A Hall sensor calibration test system and method with current commutation function

Abstract

The present invention discloses a Hall sensor calibration and testing system with a current commutation function, including 1) a host computer system for data analysis, calculation and display; 2) a lower computer system for interacting with a pneumatic actuator system, a servo motor system and a conveyor belt system; 3) a power supply system, including a DC power supply and a current commutation plate for changing the direction of the DC power supply, 4) a pneumatic actuator system for sending the Hall sensor to be tested into a component connection system; 5) a conveyor belt system for transmitting the Hall sensor to be tested; 6) a data acquisition system for collecting calibration and test data from the component connection system; 7) a servo motor system, and 8) a component connection system. The present invention also discloses a method for calibrating and testing a Hall sensor using such a system. The Hall sensor calibration and testing system and method with a current commutation function of the present invention have the advantages of high test efficiency, high precision, high degree of automation, etc.

Description

Technical Field

[0001] The invention relates to the field of Hall sensor manufacturing, and in particular to a Hall sensor calibration test system and method with a current commutation function. Background Art

[0002] As a magnetoelectric conversion device based on the Hall effect, Hall sensors are widely used in industrial automation, automobile manufacturing, aerospace and other fields to detect parameters such as magnetic field strength, current size and direction. In the development, production and application of Hall sensors, calibration and testing are the key to ensuring product quality and reliability.

[0003] At present, the Hall sensor test systems on the market face the following problems:

[0004] 1) Some operations of existing Hall sensor calibration and testing are performed manually. During the calibration and testing process, due to the high current output of the power supply instrument and the need for manual plugging, long-term manual testing has safety risks and complicated processes.

[0005] 2) At present, most calibration and testing are performed using a single current direction, which limits the comprehensiveness and accuracy of calibration and testing to a certain extent. For example, when testing the current sensitivity of a Hall sensor, if only a single current direction is used, it may not be able to fully reflect the performance differences of the sensor under different current directions. In addition, certain application scenarios, such as current commutation in motor control, require the Hall sensor to accurately detect and respond to rapid changes in current direction, and existing test systems often cannot meet this requirement.

[0006] 3) The existing Hall sensor test system still has problems such as cumbersome test steps, long test time, and low test accuracy. For example, in order to test the output characteristics of the Hall sensor under different current intensities, the tester needs to manually adjust the current source and record the output data of the sensor multiple times, which not only increases the workload of the test, but also may affect the accuracy of the test results due to human operation errors.

[0007] In view of the above problems existing in the existing Hall sensor testing system, a Hall sensor testing system and method with high automation and complete functions is needed. Summary of the invention

[0008] The present invention proposes a Hall sensor calibration and testing system with a current commutation function, which automatically realizes rapid switching and precise control of the current direction, and improves the automation of the test through a pneumatic actuator system, a servo motor system, a conveyor belt system, etc., thereby shortening the calibration test time, improving the calibration accuracy and efficiency, and ensuring the comprehensiveness and accuracy of the test.

[0009] The first object of the present invention is to provide a Hall sensor calibration and testing system with a current commutation function, comprising the following modules:

[0010] 1) A component connection system, wherein the component connection system comprises a test pin board, a Hall sensor to be tested and a standard Hall sensor, the pins of the Hall sensor to be tested and the standard Hall sensor are electrically connected to the test pin board, and the Hall sensor to be tested comprises an adjustable resistor;

[0011] 2) a power supply system electrically and data-connected to the component connection system, the power supply system comprising a DC power supply and a current reversing plate for changing the direction of the DC power supply;

[0012] 3) a data acquisition system electrically and digitally connected to the component connection system, for acquiring calibration and test data from the component connection system;

[0013] 4) A host computer system connected to the data acquisition system, used to provide a user interface, set test parameters, receive and process data from the data acquisition system, perform data analysis, storage and display, and perform waveform comparison and servo motion calculation;

[0014] 5) A slave computer system connected to the data of the master computer system;

[0015] 6) A pneumatic actuator system connected to the data of the lower computer system, used to send the Hall sensor to be tested into the component connection system;

[0016] 7) A servo motor system connected to the upper computer system and the lower computer system, wherein the servo motor system includes a motion guide rail, a servo motor moving on the guide rail, and a programmable logic controller for controlling the motion of the servo motor; the servo motor system also includes a screwdriver connected to the output shaft of the servo motor;

[0017] 8) A conveyor belt system connected to the data of the lower computer system, used for conveying the Hall sensor to be tested.

