Absolute encoder operation error analysis method and system

Abstract

The present invention relates to the technical field of encoder operation and maintenance management, and in particular to a method and system for analyzing the operation errors of an absolute encoder, which more accurately identifies whether the specific source of the error is an internal equipment problem or an external environmental factor through analysis of the elimination of external environmental factors. The method is applied to an encoder operation monitoring system, and when the encoder operation monitoring system detects that an absolute encoder has an error, an error analysis instruction is generated. The method comprises: in response to the error analysis instruction, parsing the error analysis instruction to obtain the address of the absolute encoder that needs to be error analyzed, the absolute encoder model, and the error analysis time window; configuring an error analysis test strategy based on the absolute encoder model and the absolute encoder address; based on the error analysis test strategy, performing a test within the error analysis time window, and comprehensively evaluating the test results to obtain a first error test result.

Description

Technical Field

[0001] The present invention relates to the technical field of encoder operation and maintenance management, and in particular to a method and system for analyzing operation errors of an absolute encoder. Background Art

[0002] The absolute encoder is a precision position measurement device widely used in industrial automation, robotics, CNC machine tools and other fields. It can provide precise position information relative to a reference point and determine the specific position of the shaft without the need for a zero return operation. The absolute encoder converts mechanical motion into digital signal output, allowing the control system to obtain the accurate position of the equipment in real time. To ensure product quality and production efficiency, it is necessary to ensure that the absolute encoder on the production equipment operates stably and reliably. However, due to the influence of various factors, the absolute encoder will have operating errors. If not discovered and corrected in time, it is easy to lead to product quality decline, production line shutdown and even safety accidents.

[0003] Existing error analysis methods often focus on the performance testing of the absolute encoder itself, while ignoring the impact of external production environment factors on encoder accuracy, making it difficult to accurately identify and analyze the sources of absolute encoder errors, including internal and external factors. Summary of the Invention

[0004] In order to solve the above technical problems, the present invention provides an absolute encoder operation error analysis method and system that eliminates the influence of external environmental factors and more accurately identifies whether the specific source of the error is an internal equipment problem or an external environmental factor.

[0005] In a first aspect, the present invention provides an absolute encoder operation error analysis method, which is applied to an encoder operation monitoring system. When the encoder operation monitoring system detects an error in the absolute encoder, an error analysis instruction is generated. The method includes:

[0006] In response to the error analysis instruction, the error analysis instruction is parsed to obtain the address of the absolute encoder that needs to be error analyzed, the absolute encoder model and the error analysis time window;

[0007] Based on the absolute encoder model and the absolute encoder address, configure an error analysis test strategy;

[0008] Based on the error analysis test strategy, perform a test within the error analysis time window, and comprehensively evaluate the test results to obtain a first error test result;

[0009] Performing an environmental external factor influence elimination analysis on the first error test result to obtain a second error test result;

[0010] Based on a preset encoder error accuracy threshold, the second error test result is compared and determined to obtain the absolute value encoder error analysis result.

[0011] Furthermore, the error analysis test strategy includes static testing, dynamic testing and load testing;

[0012] Among them, the static test is used to detect the output accuracy of the absolute encoder when it is in a fixed position; the dynamic test is used to detect the output accuracy of the encoder during continuous movement; and the load test is used to detect the output stability of the encoder when it is subjected to different loads.

[0013] Furthermore, the static test method includes:

[0014] Determine a test position set according to the absolute encoder model; the test position set covers the entire working range of the absolute encoder, and the test position set includes at least a zero point, a mid-range point, and a full-range point;

[0015] At each test position in the test position set, placing the absolute encoder in a stationary state and using a measuring device to record initial output data of the encoder;

[0016] Applying preset test conditions to each test position, wherein the preset test conditions simulate environmental factors in actual use of the absolute encoder;

[0017] After applying the preset test conditions, the measuring equipment is used again to record the output data of the absolute encoder. Multiple measurements are performed at each test position and the average value is taken to obtain the actual output data at the corresponding test position.

[0018] The difference between the actual output data and the initial output data at each test position is calculated to obtain the static test error value.

[0019] Furthermore, the dynamic test method includes:

[0020] According to the absolute encoder model, setting at least one test acceleration track;

[0021] The absolute encoder is tested continuously according to the set test acceleration trajectory, and the dynamic output data of the absolute encoder is collected in real time. The dynamic output data includes the speed and acceleration at different time nodes;

[0022] Repeat the test multiple times for each test acceleration trajectory. Set a time interval between each test to allow the encoder to fully stabilize and eliminate non-steady-state effects. Calculate the average value of the multiple repeated tests as the actual dynamic output data of the corresponding test acceleration trajectory.

