Detection method and system of torque sensor

Abstract

The invention discloses a detection and monitoring system for a torque sensor, which comprises a power supply module, a current-to-voltage module, a signal processing module and a logic processing module, and is characterized in that the power supply module and the current-to-voltage module are used for supplying power to the torque sensor and converting current data into voltage data; the signal processing module is used for analyzing a specific protocol message transmitted by a torque sensor and transmitting an analysis result to the logic processing module; and the logic processing module is used for carrying out detection logic judgment on the torque sensor and displaying judgment information. According to the invention, a specific protocol message transmitted by the torque sensor is analyzed, the analyzed result is dynamically displayed in real time through the upper computer, the fault type of the sensor is judged according to the detection logic, the corresponding FTA is given for the fault type, and the rapid diagnosis of the sensor fault is completed.

Description

Technical Field

[0001] The present invention relates to the field of automobiles, and in particular to a detection method and system for a torque sensor. Background Art

[0002] Torque sensors are sensors that sense torsional torque on various rotating or non-rotating mechanical parts. Torque sensors convert physical changes in torque into precise electrical signals.

[0003] The torque sensors in the current prior art take a long time to manually process data, have low test efficiency, and generally have low test accuracy. Summary of the invention

[0004] The present invention provides a torque sensor detection and monitoring system, which parses specific protocol messages transmitted by the torque sensor, dynamically displays the parsed results in real time through a host computer, determines the type of fault occurring in the sensor based on the detection logic, gives a corresponding FTA for the fault type, and completes rapid diagnosis of the sensor fault.

[0005] In order to solve the above technical problems, the present invention provides a torque sensor detection and monitoring system, including a power supply module and a current-to-voltage module, a signal processing module and a logic processing module, wherein the power supply module and the current-to-voltage module are used to supply power to the torque sensor and convert current data into voltage data; the signal processing module is used to parse the specific protocol message transmitted by the torque sensor, and transmit the parsed result to the logic processing module; the logic processing module is used to judge the torque sensor detection logic and display the judgment information.

[0006] Preferably, the signal processing module includes:

[0007] Clock frequency division module: used to divide the system clock frequency;

[0008] Decoding module: receives sensor signals and performs PAS decoding;

[0009] Synchronous storage module: receives and stores the parallel data decoded by the upper module;

[0010] Message sending module: used to read the data stored in the synchronous storage module, and convert the data into serial data to transmit to the IPC logic processing module.

[0011] Preferably, the clock frequency division module is implemented as follows: an internal counter is set and internal parameters are set; after power-on, the system reset signal is low, and the system performs a reset operation; after three system clock cycles, the system reset signal is pulled high, and the internal counter performs an increment operation after each clock rising edge.

[0012] Preferably, the decoding module implements the steps of: performing PAS decoding on the 26-bit high and low level signals of the sensor, using Manchester decoding rules, defining high and low level states, performing data selection on a specific DATA segment, and transmitting the decoded 8-bit data in parallel to the synchronous storage module.

[0013] Preferably, the synchronous storage module stores data with a bit width of 8 and a depth of 256.

[0014] Preferably, the message sending module obtains data from the synchronous storage module by sending a completion flag, and converts 8-bit parallel data into serial data through the UART protocol and transmits it to the IPC.

[0015] Preferably, the logic processing module includes a torque value detection module, a torque circle radius detection module, a short circuit and open circuit detection module and a display module.

[0016] Preferably, the torque circle radius detection module is implemented by:

[0017] Step S101, calculating a digital quantity through a group of incoming data messages;

[0018] Step S102, the calculation result is transmitted to the logic diagnosis module for determination with a given digital value threshold;

[0019] Step S103, if the torque circle exceeds the upper limit or the lower limit, it is determined that the sensor is failed;

[0020] Step S104, giving a fault code and a fault FTA.

[0021] Preferably, the torque value detection module is implemented by:

[0022] Step S201, calculating a digital quantity through a group of incoming data messages;

[0023] Step S202, calculating the relative angle between the actual input axis and the output axis of the digital quantity through an inverse trigonometric function;

[0024] Step S203, multiplying the calculated actual relative angle value by the torsion bar stiffness coefficient to obtain the actual torque;

[0025] Step S204, transferring the calculation result to the logic diagnosis module and performing three state determinations with the given torque threshold;

[0026] Step S205: If the torque value exceeds the upper limit or the lower limit or the torque change within a unit time exceeds the threshold range, it is determined that the sensor has failed;

[0027] Step S206, giving a fault code and a fault FTA.

