A position detection system and detection method based on a three-dimensional Hall array

Abstract

The present invention discloses a position detection system and a detection method based on a three-dimensional Hall array, belonging to the field of linear displacement detection. The system includes a reader and a magnetic source component; the reader includes a plurality of PCB boards stacked three-dimensionally and linearly Hall element arrays arranged on the PCB boards; the magnetic source component is provided with several segments, each segment includes a housing and a plurality of cylindrical permanent magnets arranged at intervals in a straight line inside the housing, the placement angle of each permanent magnet is any one of 0°, 45°, 90°, 135°, 180°, 225°, 270°, 315°, and the interval distance of the plurality of permanent magnets is set at an equal distance according to a certain preset value or magnified by its multiple. The present invention arranges the linear Hall elements inside the reader in an array and performs specific coding on the magnetic source component, so that the reader can detect displacement by detecting different magnetic induction intensities, thereby changing the measurement range from a two-dimensional space to a three-dimensional space and expanding the position detection range.

Description

Technical Field

[0001] The present invention relates to the field of linear displacement detection, including various application fields such as mechanical manufacturing, petroleum, transportation, metallurgy, water conservancy and hydropower, universities and colleges, etc., and particularly relates to a position detection system and a detection method based on a three-dimensional Hall array. Background Art

[0002] Linear displacement sensors are widely used in the mechanical manufacturing industry, industrial production industry, transportation applications, etc., and are used to measure product dimensions and mechanical movement displacements... Linear displacement sensors are very widely used in industrial production. For trolleys, traveling cranes, gantry cranes, etc., a reliable linear displacement sensor is required to meet the requirements of safe production and automatic control; when producing infrastructure tracks, linear displacement sensors are applied, which makes it possible to provide high-precision control and automation of the control process for traveling cranes. During the operation of rail trains, linear displacement sensors can accurately locate the stopping points of the trains.

[0003] At present, the following various technologies exist in the field of linear displacement detection:

[0004] (1) Magnetic grating linear displacement sensor

[0005] A magnetic grating sensor is a displacement sensor that measures using the magnetic interaction between a magnetic grating and a magnetic head. It is a new type of digital sensor with low cost and easy installation and use. However, the gap between the magnetic grating and the magnetic head needs to be less than 1 mm;

[0006] (2) Capacitive grating linear displacement sensor

[0007] A capacitive grating sensor is a capacitive digital sensor based on the variable area working principle and can measure large displacements. Compared with other digital displacement sensors, such as gratings and inductosyns, it has the outstanding characteristics of small volume, simple structure, high resolution and accuracy, fast measurement speed, low power consumption, low cost, and low requirements for the use environment. Therefore, it occupies a very important position in electronic measurement technology. However, the gap between the moving grating and the fixed grating needs to be less than 0.5 mm;

[0008] (3) Absolute linear encoder

[0009] An absolute linear encoder consists of two parts: an induction scale and a reader. The induction scale is a multi-segment splicing, with permanent magnets installed inside and a certain coding arrangement. The reader moves parallel to the induction scale, and the installation gap between the reader and the induction scale needs to be controlled between 25 - 55 mm. Summary of the Invention

[0010] In view of one or more of the above-mentioned defects or improvement requirements of the prior art, the present invention provides a position detection system and a detection method based on a three-dimensional Hall array, belonging to an array-type magnetic induction sensor, and realizing linear displacement detection with a high gap by adopting a new technology. The present invention has the characteristics of convenient installation, high stability, high reliability, long service life, delicate structure, strong environmental adaptability, etc.

[0011] To achieve the above object, the present invention is implemented by adopting the following technical solutions:

[0012] A position detection system based on a three-dimensional Hall array includes a reader and a magnetic source component;

[0013] The magnetic source component is of a multi-segment spliced structure and is arranged in parallel with the reader;

[0014] The reader includes multiple layers of PCB boards stacked three-dimensionally and a linear Hall element array arranged on the PCB boards.

