Broken line sensor detection system

Abstract

The invention discloses a broken line sensor detection system. The system comprises a broken line detection circuit, a controller and an output indication circuit, the broken line detection circuit is connected with the controller, and the broken line detection circuit is used for detecting detected equipment, outputting a broken line detection signal and transmitting the broken line detection signal to the controller; and the controller is connected with the output indication circuit, and the controller is used for receiving the broken line detection signal and controlling the output indication circuit to output a broken line detection result corresponding to the detected equipment when a characteristic value of the broken line detection signal exceeds a preset broken line threshold value. The invention aims to solve the problems of long time consumption, low efficiency and high equipment cost of the existing broken line detection technology, and provides an efficient and real-time broken line sensor detection system, so that the broken line state of a detected object can be quickly and accurately monitored.

Description

Technical Field

[0001] The present application relates to the field of automated detection technology, and in particular to a wire break sensor detection system. Background Art

[0002] As the "neurons" of industrial systems, the importance of sensors is self-evident. They play a vital role in automation equipment. As a type of sensor, the application principle of the broken wire sensor is relatively intuitive but extremely critical. In the normal production process, the detected wire continues to move, which is a sign of normal operation of the production line. Once the wire breaks, it means that the production process is abnormal. At this time, the work must be stopped immediately and repaired, and the alarm mechanism is triggered. The working principle of the broken wire sensor is to continuously monitor the existence and status of the thread. When the thread is normal and in working condition, the sensor will output a normal signal, indicating that everything is normal on the production line. However, once the thread breaks during operation, the sensor can quickly detect this change and immediately output an abnormal signal to alert the operator to pay attention and take corresponding measures.

[0003] At present, there are various detection technologies for broken wire sensors, but each has different advantages and disadvantages. Ordinary sensors often use gravity detection technology to monitor the tension of the wire. However, this detection method has high requirements for mechanical equipment and may increase the complexity and maintenance cost of the system. Another detection technology is to use image equipment to detect image differences. Although this method is accurate, the equipment cost is high and the processing technology requirements are relatively high. Therefore, it may not be suitable for all application scenarios. Photoelectric sensing technology is also a commonly used broken wire detection technology. It determines whether the wire end is broken by detecting the light reflection or occlusion of the wire end. However, the reliability of this technology is often difficult to reach the ideal level, especially when facing different objects to be inspected. Without the use of a microcontroller (MCU) system, photoelectric sensing technology is difficult to adapt to various complex scenarios. Summary of the invention

[0004] The main purpose of this application is to provide a broken wire sensor detection system, which aims to solve the limitations of existing broken wire detection technology, such as long time consumption, low efficiency and high equipment cost. By providing an efficient and real-time broken wire sensor detection system, it is possible to quickly and accurately monitor the broken wire status of the detected object.

[0005] To achieve the above-mentioned purpose, an embodiment of the present application provides a disconnection sensor detection system, the system mainly comprising a disconnection detection circuit, a controller and an output indication circuit; wherein: The disconnection detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The controller is connected to the output indication circuit, and is used to receive the disconnection detection signal, and when the characteristic value of the disconnection detection signal exceeds a preset disconnection threshold, control the output indication circuit to output a disconnection detection result corresponding to the detected device.

[0006] In one embodiment, the disconnection detection circuit includes a photodiode detection circuit and a filter circuit; wherein: The photodiode detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The filter circuit is connected to the photodiode detection circuit, and the filter circuit is used to filter the disconnection detection signal of the photodiode detection circuit.

[0007] In one embodiment, the photodiode detection circuit includes a first resistor, a second resistor, a third resistor, a first transistor and a photodiode, wherein: The first end of the first resistor is respectively connected to the anode of the photosensitive diode, the base of the first transistor and the first end of the second resistor, and the second end of the first resistor is grounded; the first end of the second resistor is respectively connected to the emitter of the first transistor and the first end of the third resistor, and the second end of the second resistor is grounded; the first end of the third resistor is respectively connected to the emitter of the first transistor, and the second end of the third resistor is connected to the controller; the anode of the photosensitive diode is respectively connected to the base of the first transistor and the first end of the first resistor, the cathode of the photosensitive diode is connected to the filter circuit, and the collector of the first transistor is connected to the power supply terminal.

[0008] In one embodiment, the filtering circuit includes a fourth resistor, a first capacitor, and a second capacitor, wherein: The first end of the fourth resistor is connected to the cathode of the photodiode and the first end of the first capacitor respectively, and the second end of the fourth resistor is connected to the first end of the second capacitor and the power supply end respectively; the second end of the first capacitor and the second end of the second capacitor are grounded.

[0009] In one embodiment, the wire break sensor detection system comprises a pulse control circuit; wherein: The pulse control circuit is connected to the controller, and is used to send a pulse signal to the device under test so that the disconnection detection circuit detects the state of the device under test.

[0010] In one embodiment, the pulse control circuit includes a fourth capacitor, a second transistor, a sixth resistor, and a seventh resistor; wherein: The first end of the fourth capacitor is respectively connected to the first end of the sixth resistor and the third end of the controller, the second end of the fourth capacitor is respectively connected to the second end of the sixth resistor and the base of the second transistor, the emitter of the second transistor is connected to the first end of the seventh resistor, the collector of the second transistor is grounded, and the second end of the seventh resistor is connected to the device under inspection.

