Lead position detection device and detection method

Abstract

The present application discloses a lead position detection device and a detection method. The device includes a power supply module, a signal acquisition module, a signal processing module, and a communication output module; the power supply module provides voltage; the signal acquisition module includes N groups of infrared opposed components, the signal processing module includes a current-voltage conversion unit, a signal amplification and filtering unit, and a signal processing unit. The current-voltage conversion unit converts a current signal into a voltage signal; the signal amplification and filtering unit amplifies and filters the voltage signal; the signal processing unit compares the processed voltage with a pre-stored reference voltage to obtain lead position information; the communication output module outputs the lead position information to a controller. The present application performs real-time detection through N groups of infrared opposed components. After the signal processing module processes and calculates the data and compares it with the pre-stored reference voltage, accurate lead position information is obtained, achieving the effects of real-time monitoring, controllable range, and improved detection accuracy.

Description

Technical Field

[0001] This application belongs to the technical field of semiconductor component bonding, and relates to a lead position detection device and a detection method. Background Art

[0002] In the semiconductor industry, signal interconnection between chips and electrical interconnection between chips and substrates are achieved through leads. When a wire bonder performs lead bonding, it needs to detect the position of the leads in real time to continuously supply the leads and ensure that the tension of the leads remains consistent.

[0003] Currently, commonly used non-contact detection devices require the object to be detected not to be too small, and the detection range is very small. For leads with a very small diameter or a large movement amplitude, the detection purpose cannot be achieved. Summary of the Invention

[0004] To solve the problems in the related art, this application provides a lead position detection device and a detection method. The technical solutions are as follows:

[0005] In a first aspect, this application provides a lead position detection device, which includes a power supply module, a signal acquisition module, a signal processing module, and a communication output module;

[0006] The power supply module is configured to provide voltage to the signal acquisition module and the signal processing module;

[0007] The signal acquisition module includes N groups of infrared opposed components. Each group of infrared opposed components corresponds to a signal source channel, and each group of infrared opposed components includes an infrared signal transmitter and an infrared signal receiver that are relatively spaced apart;

[0008] The signal processing module includes a current-voltage conversion unit, a signal amplification and filtering unit, and a signal processing unit. The current-voltage conversion unit is configured to receive the current signal obtained by the infrared signal receiver and convert the obtained current signal into a voltage signal; the signal amplification and filtering unit is configured to amplify and filter the voltage signal output by the current-voltage conversion unit to obtain a processed voltage; the signal processing unit is configured to collect the processed voltage and compare the processed voltage with a pre-stored reference voltage to obtain lead position information;

[0009] The communication output module is configured to output the lead position information obtained by the signal processing module to a controller.

[0010] The current signals of N groups of infrared pair components are collected in real time through the signal acquisition module. After being processed and calculated by the signal processing module and compared with the pre-stored reference voltage, accurate lead position information is obtained, achieving the effects of real-time monitoring, controllable range, and improved detection accuracy.

[0011] Optionally, the lead position detection device further includes N switches, and the N switches are respectively arranged between the N groups of infrared pair components and the current-voltage conversion unit to conduct or disconnect the circuit between the infrared pair components and the current-voltage conversion unit.

[0012] By setting N switches, the N groups of infrared pair components are respectively conducted with the current-voltage conversion unit, realizing the function of a current-voltage conversion unit polling and detecting all signal source channels.

[0013] In a second aspect, the present application further provides a lead position detection method, which adopts the lead position detection device provided in the first aspect and various optional manners of the first aspect. The lead position detection method includes:

[0014] After power-on, obtain the reference voltages of N signal source channels;

[0015] When performing the i-th determination, sequentially read the real-time voltages of N signal source channels;

[0016] For each signal source channel, compare the real-time voltage of the signal source channel with the reference voltage of the signal source channel to determine the candidate signal source channels;

[0017] According to the optimal signal source channel determined from the candidate signal source channels, determine the position information corresponding to the optimal signal source channel as the position information of the lead, and complete the i-th determination.

[0018] By setting N signal source channels, comparing the real-time voltage of each signal source channel with the preset reference voltage to obtain the candidate signal source channels, and then determining the optimal signal source channel from the candidate signal source channels, so as to determine the actual position of the lead. After multiple screening calculations, the interference of error data is excluded to obtain accurate lead position information.

[0019] Optionally, the obtaining of the reference voltages of N signal source channels includes:

[0020] Judge whether the reference voltages of N signal source channels are stored in the flash memory;

[0021] If the reference voltages of N signal source channels are stored in the flash memory, read out the reference voltages of N signal source channels;

[0022] If the reference voltages of the N signal source channels have not been stored in the flash memory, an initialization process is executed to obtain the reference voltages of the N signal source channels.

[0023] By pre-judging whether the reference voltages of the N signal source channels are pre-stored in the flash memory, the subsequent judgment logic is selected to ensure the smooth comparison of the reference voltage and the real-time voltage.

[0024] Optionally, the execution of the initialization process to obtain the reference voltages of the N signal source channels includes:

[0025] Successively turn on the N signal source channels, and none of the N signal source channels are blocked;

[0026] Calculate the reference voltages of the N signal source channels from the N groups of voltages collected by the signal processing unit in sequence.

