Multi-circle memory optomagnetic encoder hybrid system

Abstract

The invention discloses a multi-turn memory optomagnetic encoder hybrid system, belongs to the technical field of position and angle measurement encoders, and aims at solving the problems that an existing optomagnetic hybrid encoder is complex in signal processing, long in axial length, insufficient in precision stability and prone to losing the number of turns and the position. The system comprises an optical encoder, a gallium arsenide magnetic signal acquisition sensor, a multi-antipode unequal magnetic ring, a processor, a hardware circuit, an ultra-low power consumption circuit, a signal acquisition module, a signal processing module and the like, integrates self-developed magnetic angle analysis, turn number memory correction and other algorithms, and adopts dual-redundancy design and intelligent signal mode switching. The method simplifies the signal processing flow, shortens the axial length, improves the measurement precision and stability, enhances the environmental adaptability and fault-tolerant capability, prolongs the endurance, and is suitable for the position angle measurement in a high-precision and severe environment.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of position and angle measurement encoder technology, in particular to a multi-turn memory optical-magnetic encoder hybrid system. BACKGROUND

[0002] In the field of position and angle measurement, photoelectric encoders convert mechanical displacement into pulses or digital quantities through photoelectric conversion, with the advantages of high measurement accuracy, fast response and stable performance, but are easily affected by pollution and have poor anti-interference ability; magnetic encoders rely on magnetic sensing devices to obtain the absolute position of the rotor by using magnetic field changes, and have the characteristics of anti-shock, corrosion resistance, pollution resistance and simple structure, but have insufficient precision at high speed. In order to combine the advantages of the two, optical-magnetic hybrid encoders have emerged, which solve position information by coordinating optical and magnetic signals, to a certain extent, reducing the interference of pollution and vibration on the accuracy of position information.

[0003] However, the existing optical-magnetic hybrid encoders still have many technical defects: first, two magnetic sensing chips are usually needed to determine the absolute position, the signal processing process is complex, increasing the hardware cost and algorithm difficulty; second, they are mostly simply integrated with optical and magnetic encoders, resulting in a longer axial length, which is not conducive to miniaturization and integration applications; third, in high-precision application scenarios, the precision and stability are insufficient, making it difficult to meet the measurement requirements in complex and harsh environments; fourth, there is a lack of effective optical and magnetic encoder coordination mechanism, which cannot fully exert the advantages of the two, affecting the overall performance and reliability of the system; fifth, multi-turn encoders have deficiencies in turn number memory and absolute position matching, the initial calibration value acquisition method is not accurate, and problems such as turn number loss and position loss are prone to occur; sixth, the detection precision and anti-interference ability of multi-turn counting correction equipment are weak, and there are limitations in data processing and position solving, making it difficult to meet the efficient multi-turn data acquisition and solving requirements in complex scenarios. Therefore, a multi-turn memory optical-magnetic encoder hybrid system is proposed, which can solve the above problems and has the advantages of high precision, anti-pollution, structure simplification and efficiency improvement. SUMMARY

[0004] The present application provides a multi-turn memory optical-magnetic encoder hybrid system to solve the problems in the background art.

[0005] The specific technical solution is as follows: The application discloses a multi-turn memory optical-magnetic encoder hybrid system, which comprises an optical encoder, a magnetic signal acquisition sensor, a processor, a hardware circuit, an ultra-low power circuit, and a signal acquisition module, a signal processing module, a fault-tolerant correction module, a low-power module and an angle analysis module integrated in the system; the processor is electrically connected with the hardware circuit, the ultra-low power circuit, the magnetic signal acquisition sensor and the optical encoder; the angle analysis module is integrated with a magnetic angle analysis algorithm, which is used for analyzing the electric signal output by the magnetic field change sensed by the magnetic signal acquisition sensor into an absolute position value; the signal processing module comprises a turn memory and correction algorithm, which is used for realizing storage, reading and automatic correction of the turn memory value; the signal acquisition module is used for synchronously acquiring the optical signal output by the optical encoder and the magnetic signal output by the magnetic signal acquisition sensor, and transmitting the acquired signals to the signal processing module; the fault-tolerant correction module is used for checking and correcting the acquired signals and the calculated position information; and the low-power module is used for controlling the power consumption of the system.

[0006] As a preferred scheme of the application, the optical encoder comprises an optical-electric conversion circuit, an operation single-end output circuit, a comparator circuit and a differential operation circuit; the optical-electric conversion circuit is used for converting the optical signal into an initial electric signal; the operation single-end output circuit, the comparator circuit and the differential operation circuit sequentially process the initial electric signal; and the processed electric signal is transmitted to the processor.

[0007] As a preferred scheme of the application, the magnetic signal acquisition sensor is a gallium arsenide sensor, which is electrically connected with the signal acquisition module, used for acquiring the external magnetic field signal, converting the magnetic field signal into an electric signal and then transmitting the electric signal to the signal acquisition module.

[0008] As a preferred scheme of the application, a plurality of pairs of uneven magnetic rings are further included, which are arranged in cooperation with the magnetic signal acquisition sensor, used for providing a coarse position detection reference; a coarse position decoding module is arranged in the signal processing module, which recognizes a plurality of position areas through a binary encoder and outputs an n-bit coarse position code based on the magnetic signals of the plurality of pairs of uneven magnetic rings acquired by the magnetic signal acquisition sensor.

[0009] As a preferred scheme of the application, the magnetic angle analysis algorithm of the angle analysis module comprises an adaptive compensation algorithm, which comprises a temperature compensation algorithm and an error self-calibration algorithm, used for performing temperature error compensation and real-time error calibration on the analyzed absolute position value.

[0010] As a preferred scheme of the present application, the fault-tolerant correction module adopts a dual-redundancy design, including dual-sensor redundancy and dual-storage redundancy; the dual-sensor redundancy is that the optical encoder and the magnetic signal acquisition sensor back up each other, when one of the dual sensors fails, the other sensor continues to output signals; the dual-storage redundancy is that important parameters in the system are stored in dual backup to avoid parameter loss.

[0011] As a preferred scheme of the present application, the functions of the low-power consumption module include configuring the processor into a low-power consumption mode, and an intelligent power management function; the intelligent power management function adjusts the power supply power according to the working state of the system, prolonging the running time of the system when there is no external power supply.

[0012] As a preferred scheme of the present application, it further includes a built-in metal shielding layer made of permalloy and arranged outside the magnetic signal acquisition sensor, which is used to isolate the magnetic field interference in the external environment and ensure the accuracy of the signal acquisition of the magnetic signal acquisition sensor.

[0013] As a preferred scheme of the present application, the signal processing module has a signal mode switching function, including an optical signal dominant mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality evaluation; in a clean environment, the system switches to the optical signal dominant mode, and preferentially uses the signal output by the optical encoder for position solving; in a polluted environment, the system switches to the magnetic signal backup mode, and uses the signal output by the magnetic signal acquisition sensor for position solving; the intelligent dynamic weight adjustment algorithm dynamically adjusts the weight of the two signals in position solving according to the quality evaluation results of the optical signal and the magnetic signal.

