Non-contact transmission chain elongation detection method and system based on Hall proximity switch

Abstract

The invention discloses a non-contact transmission chain elongation detection method and system based on Hall proximity switches, and relates to the technical field of chain transmission state detection.The method comprises the steps that a phase alarm threshold value is deduced by obtaining basic parameters of a Hall proximity switch set and the standard pitch of a chain, and the phase alarm threshold value is obtained; a Hall assembly is arranged at an opposite detection position of a chain metal transmission part, and a phase difference is calculated in real time by means of an operation square wave signal and is compared with a threshold value; due to the fact that the Hall element is based on the non-contact detection characteristic of electromagnetic induction, periodic motion of a metal part can be stably sensed in severe environments such as oil contamination, dust and moisture, the defect that a laser light path is polluted or contact measurement is abraded is overcome, meanwhile, the chain elongation can be accurately quantified through a phase difference algorithm, real-time and low-loss online detection is achieved, and the detection accuracy is improved. Therefore, the technical problem that the elongation of the transmission chain in a harsh industrial scene is difficult to detect accurately in real time and with low loss is effectively solved.

Description

Technical Field

[0001] This invention relates to the field of chain drive condition detection technology, and in particular to a non-contact chain elongation detection method and system based on Hall effect proximity switches. Background Technology

[0002] In fields such as industrial automation, logistics transportation, and construction machinery, the transmission chain is a core component of power transmission, and its operating status directly affects the accuracy, reliability, and service life of the equipment. Under long-term load and wear, the chain is prone to elongation and deformation. If it cannot be detected in time, it may lead to equipment jamming, tooth skipping, or even shutdown failure. Therefore, there is an urgent need for real-time and accurate detection of chain elongation.

[0003] Currently, the elongation detection of transmission chains mainly relies on manual measurement, laser measurement, and contact mechanical measurement techniques. However, industrial sites are generally characterized by harsh environments such as confined spaces, oil stains, dust accumulation, humidity, and large temperature fluctuations, which exposes significant limitations in practical applications: manual measurement is limited by subjective judgment and operational efficiency, making it difficult to achieve continuous and real-time detection, and the accuracy of detecting micron-level elongation is highly dependent on personnel skills and responsibility, easily introducing errors; although laser measurement has high accuracy, the optical path is easily interfered with or even blocked by oil stains, dust, and water vapor, and high-precision sensors are expensive and have strict installation space requirements, making them difficult to adapt to compact equipment; contact mechanical measurement requires the deployment of complex devices near the chain, facing the dilemma of insufficient installation space, and the direct contact microswitches may accelerate wear on themselves and the chain due to long-term friction, affecting the reliability of detection and the life of equipment.

[0004] Therefore, existing chain elongation detection methods generally suffer from problems such as stringent working environment requirements, high implementation costs, poor installation adaptability, and inability to achieve real-time continuous detection. Furthermore, manual and contact-based solutions are also subject to interference from human factors or mechanical wear, making it difficult to meet the technical requirements for efficient and accurate detection of chain elongation in harsh industrial scenarios. There is an urgent need to break through traditional technical approaches and develop detection solutions that are more environmentally adaptable and practical. Summary of the Invention

[0005] This invention provides a non-contact transmission chain elongation detection method and system based on Hall effect proximity switches, which solves the technical problem of how to achieve real-time, accurate and low-loss online detection of transmission chain elongation in harsh environments.

[0006] The first aspect of this invention provides a non-contact transmission chain elongation detection method based on a Hall proximity switch, comprising: Obtain the basic parameters of the Hall proximity switch assembly and the standard pitch of the chain; Calculate the phase alarm threshold based on the aforementioned basic parameters and the standard pitch; The Hall proximity switch assembly is installed at the detection position opposite to the chain metal drive component, and the real-time phase difference is calculated based on the detected running square wave signal. The detection result is generated by comparing the real-time phase difference with the phase alarm threshold.

[0007] Optionally, the detection position of the chain metal transmission component is specifically defined as follows: The detection area corresponding to the metal transmission component of the chain is such that the probe of the Hall proximity switch group is directly facing the metal transmission component along a direction perpendicular to the chain movement direction, and the distance between the probe and the metal transmission component is within a preset effective sensing range.

