Power transmission mechanism abnormality detection device and method

Abstract

The application discloses a kind of detection device and method of power transmission mechanism exception, which is coaxially arranged synchronous speed measuring turntable in the driving wheel of power transmission mechanism in the device;Multiple round holes are opened at the circumferential edge of synchronous speed measuring turntable;Speed sensor is arranged at any position on the circle formed by connecting the center of all openings in synchronous speed measuring turntable;The position of speed sensor is the same in each synchronous speed measuring turntable;Each speed sensor is connected with a pulse signal conversion amplification circuit;Pulse signal conversion amplification circuit is connected with corresponding timer through microprocessor;Microprocessor is connected with CAN transceiver;Microprocessor is connected with sliding rheostat;Sliding rheostat is used as the maximum deviation input of transmission speed;When the deviation of speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of sliding rheostat, the driving wheel of control power transmission mechanism stops rotating.The application can improve the safety and accuracy of monitoring power transmission mechanism.

Description

Technical Field

[0001] This invention relates to the field of transmission mechanism testing, and in particular to a device and method for detecting abnormalities in power transmission mechanisms. Background Technology

[0002] like Figure 1 As shown, existing transmission mechanisms for lifting or transporting materials employ one (or more) driving wheels to drive four driven wheels, such as... Figure 1 The driven wheels 1#-4# in the middle are linked to the driving wheel via a chain drive mechanism to maintain consistent speeds and achieve synchronized movement. This drives the central horizontal plate to vertically lift the materials placed on it. Figure 1 The vehicle shown is transported to the target height position by lifting or lowering.

[0003] If any part or step of the power transmission mechanism fails, the driving and driven wheels will rotate at different speeds, causing the horizontal plate to tilt. This can result in mechanical damage to the transmission mechanism or, in severe cases, the falling of materials, leading to a safety accident. To monitor the operating status of the transmission mechanism, current patents propose using vibration or sound sensors to collect signals. These time-domain signals are then converted into frequency-domain signals using Fourier transform, and spectral analysis is used to determine whether the transmission mechanism is functioning correctly.

[0004] However, existing solutions for monitoring transmission mechanisms have the following drawbacks:

[0005] 1. It has high requirements for hardware computing power, and the time-domain to frequency-domain conversion involves a large amount of data calculation, resulting in poor real-time performance.

[0006] 2. It can only identify some of the situations that cause transmission failure; for example, vibration or sound sensors cannot identify problems such as loosening or slipping of the belt drive mechanism.

[0007] 2. Due to the limitation of sensor detection distance, it cannot meet the detection requirements of large-sized power transmission mechanisms.

[0008] 3. Weak anti-interference ability; when vibration or sound sensors are used in mobile scenarios, road bumps and horn noises can easily cause the sensors to misjudge.

[0009] 4. Inability to accurately locate the fault location; vibration or sound sensors can only roughly determine that there is a fault in the transmission mechanism, but cannot accurately locate the location where the fault occurred.

[0010] To address the aforementioned shortcomings, a new monitoring method or system is proposed to improve the accuracy of monitoring power transmission mechanisms. Summary of the Invention

[0011] The purpose of this invention is to provide a detection device and method for abnormalities in power transmission mechanisms, which can improve the accuracy of monitoring power transmission mechanisms.

[0012] To achieve the above objectives, the present invention provides the following solution:

[0013] A device for detecting abnormalities in a power transmission mechanism includes: a synchronous speed measuring turntable, a speed sensor, a pulse signal conversion and amplification circuit, a microprocessor, a timer, a sliding rheostat, and a CAN transceiver;

[0014] The synchronous speed measuring turntable is coaxially arranged at the driving wheel of the power transmission mechanism; multiple circular holes are opened at the circumferential edge of the synchronous speed measuring turntable; a speed sensor is set at any position on the circle formed by connecting the centers of all the holes in the synchronous speed measuring turntable; the position of the speed sensor is the same in each synchronous speed measuring turntable; the driving wheel includes a driving wheel and a driven wheel;

[0015] Each speed sensor is connected to one of the pulse signal conversion and amplification circuits; the pulse signal transmission circuit is connected to the corresponding timer through the microprocessor; the microprocessor is connected to the CAN transceiver; the microprocessor is also connected to the sliding rheostat; the sliding rheostat is used as the maximum deviation input of the transmission speed; when the deviation of the speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the power transmission mechanism is controlled to stop rotating;

[0016] The speed sensor is used to acquire the pulse signal of the synchronous speed measuring turntable; the pulse signal conversion and amplification circuit is used to output a high-level voltage or a low-level voltage according to the pulse signal; the microprocessor is used to perform voltage compatibility testing on the output result of the pulse signal conversion and amplification circuit; the timer is used to determine the rotational speed signal of the synchronous speed measuring turntable according to the voltage-compatible output result.