[0011] In one embodiment, the controller includes a first main control chip, a third capacitor, a fifth resistor, and a first light emitting diode; wherein: The first end of the first main control chip is respectively connected to the first end of the third capacitor and the power supply end, the second end of the first main control chip is connected to the output indication circuit, the third end of the first main control chip is connected to the pulse control circuit, the fourth end of the first main control chip is connected to the first end of the fifth resistor, the fifth end and the sixth end of the first main control chip are respectively connected to the key circuit, the seventh end of the first main control chip is connected to the second end of the third resistor of the photosensitive diode detection circuit, and the eighth end of the first main control chip is respectively connected to the second end of the third capacitor and the ground; the second end of the fifth resistor is connected to the anode of the first light-emitting diode, and the cathode of the first light-emitting diode is grounded.

[0012] In one embodiment, the disconnection sensor detection system further includes a key circuit; wherein: The key circuit is connected to the controller, and the key circuit is used to perform key setting on the preset disconnection threshold.

[0013] In one embodiment, the output indication circuit includes an eighth resistor, a third transistor, and a first Schottky diode; wherein: The first end of the eighth resistor is connected to the second end of the first main control chip, the second end of the eighth resistor is connected to the base of the third transistor, the emitter of the third transistor is connected to the cathode of the first Schottky diode, and the collector of the third transistor and the anode of the first Schottky diode are grounded.

[0014] In one embodiment, the wire break sensor detection system further includes an adaptation circuit; The adaptation circuit is connected to the output indication circuit and the controller respectively, and the adaptation circuit is used to adapt to the device under test.

[0015] The above one or more technical solutions provided by this application may have the following advantages or at least achieve the following technical effects: The present application discloses a wire break sensor detection system, which relates to the field of automated detection technology. The system mainly includes a wire break detection circuit, a controller, and an output indication circuit; the wire break detection circuit is connected to the controller, and the wire break detection circuit is used to detect the device under inspection, and output a wire break detection signal to transmit to the controller; the controller is connected to the output indication circuit, and the controller is used to receive the wire break detection signal, and when the characteristic value of the wire break detection signal exceeds a preset wire break threshold, control the output indication circuit to output the wire break detection result corresponding to the device under inspection. The present application aims to solve the limitations of the existing wire break detection technology, which is time-consuming, inefficient, and has high equipment costs. By providing an efficient and real-time wire break sensor detection system, it is possible to quickly and accurately monitor the wire break status of the object under inspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0017] Figure 1 It is a schematic diagram of the structure of the wire break sensor detection system proposed in the embodiment of the present application; Figure 2 Schematic diagram of a disconnection detection circuit of a first embodiment of a disconnection sensor detection system proposed in an embodiment of the present application; Figure 3 A schematic diagram of a pulse control circuit of a first embodiment of a broken wire sensor detection system proposed in an embodiment of the present application; Figure 4 A schematic diagram of a controller circuit of a second embodiment of a broken wire sensor detection system proposed in an embodiment of the present application; Figure 5 This is a schematic diagram of the output indication circuit of the second embodiment of the broken wire sensor detection system proposed in the embodiment of the present application.

[0018] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0020] It should be noted that if the embodiments of the present application involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0021] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present application, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme that satisfies both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in the field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0022] The present application introduces a disconnection sensor detection system, which aims to achieve the switching of system status, learning and fine-tuning of sensor disconnection thresholds, and switching of output adaptation modes through key operations. After the system is powered on, it is in working state by default, and the output red light is on, indicating that the system has started and is in normal working mode. When the system is powered on, the hardware is initialized first, including clock setting, GPIO port configuration, etc. After the initialization is completed, the system state variable is set to 0, indicating that the system is in working state. Configure the fourth port of the controller to output mode, and light up the red light as an indication of system startup. During the initialization process, the system state variable is saved in a global or static variable so that subsequent operations can read and modify the state. Ensure that the output state of the fourth port of the controller is consistent with the system state variable, that is, when the system state is 0, the red light is on. Press the "+" key and the "-" key to learn the technical implementation of disconnection and normal By pressing the "+" key for a long time and pressing the "+" key, the system can learn the sensor detection values ​​in the disconnection and normal states, and automatically adjust the threshold to adapt to different environments. Long press the "+" key to enter the learning state. When it is detected that the "+" key is long pressed for more than 3 seconds, the system state variable is set to 1, indicating that the system enters the learning state. At the same time, switch the output state of the fourth port of the controller so that the red light starts flashing as an indication of entering the learning state. Release the "+" key to learn the disconnection detection value. When the "+" key is released, the system starts to read the detection value of the current sensor and save it as the disconnection detection value. At this time, the system is still in the learning state and the red light continues to flash. Move the sensor and press the "+" key to enter the working state, and move the sensor to the end of the line in the normal state. Press the "+" key to set the system state variable to 0, indicating that the system enters the working state. After releasing the "+" key, the system starts to learn the detection value of normal operation and automatically adjusts the new threshold value according to the value. After the adjustment is completed, save the new threshold value to the power-off non-loss storage area (such as EEPROM or Flash) to ensure that the correct threshold value can still be used after the system is restarted.

[0023] The system automatically calculates a suitable threshold value based on the learned disconnection detection threshold value and normal detection threshold value. The threshold calculation method involves mathematical operations, weighted average, filtering algorithms, etc. to ensure the accuracy and stability of the threshold value. The technical implementation of fine-tuning the threshold value by pressing the "+" and "-" keys. When the system is in working state, by pressing the "+" and "-" keys, the user can fine-tune the threshold value of the sensor to adapt to different environments or needs. When the system is in working state (the system state variable is 0), the input of the "+" and "-" keys is continuously detected. When the "+" key is detected to be pressed, the current threshold value is increased by 1. When the "-" key is detected to be pressed, the current threshold value is reduced by 1. After each key operation, the threshold value is updated and saved to the power-off non-loss storage area. During the fine-tuning process, the change of the current threshold value can be displayed through other indicator lights or display screens so that the user can understand the adjustment effect. By pressing the "-" key for 3 seconds, the user can switch between adaptation modes, and the output state will also change synchronously. When the system is in working state (system state variable is 0), the long press input of the "-" key is continuously detected. If the "-" key is detected to be pressed for more than 3 seconds, the mode switching process is entered.

