A wireless cable-pulling displacement sensor system

Abstract

The present invention belongs to the technical field of displacement sensors, and specifically discloses a wireless wire-pulling displacement sensor system, comprising: a mobile end installed on a measured object and a winding end installed on a fixed object, with the mobile end and the winding end connected by a wire; a calculation module that calculates a second linear parameter of the measured object according to an angle parameter through a contained calculation model and transmits it to a remote end through wireless transmission; a first signal module respectively arranged on the winding end and the fixed object; a correction factor for correcting the angle parameter at each moment is further set on the calculation module, and the correction factor is calibrated according to the linear distance between the two first signal modules; a second signal module is arranged on the mobile end; the calculation module updates the correction factor according to the linear distance and the angle parameter corresponding to the current electrical signal; it has the following advantages: through the dynamic update of the correction factor, it ensures that the system maintains high precision and stability during long-term use and in complex environments.

Description

Technical Field

[0001] The present invention relates to the technical field of displacement sensors, and more particularly, to a wireless wire-pulling displacement sensor system. Background Art

[0002] Existing wireless wire-pulling displacement sensors measure the displacement of an object through the amount of elongation of a wire, and convert it into displacement data through the rotation angle of a reel. However, in sensors with multi-turn winding designs, the winding of the wire on the reel may lead to a series of error sources. Especially under the influence of wire wear and temperature changes, these factors may significantly affect the measurement accuracy of the sensor.

[0003] First of all, the wear of the wire will cause its surface to gradually become rough, thereby reducing the cross-sectional area. The cross-sectional area of the wire directly affects the elasticity and elongation of the wire. The worn wire may have different elongation amounts under the same tensile force. Since the elongation amount of the wire is closely related to the change in the rotation angle of the reel, the change in the cross-sectional area will cause a deviation in the relationship between the reel angle and the actual displacement, thereby affecting the angle measurement accuracy of the rotary encoder. Especially after the accumulation of wear after long-term use, the error may continuously increase.

[0004] Secondly, temperature changes will also affect the cross-sectional area and length of the wire. As the temperature rises, the wire (especially a metal wire) will expand, and the cross-sectional area may increase; when the temperature drops, the wire may contract, and the cross-sectional area decreases. The change in temperature causes a slight change in the length of the wire, which in turn affects the displacement calculated through the rotation angle of the reel. Especially in high-temperature or low-temperature environments, the change in the material properties of the wire will significantly affect the measurement accuracy.

[0005] For wires with multi-turn winding designs, in addition to wear and temperature changes affecting the cross-sectional area, the tension of the wire may also be uneven. The multi-turn winding design means that the wires in different turns will be affected by different degrees of friction and tension. The outer wires bear more friction, while the inner wires are affected by less friction. This uneven tension may cause a change in the stretchability of the wire, further affecting the change in the reel angle, and thus affecting the accurate measurement of the rotary encoder.

[0006] Therefore, a wireless wire-pulling displacement sensor system is proposed to solve the above-mentioned problems. Summary of the Invention

[0007] The present invention aims to provide a wireless wire-pulling displacement sensor system to solve or improve the problems in the use process of wireless wire-pulling displacement sensors, such as wire wear or attachment of external foreign objects, temperature changes, and accuracy problems caused by multi-turn winding.

[0008] In view of this, the first aspect of the present invention is to provide a wireless wire-pulling displacement sensor system.

[0009] The first aspect of the present invention provides a wireless wire-pulling displacement sensor system, including: a mobile end installed on the object to be measured and a winding end installed on a fixed object, the mobile end and the winding end are connected by a wire, and the wire is used to convert the first linear parameter of the mobile end into the angular parameter of the winding end; a calculation module, which calculates the second linear parameter of the object to be measured according to the angular parameter through the included calculation model and sends it to the remote end through wireless transmission; a first signal module, which is respectively arranged on the winding end and the fixed object; a correction factor for correcting the angular parameter at each moment is also set on the calculation module, and the correction factor is calibrated according to the linear distance between the two first signal modules; a second signal module, which is arranged on the mobile end; when the second signal module acts on the first signal module, the first signal module generates an electrical signal and transmits it to the calculation module; the calculation module updates the correction factor according to the linear distance and the angular parameter corresponding to the current electrical signal.

[0010] In any of the above technical solutions, the wireless wire-pulling displacement sensor system further includes a calibration module for updating the measuring range of the wire according to the correction factor at each moment.

[0011] In any of the above technical solutions, the calibration module is further used to divide the measuring range into n line segments according to the linear distance and generate a judgment factor for judging whether the wire is qualified between adjacent line segments.

[0012] In any of the above technical solutions, the judgment factor is generated by the angular parameters corresponding to adjacent line segments.