[0008] Optionally, the step of calculating the real-time phase difference based on the detected running square wave signal includes: Edge detection is performed on the detected running square wave signal to obtain the link edge time series of the Hall proximity switch group; The single-path periodic sequence of the chain is calculated using the link edge time series; The time difference sequence of the chain is calculated using the link edge time series; By performing a ratio calculation between the time difference sequence and the single-path periodic sequence, a single-link continuous phase difference sequence is obtained; The real-time phase difference is obtained by averaging the continuous phase difference sequence of the single-link segment using the sliding window averaging method.

[0009] Optionally, the step of comparing the real-time phase difference with the phase alarm threshold to generate a detection result includes: Compare the real-time phase difference with the phase alarm threshold; When the real-time phase difference is greater than the phase alarm threshold, it is determined that the chain elongation exceeds the limit; When the real-time phase difference is less than or equal to the phase alarm threshold, the chain is determined to be in normal condition, and the process jumps to the step of calculating the real-time phase difference based on the detected running square wave signal.

[0010] Optionally, the basic parameters include the probe center-to-center distance and the elongation alarm threshold, and the calculation of the phase alarm threshold based on the basic parameters and the standard pitch includes: The remaining spacing is determined by using the probe center-to-center distance and the standard pitch. The first sum is obtained by performing a summation operation using the elongation alarm threshold and a preset standard coefficient; The second multiplication value is obtained by multiplying the standard pitch with the first sum. The phase alarm threshold is obtained by performing a ratio calculation between the remaining spacing and the second multiplier.

[0011] Optionally, it also includes: When the chain is running unloaded, the unloaded phase difference is calculated based on the acquired running square wave signal; Calculate the initial phase value based on the aforementioned basic parameters and the standard pitch; When the deviation between the initial phase value and the no-load phase difference is greater than a preset deviation threshold, the Hall proximity switch group is determined to be installed abnormally. When the chain cannot run under no-load conditions, the load phase difference is calculated based on the acquired running square wave signal. The load phase value is calculated based on the aforementioned basic parameters and the theoretical pitch of the chain; If the deviation between the load phase value and the load phase difference is greater than a preset load deviation threshold, the Hall proximity switch group is determined to be installed abnormally.

[0012] Optionally, the calculation of the initial phase value based on the basic parameters and the standard pitch includes: The remaining spacing is determined by using the probe center-to-center distance and the standard pitch. The initial phase value is obtained by calculating the ratio between the remaining pitch and the standard pitch.

[0013] Optionally, determining the remaining spacing using the probe center spacing and the standard pitch includes: The first ratio is obtained by calculating the ratio between the center-to-center distance of the probe and the standard pitch. Round the first ratio down to obtain the pitch number; The first multiplication value is obtained by multiplying the pitch number with the standard pitch. The remaining distance is obtained by performing a difference calculation between the center-to-center distance of the probe and the first multiplication value.

[0014] A second aspect of the present invention provides a non-contact transmission chain elongation detection system based on a Hall proximity switch, comprising: The acquisition module is used to acquire the basic parameters of the Hall proximity switch group and the standard pitch of the chain. The processing module is used to calculate the phase alarm threshold based on the basic parameters and the standard pitch; The mounting module is used to install the Hall proximity switch group on the detection position of the chain metal transmission component and calculate the real-time phase difference based on the detected running square wave signal. The detection module is used to compare the real-time phase difference with the phase alarm threshold and generate a detection result.

[0015] A third aspect of the present invention provides an electronic device, including a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor performs the steps of the non-contact transmission chain elongation detection method based on Hall proximity switches as described in any of the preceding claims.