[0024] refer to Figure 1 , Figure 1 It is a structural schematic diagram of the disconnection sensor detection system proposed in the embodiment of the present application.

[0025] In this embodiment, the disconnection sensor detection system includes a disconnection detection circuit, a controller, and an output indication circuit; wherein: The disconnection detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The controller is connected to the output indication circuit, and is used to receive the disconnection detection signal, and when the characteristic value of the disconnection detection signal exceeds a preset disconnection threshold, control the output indication circuit to output a disconnection detection result corresponding to the detected device.

[0026] Specifically, in this embodiment, the disconnection sensor detection system is a system that can be widely used to detect whether a detected device (such as a wire, cable, sensor line, etc.) is disconnected. The system achieves accurate detection of disconnection of the detected device through the coordinated work of three main parts: a disconnection detection circuit, a controller, and an output indication circuit, and outputs a corresponding indication signal when a disconnection is detected.

[0027] As a non-contact detection technology, photoelectric sensing technology has been widely used in the field of broken wire detection due to its high precision, high sensitivity and fast response. This technology determines whether the wire end is broken by detecting the light reflection or occlusion of the wire end, providing a reliable means of broken wire detection for many fields such as industrial automation, communication equipment maintenance and daily life. Photoelectric sensing technology is based on the photoelectric effect, that is, the process of converting light signals into electrical signals. When light shines on the photoelectric sensor, the photoelectric devices (such as photodiodes, phototransistors, etc.) in the sensor absorb light energy and convert it into electrical energy, thereby generating an electrical signal. The size of this electrical signal is related to the intensity and wavelength of the light and the characteristics of the photoelectric device. In broken wire detection, photoelectric sensing technology mainly uses reflective or occluded photoelectric sensors. Reflective sensors emit light to the object to be detected and receive the light reflected back by the object; occluded sensors determine the existence or state of the object by detecting whether the light is blocked by the object.

[0028] In the reflective photoelectric induction wire break detection, the sensor emits light to the wire end, and the wire end reflects part of the light back to the sensor. When the wire end is intact, the intensity of the reflected light fluctuates within a certain range; when the wire end is broken, the intensity of the reflected light changes significantly (such as weakening or disappearing), and this change is captured by the sensor and converted into an electrical signal output. The key to reflective photoelectric induction wire break detection is to ensure that the light emitted by the sensor can accurately illuminate the wire end, and the reflected light can be effectively received by the sensor. This requires that the sensor's parameters such as the emission angle, receiving angle, and distance from the object to be detected be reasonably set. The shielding photoelectric induction wire break detection determines the state of the wire end by detecting whether the light is blocked by the wire end. The sensor emits light to form a light curtain or beam. When the wire end is intact and located on the light path, it will block part or all of the light; when the wire end is broken, the light will no longer be blocked or the degree of blocking will change. This change is also captured by the sensor and converted into an electrical signal output. The advantage of shielding photoelectric induction wire break detection is that its detection range is relatively fixed and the requirements for the reflection characteristics of light are not high. However, it requires that the object to be detected (i.e., the thread end) must be in the light path and the obstruction degree is large enough to trigger the sensor.

[0029] The controller is another core part of the system, which is used to receive the disconnection detection signal output by the disconnection detection circuit and judge whether it exceeds the preset disconnection threshold according to the characteristic value of the signal. If it exceeds the threshold, the controller controls the output indication circuit to output the disconnection detection result. The working principle of the controller is mainly based on signal processing and judgment logic. When receiving the disconnection detection signal, the controller first pre-processes the signal, such as filtering, amplification, etc., to improve the reliability and accuracy of the signal. Then, the controller extracts the characteristic value of the signal (such as voltage value, current value, resistance value, etc.) and compares it with the preset disconnection threshold. If the characteristic value exceeds the threshold, it is judged as disconnection; otherwise, it is judged as normal. There are many ways to implement the controller, such as single-chip microcomputer, PLC (programmable logic controller), DSP (digital signal processor), etc. The single-chip microcomputer has the advantages of small size, low power consumption, strong function, high reliability, etc., and is very suitable for the controller of the disconnection sensor detection system. The single-chip microcomputer receives the analog signal output by the disconnection detection circuit through the internal ADC (analog-to-digital converter) module and converts it into a digital signal for processing. The microcontroller contains a wealth of peripheral resources, such as timers, interrupts, communication interfaces, etc., which can easily implement functions such as signal preprocessing, feature value extraction, threshold comparison, etc. At the same time, the microcontroller can also implement complex judgment logic and control strategies through programming to meet different detection requirements.

[0030] The output indication circuit is used to output corresponding indication signals when the controller determines that the line is broken. These indication signals can be in the form of lights, sounds, display screens, etc., so that users can intuitively understand the status of the device under inspection. The working principle of the output indication circuit is mainly based on the control signal of the controller. When the controller determines that the line is broken, it will output a control signal to the output indication circuit. After receiving the control signal, the output indication circuit outputs the corresponding indication signal according to the preset indication method (such as lighting the indicator light, sounding the alarm, etc.).