[0014] As a preferred scheme of the present application, the number of laps memory and correction algorithm of the signal processing module contains a position matching algorithm, which includes an absolute position and number of laps memory value matching method, and a reference position dynamic updating algorithm; the absolute position and number of laps memory value matching method is used to associate and match the absolute position value obtained by the angle analysis module with the number of laps memory value, and the reference position dynamic updating algorithm is used to update the reference position according to the real-time solving result, improving the position matching accuracy.

[0015] As a preferred scheme of the present application, the hardware circuit comprises core control hardware, signal acquisition hardware, signal processing hardware and fault-tolerant and anti-interference hardware; the core control hardware is a micro control unit integrating a special operation unit of a magnetic angle analysis algorithm, the micro control unit is connected with an optical encoder and a magnetic signal acquisition sensor through an SPI interface, and is connected with an ultra-low power circuit through an I2C interface; the signal acquisition hardware comprises a magnetic signal acquisition circuit comprising a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit comprising an optical-electric conversion circuit, an operation single-ended output circuit, a comparator circuit and a differential operation circuit; the signal processing hardware comprises a double storage circuit composed of a non-volatile memory and a coarse position decoding hardware module; the fault-tolerant and anti-interference hardware comprises a metal shielding layer made of permalloy, a surge suppression circuit and an electromagnetic compatibility filter circuit.

[0016] As a preferred scheme of the present application, the ultra-low power circuit comprises a power management unit, a sleep wake-up circuit and a dynamic power consumption adjustment circuit; the power management unit is a low static current power management chip with multi-gear output voltage adjustment function, which is connected with the micro control unit to receive power consumption control instructions; the sleep wake-up circuit comprises a signal trigger wake-up sub-circuit for detecting signal changes and a timing wake-up sub-circuit composed of a low power real-time clock; the dynamic power consumption adjustment circuit is linked with the signal acquisition module, and can cut off the redundant power supply of the optical encoder and adjust the operation main frequency of the micro control unit according to the position change state.

[0017] The present application has the following beneficial effects: 1. Simplify signal processing process and reduce system complexity: through cooperation of multiple pairs of non-uniform magnetic rings and a coarse position decoding module, the position range can be quickly determined without additional zero point searching, and cumulative error is eliminated; the angle analysis module integrates a magnetic angle analysis algorithm, and only needs to rely on a processor to complete the analysis of magnetic signals to absolute position values, without using two magnetic inductive chips, thereby effectively simplifying the complex signal processing process of existing optical-magnetic hybrid encoders, reducing system hardware cost and algorithm difficulty.

[0018] 2. Optimize structure design and adapt to miniaturization and integration requirements: abandoning the existing optical-magnetic hybrid encoder "simple integration of optical encoder and magnetic encoder", through multi-module integration design (signal acquisition, processing, fault correction, low power module integration in the system) and compact cooperation of multiple pairs of non-uniform magnetic rings and magnetic signal acquisition sensors, the axial length of the system is significantly shortened, and the system is more suitable for small-sized and integrated application scenarios.

[0019] 3. Improve the accuracy and stability of position measurement: optical encoders provide high-resolution reference signals, and magnetic encoders provide reliable absolute position areas and multi-turn memories, both of which are used to solve the problem; adaptive compensation algorithm of angle analysis module (temperature compensation, error self-calibration) offsets the influence of temperature and real-time error on analysis results; position matching algorithm corrects deviation by dynamically updating reference position, and multi-dimensional position calculation accuracy is ensured; at the same time, double sensor redundancy, double storage redundancy and anti-interference hardware (surge suppression circuit, electromagnetic compatibility filter circuit, permalloy metal shielding layer) reduce the influence of external interference and failure on the system, improve the overall operation stability, and meet the measurement requirements in harsh environments with high precision.

[0020] 4. Enhance environmental adaptability and broaden application scenarios: based on the signal mode switching function of environmental cleanliness (photoelectric signal dominant mode, magnetic signal backup mode), the system can rely on photoelectric signals to achieve high-precision measurement in clean environments, and can ensure measurement reliability through magnetic signals in polluted environments; intelligent dynamic weight adjustment algorithm optimizes the calculation basis according to signal quality, further improves the system's adaptability to different environments, and breaks through the limitations of existing optical and magnetic hybrid encoders.

[0021] 5. Optimize power consumption control and prolong battery life: low-power processor mode and intelligent power management function of low-power module, combined with multi-gear voltage regulation, sleep and wake-up control, dynamic power consumption adjustment (cut off redundant power supply, adjust the main frequency) of ultra-low power circuit, greatly reduce the invalid power consumption of the system in non-high load state, effectively prolong the running time of the system in the scene without external power supply, and improve the applicability of the system in mobile devices and scenes without external power supply.

[0022] 6. Strengthen fault tolerance and ensure reliable operation of the system: dual-sensor redundancy avoids signal interruption caused by single-sensor failure, dual-storage redundancy prevents important parameter loss, anti-interference hardware reduces external electromagnetic and magnetic field interference, and multi-dimensional fault tolerance improves the system's fault tolerance, reduces the risk of position calculation interruption and error caused by component failure or external interference, and ensures long-term reliable operation of the system. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 The connection relationship block diagram of the multi-turn memory optical and magnetic encoder hybrid system provided by the embodiment of the application is provided; Figure 2 The structure diagram of the multi-pole uneven magnetic ring in the multi-turn memory optical and magnetic encoder hybrid system provided by the embodiment of the application is provided; Figure 3 The magnetic signal waveform diagram collected by the multi-turn memory optical and magnetic encoder hybrid system provided by the embodiment of the application is provided; Figure 4The calculated angle diagram of the multi-turn memory optical-magnetic encoder hybrid system provided by the embodiment of the present application; Figure 5 The structural schematic diagram of a single encoder provided by the embodiment of the present application; Figure 6 The structural schematic diagram of a double encoder provided by the embodiment of the present application.

[0024] The figure reference: optical encoder 1, magnetic signal acquisition sensor 2. DETAILED DESCRIPTION

[0025] The technical solutions of the present application will be further described below in combination with the drawings and through specific embodiments.

[0026] Wherein, the drawings are only used for exemplary illustration, and the representation is only a schematic diagram, not a physical diagram, and cannot be understood as a limitation on the present application; in order to better illustrate the embodiments of the present application, some components of the drawings will be omitted, enlarged or reduced, and do not represent the size of the actual product; for those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings can be omitted.