[0018] Preferably, the current reversing plate includes two contactors, and the host computer realizes current reversal by controlling the closing and opening of the contactors.

[0019] Preferably, the motion guide rail of the servo motor system is a 3+1 axis motion guide rail, including an X-axis, a Y-axis, a Z-axis and a rotation axis.

[0020] Preferably, the adjustable resistor includes a zero adjustment resistor and an amplitude adjustment resistor.

[0021] Preferably, the conveyor belt system includes a conveyor belt, an integrated drive and control motor for controlling the movement of the conveyor belt, and a position sensor for detecting the position of the conveyor belt.

[0022] Preferably, the data acquisition system includes a multimeter and an oscilloscope.

[0023] Preferably, the pneumatic actuator system includes a pneumatic actuator, a solenoid valve for controlling the movement of the pneumatic actuator, and an air pressure source for providing power to the pneumatic actuator.

[0024] A second object of the present invention is to provide a Hall sensor calibration test method. In the aforementioned Hall sensor calibration test system, the method comprises the following steps:

[0025] 1) The Hall sensor to be tested is received, enters the conveyor system, and follows the conveyor to the vicinity of the component connection system;

[0026] 2) The pneumatic actuator system moves the Hall sensor to be tested and sends it to the component connection system to complete the electrical connection between the Hall sensor to be tested and the test needle board;

[0027] 3) The host computer system controls the power supply system to provide test current, and the data acquisition system collects the data of the Hall sensor to be tested and the standard Hall sensor, and sends it to the host computer system for calculation and waveform comparison;

[0028] 4) The host computer system controls the movement of the servo motor system, so that the screwdriver connected to the output shaft of the servo motor moves to the adjustable resistance position of the Hall sensor to be tested, adjusts the adjustable resistance, and monitors the output signal of the Hall sensor to be tested;

[0029] 5) The host computer system controls the power supply system to change the test current size and direction, continuously monitors the output signal of the Hall sensor to be tested, and fine-tunes the adjustable resistance size according to the calculation and analysis results of the host computer system to complete the calibration of the Hall sensor to be tested;

[0030] 6) The host computer system controls the power supply system to test the calibrated Hall sensor to be tested, including applying currents of different magnitudes and directions, and checking whether the output of the Hall sensor to be tested meets the requirements through the data acquisition system and the host computer system;

[0031] 7) The tested Hall sensor is sent out of the calibration test system to complete the automated test of the Hall sensor.

[0032] The Hall sensor calibration test system and method with current commutation function of the present invention has the following beneficial effects:

[0033] 1) The present invention enables the current direction to be switched quickly and accurately through the design of the current commutation plate, thereby being able to calibrate and test the Hall sensor by changing the current direction, thereby improving the continuity and accuracy of the test.

[0034] 2) The servo motor system uses a 3+1 axis motion guide rail to accurately control the motor speed and position, precisely control the rotation operation, adjust the adjustable resistance of the Hall sensor, and calibrate the Hall sensor according to the instructions of the upper and lower computer systems, thereby improving the calibration accuracy and automation level.

[0035] 3) The pneumatic actuator system is used to send the Hall sensor to be tested into the component connection system, which is accurate and reliable.

[0036] 4) The lower computer system controls the operation of each system according to the instructions of the upper computer system. It can also conveniently set calibration and test parameters, monitor the calibration and test process and results, and improve the automation of calibration and testing.