[0017] Optionally, the CAN transceiver is used to package the rotational speed signal of each synchronous speed measuring turntable into a CAN network data frame, and send it to the CAN bus at a period of 1 second, so that the monitor can read the current rotational speed data of each moving wheel.

[0018] Optionally, it also includes: a relay;

[0019] The relay is connected to the microprocessor output pin;

[0020] The relay is used to stop the drive wheel of the power transmission mechanism from rotating when the deviation of the rotation speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, according to the drive control of the microprocessor.

[0021] Optionally, the number of holes on the synchronous speed measuring turntable is less than or equal to the response frequency of the speed measuring sensor.

[0022] Optionally, the speed sensor is a Hall effect speed sensor, a magnetoelectric vehicle speed sensor, a Hall effect vehicle speed sensor, or a photoelectric vehicle speed sensor.

[0023] Optionally, the pulse signal conversion and amplification circuit includes: a sampling resistor, a reference voltage, and a comparator amplifier;

[0024] One end of the sampling resistor is grounded, and the other end of the resistor is connected to the speed sensor and the positive input terminal of the comparator amplifier, respectively; one end of the reference voltage is grounded, and the other end of the reference voltage is connected to the inverting input terminal of the comparator amplifier.

[0025] The comparator amplifier is used to output a high-level voltage or a low-level voltage based on the comparison result between the reference voltage and the pulse signal.

[0026] Optionally, the number of timers is the same as the number of synchronous speed measuring turntables.

[0027] A method for detecting abnormalities in a power transmission mechanism, used to implement the aforementioned device for detecting abnormalities in a power transmission mechanism; the method includes:

[0028] Acquire the pulse signal from the speed sensor on each synchronous speed measuring turntable;

[0029] The pulse signal is output as a high-level voltage or a low-level voltage using a pulse signal transmission circuit.

[0030] Use a microprocessor to ensure voltage compatibility of the output results;

[0031] The rotational speed signal of the synchronous speed measuring turntable is determined by using a timer to analyze the voltage-compatible output results.

[0032] When the deviation of the rotational speed signals of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the control power transmission mechanism stops rotating.

[0033] Optionally, the step of using a pulse signal conversion and amplification circuit to output a high-level voltage or a low-level voltage from the pulse signal specifically includes:

[0034] The output result ΔV is determined using the formula ΔV = Vp - Vn;

[0035] Where Vp is the pulse signal and Vn is the reference voltage; when ΔV is positive, the output of the operational amplifier is close to the positive power supply voltage, which is a high-level voltage; when ΔV is negative, the output of the operational amplifier is close to the negative power supply voltage, which is a low-level voltage.

[0036] Optionally, it also includes: packaging the rotational speed signal of each synchronous speed measuring turntable into a CAN network data frame, and sending it to the CAN bus at a 1-second interval, so that the monitor can read the current rotational speed data of each moving wheel.

[0037] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0038] This invention provides a device and method for detecting abnormalities in a power transmission mechanism. A synchronous speed measuring turntable is coaxially mounted at the driving wheel of the power transmission mechanism. Speed ​​sensors are placed at arbitrary positions on a circle formed by connecting the centers of all the openings on the turntable. The speed sensors acquire pulse signals from the turntable, and a timer is used to connect to a corresponding pulse capture channel to determine the rotational speed signal, thus detecting abnormalities in the power transmission mechanism. This invention can identify all types of transmission abnormalities in the power transmission mechanism, providing early warnings for various fault modes and offering enhanced monitoring capabilities. The detection of abnormalities in the power transmission mechanism is not limited by the transmission distance. It has strong anti-interference capabilities and can be applied to static, moving, and high-noise application scenarios, expanding its applicability without affecting other production operations. This invention can accurately locate fault points; the wheel speed sensors are distributed for precise fault location, and fault points can be located based on abnormal rotational speed sensor data. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 A schematic diagram of the application structure of the synchronous transmission mechanism;