[0031] Furthermore, in this embodiment, the disconnection detection circuit includes a photodiode detection circuit and a filter circuit; wherein: The photodiode detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The filter circuit is connected to the photodiode detection circuit, and the filter circuit is used to filter the disconnection detection signal of the photodiode detection circuit.

[0032] Specifically, in this embodiment, the photoelectric sensing broken wire detection technology has been widely used in many fields such as industrial automation, communication equipment maintenance and daily life due to its advantages of non-contact, high precision, high sensitivity and fast response. This technology mainly relies on photoelectric sensors to determine whether the wire end is broken by detecting the light reflection or shielding of the wire end. A photodiode (also known as a photodiode or a photodiode) is a photoelectric device that converts light signals into electrical signals. In the photoelectric sensing broken wire detection circuit, the photodiode detection circuit plays a vital role.

[0033] In the photoelectric sensing disconnection detection circuit, the photodiode detection circuit works together with the filter circuit to realize the disconnection detection function. Figure 2 , Figure 2 The present invention is a schematic diagram of a disconnection detection circuit of the first embodiment of the disconnection sensor detection system proposed in the embodiment of the present application. The photodiode detection circuit is responsible for detecting the wire end of the device under test and outputting a disconnection detection signal; while the filter circuit filters the disconnection detection signal to eliminate noise interference and improve the stability of the signal. When the light emitted by the light source is irradiated onto the wire end of the device under test, the light reflected by the wire end is received by the photodiode and converted into an electrical signal for output. This electrical signal is amplified to form a disconnection detection signal and transmitted to the filter circuit. The filter circuit filters the disconnection detection signal to eliminate high-frequency noise interference and transmits the processed signal to the controller. The controller judges the disconnection detection signal according to a preset threshold value, and triggers an alarm or control output when the signal exceeds the threshold value. In the design process of the photoelectric induction disconnection detection circuit, the parameters of the photodiode detection circuit and the filter circuit need to be optimized and adjusted to ensure the stability and accuracy of the system. The intensity of the light source should be moderate to ensure that it can fully irradiate the wire end of the device under test and generate sufficient reflected light. An overly strong light source may cause the photodiode to be saturated or damaged; while an overly weak light source may not generate enough reflected light to trigger disconnection detection. Selection and adjustment of photodiodes: Select appropriate photodiodes according to application requirements, and adjust parameters such as reverse bias voltage and current limiting resistor according to actual conditions to ensure their normal operation. Adjust the cutoff frequency, passband gain, stopband attenuation and other parameters of the filter circuit according to the frequency characteristics and noise interference of the disconnection detection signal to ensure the best filtering effect. In the application process of the photoelectric induction disconnection detection circuit, various interference factors may be encountered, such as electromagnetic interference, light interference, etc. In order to ensure the stability and accuracy of the system, corresponding protective measures need to be taken. Shielding, grounding and filtering are used in circuit design to suppress the influence of electromagnetic interference. In addition, components and circuits with anti-electromagnetic interference capabilities can be selected to improve the anti-interference ability of the system.

[0034] Photoelectric induction wire break detection circuits have been widely used in many fields such as industrial automation, communication equipment maintenance, and daily life. For example, in textile machinery, photoelectric induction wire break detection circuits can be used to monitor the breakage of yarn in real time; in communication equipment, this technology can be used to detect the breakage of optical fiber or coaxial cable; in smart homes, this technology can be used to detect the breakage of objects such as curtain rails or wires. In order to evaluate the performance of photoelectric induction wire break detection circuits, the following aspects can be considered: Sensitivity refers to the system's sensitivity to disconnection detection. The higher the sensitivity, the more accurately the system can detect minor disconnections; but too high a sensitivity may also lead to an increase in false alarms or missed alarms. Stability refers to the system's ability to maintain consistent performance under different environmental conditions. A system with good stability can work stably under various environmental conditions and output accurate disconnection detection signals. Anti-interference ability refers to the system's resistance to external interference factors. A system with strong anti-interference ability can work normally and output accurate disconnection detection signals in harsh environments such as electromagnetic interference and optical interference. Power consumption and cost are one of the important indicators for evaluating system performance. Low-power and low-cost systems can reduce operating costs and energy consumption, and improve the economy and practicality of the system.

[0035] Furthermore, in this embodiment, the photodiode detection circuit includes a first resistor R1, a second resistor R2, a third resistor R3, a first transistor Q1 and a photodiode D1, wherein: The first end of the first resistor R1 is respectively connected to the anode of the photosensitive diode D1, the base of the first transistor Q1 and the first end of the second resistor R2, and the second end of the first resistor R1 is grounded; the first end of the second resistor R2 is respectively connected to the emitter of the first transistor Q1 and the first end of the third resistor R3, and the second end of the second resistor R2 is grounded; the first end of the third resistor R3 is respectively connected to the emitter of the first transistor Q1, and the second end of the third resistor R3 is connected to the controller; the anode of the photosensitive diode D1 is respectively connected to the base of the first transistor Q1 and the first end of the first resistor R1, the cathode of the photosensitive diode D1 is connected to the filter circuit, and the collector of the first transistor Q1 is connected to the power supply terminal.

