A method for encoder safety redundancy and readable storage medium

Abstract

The present invention relates to the field of encoder technology, and specifically to an encoder safety redundancy method and a readable storage medium. The present invention compares the continuous signals of an electromagnetic encoder and a photoelectric encoder to determine the installation position of the photoelectric encoder code disk and a photocell; performs position calibration on the photoelectric encoder and the electromagnetic encoder, and stores the data in the encoder; and initializes the absolute position of the encoder; after power-on, accumulates the pulse quadrature counts of each code channel, and records the absolute position and number of turns obtained by the electromagnetic encoder; compares the grating count pulses of each code channel and the electromagnetic encoder to compensate for the error of the absolute position of the factory calibration data; and according to the situation of the error accumulation over time, warns the customer to check and replace or reminds the user to take corresponding measures. The present invention adds an electromagnetic encoder, utilizes the high reliability and environmental adaptability of the electromagnetic encoder to cooperate with the photoelectric encoder for redundant solution, and thus improves the safety and reliability of the photoelectric encoder.

Description

Technical Field

[0001] The present invention relates to the technical field of encoders, and in particular to an encoder safety redundancy method and a readable storage medium. Background Art

[0002] Encoders are high-precision sensors that can provide position and speed information. They are widely used in modern industrial automation production, manipulators, and various occasions that require precise positioning. According to the detection principle, they can be mainly divided into photoelectric, electromagnetic, inductive, etc. Among photoelectric encoders, according to the grating code disk encoding, they can be mainly divided into photoelectric absolute encoders such as Vernier code, M sequence, Gray code, etc.

[0003] The electromagnetic encoder uses a special magnetoresistive chip to output corresponding sine and cosine signals under a specific rotating magnetic field. By calculating the inverse tangent of this set of sine and cosine signals, the single-turn position of the encoder with a certain accuracy can be obtained. The more mature magnetic encoders in the industry generally output 17 bits of effective absolute position information.

[0004] The vernier encoder uses the circular vernier principle. By burning a grating on transparent glass, the light source projects a light and dark grating, and then the photocell receives the light to generate sine and cosine signals. The existing solution burns three code channels on the code disk: the vernier code channel (N code channel), the segment code channel (S code channel) and the main code channel (M code channel). Figure 2 As shown in the figure, the absolute position information is obtained by vernier solution. The solution principle is simple and easy to implement, but in actual production and use, the grating code disk is easily contaminated or even broken, and the vernier principle cannot identify the risk of code disk contamination and breakage, which will cause errors in absolute position information and lead to serious consequences.

[0005] Each line of the grating code disk can generate a period of sine and cosine signals. The absolute position of the magnetic encoder can be used to locate the current line of a grating code channel, such as the M code channel. Then, the electronic angle obtained by the magnetic encoder and the current grating line can be used to obtain a high-precision encoder position. Figure 3 shown.

[0006] Although optical encoders can provide higher-resolution position information, they are usually subject to the risk of code disk contamination, and even worse, the risk of accidental code disk breakage. This risk is difficult to detect, and there has been no good way to detect encoder failure in existing solutions. Although electromagnetic encoders have lower resolution, they are highly resistant to contamination and can work in harsh environments. Using electromagnetic encoders to assist optical encoders to detect abnormal phenomena that may occur in optical encoders, such as code disk contamination or code disk breakage and other dangerous situations, can improve the safety and reliability of optical encoders.

[0007] Although the existing solutions also use magnetic induction chips as an aid, the use of magnetic induction chips is relatively simple, and they are not used as a means to prevent the optical encoder from failing. Summary of the invention

[0008] In view of the deficiencies in the prior art, the present invention discloses a safety redundancy method for an encoder and a readable storage medium, which are used to solve the problems that the existing vernier photoelectric encoder has a single method for obtaining absolute position information, has no redundant solution to ensure the accuracy of the absolute position information of the optical encoder, has no effective means to identify the abnormality when the encoder code disk is contaminated or even cracked and shattered, and when electrical components such as photocells are damaged, resulting in abnormal photoelectric signals, and some solutions for adding magnetic induction chips are simple to use, and do not use them for reliable redundant solution, nor use them as a solution for detecting encoder abnormalities.