[0027] Calculate the reference voltage from the collected voltage to reduce errors.

[0028] Optionally, the comparison of the real-time voltage of the signal source channel and the reference voltage of the signal source channel to determine the signal source channel to be selected includes:

[0029] Add the reference voltage of the signal source channel to the adjustment voltage of the signal source channel to obtain a voltage sum value;

[0030] Compare the real-time voltage of the signal source channel with the voltage sum value;

[0031] When the real-time voltage of the signal source channel is less than the power sum value, it is determined that the signal source channel is the signal source channel to be selected.

[0032] By introducing an adjustment voltage, the occurrence of large errors affecting the detection effect is avoided.

[0033] Optionally, the addition of the reference voltage of the signal source channel and the adjustment voltage of the signal source channel includes:

[0034] Obtain the optimal signal source channel determined in the (i - 1)-th determination, and calculate the difference between the signal source channel and the optimal signal source channel determined in the (i - 1)-th determination;

[0035] According to the pre-stored correspondence between the difference and the adjustment voltage, determine the adjustment voltage corresponding to the calculated difference.

[0036] The magnitude of the adjustment voltage is determined according to the positional relationship between the i-th and the (i - 1)-th times, avoiding the occurrence of large misdetection situations

[0037] Optionally, the signal source channels in the lead position detection device include n odd signal source channels and n even signal source channels. The signal source channels to be selected include a to-be-selected odd signal source channel and a to-be-selected even signal source channel. Determining the optimal signal source channel from the signal source channels to be selected includes:

[0038] Determining the optimal odd signal source channel from the to-be-selected odd signal source channels;

[0039] Determining the optimal even signal source channel from the to-be-selected even signal source channels;

[0040] If the optimal odd signal source channel is determined and the optimal even signal source channel is not determined, then use the optimal odd signal source channel as the optimal signal source channel;

[0041] If the optimal even signal source channel is determined and the optimal odd signal source channel is not determined, then use the optimal even signal source channel as the optimal signal source channel;

[0042] If the optimal odd signal source channel is determined and the optimal even signal source channel is determined, then calculate the optimal signal source channel based on the optimal odd signal source channel and the optimal even signal source channel;.

[0043] By setting the odd signal source channel and the even signal source channel, the detection result is made more accurate.

[0044] Optionally, determining the optimal odd signal source channel from the to-be-selected odd signal source channels includes:

[0045] Selecting the odd signal source channel from the to-be-selected odd signal source channels that is closest to the position of the optimal odd signal source channel determined in the (i - 1)-th determination;

[0046] If there is only one such closest odd signal source channel, determine whether the selected to-be-selected odd signal source channel is the same as or adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination;

[0047] If the selected to-be-selected odd signal source channel is the same as or adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination, then determine the to-be-selected odd signal source channel as the optimal odd signal source channel determined in the i-th determination;

[0048] If the selected to-be-selected odd signal source channel is different from and not adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination, then determine the optimal odd signal source channel determined in the (i - 1)-th determination as the optimal odd signal source channel determined in the i-th determination;

[0049] If there are two such closest odd signal source channels, then determine the smaller odd signal source channel as the optimal odd signal source channel determined in the i-th determination.

[0050] By comparing the position of the i-th candidate odd signal source channel with the position of the optimal odd signal source channel determined in the (i - 1)-th time, the optimal odd signal source channel in the i-th time is determined, ensuring the accuracy of the optimal odd signal source channel.

[0051] Optionally, determining the optimal even signal source channel according to the candidate even signal source channel includes:

[0052] Selecting the even signal source channel with the closest position to the optimal even signal source channel determined in the (i - 1)-th time from the candidate even signal source channels;

[0053] If there is only one such closest even signal source channel, determining whether the selected candidate even signal source channel is the same as or adjacent to the optimal even signal source channel determined in the (i - 1)-th time;

[0054] If the selected candidate even signal source channel is the same as or adjacent to the optimal even signal source channel determined in the (i - 1)-th time, determining the candidate even signal source channel as the optimal even signal source channel determined in the i-th time;

[0055] If the selected candidate even signal source channel is neither the same as nor adjacent to the optimal even signal source channel determined in the (i - 1)-th time, determining the optimal even signal source channel determined in the (i - 1)-th time as the optimal even signal source channel determined in the i-th time;

[0056] If there are two such closest even signal source channels, determining the smaller even signal source channel as the optimal even signal source channel determined in the i-th time.

[0057] By comparing the position of the i-th candidate even signal source channel with the position of the optimal even signal source channel determined in the (i - 1)-th time, the optimal even signal source channel in the i-th time is determined, ensuring the accuracy of the optimal even signal source channel.