[0037] The present invention provides a Hall sensor calibration test system and method with a current commutation function, which has the advantages of high test efficiency, high precision, high degree of automation, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 This is a block diagram of a Hall sensor calibration and testing system with current commutation function according to an embodiment of the present invention;

[0039] Figure 2 This is a layout diagram of a Hall sensor calibration and testing system with a current commutation function according to an embodiment of the present invention;

[0040] Figure 3 This is a current commutation board control diagram of a Hall sensor calibration and testing system with a current commutation function according to an embodiment of the present invention.

[0041] Explanation of the accompanying drawings: 1-data acquisition system; 2-power supply system; 3-conveyor belt system; 4-lower computer system; 5-servo drive system; 6-motion guide rail; 7-upper computer system; 8-material outlet. DETAILED DESCRIPTION

[0042] In order to further understand the present invention, the embodiments of the present invention are described below in conjunction with examples, but it should be understood that these descriptions are only for further illustrating the features and advantages of the present invention, rather than limiting the claims of the present invention. Embodiment 1

[0043] The present invention provides a Hall sensor calibration and testing system with current commutation function, such as Figure 1As shown, it includes the upper computer system, the lower computer system, the power supply system, the pneumatic execution system, the conveyor belt system, the data acquisition system, the servo motor system, the component connection system and other parts. The layout of each part is as follows Figure 2 shown.

[0044] The host system includes a computer host, a display and its related software, providing a user interactive interface to facilitate calibration and test personnel to monitor the process and results. The host system can be used to set test parameters through the slave system, and can also receive and process data from the slave system and data acquisition system for data analysis, storage and display. The functions completed by the host system also include:

[0045] 1) Waveform comparison. The host computer system collects waveform data from the pins of the Hall sensor to be tested through the data acquisition system. These data include voltage, current and other signals. These data are compared with the data collected from the standard Hall sensor. Correlation analysis, peak detection, spectrum analysis, etc. can be performed to calculate the similarity or difference between the waveforms to calibrate the Hall sensor to be tested or evaluate the performance of the Hall sensor to be tested.

[0046] 2) Servo motion calculation. The host computer system calculates and analyzes the motion state and motion parameters of the servo motor. The servo system is a closed-loop control system that achieves precise control of the motor motion through a feedback mechanism. Servo motion calculation includes the calculation of motion parameters such as position and speed, as well as the planning and optimization of motion trajectory.

[0047] The lower computer system of the embodiment of the present invention includes an MCU (Microcontroller Unit), and related circuits and interfaces. The lower computer system interacts with the pneumatic actuator system, servo motor system, conveyor belt system, etc. according to the instructions of the upper computer system.

[0048] 1) After receiving the instructions from the upper computer, the lower computer system will perform corresponding processing, such as parsing the instructions, calculating the control parameters, etc., to control the operation of the transmission belt system and complete the material reception and delivery.

[0049] 2) After receiving the signal from the position sensor, the lower computer system controls the pneumatic actuator system to send the Hall sensor to be tested into the predetermined component connection system.

[0050] 3) The lower computer system transmits the positioning signal of the Hall sensor to be tested to the servo motor system.

[0051] The power supply system of the embodiment of the present invention includes a DC power supply, a current commutation board and its related circuits and protection devices, which provide a stable and reliable power supply for the Hall sensor and other parts of the test system. During the current commutation process, the rapid response and stable output of the power supply are ensured. The current size of the DC power supply required in the Hall test system mainly depends on the type and specification of the Hall sensor and the requirements of the test system. In the embodiment of the present invention, a 500A DC test power supply can be provided.