[0009] The present invention is achieved through the following technical solutions:

[0010] In a first aspect, the present invention discloses an encoder safety redundancy method, comprising the following steps:

[0011] S1 compares the continuous signals of the electromagnetic encoder and the photoelectric encoder to determine the installation position of the photoelectric encoder code disk and photocell;

[0012] S2 calibrates the position of the photoelectric encoder and the electromagnetic encoder and stores the data in the encoder;

[0013] S3 performs redundant calculations and judgments through four positions to initialize the absolute position of the encoder;

[0014] After S4 is powered on, it accumulates the pulse quadrature counts of each code channel and records the absolute position and number of turns obtained by the electromagnetic encoder;

[0015] S5 compares the grating count pulses of each code channel with the electromagnetic encoder to compensate for the absolute position error of the factory calibration data;

[0016] S6 warns customers to check and replace the components or to take appropriate measures based on the accumulated errors over time.

[0017] Furthermore, in the method, when the encoder is powered on to initialize the absolute position, the absolute position of the electromagnetic encoder and the current electrical angle of the M code channel are used to compensate the factory calibration data to obtain position 1.

[0018] Furthermore, in the method, when the encoder is powered on to initialize the absolute position, the absolute position of the electromagnetic encoder and the current electrical angle of the N code channel are used to compensate the factory calibration data to obtain position 2.

[0019] Furthermore, in the method, when the encoder is powered on to initialize the absolute position, the absolute position of the electromagnetic encoder and the current electrical angle of the S code channel are used to compensate the factory calibration data to obtain position 3.

[0020] Furthermore, in the method, when the encoder is powered on to initialize the absolute position, position 4 is obtained by solving the three code channel cursors M, N, and S.

[0021] Furthermore, in the method, each time the encoder is powered on, the pulse quadrature counts of the M, N, and S code channels are accumulated, and the number of revolutions is increased or decreased with each revolution, while the absolute position and number of revolutions obtained by the electromagnetic encoder are recorded.

[0022] Furthermore, in the method, the absolute position error of the factory calibration data of the grating count pulses and the electromagnetic encoder of each code channel is compared. If this error becomes larger and larger with time accumulation, it is judged that the corresponding grating code channel has a more serious problem and the position of the encoder is unreliable, and the customer is warned to check and replace it.

[0023] Furthermore, in the method, the absolute position error of the factory calibration data of each code channel grating count pulse and the electromagnetic encoder is compensated. If the error is only a local position error within one circle and will not accumulate, the user is reminded to take corresponding measures according to the error size and usage scenario.

[0024] Furthermore, the method prevents and warns against encoder damage by comparing the redundancy of the photoelectric signal during encoder production and actual operation, and reminds the user to perform inspection and maintenance in a timely manner.

[0025] In a second aspect, the present invention discloses a read storage medium having a computer program stored thereon, wherein the program, when executed by a processor, implements the encoder safety redundancy method described in the first aspect.

[0026] The beneficial effects of the present invention are:

[0027] The present invention adds an electromagnetic encoder, utilizes the high reliability and environmental adaptability of the electromagnetic encoder to cooperate with the photoelectric encoder for redundant solution, thereby improving the safety and reliability of the photoelectric encoder. At the same time, during the production and actual operation of the encoder, redundant comparison with the photoelectric signal is used to prevent and warn the encoder from being damaged, and remind users to check and maintain in time to avoid losses. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention 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 invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 This is a flow chart for judging the actual use of the present invention;

[0030] Figure 2 It is the principle diagram of the circular cursor of the prior art;

[0031] Figure 3 It is a schematic diagram of the principle of obtaining a high-precision absolute position using the engraved lines obtained by a magnetic encoder and the electronic angle obtained within the current grating engraved lines in the prior art. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] Example 1

[0034] The present invention discloses Figure 1 An encoder safety redundancy method is shown, comprising the following steps:

[0035] S1 compares the continuous signals of the electromagnetic encoder and the photoelectric encoder to determine the installation position of the photoelectric encoder code disk and photocell;

[0036] S2 calibrates the position of the photoelectric encoder and the electromagnetic encoder and stores the data in the encoder;

[0037] S3 performs redundant calculations and judgments through four positions to initialize the absolute position of the encoder;

[0038] After S4 is powered on, it accumulates the pulse quadrature counts of each code channel and records the absolute position and number of turns obtained by the electromagnetic encoder;

[0039] S5 compares the grating count pulses of each code channel with the electromagnetic encoder to compensate for the absolute position error of the factory calibration data;

[0040] S6 warns customers to check and replace the components or to take appropriate measures based on the accumulated errors over time.