[0036] Specifically, in the design of the photodiode D1 detection circuit, the resistance value of the first resistor R1 should be determined according to the dark current and maximum operating current of the photodiode D1. Dark current is the leakage current of the photodiode D1 under no light conditions, which affects the noise level and sensitivity of the circuit. The maximum operating current is the operating current of the photodiode D1 under maximum light conditions, which should be less than the rated current of the photodiode D1 to prevent damage. The resistance value of the first resistor R1 should be large enough to limit the dark current, and small enough to ensure that the photodiode D1 can work normally under maximum light conditions. The resistance value of the second resistor R2 should be determined according to the base current and emitter current of the first transistor Q1. The base current is a key parameter for controlling the conduction degree of the transistor, and it should be small enough to prevent the transistor from overheating and damage. The emitter current is the current output by the transistor, and it should be large enough to ensure the amplitude and stability of the output signal. The resistance value of the second resistor R2 should form a suitable voltage divider circuit together with the third resistor R3 so that the voltage range of the output signal meets the input requirements of the controller. The resistance value of the third resistor R3 should be determined according to the voltage range of the output signal and the input impedance of the controller. The voltage range of the output signal should be large enough to distinguish different lighting conditions, while avoiding exceeding the input voltage range of the controller. The input impedance of the controller should be high enough to reduce the attenuation and interference of the output signal. The resistance value of the third resistor R3 should be appropriately selected to balance the voltage range and stability of the output signal. The selection of the photodiode D1 should be determined according to the lighting conditions, wavelength range and sensitivity requirements of the application environment. The lighting conditions determine the response speed and dark current size of the photodiode D1; the wavelength range determines the sensitivity to specific light; the sensitivity of the photodiode D1 determines the sensitivity to light changes. When selecting, these factors should be considered comprehensively to meet the application requirements. The working principle of the photodiode detection circuit is based on the photoelectric effect and the amplification of the transistor. When light shines on the photodiode D1, the photodiode D1 absorbs light energy and generates photocurrent. The photocurrent flows into the base of the first transistor Q1 through the first resistor R1, turning on the first transistor Q1. As the photocurrent increases, the collector-emitter current of the first transistor Q1 also increases, causing the voltage drop on the third resistor R3 to increase, thereby outputting a voltage signal proportional to the photocurrent. When the light is blocked or weakened, the photocurrent generated by the photodiode D1 decreases, causing the conduction degree of the first transistor Q1 to decrease, the voltage drop on the third resistor R3 to decrease, and the output voltage signal also decreases. By monitoring the changes in this voltage signal, the controller can determine whether the light is blocked or weakened, and then realize disconnection detection. The selection of the first transistor Q1 should be determined based on parameters such as its amplification factor, saturation voltage, and maximum power consumption.The amplification factor determines the degree of amplification of the photocurrent by the first transistor Q1; the saturation voltage determines the output voltage of the first transistor Q1 under the maximum conduction condition; the maximum power consumption determines the stability and reliability of the first transistor Q1 under long-term operation. When selecting a transistor, ensure that these parameters meet the application requirements and leave enough margin.

[0037] Furthermore, in this embodiment, the filtering circuit includes a fourth resistor R4, a first capacitor C1, and a second capacitor C2, wherein: The first end of the fourth resistor R4 is respectively connected to the cathode of the photosensitive diode D1 and the first end of the first capacitor C1, and the second end of the fourth resistor R4 is respectively connected to the first end of the second capacitor C2 and the power supply end; the second end of the first capacitor C1 and the second end of the second capacitor C2 are grounded.

[0038] Specifically, in the photodiode detection circuit, the filter circuit plays a vital role. It can not only effectively eliminate high-frequency noise and interference in the circuit, but also smooth the photocurrent generated by the photodiode D1 to ensure the stability and accuracy of the output signal. The filter circuit is mainly composed of a fourth resistor R4, a first capacitor C1 and a second capacitor C2. The first end of the fourth resistor R4 is connected to the cathode of the photodiode D1 and the first end of the first capacitor C1. The fourth resistor R4 plays the role of current limiting and impedance matching in the circuit, which can prevent excessive current from damaging the photodiode D1 and subsequent circuits, and ensure that the photocurrent can be smoothly transmitted to the filter circuit. The first end of the first capacitor C1 is connected to the first end of the fourth resistor R4, and the second end is grounded. As part of a high-pass filter, the first capacitor C1 can filter out low-frequency noise and interference in the circuit, while allowing high-frequency signals (i.e., high-frequency components in the photocurrent) to pass. However, in practical applications, since the frequency of the photocurrent is usually low, the first capacitor C1 plays a more role in smoothing the photocurrent, reducing its fluctuations and noise. The first end of the second capacitor C2 is connected to the second end of the fourth resistor R4 and the power supply end, and the second end is grounded. As part of the low-pass filter, the second capacitor C2 can filter out high-frequency noise and interference in the circuit to ensure the stability and accuracy of the output signal. At the same time, the second capacitor C2 and the fourth resistor R4 together form an RC filter circuit to further smooth the photocurrent and generate a stable DC output.

[0039] The working principle of the filter circuit is based on the charge and discharge characteristics of the capacitor and the current limiting effect of the resistor. When the photodiode D1 is illuminated, a photocurrent is generated and transmitted to the filter circuit. The photocurrent is first limited and impedance matched by the fourth resistor R4, and then filtered by the first capacitor C1 and the second capacitor C2 respectively. Since the frequency of the photocurrent is usually low, the first capacitor C1 mainly plays the role of smoothing the photocurrent in the circuit. When the photocurrent increases, the first capacitor C1 will charge and store the charge; when the photocurrent decreases, the first capacitor C1 will discharge and release the charge. In this way, the first capacitor C1 can reduce the fluctuation and noise of the photocurrent, making it smoother and more stable. The second capacitor C2 and the fourth resistor R4 together form an RC filter circuit to further smooth the photocurrent and generate a stable DC output. When the photocurrent passes through the fourth resistor R4, a voltage drop proportional to the photocurrent will be generated on the second capacitor C2. Due to the capacitance effect of the second capacitor C2, the voltage drop will gradually stabilize over time and generate a stable DC output signal. This DC output signal can be used as an input signal for subsequent circuits to achieve functions such as disconnection detection.