[0015] As a preference of the above solution, the PCB board is provided with three layers, and the linear Hall elements on each layer of the PCB board are arranged in a matrix distribution, and the number of arrays is an odd number of rows multiplied by a power of 2 columns.

[0016] As a preference of the above solution, the distance between each layer of linear Hall elements is equal, and the columns of adjacent two layers of Hall elements are staggered by Z millimeters from each other, and Z is a multiple of 6.

[0017] As a preference of the above solution, the reader further includes a housing, which is wrapped outside the PCB board and the linear Hall elements, and a waterproof plug and an outgoing line end are provided on the housing.

[0018] As a preference of the above solution, the magnetic source component is provided with several segments, and each segment includes a housing and a plurality of cylindrical permanent magnets arranged at straight intervals inside the housing.

[0019] As a preference of the above solution, the placement angle of each permanent magnet is any one of 0°, 45°, 90°, 135°, 180°, 225°, 270°, 315°.

[0020] As a preference of the above solution, the interval distance of the plurality of permanent magnets is set at equal intervals according to a certain preset value or magnified by its multiple.

[0021] A detection method for a position detection system based on a three-dimensional Hall array includes the following steps:

[0022] S1. Install the reader on the moving vehicle, install the magnetic source component at a fixed position on the side of the moving vehicle, the reader moves parallel to the magnetic source component together with the moving vehicle, and a Hall effect occurs between the reader and the magnetic source component;

[0023] S2. Obtain the real-time induced electromotive force generated by the Hall effect when each single magnetic source of the magnetic source component during the movement interacts with Hall elements at different positions in the Hall array;

[0024] S3. Calculate the displacement according to the measured real-time induced electromotive force.

[0025] As an optimization of the above solution, calculate the induced electromotive force according to the following formulas (1) and (2)

[0026] B(x) = Bo * L * L / [(2x + L) * (2x + L)] (1)

[0027] E H = KB(x)Icosθ (2)

[0028] In the formula, B(x) is the magnetic induction intensity detected by the reader, Bo is the surface magnetism of the permanent magnet, which can be measured by a gaussmeter; L is the height of the cylindrical magnet, which is known; x is the distance from the center of the cylindrical permanent magnet to the center of the Hall element; E H is the Hall effect induced electromotive force; K is the sensitivity of the Hall device, which is a constant; I is the working current of the Hall element; θ is the included angle formed by the magnetic field formed by the magnetic source and the Hall element;

[0029] Calculate the displacement according to the following formula (3)

[0030] X = A * E H (3)

[0031] In the formula, X is the displacement, and A is the distance between adjacent linear Hall elements.

[0032] As an optimization of the above solution, when calculating the displacement, the five-point averaging method is used to obtain the displacement, and the average value of the displacements measured by the three layers of corresponding Hall elements is taken as the final displacement result.

[0033] Due to the above structure, the beneficial effects of the present invention are as follows:

[0034] The position detection system of the present application consists of a magnetic source component and a reader. The working gap between them can range from a few millimeters to several hundred millimeters, adapting to the use of object position and sensors in high-gap places. The present invention overcomes the deficiencies of a large number of displacement sensor products, such as the vertical height limitation between the reader and the inductor and the range limitation. Through the three-dimensional setting of the reader, specific coding of the magnetic source component, and then through the splicing installation method and structural innovation, the application measurement range can be extended to the hundred-meter level, and the product application field will be more extensive. Specifically, it has the following advantages:

[0035] 1. Non-contact measurement, long service life, high stability, and high reliability;

[0036] 2. The structural form can be diversified, enabling a wide measurement range, convenient installation and maintenance, and a compact and delicate appearance.

[0037] 3. The gap between the magnetic source component and the reader has strong adaptability, and the application scenarios are very extensive.

[0038] 4. It has strong anti-interference ability and is not affected by various electromagnetic interferences.

[0039] 5. It can achieve absolute position positioning of the moving slot. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly introduced below.