[0013] In any of the above technical solutions, the wireless wire-pulling displacement sensor system further includes a clock module for obtaining the time data when the angular parameter changes; the calculation module generates the angular parameter corresponding to each line segment through the time data and the linear distance.

[0014] In any of the above technical solutions, the clock module starts to obtain the time data when the mobile end approaches the winding end.

[0015] In any of the above technical solutions, whether the wire is qualified is judged by the following rule: when the absolute value of at least one judgment factor is greater than a preset threshold, the wire is judged to be unqualified; when the absolute values of all judgment factors are less than or equal to the preset threshold, the wire is judged to be qualified.

[0016] In any of the above technical solutions, the wireless wire-pulling displacement sensor system further includes a wireless module for transmitting the second linear parameter; when the wire is determined to be unqualified, the wireless module sends an alarm message to a remote end.

[0017] In any of the above technical solutions, the second signal module and the first signal module disposed at the winding end form a normally closed switch circuit, and an electrical signal is generated when the normally closed switch circuit is in an open state.

[0018] In any of the above technical solutions, the second signal module and the first signal module disposed on the fixed object form a normally open switch circuit, and an electrical signal is generated when the normally open switch circuit is in a closed state.

[0019] Advantages of the present invention compared with the prior art:

[0020] Through the synergistic effect of the first signal module and the second signal module, combined with the update of the real-time correction factor, it is ensured that the system can provide high-precision displacement measurement. Especially when the wire is affected by wear, temperature change or external factors, the dynamic update of the correction factor can ensure that the conversion relationship between the angular parameter and the displacement is always accurate, thus ensuring the measurement accuracy.

[0021] The calculation module updates the correction factor according to the real-time electrical signal and the linear distance, and can cope with the errors caused by factors such as wire wear, temperature change or external environmental pollution. The system can adapt to changes during long-term use or in a complex environment, ensuring the continuous stability of the measurement result, and avoiding the loss of accuracy caused by equipment aging or environmental changes.

[0022] The additional aspects and advantages of the embodiments according to the present invention will become apparent in the following description part, or will be understood through the practice of the embodiments according to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and / or additional aspects and advantages of the present invention will become apparent and be readily understood from the description of the embodiments in conjunction with the following drawings, wherein:

[0024] Figure 1 is the structural logic block diagram of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] In order to more clearly understand the above objects, features and advantages of the present invention, the present invention will be further described in detail below with reference to the drawings and specific embodiments. It should be noted that, without conflict, the embodiments of the present application and the features in the embodiments can be combined with each other.

[0026] In the following description, many specific details are set forth in order to provide a thorough understanding of the present invention. However, the present invention may be practiced in other ways different from those described herein. Therefore, the scope of protection of the present invention is not limited by the specific embodiments disclosed below.

[0027] Please refer to Figure 1 , and a wireless cable-pulling displacement sensor system according to some embodiments of the present invention will be described below.

[0028] An embodiment of the first aspect of the present invention provides a wireless cable-pulling displacement sensor system. In some embodiments of the present invention, as Figure 1 shown, the wireless cable-pulling displacement sensor system includes:

[0029] A mobile end installed on the object to be measured and a winding end installed on a fixed object. The distance between the mobile end and the fixed object changes due to the movement of the mobile end. The mobile end and the winding end are connected by a cable. The cable is used to convert the first linear parameter of the mobile end into an angular parameter of the winding end, and the encoder or potentiometer at the receiving end obtains the change in the rotation angle generated by the winding drum of the cable. The mobile end, the winding end, and the cable form a cable sensor.

[0030] A calculation module that calculates the second linear parameter of the object to be measured according to the angular parameter through the included calculation model and transmits it wirelessly to the remote end. The calculation model can convert the detected angular parameter into a numerical form of the movement distance required by the remote end through calculation.

[0031] A first signal module is respectively arranged on the winding end and the fixed object; a correction factor for correcting the angular parameter at each moment is also set on the calculation module, and the correction factor is calibrated according to the linear distance between the two first signal modules.

[0032] A second signal module is arranged on the mobile end; when the second signal module interacts with the first signal module, the first signal module generates an electrical signal and transmits it to the calculation module, so that the calculation module actually obtains the fixed numerical value of the distance between the mobile end and the fixed object without being affected by the abnormal operation of the cable. The calculation module updates the correction factor according to the linear distance and the angular parameter corresponding to the current electrical signal, so that the cable can correctly correspond the detected angular parameter to the first linear parameter under the influence of temperature, environmental foreign objects, and its own wear, so as to enable the remote end to obtain the working state of the cable under the non-visible condition at the current moment and accurately give the change in the linear distance between the object to be measured and the fixed object.