[0058] Optionally, the signal source channels in the lead position detection device include n odd signal source channels or n even signal source channels, the candidate signal source channels are candidate odd signal source channels or candidate even signal source channels, and determining the optimal signal source channel according to the candidate signal source channel includes:

[0059] Selecting the signal source channel with the closest position to the optimal signal source channel determined in the (i - 1)-th time from the candidate signal source channels;

[0060] Determining whether the selected candidate signal source channel is the same as or adjacent to the optimal signal source channel determined in the (i - 1)-th time;

[0061] If the selected candidate signal source channel is the same as or adjacent to the optimal signal source channel determined in the (i - 1)-th determination, then the candidate signal source channel determined as the optimal signal source channel in the i-th determination;

[0062] If the selected candidate signal source channel is different from and not adjacent to the optimal signal source channel determined in the (i - 1)-th determination, then the optimal signal source channel determined in the (i - 1)-th determination is determined as the optimal signal source channel in the i-th determination;

[0063] If there are two closest signal source channels, then the smaller signal source channel is determined as the optimal signal source channel in the i-th determination.

[0064] By comparing the positions of the i-th candidate signal source channel and the optimal signal source channel determined in the (i - 1)-th determination, the i-th optimal signal source channel is determined to ensure the accuracy of the optimal signal source channel.

[0065] Optionally, calculating the optimal signal source channel according to the optimal odd signal source channel and the optimal even signal source channel includes:

[0066] Calculating the average value of the odd value corresponding to the optimal odd signal source channel and the even value corresponding to the optimal even signal source channel;

[0067] Taking the signal source channel corresponding to the integer value after rounding the average value as the optimal signal source channel.

[0068] Optionally, calculating the optimal signal source channel according to the optimal odd signal source channel and the optimal even signal source channel includes:

[0069] Calculating the first difference between the odd value corresponding to the optimal odd signal source channel and the even value corresponding to the optimal even signal source channel;

[0070] When the first difference is greater than the first predetermined difference, then the signal source channel with a smaller value is determined as the optimal signal source channel and an alarm prompt is given.

[0071] By comparing the first difference with the first predetermined difference, it is judged whether there is an excessive inclination in the lead position.

[0072] Optionally, the lead position detection method further includes:

[0073] After power-on, the first reference voltage of the signal processing unit is obtained in real time;

[0074] Calculating the second difference between the first reference voltage and the second reference voltage of the pre-stored signal processing unit;

[0075] When the second difference is greater than the second predetermined difference, then an alarm prompt is given.

[0076] By calculating the second difference between the first reference voltage and the pre-stored second reference voltage, if it is outside the error range, an alarm is given to protect the controller.

[0077] Optionally, the lead position detection method further includes:

[0078] Comparing the real-time voltages of all signal source channels with a predetermined occlusion voltage, where the predetermined occlusion voltage is the voltage when all signal source channels are occluded; when the real-time voltages of all signal source channels are less than the predetermined occlusion voltage within a predetermined time duration, the reference voltage stored in the flash memory is cleared.

[0079] Or,

[0080] Calculating the product of the initial voltage and the predetermined wire occlusion rate, comparing the real-time voltages of all signal source channels with the product of the initial voltage and the predetermined wire occlusion rate, where the initial voltage is the voltage determined when all signal source channels are not occluded; when the real-time voltages of all signal source channels are less than the product of the initial voltage and the predetermined wire occlusion rate within a predetermined time duration, the reference voltage is cleared.

[0081] By setting a clearing program, it is convenient to quickly clear the reference voltage for recalibration.

[0082] It should be understood that the above general description and the following detailed description are only exemplary and do not limit the present invention. Description of the Drawings

[0083] The drawings here are incorporated into the specification and form a part of this specification, showing the embodiments in line with the present application, and are used together with the specification to explain the principles of the present application.

[0084] Figure 1 is a schematic structural diagram of a lead position detection device provided in an embodiment of the present application;

[0085] Figure 2 is a flowchart of a lead position detection method provided in an embodiment of the present application;

[0086] Figure 3 is a flowchart of obtaining a reference voltage in a lead position detection method provided in an embodiment of the present application;

[0087] Figure 4 is a flowchart of determining candidate signal source channels in a lead position detection method provided in an embodiment of the present application;

[0088] Figure 5 is a flowchart of determining the optimal signal source channel in a lead position detection method provided in an embodiment of the present application;

[0089] Figure 6 It is a layout schematic diagram of the infrared pair-emitting components in the signal acquisition module provided in an embodiment of the present application. Detailed implementation manners

[0090] Here, the exemplary embodiments will be described in detail, and the examples are shown in the drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementation manners described in the following exemplary embodiments do not represent all implementation manners consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the appended claims.

[0091] Figure 1 It is a structural schematic diagram of the lead position detection device provided in an embodiment of the present application. The lead position detection device provided by the present application may include a power supply module 10, a signal acquisition module 20, a signal processing module 30, and a communication output module 40.

[0092] The power supply module 10, as the basis for the stable operation of the lead position detection device, provides reliable voltage and energy for the lead position detection device. In an implementable embodiment, the power supply module 10 is electrically connected to the signal acquisition module 20 and the signal processing module 30. The power supply module 10 is configured to provide voltage to the signal acquisition module 20 and the signal processing module 30. According to actual requirements, the power supply module 10 can achieve voltage conversion through boost and buck circuits to provide multiple voltages including 3.3V, 5V, ±9V, etc. for the lead position detection device.