[0041] Figure 1 FIG. is a three-dimensional structural schematic diagram of the position detection system of the present invention;

[0042] Figure 2 FIG. is a cross-sectional view of the position detection system of the present invention;

[0043] Figure 3 FIG. is an internal structural schematic diagram of the position detection system of the present invention;

[0044] Figure 4 FIG. is a distribution diagram of magnetic induction lines at a vertical angle of the magnetic source body of the present invention;

[0045] Figure 5 FIG. is a curve diagram of voltage values of matrix arrangements of each Hall element of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0046] The technical solutions of the present invention will be clearly and completely described below with reference to the drawings of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope of protection of the present invention.

[0047] As Figures 1 to 3 shown, this embodiment provides a position detection system based on a three-dimensional Hall array, including a reader 11 and a magnetic source component 1; the magnetic source component 1 is a multi-segment splicing structure and is arranged in parallel with the reader 11; the reader 11 includes a multi-layer three-dimensional stacked PCB board and a linear Hall element array arranged on the PCB board.

[0048] In this embodiment, the PCB board is provided with three layers, and the linear Hall elements on each layer of the PCB board are arranged in a matrix distribution, and the number of arrays is an odd number of rows × 2 n columns (n is a natural number), that is: the number of arrays of the first-layer Hall element 2 is an odd number of rows × 2 nColumns (n is a natural number) are distributed on the first-layer PCB board 5, and the number of rows of the second-layer Hall element 3 array is an odd number × 2 n Columns (n is a natural number) are distributed on the second-layer PCB board 6, and the number of rows of the third-layer Hall element 4 array is an odd number × 2 n Columns (n is a natural number) are distributed on the third-layer PCB board 7. The linear Hall element arrays are marked as the first-layer Hall array [a1, a2, a3..an-1, an], the second-layer Hall array [b1, b2, b3..bn-1, bn], and the third-layer Hall array [c1, c2, c3..cn-1, cn].

[0049] In this embodiment, the spacing between each layer of linear Hall elements is equal, and the columns of adjacent two layers of Hall elements are staggered by Z millimeters from each other, where Z is a multiple of 6.

[0050] In this embodiment, the reader 11 further includes a housing 8, which is wrapped outside the PCB board and the linear Hall elements. A waterproof plug 9 and a wire outlet end 10 are provided on the housing 8.

[0051] In this embodiment, the magnetic source component 1 has several segments, and each segment includes a housing and a plurality of cylindrical permanent magnets arranged at intervals in a straight line inside the housing.

[0052] In this embodiment, the magnetic source component 1 can be specifically encoded, and the encoding method is: a: According to the polarity of the magnets, the distribution angle of each permanent magnet is any one of 0°, 45°, 90°, 135°, 180°, 225°, 270°, 315°. b: According to the distance between the magnets, the interval distances of the plurality of permanent magnets are equidistantly set according to a certain preset value (such as 5.5 millimeters) or magnified by its multiple, that is, the minimum distance between the permanent magnets is D min millimeters, the maximum distance is D max millimeters, and the magnets are arranged at an integer multiple of a length of U len (standard spacing).

[0053] The working principle of the above structure:

[0054] The position measurement principle is that the magnetic source coding array and the Hall coding array work in coordination. The Hall coding array is called the "reader", and the magnetic source coding array is called the "inductive scale". When the Hall element moves along the surface of the fixed track formed by the magnetic sources at a certain gap, the induced electromotive force generated by the Hall effect between a single magnetic source (with a random magnetic source angle) and Hall elements at different positions in the "reader" is different (the smaller the distance x from the center of the cylindrical permanent magnet to the center of the Hall element, the greater the induced electromotive force); since each magnetic source in the magnetic source coding array is placed at a certain angle, that is, the magnetic fields formed by magnetic sources at different angles will form an angle θ with the Hall elements in the "reader", and the position of the Hall element is different, the angle θ is also different, and the condition for generating the induced electromotive force is that the magnetic field direction is orthogonal to the current direction, so the induced electromotive force E H = KB(x)Icosθ. Then, the induced electromotive forces generated by magnetic sources at different angles in the "inductive scale" and the same "reader" through the Hall effect are different, and the induced electromotive forces generated by Hall elements at different positions are also different. Thus, the displacement can be calculated based on the induced electromotive force, and then the position can be calibrated.