[0027] The same or similar reference numerals in the drawings of the embodiments of the present application correspond to the same or similar components; in the description of the present application, it should be understood that if the terms such as "upper", "lower", "left", "right", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore the terms describing the positional relationship in the drawings are only used for exemplary illustration, and cannot be understood as a limitation on the present application, for those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0028] In the description of the present application, unless otherwise explicitly specified and limited, if the term "connection" and the like appear to indicate the connection relationship between components, the term should be broadly understood, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two components or the interaction relationship between two components. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0029] Embodiment: the multi-turn memory optical-magnetic encoder hybrid system provided by the embodiment, like Figures 1-6As shown, it comprises an optical encoder 1, a magnetic signal acquisition sensor 2, a processor, a hardware circuit, an ultra-low power circuit, and signal acquisition modules, signal processing modules, fault-tolerant correction modules, low-power modules and angle analysis modules integrated in the system; the processor is electrically connected with the hardware circuit, the ultra-low power circuit, the magnetic signal acquisition sensor 2 and the optical encoder 1, the angle analysis module integrates a magnetic angle analysis algorithm for analyzing the electric signal output by the magnetic field change sensed by the magnetic signal acquisition sensor 2 into an absolute position value; the signal processing module contains a number of memory and correction algorithms for realizing the storage, reading and automatic correction of the number of memory values; the signal acquisition module is used for synchronously acquiring the optical signal output by the optical encoder 1 and the magnetic signal output by the magnetic signal acquisition sensor 2, and transmitting the acquired signals to the signal processing module; the fault-tolerant correction module is used for checking and correcting the acquired signals and the calculated position information, and the low-power module is used for controlling the system power consumption.

[0030] By setting the optical encoder 1, the magnetic signal acquisition sensor 2, the processor, the hardware circuit, the ultra-low power circuit, and the signal acquisition modules, the signal processing modules (containing the number of memory and correction algorithms), the fault-tolerant correction modules, the low-power modules and the angle analysis modules (integrating the magnetic angle analysis algorithm), and electrically connecting the processor with the hardware circuit, the ultra-low power circuit, the magnetic signal acquisition sensor 2 and the optical encoder 1, the signal acquisition module synchronously acquires the optical and magnetic signals and transmits them to the signal processing module, the angle analysis module analyzes the absolute position value, the fault-tolerant correction module checks and corrects errors, and the low-power module controls the system power consumption; this scheme realizes the cooperative work of optical and magnetic signals, simplifies the complex signal processing process of the existing optical and magnetic hybrid encoders, solves the problems of easy loss of position and redundant structure, improves the integrity and reliability of position calculation through fault-tolerant correction, controls the overall power consumption through the low-power module, and improves the comprehensive operation performance of the system.

[0031] The system has adaptive adaptation capability of single encoder and double encoder, the signal acquisition module can automatically identify the number (single / double) and type (optical encoder 1 / magnetic signal acquisition sensor 2 combination) of encoder deployment, without manually modifying the hardware circuit or core algorithm parameters, it can match the corresponding signal processing logic and adapt to different precision requirements of motor operation scenes.

[0032] Specifically, in the embodiment, the optical encoder 1 comprises an optical-electric conversion circuit, an operation single-end output circuit, a comparator circuit and a differential operation circuit; the optical-electric conversion circuit is used for converting an optical signal into an initial electric signal, the operation single-end output circuit, the comparator circuit and the differential operation circuit sequentially process the initial electric signal, and the processed electric signal is transmitted to a processor. The optical encoder 1 comprises the optical-electric conversion circuit, the operation single-end output circuit, the comparator circuit and the differential operation circuit, the optical-electric conversion circuit converts the optical signal into the initial electric signal, and then the initial electric signal is sequentially processed by the operation single-end output circuit, the comparator circuit and the differential operation circuit and transmitted to the processor; in the scheme, the operation single-end output circuit amplifies the initial electric signal, the comparator circuit eliminates noise interference through threshold discrimination, and the differential operation circuit converts the single-end signal into a differential signal with stronger anti-interference capability, effectively reduces interference in the transmission process after the optical signal is converted into the electric signal, improves the stability and accuracy of the electric signal, and provides reliable optical signal data support for subsequent position calculation of the processor.

[0033] Specifically, in the embodiment, the magnetic signal acquisition sensor 2 is a gallium arsenide sensor, which is electrically connected with the signal acquisition module, used for acquiring an external magnetic field signal and converting the magnetic field signal into an electric signal and then transmitting the electric signal to the signal acquisition module. The magnetic signal acquisition sensor 2 is a gallium arsenide sensor, which is electrically connected with the signal acquisition module, used for acquiring an external magnetic field signal and converting the magnetic field signal into an electric signal and then transmitting the electric signal to the signal acquisition module; the gallium arsenide sensor has high magnetic field sensitivity, can accurately sense the change of the magnetic field and stably convert it into an electric signal, avoids the problem of insufficient signal acquisition accuracy of the existing ordinary magnetic sensor, provides a high-quality magnetic signal source for the angle analysis module to analyze the absolute value of the position, and improves the reliability of the magnetic signal acquisition.

[0034] Specifically, in the embodiment, a plurality of pairs of non-uniform magnetic rings are further included, which are arranged in cooperation with the magnetic signal acquisition sensor 2 and used for providing a coarse position detection reference; a coarse position decoding module is arranged in the signal processing module, which identifies a plurality of position regions through a binary encoder based on the magnetic signals of the plurality of pairs of non-uniform magnetic rings acquired by the magnetic signal acquisition sensor 2 and outputs an n-bit coarse position code. The system is additionally provided with the plurality of pairs of non-uniform magnetic rings, which are arranged in cooperation with the magnetic signal acquisition sensor 2, and the coarse position decoding module is arranged in the signal processing module, which outputs the n-bit coarse position code through the binary encoder based on the magnetic signals acquired by the magnetic signal acquisition sensor 2; the plurality of pairs of non-uniform magnetic rings provide an explicit coarse position detection reference, the coarse position decoding module can quickly identify the position region and output the coarse position code without searching for a zero point like an incremental encoder, can quickly determine the absolute position range, eliminate the cumulative error, simplify the initial process of position positioning, and improve the efficiency and accuracy of the determination of the position range.

[0035] Specifically, in the embodiment, the magnetic angle analysis algorithm of the angle analysis module includes an adaptive compensation algorithm, which includes a temperature compensation algorithm and an error self-calibration algorithm, for temperature error compensation and real-time error calibration of the analyzed position absolute value. The magnetic angle analysis algorithm of the angle analysis module includes an adaptive compensation algorithm, which includes a temperature compensation algorithm and an error self-calibration algorithm, for temperature error compensation and real-time error calibration of the position absolute value; the temperature compensation algorithm can offset the influence of temperature change on magnetic signal analysis, and the error self-calibration algorithm can correct the deviation in the analysis process in real time, avoiding the problem that existing analysis algorithms are greatly affected by environmental temperature and real-time error, reducing the interference of temperature and real-time error on position absolute value analysis, and improving the precision of the position absolute value output by the angle analysis module.