[0023] The actual dynamic output data is matched with the test acceleration trajectory, and the ratio of the number of unmatched time nodes to the total number of collected time nodes is used as the dynamic test error value.

[0024] Furthermore, the load test method includes:

[0025] Determine the measuring device and load applying device according to the absolute encoder model, and determine the load test parameters, including the test load range and step size;

[0026] Use a load applying device to apply an initial test load to the absolute encoder and keep it stable while recording the initial output data of the absolute encoder;

[0027] According to the predetermined load range and step size, gradually increase the load to the maximum test load, maintain a stable state at each load point for a set time, and record the response time of the absolute encoder at different load points;

[0028] Calculate the standard square deviation of the response time at different load points as the stable characteristic value of the load test.

[0029] Furthermore, the test is performed within the error analysis time window, and the calculation formula for comprehensively evaluating the test results is:

[0030] E1=W s ×E s +W d ×E d +W i ×E i ;

[0031] Among them, E1 represents the first error test result; E s Represents the standardized static test error value; E d Represents the normalized dynamic test error value; E i W represents the stable characteristic value of the load test after standardization; s 、W d and W i They represent the static test error value weight, dynamic test error value weight and load test stable characteristic value weight respectively.

[0032] Furthermore, the environmental external factors include electromagnetic interference characteristics and mechanical vibration characteristics at the location of the absolute encoder. Considering the electromagnetic interference characteristics and mechanical vibration characteristics, the calculation formula for performing environmental external factor influence elimination analysis on the first error test result is:

[0033] E2=E1-(C e ×E1+C u ×E1);

[0034] Wherein, E2 represents the second error test result after adjustment; C e is the electromagnetic interference correction factor; C u is the mechanical vibration correction factor.

[0035] On the other hand, the present application also provides an absolute encoder operation error analysis system, the system comprising:

[0036] The error monitoring module is used to monitor the operating status of the absolute encoder in real time and generate an error analysis instruction when an error is detected in the encoder;

[0037] The instruction parsing module is used to respond to the error analysis instruction and parse it to obtain the absolute encoder address, absolute encoder model and error analysis time window that need to be analyzed;

[0038] A test strategy configuration module configures an error analysis test strategy for the absolute encoder to be analyzed based on the absolute encoder model and absolute encoder address obtained by analysis;

[0039] An error test execution module tests the absolute value encoder to be analyzed according to the configured error analysis test strategy within the error analysis time window, and comprehensively evaluates the test results to obtain a first error test result;

[0040] An environmental external factor influence analysis module considers the electromagnetic interference characteristics and mechanical vibration characteristics of the absolute encoder's location, performs an environmental external factor influence elimination analysis on the first error test result, obtains a second error test result, and uses it as the absolute encoder error analysis result;

[0041] The error judgment module compares the absolute encoder error analysis results based on the preset encoder error accuracy threshold to determine the source of the error. If the error analysis result is less than the preset threshold, it indicates that the error source is an external environmental factor. If the error analysis result is not less than the preset threshold, it indicates that the error source is an internal device factor.

[0042] In a third aspect, the present application provides an electronic device comprising a bus, a transceiver, a memory, a processor, and a computer program stored in the memory and runnable on the processor, wherein the transceiver, the memory, and the processor are connected via the bus, and the computer program implements the steps of any one of the above methods when executed by the processor.

[0043] In a fourth aspect, the present application further provides a computer-readable storage medium having a computer program stored thereon, which implements the steps in any one of the above methods when executed by a processor.

[0044] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention not only focuses on the performance detection of the absolute encoder itself, but also specifically introduces the analysis of external production environment factors such as electromagnetic interference and mechanical vibration; through the analysis of the elimination of external environmental factors, it is possible to more accurately identify whether the specific source of the error is an internal equipment problem or an external environmental factor; by determining the error analysis time window based on the production idle time period, it effectively avoids the interference that may be caused by error analysis during normal production, thereby ensuring the continuity and efficiency of production; automatically parses the error analysis instructions and configures the corresponding test strategy, making the entire process more efficient and reducing the possibility of human intervention; using the preset encoder error accuracy threshold to compare with the actual error analysis results can help quickly determine the source of the error, and then take targeted maintenance or adjustment measures to improve the speed and accuracy of fault diagnosis. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a flow chart of the absolute encoder operation error analysis method in Example 1;

[0046] Figure 2 It is a structural diagram of the absolute encoder operation error analysis system in Example 2. DETAILED DESCRIPTION

[0047] In the description of this application, those skilled in the art should know that this application can be implemented as a method, an apparatus, an electronic device, and a computer-readable storage medium. Therefore, this application can be specifically implemented in the following forms: complete hardware, complete software (including firmware, resident software, microcode, etc.), or a combination of hardware and software. In addition, in some embodiments, this application can also be implemented in the form of a computer program product in one or more computer-readable storage media, wherein the computer-readable storage medium contains computer program code.