[0016] As can be seen from the above technical solutions, the present invention has the following advantages: This invention obtains the basic parameters of the Hall proximity switch group and the standard pitch of the chain, derives the phase alarm threshold, deploys the Hall component at the detection position facing the metal transmission component of the chain, and calculates the phase difference in real time based on the running square wave signal and compares it with the threshold. Since the Hall element is based on the non-contact detection characteristics of electromagnetic induction, it can stably sense the periodic movement of metal components in harsh environments such as oil, dust, and humidity, avoiding the defects of laser optical path contamination or wear of contact measurement. At the same time, the phase difference algorithm can accurately quantify the chain elongation, realize real-time and low-loss online detection, and thus effectively solve the technical problem of difficulty in real-time, accurate and low-loss detection of transmission chain elongation in harsh industrial scenarios. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A flowchart illustrating the steps of a non-contact transmission chain elongation detection method based on a Hall proximity switch provided in an embodiment of the present invention; Figure 2 A schematic diagram of a Hall proximity switch assembly provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of a Hall proximity switch assembly installed on the side of a chain, according to an embodiment of the present invention. Figure 4 This is a schematic diagram of a Hall proximity switch assembly installed above a chain, according to an embodiment of the present invention. Figure 5 A schematic diagram illustrating the phase difference change of the square wave signal before and after the actual chain elongation provided in an embodiment of the present invention; Figure 6 This is a structural block diagram of a non-contact transmission chain elongation detection system based on a Hall proximity switch, provided in an embodiment of the present invention. Figure 7 This is a structural block diagram of an electronic device provided in an embodiment of the present invention. Detailed Implementation

[0019] This invention provides a non-contact transmission chain elongation detection method and system based on Hall effect proximity switches, which solves the technical problem of how to achieve real-time, accurate and low-loss online detection of transmission chain elongation in harsh environments.

[0020] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0021] Current methods for detecting the elongation of transmission chains mainly rely on manual measurement, laser measurement, or contact mechanical measurement. However, these methods have significant limitations in harsh industrial environments characterized by confined spaces, oil contamination, dust, humidity, and large temperature variations. Manual Measurement: Chain elongation is a continuous deterioration process. The frequency of manual chain monitoring depends on the maintenance cycle. During this period, chain elongation exceeding the threshold may go undetected, posing a potential failure risk. Furthermore, manual chain elongation measurement involves preliminary operations such as chain tensioning, and the accuracy of the measurement results depends on the standardization of these operations. Since chain elongation is extremely small (e.g., with an elongation threshold of 2%, a chain with a pitch of 25.4 mm will only elongate by 0.508 mm), manual measurement is prone to significant errors.

[0022] Contact mechanical measurement: Current contact mechanical measurement methods require complex devices to be installed above the chain suspension section, which requires a large installation space, and the actual industrial scenarios often cannot meet the installation conditions; some contact measurement methods use microswitches, and the contact between the switch and the chain can easily cause chain wear.

[0023] Laser measurement: Laser sensors rely on emitting and receiving light to determine the presence of objects, requiring clean and unobstructed light transmission and reception areas. However, industrial environments often contain significant amounts of dust and oil contamination, and in some scenarios, liquids (such as rain or spills) and frost can interfere with the use of laser sensors. Secondly, laser sensors need to be installed on both sides of a suspended chain, requiring substantial installation space, which is often unavailable in practical industrial settings. Furthermore, monitoring minute chain elongations necessitates high-precision sensors, resulting in high costs.

[0024] Therefore, this invention aims to solve the technical problems of existing chain elongation detection methods, such as stringent working environment requirements, high cost, difficult installation, inability to provide real-time continuous monitoring, and susceptibility to human factors affecting accuracy. This invention provides a non-contact transmission chain elongation detection method based on a Hall effect proximity switch. By employing a compact and environmentally adaptable Hall effect sensor, it achieves high-precision, low-cost, and easy-to-install real-time online monitoring even in harsh environments.

[0025] Specifically, this invention, through its innovative use of dual Hall effect proximity switch phase difference detection technology, effectively overcomes many shortcomings of existing chain elongation detection methods, and possesses significant technical advantages: First, it exhibits exceptional environmental adaptability and a wide range of applications. The core component of this invention is a Hall effect proximity switch, which operates based on the principle of magnetic field induction and is naturally immune to optical or physical obstructions such as oil, dust, liquids, and mist. Therefore, this method can withstand harsh industrial environments where traditional laser or photoelectric sensors cannot operate, and can also operate stably under complex conditions such as frost and drastic temperature changes, thus solving the problem of existing technologies' dependence on clean environments.