[0036] Specifically, in the embodiment, the fault-tolerant correction module adopts a dual-redundancy design, including dual-sensor redundancy and dual-storage redundancy; the dual-sensor redundancy is that the optical encoder 1 and the magnetic signal acquisition sensor 2 back up each other, and when one of the dual sensors fails, the other sensor continues to output signals; the dual-storage redundancy is that important parameters in the system are stored in dual backup to avoid parameter loss. The fault-tolerant correction module adopts a dual-redundancy design, including dual-sensor redundancy that the optical encoder 1 and the magnetic signal acquisition sensor 2 back up each other, and dual-storage redundancy that important parameters are stored in dual backup; the dual-sensor redundancy can continue to output signals by the other sensor when one of the sensors fails, avoiding signal interruption caused by sensor failure; the dual-storage redundancy can prevent important parameter loss, avoid the problem of poor fault tolerance of existing systems, improve the stability of the system when the sensor fails or the parameter storage is abnormal, and reduce the position calculation interruption or error.

[0037] Specifically, in the embodiment, the low-power module has functions of configuring the processor into a low-power mode and intelligent power management; the intelligent power management adjusts the power supply power according to the working state of the system, prolonging the running time of the system without external power supply. The low-power module has the function of configuring the processor into a low-power mode, and has the intelligent power management function of adjusting the power supply power according to the working state of the system; by configuring the low-power mode of the processor and adjusting the power supply power according to the working state, the power consumption of the system in a non-high load state can be reduced, the problem of high power consumption and poor endurance of existing encoders can be avoided, the running time of the system without external power supply can be prolonged, and the applicability of the system in the scene without external power supply can be improved.

[0038] Specifically, in the embodiment, a built-in metal shielding layer is further included, which is made of permalloy and arranged outside the magnetic signal acquisition sensor 2, for isolating the magnetic field interference in the external environment and ensuring the accuracy of the signal acquisition of the magnetic signal acquisition sensor 2. The system is additionally provided with the built-in metal shielding layer, which is made of permalloy and arranged outside the magnetic signal acquisition sensor 2; the permalloy has excellent magnetic shielding performance, can isolate the magnetic field interference in the external environment, avoid the influence of the external magnetic field on the magnetic field signal acquired by the magnetic signal acquisition sensor 2, prevent the existing magnetic signal from being easily interfered by the external magnetic field, ensure the accuracy of the output electric signal of the magnetic signal acquisition sensor 2, and improve the reliability of the magnetic signal acquisition.

[0039] Specifically, in the embodiment, the signal processing module has a signal mode switching function, including an optical signal dominant mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality evaluation; in a clean environment, the system switches to the optical signal dominant mode, and preferentially uses the signal output by the optical encoder 1 for position calculation; in a polluted environment, the system switches to the magnetic signal backup mode, and uses the signal output by the magnetic signal acquisition sensor 2 for position calculation; the intelligent dynamic weight adjustment algorithm dynamically adjusts the weight of the two signals in position calculation according to the quality evaluation results of the optical signal and the magnetic signal. The signal processing module has a signal mode switching function, including an optical signal dominant mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality evaluation; the optical signal dominant mode is used in a clean environment, the magnetic signal backup mode is used in a polluted environment, and the intelligent dynamic weight adjustment algorithm adjusts the weight of the two signals in position calculation according to the signal quality; the optical signal has high precision in a clean environment, and the use of the optical signal dominant mode can improve the position calculation precision; the optical signal is easily polluted in a polluted environment, and the use of the magnetic signal backup mode can ensure signal reliability; the intelligent dynamic weight adjustment algorithm can select the optimal calculation mode according to the quality of the two signals, avoid the poor environmental adaptability of the existing system, improve the adaptability of the system to different environments, and optimize the precision and reliability of position calculation.

[0040] Specifically, in the embodiment, the turn count memory and correction algorithm of the signal processing module comprises a position matching algorithm, the position matching algorithm comprises an absolute position and turn count memory value matching method, and a reference position dynamic updating algorithm; the absolute position and turn count memory value matching method is used for associatively matching the absolute position value obtained by the angle analysis module with the turn count memory value, and the reference position dynamic updating algorithm is used for updating the reference position according to the real-time solving result, thereby improving the position matching precision. The turn count memory and correction algorithm of the signal processing module comprises a position matching algorithm, the position matching algorithm comprises an absolute position and turn count memory value matching method and a reference position dynamic updating algorithm, the absolute position and turn count memory value matching method is used for associatively matching the two, and the reference position dynamic updating algorithm is used for updating the reference position according to the real-time solving result; the associatively matching can ensure the consistency of the absolute position value and the turn count memory value, and the dynamic updating of the reference position can correct the deviation of the reference position, thereby avoiding the problems of the existing multi-turn encoder that the turn count and the position matching are not accurate and the fixed reference position leads to errors, and improving the accuracy of the turn count recording and the position determination.

[0041] Specifically, in the embodiment, the hardware circuit includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware; the core control hardware is a micro control unit integrating a special operation unit for magnetic angle analysis algorithm, the micro control unit is connected with an optical encoder 1 and a magnetic signal acquisition sensor 2 through an SPI interface, and is connected with an ultra-low power circuit through an I2C interface; the signal acquisition hardware includes a magnetic signal acquisition circuit including a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit including a photoelectric conversion circuit, an operation single-ended output circuit, a comparator circuit, and a differential operation circuit; the signal processing hardware includes a double storage circuit composed of a non-volatile memory and a coarse position decoding hardware module; the fault-tolerant and anti-interference hardware includes a metal shielding layer made of permalloy, a surge suppression circuit, and an electromagnetic compatibility filter circuit. The hardware circuit includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware, the core control hardware is a micro control unit integrating a special operation unit for magnetic angle analysis algorithm (connected with the optical encoder 1 and the magnetic signal acquisition sensor 2 through the SPI interface, and connected with the ultra-low power circuit through the I2C interface), the signal acquisition hardware includes a magnetic signal acquisition circuit including a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit including a photoelectric conversion circuit, the signal processing hardware includes a double storage circuit composed of a non-volatile memory and a coarse position decoding hardware module, and the fault-tolerant and anti-interference hardware includes a metal shielding layer, a surge suppression circuit, and an electromagnetic compatibility filter circuit; the special operation unit of the core control hardware improves the magnetic angle analysis efficiency, and the interface connection ensures reliable data transmission; the signal conditioning circuit of the signal acquisition hardware optimizes the magnetic signal, and the optical signal acquisition circuit optimizes the optical signal; the double storage circuit and the coarse position decoding hardware module of the signal processing hardware improve the processing reliability and efficiency; the fault-tolerant and anti-interference hardware reduces the influence of external interference and component failure, avoids the problems of low signal processing efficiency, poor anti-interference, and weak fault tolerance of the existing hardware circuit, and improves the signal acquisition, processing, anti-interference, and fault tolerance capabilities of the hardware level as a whole.

