A monitoring system and monitoring method with a new combined digital sensor

Abstract

The present invention discloses a monitoring system and a monitoring method with a novel combined digital sensor. The monitoring system includes a metal object to be measured, a digital displacement device, and at least two sensor probes. The digital displacement device includes a data processing module, a communication module, at least two signal processing sub-modules, and at least two output control sub-modules. Each signal processing sub-module is electrically connected to a sensor probe, and each output control sub-module is electrically connected to the data processing module. The signal processing sub-module receives the voltage signal sent by the sensor probe electrically connected to it, and processes the voltage signal into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module. After the digital signal is received by an output control sub-module, it is compared with a reference signal, and the output control sub-module issues a switch quantity control signal according to the comparison result. The monitoring system of the present invention can expand the monitoring range and realize real-time diagnosis of equipment abnormalities.

Description

Technical Field

[0001] The present invention relates to a sensor monitoring system applied in the field of automation, and particularly to a monitoring system and a monitoring method with a novel combined digital sensor. Background Art

[0002] As a detection device, a sensor converts a measured physical quantity into an electrical signal to realize subsequent reprocessing of the obtained information through means such as transmission, processing, storage, display, recording, and control. Taking the existing displacement sensor as an example, it detects displacement by using the interference of metal on the electromagnetic field, and obtains a displacement analog quantity. Simply applying this analog quantity can play the role of a switch. For example, when the detected distance is close to the preset threshold range, it will control the corresponding PLC device to act; for a more complex application, this analog quantity can play the role of monitoring and statistics. For example, this analog quantity is displayed as a continuous waveform, and the distance change information can be obtained through this continuous waveform.

[0003] However, the application of this analog quantity also has defects: First, the intermediate quantity read through the analog quantity needs to be indirectly obtained through means such as conversion and oscilloscope to obtain the corresponding state value representing the distance; moreover, neither the state value nor the intermediate quantity is an intuitive numerical value, which cannot be further used for data analysis, and this will affect the smooth progress of subsequent data statistics and error analysis work.

[0004] At present, sensors are also particularly widely used in the field of industrial automation. For example, the measuring and packaging machine used to detect various inductive products and automatically tape them. Due to the space limitation of the measuring and packaging machine, the insertion part of the conventional measuring and packaging machine can only use sensors with an effective detection range of 0.6 mm. In order to expand the detection range, technicians use two sensors for detection and successfully increase the effective detection range to 1.2 mm. However, in the prior art, the two sensors generally used for detection are independent of each other and have no connection. Although this "each does its own thing" working method effectively expands the detection range, it cannot realize real-time detection and abnormal diagnosis of the moving distance of the insertion part of the measuring and packaging machine, which is not conducive to long-term production and processing and affects the processing yield.

[0005] Therefore, it is urgent to propose a new technical solution to solve the above problems. Summary of the Invention

[0006] The insertion parts of conventional packet measuring machines can only use sensors with an effective detection range of 0.6 mm. To expand the effective detection range, two sensors are generally used in the prior art for detection, and the two sensors operate independently. Although the detection range is effectively expanded, real-time detection of the moving distance of this part and abnormal diagnosis cannot be achieved, which is not conducive to long-term production and processing, affects the processing yield, and the analog quantities measured by the existing sensors cannot be further used for data analysis, which is not conducive to later data statistics and error analysis.

[0007] The purpose of the present invention is to solve the problems existing in the prior art. On the one hand, the present invention provides a monitoring system with a novel combined digital sensor, and the technical solution adopted is as follows:

[0008] A monitoring system with a novel combined digital sensor, which includes:

[0009] At least two sensor probes, each of the sensor probes includes a coil, and the coil forms an electromagnetic field after being energized;

[0010] A metal object to be measured, the distance between it and the sensor probe has a functional relationship with the magnetic field intensity of the electromagnetic field;

[0011] A digital displacement device, which includes a signal processing module, a data processing module, an output control module and a communication module. The signal processing module includes at least two signal processing sub-modules, each of the signal processing sub-modules is electrically connected to one of the sensor probes, and the output control module includes at least two output control sub-modules, each of the output control sub-modules is electrically connected to the data processing module;

[0012] The signal processing sub-module receives the voltage signal representing the magnetic field intensity of the electromagnetic field sent by the sensor probe electrically connected to it, and processes the voltage signal into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module. The digital signal is stored by the data processing module and received by one of the output control sub-modules and compared with a reference signal. The output control sub-module issues a switching quantity control signal according to the comparison result, and the switching quantity control signal controls the action of the PLC program of the external device.

[0013] Further in the above technical solution, each of the signal processing sub-modules is signal-connected to one of the output control sub-modules, and each signal processing sub-module is signal-connected to the data processing module; the signal processing sub-module performs signal conditioning on the voltage signal sent by the sensor probe through an oscillation circuit, a detection circuit, a balance circuit, and a variable gain amplification circuit to obtain a displacement signal; the data processing module has a data processor, a data storage, and at least two high-speed AD converters, each high-speed AD converter is signal-connected to one of the signal processing sub-modules, the displacement signal obtained by the signal processing sub-module is collected and converted into a digital signal by the high-speed AD converter signal-connected to it, after the data processor processes the digital signal, the digital signal is stored in the data storage, and the digital signal is stored and updated in real time in the data storage; the data processing module also stores the reference signal, and the reference signal is used as a comparison reference for each output control sub-module to compare digital signals.

[0014] Further, each of the output control sub-modules is signal-connected to the external device, each of the output control sub-modules includes a comparator, the comparator numerically compares the digital signal sent by the data processing module with the reference signal, and outputs a switch quantity control signal according to the comparison result, and after receiving the switch quantity control signal sent by the output control sub-module, the external device adjusts its own operating state according to the switch quantity control signal.

[0015] Further, the switch quantity control signal is an I / O signal, and the I / O signal controls the PLC program action of the external device; the external device includes a bag measuring machine, the switch quantity control signal controls the PLC program of the bag measuring machine regarding the vacuum suction nozzle of the insertion part, if the switch quantity control signal is at a high level, the switch quantity control signal controls the PLC program of the vacuum suction nozzle of the insertion part to continue to act; if the switch quantity control signal is at a low level, the switch quantity control signal controls the PLC program of the vacuum suction nozzle of the insertion part to stop acting.

[0016] Further, the two sensor probes are arranged oppositely, the metal object to be measured is placed between the two sensor probes, and the metal object to be measured reciprocates between the two sensor probes under the drive of the driving member; each of the sensor probes is a field source of the electromagnetic field generated by it, the metal object to be measured is placed within the coverage area of the electromagnetic field. When the metal object to be measured approaches the sensor probe from far to near, the magnetic field intensity of the electromagnetic field decreases from large to small, and the attenuation degree of the magnetic field intensity of the electromagnetic field also increases from small to large. The data processor calculates the distance value between the metal object to be measured and the sensor probe according to the functional relationship between the distance between the metal object to be measured and the sensor probe and the magnetic field intensity of the electromagnetic field, and displays the distance value on the display interface of the external system. The distance value is displayed on the display interface as a continuous displacement change curve, and the continuous displacement change curve characterizes the real-time distance between the metal object to be measured and the sensor probe; the data processing module sets the reference signal according to the continuous displacement change curve.