[0033] A wireless cable - type displacement sensor system provided by the present invention has a mobile end installed on the object to be measured and a winding end installed on a fixed object. The system connects these two ends through a cable, and the movement (i.e., displacement) of the mobile end causes an angular change at the winding end, which is ultimately converted into an electrical signal. The mobile end is usually installed on the object to be measured, such as the end of a robotic arm, a measurement point on a bridge, or other moving parts of a device. As the object to be measured moves, the mobile end displaces relative to the winding end, causing the cable to stretch or relax. The movement mode of the mobile end can be linear, horizontal, vertical, etc. in different directions, depending on the specific measurement requirements. The winding end is fixedly installed on a stationary base, usually at a position with stable structure and not moving with the object to be measured. The core function of the winding end is to be connected to the cable. When the cable is stretched, the reel of the winding end rotates, generating an angular change. This angular change reflects the change in the length of the cable, thus indirectly indicating the displacement of the object to be measured.

[0034] In a wireless cable - type displacement sensor system, the core role of the cable is to convert the linear displacement of the mobile end into an angular change at the winding end. The cable is usually made of high - strength and durable materials, such as steel wire ropes or special synthetic materials, with a certain tension and flexibility, capable of withstanding the friction and stretching during long - term use. When the mobile end displaces, the cable changes accordingly. The change in the length of the cable causes the reel at the winding end to rotate, generating an angular change proportional to the displacement. This angular change can be accurately detected by sensors such as encoders or potentiometers. Specifically, an encoder or a potentiometer can sense the minute changes in the rotation angle of the cable reel and convert these angular changes into corresponding electrical signals, thereby reflecting the displacement of the object.

[0035] The calculation module processes the angular parameters obtained by the sensor and converts them into actual displacement data or movement distance. These data will be further transmitted to a remote control system for various applications such as real - time monitoring and data analysis. The calculation module converts the detected angular change into a physically meaningful quantity (such as displacement, movement distance, etc.) through a preset calculation model. These physical quantities are usually represented in numerical form, facilitating subsequent system control and judgment. The input of the calculation module comes from measuring devices such as encoders or potentiometers in the wireless cable - type displacement sensor system. These devices obtain angular parameters based on the rotation angle of the reel at the winding end. These angular parameters reflect the elongation or contraction degree of the cable, further affecting the position change of the mobile end. For example, when the reel at the winding end rotates, the encoder records the rotation angle of the reel, thereby calculating the change in the length of the cable. This angular information is transmitted as an input to the calculation module.

[0036] The calculation module uses known mathematical models to calculate the second linear parameter of the object under test based on the angle parameter. These linear parameters usually manifest as the displacement or movement distance of the object. Through a geometric transformation model (such as using the relationship between the angle and the reel radius), the actual physical displacement value is calculated. For example, in bridge monitoring applications, the calculation module will transmit the displacement data to the central monitoring platform in real time via a wireless network. The platform generates a real-time report based on the received data to monitor the health status of the bridge.

[0037] The first signal module is mainly deployed at the winding end and the fixed object. Specifically, the role of the first signal module is to establish a signal interaction mechanism between the winding end and the fixed object. It receives the electrical signal from the second signal module and transmits it to the calculation module, thereby ensuring that the calculation module can accurately calculate the linear distance between the mobile end and the fixed object. To ensure the accuracy of the signal and the reliability of the system, the signal transmission between the first signal module and the calculation module is crucial. Only through precise signal transmission can the system obtain effective data. When deploying, the installation position of the first signal module should consider its relative position relationship with the second signal module. The first signal module usually needs to move relative to the second signal module to establish physical contact between the two signal modules and generate an effective electrical signal when in contact. For example, in bridge monitoring, the first signal module can be installed at a fixed position of the bridge (such as the foundation part or the load-bearing bracket of the bridge). When the second signal module (installed on another part of the bridge or the monitoring point) comes into contact with the first signal module, the first signal module calculates the physical displacement related to the contact through the received electrical signal. The signal transmission ensures that the displacement between the mobile end and the fixed object can be transmitted to the calculation module in real time.

[0038] The calculation module not only receives the electrical signal from the first signal module but also is equipped with a correction factor to correct the angle parameter at each moment, thereby improving the accuracy and stability of the system. The role of the correction factor is to cope with the environmental changes and fluctuations in the working state that the system may encounter, ensuring the consistency between the angle and the actual displacement. The correction factor is calibrated according to the linear distance between the two first signal modules. Because the wire may be affected by temperature changes, environmental factors, or due to wear of the wire itself during operation, resulting in measurement errors, the correction factor can adjust the measurement results of the system in real time to ensure the accuracy of the calculation results. The calibration process is to measure the linear distance between the two first signal modules during the initial setup or maintenance process and use this value to calibrate the correction factor in the calculation module. This calibration value is the basis for the normal operation of the system. Any measurement errors caused by external environmental changes, equipment wear, or temperature changes can be corrected through the dynamic adjustment of the correction factor.