[0041] Figure 2 A schematic diagram of the structure of a power transmission mechanism abnormality detection device provided by the present invention;

[0042] Figure 3 A schematic diagram showing the installation location of the Hall sensor;

[0043] Figure 4 This is a schematic diagram of a timer loop counting;

[0044] Figure 5 This is a schematic diagram of pulse capture under normal conditions;

[0045] Figure 6This is a schematic diagram illustrating pulse capture timeout handling under special circumstances. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] The purpose of this invention is to provide a detection device and method for abnormal power transmission mechanisms, which can improve the accuracy of monitoring power transmission mechanisms.

[0048] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0049] like Figure 2 As shown, the present invention provides a detection device for abnormal power transmission mechanism, comprising: a synchronous speed measuring turntable, a speed measuring sensor, a pulse signal transmission circuit, a microprocessor, a timer, a sliding rheostat, and a CAN transceiver.

[0050] The synchronous speed measuring turntable is coaxially mounted at the driving wheel of the power transmission mechanism; multiple circular holes are formed on the circumferential edge of the synchronous speed measuring turntable; a speed sensor is placed at any position on the circle formed by connecting the centers of all the holes in the synchronous speed measuring turntable, and so on. Figure 3 As shown; the speed sensor is positioned in the same location in each synchronous speed measuring turntable; the moving wheel includes a driving wheel and a driven wheel;

[0051] Each speed sensor is connected to one of the pulse signal conversion and amplification circuits; the pulse signal transmission circuit is connected to a corresponding timer via the microprocessor; the microprocessor is connected to a CAN transceiver; the microprocessor is also connected to the sliding rheostat; the sliding rheostat is used as the maximum deviation input of the transmission speed to match different transmission mechanisms; when the deviation of the speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the power transmission mechanism is controlled to stop rotating;

[0052] The speed sensor is used to acquire the pulse signal of the synchronous speed measuring turntable; the pulse signal conversion and amplification circuit is used to output a high-level voltage or a low-level voltage according to the pulse signal; the microprocessor is used to perform voltage compatibility testing on the output result of the pulse signal conversion and amplification circuit; the timer is used to determine the rotation speed signal of the synchronous speed measuring turntable according to the voltage-compatible output result; the CAN transceiver is used to package the rotation speed signal of each synchronous speed measuring turntable into a CAN network data frame, and send it to the CAN bus at a period of 1 second, so that the monitor can read the current rotation speed data of each moving wheel.

[0053] The speed sensor includes, but is not limited to, Hall effect speed sensors, magnetoelectric vehicle speed sensors, Hall effect vehicle speed sensors, or photoelectric vehicle speed sensors.

[0054] As a specific embodiment, the present invention also includes: a relay;

[0055] The relay is connected to the microprocessor output pin;

[0056] The relay is used to stop the drive wheel of the power transmission mechanism from rotating when the deviation of the rotation speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, according to the drive control of the microprocessor.

[0057] like Figure 2 As shown, one driving wheel drives four driven wheels. Coaxial synchronous speed measuring discs are installed at the driving (driven) wheels, requiring a total of five synchronous speed measuring discs. Figure 2 (Only four are shown in the image) to check for transmission abnormalities in the synchronous lifting system, ensuring that the angular velocities of the driving (driven) wheels and the synchronous speed measuring turntables remain consistent. Holes should be drilled on the circumferential edge of each synchronous speed measuring turntable; the more holes, the higher the speed measurement accuracy.

[0058] The more openings there are, the more times the corresponding count occurs within one revolution. For example, if one revolution corresponds to 360°, and there are 36 openings, the angle between two adjacent openings is 10°; if there are 360 ​​openings, the angle between two adjacent openings is 1°. A greater number of openings allows for a more accurate reflection of the motion state. The number of openings is related to the size of the synchronous speed measuring turntable; the larger the turntable, the more openings there are. However, the number of holes on the synchronous speed measuring turntable is less than or equal to the response frequency of the speed sensor, for example, 20KHz.