[0028] Preferably, the short circuit and open circuit detection module is implemented by:

[0029] Step S301, calculating the actual loop current value by the voltage drop of the current signal flowing through the two ends of the resistor;

[0030] Step S302, comparing the calculated current value with a set threshold;

[0031] Step S303, judging whether a circuit short circuit or a circuit open circuit occurs according to the comparison result;

[0032] Step S304, giving a fault code and a fault FTA.

[0033] The present invention is based on three torque sensor detection logics and decomposes the test items into five detection thresholds. The IPC performs logical operations and mutual verification with the detection thresholds through the parsed underlying data, and then outputs a fault code. The detection program and the sensor fault have a unique mapping relationship, thereby improving the test coverage.

[0034] At the same time, the present invention adds logical judgment and analytical processing of data to the underlying data processing module, thereby reducing the time for manual data processing and improving test efficiency.

[0035] In addition, the present invention can realize customized development of test sequences for the sensor testing requirements of the protocol, clarify the test process, store all test data, and increase the accuracy of sensor automation testing. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments:

[0037] Figure 1 A block diagram of the torque sensor monitoring system of the present invention is designed.

[0038] Figure 2 This is a diagram of the internal circuit module of the signal processing module of the torque sensor monitoring system of the present invention.

[0039] Figure 3 This is a circuit logic block diagram of the clock frequency division module of the torque sensor monitoring system of the present invention.

[0040] Figure 4 This is a logic block diagram of the circuit module of the decoding module of the torque sensor monitoring system of the present invention.

[0041] Figure 5 This is a logic block diagram of the synchronous storage module of the torque sensor monitoring system of the present invention.

[0042] Figure 6 This is a logic block diagram of the message sending module of the torque sensor monitoring system of the present invention.

[0043] Figure 7This is a block diagram of the torque circle radius detection module of the torque sensor monitoring system of the present invention.

[0044] Figure 8 This is a block diagram of the torque value detection module of the torque sensor monitoring system of the present invention.

[0045] Fig. 9 This is a block diagram of the short circuit and open circuit detection module of the torque sensor monitoring system of the present invention. DETAILED DESCRIPTION

[0046] The following describes the implementation methods of the present invention through specific specific embodiments, and those skilled in the art can fully understand other advantages and technical effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through different specific implementation methods, and the details in this specification can also be applied based on different viewpoints, and various modifications or changes can be made without deviating from the overall design concept of the invention. It should be noted that the following embodiments and the features in the embodiments can be combined with each other in the absence of conflict. The following exemplary embodiments of the present invention can be implemented in a variety of different forms and should not be interpreted as being limited to the specific embodiments described herein. It should be understood that these embodiments are provided to make the disclosure of the present invention thorough and complete, and to fully convey the technical solutions of these exemplary specific embodiments to those skilled in the art.

[0047] Example 1

[0048] The present invention is based on the hardware equipment required for torque sensor testing (such as Figure 1 As shown in FIG. 1 ), the structure includes a power supply module, a signal processing module, and an IPC logic processing module. Since the selection of components and the structure of the torque sensor test system are well-known, the present invention does not describe its hardware.

[0049] The present invention converts the sensor current detection signal into a voltage signal through TS3022 and feeds it into the signal processing module. The signal processing module (EP4CE10F17C8) includes 4 submodules, such as Figure 2 As shown: clock division module (DIVIDE_CLK), decoding module (MANCHESTER_RX), synchronous storage module (SYNC_FIFO), and message sending module (UART_TX). Figure 2 The module names and corresponding functions are shown in Table 1:

[0050]

[0051] Table 1

[0052] like Figure 2As shown, the internal circuit implementation principle is: the clock division module DIVIDE_CLK module divides the inherent 50MHZ system clock of EP4CE10F17C8 by 25 to obtain the required 2MHZ clock signal, which is provided to the three modules of the subsequent stage MANCHESTER_RX, SYNC_FIFO, and UART_TX; the decoding module MANCHESTER_RX module performs PAS decoding on the 26-bit high and low level signals of the sensor, adopts Manchester decoding rules, defines the high and low level states: "01"->"0", "10"->"1", selects data for a specific DATA segment, and transmits the decoded 8-bit data in parallel to the synchronous storage module SYNC_FIFO. The synchronous storage module SYNC_FIFO stores data with a bit width of 8 and a depth of 256. The message sending module UART_TX takes data from the upper module (SYNC_FIFO) by sending the completion flag bit, and converts the 8-bit parallel data into serial data and transmits it to the IPC through the UART protocol.