[0039] The second signal module is set on the mobile device. Its function is to interact with the first signal module, trigger the first signal module to generate an electrical signal and transmit it to the calculation module. When the second signal module receives the electrical signal sent by the first signal module, it will start the entire measurement process. The calculation module obtains distance data based on the received electrical signal and performs further correction calculations to ensure the accuracy of the measurement. When the second signal module comes into contact with the first signal module, the first signal module will generate an electrical signal and transmit it to the calculation module, thereby starting the displacement measurement and data transmission functions of the system. The second signal module can be installed on the movable part of the automation device (such as the end of the robotic arm). Each time this part comes into contact with the first signal module, the displacement data is collected and processed by the calculation module through wireless transmission to ensure that the position change of the device is recorded in real time.

[0040] To ensure that the wire-pulling displacement sensor can cope with different working environments and state changes, the calculation module will update the correction factor according to the current angle change based on the electrical signal received through the second signal module each time. In this way, the calculation module can perform self-calibration in real time to ensure the measurement accuracy of the system. Whenever an interaction occurs between the second signal module and the first signal module, the system will automatically adjust the correction factor according to the actual situation (such as the deviation between the actual displacement and the calculation result). In this way, even when the wire is affected by factors such as temperature change, environmental foreign objects, or its own wear, the system can still provide accurate displacement calculation results. For example, if the wire shows wear or stretching due to long-term use, the calculation module dynamically compensates for these physical changes through the correction factor to ensure the accuracy of the data.

[0041] In summary, by adding a correction factor to the calculation module, this factor is calibrated according to the linear distance between the two first signal modules and is updated in real time according to factors such as temperature change, wear, and tension during each use. By dynamically adjusting the correction factor, the errors caused by wire wear, temperature change, and tension non-uniformity can be compensated. In this way, the sensor can still maintain the measurement accuracy when the wire changes. It can monitor and dynamically adjust the angle parameters in real time. Even if the material of the wire deforms due to temperature change or long-term use, the calculation module can still accurately reflect the actual displacement according to the update of the correction factor. With the interaction between the first signal module and the second signal module, the system can compensate for the tension non-uniformity of the wire to a certain extent. Especially in the case of a multi-turn winding design, the tension non-uniformity between different turns is corrected through the dynamic adjustment of the calculation module, thereby avoiding the telescopic change caused by the friction difference between the outer and inner wires.

[0042] In any of the above embodiments, the wireless wire-pulling displacement sensor system further includes a calibration module for updating the range of the wire according to the correction factor at each moment. Since the length of the wire is also affected by temperature, the actual length will be greatly affected. And since the correction factor is calibrated by the linear distance between two first signal modules and is a fixed value, under the conditions of changes in the cross-section and diameter of the wire caused by wear, changes in length affected by temperature, and excessive adhesion of small impurities such as external dust on the wire surface, for a fixed correction factor, the wire length required to generate the same original set angle parameter through winding will also change. Therefore, it is necessary to update the range of the wire at each moment to ensure that the angle parameter and the first linear parameter always have a correct corresponding relationship, avoid affecting the calculation of the second linear parameter from the subsequent angle parameter, and achieve the decoupling of the overall calculation into two different corrections, one for compensating the errors caused by environmental factors such as temperature and foreign objects, and the other for compensating the errors caused by different circumferences due to multi-turn winding.

[0043] In any of the above embodiments, the calibration module is further configured to divide the range into n line segments according to the linear distance and generate a judgment factor for determining whether the wire is qualified between adjacent line segments. The setting of the linear distance is less than the range, so that a larger distance can be corrected by a smaller distance and a more accurate correction factor, especially when a wire with an extremely long range is required for correction in engineering. And dividing it into n line segments can better understand the conversion differences of different positions of the wire under the angle parameter during long-term use, so as to avoid different angle parameter conversions due to different positions of the wire at the same movement distance.

[0044] In this embodiment, the correction factor is calibrated based on the linear distance between two first signal modules, and the calibrated value is a fixed value. However, due to factors such as temperature changes, wire rope wear, and external contamination, the length and elasticity of the wire rope may change. Therefore, a fixed correction factor cannot adapt to all environmental and usage conditions. In this case, the calibration module dynamically updates the measurement range of the wire rope according to the correction factor at the current moment. This real-time update ensures that the relationship between the length and angle parameters of the wire rope is always accurate at each moment, thus avoiding measurement deviations caused by error accumulation. Temperature change is an important factor affecting the length of the wire rope. As the temperature rises, the wire rope (especially the metal wire rope) may expand, resulting in an increase in length; while in a low-temperature environment, the wire rope may contract, causing its length to decrease. If this small change caused by temperature is not compensated, it may lead to a deviation in the relationship between the angle and displacement. In addition, the wear of the wire rope will also affect its cross-section and diameter, changing the elasticity and stretchability of the wire rope. Impurities such as dust or oil stains accumulated on the surface of the wire rope will also increase the friction force, resulting in uneven stretchability of the wire rope, thereby affecting the accurate measurement of displacement. Therefore, the system needs to adjust the correction factor according to the real-time environmental conditions (temperature, wear, contamination, etc.) to ensure that the length change of the wire rope can be accurately compensated and will not affect the subsequent conversion relationship between the angle parameter and displacement.