[0059] As a specific embodiment, when the speed sensor is a Hall effect speed sensor, the Hall effect speed sensor can output a pulse current (voltage) signal. If the Hall effect speed sensor outputs a pulse current signal, this current signal is converted into a voltage signal through a sampling resistor; if the Hall effect speed sensor outputs a pulse voltage signal, this voltage signal remains unchanged after passing through the sampling resistor. The pulse voltage signal is connected to the positive input terminal Vp of the operational amplifier, and the inverting input terminal Vn of the operational amplifier is connected to a 0.5V reference voltage.

[0060] The pulse signal conversion and amplification circuit includes a sampling resistor, a reference voltage, and a comparator amplifier, which converts a small current (voltage) into a voltage compatible with a microcontroller system.

[0061] One end of the sampling resistor is grounded, and the other end of the resistor is connected to the speed sensor and the positive input terminal of the comparator amplifier, respectively; one end of the reference voltage is grounded, and the other end of the reference voltage is connected to the inverting input terminal of the comparator amplifier.

[0062] The comparator amplifier is used to output a high-level voltage or a low-level voltage based on the comparison result between the reference voltage and the pulse signal.

[0063] The number of timers is the same as the number of synchronous speed measuring discs. The number of synchronous speed measuring discs is determined by the number of timers, because the rotation process of the synchronous speed measuring discs requires individual timing to obtain the disc rotation speed.

[0064] Each timer is connected to a corresponding pulse capture channel. The current rotational speed value is obtained by measuring the time difference between two consecutive rising (falling) edges of the pulse signal. The specific calculation process is as follows:

[0065] like Figure 4 As shown, under normal circumstances, the timer continuously increases at a fixed frequency F1. At time t0, the count reaches ARR (ARR is the maximum count value of the timer). After overflow, the count value is 0, and it continues to increase in a loop.

[0066] like Figure 5 As shown, at time t1, the external Hall sensor input changes from high to low level, and a falling edge occurs in the signal. At this time, the timer count value corresponding to the input capture channel is cleared to zero. At time t2, the external input changes from high to low level, and a falling edge occurs in the signal. The count value at this time is read as n, and the current real-time pulse frequency F2 = T1 / n can be calculated. Then, the timer count value is cleared to zero, and the calculation is repeated in a loop.

[0067] like Figure 6As shown, in special cases, since the speed measurement data depends on two falling edges, if the synchronization mechanism stops after the first falling edge, the pulse period value cannot be refreshed, resulting in the pulse period value becoming invalid and causing system misjudgment. Therefore, a timer timeout mechanism is introduced. When the timer counts N = 1S / F1, the current pulse period value F2 = 0, that is, the current speed is 0.

[0068] The present invention provides a method for detecting abnormalities in a power transmission mechanism, used to implement the aforementioned device for detecting abnormalities in a power transmission mechanism; the method includes:

[0069] S101, acquire the pulse signal of the speed sensor on each synchronous speed measuring turntable;

[0070] S102, the pulse signal is output as a high-level voltage or a low-level voltage using a pulse signal conversion and amplification circuit;

[0071] S103 uses a microprocessor to ensure voltage compatibility of the output results;

[0072] S104 uses a timer to determine the rotational speed signal of the synchronous speed measuring turntable by using the voltage-compatible output result;

[0073] S105: When the deviation of the rotational speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the power transmission mechanism is controlled to stop rotating.

[0074] S102 specifically includes:

[0075] The output result ΔV is determined using the formula ΔV = Vp - Vn;

[0076] The microprocessor and operational amplifier are powered by non-isolated power supplies with the same supply voltage. Vp is a pulse signal and Vn is a reference voltage. When ΔV is positive, the output of the operational amplifier is close to the positive power supply voltage, which is a high-level voltage. When ΔV is negative, the output of the operational amplifier is close to the negative power supply voltage, which is a low-level voltage.

[0077] The present invention provides a method for detecting abnormalities in a power transmission mechanism, which further includes: processing the rotational speed signal of each synchronous speed measuring turntable into a data packet to form a CAN network data frame, and sending it to the CAN bus at a period of 1 second, and reading the current rotational speed data of each driving wheel through a monitor.

[0078] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to the method section.