[0048] The computer-readable storage medium may be any combination of one or more computer-readable storage media. Computer-readable storage media include: electrical, magnetic, optical, electromagnetic, infrared or semiconductor systems, devices or components, or any combination thereof. More specific examples of computer-readable storage media include: portable computer disks, hard disks, random access memories, read-only memories, erasable programmable read-only memories, flash memory, optical fibers, optical disc read-only memories, optical storage devices, magnetic storage devices, or any combination thereof. In this application, a computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, device, or component.

[0049] The acquisition, storage, use, and processing of data in this application's technical solution comply with relevant national laws.

[0050] This application describes the provided methods, devices, and electronic devices through flowcharts and / or block diagrams.

[0051] It should be understood that each block in the flowchart and / or block diagram, as well as combinations of blocks in the flowchart and / or block diagram, can be implemented by computer-readable program instructions. These computer-readable program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device, thereby producing a machine. These computer-readable program instructions are executed by the computer or other programmable data processing device to produce a device that implements the functions / operations specified in the blocks in the flowchart and / or block diagram.

[0052] These computer-readable program instructions may also be stored in a computer-readable storage medium that enables a computer or other programmable data processing device to operate in a specific manner. In this way, the instructions stored in the computer-readable storage medium produce an instruction device product that implements the functions / operations specified in the blocks in the flowchart and / or block diagram.

[0053] Computer-readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device, so that a series of operational steps are performed on the computer, other programmable data processing apparatus, or other device to produce a computer-implemented process, thereby enabling the instructions executed on the computer or other programmable data processing apparatus to provide a process that implements the functions / operations specified by the blocks in the flowchart and / or block diagram.

[0054] The present application is described below in conjunction with the accompanying drawings.

[0055] Example 1: Figure 1 As shown, a method for analyzing an absolute encoder operation error of the present invention is applied to an encoder operation monitoring system. When the encoder operation monitoring system detects an error in the absolute encoder, an error analysis instruction is generated. The method specifically includes the following steps:

[0056] Step S1: In response to an error analysis instruction, the error analysis instruction is parsed to obtain the address of the absolute encoder requiring error analysis, the absolute encoder model, and the error analysis time window; the error analysis time window is determined based on a production idle time period to avoid affecting equipment production during error analysis;

[0057] In the encoder operation monitoring system, when the output data of the absolute encoder is monitored to exceed the preset normal range or exhibit unstable characteristics, the encoder operation monitoring system will automatically generate an error analysis instruction; the error analysis instruction is intended to start a detailed error analysis process for the specific encoder to determine the cause of the error and take appropriate corrective measures; after receiving the error analysis instruction, the instruction parsing module in the system first performs a preliminary format verification and integrity check to ensure that the instruction contains all necessary information; if the instruction format is correct and complete, it proceeds to the next step; otherwise, the system will record an error log and may notify the administrator for manual intervention.

[0058] Next, we conduct an in-depth analysis of the error analysis instructions and extract the following key information:

[0059] Absolute encoder address: Each absolute encoder installed on site has a unique address identifier that is used to distinguish different devices in network communications; this address allows the system to accurately locate the target encoder that needs to be analyzed;

[0060] Absolute encoder model: Different absolute encoder models have different technical specifications, performance parameters, and potential failure modes; understanding the specific model is crucial to subsequently configuring the correct test strategy;

[0061] Error analysis time window: The error analysis time window is determined based on the production idle time period to ensure that the normal production of the equipment will not be disturbed when the error analysis is performed. The determination of this time window needs to take into account factors such as the production line operation plan, the equipment maintenance cycle and possible downtime. By selecting the production idle time period for error analysis, the impact on production can be minimized while ensuring the smooth progress of the analysis process.

[0062] Through the above steps, step S1 ensures that the error analysis instructions are accurately parsed and lays a solid foundation for the subsequent error analysis process, which not only improves the automation level of the system, but also reduces the possibility of human intervention, ensuring the efficiency and accuracy of the entire error analysis process.

