Coupling with composite detection function

Abstract

The invention discloses a coupling with a composite detection function, which comprises a base integrated with a control box and an intermediate body, the intermediate body is detachably sleeved with a stator disc and a rotor disc, the rotor disc is provided with a grating disc, the stator disc is provided with a light sensing device for sensing the grating disc, and the light sensing device is electrically connected with a processing unit in the control box; the intermediate is provided with a strain gauge, and the resistance of the strain gauge changes according to torque deformation of the intermediate during rotation; the strain gauge and a first induction coil on the rotor disc form a loop through an amplifying circuit, a second induction coil corresponding to the first induction coil is arranged on the stator disc, and electromagnetic induction is adopted to transmit data; the second induction coil is electrically connected with the processing unit in the control box, and transmits the received electric signals related to the resistance change of the strain gauge to the processing unit. Measurement of specific data such as torque, rotating speed and the like is integrated, the utilization rate of installation space is high, and overall structural design and space planning are facilitated.

Description

Technical Field

[0001] The invention belongs to the technical field of couplings and relates to a coupling with a composite detection function. Background Art

[0002] Couplings play an extremely important role in the transmission system of modern industry. With the progress of industrial development, the performance requirements for couplings have been raised to a new level. Performance such as vibration reduction, reliability, safety, long service life and noise reduction are all required to meet high-level standards. Moreover, in order to adapt to the trend of intelligent and digital industrial development, it is particularly important to give couplings self-detection capabilities. This self-detection capability can record the operating status of the coupling in real time, thereby providing a basis for analyzing the operating conditions of the motor input and load output ends, helping to determine the equipment pre-maintenance cycle. At the same time, its real-time transmitted data combined with the preset alarm limit can become an important part of the construction of intelligent systems and digital factories.

[0003] However, in the existing technical means, monitoring a certain stress state of the coupling is mainly achieved by adding corresponding measuring sensors in the transmission system. This solution does have certain advantages. It can measure a variety of different parameters to meet the monitoring needs of different aspects of the coupling.

[0004] However, this solution also exposes many disadvantages. First, from the perspective of cost, as the number of sensors in the coupling transmission system increases, the cost of use will inevitably increase. This is not only the purchase cost of the sensor itself, but also the cost increase caused by the additional requirements for the electrical signal processing part of the system due to the increase in the number of sensors, such as the need for more signal channels, signal processing equipment, and additional power supply. Secondly, there are many inconveniences in installation. On the one hand, it is necessary to select sensors with appropriate ranges and installation positions based on existing equipment, which is a complicated and time-consuming process; on the other hand, many transmission mechanisms (systems) may not have enough installation space to accommodate these sensors. If the measurement purpose is to be met, component replacement is required, which will undoubtedly lead to additional cost increases. Finally, from the perspective of safety and stability, the coupling is in a rotating state when it is working normally, and too many sensor cables will cause wiring difficulties. In a high-speed rotating system, there is also a risk that the cable will be caught in the rotating mechanism, which will cause downtime accidents and cause unstable signal transmission, affecting the normal operation of the entire transmission system.

[0005] Therefore, it is necessary to improve the prior art to overcome the defects in the prior art. Summary of the invention

[0006] The object of the present invention is to provide a coupling with a composite detection function, which solves at least one problem mentioned in the background technology by improving the structure and function.

[0007] The objective of the present invention is achieved through the following technical solutions: A coupling with a composite detection function, installed between a motor shaft and a load device, comprises a base with an integrated control box and an intermediate body, wherein the base is provided with a stator disk connected to the base; a rotor disk is fixedly connected to the intermediate body and can rotate with the intermediate body, and the stator disk is non-contactly connected to the rotor disk on the intermediate disk and adopts electromagnetic induction to transmit data; The rotor disk is provided with a grating disk, the stator disk is provided with a photosensitive device for sensing the grating disk, and the photosensitive device is electrically connected to a processing unit in a control box; The intermediate body is provided with a strain gauge, and the resistance of the strain gauge changes according to the torque deformation of the intermediate body during rotation; the strain gauge forms a loop with the first induction coil on the rotor disk through an amplifying circuit, and the stator disk is provided with a second induction coil corresponding to the first induction coil, and electromagnetic induction is used to transmit data; the second induction coil is electrically connected to the processing unit in the control box, and transmits the received electrical signal of the resistance change of the strain gauge to the processing unit.