[0042] Specifically, in the embodiment, the ultra-low power circuit includes a power management unit, a hibernation wake-up circuit, and a dynamic power consumption adjustment circuit; the power management unit is a low quiescent current power management chip with multi-gear output voltage adjustment function, which is connected with the micro control unit to receive power consumption control instructions; the hibernation wake-up circuit includes a signal trigger wake-up sub-circuit for detecting signal changes and a timing wake-up sub-circuit composed of a low-power real-time clock; the dynamic power consumption adjustment circuit is linked with the signal acquisition module, and can cut off the redundant power supply of the optical encoder 1 and adjust the operating frequency of the micro control unit according to the position change state. The ultra-low power circuit includes a power management unit, a hibernation wake-up circuit, and a dynamic power consumption adjustment circuit, the power management unit is a low quiescent current power management chip with multi-gear output voltage adjustment function (connected with the micro control unit), the hibernation wake-up circuit includes a signal trigger wake-up sub-circuit and a timing wake-up sub-circuit composed of a low-power real-time clock, and the dynamic power consumption adjustment circuit is linked with the signal acquisition module (which can cut off the redundant power supply of the optical encoder 1 and adjust the operating frequency of the micro control unit); the multi-gear voltage regulation of the power management unit reduces the static power consumption, the hibernation wake-up circuit makes the system hibernate when it is not working and wakes up when it is needed to reduce invalid power consumption, and the dynamic power consumption adjustment circuit adjusts the power supply and the main frequency according to the position change to further optimize the power consumption, thereby avoiding the problems of existing ultra-low power circuits, such as imprecise power consumption control and short battery life, greatly reducing the system power consumption, prolonging the battery life, and ensuring the real-time performance of the system when it is working.

[0043] Specifically, in the embodiment, the self-developed magnetic angle analysis algorithm includes an adaptive compensation algorithm, the adaptive compensation algorithm includes an adaptive compensation algorithm and an error self-calibration algorithm, wherein: Temperature compensation algorithm: real-time collection of environmental temperature data fed back by a temperature sensor (integrated in the hardware circuit) in the system, establishment of a correlation model of temperature and magnetic signal analysis error; when the environmental temperature changes, the algorithm automatically retrieves the preset compensation parameters according to the model to correct the deviation of the position absolute value corresponding to the output electrical signal of the magnetic signal acquisition sensor 2 (gallium arsenide sensor), offset the magnetic signal sensing deviation caused by temperature change, and ensure the stability of the position analysis accuracy at different temperatures.

[0044] Error self-calibration algorithm: taking the high-resolution signal output by the optical encoder 1 as a reference, periodically comparing the position absolute value analyzed by the magnetic signal with the optical signal calculation result; if the deviation exceeds the preset threshold, the algorithm automatically calculates the deviation and generates a calibration coefficient to update the magnetic angle analysis parameters and correct the cumulative error in the magnetic signal analysis process in real time without manual intervention to maintain the analysis accuracy.

[0045] Specifically, in the embodiment, the coarse position decoding algorithm is based on the magnetic signal acquisition sensor 2 acquires a plurality of pairs of magnetic ring magnetic field signals of unequal poles. The algorithm first filters and denoises the magnetic signals to eliminate environmental interference signals. Then, through the binary encoder logic, the plurality of position regions divided by the plurality of pairs of magnetic ring magnetic fields of unequal poles are corresponded to the preset binary code, the position region to which the current magnetic field signal belongs is identified, and an n-bit coarse position code is output. The code directly defines the large area where the current mechanical angle is located, provides an initial range for subsequent accurate position calculation, avoids the process of finding the zero point of the incremental encoder, and shortens the position positioning time.

[0046] Specifically, in the embodiment, the number of laps memory and correction algorithm is as follows: 1. Number of laps memory value storage and reading: a dual storage circuit composed of a non-volatile memory in a hardware circuit is used to store the number of laps memory value calculated each time to two storage units; when reading, the data in the main storage unit is preferentially called, and if the data in the main storage unit is abnormal, the data in the backup storage unit is automatically switched to read to prevent the number of laps memory value from being lost.

[0047] 2. Double signal source lap automatic correction: real-time comparison of the number of laps change calculated by the optical encoder 1 signal and the number of laps change calculated by the magnetic signal; if the two are inconsistent and the deviation exceeds the allowed range, the algorithm judges the signal effectiveness (preferably based on the photoelectric signal in a clean environment and the magnetic signal in a polluted environment), and corrects the number of laps calculation result of the other signal according to the number of laps corresponding to the effective signal to ensure the accuracy of the number of laps record.

[0048] Specifically, in the embodiment, the position matching algorithm is as follows: 1. Absolute position and number of laps memory value matching: the absolute value of the position output by the angle analysis module is associated with the number of laps memory value to establish a "number of laps-absolute position" correspondence; after each calculation, the algorithm verifies whether the current position absolute value is within the preset position range of the corresponding number of laps, and if it is out of range, the number of laps memory value or the position absolute value is automatically adjusted to ensure that the two match.

[0049] 2. Reference position dynamic update: based on the accurate position results of multiple consecutive calculations, the algorithm calculates the position change trend in real time; when it is detected that the position calculation result is stable (fluctuation is less than a preset value), the current position is automatically updated as a new reference position to replace the initial reference position, avoiding the accumulation of deviation of the initial reference position over time affecting the subsequent calculation accuracy.

[0050] Specifically, in the present embodiment, the intelligent dynamic weight adjustment algorithm: real-time evaluation of the quality of the optical signal and the magnetic signal (such as the signal-to-noise ratio of the optical signal, the stability of the magnetic signal), and assign weight coefficients to the two signals respectively; in a clean environment, the optical signal quality is high, the algorithm increases the weight of the optical signal (more than 50%), and the optical signal is used to solve the position; in a polluted environment, the magnetic signal quality is better, the algorithm increases the weight of the magnetic signal; if the quality of the two signals is similar, the weight is distributed according to the preset proportion, and the solving results of the two are fused, and the accuracy and reliability are considered.

[0051] In addition, as shown in Figures 5-6 The adaptive configuration of the single / dual encoder of the system specifically includes the following two application modes: Single encoder adaptive application configuration: only one set of encoder (optical encoder 1 or magnetic signal acquisition sensor 2 combined with multiple pairs of uneven magnetic rings, or a combination of one multiple pairs of uneven magnetic rings and one optical encoder 1) needs to be deployed at the motor end to meet the basic operation requirements of the motor; after the signal acquisition module automatically detects the single encoder signal, there is no need to start the dual signal cooperative solving logic, and the signal processing process of the corresponding type of encoder is directly called (optical encoder 1 calls the photoelectric conversion-differential operation link, magnetic signal acquisition sensor 2 combination or multiple pairs of uneven magnetic rings and optical encoder 1 combination calls coarse position decoding-magnetic angle analysis link), and the single sensor fault warning function of the fault correction module is enabled at the same time, ensuring the stability and low power consumption in the basic operation scene; this mode is suitable for ordinary motor driving scenes without high precision requirements, such as small conveying equipment and ordinary transmission motors.