[0017] Further, an external system is also included. The communication module transmits the digital signal processed by the data processing module to the external system. The communication module has a receiving port and a sending port. The receiving port receives the digital signal, and the sending port transmits the digital signal to the external system. The external system includes a host computer system. The host computer system has a central processing unit. After receiving the digital signal, the central processing unit conducts data sorting and analysis on it. After obtaining the analysis result, it adjusts the program commands of the host computer system according to the analysis result, so that the lower computer controlled by the program of the host computer system makes an action adjustment.

[0018] Further, the host computer system sends a signal instruction to the data processing module through the communication module. The data processing module receives the signal instruction and transmits the signal instruction to the signal processing sub-module. The signal processing sub-module balances and gains the voltage signal received from the sensor probe according to the signal instruction.

[0019] On the other hand, the present invention also provides a monitoring method for a monitoring system with a novel combined digital sensor, which includes:

[0020] Two sensor probes are arranged oppositely at the insertion part of the bag measuring machine, and a metal object to be measured is arranged between the two sensor probes.

[0021] The sensor probe is powered on, and the coil in the sensor probe generates an electromagnetic field under the action of the electric current. The sensor probe forms a field source.

[0022] When the metal object to be measured moves between the two sensor probes, the magnetic field intensity of the electromagnetic field generated by one sensor probe close to the metal object to be measured attenuates, and the voltage signal value representing the magnetic field intensity of the electromagnetic field emitted by this sensor probe decreases;

[0023] A signal processing sub-module of the digital displacement device receives the voltage signal, performs signal conditioning on the voltage signal, and outputs an analog displacement signal representing the distance between the metal detection object and this sensor probe;

[0024] The analog displacement signal is converted into a digital signal by the data processing module of the digital displacement device and stored;

[0025] An output control sub-module of the digital displacement device receives the digital signal, compares the digital signal with a reference signal stored in the data processing module numerically, and then outputs a digital control signal according to the comparison result.

[0026] The digital control signal controls the PLC program action of the vacuum suction nozzle of the bag measuring machine regarding the insertion part.

[0027] The above technical solution further includes: the sensor probe converts the magnetic signal into a voltage signal, and the voltage signal is subjected to signal conditioning through the oscillation circuit, detection circuit, balance circuit, and variable gain amplifier circuit of the signal processing sub-module. The voltage signal is converted into a displacement signal, and the displacement signal is converted into a digital signal by a high-speed AD converter of the data processing module. This digital signal is subjected to signal processing in the data processor of the data processing module, including interference signal removal processing. The processed digital signal is stored in real time in the data storage of the data processing module, and the data in the data storage is updated in real time.

[0028] The above technical solution further includes: the output control sub-module compares the digital signal received from the data processing module with the reference signal stored in the data processing module numerically, and outputs the digital control signal according to the comparison result. The digital control signal is an I / O signal. If the digital control signal is at a high level, the digital control signal controls the PLC program of the vacuum suction nozzle of the bag measuring machine regarding the insertion part to continue to act. If the digital control signal is at a low level, the digital control signal controls the PLC program of the vacuum suction nozzle of the bag measuring machine regarding the insertion part to stop acting.

[0029] Compared with the prior art, the present invention has one or more of the following beneficial effects:

[0030] 1. The monitoring system with a new type of combined digital sensor according to the present invention can not only convert the analog quantity obtained by traditional technologies into directly readable digital quantities, but also complete multi-point monitoring through multiple sensor probes. The data obtained from multi-point monitoring are respectively transmitted to a data processing module for analysis and processing, and then compared and output, so as to complete multi-point control. If the monitoring system with the new type of combined digital sensor according to the present invention is applied to a packet measuring machine, two sensor probes can be oppositely arranged at the insertion part of the packet measuring machine without changing the original installation mechanism, realizing a detection range of 1.2 mm, and various abnormalities during the operation of the insertion part of the equipment can be diagnosed in real time through the mutual cooperation of the two sensor probes, improving the product quality.

[0031] 2. The host computer system according to the present invention sends a signal instruction to the data processing module through the communication module. The data processing module receives the signal instruction and sends the signal instruction to the signal processing sub-module. The signal processing sub-module balances and gains the voltage signal received from the sensor probe according to the signal instruction. Therefore, by using the monitoring system according to the present invention, the working state of the sensor can be adaptively adjusted. The sensor will self-balance and adjust the balance and gain of the circuit according to the instructions of the host computer in a specific state of the equipment, so that its own working state is optimal. Therefore, the balance circuit and variable gain amplifier circuit in the present invention can eliminate the external factors of obstacles of electronic components, ensure the monitoring accuracy, balance the monitoring system, so that the whole monitoring system has an adaptive function and will not reduce the monitoring accuracy due to problems such as sensor aging or component aging, and the overall monitoring performance of the monitoring system is more stable.

[0032] 3. The monitoring system with the new type of combined digital sensor according to the present invention can obtain directly readable digital quantities. The read values can be stored and statistically analyzed, and then used for analysis and comparison after sorting. If this monitoring method is applied to high-precision equipment, precise monitoring of micro distances can be realized, the monitored data can be collected, and then sorted, statistically analyzed, and the obtained analysis results can guide technicians to predict and timely improve equipment failures or product defects, making the improvement measures based on data and more reliable and accurate. This is a great innovation in the production process, which can reduce the error rate, save production costs and improve efficiency.

[0033] 4. The present invention detects the distance between the metal sheet and the field source based on the principle that the metal sheet can interfere with the magnetic field intensity of the electromagnetic field. Then, the attenuation relationship between this distance and the magnetic field intensity is displayed as a waveform by an oscillating circuit. This waveform represents the real-time distance between the metal sheet and the field source. Then, the waveform is conditioned into an analog signal through signal conditioning. This analog signal has two application methods: ① Connect the analog signal to a comparator, and after comparison and adjustment by the comparator, it is converted into a switch quantity control signal. This switch quantity control signal can be received by an external device and adjust the operating state of the external device; ② Connect the analog signal to a digital displacement device. The digital displacement device converts the voltage signal sent by the sensor probe into a displacement signal. Compared with the traditional sensor detection method, the monitoring system of the present invention can convert the detected distance status quantity into a numerical value, which can be directly read. The directly read numerical signal can also be connected to the upper computer system through a data transmission module. One upper computer system can receive the numerical signals sent by multiple different data transmission modules. In this way, one can control multiple devices. By using one upper computer system to detect multiple monitoring modules, compared with one-on-one single manual control, the detection system of the present invention is faster, more accurate, saves management costs, reduces human intervention, and scientifically reduces production errors caused by human factors.

[0034] 5. The digital displacement device of the present invention can directly quantify the detected physical quantity to be measured into a numerical value, which can be used for later data analysis. Compared with the traditional sensor that can only read a status value, and this status value needs to be assisted by means such as an oscilloscope to display a waveform, and this waveform only shows an approximate state and cannot be accurately read. By comparing the two, the advantages of the present invention can be found. Digitalizing the physical quantity to be measured increases its readability. Later, this number can be used for statistics and analysis, and the machine parameters, status, programs, etc. can also be adjusted based on the analysis results.

[0035] 6. The present invention digitalizes the physical quantity to be measured by the sensor. These numbers can be transmitted through a communication module, such as using the 485 communication protocol to transmit data. After the data is transmitted to the upper computer system, centralized control and monitoring can be carried out. After the data is stored, it can also be sorted and analyzed. For example, according to the fault or defect situation, the relevant data can be found accordingly, compared with the time period with a high yield rate of good products, and the cause of the fault or defect can be analyzed, and then the equipment can be adjusted and improved, so as to improve the reliability of equipment operation and the yield rate of product production, save costs, and improve production efficiency.