[0093] The signal acquisition module 20 includes a signal acquisition unit 21 and N groups of infrared pair-emitting components 22. Each group of infrared pair-emitting components includes an infrared signal emitter and an infrared signal receiver that are relatively spaced apart. A signal acquisition space is provided between each group of infrared signal emitters and infrared signal receivers. A set of relatively arranged infrared signal emitters and infrared signal receivers and the corresponding signal acquisition space form a signal source channel.

[0094] The signal processing module 30 includes a current-voltage conversion unit 31, a signal amplification and filtering unit 32, and a signal processing unit 33. The current-voltage conversion unit 31 is configured to receive the current signal obtained by the infrared signal receiver and convert the obtained current signal into a voltage signal; the signal amplification and filtering unit 32 is configured to amplify and filter the voltage signal output by the current-voltage conversion unit 31 to obtain the processed voltage; the signal processing unit 33 is configured to collect the processed voltage and compare the processed voltage with a pre-stored reference voltage to obtain the lead position information.

[0095] The communication output module 40 is configured to output the lead position information obtained by the signal processing module 30 to the controller. Optionally, the communication output module 40 includes a serial bus communication unit and a parallel bus output unit, wherein the serial bus communication unit is mainly used for transmitting the internal operating parameters of the lead position detection device and some alarm parameters; the parallel bus output unit is mainly composed of an n-bit parallel output bus, and is mainly used to transmit the lead position information and synchronization signal to a controller such as a PLC at high speed.

[0096] In an optional embodiment, the lead position detection device further includes N switches, which are respectively arranged between the N groups of infrared radiation components and the current-voltage conversion unit 31, so as to be used to turn on or off the circuit between the infrared radiation components and the current-voltage conversion unit 31. By setting N switches, the N groups of infrared radiation components are respectively turned on with the current-voltage conversion unit, so that the current-voltage conversion unit processes the voltage of one signal source channel each time, thereby realizing the function of one current-voltage conversion unit polling and detecting all signal source channels.

[0097] To summarize, the lead position detection device provided by the present application sets up N groups of infrared counter-radiation components, and collects the current signals of the N groups of infrared counter-radiation components in real time through the signal acquisition module. After processing and calculation by the signal processing module, it is compared with the pre-stored reference voltage to obtain accurate lead position information, thereby realizing real-time monitoring, controllable range, and improved detection accuracy.

[0098] Figure 2 is a flow chart of a lead position detection method provided in one embodiment of the present application. The lead position detection method provided in the present application can be used as follows Figure 1 The lead wire position detection device shown in the figure, the lead wire position detection method may include the following steps:

[0099] Step 100, after power-on, obtain the reference voltages of N signal source channels.

[0100] Optionally, in an achievable implementation, as Figure 3 As shown, Figure 3 This is a flow chart for obtaining the reference voltage in this embodiment, and the specific steps are as follows: after the lead position detection device is powered on, the information acquisition module is initialized 110 to preferentially determine whether the reference voltages of N signal source channels are stored in the flash memory 120; if the reference voltages of N signal source channels are already stored in the flash memory, the reference voltages of the N signal source channels are directly read out 130; if the reference voltages of N signal source channels are not yet stored in the flash memory, the initialization process is executed to obtain the reference voltages of N signal source channels 140.

[0101] Optionally, in this embodiment, when none of the N signal source channels are blocked, the N signal source channels are sequentially turned on by polling, and N groups of voltages are sequentially collected by the signal processing unit to calculate the reference voltages of the N signal source channels respectively.

[0102] Specifically, first, collect the real-time voltage enough times for each signal source channel, perform mean filtering on the collected multiple groups of data through the signal amplification and filtering unit to obtain the initial voltage value of each signal source channel, and then calculate the reference voltage of each signal source channel through formula (1). Optionally, during the actual process of collecting real-time voltage, the real-time voltage can be continuously collected 50, 80, 100, or 200 times for each signal source channel.

[0103]

[0104] Among them, V compare [i] represents the channel reference voltage, V init [i] represents the initial voltage after mean filtering when the channel is not blocked, COVER_RATE% represents the lead occlusion rate, which refers to the percentage of the channel blocked by the lead; V cover represents the channel occlusion voltage, which refers to the voltage value when the channel is completely blocked. After multiple experiments, the lead occlusion rate and channel occlusion voltage of different leads can be determined, so as to obtain the reference voltage of the channel more accurately. After calculating the reference voltages of the N signal source channels respectively, save the reference voltage values to the flash memory, so that when power is restored after power-off and continued use, there is no need to recalculate the reference voltage values.

[0105] Step 200, when making the i-th determination, sequentially read the real-time voltages of the N signal source channels.

[0106] Step 300, for each signal source channel, compare the real-time voltage of the signal source channel with the reference voltage of the signal source channel to determine the candidate signal source channels.

[0107] Optionally, in an implementable embodiment, as Figure 4 shown, Figure 4 is the flowchart for determining the candidate signal source channels in this embodiment. The specific steps are as follows: add the reference voltage of the signal source channel to the adjusted voltage of the signal source channel to obtain the voltage sum value 310; poll and read the real-time voltage of each signal source channel 320; compare the real-time voltage of the signal source channel with the voltage sum value 330; when the real-time voltage of the signal source channel is less than the power sum value, it is determined that the signal source channel is a candidate signal source channel 340.