[0040] Furthermore, in this embodiment, the wire break sensor detection system includes a pulse control circuit; wherein: The pulse control circuit is connected to the controller, and is used to send a pulse signal to the device under test so that the disconnection detection circuit detects the state of the device under test.

[0041] Specifically, in this embodiment, the pulse control circuit generates a pulse signal with a certain frequency and duty cycle through an oscillator or timer inside the controller. Figure 3 As shown, Figure 3 Schematic diagram of the pulse control circuit of the first embodiment of the disconnection sensor detection system proposed in the embodiments of the present application. These pulse signals can be square waves, sine waves, or other forms of waveforms, depending on the needs and design of the system. The generated pulse signal is transmitted to the device under test via a wire or wirelessly. In the device under test, these pulse signals are used to excite sensors or actuators to detect their status or perform corresponding actions. When the device under test is in a normal state, the disconnection detection circuit receives a stable pulse signal and converts it into a corresponding electrical signal or digital signal. However, when a disconnection fault occurs in the device under test, the disconnection detection circuit will not be able to receive a complete pulse signal, or the received signal will change significantly. At this time, the pulse control circuit will detect this change and send an alarm or shutdown signal to the system through the controller.

[0042] Furthermore, in this embodiment, the pulse control circuit includes a fourth capacitor C4, a second transistor Q2, a sixth resistor R6, and a seventh resistor R7; wherein: The first end of the fourth capacitor C4 is respectively connected to the first end of the sixth resistor R6 and the third end of the controller, the second end of the fourth capacitor C4 is respectively connected to the second end of the sixth resistor R6 and the base of the second transistor Q2, the emitter of the second transistor Q2 is connected to the first end of the seventh resistor R7, the collector of the second transistor Q2 is grounded, and the second end of the seventh resistor R7 is connected to the device under inspection.

[0043] Specifically, in this embodiment, when the controller sends a pulse signal, the signal is first charged and discharged through the fourth capacitor C4, and then transmitted to the base of the second transistor Q2 after voltage division by the sixth resistor R6. After receiving sufficient base current, the transistor will change from the cut-off state to the saturation state, allowing current to flow from its emitter to the collector (but in this circuit, the collector is grounded, so the current actually flows back to the power supply through the seventh resistor R7). This process realizes the amplification and transmission of the signal. Since the transistor works in a switching state, its turn-on and turn-off speeds are very fast, so a stable and high-speed pulse signal can be generated. At the same time, the combination of capacitors and resistors can also shape the pulse signal to make it more in line with the needs of the system.

[0044] Based on the first embodiment of the present application, in the second embodiment of the present application, the same or similar contents as those in the above-mentioned embodiment 1 can refer to the above introduction, and will not be repeated later. Figure 4 , Figure 4 This is a schematic diagram of a controller circuit of a second embodiment of a broken wire sensor detection system proposed in an embodiment of the present application.

[0045] Furthermore, in this embodiment, the controller includes a first main control chip U1, a third capacitor C3, a fifth resistor R5, and a first light emitting diode LED1; wherein: The first end of the first main control chip U1 is respectively connected to the first end of the third capacitor C3 and the power supply end, the second end of the first main control chip U1 is connected to the output indication circuit, the third end of the first main control chip U1 is connected to the pulse control circuit, the fourth end of the first main control chip U1 is connected to the first end of the fifth resistor R5, the fifth end and the sixth end of the first main control chip U1 are respectively connected to the key circuit, the seventh end of the first main control chip U1 is connected to the second end of the third resistor R3 of the photosensitive diode detection circuit, and the eighth end of the first main control chip U1 is respectively connected to the second end of the third capacitor C3 and the ground; the second end of the fifth resistor R5 is connected to the anode of the first light-emitting diode LED1, and the cathode of the first light-emitting diode LED1 is grounded.

[0046] Specifically, in the disconnection sensor detection system, the controller, as the core component of the system, is responsible for receiving, processing and outputting control signals to ensure the stable operation of the system. This embodiment will analyze in detail the controller including the first main control chip U1, the third capacitor C3, the fifth resistor R5, the first light-emitting diode LED1 and other components. When the power is turned on, the current passes through the filtering effect of the third capacitor C3 to provide a stable power input for the first main control chip U1. The filtering effect of the capacitor can reduce the impact of power fluctuations on the chip and ensure the stable operation of the chip. The first main control chip U1 receives input signals from sensors, key circuits, photodiode detection circuits and the like through its various ports. After the logic operation and data processing inside the chip, these signals are converted into corresponding control signals and output to components such as the pulse control circuit and the output indication circuit. According to the processing result of the input signal, the first main control chip U1 will output corresponding control signals to the pulse control circuit. These control signals are used to control the generation and transmission of pulse signals to ensure that the device under test can normally receive and respond to pulse signals. At the same time, the chip will also output a status indication signal through the output indication circuit, such as the on and off state of LED1, to display the working status of the controller. The key circuit is used to receive user operation instructions, such as start, stop, learning and fine-tuning of sensor disconnection threshold, etc. These instructions are transmitted to the first main control chip U1 through the key circuit for processing. The photodiode detection circuit is used to detect the intensity of ambient light or the presence or absence of a specific light source, and convert the detection results into electrical signals and transmit them to the chip for processing. These functions increase the flexibility and scope of application of the controller. The first light-emitting diode LED1 is used as an output indication component, and its on and off state is controlled by the first main control chip U1. When the controller is in normal working state, LED1 will light up; when a fault or abnormal situation occurs, LED1 will go out or flash to indicate the fault. This indication method allows users to intuitively understand the working status of the controller, which is convenient for timely detection and handling of faults.