[0036] 7. The sensor probe of the present invention detects the measured physical quantity and emits a voltage signal, and transmits the voltage signal to the digital displacement device. The digital displacement device performs signal conditioning on the electrical signal to obtain a displacement signal. This displacement signal is converted into a digital signal by a high-speed AD converter. In this way, a data signal is collected, which realizes the real-time monitoring and recording of the electrical signal representing the measured physical quantity and its conversion into a data signal, achieving the purpose of high-speed and accurate signal monitoring.

[0037] 8. The detection system with a digital sensor of the present invention is applicable to high-speed measurement of small distances and distance monitoring of some high-precision devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0039] Figure 1 It is a system block diagram of the working principle of the monitoring system of the present invention;

[0040] Figure 2 It is a schematic diagram of the transmission characteristics obtained by detecting the effective detection distance of a single sensor in an embodiment;

[0041] Figure 3 It is a schematic enlarged side view of a partial structure of the insertion part of the bag measuring machine in an embodiment of the present invention, where only the relevant partial structure of the insertion part is schematically shown;

[0042] Figure 4 It is a waveform schematic diagram of monitoring the movement trajectory of the vacuum suction nozzle of the insertion part of the bag measuring machine by using the monitoring system of the present invention in an embodiment;

[0043] Figure 5 It is a waveform schematic diagram of monitoring the movement trajectory of the vacuum suction nozzle of the insertion part of the bag measuring machine by using the monitoring system of the present invention in another embodiment.

[0044] Wherein: 10 - Sensor probe A, 11 - Sensor probe B;

[0045] 20 - Digital displacement device,

[0046] 210 - Signal processing sub-module (signal-connected to sensor probe A), 211 - Signal processing sub-module (signal-connected to sensor probe B),

[0047] 220 - Data processing module, 221 - High - speed AD converter (signal - connected to sensor probe A), 222 - High - speed AD converter (signal - connected to sensor probe B), 223 - Data processor, 224 - Data storage

[0048] 230 - Output control sub - module (signal - connected to sensor probe A), 231 - Output control sub - module (signal - connected to sensor probe B);

[0049] 240 - Communication module,

[0050] 30 - Host computer system,

[0051] 40 - External device;

[0052] 100 - Electromagnet, 110 - Electromagnet shaft, 120 - First baffle, 130 - Second baffle, 140 - Elastic sheet, 150 - Buffer pad, 160 - Coupling, 170 - Vacuum suction nozzle, 180 - Spring. Detailed implementation mode

[0053] Next, the technical solutions of the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0054] Next, the gist of the present invention will be further described in conjunction with the drawings and embodiments.

[0055] Embodiment 1:

[0056] Due to space limitations, the insertion parts of conventional packet - measuring machines can only use sensors with an effective detection range of 0.6 mm. In order to expand the effective detection range, generally two sensors are used for detection in the prior art, and the two sensors operate independently. Although the detection range is effectively expanded, it is impossible to realize real - time detection of the moving distance of this part and abnormal diagnosis, which is not conducive to long - term production and processing, affects the processing yield, and the analog quantities measured by the existing sensors cannot be further used for data analysis, which is not conducive to later data statistics and error analysis.

[0057] To solve the above problems, the present invention proposes a monitoring system with a new combined digital sensor. See Figures 1-5The monitoring system will be described below. The monitoring system includes at least two sensor probes, a metal object to be measured, and a digital displacement device 20 for receiving and processing signals. Applying the monitoring system of the present invention to the insertion part of a packet measuring machine means relatively arranging two sensor probes at the monitoring positions of the insertion part. Each sensor probe is respectively connected to the digital displacement device 20. The voltage signals monitored by the sensors are digitally processed by a data processing module 220 in the digital displacement device 20. The data processing module 220 simultaneously collects dual-channel data, and then calculates the travel distance and determines the magnitude and duration of the jitter of the vacuum suction nozzle 170 in the insertion part of the packet measuring machine.

[0058] See Figure 1 , each sensor probe of the present invention may include a coil, and an electromagnetic field is formed after the coil is energized; the distance between the metal object to be measured and the sensor probe has a functional relationship with the magnetic field strength of the electromagnetic field; the digital displacement device 20 includes a signal processing module, a data processing module 220, an output control module, and a communication module 240. The signal processing module includes at least two signal processing sub-modules 210, 211. Each signal processing sub-module is electrically connected to one of the sensor probes. The output control module includes at least two output control sub-modules 230, 231. Each output control sub-module is electrically connected to the data processing module 220. The signal processing sub-module 210 receives the voltage signal representing the magnetic field strength of the electromagnetic field sent by the sensor probe A electrically connected to it, and processes the voltage signal into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module 220. The digital signal is stored by the data processing module 220 and received by one of the output control sub-modules 230 and compared with a reference signal. The output control sub-module 230 issues a switching quantity control signal according to the comparison result, and the switching quantity control signal controls the action of the PLC program of the external device 40.

[0059] As a preferred embodiment, an external system (an external system can be connected to multiple monitoring devices) can be added to the monitoring system of the present invention. It is signal-connected to the communication module 240, and after receiving the digital signal transmitted by the communication module 240, it sorts out and analyzes the digital signal to obtain an analysis result, and then adjusts the program according to the analysis result. See Figure 1 .

[0060] As a preferred embodiment, an external device 40 may also be added on the basis of the above technical solution. The external device 40 is signal-connected to each of the output control sub-modules 230 / 231. After receiving the digital control signal sent by the output control sub-module 230 / 231, the external device 40 adjusts its own operating state according to the digital control signal. That is, it is an extended application of the monitoring system of the present invention in cooperation with the external device 40, and the monitoring system is used to monitor the actions of the external device 40 in real time.

[0061] In one embodiment, the digital control signal may be an I / O signal, and the I / O signal controls the PLC program action of the external device 40. If the digital control signal is at a high level, the digital control signal controls the PLC program of the external device 40 to continue to act; if the digital control signal is at a low level, the digital control signal controls the PLC program of the external device 40 to stop acting. At this time, it indicates that there is a mistake in the action of the external device 40 and needs to be corrected. After the action mistake is processed, the digital control signal becomes high level, and the PLC program of the external device 40 continues to act. Furthermore, if the actions of the external device 40 frequently make mistakes, it proves that the external device 40 needs to be repaired.

[0062] In one embodiment, the above external device 40 may be a high-precision bag measuring machine. This embodiment mainly takes the bag measuring machine that packs components into the storage slots in the carrier tape as an example for introduction. Obviously, in some embodiments, since other component processing devices adopt the same monitoring and management scheme, according to the teachings in this article, those of ordinary skill in the art can also apply the monitoring and management scheme described in detail in this article to other types of devices.

[0063] Figure 3 It is a schematic enlarged side view of a partial structure of the insertion part of the bag measuring machine described in the embodiment of the present invention, in which only the relevant partial structure of the insertion part is schematically shown.