[0108] Optionally, first obtain the optimal signal source channel determined in the (i - 1)-th determination, and calculate the difference between the signal source channel in the i-th time and the optimal signal source channel determined in the (i - 1)-th determination; according to the pre-stored correspondence between the difference and the adjustment voltage, determine the adjustment voltage corresponding to the calculated difference. In this embodiment, the closer the polling channel is to the channel where the lead was located last time, the greater the adjustment value given. Optionally, if the optimal signal source channel determined last time is the No. 5 signal source channel, then in this polling, a larger adjustment value is given to the No. 4 signal source channel, the No. 5 signal source channel, and the No. 6 signal source channel, a smaller adjustment value is given to the No. 3 signal source channel and the No. 7 signal source channel, and the adjustment value given to the remaining channels is recorded as 0, that is, no adjustment value is given. The comparison formula is as follows:

[0109] V channel [i]<V compare [i]+V CmpAdj [i] (2)

[0110] Among them, V channel [i] represents the real-time voltage value of the channel, V compare [i] represents the reference voltage of the channel, V CmpAdj [i] represents the adjustment voltage value of the channel.

[0111] Step 400, determine the optimal signal source channel according to the to-be-selected signal source channel, and determine the position information corresponding to the optimal signal source channel as the position information of the lead, and complete the i-th determination.

[0112] Optionally, in an implementable embodiment, as Figure 5 shown, Figure 5The flowchart for determining the optimal signal source channel in this embodiment is as follows. The specific steps are as follows: When determining the optimal signal source channel, first judge the number of candidate signal source channels that have been determined. If there is only 1 candidate signal source channel, this is the most ideal and common situation. Then judge whether the candidate signal source channel is the same as or adjacent to the previous optimal signal source channel 410. If it is the same or adjacent, then determine this candidate signal source channel as the optimal signal source channel 420. Otherwise, determine the previously determined optimal signal source channel as the current optimal signal source channel 430. After determining the position information of the lead wire, output it through the communication module 440. In some cases, the number of candidate signal source channels determined may be two, and both of these candidate signal source channels are adjacent to the previously determined optimal signal source channel, that is, the two candidate signal source channels determined this time are the signal source channels before and after the previously determined optimal signal source channel. Then determine the signal source channel with the smaller number among these two candidate signal source channels as the current optimal signal source channel. For example, if the previously determined optimal signal source channel is the 7th signal source channel and the two candidate signal source channels are the 6th signal source channel and the 8th signal source channel, then determine the 6th signal source channel as the current optimal signal source channel.

[0113] In an implementable embodiment, each signal source channel represents a set of infrared opposed components. N groups of signal source channels are evenly divided into odd signal source channels and even signal source channels according to the numbers. The odd signal source channels and the even signal source channels are arranged in parallel and are both configured to sense the position of the lead wire. As Figure 6 shown, the signal source channels numbered 1, 3, 5, 7, 9, 11, 13, 15... are odd signal source channels, and the signal source channels numbered 2, 4, 6, 8, 10, 12, 14, 16... are even signal source channels. The odd signal source channels and the even signal source channels are both judged separately according to the Figure 2 shown judgment flowchart to respectively determine an optimal odd signal source channel OddPos and an optimal even signal source channel EvenPos, and calculate the final optimal signal source channel Pos according to the determined optimal odd signal source channel OddPos and optimal even signal source channel EvenPos.

[0114] Due to the influence of the lead diameter or the device working environment, it may occur that no position information is collected. The following is a list according to different situations. Optionally, if the optimal odd signal source channel OddPos is determined and the optimal even signal source channel EvenPos is not determined, then the optimal odd signal source channel OddPos is used as the optimal signal source channel Pos; if the optimal even signal source channel EvenPos is determined and the optimal odd signal source channel OddPos is not determined, then the optimal even signal source channel EvenPos is used as the optimal signal source channel; if the optimal odd signal source channel OddPos and the optimal even signal source channel EvenPos are determined, then calculate the average value of the odd value corresponding to the optimal odd signal source channel OddPos and the even value corresponding to the optimal even signal source channel EvenPos. The calculation formula is as follows:

[0115] Pos = (OddPos + EvenPos) / 2 (3)

[0116] The signal source channel corresponding to the integer value obtained by rounding the average value is used as the optimal signal source channel Pos.