[0063] Step S2: configuring an error analysis test strategy for the absolute encoder to be analyzed based on the absolute encoder model and the absolute encoder address; the error analysis test strategy includes a static test, a dynamic test, and a load test;

[0064] The static test is designed to evaluate the output accuracy of the absolute encoder at a fixed position to ensure that it provides accurate position information in a stationary state. The static test method includes:

[0065] a1. Determine the operating range of the absolute encoder based on its model and technical specifications, and select a set of test positions that cover the entire operating range; these positions include the zero point (starting position), the mid-range point (midpoint of the operating range), and the full-scale point (end position). By selecting representative test positions, you can ensure a comprehensive evaluation of the encoder's performance, not just the performance at a specific position.

[0066] a2. At each test position, place the absolute encoder in a stationary state and use a high-precision measuring device (such as a laser rangefinder, grating ruler, etc.) to record the encoder's initial output data; obtain the original reading under interference-free conditions to provide a benchmark reference for subsequent analysis;

[0067] a3. Simulate the environmental factors that the absolute encoder will experience in actual use, such as temperature, humidity, electromagnetic interference, vibration, etc., and apply them to the encoder. These conditions should be set according to the encoder's operating environment and specification requirements. This will test the encoder's stability under different environmental conditions and more realistically reflect its performance in actual applications.

[0068] a4. After applying the preset test conditions, use the measuring equipment again to record the output data of the absolute encoder. Perform multiple measurements at each test position and take the average value to obtain the actual output data at the corresponding test position.

[0069] a5. Calculate the difference between the actual output data and the initial output data at each test position to obtain the static test error value, which intuitively shows the accuracy loss of the encoder at a fixed position, making it easier to identify potential problems.

[0070] Secondly, dynamic testing is used to evaluate the output accuracy of the absolute encoder during continuous movement to ensure that it can provide reliable position feedback under dynamic conditions. The dynamic testing method includes:

[0071] b1. Design at least one test acceleration trajectory based on the encoder model. This trajectory should fully demonstrate the encoder's response characteristics over the entire operating range. By setting a reasonable acceleration trajectory, you can fully examine the encoder's performance at various speeds and accelerations.

[0072] b2. Continuously test the absolute encoder according to the set test acceleration trajectory and collect the absolute encoder's dynamic output data in real time. The dynamic output data includes speed and acceleration at different time nodes. Real-time monitoring of the encoder's dynamic behavior helps to detect any changes that may affect accuracy.

[0073] b3. Repeat the test multiple times for each test acceleration trajectory. Set a time interval between each test to allow the encoder to fully stabilize and eliminate non-steady-state effects. Calculate the average value of the multiple repeated tests as the actual dynamic output data for the corresponding test acceleration trajectory. This eliminates non-steady-state effects, ensures that the test results are not interfered with by accidental factors, and improves the repeatability and reliability of the test.

[0074] b4. Match the actual dynamic output data with the test acceleration trajectory, and use the ratio of the number of unmatched time nodes to the total number of acquired time nodes as the dynamic test error value; by quantifying the accuracy deviation of the encoder under dynamic conditions, it helps to identify possible control or mechanical problems.

[0075] The load test is designed to verify the output stability of the absolute encoder under different loads to ensure that it can still maintain accuracy in the actual operating environment. The load test method includes:

[0076] c1. Determine the measuring equipment and load application device based on the absolute encoder model, and determine the load test parameters, including the test load range and step size. By properly selecting the test equipment and parameters, real application scenarios can be simulated to provide more representative test results.

[0077] c2. Use a load applying device to apply an initial test load to the absolute encoder and keep it stable while recording the initial output data of the absolute encoder;

[0078] c3. Gradually increase the load to the maximum test load according to the predetermined load range and step size, maintaining a stable state at each load point for a set period of time, and recording the response time of the absolute encoder at different load points. This allows you to evaluate the encoder's response speed and stability under different loads, ensuring it can quickly adapt to changes in actual work.

[0079] c4. Calculate the standard square deviation of the response time at different load points as the load test stability characteristic value; it can provide a quantitative indicator to measure the stability of the encoder under different load conditions, which helps to identify potential problem points.

[0080] In summary, static testing, dynamic testing, and load testing each have their own focus, evaluating the performance of absolute encoders from different perspectives. Static testing focuses on accuracy in a stationary state, dynamic testing focuses on performance in motion, and load testing verifies stability under different load conditions. Combining these three test methods can provide a comprehensive understanding of the encoder's operating characteristics, ensuring that it can provide reliable performance in various situations.

[0081] Step S3: Based on the error analysis test strategy, the absolute value encoder to be analyzed is tested within the error analysis time window, and the test results are comprehensively evaluated to obtain a first error test result;

[0082] In step S3, according to the previously configured error analysis test strategy, the selected absolute encoder is actually tested within the determined error analysis time window; this step aims to collect the encoder's output data through a series of preset test methods, such as static test, dynamic test and load test, and evaluate its operating status accordingly.