[0055] Based on the above structure, this embodiment also provides a detection method for a position detection system based on a three-dimensional Hall array, including the following steps:

[0056] S1. Install the reader on the moving vehicle, and install the magnetic source component at a fixed position on the side of the moving vehicle (such as the ground, a fixed bracket), and move along the fixed track with the moving vehicle, and have the Hall effect with the magnetic source component on the track;

[0057] S2. Obtain the real-time induced electromotive force generated by the Hall effect between each single magnetic source of the magnetic source component and Hall elements at different positions in the Hall array during the movement process;

[0058] Before the reader works, a non-magnetized zeroing save is required for the Hall array of the reader (taking the array of 3×8 Hall elements on each layer of the PCB board as an example, the first-layer Hall array [a1, a2, a3..an-1, a24], the second-layer Hall array [b1, b2, b3..bn-1, b24], the third-layer Hall array [c1, c2, c3..cn-1, c24]) to make all the Hall array data zero;

[0059] During the movement process, the reader calculates the real-time induced electromotive force according to the following formulas (1), (2)

[0060] B(x) = Bo*L*L / [(2x + L)*(2x + L)] (1)

[0061] E H = KB(x)Icosθ (2)

[0062] Wherein, B(x) is the magnetic induction intensity detected by the reader, Bo is the surface magnetic of the permanent magnet, which can be measured by a gaussmeter; L is the height of the cylindrical magnet, which is known; x is the distance from the center of the cylindrical permanent magnet to the center of the Hall element; E H is the Hall effect induced electromotive force; K is the sensitivity of the Hall device, which is a constant; I is the working current of the Hall element; θ is the included angle formed by the magnetic field formed by the magnetic source and the Hall element;

[0063] S3. Calculate the displacement according to the measured real-time induced electromotive force;

[0064] Specifically, calculate the displacement according to the following formula (3)

[0065] X = A * E H (3)

[0066] Wherein, X is the displacement, and A is the distance between adjacent linear Hall elements.

[0067] In this embodiment, when calculating the displacement, the five-point averaging method is used for each layer to obtain the displacement, and the average value of the displacements measured by the corresponding Hall elements in three layers is taken as the final displacement result.

[0068] Through the Hall array, a two-dimensional plane list data of magnetic induction voltage can be obtained, such as Figure 5 shown, and the voltage distribution between each Hall element is obtained as follows: E H [a1, a2, a3, a4, a5, a6, a7, a8, a9, a10, a11, a12, a13, a14, a15, a16, a17, a18, a19, a20, a21, a22, a23, a24] = [-1, 2, 3, 5, 6, 7, 10, 12, 13, 14, 16, 15, 12, 13, 11, 7, 7, 5, 4, 2, 2, 2, 2, -1]; E H [b1, b2, b3, b4, b5, b6, b7, b8, b9, b10, b11, b12, b13, b14, b15, b16, b17, b18, b19, b20, b21, b22, b23, b24] = [0, 1, 2, 5, 6, 7, 8, 11, 11, 13, 14, 15, 14, 11, 13, 11, 8, 7, 4, 3, 2, 3, 0, 2]; E H[c1, c2, c3, c4, c5, c6, c7, c8, c9, c10, c11, c12, c13, c14, c15, c16, c17, c18, c19, c20, c21, c22, c23, c24] = [0, 1, 2, 4, 5, 7, 8, 11, 11, 12, 13, 14, 13, 10, 11, 11, 6, 6, 3, 3, 1, 2, 0, 1]; From the analysis of the graph, it can be seen that the Hall element No. a11 of the reader has an obvious peak E H With the highest characteristic, take 2 columns on each side of the 11th of each layer of the Hall array to establish three new lists

[0069] E H [a9, a10, a11, a12, a13];

[0070] E H [b9, b10, b11, b12, b13];

[0071] E H [c9, c10, c11, c12, c13];

[0072] Calculate the following expansion

[0073] X1 = A * (E H [a9] + E H [a10] + E H [a11] + E H [a12] + E H [a13]) / 5;