[0008] As a further improvement of an embodiment of the present invention, the stator disk and the rotor disk are isolated and protected by an outer cover.

[0009] As a further improvement of an embodiment of the present invention, the intermediate body is in an "I"-shaped structure, both ends of the intermediate body are flanges, and the intermediate body is made of a rigid material with good wear resistance.

[0010] As a further improvement of an embodiment of the present invention, the rigid material is 40CrNiMoA alloy steel.

[0011] As a further improvement of one embodiment of the present invention, the grating disk is provided with a specific number of grating holes in a circumferential direction, the photosensitive device emits a light signal and senses the reflection of light that does not pass through the grating holes on the grating disk, and converts the received light into a pulse signal and transmits it to the processing unit.

[0012] As a further improvement of an embodiment of the present invention, the light sensing device includes a photoelectric sensor.

[0013] As a further improvement of one embodiment of the present invention, the processing unit includes a data processing module and a power module, a reset module, a storage module, an output module and an acquisition module electrically connected to the data processing module, and the output module transmits data with the back-end device or the host computer via wireless transmission or wired transmission.

[0014] As a further improvement of an embodiment of the present invention, the rotor disk is composed of an upper rotor disk and a lower rotor disk, and the upper rotor disk and the lower rotor disk are fastened to the intermediate body by screws and cured by glue.

[0015] As a further improvement of an embodiment of the present invention, the stator disc is composed of an upper stator disc and a lower stator disc, and the upper stator disc and the lower stator disc are fastened by screws.

[0016] As a further improvement of an embodiment of the present invention, a data connector electrically connected to the processing unit is provided on the base.

[0017] As a further improvement of an embodiment of the present invention, a sealing plate for sealing one side of the control box is provided on the base, and the sealing plate is fixed to the base by screws.

[0018] The above technical solution has the following beneficial effects: the rotation speed is monitored by integrating a grating disk on the rotor disk and arranging a photosensitive device on the stator disk, and the torque is measured by sensing the resistance change of the strain gauge, so that the measurement of specific data such as torque and rotation speed can be integrated into one, and the utilization rate of the installation space is high, which is more beneficial to the overall structural design and space planning; the stator disk, as an accessory, only needs to be removed and then installed, and does not need to be replaced together with the coupling; data transmission adopts wireless transmission and is no longer restricted by the use of cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0020] The structures, proportions, sizes, etc. illustrated in this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with the technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantial technical significance. Any structural modification, change in proportion or adjustment of size shall still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and purposes that can be achieved by the present invention.

[0021] Figure 1 A schematic diagram of the three-dimensional structure provided by the present invention (missing the diaphragm and the sleeve).

[0022] Figure 2 for Figure 1 Schematic diagram of the three-dimensional structure of the hidden outer cover.

[0023] Figure 3 This is a structural block diagram of the processing unit provided by the present invention.

[0024] Figure 4 This is a schematic diagram of the three-dimensional structure provided by the present invention.

[0025] In the figure: 1-base; 11-covering plate; 12-data connector; 2-intermediate; 21, 22-flange; 3- Outer cover; 4- stator plate; 5- rotor disk; 51- grating disk; 6- diaphragm; 7- Bushing. DETAILED DESCRIPTION

[0026] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0027] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meanings as commonly understood by ordinary technicians in the technical field to which this application belongs.