[0083] The static test error value is calculated from the difference between the actual output data and the initial output data at each test position; the dynamic test error value is obtained by matching the actual dynamic output data with the expected test acceleration trajectory and calculating the proportion of unmatched nodes; the load test stability characteristic value is obtained by calculating the standard square difference of the response time at different load points; the specific test process is described in step S2;

[0084] In order to ensure the comparability of different types of test results, the above three error indicators need to be standardized or normalized: if the units or dimensions of the various test indicators are different, they can be standardized by subtracting the mean and then dividing by the standard deviation; for some specific cases, all error values can be mapped to a fixed range (such as between 0 and 1) to facilitate the subsequent application of weighted averaging or other comprehensive evaluation methods.

[0085] Taking into account that the importance of different test types may vary, a weight can be assigned to each test result based on the actual situation; for example, if static accuracy is very important, a higher weight can be given to the static test error value; for high-speed motion application scenarios, the weight of the dynamic test error value may be greater; in cases involving heavy load operations, the weight of the load test stability characteristic value will also increase accordingly.

[0086] Specifically, the calculation formula for comprehensive evaluation of the test results is as follows:

[0087] E1=W s ×E s +W d ×E d +W i ×E i ;

[0088] Among them, E1 represents the first error test result; E s Represents the standardized static test error value; E d Represents the normalized dynamic test error value; E i W represents the stable characteristic value of the load test after standardization;s 、W d and W i They represent the static test error value weight, dynamic test error value weight and load test stable characteristic value weight respectively.

[0089] To sum up, the first error test result in step S3 is obtained based on the comprehensive calculation of the static test error value, the dynamic test error value and the load test stability characteristic value. The first error test result reflects the overall error situation of the encoder under the current operating state. The larger the first error test result, the greater the error of the encoder; conversely, the higher the accuracy of the encoder.

[0090] Step S4: Considering the electromagnetic interference characteristics and mechanical vibration characteristics of the position where the absolute encoder is located, perform an analysis on the first error test result to eliminate the influence of external environmental factors, obtain a second error test result, and use the second error test result as the absolute encoder error analysis result;

[0091] In step S4, the error condition of the encoder itself is determined more accurately by eliminating the influence of external environmental factors such as the electromagnetic interference characteristics and mechanical vibration characteristics of the absolute encoder's location on its error test results; based on the analysis results of the electromagnetic interference and mechanical vibration, a correction factor is introduced for the first error test result; the correction factor is intended to quantify the contribution of external environmental factors to the encoder error and deduct this part of the influence from the original error test result.

[0092] The method for determining the electromagnetic interference correction factor includes:

[0093] A1. Use electromagnetic field measurement equipment to conduct detailed electromagnetic field strength measurements around the encoder installation location, including field strength distribution at different frequencies. Analyze the measurement results to identify potential sources of electromagnetic interference, such as nearby power lines, radio equipment, and motors. Evaluate the potential impact of electromagnetic interference on encoder signal transmission, including signal distortion, loss, or bit errors.

[0094] A2. Based on the electromagnetic field measurement data and the electrical characteristics of the encoder, establish an electromagnetic interference mathematical model. The electromagnetic interference mathematical model can describe how electromagnetic interference affects the signal quality and accuracy of the encoder, including parameters such as the amplitude, frequency, and phase of the interference.

[0095] A3. Determine the specific degree of influence of electromagnetic interference on encoder error through experiments and simulation analysis; derive the electromagnetic interference correction factor based on the degree of influence; the electromagnetic interference correction factor is used to quantify the degree of influence of electromagnetic interference on encoder error;

[0096] A4. Test under different electromagnetic interference conditions to verify the effectiveness and accuracy of the electromagnetic interference correction factor; based on the test results, adjust and optimize the electromagnetic interference correction factor to ensure its reliability and accuracy in actual application.

[0097] In addition, the method for determining the mechanical vibration correction factor includes:

[0098] B1. Use vibration sensors to monitor the mechanical vibration of the encoder and its mounting components, obtaining key parameters such as vibration frequency and amplitude. Analyze vibration data to identify potential vibration sources, such as looseness, imbalance, or wear of mechanical components. Evaluate the impact of mechanical vibration on the encoder shaft stability and signal output, including minor shaft displacement and degradation of signal quality.

[0099] B2. Build a mathematical model of mechanical vibration based on vibration measurement data and the mechanical characteristics of the encoder. This model can describe how mechanical vibration affects the accuracy and stability of the encoder, including parameters such as vibration amplitude, frequency, and phase.