[0052] Dual encoder adaptive application configuration: dual encoders are deployed at the high-speed end and the low-speed end of the motor, and can be used independently as products, or can be used cooperatively to achieve high-precision position solving; the typical configuration is to deploy encoders at the high-speed end and the low-speed end of the motor (optical encoder 1 at the high-speed end and magnetic signal acquisition sensor 2 combined with multiple pairs of uneven magnetic rings at the low-speed end, or vice versa), which is suitable for high-precision motor operation requirements (such as high-precision transmission scenes of frameless torque motors combined with precision harmonic reducers); after the signal acquisition module detects the dual encoder signal, it automatically starts the dual signal cooperative solving logic, and through the intelligent dynamic weight adjustment algorithm of the signal processing module, the quality of the encoder signals at the high-speed end and the low-speed end is evaluated and the weight is distributed (such as increasing the weight of the high-speed end optical encoder 1 to ensure dynamic accuracy when the motor is running at high speed, and increasing the weight of the low-speed end magnetic signal to ensure absolute position accuracy when the low-speed end load is stable); at the same time, the dual sensor redundancy function of the fault correction module is fully activated, and the high-speed end and the low-speed end encoders can back up each other, and if any encoder fails, the system automatically switches to the signal solving of the other encoder, ensuring continuous and reliable operation in high-precision scenes; this mode is suitable for high-precision control fields, such as industrial robot joint motors, precision machine tool spindle motors, and medical device driving motors.

[0053] Specifically, in the present embodiment, the environmental cleanliness detection mechanism of the present system is realized by relying on the signal characteristics of the optical encoder 1 and the signal quality evaluation capability of the signal processing module. The logic is "light signal quality inversely deduces environmental cleanliness". Because the optical encoder 1 is easily affected by dust, oil stains and other pollution, the decrease of environmental cleanliness will directly lead to the attenuation of light signal and the increase of noise. Therefore, the current environmental cleanliness state can be accurately judged through the light signal quality evaluation algorithm. The specific implementation process and related design are as follows: 1. Light signal key parameter acquisition: The signal acquisition module synchronously acquires the core parameters of the light signal output by the optical encoder 1 after processing, including the signal-to-noise ratio of the light signal (the ratio of the effective signal to the noise in the output signal of the photoelectric conversion circuit), the signal amplitude stability (the fluctuation amplitude of the output voltage of the single-ended output circuit), and the signal edge definition (the steepness of the rising / falling edge of the square wave signal output by the comparator circuit). The above parameters are transmitted to the signal processing module through the differential operation circuit of the optical encoder 1 to ensure the anti-interference of the collected data.

[0054] 2. Signal quality evaluation threshold setting: The signal processing module is built-in with a light signal quality evaluation threshold. The threshold is based on the signal parameter calibration of the optical encoder 1 in the standard clean environment (such as setting the signal-to-noise ratio ≥ 30 dB, the signal amplitude fluctuation ≤ 5%, and the edge rising time ≤ 100 ns as the clean environment judgment criterion). The threshold judgment logic cooperates with the threshold discrimination function of the comparator circuit to avoid misjudgment caused by single parameter abnormality.

[0055] 3. Environmental cleanliness algorithm judgment: The signal processing module runs the light signal quality evaluation algorithm to analyze the collected parameters in real time. (1) If all parameters meet the clean environment threshold, it is determined that the current environment is clean, and the "photoelectric signal dominant mode" is triggered. The signal processing module increases the weight of the light signal in position solving, and preferentially uses the high-resolution signal of the optical encoder 1 for solving to fully exert its precision advantage. (2) If any parameter exceeds the threshold (such as signal-to-noise ratio < 30 dB, amplitude fluctuation > 5%), it is determined that the environmental cleanliness decreases (there is pollution). The algorithm further analyzes the signal degradation trend: if the parameter temporarily exceeds the threshold, it is determined as temporary interference, and the photoelectric signal dominant mode is maintained and the noise filtering is strengthened through the comparator circuit; if the parameter continuously exceeds the threshold for 3 sampling periods, it is determined as continuous environmental pollution, and the "magnetic signal backup mode" is triggered. The signal processing module automatically switches to the solving mode dominated by the output signal of the magnetic signal acquisition sensor 2 (gallium arsenide sensor), avoiding the influence of pollution on the light signal. 4. Coordination with system modules: The detection mechanism is deeply coordinated with the "intelligent dynamic weight adjustment algorithm" of the signal processing module. When the environmental cleanliness is in a critical state (the parameters are close to the threshold), the algorithm dynamically adjusts the weight of the light signal and the magnetic signal (such as the light signal weight from 70% to 50%, and the magnetic signal weight from 30% to 50%), realizing the smooth transition of the two signals. At the same time, the fault correction module records the abnormal situation of the light signal quality. If the light signal cannot be restored for a long time due to continuous pollution, the system sends a calibration prompt through the state interface of the hardware circuit, reminding the maintenance personnel to clean the optical encoder 1, and ensuring that the detection mechanism is consistent with the existing fault tolerance and maintenance logic.

[0056] Working principle: The system takes "cooperative collection of light and magnetic signals - multi-module linkage processing - fault tolerance and low power consumption control" as the main working logic, and each component and module cooperates according to the following process: 1. Signal acquisition stage: The optical encoder 1 converts the light signal into an initial electrical signal through the internal photoelectric conversion circuit, amplifies it through the operational single-ended output circuit, discriminates and denoises it through the comparator circuit threshold, converts it into an anti-interference differential signal through the differential operation circuit, and then transmits it to the signal acquisition module. The magnetic signal acquisition sensor 2 (gallium arsenide sensor) collects the magnetic field signal generated by the cooperation of multiple pairs of uneven magnetic rings, converts it into an electrical signal, and also transmits it to the signal acquisition module. The signal acquisition module synchronously receives the two signals and transmits them to the signal processing module.

[0057] 2. Signal processing and position solving stage: The coarse position decoding module in the signal processing module is based on the magnetic signal, which identifies the position area through the binary encoder and outputs an n-bit coarse position code, quickly determining the position range. The angle analysis module relies on the integrated magnetic angle analysis algorithm to analyze the electrical signal corresponding to the magnetic signal into a position absolute value. The adaptive compensation algorithm (including temperature compensation algorithm and error self-calibration algorithm) in the algorithm offsets the temperature error and corrects the real-time deviation of the position absolute value. At the same time, the revolution memory and correction algorithm of the signal processing module realizes the storage and reading of the revolution memory value, and the position matching algorithm contained in it associates and matches the position absolute value output by the angle analysis module with the revolution memory value, and corrects the reference position according to the real-time solving result through the reference position dynamic updating algorithm, finally completing the accurate position solving.

[0058] 3. Fault-tolerant and power control stage: The fault-tolerant correction module ensures system stability through double redundancy design - double sensor redundancy makes the optical encoder 1 and the magnetic signal acquisition sensor 2 back up each other, and when any sensor fails, the other sensor can continue to output signals; double storage redundancy stores important system parameters in double backup to avoid parameter loss; the surge suppression circuit in the hardware circuit, the electromagnetic compatibility filter circuit and the permalloy metal shielding layer outside the magnetic signal acquisition sensor 2 further reduce external electromagnetic and magnetic field interference. The low-power module realizes power control by configuring the processor to low-power mode and adjusting the power supply power according to the working state through the intelligent power management function; the power management unit of the ultra-low power circuit (low static current, multi-gear voltage regulation), the sleep wake-up circuit (signal trigger wake-up sub-circuit and low-power real-time clock timing wake-up sub-circuit), and the dynamic power adjustment circuit (linked with the signal acquisition module, according to the position change to cut off the redundant power supply of the optical encoder 1, adjust the processor operation frequency), further optimize the power control.