[0028] In the present invention, unless otherwise specified, the directional words used, such as "up, down, top, bottom", usually refer to the directions shown in the drawings, or to the components themselves in the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "inside and outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directional words are not used to limit the present invention. Example

[0029] See also Figure 1-Figure 4 As shown, a coupling with a composite detection function is installed between the motor shaft and the load device, including a base 1 and an intermediate body 2 with an integrated control box, a stator disc 4 connected to the base is provided on the base 1; a rotor disc 5 is fixedly connected to the intermediate body 2 and can rotate with the intermediate body 2, and the stator disc 4 and the rotor disc on the intermediate disc 2 are non-contactly connected and adopt electromagnetic induction to transmit data. Among them, the stator disc 4 and the rotor disc 5 are isolated and protected by an outer cover 3.

[0030] In particular, a grating disk 51 is provided on the rotor disk 5, and a photosensitive device that senses the grating disk 51 is provided on the stator disk 4. The combination of the grating disk 51 and the photosensitive device provides an accurate means for detection. Specifically, a specific number of grating holes are provided on the grating disk 51 in the circumferential direction. When the rotor disk 5 rotates, the grating disk 51 rotates together. After the photosensitive device (which can be a photoelectric sensor) sends out a light signal, it collects the light reflected on the grating disk 51, and the number of holes in the grating disk 51 is used as the corresponding collection accuracy. The received light is converted into a pulse signal and transmitted to the processing unit in the control box (that is, the photosensitive device sends out a light signal and senses the reflection of the light that does not pass through the grating holes on the grating disk 51, and converts the received light into a pulse signal and transmits it to the processing unit). The processing unit can accurately calculate important parameters such as the rotation speed and rotation angle of the rotor disk 5 based on information such as the frequency of the pulse signal and the number of grating holes. This design realizes accurate monitoring of the operating status of the coupling, which is conducive to efficient and stable transmission between the motor and the load equipment.

[0031] In addition, in this embodiment, a strain gauge is provided on the intermediate body 2. The installation steps of the strain gauge are as follows: first, clean the surface of the intermediate body 2 and preheat it, then stick two sets of strain gauges to the surface of the intermediate body 2 and fix them with high temperature resistant tape; then place the pasted sample in a 190°C environment for 1.5 hours to cure the glue; next, lead the connection wire from the strain gauge to the circuit board to form a Wheatstone bridge; then weld the lead wire, and use special equipment to compensate the zero point of the strain gauge; finally, apply protective glue on the surface and fix the lead wire.

[0032] During the operation of the coupling, when the intermediate body 2 is subjected to torque, it will deform. Since the strain gauge is attached to the rotor disk 5 and corresponds to the intermediate body 2, the torque deformation of the intermediate body 2 will change the resistance of the strain gauge. The strain gauge forms a loop with the first induction coil on the rotor disk 5 through the amplifier circuit. The role of the amplifier circuit is crucial because the change in the resistance of the strain gauge is usually very small. The amplifier circuit can convert this small resistance change into a detectable electrical signal and cause a change in current in the loop.

[0033] The stator disk 4 is provided with a second induction coil corresponding to the first induction coil, and electromagnetic induction is used to transmit data. According to the principle of electromagnetic induction, when the current in the first induction coil on the rotor disk 5 changes due to the change in strain gauge resistance, a changing magnetic field will be generated. When the second induction coil on the stator disk 4 is in this changing magnetic field, an induced electromotive force will be generated. The second induction coil is electrically connected to the processing unit in the control box, so that the received electrical signal related to the change in strain gauge resistance is transmitted to the processing unit. The processing unit can further analyze information such as the size of the torque applied to the intermediate body 2 based on these electrical signals, providing more accurate data support for the working status monitoring, fault warning and equipment maintenance of the coupling.

[0034] Specifically, the intermediate body 2 is an I-shaped structure, with flanges 21 and 22 at both ends, and the flanges 21 and 22 are respectively connected to the sleeve 7 through the diaphragm 6. The intermediate body 2 is made of a rigid material, such as 40CrNiMoA alloy steel, which has good wear resistance.