[0100] B3. Determine the specific extent of the impact of mechanical vibration on encoder error through experiments and simulation analysis; derive the mechanical vibration correction factor based on the impact; the mechanical vibration correction factor is used to quantify the impact of mechanical vibration on encoder error;

[0101] B4. Conduct tests under different vibration conditions to verify the effectiveness and accuracy of the mechanical vibration correction factor; based on the test results, adjust and optimize the mechanical vibration correction factor to ensure its reliability and accuracy in actual applications.

[0102] After obtaining the first error test result, the first error test result is adjusted using the derived electromagnetic interference correction factor and mechanical vibration correction factor. The error test result after adjustment by the electromagnetic interference correction factor and the mechanical vibration correction factor is the second error test result, which more accurately reflects the performance status of the encoder itself. In actual applications, the correction factors are regularly optimized and adjusted according to the usage of the encoder and environmental changes. Through continuous experiments and tests, data is accumulated and the derivation method of the correction factors is improved to improve their accuracy and reliability. The calculation formula for adjusting the first error test result using the derived electromagnetic interference correction factor and the mechanical vibration correction factor is as follows:

[0103] E2=E1-(C e ×E1+C u ×E1);

[0104] Wherein, E2 represents the second error test result after adjustment; C e is the electromagnetic interference correction factor; Cu is the mechanical vibration correction factor.

[0105] Through the above steps, step S4 not only takes into account the impact of external production environment factors on the accuracy of the absolute encoder, but also eliminates the interference of these external factors through scientific methods, thereby improving the accuracy and reliability of error analysis, helping to promptly discover and correct potential problems and ensure the stable operation of production equipment; in addition, the correction factor is regularly optimized and adjusted, and its accuracy and reliability can be continuously improved by accumulating data through continuous experiments and tests and improving the derivation method of the correction factor.

[0106] Step S5: Based on the preset encoder error accuracy threshold, compare the absolute encoder error analysis results. If the absolute encoder error analysis result is less than the preset encoder error accuracy threshold, it means that the source of the absolute encoder error is external environmental factors; if the absolute encoder error analysis result is not less than the preset encoder error accuracy threshold, it means that the source of the absolute encoder error is internal equipment factors.

[0107] Specifically, a reasonable encoder error accuracy threshold should be set based on the application scenario and technical specifications of the absolute encoder. The encoder error accuracy threshold should take into account the maximum allowable error range of the encoder under normal operating conditions and be sensitive enough to detect potential problems. As the equipment ages and environmental conditions change, regular evaluation and adjustment may be required to ensure that it always adapts to the current working environment and technical requirements.

[0108] Obtaining the second error test result after eliminating the influence of external environmental factors from step S4;

[0109] If the absolute encoder error analysis result is less than the preset encoder error accuracy threshold, it means that even after eliminating the influence of external environmental factors, the remaining error is still within the acceptable range. This indicates that the original error is mainly caused by external environmental factors such as electromagnetic interference or mechanical vibration. In this case, a series of measures can be taken to improve environmental conditions, such as adding shielding measures to reduce electromagnetic interference, strengthening the installation structure to reduce mechanical vibration, etc. At the same time, other equipment that may be affected should also be optimized simultaneously.

[0110] If the absolute encoder error analysis result is not less than the preset encoder error accuracy threshold, it means that even after eliminating the influence of external environmental factors, the encoder itself still has unexpected errors. This may be caused by improper installation, material aging, internal component failure, etc. In this case, it is necessary to arrange for professional technicians to conduct a comprehensive inspection of the encoder and related systems. The inspection content should include but is not limited to the installation status, connection stability, sensor health, etc.

[0111] Through the above method, in step S5, not only can the specific source of the error be effectively distinguished, but also a clear direction can be provided for subsequent improvement measures, thereby ensuring that the absolute encoder can operate in an optimal state and support an efficient and stable production process. This method emphasizes the importance of comprehensive consideration of internal and external factors, which helps to build a more robust and reliable industrial automation system.

[0112] Example 2: Figure 2 As shown, an absolute encoder operation error analysis system of the present invention specifically includes the following modules:

[0113] The error monitoring module is used to monitor the operating status of the absolute encoder in real time and generate error analysis instructions when an encoder error is detected. This module is the core part of the encoder operation monitoring system and can continuously monitor the encoder's output data to ensure its accuracy.

[0114] The instruction parsing module is used to respond to the error analysis instruction and parse it to obtain the absolute encoder address and model number and error analysis time window for error analysis. This module can accurately parse the key information in the instruction and provide the necessary data support for subsequent error analysis.

[0115] The test strategy configuration module configures the error analysis test strategy for the absolute encoder to be analyzed based on the model and address of the absolute encoder obtained by analysis. This module can formulate a suitable test plan based on the model and characteristics of the encoder to ensure the accuracy and effectiveness of the test results.