[0052] The current commutation board is a component that realizes rapid switching and precise control of current direction. Its control diagram is as follows: Figure 3 As shown in the figure, there are two contactors KM1 and KM2, which play the role of switching the direction of current. When contactor KM1 is in the disconnected state, contactor KM2 will close and the current will flow in the forward direction. When contactor KM2 is disconnected, contactor KM1 will close and the current will flow in the reverse direction. This design can achieve fast current reversal and meet the needs of Hall sensor automated testing. When the test system needs to change the current direction, the host computer will send a signal to the current reversing board, which will trigger the contactor to operate, thereby switching the current direction.

[0053] The current commutation board of the embodiment of the present invention can quickly change the direction of the current and frequently operate to test the Hall sensor, thereby ensuring the continuity and accuracy of the test. The current commutation board can work in conjunction with a servo motor system, a pneumatic execution system, etc. to achieve automated testing. This helps reduce manual intervention and improve test efficiency and accuracy.

[0054] The pneumatic actuator system of the embodiment of the present invention includes a pneumatic actuator, a solenoid valve, a pneumatic pressure source and related control circuits. According to the instructions of the lower computer system, the Hall sensor to be tested is quickly and accurately moved and installed on the component connection system to realize automated testing.

[0055] The conveyor belt system of the embodiment of the present invention is used to transport the Hall sensor to be tested from one place to another to achieve continuous or batch testing. During the test process, the smooth transportation and accurate positioning of the object are ensured. The conveyor belt system includes a conveyor belt, a position sensor, a drive-control integrated motor and other parts.

[0056] 1) The position sensor is used to accurately detect the position and state of objects on the conveyor belt, including whether the Hall sensor to be tested has reached the specified position. Ensure that the transportation process of the object on the conveyor belt conforms to the preset path and timing. The position sensor can be implemented by a photoelectric switch, and its signal can be transmitted to the lower computer system for processing.

[0057] 2) The drive-control motor is the power source of the conveyor belt system. It provides the necessary mechanical energy to drive the conveyor belt to move, so that objects can be transported from one place to another on the conveyor belt. The drive-control motor has precise control functions. By adjusting the speed and direction of the motor, the speed and direction of the conveyor belt can be precisely controlled, which helps to achieve smooth transportation and accurate positioning of objects and ensure the smooth progress of the test process.

[0058] The data acquisition system of the embodiment of the present invention includes a digital multimeter, an oscilloscope and related interfaces and software. During the test process, the test data is collected and transmitted to the host computer system for analysis and processing such as waveform comparison.

[0059] The servo motor system of the embodiment of the present invention accurately controls the speed and position of the servo motor according to the instructions of the upper computer system and the positioning signal of the lower computer, controls the motor to rotate the screwdriver, and calibrates the Hall sensor. During the test, the servo motor system provides stable power output and precise position control, and improves the control accuracy and stability through closed-loop control. The servo motor system includes a motion guide rail, a servo motor, a PLC (Programmable Logic Controller), an encoder, and other parts.

[0060] 1) The motion guide is responsible for providing a precise linear or rotational motion path. The embodiment of the present invention uses a 3+1 axis motion guide, which can improve the accuracy, stability and flexibility of the motion. The motion guide has three basic motion axes, including the X-axis, the Y-axis and the Z-axis. These three axes together constitute the basic motion framework in the three-dimensional space, allowing the motor to move in any direction in the three-dimensional space. The motion guide also provides an additional motion axis, which can achieve more complex motion trajectories and more precise position control. In the Hall sensor test system, this additional axis can control the screwdriver to calibrate the Hall sensor.

[0061] 2) PLC is the main controller of the servo system. It can communicate with the host computer through EtherCAT, and can also receive the in-position signal transmitted by the position sensor through the lower computer. PLC sends control signals to the servo motor through the output port according to the control instructions or data. The servo motor performs motion control such as positioning and speed control according to the received control signals, thus realizing precise control of the servo motor.

[0062] 3) The encoder is a feedback device in the servo motor system, which can detect the position and speed information of the motor in real time. The encoder can be installed on the output shaft of the motor and rotates as the motor rotates. The encoder will feed back the actual position and speed information of the motor to the PLC so that the PLC can perform closed-loop control or fault diagnosis, thereby improving the stability and accuracy of the system.