[0045] To cope with different types of errors, the present invention adopts a design of correction decoupling, that is, the correction in the overall calculation is divided into two independent correction factors. One correction factor is mainly used to compensate for the change in the length of the wire rope caused by environmental factors such as temperature changes and foreign object contamination. This correction factor can be updated in real time and compensate for the errors caused by changes in the external environment. The other correction factor is specifically used to compensate for the errors generated by the multi-turn winding of the wire rope. Especially between different turns, due to different friction forces, the wire rope shows different stretchabilities, resulting in different stretch amounts of the wire rope at different positions under the same angle. By processing these two correction factors separately, the system can more precisely handle the performance changes of the wire rope in different usage environments, thereby improving the accuracy and stability of the overall measurement. Combining these two independent correction factors, the system can continuously maintain high-precision displacement measurement under changing environmental conditions. The dynamic update of the correction factor and the real-time adjustment of the measurement range ensure that the relationship between the length and angle of the wire rope is always correct. Even in the case of long-term use and complex environmental changes, the system can still effectively compensate for the effects caused by factors such as temperature changes, wear, and foreign object attachment, ensuring the reliability of the measurement results.

[0046] In any of the above embodiments, the judgment factor is generated based on the angle parameters corresponding to adjacent line segments. The angle parameters of rotation can intuitively reflect the change in detection accuracy under different line segments, providing an observable basis for judging the detection life of the wire rope later.

[0047] In this embodiment, the judgment factor is generated by the angle parameters corresponding to adjacent line segments. Specifically, the system calculates the angle parameter of each line segment according to the relationship between each small section of the pull wire (i.e., the pull wire range corresponding to each line segment) and the angle. These angle parameters reflect the elongation and tension changes of the pull wire under different working conditions, and thus affect the stretchability and measurement accuracy of the pull wire. The judgment factor judges whether the pull wire has reached its service life by monitoring the changes in these angle parameters. Each adjacent line segment represents a small range of the pull wire. Through the angle parameters of this small range, the system can monitor the performance changes of the pull wire within these small sections. For example, when the pull wire is worn or affected by the external environment (such as temperature, humidity, etc.), the angle parameters of different line segments will change slightly. These changes reflect the physical state of the pull wire at different positions. Therefore, the angle parameter can be used as a basis for measuring whether the pull wire meets the use standard. Assume that the range of the pull wire is divided into 10 line segments, and each line segment represents a measurement range of 1 meter. As the use time of the pull wire increases, the outer pull wire may be worn due to frequent friction, resulting in a deviation of the angle parameter of this line segment from the angle parameter in the new state. By comparing the angle parameters of adjacent line segments, the system can detect this deviation and monitor it through the judgment factor.

[0048] The angle parameter essentially describes the angle of rotation of the pull wire reel and reflects the changes of the pull wire during the actual measurement process. When the system detects an abnormal deviation in the angle parameter of a certain line segment, it means that the pull wire of this line segment may have been worn, the stretchability has changed, or there are other factors affecting the accuracy. When the change in the angle parameter exceeds the preset range, the judgment factor will judge that a significant change has occurred in this section of the pull wire, which means that the performance of the pull wire can no longer meet the accuracy requirements of the system. Therefore, the judgment factor can provide users with an accurate determination of the service life of the pull wire, helping users to perform maintenance or replacement in a timely manner.

[0049] In any of the above embodiments, the wireless pull-wire displacement sensor system further includes a clock module for obtaining the time data when the angle parameter changes; the calculation module generates the angle parameter corresponding to each line segment through the time data and the linear distance. The time parameter includes the point information of the time point and the multi-segment information of the time period, for estimating the number and position of the line segments used by the pull wire in the current motion detection when the mobile terminal is in a uniform motion state.

[0050] In this embodiment, in the uniform motion state, the clock module and the calculation module work together to help the system estimate the number and position of line segments used in a certain motion detection. The uniform motion state generally means that the wire rope maintains a constant speed change throughout the measurement process. The system can estimate the different line segment ranges covered by the wire rope during the motion by analyzing the angle change and displacement change in each time period. When the system is in a uniform motion state, the relationship between time and displacement is relatively simple, and the number of wire rope segments used in each time period can be calculated from the time data and the linear distance. For example, the calculation module can estimate the number of line segments covered by the wire rope in this time period based on the displacement change per unit time. The precise control of the measurement accuracy of the wire rope in the uniform motion state is achieved. The clock module obtains the time data at each angle change, combines the linear distance to generate the angle parameter of each line segment, and further provides an accurate basis for subsequent displacement estimation. Through in-depth analysis and calculation of the time data, the system can not only accurately estimate the displacement of the wire rope, but also maintain high-precision measurement during long-term use, especially in complex uniform motion detection, ensuring the precise monitoring of each line segment.