[0116] The error test execution module tests the absolute value encoder to be analyzed according to the configured test strategy within the error analysis time window, and comprehensively evaluates the test results to obtain the first error test result. This module can ensure that the test process is carried out without affecting normal production and at the same time ensure the reliability of the test results.

[0117] The environmental external factor impact analysis module considers the electromagnetic interference characteristics and mechanical vibration characteristics of the absolute encoder's location, performs an environmental external factor impact elimination analysis on the first error test result, obtains a second error test result, and uses it as the absolute encoder error analysis result. This module can accurately identify and eliminate the impact of environmental external factors on encoder accuracy, improving the accuracy of error analysis.

[0118] The error judgment module compares the absolute encoder error analysis results based on the preset encoder error accuracy threshold to determine the source of the error. If the error analysis result is less than the preset threshold, the error source is external to the environment. If the error analysis result is not less than the preset threshold, the error source is internal to the equipment. This module can provide strong support for subsequent troubleshooting and maintenance.

[0119] In this embodiment, through the error monitoring module, the system can monitor the operating status of the absolute encoder in real time. Once an error is detected, an error analysis instruction is immediately generated, which helps to promptly discover and handle encoder errors, thereby avoiding larger problems caused by error accumulation. The system not only focuses on the performance of the absolute encoder itself, but also considers the impact of external factors such as electromagnetic interference and mechanical vibration on the encoder accuracy through the environmental external factor impact analysis module, which can more accurately identify the source of the error and improve the accuracy of the analysis. The system adopts a modular design, including multiple modules such as error monitoring, instruction parsing, test strategy configuration, error test execution, environmental external factor impact analysis and error judgment, making the system structure clear, easy to maintain and expand, and also easy to customize according to specific needs. Through the instruction parsing module and the test strategy configuration module, the system can formulate an appropriate test plan according to the model and characteristics of the encoder to ensure the accuracy and effectiveness of the test results. At the same time, the error test execution module can perform tests without affecting normal production, ensuring the efficiency of the test process. The error judgment module can compare the error analysis results according to the preset encoder error accuracy threshold, determine the source of the error, provide strong support for subsequent troubleshooting and maintenance, and help reduce downtime and production costs.

[0120] The various variations and specific embodiments of the absolute value encoder operation error analysis method in the aforementioned embodiment 1 are also applicable to the absolute value encoder operation error analysis system of this embodiment. Through the aforementioned detailed description of the absolute value encoder operation error analysis method, those skilled in the art can clearly understand the implementation method of the absolute value encoder operation error analysis system in this embodiment. Therefore, for the sake of brevity of the specification, it will not be described in detail here.

[0121] In addition, the present application also provides an electronic device, including a bus, a transceiver, a memory, a processor, and a computer program stored in the memory and runnable on the processor. The transceiver, the memory, and the processor are respectively connected via a bus. When the computer program is executed by the processor, each process of the above-mentioned method embodiment for controlling output data is implemented, and the same technical effect can be achieved. To avoid repetition, it will not be described here.

[0122] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for analyzing the running error of an absolute encoder, characterized in that: The method is applied to an encoder operation monitoring system. When the encoder operation monitoring system detects an error in an absolute encoder, an error analysis instruction is generated. The method includes: In response to the error analysis instruction, the error analysis instruction is parsed to obtain the address of the absolute encoder that needs to be error analyzed, the absolute encoder model and the error analysis time window; Based on the absolute encoder model and the absolute encoder address, configuring an error analysis test strategy for the absolute encoder to be analyzed; Based on the error analysis test strategy, the absolute value encoder to be analyzed is tested within the error analysis time window, and the test results are comprehensively evaluated to obtain a first error test result; Considering the electromagnetic interference characteristics and mechanical vibration characteristics of the position where the absolute encoder is located, performing an analysis on the first error test result to eliminate the influence of external environmental factors, obtaining a second error test result, and using the second error test result as the absolute encoder error analysis result; Based on the preset encoder error accuracy threshold, the absolute encoder error analysis results are compared. If the absolute encoder error analysis result is less than the preset encoder error accuracy threshold, it indicates that the absolute encoder error source is an external environmental factor. If the absolute encoder error analysis result is not less than the preset encoder error accuracy threshold, it indicates that the absolute encoder error source is an internal device factor. The absolute value encoder to be analyzed is tested within the error analysis time window, and the calculation formula for comprehensive evaluation of the test results is: E1=W s ×E s +W d ×E d +W i ×E i ; Among them, E1 represents the first error test result; E s Represents the standardized static test error value; E d Represents the normalized dynamic test error value; E i W represents the stable characteristic value of the load test after standardization; s 、W d and W i They represent the static test error value weight, dynamic test error value weight and load test stable characteristic value weight respectively; Taking into account the electromagnetic interference characteristics and mechanical vibration characteristics of the absolute encoder, the calculation formula for analyzing the elimination of environmental external factors on the first error test result is: E2=E1-(C e ×E1+C u ×E1); Wherein, E2 represents the second error test result after adjustment; C e is the electromagnetic interference correction factor; C u is the mechanical vibration correction factor.