[0063] 4) Servo motor is the actuator of the servo system. It can convert electrical signals into mechanical motion. It has the characteristics of high precision, fast response and low noise, and can meet the needs of various complex control tasks.

[0064] 5) The screwdriver is connected to the output shaft of the servo motor. It can adjust the adjustable resistance of the Hall sensor to be tested according to the calculation results to complete the calibration of the Hall sensor to meet the product standard requirements. The adjustable resistance of the Hall sensor to be tested includes zero adjustment resistance and amplitude adjustment resistance. The zero adjustment resistance is used to adjust the output voltage of the sensor in the absence of a magnetic field to ensure that the output signal of the sensor is zero in the absence of a magnetic field. The amplitude adjustment resistance is used to adjust the output voltage range or sensitivity of the sensor under the action of a magnetic field.

[0065] The component connection system of the embodiment of the present invention includes a Hall sensor to be tested, a test pin board and a standard Hall sensor.

[0066] 1) After the Hall sensor to be tested reaches the predetermined position through the conveyor belt, it is sent to the component connection system by the pneumatic actuator system, and the pins of the Hall sensor to be tested are electrically connected to the test pins on the test pin board. Common types of Hall sensors are three-pin and four-pin types. The pins of the three-pin Hall sensor are the power supply terminal, the ground terminal and the signal output terminal. The four-pin Hall sensor contains two power supply pins, one output pin and one ground pin.

[0067] 2) Standard Hall sensors are usually used as references or benchmarks in test systems to evaluate the performance of the Hall sensor to be tested. By comparing with the Hall sensor to be tested, it can be determined whether the performance indicators such as sensitivity, linearity, and stability of the Hall sensor to be tested meet the requirements. The standard Hall sensor also needs to be physically and electrically connected to the test pin board.

[0068] In summary, the Hall sensor calibration and testing system with current commutation function according to the embodiment of the present invention has complete structures and clear functions, and can realize efficient and accurate testing and calibration of the Hall sensor. Embodiment 2

[0069] The present invention provides a calibration and testing method for a Hall sensor with a current commutation function, and the following steps are used to calibrate and test the Hall sensor:

[0070] S1. The Hall sensor to be tested is received, enters the conveyor belt system, and follows the conveyor belt to the predetermined position.

[0071] S2. The position sensor triggers the pneumatic actuator system to move the Hall sensor to be tested and send it to the component connection system. The pins of the Hall sensor to be tested are electrically connected to the test pin board. A standard Hall sensor can be connected to the component connection system for waveform comparison with the sensor to be tested.

[0072] S3. The host computer system controls the power supply system to provide test current. The data acquisition system collects data from the Hall sensor to be tested and the standard Hall sensor, and sends the data to the host computer system for calculation and waveform comparison.

[0073] S4. The host computer system controls the movement of the servo motor system. The servo motor drives the screwdriver to move to adjust the adjustable resistance of the Hall sensor to be tested.

[0074] S5. The host computer system controls the power supply system to change the test current size and direction, and the screwdriver makes further fine adjustments to the Hall sensor to be tested until it meets the standard requirements, completing the calibration of the Hall sensor to be tested.

[0075] S6. The host computer system controls the power supply system to test the adjusted Hall sensor.

[0076] The test involves applying currents of different magnitudes and directions to the Hall sensor to be tested, and checking whether the output voltage of the Hall sensor to be tested meets the standard requirements through the data acquisition system and the host computer system.

[0077] S7, sending the tested Hall sensor to the calibration test system to complete the automated test of the Hall sensor to be tested.