[0051] In any of the above embodiments, the clock module starts to obtain time data when the mobile end approaches the winding end. Since the mobile end is usually in the operation output state of the device when it moves away from the fixed object, the motion speed is likely to be variable at this time. However, when the mobile end approaches the fixed object, it is in the reset working condition of the device, and a stable motion condition will occur at this time. Therefore, it is easy to obtain an accurate relationship between the line segment and the angle parameter in the reset working condition. The downward rounding method is used for the divided n value, and the wire rope part corresponding to the non-integer value is removed in the current calibration calculation.

[0052] In this embodiment, the startup of the clock module and the acquisition of time data are judged based on the changes in the operating state and reset condition of the device. In the reset condition, the clock module will start and begin to record accurate time data for subsequent calculations. During this process, the clock module is responsible for tracking the time changes during the movement process and transmitting this data to the calculation module to help the calculation module generate the angle parameters corresponding to each line segment in combination with the linear distance. When the device enters the reset condition, the movement speed of the mobile end tends to be stable, which means that it is very easy to obtain an accurate relationship between the angle parameters and the line segments at this stage. In the reset condition, the mobile end is close to the winding end, and the telescopic characteristics and angle changes of the wire can be measured almost at a constant speed, thereby improving the accuracy between the angle and the displacement. This stable state makes the combination of time data and linear distance more accurate, and the relationship between the calculated angle parameters and the actual displacement has almost no error. On an automated production line, when the device performs a reset operation, the movement speed of the robotic arm is usually slow and predictable. At this time, the clock module can accurately record the changes at each time point and combine them with the length change of the wire to ensure the accurate calculation of the angle parameters.

[0053] When the device is reset, the telescopic change of the wire is relatively controllable, and the relative movement between the mobile end and the winding end is slow and constant. At this time, the relationship between the angle change and the wire length remains consistent, and the time data recorded by the clock module can accurately correspond to the angle change of each line segment. Therefore, through the combination of the time data obtained by the clock module and the linear distance, the angle parameters of each line segment can be calculated more accurately, thus ensuring the measurement accuracy.

[0054] In any of the above embodiments, whether the wire is qualified is judged by the following rules:

[0055] When the absolute value of at least one judgment factor is greater than the preset threshold, it indicates that there is at least one segment of the wire with uneven measurement compared to other segments, and there will be a large deviation when the mobile end makes the same movement and the wire is measured at different positions. This is a structural damage, defect, or abnormality that cannot be corrected, so the wire is judged as unqualified.

[0056] When the absolute value of all judgment factors is less than or equal to the preset threshold, it indicates that the measurement scales between all segments of the wire are relatively uniform and the conversion of the angle parameters is relatively smooth, so the wire is judged as qualified.

[0057] In this embodiment, when the absolute value of at least one judgment factor is greater than the preset threshold, the system determines that the wire rope is unqualified. This situation indicates that there is significant measurement non-uniformity at at least one position of the wire rope, that is, when the same movement is performed at different positions of the wire rope, there will be a large deviation in the measurement results. This deviation may be due to an irreparable structural damage, defect or abnormality in a certain section of the wire rope, which cannot be eliminated by adjusting the subsequent correction factor. Therefore, the wire rope needs to be determined as unqualified. The judgment factor reflects the angular conversion and measurement non-uniformity between different sections of the wire rope. When the absolute value of the judgment factor is large, it indicates that there is a large measurement difference between a certain part of the wire rope and other parts, which may be caused by factors such as local wear, mechanical damage or material problems of the wire rope. This non-uniformity will cause the angular parameters at different positions of the wire rope to change inconsistently under the same movement, resulting in errors. At this time, even if the errors of other parts are adjusted by the correction factor, the local damage or defect cannot be solved.

[0058] When the absolute value of all judgment factors is less than or equal to the preset threshold, it means that the measurement scales between all sections of the wire rope are relatively uniform, and the conversion process of the angular parameters is relatively stable and linearly consistent. At this time, the wire rope is determined to be qualified, indicating that its stretchability and performance are consistent between each section, and it can provide accurate displacement measurement. When the absolute value of all judgment factors is less than or equal to the preset threshold, it means that there is no significant difference in the measurement scales between different positions of the wire rope, and the conversion relationship between the angular parameters and the displacement is relatively smooth. The system compensates for the small changes of the wire rope through the correction factor, so that the angular parameters of each line segment can be consistent with the displacement change, ensuring that the system can provide accurate displacement data. If the measurement results at each position of the wire rope are relatively uniform and the conversion of the angular parameters is relatively stable, it means that the performance of the wire rope has not been affected by local damage or external factors. In this case, the correction factor can effectively correct the small errors of the wire rope, ensuring high-precision displacement calculation. At this time, the entire system can maintain consistent measurement accuracy during long-term operation, ensuring the reliability and accuracy of the wire rope.