[0079] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A detection device for abnormalities in a power transmission mechanism, characterized in that, include: Synchronous speed measuring turntable, speed sensor, pulse signal conversion and amplification circuit, microprocessor, timer and CAN transceiver; The synchronous speed measuring turntable is coaxially arranged at the driving wheel of the power transmission mechanism; multiple circular holes are opened at the circumferential edge of the synchronous speed measuring turntable; A speed sensor is placed at any position on the circle formed by connecting the centers of all the openings in the synchronous speed measuring turntable; the positions of the speed sensors are the same in each synchronous speed measuring turntable; the moving wheel includes a driving wheel and a driven wheel; Each speed sensor is connected to one of the pulse signal conversion and amplification circuits; the pulse signal conversion and amplification circuit is connected to a corresponding timer through the microprocessor; the microprocessor is connected to a CAN transceiver; the microprocessor is also connected to a sliding rheostat; the sliding rheostat is used as the maximum deviation input of the transmission speed; when the deviation of the speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the power transmission mechanism is controlled to stop rotating; The speed sensor is used to acquire the pulse signal of the synchronous speed measuring turntable; the pulse signal conversion and amplification circuit is used to output a high-level voltage or a low-level voltage according to the pulse signal; the microprocessor is used to perform voltage compatibility testing on the output of the pulse signal conversion and amplification circuit; the timer is used to determine the rotational speed signal of the synchronous speed measuring turntable according to the voltage-compatible output. The CAN transceiver is used to package the rotation speed signal of each synchronous speed measuring turntable into a CAN network data frame, and send it to the CAN bus at a period of 1 second. The monitor reads the current rotation speed data of each wheel. A detection device for abnormalities in a power transmission mechanism also includes: a relay; The relay is connected to the microprocessor output pin; The relay is used to stop the drive wheel of the power transmission mechanism from rotating when the deviation of the rotation speed signal of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, according to the drive control of the microprocessor.

2. The detection device for abnormality of power transmission mechanism according to claim 1, characterized in that, The number of holes on the synchronous speed measuring turntable is less than or equal to the response frequency of the speed measuring sensor.

3. The detection device for abnormality of power transmission mechanism according to claim 1, characterized in that, The speed sensor is a Hall effect speed sensor, a magnetoelectric speed sensor, a Hall effect speed sensor, or a photoelectric speed sensor.

4. The detection device for abnormality of power transmission mechanism according to claim 1, characterized in that, The pulse signal conversion and amplification circuit includes: a sampling resistor, a reference voltage, and a comparator amplifier; One end of the sampling resistor is grounded, and the other end of the resistor is connected to the speed sensor and the positive input terminal of the comparator amplifier, respectively; one end of the reference voltage is grounded, and the other end of the reference voltage is connected to the inverting input terminal of the comparator amplifier. The comparator amplifier is used to output a high-level voltage or a low-level voltage based on the comparison result between the reference voltage and the pulse signal.

5. The detection device for abnormality of power transmission mechanism according to claim 1, characterized in that, The number of timers is the same as the number of synchronous speed measuring turntables.

6. A method for detecting abnormalities in a power transmission mechanism, used to implement the power transmission mechanism abnormality detection device according to any one of claims 1-5; characterized in that, The method includes: Acquire the pulse signal from the speed sensor on each synchronous speed measuring turntable; The pulse signal is converted and amplified to output a high-level voltage or a low-level voltage using a pulse signal conversion and amplification circuit. Use a microprocessor to ensure voltage compatibility of the output results; The rotational speed signal of the synchronous speed measuring turntable is determined by using a timer to analyze the voltage-compatible output results. When the deviation of the rotational speed signals of each synchronous speed measuring turntable exceeds the maximum deviation of the sliding rheostat, the drive wheel of the control power transmission mechanism stops rotating.

7. The method for detecting abnormalities in a power transmission mechanism according to claim 6, characterized in that, The step of using a pulse signal conversion and amplification circuit to output a high-level voltage or a low-level voltage from the pulse signal specifically includes: Using formula Determine the output result ; in, It is a pulse signal. As the reference voltage; when When the value is +, the output of the operational amplifier is close to the positive power supply voltage, which is a high-level voltage. When the value is -, the output of the operational amplifier is close to the negative power supply voltage, which is a low-level voltage.

8. The method for detecting abnormalities in a power transmission mechanism according to claim 6, characterized in that, Also includes: The rotational speed signal of each synchronous speed measuring turntable is packaged and processed into a CAN network data frame, which is then sent to the CAN bus at a 1-second interval. The monitor reads the current rotational speed data of each moving wheel.

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