[0059] 4. Environmental adaptation stage: The signal mode switching function of the signal processing module dynamically adjusts the working mode according to the environmental state - in a clean environment, switch to the photoelectric signal dominant mode, preferentially use high-precision photoelectric signal to solve the position; in a polluted environment, switch to the magnetic signal backup mode, rely on the anti-pollution characteristics of the magnetic signal to ensure signal reliability; the intelligent dynamic weight adjustment algorithm based on signal quality evaluation dynamically adjusts the weight of light and magnetic signals in position solving according to the quality of the two signals, ensuring the accuracy and reliability of position solving in different environments.

[0060] Method for use: 1. Environmental adaptation and mode selection: After deploying the system in the target measurement scene, the system automatically detects the environmental cleanliness - if the environment is clean (no obvious dust, oil stains and other pollutants), the signal processing module automatically switches to the photoelectric signal dominant mode, and preferentially uses the signal output by the optical encoder 1 as the core basis for position solving; if the environment is polluted (dust, oil stains and other factors that may affect photoelectric signals), the system automatically switches to the magnetic signal backup mode, and uses the signal collected by the magnetic signal acquisition sensor 2 as the main position solving signal; regardless of the environment, the intelligent dynamic weight adjustment algorithm will evaluate the quality of the light and magnetic signals in real time, and dynamically adjust the weight of the two in solving, to ensure the optimal solving result.

[0061] 2. Power-on initialization and position calibration: After the system is powered on, the signal acquisition module synchronously acquires the initial signals of the optical encoder 1 and the magnetic signal acquisition sensor 2. The coarse position decoding module of the signal processing module outputs an n-bit coarse position code based on the signals collected by the magnetic signal acquisition sensor 2, quickly determining the approximate range of the current position without the need for additional zero-point search operations like incremental encoders. The angle resolution module resolves the initial position absolute value through a magnetic angle resolution algorithm, and a self-adaptive compensation algorithm simultaneously compensates for temperature errors and real-time errors. The position matching algorithm associates and matches the initial position absolute value with the number of turns memory value, completing the initial position calibration.

[0062] 3. Normal operation and data processing: After calibration is complete, the system enters a normal measurement state, and the signal acquisition module continuously and synchronously acquires optical and magnetic signals and transmits them to the signal processing module. The signal processing module processes the signals according to the working mode, realizes real-time updating and storage of the number of turns memory value in combination with the number of turns memory and correction algorithm, dynamically updates the reference position through the position matching algorithm, and ensures the accuracy of position calculation. The processor receives the processed signals and calculation results and outputs the final position and angle measurement data. The fault tolerance correction module checks the acquired signals and calculation results in real time. If a sensor fault or parameter anomaly is found, the dual-redundancy backup (switching to a backup sensor or calling backup parameters) is immediately started to ensure uninterrupted system operation.

[0063] 4. Low-power control and endurance management: When the signal acquisition module detects that the encoder is stationary (no position change), the low-power module automatically configures the processor to low-power mode, and the dynamic power consumption adjustment circuit of the ultra-low-power circuit cuts off the redundant power supply of the optical encoder 1 and reduces the processor operating frequency. If there is no position change for a long time, the low-power real-time clock of the sleep-wake circuit wakes up the processor for short signal acquisition at a preset period (e.g., 10ms-1s adjustable). After acquisition is complete, the processor is immediately controlled to return to sleep state. When the signal acquisition module detects a position change, the system quickly restores full-power supply of the optical encoder 1 and normal operating frequency of the processor to ensure real-time calculation when the position changes.

[0064] 5. Fault response and maintenance: If the system experiences signal interruption or calculation anomaly, the fault tolerance correction module automatically checks the sensor status and parameter storage situation. If the optical encoder 1 fails, it immediately switches to the magnetic signal acquisition sensor 2 to output signals alone. If the magnetic signal acquisition sensor 2 fails, it switches to the optical encoder 1 to output signals alone. If parameters are lost, backup parameters in dual-storage redundancy are called to restore system operation. During routine maintenance, the working status of each hardware unit (such as the power management unit, processor, and sensor) can be checked through the state detection interface of the hardware circuit, and basic fault troubleshooting can be completed without disassembling the system.

[0065] In summary, the multi-turn memory optical-magnetic encoder hybrid system provided by the embodiment has the following advantages: 1. Simplify signal processing procedures and reduce system complexity: By cooperating with the coarse position decoding module through multiple pairs of unequal magnetic rings, the system can quickly determine the position range without additional zero point searching, eliminating cumulative errors; the angle resolution module integrates a magnetic angle resolution algorithm, which can complete the resolution of magnetic signals to absolute position values relying only on the processor, without the need for two magnetic inductive chips, effectively simplifying the complex signal processing procedures of existing optical-magnetic hybrid encoders, reducing system hardware costs and algorithm difficulty.

[0066] 2. Optimize structural design to adapt to miniaturization and integration requirements: Abandoning the existing optical-magnetic hybrid encoder "simple integration of optical encoder 1 and magnetic encoder" approach, through multi-module integration design (signal acquisition, processing, fault tolerance correction, and low-power consumption module integration in the system) and the compact cooperation of multiple pairs of unequal magnetic rings and magnetic signal acquisition sensor 2, the system axial length is significantly shortened, making it more suitable for small-sized and integrated application scenarios.

[0067] 3. Improve position measurement accuracy and stability: Optical encoder 1 provides high-resolution reference signals, and the magnetic encoder provides reliable absolute position regions and multi-turn memory, both of which work together to solve the problem; the adaptive compensation algorithm (temperature compensation and error self-calibration) of the angle resolution module offsets the influence of temperature and real-time errors on the resolution results; the position matching algorithm corrects the deviation by dynamically updating the reference position, ensuring position resolution accuracy in multiple dimensions; at the same time, dual-sensor redundancy, dual-storage redundancy, and anti-interference hardware (surge suppression circuit, electromagnetic compatibility filter circuit, and permalloy metal shielding layer) reduce the impact of external interference and faults on the system, improve overall operational stability, and meet the measurement requirements in harsh environments with high precision.

[0068] 4. Enhance environmental adaptability and broaden application scenarios: Based on the signal mode switching function (photoelectric signal dominant mode and magnetic signal backup mode) according to environmental cleanliness, the system can rely on photoelectric signals to achieve high-precision measurement in clean environments, and can ensure measurement reliability through magnetic signals in polluted environments; the intelligent dynamic weight adjustment algorithm optimizes the resolution basis according to signal quality, further improving the system's adaptability to different environments and breaking through the limitations of existing optical-magnetic hybrid encoders.