[0117] The following is an illustration by way of example. In an achievable implementation manner, a total of 32 signal source channels are set up. According to the numbers, they are evenly divided into 16 groups of odd signal source channels and 16 groups of even signal source channels. The 1st, 3rd, 5th... 31st signal source channels are defined as odd signal source channels and are located on a straight line; the 2nd, 4th, 6th... 32nd signal source channels are defined as even signal source channels and are located on a straight line. The straight line where the odd signal source channels are located is parallel to the straight line where the even signal source channels are located. If the previously determined optimal odd signal source channel is the 11th signal source channel and the previously determined optimal even signal source channel is the 14th signal source channel. According to step 230, among the odd signal source channels, a relatively large adjustment value is given to the 9th, 11th, and 13th signal source channels, a relatively small adjustment value is given to the 7th and 15th signal source channels, and the adjustment values of the remaining odd signal source channels are set to 0; similarly, among the even signal source channels, a relatively large adjustment value is given to the 12th, 14th, and 16th signal source channels, a relatively small adjustment value is given to the 10th and 18th signal source channels, and the adjustment values of the remaining even signal source channels are set to 0. Through calculation using formula (2), the optimal odd signal source channel and the optimal even signal source channel are obtained. For example, if the determined optimal odd signal source channel is the 11th signal source channel and the optimal even signal source channel is not determined, then the 11th signal source channel is taken as the optimal signal source channel; if the determined optimal even signal source channel is the 14th signal source channel and the optimal odd signal source channel is not determined, then the 14th signal source channel is taken as the optimal signal source channel; if the determined optimal odd signal source channel is the 11th signal source channel and the determined optimal even signal source channel is the 14th signal source channel, then after calculation using formula (3) and rounding, the 12th signal source channel is obtained as the final optimal signal source channel.

[0118] Optionally, when calculating the optimal signal source channel, if the optimal odd signal source channel and the optimal even signal source channel are determined simultaneously, it is necessary to monitor in real time the first difference between the previously determined optimal odd signal source channel and the optimal even signal source channel. When the first difference is greater than the first predetermined difference, the signal source channel with a smaller value is determined as the optimal signal source channel and an alarm prompt is given. This situation indicates that there is a relatively large inclination in the position of the lead wire, and it is possible that the lead wire is stuck somewhere.

[0119] Optionally, if the finally obtained optimal signal source channel is at the top signal source channel or the bottom signal source channel, an alarm prompt is given. This situation indicates that the lead wire may exceed the detection range at any time, and it is necessary to adjust the position of the lead wire in the detection device to ensure the accuracy of the detection.

[0120] Optionally, when determining the candidate signal source channels, continuous sampling is performed, and the judgment in step 230 is carried out for each sampling to obtain the corresponding candidate signal source channels. When the same candidate signal source channel is obtained a predetermined number of times, the candidate signal source channel is determined as the final candidate signal source channel. Through multiple measurements, the situation where single detection may produce errors is avoided.

[0121] Optionally, when determining the optimal signal source channel, continuous sampling is performed, and the judgment in step 240 is carried out for each sampling to obtain the corresponding optimal signal source channel. When the same optimal signal source channel is obtained a predetermined number of times, the optimal signal source channel is determined as the final optimal signal source channel. Through multiple measurements, the situation where single detection may produce errors is avoided.

[0122] Optionally, after power-on, the first reference voltage of the signal processing unit is obtained in real time; the second difference between the first reference voltage and the pre-stored second reference voltage of the signal processing unit is calculated; when the second difference is greater than the second predetermined difference, an alarm prompt will be given. The reference voltage is the voltage value at both ends of the signal processing unit. Multiple measurements are performed in advance, and the second reference voltage is obtained after mean filtering and stored in the flash memory; when the signal processing unit obtains the first reference voltage in real time during normal operation, when it is found that the second difference between the first reference voltage and the second reference voltage is greater than the preset second predetermined difference, an alarm prompt is given. During normal operation, the second reference voltage may fluctuate, but if the fluctuation exceeds the limit value, it may damage the signal processing unit, so a protection program is set.

[0123] Optionally, the lead position detection method further includes a clearing program, and the specific determination process is as follows:

[0124] Optionally, the real-time voltages of all signal source channels are compared with a predetermined occlusion voltage, and the predetermined occlusion voltage is the voltage when all signal source channels are occluded; when the real-time voltages of all signal source channels are less than the predetermined occlusion voltage within a predetermined time period, the reference voltage stored in the flash memory is cleared;

[0125] Alternatively, in another embodiment, the product of the initial voltage and the predetermined wire occlusion rate is calculated, and the real-time voltages of all signal source channels are compared with the product of the initial voltage and the predetermined wire occlusion rate. When the real-time voltages of all signal source channels are less than the product of the initial voltage and the predetermined wire occlusion rate within a predetermined time period, the reference voltage is cleared, where the initial voltage is the voltage value calculated after mean filtering of the data obtained by collecting 100 times when all signal source channels are not occluded.

[0126] In an implementable embodiment, the preset duration can be set to 5 s. When the voltages of all signal source channels are blocked for 5 s, the clearing program is entered to clear the reference voltage in the flash memory. After the next power-on, the system automatically enters the sub-process of obtaining and saving the reference voltage. By setting the clearing program, it is convenient to quickly clear the reference voltage for recalibration.

[0127] In summary, for the lead position detection method provided in this application, by setting N signal source channels, comparing the real-time voltage of each signal source channel with the preset reference voltage to obtain the candidate signal source channels, and then determining the optimal signal source channel from the candidate signal source channels, the actual position of the lead is determined. Through multiple screenings and calculations in the whole process, the interference of error data can be excluded to obtain accurate lead position information, and the real-time position information of the lead is transmitted to a controller such as a PLC.