[0035] From the basic function of the coupling, the intermediate body 2, as an important part connecting the motor shaft and the load equipment, must achieve the functions of transmitting power, compensating for axial and radial displacement deviations, and buffering vibrations. The wear-resistant performance ensures the reliability of the intermediate body during long-term use and reduces the performance degradation caused by wear. Since the strain gauge is set at the position corresponding to the intermediate body, this torque deformation can be easily sensed by the strain gauge, and the strain gauge then changes its resistance. The relevant signal is transmitted to the processing unit in the control box through the subsequent induction coil and circuit, realizing accurate detection of the stress condition of the intermediate body.

[0036] like Figure 3 As shown, the processing unit is an integrated circuit board, which has a data processing module and a power module, a reset module, a storage module, an output module and a collection module electrically connected to the data processing module. The acquisition module receives signals from the photosensitive device and the second induction coil, and performs preliminary conditioning on these signals, such as filtering and amplification, so that the signals meet the input requirements of the data processing module and ensure the accuracy of subsequent data processing.

[0037] The data processing module is the key part of the processing unit. It is responsible for processing the various signals received from the photosensitive device (the pulse signal generated by the processing of the inductive grating disk feedback) and the second induction coil (the electrical signal related to the change of the resistance of the strain gauge). It uses the pre-set algorithm to analyze and calculate these signals to obtain various parameters about the working status of the coupling, such as speed, rotation angle, torque size and other information.

[0038] The power module provides the necessary power for the entire processing unit. It converts and stabilizes the external input power to ensure that stable and appropriate voltage is provided to the data processing module, reset module, storage module, output module and acquisition module to ensure the normal operation of each module. Without a stable power supply, other modules will not be able to operate normally.

[0039] The reset module is used to restore the processing unit to its initial state under certain circumstances. For example, when the processing unit encounters a program error, runs abnormally, or receives an external reset command, the reset module can restore various registers, counters and other components to their default values, allowing the processing unit to resume normal operation and ensure the accuracy and stability of data processing.

[0040] The storage module is used to store various data during the operation of the processing unit. It includes pre-set parameters, such as the number of grating holes used to calculate the rotation speed, and temporarily stored data during operation, such as the collected pulse signals and electrical signal data, and intermediate results processed by the data processing module. It provides data caching for continuous data processing and subsequent queries.

[0041] The output module is mainly responsible for sending the data about the working status of the coupling obtained after processing by the processing unit. It transmits data with the back-end device or the host computer through wireless transmission or wired transmission. The wireless transmission method facilitates remote monitoring and centralized management of data, allowing operators to obtain real-time information on the working status of the coupling at a distance from the coupling, which is convenient for effective control and maintenance of the entire system.

[0042] The debugging module plays a key role in the development, testing and subsequent maintenance of the coupling. During the development phase, it allows engineers to adjust and optimize the data processing algorithms in the processing unit to accurately process the signals from the photosensitive device and the induction coil. During the test process, the debugging module can set different test parameters, simulate the signal input under various working conditions, and check whether the output of the processing unit meets expectations. During maintenance, technicians can use the debugging module to troubleshoot the processing unit and find possible problems.

[0043] The self-detection module is responsible for testing the processing unit of the coupling itself. It performs self-tests on the data processing module, power module, storage module and other components regularly or on demand. For example, it can detect whether the operation function of the data processing module is normal, whether the voltage output of the power module is stable, whether the data reading and writing of the storage module is correct, etc. Once any abnormal situation is found, the self-detection module will promptly send an alarm message to the relevant system so that corresponding maintenance measures can be taken to ensure the normal operation of the coupling.