[0041] In this embodiment, when the encoder is powered on and initialized to the absolute position, the absolute position of the electromagnetic encoder and the current electrical angle of the M code channel are used to compensate for the factory calibration data to obtain position 1; the absolute position of the electromagnetic encoder and the current electrical angle of the N code channel are used to compensate for the factory calibration data to obtain position 2; the absolute position of the electromagnetic encoder and the current electrical angle of the S code channel are used to compensate for the factory calibration data to obtain position 3; and position 4 is obtained by solving the cursors of the M, N, and S code channels.

[0042] In this embodiment, each time the encoder is powered on, the pulse quadrature counts of the M, N, and S code channels are accumulated, and the number of revolutions is increased or decreased for each revolution, while the absolute position and number of revolutions obtained by the electromagnetic encoder are recorded.

[0043] In this embodiment, the absolute position error of the factory calibration data of the grating count pulses and electromagnetic encoder compensation of each code channel is compared. If this error becomes larger and larger with time accumulation, it is judged that there is a more serious problem with the corresponding grating code channel, and the position of the encoder is unreliable, and the customer is warned to check and replace it.

[0044] In this embodiment, the absolute position error of the factory calibration data of each code channel grating count pulse and the electromagnetic encoder is compensated. If the error is only a local position error within one circle and will not accumulate, the user is reminded to take corresponding measures according to the error size and usage occasions.

[0045] Example 2

[0046] This embodiment discloses an encoder redundancy resolution method that adds an electromagnetic encoder as a redundancy judgment for an optical encoder.

[0047] In this embodiment, during the encoder production stage, the continuous signals of the electromagnetic encoder and the photoelectric encoder are compared to determine whether the photoelectric encoder code disk and photocell are installed in place. After detection without problems, the photoelectric encoder and the electromagnetic encoder are calibrated and the data is stored in the encoder.

[0048] In this embodiment, whenever the encoder is powered on and initialized to the absolute position during customer use, the absolute position of the electromagnetic encoder and the current electrical angle of the M code channel are used to compensate for the factory calibration data to obtain position 1, the absolute position of the electromagnetic encoder and the current electrical angle of the N code channel are used to compensate for the factory calibration data to obtain position 2, the absolute position of the electromagnetic encoder and the current electrical angle of the S code channel are used to compensate for the factory calibration data to obtain position 3, and the MNS three code channel cursors are used to calculate position 4. Redundant calculations are performed through these four positions to determine (for example, comparing the maximum and minimum values ​​therein) whether the initialized absolute position is reliable and whether the encoder can be used normally.

[0049] In this embodiment, during the normal operation stage of the encoder, because the sine and cosine signals of the M, N, and S code channels are converted into orthogonal signals through comparators and connected to the microprocessor in the circuit, the pulse quadrature counts of the M, N, and S code channels are accumulated each time the encoder is powered on, and the number of turns is increased or decreased with each turn, and the absolute position and number of turns obtained by the electromagnetic encoder are recorded at the same time.

[0050] In this embodiment, by comparing the grating count pulses of each code channel and the absolute position error of the electromagnetic encoder compensation factory calibration data, if this error diverges and becomes larger and larger under time accumulation, it can be determined that the corresponding grating code channel has a more serious problem (serious pollution, code disk breakage, photocell damage), and the position of the encoder is unreliable, and the customer is warned to check and replace it; if there is only an error in the local position within a circle and it will not accumulate, the user is reminded to take corresponding measures according to the error size and usage occasions.