2. The absolute encoder operation error analysis method according to claim 1, characterized in that: The error analysis test strategy includes static test, dynamic test and load test; Among them, the static test is used to detect the output accuracy of the absolute encoder when it is in a fixed position; the dynamic test is used to detect the output accuracy of the encoder during continuous movement; and the load test is used to detect the output stability of the encoder when it is subjected to different loads.

3. The absolute encoder operation error analysis method according to claim 2, characterized in that: The static test method includes: Determine a test position set according to the absolute encoder model; the test position set covers the entire working range of the absolute encoder, and the test position set includes at least a zero point, a mid-range point, and a full-range point; At each test position in the test position set, placing the absolute encoder in a stationary state and using a measuring device to record initial output data of the encoder; Applying preset test conditions to each test position, wherein the preset test conditions simulate environmental factors in actual use of the absolute encoder; After applying the preset test conditions, the measuring equipment is used again to record the output data of the absolute encoder. Multiple measurements are performed at each test position and the average value is taken to obtain the actual output data at the corresponding test position. The difference between the actual output data and the initial output data at each test position is calculated to obtain the static test error value.

4. The absolute encoder operation error analysis method according to claim 3, characterized in that: The dynamic test method includes: According to the absolute encoder model, setting at least one test acceleration track; The absolute encoder is tested continuously according to the set test acceleration trajectory, and the dynamic output data of the absolute encoder is collected in real time. The dynamic output data includes the speed and acceleration at different time nodes; Repeat the test multiple times for each test acceleration trajectory. Set a time interval between each test to allow the encoder to fully stabilize and eliminate non-steady-state effects. Calculate the average value of the multiple repeated tests as the actual dynamic output data of the corresponding test acceleration trajectory. The actual dynamic output data is matched with the test acceleration trajectory, and the ratio of the number of unmatched time nodes to the total number of collected time nodes is used as the dynamic test error value.

5. The absolute encoder operation error analysis method according to claim 4, characterized in that: The load test method includes: Determine the measuring device and load applying device according to the absolute encoder model, and determine the load test parameters, including the test load range and step size; Use a load applying device to apply an initial test load to the absolute encoder and keep it stable while recording the initial output data of the absolute encoder; According to the predetermined load range and step size, gradually increase the load to the maximum test load, maintain a stable state at each load point for a set time, and record the response time of the absolute encoder at different load points; Calculate the standard square deviation of the response time at different load points as the stable characteristic value of the load test.

6. An absolute encoder operation error analysis system, characterized in that: The system is applied to the absolute encoder operation error analysis method according to claim 1, and the system includes: The error monitoring module is used to monitor the operating status of the absolute encoder in real time and generate an error analysis instruction when an error is detected in the encoder; The instruction parsing module is used to respond to the error analysis instruction and parse it to obtain the absolute encoder address, absolute encoder model and error analysis time window that need to be analyzed; A test strategy configuration module configures an error analysis test strategy for the absolute encoder to be analyzed based on the absolute encoder model and absolute encoder address obtained by analysis; An error test execution module tests the absolute value encoder to be analyzed according to the configured error analysis test strategy within the error analysis time window, and comprehensively evaluates the test results to obtain a first error test result; An environmental external factor influence analysis module considers the electromagnetic interference characteristics and mechanical vibration characteristics of the absolute encoder's location, performs an environmental external factor influence elimination analysis on the first error test result, obtains a second error test result, and uses it as the absolute encoder error analysis result; The error judgment module compares the absolute encoder error analysis results based on the preset encoder error accuracy threshold to determine the source of the error. If the error analysis result is less than the preset threshold, it indicates that the error source is an external environmental factor. If the error analysis result is not less than the preset threshold, it indicates that the error source is an internal device factor.

7. An electronic device for analyzing the operation error of an absolute encoder, comprising a bus, a transceiver, a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the transceiver, the memory, and the processor are connected via the bus, and characterized in that: When the computer program is executed by the processor, the steps of the method according to any one of claims 1 to 5 are implemented.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method according to any one of claims 1 to 5 are implemented.

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