[0059] By introducing the design of the judgment factor and the preset threshold, the present invention provides a precise wire rope health monitoring mechanism for the wireless wire rope displacement sensor system. The judgment factor can not only help the system to timely detect local damage, defects or abnormalities of the wire rope during operation, but also judge whether the wire rope meets the accuracy requirements of the system according to the measurement uniformity of the wire rope.

[0060] Specifically, if the system design requires a measurement accuracy of 1 mm, then the preset threshold may need to be controlled within 0.1 mm; in a high-precision system, the preset threshold may need to be controlled within a smaller range, such as 0.01 mm.

[0061] In any of the above embodiments, the wireless wire-pulling displacement sensor system further includes a wireless module for transmitting the second linear parameter so that the remote end can obtain the movement distance status of the mobile end in real time; when the wire is determined to be unqualified, the wireless module sends an alarm message to the remote end so that the remote end can know that the service life of the wire has reached or there is an irresistible foreign object pollution or structural jamming without performing on-site detection.

[0062] In this embodiment, the role of the wireless module in the system is to transmit the movement data of the mobile end in real time. The system transmits the second linear parameter, that is, the displacement or movement distance of the device, to the remote device in real time through wireless communication technology. The remote control system, monitoring platform or operator can, based on the received data, grasp the displacement status of the device in real time, and conduct monitoring, analysis and decision-making. This makes remote monitoring more flexible and efficient, and enables the staff to obtain the device status without having to go to the site for on-site inspection. Secondly, through wireless transmission, multiple wire-pulling sensors can be remotely monitored simultaneously, facilitating large-scale and multi-point real-time monitoring and data integration. Whether in application scenarios such as industrial automation, building monitoring or bridge health monitoring, the ability to obtain movement data in real time can greatly improve the response speed and efficiency of the monitoring system.

[0063] In addition to transmitting movement data, the wireless module also undertakes a key alarm function. When the wire is determined to be unqualified, the system sends an alarm message to the remote end through the wireless module. The alarm system can promptly inform the remote staff that the wire has reached the service life or the wire cannot continue to work properly due to external foreign object pollution, structural damage and other factors, thus avoiding the routine inspection and manual detection of on-site personnel. The alarm mechanism provides significant advantages for the system. First of all, the system can feed back to the remote end at the first time when a problem occurs, ensuring that the remote staff knows the device status in the first time and can take measures such as replacement, repair or adjustment in time. Secondly, the wireless module can provide the convenience of remote maintenance, enabling the health status of the system to be monitored anytime and anywhere, and greatly reducing the risk brought by device failures. The combination of remote monitoring and alarm functions is realized. The staff does not need to regularly go to the site to check the wire status. The system can effectively inform whether the device has a fault through real-time data transmission and alarm functions, ensuring that problems can be responded to in time when the device has problems. This not only reduces the workload of manual detection, but also reduces the maintenance delay or system shutdown caused by the failure to detect problems in time. In intelligent building monitoring, if the wire is polluted or damaged due to temperature changes, long-term use or external interference, the traditional system may need on-site detection to find the problem, while the wireless module of the present invention can automatically transmit the alarm message to the remote personnel, avoiding the frequent need for on-site manual inspection.

[0064] In any of the above embodiments, the second signal module and the first signal module disposed at the winding end form a normally closed switch circuit. When the normally closed switch circuit is in an open state, an electrical signal is generated, and only the first and the last of a series of electrical signals are recorded. On the one hand, it can be known that the mobile end has moved away from the winding end, and on the other hand, one end of the initial line segment of the pulling wire is calibrated.

[0065] In this embodiment, the design of the normally closed switch circuit is such that the circuit is normally in a closed state, and only when the contact between the second signal module and the first signal module is broken, the circuit will enter an open state, thereby triggering the generation of an electrical signal. In short, when the pulling wire of the mobile end undergoes a certain displacement, causing the second signal module to separate from the winding end (i.e., disconnect from the first signal module), the normally closed switch circuit will switch to an open state and generate an electrical signal. Through this process, the system can not only record the separation between the mobile end and the winding end, but also ensure that every change in displacement can be traced. When the second signal module disconnects from the first signal module and generates an electrical signal, the system can perceive the separation state between the mobile end and the winding end in real time. This operation can be regarded as a landmark event, indicating that the pulling wire of the mobile end has moved or there has been a change in a certain state. In practical applications, it can accurately mark the start or end of the device's working state, helping the system record key events and trigger subsequent measurement and control operations.