[0051] This embodiment solves the problem that the existing vernier photoelectric encoder has a single method for obtaining absolute position information, and there is no redundant solution to ensure the accuracy of the absolute position information of the optical encoder. When the encoder code disk is contaminated or even cracked and broken, and when electrical components such as photocells are damaged and the photoelectric signal is abnormal, there is no effective means to identify the abnormality. In this way, the absolute position information is still calculated based on the wrong signal, which will cause the host computer that receives the encoder position to make an erroneous judgment. Some solutions of adding a magnetic sensing chip are simple to use, and the magnetic sensing chip is not used for reliable redundant solution, nor is it used as a solution for detecting encoder abnormalities.

[0052] Example 3

[0053] This embodiment discloses a read storage medium having a computer program stored thereon, wherein the program implements an encoder safety redundancy method when executed by a processor.

[0054] In summary, the present invention adds an electromagnetic encoder, utilizes the high reliability and environmental adaptability of the electromagnetic encoder to cooperate with the photoelectric encoder for redundant solution, thereby improving the safety and reliability of the photoelectric encoder. At the same time, during the production and actual operation of the encoder, redundant comparison with the photoelectric signal is used to prevent and warn of encoder damage, reminding users to check and maintain in time to avoid losses.

[0055] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An encoder safety redundancy method, characterized in that: The method comprises the following steps: S1 compares the continuous signals of the electromagnetic encoder and the photoelectric encoder to determine the installation position of the photoelectric encoder code disk and photocell; S2 calibrates the position of the photoelectric encoder and the electromagnetic encoder and stores the data in the encoder; S3 performs redundant calculations and judgments through four positions to initialize the absolute position of the encoder; After S4 is powered on, it accumulates the pulse quadrature counts of each code channel and records the absolute position and number of turns obtained by the electromagnetic encoder; S5 compares the grating count pulses of each code channel with the electromagnetic encoder to compensate for the absolute position error of the factory calibration data; S6 warns customers to check and replace the components or to take appropriate measures based on the accumulated errors over time.

2. The encoder safety redundancy method according to claim 1, characterized in that: In the method, when the encoder is powered on and the absolute position is initialized, the absolute position of the electromagnetic encoder and the current electrical angle of the M code channel are used to compensate the factory calibration data to obtain position 1.

3. The encoder safety redundancy method according to claim 1, characterized in that: In the method, when the encoder is powered on and the absolute position is initialized, the absolute position of the electromagnetic encoder and the current electrical angle of the N code channels are used to compensate the factory calibration data to obtain position 2.

4. The encoder safety redundancy method according to claim 1, characterized in that: In the method, when the encoder is powered on and the absolute position is initialized, the absolute position of the electromagnetic encoder and the current electrical angle of the S code channel are used to compensate the factory calibration data to obtain position 3.

5. The encoder safety redundancy method according to claim 1, characterized in that: In the method, when the encoder is powered on and the absolute position is initialized, position 4 is obtained by solving the three code channel cursors M, N, and S.

6. The encoder safety redundancy method according to claim 1, characterized in that: In the method, after the encoder is powered on each time, the pulse quadrature counts of the M, N, and S code channels are accumulated, and the number of revolutions is increased or decreased for each revolution, while the absolute position and number of revolutions obtained by the electromagnetic encoder are recorded.

7. The encoder safety redundancy method according to claim 1, characterized in that: In the method, the error of the absolute position of the factory calibration data of the grating count pulses and electromagnetic encoder compensation of each code channel is compared. If this error becomes larger and larger with time accumulation, it is judged that the corresponding grating code channel has a more serious problem and the position of the encoder is unreliable, and the customer is warned to check and replace it.

8. The encoder safety redundancy method according to claim 1, characterized in that: In the method, the absolute position error of the factory calibration data of the grating count pulses of each code channel and the electromagnetic encoder is compensated. If the error is only a local position error within one circle and will not accumulate, the user is reminded to take corresponding measures according to the error size and usage occasions.

9. The encoder safety redundancy method according to claim 1, characterized in that: The method prevents and warns against encoder damage by comparing the redundancy of photoelectric signals during encoder production and actual operation, and reminds users to conduct timely inspection and maintenance.

10. A readable storage medium having a computer program stored thereon, wherein: When the program is executed by a processor, the encoder safety redundancy method as described in any one of claims 1 to 9 is implemented.

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