Floating mask encoder with assembly spacer

Claim 1

A method of manufacturing a shaft position encoder requiring a minimum of precision machining and exhibiting simplified alignment characteristics and which is of the type including a rotary encoded disk including position markings thereon and a stationary detector having a mask disposed thereon for reading said position markings to produce electrical signals indicative of shaft position, comprising the steps of: mounting the encoded disk for rotation with the shaft; mounting a circuit board near the encoded disk; placing the detector between the encoded disk and the circuit board with the leads thereof passing through apertures in the circuit board; aligning the detector and the encoded disk with the surface of said mask and the surface of said disk in parallel with each other and with an air gap of less than 0.005" between their surfaces using a spacer between the detector and the encoded disk surface; mechanically securing the detector leads to the circuit board with the spacer in place; and thereafter removing the spacer.

Claim 2

A method of manufacturing a shaft position encoder requiring a minimum of precision machining and exhibiting simplified alignment characteristics and which is of the type including a rotary encoded disk including position markings thereon and a stationary detector having a mask disposed thereon for reading said position markings to produce electrical signals indicative of shaft position, comprising the steps of: mounting the encoded disk for rotation with the shaft; mounting a circuit board near the encoded disk; placing the detector between the encoded disk and the circuit board with the leads thereof passing through apertures in the circuit board; aligning the detector and the encoded disk with the surface of said mask and the surface of said disk in parallel with each other and with an air gap of less than 0.005" between their surfaces using a spacer between the detector and the encoded disk surface; mechanically securing the detector leads to the circuit board with the spacer in place; and thereafter removing the spacer.

Claim 4

A method of manufacturing a transducer for converting rotary motion to an electrical signal which requires a minimum of precision machinging, exhibiting simplified alignment characteristics and which method comprises the steps of: installing a rotatable shaft within a base; mounting a disk upon the rotatable shaft; mounting first sensing means on the base; mounting a substrate to the base, the substrate having second sensing means loosely mounted thereon, such that the first and second sensing means are disposed on opposite sides of the disk; placing spacing means between the second sensing means and the disk; radially aligning the second sensing means with the disk; and fixedly attaching the second sensing means to the substrate such that there is a predetermined air gap of less than 0.005" between the second sensing means and the disk when the spacing means is removed.

Claim 5

A method of manufacturing a transducer for converting rotary motion to an electrical signal which requires a minimum of precision machinging, exhibiting simplified alignment characteristics and which method comprises the steps of: installing a rotatable shaft within a base; mounting a disk upon the rotatable shaft; mounting first sensing means on the base; mounting a substrate to the base, the substrate having second sensing means loosely mounted thereon, such that the first and second sensing means are disposed on opposite sides of the disk; placing spacing means between the second sensing means and the disk; radially aligning the second sensing means with the disk; and fixedly attaching the second sensing means to the substrate such that there is a predetermined air gap of less than 0.005" between the second sensing means and the disk when the spacing means is removed.