[0053] Figure 3 This is the circuit logic block diagram of the clock frequency division module of the torque sensor monitoring system of the present invention. Figure 3 The signal names and corresponding signal descriptions are shown in Table 2 below:

[0054]

[0055] Table 2

[0056] like Figure 3 As shown, the implementation steps of DIVIDE_CLK are: set the internal counter count, set the internal parameters MAX_CNT = 24, TOG_CNT = 12, after power-on, the Rst_n signal is low, and the system performs a reset operation. After 3 system clock cycles, the Rst_n reset signal is pulled high, and the internal counter count is incremented by 1 after each clock rising edge.

[0057] Concurrent execution logic:

[0058] When the accumulated result of the count counter is less than 12, the frequency-divided clock signal clk is set to 1, and when the accumulated result of the count counter is greater than or equal to 12, the frequency-divided clock signal clk is set to 0;

[0059] When the accumulated result of the count counter is less than 24, the count counter performs an increment operation, and when the accumulated result of the count counter is greater than or equal to 24, the counter is cleared to 0.

[0060] Therefore, the 50MHZ clock frequency is finally divided by 25, and the new clock frequency is The duty cycle is

[0061] Figure 4 This is the logic block diagram of the decoding module circuit module of the torque sensor monitoring system of the present invention. As Figure 4 shown in the following table 3, the signal names and corresponding signal descriptions are as follows:

[0062]

[0063] Table 3

[0064] Figure 5 This is the design block diagram of the synchronous storage module of the torque sensor monitoring system of the present invention, Figure 5 and the signal names and corresponding signal descriptions in it are as shown in the following table 4:

[0065]

[0066] Table 4

[0067] Figure 6 This is the logic block diagram of the message sending module of the torque sensor monitoring system of the present invention, Figure 6 and the signal names and corresponding signal descriptions in it are as shown in the following table:

[0068]

[0069] The parsed signals are subjected to data calculation and threshold detection through the logic processing module. The logic processing module includes a torque value detection module, a torque circle radius detection module, a short circuit and open circuit detection module, and a display module. Among them, the block diagram of the torque circle radius detection module is as Figure 7 shown, and its implementation steps are as follows:

[0070] 1. Calculate the Sin & Cos digital quantities (Digits) through a group of 52 Bits data messages passed in;

[0071] 2. Pass the calculation result into the logic diagnosis module to make a determination with the given digital quantity threshold

[0072] Digits sin / cos <Digits_lower (lower limit of digital quantity);

[0073] Digits sin / cos >Digits_upper (upper limit of digital quantity);

[0074] 3. If the torque circle (Lissajous circle) exceeds the upper or lower limit, it is determined that the sensor fails;

[0075] 4. Give the fault code and fault FTA.

[0076] The parsed signal also undergoes data calculation and threshold detection through the torque value detection module, and outputs the final detection result and the failure mode of torque value exceeding the limit. Its block diagram is as Figure 8 shown, and its implementation steps are as follows:

[0077] 1. Calculate the Sin&Cos digital quantity (Digits) from a set of incoming 52Bits data packets;

[0078] 2. Calculate the relative angle value between the actual input shaft and the output shaft through the digital quantity using the inverse trigonometric function

[0079] θ = I shaft - O shaft ;

[0080] 3. Multiply the calculated actual relative angle value by the torsion bar stiffness coefficient to obtain the actual torque magnitude: T = θ ×

[0081] Stiffness;

[0082] 4. Pass the calculation result into the logic diagnosis module to perform three - state determination with the given torque threshold:

[0083] ① T < T_lower (torque lower limit);

[0084] ② T > T_upper (torque upper limit);

[0085] ③ ΔT > ΔT_upper (instantaneous torque upper limit);

[0086] 5. If the torque value exceeds the upper or lower limit or the change torque within the unit time exceeds the threshold range, it is determined that the sensor fails;

[0087] 6. Give the fault code and fault FTA.

[0088] Meanwhile, the short - circuit and open - circuit detection module calculates the current value through the construction of the peripheral hardware circuit and compares it with the short - circuit & open - circuit threshold of the loop, and outputs the final loop state detection result and the short - circuit & open - circuit failure mode, as Fig. 9 shown, and its implementation steps are as follows:

[0089] 1. Calculate the actual loop current value through the voltage drop across the resistor when the current signal flows through;

[0090] 2. Compare the calculated current value with the set threshold:

[0091] ① I < I_lower;

[0092] ② I > I_upper;

[0093] 3. If the loop current shows the above - mentioned ① situation, then a loop open - circuit occurs;

[0094] If the loop current reaches the above situation ②, the loop short circuit occurs;

[0095] 4. Give the fault code and fault FTA.