[0064] See Figure 3, the insertion part of the packet measuring machine includes a vacuum suction nozzle 170 and an electromagnet 100 that is coaxially linked with the vacuum suction nozzle 170. The electromagnet 100 is installed on a first baffle 120. The electromagnet shaft 110 of the electromagnet 100 passes through the first baffle 120 and then through a second baffle 130 that is oppositely arranged with the first baffle 120. One end of the electromagnet shaft 110 close to the second baffle 130 is connected to one end of the suction nozzle through a coupling 160. A spring 180 is also arranged between the coupling 160 and the second baffle 130. A metal elastic sheet 140 is also arranged on the electromagnet shaft 110. One end of the metal elastic sheet 140 is close to the electromagnet, and a buffer pad 150 is respectively arranged on both sides of the metal elastic sheet 140. A sensor probe is respectively arranged on the first baffle 120 and the second baffle 130. The two sensor probes (sensor probe A and sensor probe B) are oppositely arranged. The metal elastic sheet 140 connected to the electromagnet shaft 110 moves between the two sensor probes. When the electromagnet receives an action signal, the electromagnet drives the vacuum suction nozzle 170 to move upward ( Figure 3 is taken as an example for illustration. Here, "upward" or "downward" is the principle expression of the direction with reference to the illustration, and it cannot be understood as a limitation on the movement direction). At this time, the spring 180 is compressed between the coupling 160 and the second baffle 130. The upward movement of the electromagnet makes the metal elastic sheet 140 closer to the sensor probe on the first baffle 120. At this time, the magnetic field intensity of the electromagnetic field within the detection range of the sensor probe A on the first baffle 120 decays. The sensor probe A on the first baffle 120 sends a voltage signal representing the magnetic field intensity of the electromagnetic field to the signal processing sub-module 210 in the digital displacement device 20. The signal processing sub-module 210 receives this voltage signal and processes it into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module 220. The digital signal is stored by the data processing module 220 and is received by an output control sub-module 230 and compared with a reference signal. The output control sub-module 230 issues a switching quantity control signal according to the comparison result. The switching quantity control signal controls the PLC program action of the packet measuring machine regarding the vacuum suction nozzle 170 of the insertion part.

[0065] When the electromagnet receives another action signal, the electromagnet drives the vacuum suction nozzle 170 to move downward. At this time, the spring 180 is placed between the coupling 160 and the second baffle 130 and is released from the compressed state. The downward movement of the electromagnet makes the metal shrapnel 140 closer to the sensor probe on the second baffle 130. At this time, the magnetic field intensity of the electromagnetic field within the detection range of the sensor probe B on the second baffle 130 attenuates. The sensor probe B on the second baffle 130 sends a voltage signal representing the magnetic field intensity of the electromagnetic field to the signal processing sub-module (B) 211 within the digital displacement device 20. A signal processing sub-module 210 connected to the sensor probe B receives this voltage signal and processes it into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module 220. The digital signal is stored by the data processing module 220 and is received by another output control sub-module 231 and compared with a reference signal. The output control sub-module 231 issues a switching control signal according to the comparison result. The switching control signal controls the PLC program action of the vacuum suction nozzle 170 of the insertion part of the packet measuring machine.

[0066] It is worth mentioning that when the vacuum suction nozzle 170 of the insertion part is moving reciprocally at high speed, it will vibrate slightly invisibly to the naked eye when reaching the upper and lower suction end faces due to inertia or hitting edge debris. In high-precision suction actions, these slight vibrations will cause problems such as improper implantation during the process of implanting components into the component packaging carrier tape in the packet measuring machine, and improper implantation will cause the components to collide with the baffle when moving forward with the packaging carrier tape, and then scrape the components and cause defects. To solve the above problems, the monitoring system of the present invention is applied to the vacuum suction nozzle 170 of the insertion part to monitor the motion state of the vacuum suction nozzle 170 of the insertion part, and based on the monitoring results, analyze whether the micro-vibration amount and vibration time of the vacuum suction nozzle 170 of the insertion part exceed the range, so as to avoid or reduce the occurrence of defective products.

[0067] At present, due to space limitations, the insertion parts of conventional packet measuring machines can only use sensors with an effective detection range of 0.6 mm. Such a small detection range cannot achieve real-time detection of the moving distance of this part and abnormal diagnosis, which is not conducive to long-term production and processing and affects the processing yield. The novel combined digital sensor of the present invention can achieve a detection range of 1.2 mm without changing the original installation mechanism, and has real-time intelligent operation and communication functions, and can perform real-time diagnosis on various abnormalities during the operation of the equipment insertion part.

[0068] In order to verify that applying the monitoring system with the novel combined digital sensor of the present invention to the insertion part of the packet measuring machine can achieve a detection range of 1.2 mm, the present invention is tested by the following method:

[0069] Using the same micrometer, taking the average of 100 AD values at the same distance in units of 0.005 mm, for the monitoring circuit channels of sensor probe A and a signal processing sub-module 210, and for the monitoring circuit channels of sensor probe B and another signal processing sub-module 211, 200 distances are sampled respectively, and a graph is plotted as shown in Figure 2 , according to Figure 2 It can be found that when the distance reaches about 0.6 mm, the change amount per grid is less than the jitter of the level itself. Therefore, it is judged that the effective detection distance of a single channel is about 0.6 mm. Therefore, two monitoring channels are connected to the insertion part of the bag measuring machine (as described above, the two monitoring channels are respectively: the monitoring circuit channel of sensor probe A and a signal processing sub-module 210, and the monitoring circuit channel of sensor probe B and another signal processing sub-module 211. Of course, referring to Figure 1 , each of the two monitoring channels is also connected with its own output control sub-module), and the effective measurement of the nozzle stroke of 1.2 mm can be carried out.

[0070] In one embodiment, continue to refer to Figure 3 , sensor probe A is installed on the first baffle 120, and sensor probe B is installed on the second baffle 130. The sensor probe A is used to monitor the distance of the vacuum nozzle 170 in the insertion part moving upward from the upper reset surface, and the sensor probe B is used to monitor the distance of the vacuum nozzle 170 in the insertion part moving downward from the lower feeding surface. When the vacuum nozzle 170 in the insertion part stays on the upper reset surface or the lower feeding surface and has a slight vibration, corresponding to Figure 1 As shown in the principle block diagram, that is, the movement of the metal object to be measured or the metal sheet in the electromagnetic field causes interference to the magnetic field intensity of the electromagnetic field. The voltage signal originally at the amplitude starts to decay, and since the metal sheet has a slight vibration for a period of time, then similarly, the voltage signal also has a slight fluctuation that goes up and down.

[0071] The sensor probe A and the sensor probe B form the field source of the electromagnetic field. The metal sheet is placed in the coverage area of the electromagnetic field. When the metal sheet approaches the sensor probe A or the sensor probe B from far to near, the magnetic field intensity of the electromagnetic field changes from large to small, and the attenuation degree of the magnetic field intensity of the electromagnetic field also changes from small to large. The distance between the metal object to be measured and the sensor probe is in a functional relationship with the magnetic field intensity of the electromagnetic field. Specifically, the distance between the metal object to be measured and the sensor probe is in a relationship similar to a linear function with the magnetic field intensity of the electromagnetic field.