[0066] The normally closed switch circuit also plays a role in calibrating the end of the initial line segment of the pulling wire. When the circuit is in an open state, the system can use the electrical signal generated at this time to calibrate the initial position of the pulling wire. This calibration process provides an accurate starting point for subsequent displacement measurements, enabling each displacement change to be calculated based on this benchmark, ensuring the accuracy and consistency of the system measurements.

[0067] In any of the above embodiments, the second signal module and the first signal module disposed on the fixed object form a normally open switch circuit. When the normally open switch circuit is in a closed state, an electrical signal is generated, which can calibrate the other end of the initial line segment of the pulling wire, so as to record the linear distance corresponding to the correction factor.

[0068] In this embodiment, the design feature of the normally open switch circuit is that the circuit remains open in the normal state and only triggers the generation of an electrical signal when the state of the circuit changes, i.e., when it is in the closed state. The second signal module works together with the first signal module. When a specific action occurs at the initial end (the end fixed to an object) of the wire, the circuit closes and generates an electrical signal. At this time, the system can record in real time the linear distance related to this end, providing a key basis for the calculation of the correction factor and the accuracy of subsequent displacement data. When the second signal module contacts the first signal module and closes the circuit, the system generates an electrical signal, marking the calibration of the other end of the initial segment. This calibration is not only an important reference point for the state of the wire, but also the end point of the correction factor calculation, ensuring that the system can accurately calculate the corresponding linear distance of the correction factor through the calibration of this end during the entire measurement process.

[0069] The design of the normally open switch circuit combined with its corresponding correction factor calibration function improves the accuracy and reliability of the system. By accurately calibrating the initial end and generating an electrical signal, the system can ensure the accurate relationship between the correction factor and the linear distance, avoiding errors caused by the influence of the external environment on the wire. In the long-term use of the device and in complex environments, this calibration mechanism helps the system always maintain a high-precision displacement measurement ability.

[0070] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0071] The above-described embodiments are only descriptions of the preferred embodiments of the present invention and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various deformations and improvements made by those of ordinary skill in the art to the technical solutions of the present invention shall fall within the protection scope determined by the claims of the present invention.

Claims

1. A wireless wire-pulling displacement sensor system, characterized in that, Including: A mobile end installed on a robotic arm and a winding end installed on a base connected to the robotic arm. A wire is connected between the mobile end and the winding end, and the wire is used to convert a first linear parameter of the mobile end into an angular parameter of the winding end; A calculation module that calculates a second linear parameter of the robotic arm according to the angular parameter through a calculation model included therein and transmits it to a remote end through wireless transmission; A first signal module respectively disposed on the winding end and the base; a correction factor for correcting the angular parameter at each moment is further provided on the calculation module, and the correction factor is calibrated according to the linear distance between the two first signal modules; A second signal module is disposed on the mobile end; the second signal module and the first signal module disposed on the winding end form a normally closed switch circuit, and an electrical signal is generated when the normally closed switch circuit is in an open state; the second signal module and the first signal module disposed on the base form a normally open switch circuit, and an electrical signal is generated when the normally open switch circuit is in a closed state; the calculation module updates the correction factor under the condition that the wire is not visible according to the linear distance and the angular parameter corresponding to the current two electrical signals.

2. The wireless wire-pulling displacement sensor system according to claim 1, characterized in that It further includes a calibration module for updating the range of the wire according to the correction factor at each moment.

3. The wireless wire-pulling displacement sensor system according to claim 2, characterized in that The calibration module is further used to divide the range into n line segments according to the linear distance and generate a judgment factor for judging whether the wire is qualified between adjacent line segments.

4. The wireless cable-pulling displacement sensor system according to claim 3, wherein The judgment factor is generated by the angular parameters corresponding to adjacent line segments.

5. The wireless wire-pulling displacement sensor system according to claim 4, characterized in that, It further includes a clock module for obtaining time data when the angular parameter changes; the calculation module generates the angular parameter corresponding to each line segment through the time data and the linear distance.

6. The wireless cable-pulling displacement sensor system according to claim 5, wherein, The clock module starts to obtain the time data when the mobile end approaches the winding end.

7. The wireless cable-pulling displacement sensor system according to claim 3, characterized in that Whether the wire is qualified is judged by the following rules: When the absolute value of at least one judgment factor is greater than a preset threshold, the wire is judged as unqualified; When the absolute values of all judgment factors are less than or equal to the preset threshold, the wire is judged as qualified.

8. The wireless wire-pulling displacement sensor system according to claim 7, wherein It further includes a wireless module for transmitting the second linear parameter; when the wire is judged as unqualified, the wireless module sends an alarm message to the remote end.

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