[0096] The present invention is further described below with a specific embodiment.

[0097] Under the initial conditions of power-on, the system input signal sys_clk = 1'b0, rst_n = 1'b0, datin = 1'b0, after a step of 100 clock cycles (i.e. t = 100Clk Counter × 0.5us = 50us) pulls rst_n high, that is, rst_n = 1'b1, and then after 900 clock cycles, pulls the first bit of the input PAS signal high (rising edge collection), and transmits the signal through the sensor in turn. sensor =250KHZ, the sensor PAS signal passes through a step of 2000 clock cycles, and inputs a set of 26-bit high and low levels: 01010110011010101010101010, and the input data is parsed through the following steps:

[0098] Step 1: Divide the 50MHZ system clock input

[0099] a) 5-bit system clock counter CNT[4:0] counts the system clock from 0 to 24;

[0100] b) When CNT<24, CNT will continue to accumulate. If CNT=24, CNT will be set to "0" in the next clock cycle and start counting again;

[0101] c) When CNT<12, the clock signal level is pulled high, that is, Clk=1′b1. If CNT≥12, then Clk=1′b0.

[0102] d) According to the design, the divided clock cycle is 25 (0-24), the high level duration is 12 cycles (0-11), and the low level duration is 13 cycles (12-24) of the sampling clock.

[0103] The calculation formula is:

[0104]

[0105] Step 2: Parse the input data 01010110011010101010101010

[0106] a) After power-on, the system's current state Current_State is IDLE;

[0107] b) Perform a logical AND operation on the acquired data with a one - clock - cycle delay (01010110011010101010101010) and the acquired data with a two - clock - cycle delay to find the rising edge. The formula is: ~rx_data[1] & rx_data[2];

[0108] c) If Rx_Pos is pulled high, it indicates that a rising edge is detected, and the state machine jumps to the next - level START state;

[0109] d) Clk_num_cnt is full after 4 clock cycles. The formula is Judge whether Clk_num_cnt is equal to 3 (a total of 4 cycles from 0 - 3). If it is 3, pull Clk_cnt_end high and set Clk_num_cnt to "0" to start counting again; if it is not 3, increment the count by one;

[0110] e) Similarly, perform a counting operation on Bit_cnt according to this method. When Bit_cnt is detected to be 2, the state machine jumps to

[0111] DATA.

[0112] f) When the state machine is in the DATA state, detect the rising edge and the falling edge. If a rising edge is detected and 1 - bit data has not been received completely, assign "0" to Datout[9 - Bit_cnt_1]. If a rising edge is detected and 1 - bit data has not been received completely, assign "1" to Datout[9 - Bit_cnt_1]. Therefore, the finally parsed 8 - bit output data is Datout[7:0]=0x7F.

[0113]

[0114] Step 3: The IPC performs calculations and logical judgments based on the parsed data bits

[0115] a) Judge the threshold through the formula When I < I_lower, the circuit is open - circuited. When

[0116] I > I_upper, the circuit is short - circuited.

[0117] b) Perform torque - circle and torque - value calculations on the parsed data:

[0118] The torque - circle formula is:

[0119] The torque - value formula is:

[0120]

[0121] T = 2.5° / Nm×θ​

[0122] c) Judge by the above formula and threshold conditions:

[0123] when

[0124] Radius<Digits_lower&Radius>

[0125] Digits_upper, the fault code TORQSENS_SIGNAL_VECTOR and FTA are output; when T<T_lower;T> T_upper; when ΔT>ΔT_upper, the fault code TORQSENS_VALUE_OUT_OF_RANGE and FTA are output.

[0126] The beneficial effects of the present invention are:

[0127] The present invention can perform automatic detection of torque sensors through PCBA test board construction, bottom layer data module design and host computer programming, replace manual batch testing, improve test efficiency, have customized test sequences, and make the test process more accurate. At the same time, the present invention can list corresponding FTAs ​​and fault logics according to different fault types, and can quickly lock failed components on the sensor fault link.