[0072] The metal shrapnel 140 linked to the electromagnet 100 has a determined maximum stroke distance due to the installation positions of the spring 180, the first baffle 120, and the second baffle 130, as well as the cushions 150 on both sides of the shrapnel 140. Therefore, according to the electrical levels output by the sensor probe A and the sensor probe B, and in conjunction with the functional relationship between the distance between the metal object to be measured and the sensor probe and the magnetic field strength of the electromagnetic field, the displacement value detected by the sensor can be conveniently calculated, and this calculation process can be achieved through simple computer software. Therefore, compared with the traditional displacement sensor that can only show the distance range, the monitoring system with a digital sensor described in the present invention can directly display the displacement in numbers, and such directly readable values are more convenient for statistical analysis, and the quantified distance can provide data support for equipment debugging.

[0073] For example, if the sensor probe B detects a slight tremor generated when the insertion part vacuum suction nozzle 170 moves downward for feeding, then in the continuous displacement change curve representing the real-time distance between the insertion part vacuum suction nozzle 170 and the sensor probe B displayed on the display screen of the external system (i.e., the host computer system 30) described in the present invention, there will be a wavy line with a gradually decreasing vibration amplitude and finally tending to be stable, and this wavy line represents the tremor displacement change of a slight tremor generated when the insertion part vacuum suction nozzle 170 moves downward for feeding, as can be seen in Figure 4 、 5 , Figure 4 、 5 There is a small jitter curve in the waveform shown in, and the tremor displacement change of a slight tremor generated when the insertion part vacuum suction nozzle 170 moves downward for feeding is also the same as Figure 4 、 5 The waveform curve in. This shows that the monitoring system described in the present invention can perform high-speed and high-precision measurement on small distances. And this monitored wavy line can be used for analysis and detection. If the fluctuation range of this wavy line is within the reasonable fluctuation range of the insertion part vacuum suction nozzle 170 for feeding, it means that the equipment is operating normally, while if the fluctuation range of this wavy line is not within or partially exceeds the reasonable fluctuation range of the insertion part vacuum suction nozzle 170 for feeding, it means that the equipment is abnormal and needs to be repaired. Such data guidance can avoid mistakes in the production process predictably and reduce waste of parts (raw materials) and production processing waste.

[0074] A slight tremor generated when the insertion part vacuum suction nozzle 170 moves downward for feeding will cause fluctuations in the voltage signal emitted by the sensor probe, and this voltage signal is signal-conditioned by the digital displacement device 20 to obtain a displacement signal.

[0075] In one embodiment, each of the signal processing submodules is signal-connected to one of the output control submodules, and each of the signal processing submodules 210 / 211 is signal-connected to the data processing module 220. One of the signal processing submodules 210 in the digital displacement device 20 performs signal conditioning on the voltage signal sent by the sensor probe through an oscillation circuit, a detection circuit, a balancing circuit, and a variable gain amplifier circuit, thereby realizing the conversion of the voltage signal into a displacement signal.

[0076] In one embodiment, the displacement signal can be connected to a comparator of an output control submodule 230, and the obtained displacement signal can be numerically compared with a preset reference signal through the comparator, so as to monitor whether the position of the insertion part vacuum suction nozzle 170 that fluctuates up and down due to vibration is within a reasonable position range. If it is detected that it is not within the reasonable position range, the operator can let the insertion part vacuum suction nozzle 170 idle during this period, and the movement of the carrier tape for packaging components is also suspended, so as to avoid the problem that may cause poor implantation.

[0077] Even more, the comparator compares the obtained displacement signal with the preset reference signal to obtain a switch control signal (the switch control signal may be an I / O signal), and the switch control signal may be used to monitor whether the action of the vacuum suction nozzle 170 of the insertion part of the bag measuring machine is in place:

[0078] A sensor probe A is installed on the first baffle 120, and a sensor probe B is installed on the second baffle 130. The sensor probe A is used to detect whether the vacuum suction nozzle 170 of the insertion part of the packet measuring machine is reset upwards. If it is in place, it outputs a high level, otherwise it outputs a low level. The sensor probe B is used to detect whether the vacuum suction nozzle 170 of the insertion part of the packet measuring machine is in place for feeding downwards. If it is in place, it outputs a high level, otherwise it outputs a low level.

[0079] The PLC program of the vacuum suction nozzle 170 in the insertion part of the packet measuring machine controls the movement of the vacuum suction nozzle 170 in the insertion part. If the vacuum suction nozzle 170 in the insertion part moves downward to complete the feeding action, that is, the vacuum suction nozzle 170 in the insertion part moves towards the lower feeding surface, the sensor probe B detects the distance between the vacuum suction nozzle 170 in the insertion part and the lower feeding surface. The digital displacement device 20 digitizes this distance and displays it through the display interface of the external system. After receiving this displacement digit, the comparator compares it with the pre-stored reference digital signal and outputs a switching quantity control signal. If the output switching quantity control signal is high level, it indicates that the downward movement of the vacuum suction nozzle 170 in the insertion part towards the lower feeding surface has reached the position, and the PLC program controls the vacuum suction nozzle 170 in the insertion part to continue moving; if the output switching quantity control signal is low level, it indicates that the downward movement of the vacuum suction nozzle 170 in the insertion part towards the lower feeding surface has not reached the position, and the PLC program controls the vacuum suction nozzle 170 in the insertion part to stop moving. Since the vacuum suction nozzle 170 in the insertion part is moving towards the lower feeding surface at this time (regardless of whether the movement has reached the position), it has exceeded the detection range of the sensor probe A. Therefore, the comparator for detecting the distance signal of the sensor probe A shows a low level because it cannot output a high level. However, it should be noted that when the vacuum suction nozzle 170 in the insertion part moves downward at this time, it is normal for the comparator for detecting the distance signal of the sensor probe A to output a low level.

[0080] Similarly, when the vacuum suction nozzle 170 in the insertion part of the packet measuring machine moves upward for resetting, the sensor probe A detects the distance between the vacuum suction nozzle 170 in the insertion part and the upper reset surface. The digital displacement device 20 digitizes this distance and displays it through the display interface of the external system. After receiving this displacement digit, the comparator compares it with the pre-stored reference digital signal and outputs a switching quantity control signal. If the output switching quantity control signal is high level, it indicates that the upward movement of the vacuum suction nozzle 170 in the insertion part towards the upper reset surface has reached the position, and the PLC program controls the vacuum suction nozzle 170 in the insertion part to continue moving; if the output switching quantity control signal is low level, it indicates that the upward movement of the vacuum suction nozzle 170 in the insertion part towards the upper reset surface has not reached the position, and the PLC program controls the vacuum suction nozzle 170 in the insertion part to stop moving. Since the vacuum suction nozzle 170 in the insertion part is moving towards the upper reset surface at this time (regardless of whether the movement has reached the position), it has exceeded the detection range of the sensor probe B. Therefore, the comparator for detecting the distance signal of the sensor probe B shows a low level because it cannot output a high level. However, it should be noted that when the vacuum suction nozzle 170 in the insertion part moves upward at this time, it is normal for the comparator for detecting the distance signal of the sensor probe B to output a low level.

[0081] The present invention detects whether the vacuum nozzle 170 of the insertion part has completed its operation and whether intervention and adjustment are required through a digital control signal. If the operation of the vacuum nozzle 170 of the insertion part is not in place, the digital control signal acts on the PLC program to control the vacuum nozzle 170 of the insertion part to stop operating. At this time, it indicates that there is an error in the operation of the vacuum nozzle 170 of the insertion part of the packet measuring machine and correction is required. After the error handling of the operation, the PLC program controls the vacuum nozzle 170 of the insertion part to continue operating, and the digital control signal continuously monitors whether the operation of the nozzle is in place. If the operation of the vacuum nozzle 170 of the insertion part frequently fails, it proves that the packet measuring machine needs to be repaired.