[0044] The processing unit also has an alarm circuit electrically connected to the data processing module. After the data processing module analyzes and processes the data received from various sensors (such as the speed signal obtained by the photosensitive device of the sensing grating disk, and the torque signal obtained by the resistance change of the sensing strain gauge, etc.), if it is found that the data exceeds the normal working range, such as too high or too low speed, abnormal torque, etc., it will send an abnormal signal to the alarm circuit. After receiving the signal, the alarm circuit starts the corresponding alarm action according to the pre-set alarm rules. This may include sending an audible and visual alarm signal to intuitively prompt the operator that the coupling has an abnormal condition. In some automated production environments, the alarm circuit can also be connected to the monitoring system of the entire production system to transmit the alarm information to the remote monitoring terminal, so as to facilitate timely measures to avoid greater losses caused by coupling failure.

[0045] The base 1 is provided with a data connector 12 electrically connected to the processing unit. It is an interface for the processing unit to exchange data with external devices. By connecting the data connector 12 to the data line, the processing unit can transmit the working status data of the coupling to other devices, and can also receive instructions or configuration information sent by external devices.

[0046] A sealing plate 11 is provided on the base 1 to seal one side of the control box, and the sealing plate 11 is screwed to the base 1. This design effectively protects the processing unit inside the control box, preventing dust, water vapor and other impurities from entering the control box, thereby affecting the normal operation of the processing unit.

[0047] The processing unit is placed in the control box, and this layout makes the structure of the entire coupling more compact. When the processing unit needs to be replaced and maintained, since the sealing plate 11 is locked by screws, it is only necessary to remove the sealing plate to handle the processing unit. This design greatly reduces the difficulty of processing unit maintenance, and there is no need to perform complex disassembly operations on the entire coupling, saving maintenance time and cost, improving the maintainability of the equipment, and ensuring that the coupling can operate stably and long-term in an industrial environment.

[0048] In this embodiment, the rotor disc 5 is composed of an upper rotor disc and a lower rotor disc, which are fastened to the intermediate body 2 by screws and cured with glue. This fastening method ensures the stability of the connection between the rotor disc 5 and the intermediate body 2. During the assembly process, the upper and lower rotor discs are accurately fixed to the intermediate body 2 by screws, so that the rotor disc 5 can rotate stably with the intermediate body 2, meeting the transmission requirements of the coupling.

[0049] The stator plate 4 is composed of an upper stator plate and a lower stator plate, the upper stator plate and the lower stator plate are fastened by screws, and the lower stator plate is fixed to the base 1 by screws. This structural design makes the assembly of the stator plate more convenient and the structure more stable.

[0050] The coupling is an easily replaceable part in actual use, which greatly facilitates the maintenance of the equipment. The stator disc 4 is an accessory. When maintenance or replacement is required, it only needs to be removed and reinstalled, and does not need to be replaced together with the coupling. This design not only reduces maintenance costs, but also reduces the time waste and impact on the entire transmission system caused by replacing the entire coupling. When there is a problem with the stator disc, targeted treatment can be carried out quickly and efficiently to ensure the normal operation of the equipment.

[0051] The coupling of the present invention is an innovative transmission connection device having many unique advantages.

[0052] First of all, the monitoring function has been integrated. The grating disk is integrated on the rotor disk, and a photosensitive device is set in the stator disk area. The two work together to achieve accurate monitoring of the rotation speed. A specific number of grating holes are set in the circumferential direction of the grating disk. As the rotor disk rotates, the photosensitive device senses the reflected light on the grating disk and converts it into a pulse signal. After this pulse signal is transmitted to the processing unit, accurate rotation speed data can be obtained after processing. In addition, by setting a strain gauge on the intermediate body, the resistance of the strain gauge changes when the intermediate body is deformed by torque, and the torque is measured by sensing the resistance change of the strain gauge. This design that integrates the measurement of specific data such as torque and rotation speed greatly improves the functionality of the coupling.