[0074] X2 = B * (E H [b9] + E H [b10] + E H [b11] + E H [b12] + E H [b13]) / 5;

[0075] X3 = C * (E H [c9] + E H [c10] + E H [c11] + E H [c12] + E H [c13]) / 5;

[0076] In the formula, A is the distance between a1 and a2, B is the distance between b1 and b2, C is the distance between c1 and c2, A = B = C. Assuming that A, B, and C are known numbers of 10 mm, the obtained X1, X2, and X3 are accumulated to get X, X = X1 + X2 + X3; then dividing X by 3 gives the final displacement result, and the solution accuracy can reach 1 mm after multiple difference calculations of the result.

[0077] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. Detection method of a position detection system based on a three-dimensional Hall array, characterized in that: The system includes a reader and a magnetic source component; The magnetic source component is a multi-segment spliced structure and is arranged parallel to the reader; The reader includes multiple layers of PCB boards stacked three-dimensionally and a linear Hall element array arranged on the PCB boards; The detection method includes the following steps: S1. Install the reader on a moving vehicle, install the magnetic source component at a fixed position on the side of the moving vehicle, and the reader moves parallel to the magnetic source component along with the moving vehicle and generates the Hall effect with the magnetic source component; S2. Obtain the real-time induced electromotive force generated by the Hall effect between each single magnetic source of the magnetic source component and Hall elements at different positions in the Hall array during the movement; S3. Calculate the displacement according to the measured real-time induced electromotive force; Among them, the induced electromotive force is calculated according to the following formulas (1) and (2) B(x) = Bo * L * L / [(2x + L) * (2x + L)] (1) E H = KB(x)Icosθ (2) In the formula, B(x) is the magnetic induction intensity detected by the reader, Bo is the surface magnetic of the permanent magnet, which can be measured by a gaussmeter; L is the height of the cylindrical magnet, which is known; x is the distance from the center of the cylindrical permanent magnet to the center of the Hall element; E H is the Hall effect induced electromotive force; K is the sensitivity of the Hall device, which is a constant; I is the working current of the Hall element; θ is the angle formed by the magnetic field formed by the magnetic source and the Hall element; The displacement is calculated according to the following formula (3) X = A * E H (3) In the formula, X is the displacement, and A is the distance between adjacent linear Hall elements.

2. The detection method of a position detection system based on a three-dimensional Hall array according to claim 1, characterized in that: The PCB board is provided with three layers, and the linear Hall elements on each layer of the PCB board are arranged in a matrix distribution, and the number of arrays is an odd number of rows multiplied by a power of 2 columns.

3. The detection method of a position detection system based on a three-dimensional Hall array according to claim 2, characterized in that: The distance between each layer of linear Hall elements is equal, and the columns of adjacent two layers of Hall elements are staggered by Z millimeters from each other, and Z is a multiple of 6.

4. The detection method of a position detection system based on a three-dimensional Hall array according to claim 1, characterized in that: The reader further includes a housing, which wraps the outside of the PCB board and the linear Hall elements, and the housing is provided with a waterproof plug and an outlet end.

5. The detection method of a position detection system based on a three-dimensional Hall array according to claim 1, characterized in that: The magnetic source component is provided with several segments, and each segment includes a housing and a plurality of cylindrical permanent magnets arranged at intervals in a straight line inside the housing.

6. The detection method of a position detection system based on a three-dimensional Hall array according to claim 5, characterized in that: The placement angle of each permanent magnet is any one of 0°, 45°, 90°, 135°, 180°, 225°, 270°, 315°.

7. The detection method of a position detection system based on a three-dimensional Hall array according to claim 5, characterized in that: The interval distance of the multiple permanent magnets is set at an equal distance according to a certain preset value or magnified by its multiple.

8. The detection method of a position detection system based on a three-dimensional Hall array according to claim 1, characterized in that: When calculating the displacement, the five-point averaging method is used to obtain the displacement amount, and the average value of the displacement amounts measured by the corresponding Hall elements of the three layers is taken as the final displacement result.

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