[0082] In one embodiment, to implement the comparison and output function of the output control sub-module 230, the output control sub-module 230 is provided with a comparator. The comparator numerically compares the digital signal sent by the data processing module 220 with the reference signal, and outputs a digital control signal according to the comparison result. After receiving the digital control signal sent by the output control sub-module 230, the external device 40 adjusts its own operating state according to the digital control signal.

[0083] When the packet measuring machine receives the digital control signal, it adjusts the operation of the vacuum nozzle 170 of the insertion part according to the digital control signal. The operation adjustment made can affect the efficiency and production yield of the production process, thereby reducing production costs.

[0084] In one embodiment, the host computer system 30 of the present invention sends a signal command to the data processing module 220 through the communication module 240. The data processing module 220 receives the signal command and sends the signal command to the signal processing sub-module 210. The signal processing sub-module 210 balances and gains the voltage signal received from the sensor probe according to the signal command. Therefore, by using the monitoring system of the present invention, the working state of the sensor can be adaptively adjusted. The sensor will self-balance and adjust the balance and gain of the circuit according to the command of the host computer under specific states of the device, so that its own working state is optimal. Therefore, the balance circuit and variable gain amplifier circuit in the present invention can eliminate the external obstacles of electronic components, ensure the monitoring accuracy, balance the monitoring system, make the entire monitoring system have an adaptive function, and will not reduce the monitoring accuracy due to problems such as sensor aging or component aging. The overall monitoring performance of the monitoring system is more stable.

[0085] In one embodiment, the balance and gain of the present invention are adjusted and realized by an operational amplifier circuit composed of an operational amplifier and peripheral circuits. The data processing module 220 (MCU) sends commands to a digital potentiometer (not shown, which is a component in the circuit of the monitoring system of the present invention). By changing the resistance value of the digital potentiometer, the waveform change range of the received probe is changed. At the same time, the data processing module 220 (MCU) will detect this range in real time. The balance and gain (amplification) are functions realized by two independent operational amplifier circuits. The ultimate goal is to adjust the probe waveform finally given to the MCU to the range of 0 - 3V, which is convenient for the MCU to more accurately judge the distance and jitter.

[0086] In one embodiment, the data monitored by the sensor of the present invention can be connected to the host computer system 30 for big data analysis, and the results obtained from the analysis have a role in predicting the trend of the operating condition of the equipment.

[0087] Embodiment 2:

[0088] For the displacement signal obtained by the signal processing sub-module 210 mentioned in the above Embodiment 1, the present invention can also convert the displacement signal into a readable digital signal:

[0089] In one embodiment, the data processing module 220 may have at least two high-speed AD converters 221, 222, a data processor 223, and a data storage 224. Each high-speed AD converter is signal-connected to one of the signal processing sub-modules. The displacement signal obtained by the signal processing sub-module 210 is collected and converted into a digital signal by the high-speed AD converter 221. After the data processor 223 processes the digital signal, the digital signal is stored in the data storage 224, and the digital signal is stored and updated in real time in the data storage 224;

[0090] The data processing module 220 also stores the reference signal, and the reference signal serves as a comparison reference for digital signal comparison by each output control sub-module (reference numerals 230 or 231).

[0091] The data processor 223 processes the digital signal. Specifically, it can include removing interference signals, removing unreasonable or abnormal signals, and can also calculate the specific actual distance value corresponding to the displacement signal according to the functional relationship between the distance between the metal object to be measured and the sensor probe and the magnetic field intensity of the electromagnetic field. The actual distance value is directly shown on the display interface of the external system, saving the trouble of conversion.

[0092] In this step of the present invention, the conversion from the displacement signal to a readable digital signal is achieved. The displacement signal is converted into a digital signal through a high-speed A / D converter, and then the readable numerical conversion is performed by the data processor 223. In this way, the digital signal can be collected, which realizes that the electrical signal representing the physical quantity to be measured is monitored and recorded in real time and converted into a digital signal, achieving the purpose of monitoring the signal quickly and accurately.

[0093] Embodiment 3:

[0094] After the analog-to-digital signal conversion is achieved in the above Embodiment 2, the obtained digital signal can also be transmitted through the communication module 240 (RS-485 communication bus). The RS-485 communication bus has a receiving port and a sending port. The receiving port receives the displacement digital signal, and the sending port transmits the displacement digital signal to the external system.

[0095] In one embodiment, the external system can be the upper computer system 30. The communication module 240 transmits the digital signal processed by the data processing module 220 to the upper computer system 30. The data processor 223 calculates the distance value between the metal object to be measured and the sensor probe according to the functional relationship between the distance between the metal object to be measured and the sensor probe and the magnetic field intensity of the electromagnetic field, and displays the distance value on the display interface of the upper computer system 30. The distance value is displayed as a continuous displacement change curve on the display interface, and the continuous displacement change curve represents the real-time distance between the metal object to be measured and the sensor probe; the data processing module 220 sets the reference signal according to the continuous displacement change curve.

[0096] In one embodiment, the upper computer system 30 has a central processor. After receiving the displacement digital signal, the central processor performs data sorting and analysis on it. After obtaining the analysis result, the program command of the upper computer system 30 is adjusted according to the analysis result, so that the lower computer controlled by the program of the upper computer system 30 makes an action adjustment.

[0097] The digital sensor of the present invention directly quantifies the physical quantity to be measured into a numerical value, which can be used for later data analysis. Compared with traditional sensors that can only read a status value, and this status value needs to be assisted by means such as an oscilloscope to display a waveform, and this waveform only shows an approximate state and cannot be accurately read. In this way, the advantages of the present invention can be found by comparing the two. Digitalizing the physical quantity to be measured increases its readability. This number can be used for statistics and analysis later, and the machine parameters, status, programs, etc. can also be adjusted based on the analysis result.

[0098] Compared with the traditional sensor detection method, the monitoring system described in the present invention converts the detected distance status quantity into a numerical value, which can be directly read. The directly read numerical signal can also be connected to the host computer system through the data transmission module. One host computer system can receive the numerical signals sent by multiple different data transmission modules. In this way, one can control multiple devices. By using one host computer system to detect multiple monitoring modules, compared with the one-to-one single-device manual control, the detection system described in the present invention is faster, more accurate, saves management costs, reduces human intervention, and scientifically reduces production errors caused by human factors.

[0099] Embodiment 4:

[0100] The present invention also provides a monitoring method for a monitoring system with a new type of combined digital sensor, which includes the following steps:

[0101] Relatively arrange two sensor probes (sensor probe A and sensor probe B) at the insertion part of the bag measuring machine, and arrange a metal elastic sheet 140 between the two sensor probes.

[0102] Connect the sensor probes to electricity. The coils in the sensor probes generate electromagnetic fields under the action of electricity, and the sensor probes form field sources.

[0103] When the metal object to be measured moves between the two sensor probes, the magnetic field intensity of the electromagnetic field generated by one sensor probe A close to the metal object to be measured attenuates, and the voltage signal value representing the magnetic field intensity of the electromagnetic field emitted by the sensor probe A decreases.

[0104] A signal processing sub-module 210 of the digital displacement device 20 receives the voltage signal, performs signal conditioning on the voltage signal, and outputs an analog displacement signal representing the distance between the metal detection object and the sensor probe.