[0128] 1. No need to perform repetitive sensor disassembly, internal PCBA electronic failure part identification and sensor installation operations, achieving more efficient automated testing;

[0129] 2.PAS protocol has fast parsing speed, complete data parsing and verification mechanism, the measurement steps can be traced, and the frequency of data transmission F is higher than that of sensor data. sensor =250KHZ 10 times the system clock F sample =2MHZ sampling, high data accuracy;

[0130] 3. Strong scalability. It can subsequently receive data from the host computer through CAN Transever and AD Convert, replace the actual sensor to input torque to the ECU, and can parse the SENT protocol to provide effective detection for sensors of different products;

[0131] 4. Data analysis, data transmission and host computer detection modules can be repeatedly improved and have high operability;

[0132] 5. It can be used for different types of sensor detection such as SCU3 B3 / C3 / C6, CSEC, CSER, and has a wide range of uses.

[0133] The present invention has been described in detail above through specific implementation modes and embodiments, but these do not constitute limitations of the present invention. Without departing from the principles of the present invention, those skilled in the art may also make many variations and improvements, which should also be regarded as the protection scope of the present invention.

Claims

1. A torque sensor detection and monitoring system, characterized in that: It includes a power supply module, a current-to-voltage module, a signal processing module and a logic processing module, wherein: The power supply module and the current-to-voltage module are used to supply power to the torque sensor and convert current data into voltage data; The signal processing module is used to parse the specific protocol message transmitted by the torque sensor, and transmit the parsing result to the logic processing module; The logic processing module is used for detecting logic judgment of the torque sensor and displaying judgment information.

2. The torque sensor detection and monitoring system according to claim 1, characterized in that: The signal processing module comprises: Clock frequency division module: used to divide the system clock frequency; Decoding module: receives sensor signals and performs PAS decoding; Synchronous storage module: receives and stores the parallel data decoded by the upper module; Message sending module: used to read the data stored in the synchronous storage module, and convert the data into serial data to transmit to the IPC logic processing module.

3. The torque sensor detection and monitoring system according to claim 2, characterized in that: The implementation steps of the clock frequency division module are as follows: setting the internal counter and setting the internal parameters. After power-on, the system reset signal is low, and the system performs a reset operation. After three system clock cycles, the system reset signal is pulled high, and at the same time, the internal counter performs an increment operation after each clock rising edge.

4. The torque sensor detection and monitoring system according to claim 2, characterized in that: The decoding module is implemented by PAS decoding the 26-bit high and low level signals of the sensor, using Manchester decoding rules to define the high and low level states, selecting data for a specific DATA segment, and transmitting the decoded 8-bit data in parallel to the synchronous storage module.

5. The torque sensor detection and monitoring system according to claim 2, characterized in that: The synchronous storage module stores data with a bit width of 8 and a depth of 256.

6. The torque sensor detection and monitoring system according to claim 2, characterized in that: The message sending module obtains data from the synchronous storage module through the sending completion flag bit, converts the 8-bit parallel data into serial data through the UART protocol, and transmits it to the IPC.

7. The torque sensor detection and monitoring system according to claim 1, characterized in that: The logic processing module includes a torque value detection module, a torque circle radius detection module, a short circuit and open circuit detection module and a display module.

8. The torque sensor detection and monitoring system according to claim 7, characterized in that: The torque circle radius detection module is implemented as follows: Step S101, calculating a digital quantity through a group of incoming data messages; Step S102, the calculation result is transmitted to the logic diagnosis module for determination with a given digital value threshold; Step S103, if the torque circle exceeds the upper limit or the lower limit, it is determined that the sensor is failed; Step S104, giving a fault code and a fault FTA.

9. The torque sensor detection and monitoring system according to claim 7, characterized in that: The implementation steps of the torque value detection module are as follows: Step S201, calculating a digital quantity through a group of incoming data messages; Step S202, calculating the relative angle between the actual input axis and the output axis of the digital quantity through an inverse trigonometric function; Step S203, multiplying the calculated actual relative angle value by the torsion bar stiffness coefficient to obtain the actual torque; Step S204, transferring the calculation result to the logic diagnosis module and performing three state determinations with the given torque threshold; Step S205: If the torque value exceeds the upper limit or the lower limit or the torque change within a unit time exceeds the threshold range, it is determined that the sensor has failed; Step S206, giving a fault code and a fault FTA.

10. The torque sensor detection and monitoring system according to claim 7, characterized in that: The implementation steps of the short circuit and open circuit detection module are as follows: Step S301, calculating the actual loop current value by the voltage drop of the current signal flowing through the two ends of the resistor; Step S302, comparing the calculated current value with a set threshold; Step S303, judging whether a circuit short circuit or a circuit open circuit occurs according to the comparison result; Step S304, giving a fault code and a fault FTA.

Images