[0128] Those skilled in the art will readily conceive of other embodiments of this application after considering the specification and practicing the application herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common general knowledge or conventional technical means in the technical field not claimed in this application. The specification and examples are only to be considered as exemplary, and the true scope and spirit of this application are pointed out by the appended claims.

[0129] It should be understood that this application is not limited to the exact structures described above and shown in the drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is only limited by the appended claims.

Claims

1. A lead position detection device, characterized in that, The lead position detection device includes a power supply module, a signal acquisition module, a signal processing module, and a communication output module; The power supply module is configured to provide voltage to the signal acquisition module and the signal processing module; The signal acquisition module includes N groups of infrared pair emission components. Each group of infrared pair emission components corresponds to a signal source channel, and each group of infrared pair emission components includes an infrared signal emitter and an infrared signal receiver that are relatively spaced apart; The signal processing module includes a current-voltage conversion unit, a signal amplification and filtering unit, and a signal processing unit. The current-voltage conversion unit is configured to receive the current signal obtained by the infrared signal receiver and convert the obtained current signal into a voltage signal; the signal amplification and filtering unit is configured to amplify and filter the voltage signal output by the current-voltage conversion unit to obtain the processed voltage; the signal processing unit is configured to collect the processed voltage and compare the processed voltage with a pre-stored reference voltage to obtain lead position information; The communication output module is configured to output the lead position information obtained by the signal processing module to the controller; The signal processing unit is configured to collect the processed voltage and compare the processed voltage with a pre-stored reference voltage to obtain lead position information. Specifically: Obtain the reference voltages of N signal source channels pre-stored; When performing the i-th determination, sequentially collect the processed voltages of N signal source channels; For each signal source channel, compare the processed voltage of the signal source channel with the reference voltage of the signal source channel to determine a candidate signal source channel; Determine the optimal signal source channel according to the candidate signal source channel, and determine the position information corresponding to the optimal signal source channel as the position information of the lead to complete the i-th determination.

2. The lead position detection device according to claim 1, characterized in that, The lead position detection device further includes N switches, and the N switches are respectively arranged between the N groups of infrared pair emission components and the current-voltage conversion unit to conduct or disconnect the circuit between the infrared pair emission components and the current-voltage conversion unit.

3. A method for detecting the position of a lead wire, characterized in that, Using the lead position detection device as described in claim 1, the lead position detection method includes: After power-on, obtain the reference voltages of N signal source channels; When performing the i-th determination, sequentially read the real-time voltages of N signal source channels; For each signal source channel, compare the real-time voltage of the signal source channel with the reference voltage of the signal source channel to determine a candidate signal source channel; Determine the optimal signal source channel according to the candidate signal source channel, and determine the position information corresponding to the optimal signal source channel as the position information of the lead to complete the i-th determination.

4. The lead position detection method according to claim 3, wherein The obtaining of the reference voltages of N signal source channels includes: Judge whether the reference voltages of N signal source channels are stored in the flash memory; If the reference voltages of N signal source channels are stored in the flash memory, read out the reference voltages of N signal source channels; If the reference voltages of N signal source channels have not been stored in the flash memory, an initialization process is executed to obtain the reference voltages of the N signal source channels.

5. The lead position detection method according to claim 4, characterized in that, The execution of the initialization process to obtain the reference voltages of the N signal source channels includes: Successively turning on the N signal source channels, where none of the N signal source channels are blocked; Calculating the reference voltages of the N signal source channels respectively from the N groups of voltages successively collected by the signal processing unit.

6. The lead position detection method according to claim 3, characterized in that The comparison of the real-time voltage of the signal source channel with the reference voltage of the signal source channel to determine the candidate signal source channels includes: Adding the reference voltage of the signal source channel to the adjusted voltage of the signal source channel to obtain a voltage sum value; Comparing the real-time voltage of the signal source channel with the voltage sum value; When the real-time voltage of the signal source channel is less than the power sum value, it is determined that the signal source channel is the candidate signal source channel.

7. The lead position detection method according to claim 6, wherein The adding of the reference voltage of the signal source channel to the adjusted voltage of the signal source channel includes: Obtaining the optimal signal source channel determined in the (i - 1)-th determination, and calculating the difference between the signal source channel and the optimal signal source channel determined in the (i - 1)-th determination; Determining the adjusted voltage corresponding to the calculated difference according to the pre-stored correspondence between the difference and the adjusted voltage.

8. The lead position detection method according to claim 3, characterized in that The signal source channels in the lead position detection device include n odd signal source channels and n even signal source channels, the candidate signal source channels include candidate odd signal source channels and candidate even signal source channels, and the determination of the optimal signal source channel from the candidate signal source channels includes: Determining the optimal odd signal source channel from the candidate odd signal source channels; Determining the optimal even signal source channel from the candidate even signal source channels; If the optimal odd signal source channel is determined and the optimal even signal source channel is not determined, then the optimal odd signal source channel is taken as the optimal signal source channel; If the optimal even signal source channel is determined and the optimal odd signal source channel is not determined, then the optimal even signal source channel is taken as the optimal signal source channel; If the optimal odd signal source channel is determined and the optimal even signal source channel is determined, then the optimal signal source channel is calculated according to the optimal odd signal source channel and the optimal even signal source channel.