[0069] 5. Optimize power consumption control and prolong battery life: The low-power mode of the low-power module processor and the intelligent power management function, combined with the multi-gear voltage regulation, sleep-wake control, and dynamic power adjustment (cutting off redundant power supply and adjusting the main frequency) of the ultra-low-power circuit, significantly reduce the invalid power consumption of the system in non-high-load states, effectively prolong the system's running time in external power supply-free scenarios, and improve the system's applicability in mobile devices and scenarios without external power supply.

[0070] 6. Strengthen fault tolerance to ensure reliable operation of the system: dual sensor redundancy avoids signal interruption caused by single sensor failure, dual storage redundancy prevents important parameter loss, anti-interference hardware reduces external electromagnetic and magnetic field interference, multi-dimensional improves system fault tolerance, reduces the risk of position solution interruption and error caused by component failure or external interference, and ensures long-term reliable operation of the system.

[0071] 7. Realize single / dual encoder adaptive adaptation, flexible matching of multi-scene requirements: through the automatic identification function of the signal acquisition module, without hardware or algorithm parameter modification, it can be seamlessly switched between single encoder (basic precision) and dual encoder (high precision) scenes; single encoder mode reduces the hardware cost of basic scene, and dual encoder mode improves the control stability of high precision scene through dual-end signal cooperation, solves the problem of "poor scene adaptability and complex configuration" of existing encoder system, and widens the application coverage of the system in ordinary transmission and high precision control field.

[0072] In summary, the multi-turn memory optical-magnetic encoder hybrid system of the embodiment simplifies signal processing, optimizes structure design, improves precision stability, enhances environmental adaptability, optimizes power consumption control, strengthens fault tolerance, and simultaneously realizes single / dual encoder adaptive adaptation, solves the technical defects of existing optical-magnetic hybrid encoders, takes into account the basic precision and high precision scene requirements, and has wide application prospect.

[0073] The above is only the preferred embodiment of the present application, and does not limit the implementation and protection scope of the present application. For those skilled in the art, it should be realized that any equivalent replacement and obvious change made by applying the contents of the present application specification and drawings should be included in the protection scope of the present application.

Claims

1. A multi-turn memory magneto-encoder hybrid system, characterized by, The system comprises an optical encoder, a magnetic signal acquisition sensor, a processor, a hardware circuit, an ultra-low power circuit, and signal acquisition module, signal processing module, fault-tolerant correction module, low-power module and angle analysis module integrated in the system. The processor is electrically connected with the hardware circuit, the ultra-low power circuit, the magnetic signal acquisition sensor and the optical encoder, and the angle analysis module is integrated with a magnetic angle analysis algorithm for analyzing the electric signal output by the magnetic signal acquisition sensor in response to the change of the magnetic field to obtain an absolute position value. The signal processing module comprises a number of memory and correction algorithm for storing, reading and automatically correcting the memory value. The signal acquisition module is configured to synchronously acquire the optical signal output by the optical encoder and the magnetic signal output by the magnetic signal acquisition sensor and transmit the acquired signals to the signal processing module. The fault-tolerant correction module is configured to check and correct the acquired signals and the calculated position information, and the low-power module is configured to control the power consumption of the system.

2. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The optical encoder comprises a photoelectric conversion circuit, an operation single-end output circuit, a comparator circuit and a differential operation circuit.

3. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The magnetic signal acquisition sensor is a gallium arsenide sensor which is electrically connected with the signal acquisition module and configured to acquire the external magnetic field signal and convert the magnetic field signal into an electric signal and then transmit the electric signal to the signal acquisition module.

4. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The system further comprises a plurality of pairs of non-uniform magnetic rings which are arranged in cooperation with the magnetic signal acquisition sensor and configured to provide a coarse position detection reference.

5. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The angle analysis module comprises an adaptive compensation algorithm which comprises a temperature compensation algorithm and an error self-calibration algorithm and is configured to compensate the temperature error and calibrate the real-time error of the absolute position value obtained by analysis. The fault-tolerant correction module adopts a double-redundancy design including double-sensor redundancy and double-storage redundancy.

6. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The low-power module is configured to set the processor to a low-power mode and has an intelligent power management function. The multi-turn memory optical-magnetic encoder hybrid system further comprises an internal metal shielding layer made of permalloy and arranged outside the magnetic signal acquisition sensor for isolating the magnetic field interference in the external environment and ensuring the accuracy of the signal acquisition by the magnetic signal acquisition sensor.

7. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The signal processing module has a signal mode switching function, including a photoelectric signal dominant mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality evaluation; in a clean environment, the system switches to the photoelectric signal dominant mode, and the signal output by the optical encoder is preferentially used for position solving; in a polluted environment, the system switches to the magnetic signal backup mode, and the signal output by the magnetic signal acquisition sensor is used for position solving; the intelligent dynamic weight adjustment algorithm dynamically adjusts the weight of the two signals in position solving according to the quality evaluation results of the optical signal and the magnetic signal.

8. The multi-turn memory magneto-encoder hybrid system of any of claims 1-7, wherein, The number of laps memory and correction algorithm of the signal processing module contains a position matching algorithm, which includes an absolute position and number of laps memory value matching method, and a dynamic reference position updating algorithm; the absolute position and number of laps memory value matching method is used to associate and match the absolute value of the position obtained by the angle analysis module with the number of laps memory value, and the dynamic reference position updating algorithm is used to update the reference position according to the real-time solving result, thereby improving the position matching accuracy.

9. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The hardware circuit includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware; the core control hardware is a micro control unit integrated with a special operation unit for magnetic angle analysis algorithm, which is connected with the optical encoder and the magnetic signal acquisition sensor through the SPI interface, and connected with the ultra-low power circuit through the I2C interface; the signal acquisition hardware includes a magnetic signal acquisition circuit including a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit including a photoelectric conversion circuit, an operation single-ended output circuit, a comparator circuit, and a differential operation circuit; the signal processing hardware includes a double storage circuit composed of a non-volatile memory and a coarse position decoding hardware module; the fault-tolerant and anti-interference hardware includes a metal shielding layer made of permalloy, a surge suppression circuit, and an electromagnetic compatibility filter circuit.

10. The multi-turn memory magneto-encoder hybrid system of claim 1 or 9, wherein, The ultra-low power circuit includes a power management unit, a sleep wake-up circuit, and a dynamic power consumption adjustment circuit; the power management unit is a low static current power management chip with multi-gear output voltage adjustment function, which is connected with the micro control unit to receive power consumption control instructions; the sleep wake-up circuit includes a signal trigger wake-up sub-circuit for detecting signal changes and a timing wake-up sub-circuit composed of a low-power real-time clock; the dynamic power consumption adjustment circuit is linked with the signal acquisition module, and can cut off the redundant power supply of the optical encoder and adjust the operation frequency of the micro control unit according to the position change state.

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