[0078] The above embodiments are only used to help understand the method and core idea of ​​the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A Hall sensor calibration and testing system with current commutation function, characterized in that: include: 1) A component connection system, wherein the component connection system comprises a test pin board, a Hall sensor to be tested and a standard Hall sensor, the pins of the Hall sensor to be tested and the standard Hall sensor are electrically connected to the test pin board, and the Hall sensor to be tested comprises an adjustable resistor; 2) a power supply system electrically and data-connected to the component connection system, the power supply system comprising a DC power supply and a current reversing plate for changing the direction of the DC power supply; 3) a data acquisition system electrically and digitally connected to the component connection system, for acquiring calibration and test data from the component connection system; 4) A host computer system connected to the data acquisition system, used to provide a user interface, set test parameters, receive and process data from the data acquisition system, perform data analysis, storage and display, and perform waveform comparison and servo motion calculation; 5) A slave computer system connected to the data of the master computer system; 6) A pneumatic actuator system connected to the data of the lower computer system, used to send the Hall sensor to be tested into the component connection system; 7) A servo motor system connected to the upper computer system and the lower computer system, wherein the servo motor system includes a motion guide rail, a servo motor moving on the guide rail, and a programmable logic controller for controlling the motion of the servo motor; the servo motor system also includes a screwdriver connected to the output shaft of the servo motor; 8) A conveyor belt system connected to the data of the lower computer system, used for conveying the Hall sensor to be tested.

2. The Hall sensor calibration test system according to claim 1, characterized in that: The current reversing plate includes two contactors, and the host computer system realizes current reversal by controlling the closing and opening of the contactors.

3. The Hall sensor calibration test system according to claim 1, characterized in that: The motion guide rail of the servo motor system is a 3+1 axis motion guide rail, including an X-axis, a Y-axis, a Z-axis and a rotation axis.

4. The Hall sensor calibration test system according to claim 1, characterized in that: The adjustable resistor includes a zero adjustment resistor and an amplitude adjustment resistor.

5. The Hall sensor calibration test system according to claim 1, characterized in that: The conveyor belt system includes a conveyor belt, a drive-control integrated motor for controlling the movement of the conveyor belt, and a position sensor for detecting the position of the conveyor belt.

6. The Hall sensor calibration test system according to claim 1, characterized in that: The data acquisition system includes a multimeter and an oscilloscope.

7. The Hall sensor calibration and testing system according to any one of claims 1 to 6, characterized in that: The pneumatic execution system includes a pneumatic execution element, a solenoid valve for controlling the movement of the pneumatic execution element, and an air pressure source for providing power to the pneumatic execution element.

8. A Hall sensor calibration and testing method with current commutation function, using the Hall sensor calibration and testing system according to any one of claims 1 to 7, characterized in that: The following steps are involved: 1) The Hall sensor to be tested is received, enters the conveyor system, and follows the conveyor to the vicinity of the component connection system; 2) The pneumatic actuator system moves the Hall sensor to be tested and sends it to the component connection system to complete the electrical connection between the Hall sensor to be tested and the test needle board; 3) The host computer system controls the power supply system to provide test current, and the data acquisition system collects the data of the Hall sensor to be tested and the standard Hall sensor, and sends it to the host computer system for calculation and waveform comparison; 4) The host computer system controls the movement of the servo motor system, so that the screwdriver connected to the output shaft of the servo motor moves to the adjustable resistance position of the Hall sensor to be tested, adjusts the adjustable resistance, and monitors the output signal of the Hall sensor to be tested; 5) The host computer system controls the power supply system to change the test current size and direction, continuously monitors the output signal of the Hall sensor to be tested, and fine-tunes the adjustable resistance size according to the calculation and analysis results of the host computer system to complete the calibration of the Hall sensor to be tested; 6) The host computer system controls the power supply system to test the calibrated Hall sensor to be tested, including applying currents of different magnitudes and directions, and checking whether the output of the Hall sensor to be tested meets the requirements through the data acquisition system and the host computer system; 7) The tested Hall sensor to be tested is sent out to the calibration test system to complete the automated test of the Hall sensor to be tested.

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