[0053] In terms of structural design, this integrated measurement method has a high utilization rate of the installation space. Compared with the traditional method of using different devices to measure torque and speed, this coupling does not need to reserve a large amount of space for each measuring device, which is more beneficial to the overall structural design and space planning. At the same time, the stator disc and rotor disc, as important components, are designed as accessories that only need to be removed and then installed, and do not need to be replaced with the coupling. In this way, when there is a problem with the stator disc or rotor disc, it can be maintained or replaced separately, which is convenient and reduces costs.

[0054] In terms of data transmission, the use of wireless transmission is also a highlight. Traditional wired transmission requires the layout of cables, which is not only cumbersome to install, but also the cables may be worn, pulled, and other problems during use, affecting the stability of data transmission. The data transmission of this coupling adopts wireless transmission, which is no longer restricted by the use of cables, making data transmission more flexible and stable, and also facilitating data interaction between the coupling and the back-end equipment or host computer, which can better adapt to the development needs of modern industrial automation and intelligence.

[0055] In summary, the coupling of the present invention has significant advantages in terms of functional integration, structural design, component maintenance, and data transmission, and can be widely used in various industrial transmission fields.

[0056] Obviously, the above-described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0057] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0058] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein.

[0059] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A coupling with a composite detection function, installed between a motor shaft and a load device, characterized in that: It includes a base and an intermediate body with an integrated control box, wherein the base is provided with a stator disk connected to the base; the rotor disk is fixedly connected to the intermediate body and can rotate with the intermediate body, and the stator disk is non-contactly connected with the rotor disk on the intermediate disk and adopts electromagnetic induction to transmit data; the rotor disk is provided with a grating disk, and the stator disk is provided with a photosensitive device that senses the grating disk, and the photosensitive device is electrically connected to the processing unit in the control box; The intermediate body is provided with a strain gauge, and the resistance of the strain gauge changes according to the torque deformation of the intermediate body during rotation; the strain gauge forms a loop with the first induction coil on the rotor disk through an amplifying circuit, and the stator disk is provided with a second induction coil corresponding to the first induction coil, and electromagnetic induction is used to transmit data; the second induction coil is electrically connected to the processing unit in the control box, and transmits the received electrical signal of the resistance change of the strain gauge to the processing unit.

2. The coupling with composite detection function according to claim 1, characterized in that: The intermediate body is in an "I"-shaped structure, and both ends of the intermediate body are flanges. The intermediate body is made of a rigid material with good wear resistance.

3. The coupling with composite detection function according to claim 2, characterized in that: The rigid material is 40CrNiMoA alloy steel.

4. The coupling with composite detection function according to claim 1, characterized in that: The grating disk is provided with a specific number of grating holes in the circumferential direction; the photosensitive device emits a light signal and senses the reflection of the light that does not pass through the grating holes on the grating disk, and converts the received light into a pulse signal and transmits it to the processing unit.

5. The coupling with composite detection function according to claim 4, characterized in that: The light sensing device includes a photoelectric sensor.

6. The coupling with composite detection function according to claim 1, characterized in that: The processing unit includes a data processing module and a power module, a reset module, a storage module, an output module and a collection module electrically connected to the data processing module. The output module transmits data with a back-end device or a host computer through wireless transmission or wired transmission.

7. The coupling with composite detection function according to claim 1, characterized in that: The rotor disk is composed of an upper rotor disk and a lower rotor disk, and the upper rotor disk and the lower rotor disk are fastened to the intermediate body by screws and cured by glue.

8. The coupling with composite detection function according to claim 1, characterized in that: The stator plate is composed of an upper stator plate and a lower stator plate, and the upper stator plate and the lower stator plate are fastened by screws.

9. The coupling with composite detection function according to claim 1, characterized in that: The base is provided with a data connector electrically connected to the processing unit.

10. The coupling with composite detection function according to claim 1, characterized in that: A sealing plate for sealing one side of the control box is arranged on the base, and the sealing plate is fixed on the base by screws.

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