[0105] The analog displacement signal is converted into a digital signal by the data processing module 220 of the digital displacement device 20 and stored.

[0106] An output control sub-module 230 of the digital displacement device 20 receives the digital signal, compares the digital signal with the reference signal stored in the data processing module 220 numerically, and then outputs a switching quantity control signal according to the comparison result.

[0107] The switching quantity control signal controls the PLC program action of the vacuum suction nozzle 170 of the bag measuring machine regarding the insertion part.

[0108] The digital quantity control signal can be an I / O signal, which can be used to monitor whether the operation of the vacuum suction nozzle 170 of the insertion part is in place: a sensor probe A is installed on the first baffle 120, and a sensor probe B is installed on the second baffle 130. The sensor probe A is used to detect whether the vacuum suction nozzle 170 of the insertion part is in place when it resets upward. When it is in place, it outputs a high level, and when it is not in place, it outputs a low level; the sensor probe B is used to detect whether the vacuum suction nozzle 170 of the insertion part is in place when it feeds downward. When it is in place, it outputs a high level, and when it is not in place, it outputs a low level.

[0109] The PLC program of the packet measuring machine controls the operation of the vacuum suction nozzle 170 of the insertion part regarding the vacuum suction nozzle 170 of the insertion part. If the vacuum suction nozzle 170 of the insertion part moves downward to complete the feeding operation, that is, the vacuum suction nozzle 170 of the insertion part moves downward to the feeding surface, the sensor probe B detects the distance between the vacuum suction nozzle 170 of the insertion part and the lower feeding surface. The digital displacement device 20 digitizes this distance and displays it through the display interface of the external system. After receiving this displacement number, the comparator compares it with the pre-stored reference digital signal and outputs a digital quantity control signal. If the output digital quantity control signal is a high level, it indicates that the downward movement of the vacuum suction nozzle 170 of the insertion part to the feeding surface is in place, and the PLC program controls the vacuum suction nozzle 170 of the insertion part to continue to operate; if the output digital quantity control signal is a low level, it indicates that the downward movement of the vacuum suction nozzle 170 of the insertion part to the feeding surface is not in place, and the PLC program controls the vacuum suction nozzle 170 of the insertion part to stop operating. Since at this time the vacuum suction nozzle 170 of the insertion part is moving downward to the feeding surface (regardless of whether the movement is in place), it has exceeded the detection range of the sensor probe A. Therefore, the comparator that detects the distance signal of the sensor probe A cannot output a high level and displays a low level. However, it should be noted that at this time, when the vacuum suction nozzle 170 of the insertion part moves downward, it is normal for the comparator that detects the distance signal of the sensor probe A to output a low level.

[0110] Similarly, when the vacuum suction nozzle 170 of the insertion part resets upward, the sensor probe A detects the distance between the vacuum suction nozzle 170 of the insertion part and the upper reset surface. The digital displacement device 20 digitizes this distance and displays it through the display interface of the external system. After receiving this displacement digit, the comparator compares it with the pre-stored reference digital signal and outputs a switching control signal. If the output switching control signal is high level, it indicates that the vacuum suction nozzle 170 of the insertion part has reached the upper reset surface, and the PLC program controls the vacuum suction nozzle 170 of the insertion part to continue to act. If the output switching control signal is low level, it indicates that the vacuum suction nozzle 170 of the insertion part has not reached the upper reset surface, and the PLC program controls the vacuum suction nozzle 170 of the insertion part to stop acting. Since the vacuum suction nozzle 170 of the insertion part is moving upward to the upper reset surface (regardless of whether the movement is in place) at this time, it has exceeded the detection range of the sensor probe B. Therefore, the comparator for detecting the distance signal of the sensor probe B cannot output a high level and shows a low level. However, it should be noted that when the vacuum suction nozzle 170 of the insertion part moves upward at this time, it is normal for the comparator for detecting the distance signal of the sensor probe B to output a low level.

[0111] The present invention detects whether the action of the vacuum suction nozzle 170 of the insertion part is in place and whether intervention and adjustment are needed through the switching control signal. If the action of the vacuum suction nozzle 170 of the insertion part is not in place, the switching control signal acts on the PLC program to control the vacuum suction nozzle 170 of the insertion part to stop acting. This indicates that there is a mistake in the action of the vacuum suction nozzle 170 of the insertion part of the bag measuring machine and correction is needed. After the mistake in the action is processed, the PLC program controls the vacuum suction nozzle 170 of the insertion part to continue to act, and the switching control signal continuously monitors whether the action of the suction nozzle is in place. If the action of the vacuum suction nozzle 170 of the insertion part frequently makes mistakes, it proves that the bag measuring machine needs to be repaired.

[0112] In the present invention, the sensor probe converts the magnetic signal into a voltage signal. The voltage signal is subjected to signal conditioning through the oscillation circuit, detection circuit, balance circuit, and variable gain amplifier circuit of a signal processing sub-module 210. The voltage signal is converted into a displacement signal. The displacement signal is converted into a digital signal through a high-speed AD converter 221 of the data processing module 220. This digital signal is processed in the data processor 223 of the data processing module 220, including interference signal removal processing. The processed digital signal is stored in real time in the data storage 224 of the data processing module 220, and the data in the data storage 224 is updated in real time.

[0113] In summary, the monitoring system and monitoring method with digital sensors described in the present invention can convert the analog quantity obtained by traditional technology into a digital quantity. This digital quantity can be read directly, and the numerical value after reading can be stored and counted, and then used for analysis and comparison after sorting. If this monitoring method is applied to high-precision equipment, it can achieve accurate monitoring of small distances, collect the data obtained by monitoring, and then sort and statistically analyze it. The analysis results obtained can guide technical personnel to predict and promptly improve equipment failures or product defects, so that the improvement measures have data basis and are more reliable and accurate. This is a major innovation in the production process, which can reduce the trial and error rate, save production costs, and improve efficiency.

[0114] Furthermore, if the monitoring system and monitoring method with digital sensors described in the present invention are applied to 485 communication protocol for data transmission, a host computer system can be connected to hundreds of 485 communication protocols to achieve centralized control management, reduce human intervention, and scientifically reduce production errors caused by human factors.

[0115] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification.

[0116] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify and vary the above embodiments within the scope of the present invention.