[0047] Furthermore, in this embodiment, the disconnection sensor detection system further includes a key circuit; wherein: The key circuit is connected to the controller, and the key circuit is used to perform key setting on the preset disconnection threshold.

[0048] Specifically, in this embodiment, the key circuit, as an important component, provides an interface for users to interact with the system. Through SW1 and SW2 set by the key circuit, users can easily set the preset disconnection threshold, thereby adjusting the sensor detection sensitivity. Users can set the sensitivity of the system to detect disconnection by entering a specific value or selecting a preset option through the key circuit. This threshold determines under what circumstances the system will be judged as a disconnection and trigger a corresponding alarm or shutdown operation. The key circuit provides users with an intuitive and simple operating interface, allowing users to easily interact with the system and complete settings, adjustments and other operations. Through the key circuit, users can flexibly adjust the system's detection sensitivity and parameter settings according to different application scenarios and needs, thereby improving the applicability and practicality of the system.

[0049] Furthermore, in this embodiment, the output indication circuit includes an eighth resistor R8, a third transistor Q3, and a first Schottky diode SD1; wherein: The first end of the eighth resistor R8 is connected to the second end of the first main control chip U1, the second end of the eighth resistor R8 is connected to the base of the third transistor Q3, the emitter of the third transistor Q3 is connected to the cathode of the first Schottky diode SD1, and the collector of the third transistor Q3 and the anode of the first Schottky diode SD1 are grounded.

[0050] Specifically, in this embodiment, the working principle of the output indication circuit is based on the switching characteristics of the transistor and the unidirectional conductivity of the Schottky diode. Figure 5Schematic diagram of the output indication circuit of the second embodiment of the disconnection sensor detection system proposed in the embodiment of the present application. When the output end (second end) of the first main control chip U1 outputs a high level signal, the signal is limited by the eighth resistor R8 and then added to the base of the third transistor Q3, so that the transistor is turned on. At this time, the current flows from the emitter of the transistor to the collector, and flows to the ground through the first Schottky diode SD1 to form a path. In this process, the Schottky diode plays a role in protecting the circuit and preventing the current from flowing in the opposite direction. When the output end of the first main control chip U1 outputs a low level signal, the base voltage of the third transistor Q3 is reduced, which is not enough to turn on the transistor. At this time, the transistor is in the cut-off state, no current flows between the emitter and the collector, and the output indication circuit does not work. In practical applications, the output indication circuit is usually connected to an LED lamp or other indication device to intuitively display the state or detection results of the system. For example, when the first main control chip U1 detects a disconnection, the LED lamp can be lit or other indication devices can be triggered through the output indication circuit to remind the user to pay attention. The first end of the eighth resistor R8 is connected to the second end (the output end of the indication signal) of the first main control chip U1. This port is responsible for outputting control signals to indicate system status or detection results. The second end of the eighth resistor R8 is connected to the base of the third transistor Q3. The eighth resistor R8 plays the role of current limiting and protecting the transistor here, ensuring that the current input to the base of the transistor is within a safe range. The base of the third transistor Q3 is connected to the second end of the eighth resistor R8 to receive the control signal from the MCU; the emitter is connected to the cathode of the first Schottky diode SD1. When the transistor is turned on, the current flows from the emitter to the collector; the collector of the third transistor Q3 is connected to the anode of the first Schottky diode SD1 and the ground. When the transistor is turned on, a path is formed between the collector and the ground, allowing current to flow. The cathode of the first Schottky diode SD1 is connected to the emitter of the third transistor Q3. The Schottky diode here mainly plays the role of unidirectional conduction to prevent the current from flowing in the opposite direction; the anode is connected to the collector of the third transistor Q3 and the ground. When the transistor is turned on, the current flows from the cathode of the first Schottky diode SD1 to the anode, and flows back to the negative pole of the power supply through the ground to form a complete current loop.

[0051] Further, in this embodiment, the disconnection sensor detection system further includes an adaptation circuit; The adaptation circuit is connected to the output indication circuit and the controller respectively, and the adaptation circuit is used to adapt to the device under test.

[0052] Specifically, in the disconnection sensor detection system, the adapter circuit plays a vital role. It is mainly responsible for adapting to the device under test to ensure that the sensor detection system can accurately receive and process the signals from the device under test. The existence of the adapter circuit enables the sensor detection system to be flexibly applied to various types of devices under test, improving the versatility and practicality of the system. The signals output by the device under test may have different levels, waveforms or frequency characteristics. The adapter circuit can convert these signals into standard signals that can be recognized by the sensor detection system, thereby ensuring accurate transmission and processing of the signals.