9. The lead position detection method according to claim 8, characterized in that, The determination of the optimal odd signal source channel from the candidate odd signal source channels includes: Selecting the odd signal source channel closest in position to the optimal odd signal source channel determined in the (i - 1)-th determination from the candidate odd signal source channels; If there is only one of the closest odd signal source channels, determining whether the selected candidate odd signal source channel is the same as or adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination; If the selected candidate odd signal source channel is the same as or adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination, then the candidate odd signal source channel is determined as the optimal odd signal source channel determined in the i-th determination; If the selected candidate odd signal source channel is different from and not adjacent to the optimal odd signal source channel determined in the (i - 1)-th determination, then determine the optimal odd signal source channel determined in the (i - 1)-th determination as the optimal odd signal source channel determined in the i-th determination; If there are two closest odd signal source channels, then determine the smaller odd signal source channel as the optimal odd signal source channel determined in the i-th determination.

10. The lead position detection method according to claim 8, wherein The determining the optimal even signal source channel according to the candidate even signal source channels includes: Selecting, from the candidate even signal source channels, the even signal source channel that is closest in position to the optimal even signal source channel determined in the (i - 1)-th determination; If there is one closest even signal source channel, then determining whether the selected candidate even signal source channel is the same as or adjacent to the optimal even signal source channel determined in the (i - 1)-th determination; If the selected candidate even signal source channel is the same as or adjacent to the optimal even signal source channel determined in the (i - 1)-th determination, then determine the candidate even signal source channel as the optimal even signal source channel determined in the i-th determination; If the selected candidate even signal source channel is different from and not adjacent to the optimal even signal source channel determined in the (i - 1)-th determination, then determine the optimal even signal source channel determined in the (i - 1)-th determination as the optimal even signal source channel determined in the i-th determination; If there are two closest even signal source channels, then determine the even signal source channel with a smaller value as the optimal even signal source channel determined in the i-th determination.

11. The lead position detection method according to claim 3, characterized in that, The signal source channels in the lead position detection device include n odd signal source channels or n even signal source channels, the candidate signal source channels are candidate odd signal source channels or candidate even signal source channels, and the determining the optimal signal source channel according to the candidate signal source channels includes: Selecting, from the candidate signal source channels, the signal source channel that is closest in position to the optimal signal source channel determined in the (i - 1)-th determination; If there is one closest signal source channel, then determining whether the selected candidate signal source channel is the same as or adjacent to the optimal signal source channel determined in the (i - 1)-th determination; If the selected candidate signal source channel is the same as or adjacent to the optimal signal source channel determined in the (i - 1)-th determination, then determine the candidate signal source channel as the optimal signal source channel determined in the i-th determination; If the selected candidate signal source channel is different from and not adjacent to the optimal signal source channel determined in the (i - 1)-th determination, then determine the optimal signal source channel determined in the (i - 1)-th determination as the optimal signal source channel determined in the i-th determination; If there are two closest signal source channels, then determine the signal source channel with a smaller value as the optimal signal source channel determined in the i-th determination.

12. The lead position detection method according to claim 8, wherein The calculating the optimal signal source channel according to the optimal odd signal source channel and the optimal even signal source channel includes: Calculating the average value of the odd value corresponding to the optimal odd signal source channel and the even value corresponding to the optimal even signal source channel; Taking the signal source channel corresponding to the integer value of the average value as the optimal signal source channel.

13. The lead position detection method according to claim 8, characterized in that The calculating the optimal signal source channel according to the optimal odd signal source channel and the optimal even signal source channel includes: Calculate a first difference between the odd value corresponding to the optimal odd signal source channel and the even value corresponding to the optimal even signal source channel; When the first difference is greater than a first predetermined difference, determine the signal source channel with a smaller value as the optimal signal source channel and give an alarm prompt.

14. The lead position detection method according to claim 3, wherein The lead position detection method further includes: After power-on, obtain the first reference voltage of the signal processing unit in real time; Calculate a second difference between the first reference voltage and the second reference voltage of the signal processing unit stored in advance; When the second difference is greater than a second predetermined difference, give an alarm prompt.

15. The lead position detection method according to claim 3, characterized in that The lead position detection method further includes: Compare the real-time voltages of all signal source channels with a predetermined occlusion voltage, where the predetermined occlusion voltage is the voltage when all signal source channels are occluded; when the real-time voltages of all signal source channels are less than the predetermined occlusion voltage within a predetermined time period, clear the reference voltage stored in the flash memory; Or, Calculate the product of the initial voltage and the predetermined wire occlusion rate, and compare the real-time voltages of all signal source channels with the product of the initial voltage and the predetermined wire occlusion rate, where the initial voltage is the voltage determined when all signal source channels are not occluded; When the real-time voltages of all signal source channels are less than the product of the initial voltage and the predetermined wire occlusion rate within a predetermined time period, clear the reference voltage.

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