Claims

1. A monitoring system with a combined digital sensor, characterized in that, It includes: At least two sensor probes, each of the sensor probes including a coil which forms an electromagnetic field after being powered on; A metal object to be measured, the distance between which and the sensor probe has a functional relationship with the magnetic field strength of the electromagnetic field; A digital displacement device, which includes a signal processing module, a data processing module, an output control module and a communication module. The signal processing module includes at least two signal processing sub-modules, each of the signal processing sub-modules being electrically connected to one of the sensor probes. The output control module includes at least two output control sub-modules, each of the output control sub-modules being electrically connected to the data processing module; The signal processing sub-module receives a voltage signal representing the magnetic field strength of the electromagnetic field sent by the sensor probe electrically connected to it, and processes the voltage signal into a displacement signal. The displacement signal is received and processed into a digital signal by the data processing module. The digital signal is stored by the data processing module and is received by one of the output control sub-modules and compared with a reference signal. The output control sub-module issues a switching control signal according to the comparison result, and the switching control signal controls the action of the PLC program of an external device; The external device is a bag measuring machine. The insertion part of the bag measuring machine includes a vacuum suction nozzle and an electromagnet coaxially linked with the vacuum suction nozzle. The electromagnet is installed on a first baffle. The electromagnet shaft of the electromagnet passes through the first baffle and then passes through a second baffle arranged opposite to the first baffle. One end of the electromagnet shaft close to the second baffle is connected to one end of the vacuum suction nozzle through a coupling. A spring is also arranged between the coupling and the second baffle. A metal elastic sheet is also arranged on the electromagnet shaft. The metal elastic sheet is close to the electromagnet, and a buffer pad is respectively arranged on both sides of the metal elastic sheet. A sensor probe is respectively arranged on the first baffle and the second baffle, and the two sensor probes are arranged opposite to each other. The metal elastic sheet connected to the electromagnet shaft moves between the two sensor probes; One of the sensor probes is used to detect whether the vacuum suction nozzle of the insertion part of the bag measuring machine is in place when resetting upward. When in place, it outputs a high level, and when not in place, it outputs a low level. The other sensor probe is used to detect whether the vacuum suction nozzle of the insertion part of the bag measuring machine is in place when feeding downward. When in place, it outputs a high level, and when not in place, it outputs a low level.

2. The monitoring system according to claim 1, wherein Each of the signal processing sub-modules is signal-connected to one of the output control sub-modules and is signal-connected to the data processing module; The signal processing sub-module performs signal conditioning on the voltage signal sent by the sensor probe through an oscillation circuit, a detection circuit, a balance circuit, and a variable gain amplification circuit to obtain a displacement signal; The data processing module has a data processor, a data storage, and at least two high-speed AD converters. Each high-speed AD converter is signal-connected to one of the signal processing sub-modules. The displacement signal obtained by the signal processing sub-module is collected by the high-speed AD converter signal-connected to it and converted into a digital signal. After the data processor processes the digital signal, the digital signal is stored in the data storage, and the digital signal is stored and updated in real time in the data storage. The data processing module also stores the reference signal, and the reference signal serves as a comparison reference for each output control sub-module to compare digital signals.

3. The monitoring system according to claim 2, wherein Each output control sub-module is signal-connected to the external device. Each output control sub-module includes a comparator. The comparator numerically compares the digital signal sent by the data processing module with the reference signal and outputs a switching quantity control signal according to the comparison result. After receiving the switching quantity control signal sent by the output control sub-module, the external device adjusts its own operating state according to the switching quantity control signal.

4. The monitoring system according to claim 3, wherein The switching quantity control signal is an I / O signal, and the I / O signal controls the PLC program action of the external device. The external device includes a bag measuring machine. The switching quantity control signal controls the PLC program of the bag measuring machine regarding the vacuum suction nozzle of the insertion part. If the switching quantity control signal is at a high level, the switching quantity control signal controls the PLC program of the insertion part vacuum suction nozzle to continue to act; if the switching quantity control signal is at a low level, the switching quantity control signal controls the PLC program of the insertion part vacuum suction nozzle to stop acting.

5. The monitoring system according to claim 1, wherein The two sensor probes are arranged opposite to each other. The metal object to be measured is placed between the two sensor probes, and the metal object to be measured reciprocates between the two sensor probes under the drive of a driving member. Each sensor probe is a field source of the electromagnetic field it generates. The metal object to be measured is placed within the coverage area of the electromagnetic field. When the metal object to be measured approaches the sensor probe from far to near, the magnetic field intensity of the electromagnetic field changes from large to small, and the attenuation degree of the magnetic field intensity of the electromagnetic field also changes from small to large. The data processor calculates the distance value between the metal object to be measured and the sensor probe according to the functional relationship between the distance between the metal object to be measured and the sensor probe and the magnetic field intensity of the electromagnetic field, and displays the distance value on the display interface of the external system. The distance value is displayed as a continuous displacement change curve on the display interface, and the continuous displacement change curve represents the real-time distance between the metal object to be measured and the sensor probe. The data processing module sets the reference signal according to the continuous displacement change curve.

6. The monitoring system according to claim 1, wherein It further includes an external system, and the communication module transmits the digital signal obtained by the data processing module to the external system. The communication module has a receiving port and a sending port. The receiving port receives the digital signal, and the sending port transmits the digital signal to the external system. The external system includes a host computer system, and the host computer system has a central processing unit. After receiving the digital signal, the central processing unit conducts data sorting and analysis on it. After obtaining the analysis result, it adjusts the program commands of the host computer system according to the analysis result, so that the slave computer controlled by the program of the host computer system makes action adjustments.

7. The monitoring system according to claim 6, characterized in that The host computer system sends a signal instruction to the data processing module through the communication module. The data processing module receives the signal instruction and sends the signal instruction to the signal processing sub-module. The signal processing sub-module balances and gains the voltage signal received from the sensor probe according to the signal instruction.

8. A monitoring method for a monitoring system with a combined digital sensor, characterized in that, It is implemented based on the monitoring system with a combined digital sensor according to any one of claims 1-7, and it includes: Two sensor probes are oppositely arranged at the insertion part of the bag measuring machine, and a metal object to be measured is arranged between the two sensor probes. The sensor probes are powered on, and the coils in the sensor probes generate electromagnetic fields under the action of the electric current, and the sensor probes form field sources. When the metal object to be measured moves between the two sensor probes, the magnetic field intensity of the electromagnetic field generated by one sensor probe close to the metal object to be measured decays, and the voltage signal value representing the magnetic field intensity of the electromagnetic field emitted by this sensor probe decreases. A signal processing sub-module of the digital displacement device receives the voltage signal and conducts signal conditioning on the voltage signal, and outputs an analog displacement signal representing the distance between the metal detection object and this sensor probe. The analog displacement signal is converted into a digital signal by the data processing module of the digital displacement device and stored. An output control sub-module of the digital displacement device receives the digital signal, compares the digital signal with the reference signal stored in the data processing module numerically, and then outputs a switch control signal according to the comparison result. The switch control signal controls the PLC program action of the vacuum suction nozzle of the bag measuring machine regarding the insertion part.

9. The monitoring method of the monitoring system with a combined digital sensor according to claim 8, characterized in that, It further includes: The sensor probe converts the magnetic signal into a voltage signal. The voltage signal is subjected to signal conditioning through the oscillation circuit, detection circuit, balance circuit, and variable gain amplifier circuit of the signal processing sub-module, and the voltage signal is converted into a displacement signal. The displacement signal is converted into a digital signal by a high-speed AD converter of the data processing module. The digital signal is subjected to signal processing in the data processor of the data processing module, including interference signal removal processing. The processed digital signal is stored in real time in the data storage of the data processing module, and the data in the data storage is updated in real time.

10. The monitoring method of the monitoring system with a combined digital sensor according to claim 8, characterized in that, It further includes: The output control sub-module numerically compares the digital signal received from the data processing module with the reference signal stored in the data processing module, and outputs the digital quantity control signal according to the comparison result. The digital quantity control signal is an I / O signal. If the digital quantity control signal is at a high level, the digital quantity control signal controls the PLC program of the vacuum nozzle of the insertion part of the packet measuring machine to continue operating. If the digital quantity control signal is at a low level, the digital quantity control signal controls the PLC program of the vacuum nozzle of the insertion part of the packet measuring machine to stop operating.

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