encoder. Practical results are provided to demonstrate the effectiveness of the proposed method.