[0053] During signal transmission, impedance mismatch may cause signal reflection, attenuation or distortion. The adapter circuit adjusts the impedance characteristics of the circuit to achieve impedance matching with the device under test, thereby reducing the loss and interference during signal transmission. The device under test may require different power supply voltages or currents. The adapter circuit can provide power supply voltages and currents that match the device under test to ensure the normal operation of the device. When connecting the device under test, the adapter circuit can also protect the sensor detection system. For example, when the device under test fails or is abnormal, the adapter circuit can quickly cut off the connection with the device under test to prevent the fault from spreading to the sensor detection system. In the disconnection sensor detection system, the adapter circuit is connected to the output indication circuit and the controller respectively. This connection method enables the adapter circuit to receive control signals from the controller and adjust its own parameters and states according to these signals to adapt to the needs of the device under test. At the same time, the adapter circuit can also transmit the processed signal to the output indication circuit to display the system status or detection results. The adapter circuit is connected to a specific port of the controller through a signal line. These ports may include a control signal input terminal, a state feedback output terminal, etc. The controller sends control signals to the adapter circuit through these ports, such as start, stop, parameter adjustment, etc. At the same time, the adapter circuit can also send status feedback signals to the controller, such as normal operation, fault alarm, etc. The adapter circuit is also connected to the output indication circuit through a signal line. When the adapter circuit processes the signals from the device under test, it transmits these signals to the output indication circuit. The output indication circuit lights up the corresponding indicator light or triggers other indication devices according to the received signal to display the system status or detection results.

[0054] The above are only preferred embodiments of the present application, and are not intended to limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent processing scope of the present application.

Claims

1. A wire break sensor detection system, characterized in that: The system comprises a disconnection detection circuit, a controller and an output indication circuit; wherein: The disconnection detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The controller is connected to the output indication circuit, and is used to receive the disconnection detection signal, and when the characteristic value of the disconnection detection signal exceeds a preset disconnection threshold, control the output indication circuit to output a disconnection detection result corresponding to the detected device.

2. The wire breakage sensor detection system according to claim 1, characterized in that: The disconnection detection circuit comprises a photodiode detection circuit and a filter circuit; wherein: The photodiode detection circuit is connected to the controller, and is used to detect the detected device and output a disconnection detection signal to be transmitted to the controller; The filter circuit is connected to the photodiode detection circuit, and the filter circuit is used to filter the disconnection detection signal of the photodiode detection circuit.

3. The wire breakage sensor detection system according to claim 2, characterized in that: The photodiode detection circuit comprises a first resistor, a second resistor, a third resistor, a first transistor and a photodiode, wherein: The first end of the first resistor is respectively connected to the anode of the photosensitive diode, the base of the first transistor and the first end of the second resistor, and the second end of the first resistor is grounded; the first end of the second resistor is respectively connected to the emitter of the first transistor and the first end of the third resistor, and the second end of the second resistor is grounded; the first end of the third resistor is respectively connected to the emitter of the first transistor, and the second end of the third resistor is connected to the controller; the anode of the photosensitive diode is respectively connected to the base of the first transistor and the first end of the first resistor, the cathode of the photosensitive diode is connected to the filter circuit, and the collector of the first transistor is connected to the power supply terminal.

4. The wire breakage sensor detection system according to claim 3, characterized in that: The filter circuit comprises a fourth resistor, a first capacitor, and a second capacitor, wherein: The first end of the fourth resistor is respectively connected to the cathode of the photodiode and the first end of the first capacitor, and the second end of the fourth resistor is respectively connected to the first end of the second capacitor and the power supply end; the second end of the first capacitor and the second end of the second capacitor are grounded.

5. The wire breakage sensor detection system according to claim 4, characterized in that: The broken wire sensor detection system comprises a pulse control circuit; wherein: The pulse control circuit is connected to the controller, and is used to send a pulse signal to the device under test so that the disconnection detection circuit detects the state of the device under test.

6. The wire breakage sensor detection system according to claim 5, characterized in that: The pulse control circuit includes a fourth capacitor, a second transistor, a sixth resistor, and a seventh resistor; wherein: The first end of the fourth capacitor is respectively connected to the first end of the sixth resistor and the third end of the controller, the second end of the fourth capacitor is respectively connected to the second end of the sixth resistor and the base of the second transistor, the emitter of the second transistor is connected to the first end of the seventh resistor, the collector of the second transistor is grounded, and the second end of the seventh resistor is connected to the device under inspection.

7. The wire breakage sensor detection system according to claim 6, characterized in that: The controller includes a first main control chip, a third capacitor, a fifth resistor, and a first light emitting diode; wherein: The first end of the first main control chip is respectively connected to the first end of the third capacitor and the power supply end, the second end of the first main control chip is connected to the output indication circuit, the third end of the first main control chip is connected to the pulse control circuit, the fourth end of the first main control chip is connected to the first end of the fifth resistor, the fifth end and the sixth end of the first main control chip are respectively connected to the key circuit, the seventh end of the first main control chip is connected to the second end of the third resistor of the photosensitive diode detection circuit, and the eighth end of the first main control chip is respectively connected to the second end of the third capacitor and the ground; the second end of the fifth resistor is connected to the anode of the first light-emitting diode, and the cathode of the first light-emitting diode is grounded.

8. The wire breakage sensor detection system according to claim 7, characterized in that: The disconnection sensor detection system also includes a key circuit; wherein: The key circuit is connected to the controller, and the key circuit is used to perform key setting on the preset disconnection threshold.

9. The wire breakage sensor detection system according to claim 8, characterized in that: The output indication circuit includes an eighth resistor, a third transistor, and a first Schottky diode; wherein: The first end of the eighth resistor is connected to the second end of the first main control chip, the second end of the eighth resistor is connected to the base of the third transistor, the emitter of the third transistor is connected to the cathode of the first Schottky diode, and the collector of the third transistor and the anode of the first Schottky diode are grounded.

10. The wire breakage sensor detection system according to claim 9, characterized in that: The wire break sensor detection system also includes an adaptation circuit; The adaptation circuit is connected to the output indication circuit and the controller respectively, and the adaptation circuit is used to adapt to the device under test.

Images