[0026] Secondly, it achieves high-precision and high-reliability online real-time monitoring. This invention calculates minute changes in chain pitch by monitoring the phase difference between signals generated by two sensors at a fixed distance. This phase difference is only related to the chain pitch and the sensor spacing, and is completely unaffected by fluctuations in chain speed. This ensures accurate and reliable measurement results even under conditions of frequent starts and stops or inconsistent speeds. Compared to manual measurements that rely on fixed periods and are prone to human error, this invention can continuously monitor the chain elongation process 24 / 7, immediately triggering an alarm if a safety threshold is exceeded. This effectively prevents equipment failure due to excessive chain elongation, greatly improving equipment operational safety.

[0027] Finally, it offers flexible installation and low cost. The Hall effect proximity switch is compact, and the side mounting scheme (utilizing the height difference between the pin and the chain plate) and top mounting scheme designed in this invention allow the sensor assembly to be flexibly installed on the side or in confined spaces above or below the chain, solving the problem of laser measurement and some contact mechanical measurement requiring large installation spaces. Furthermore, compared to expensive high-precision laser sensors, the Hall effect proximity switch, as a mature industrial component, offers a significant cost advantage, providing a feasible technical approach for intelligent, low-cost, and large-scale deployment monitoring of transmission chain status.

[0028] Please see Figure 1 , Figure 1 The flowchart illustrates the steps of a non-contact transmission chain elongation detection method based on a Hall proximity switch, as provided in this embodiment of the invention.

[0029] This invention provides a non-contact transmission chain elongation detection method based on a Hall effect proximity switch, comprising: Step 101: Obtain the basic parameters of the Hall proximity switch group and the standard pitch of the chain.

[0030] A Hall proximity switch is a magnetic field sensor based on the Hall effect. Its basic working principle is as follows: when a current-carrying semiconductor (Hall element) is placed in a magnetic field, the charge carriers in the semiconductor are deflected by the Lorentz force, creating a potential difference, or Hall voltage, between two sides perpendicular to both the current and the magnetic field direction. The magnitude of the Hall voltage is proportional to the magnetic field strength; therefore, by measuring the Hall voltage, the strength and changes in the magnetic field can be detected.

[0031] In industrial applications, Hall effect proximity switches are commonly used for non-contact measurement of position, displacement, and velocity, and are particularly suitable for detecting metallic objects. When a metallic object (especially a ferromagnetic metal) approaches or moves away from a Hall effect proximity switch, it alters the magnetic field distribution at the sensor's location. For example, when a ferromagnetic metal (such as a chain pin or chain plate) passes by, it changes the magnetic circuit, strengthening or weakening the magnetic field, thus altering the voltage signal output by the Hall effect proximity switch. By detecting this change in voltage signal, the passage of a metallic object can be identified.

[0032] Because of this non-contact working principle, Hall effect proximity switches are not sensitive to environmental contamination such as oil, dust, liquids, and mist, and can be used in harsh working environments with large temperature variations. A Hall proximity switch group refers to a sensor set consisting of two Hall proximity switches with identical performance, used to sense the periodic movement of chain metal drive components.

[0033] Please see Figure 2 Two Hall proximity switches of the same specifications (denoted as switch A and switch B) are fixed in parallel by a fixing component to form a Hall proximity switch group. In the figure, L is the center distance between the probes, 1 is Hall proximity switch A, 2 is Hall proximity switch B, and 3 is the sensor fixing component.

[0034] The center-to-center distance between the probes is measured using a laser rangefinder or a high-precision vernier caliper. First, fix the sensor mounting brackets to ensure that the two probes are parallel. Measure the straight-line distance between the centers of the two probes multiple times and take the average value as L to reduce installation errors.

[0035] The basic parameters refer to the center distance between the two probes in the Hall proximity switch group and the elongation alarm threshold, with the elongation alarm threshold preferably being 2%.

[0036] The chain refers to the metal transmission chain to be tested, which is responsible for power transmission.

[0037] Standard pitch refers to the theoretical design pitch of a single link in a brand new chain condition, or it can be the average pitch measured during no-load operation.

[0038] First, check the specifications to obtain the standard pitch directly from the chain model, or randomly select 5 consecutive chain links, use a digital vernier caliper to measure the center distance between adjacent pins, and take the average value as the standard pitch.

[0039] In an embodiment of the present invention, Step 102: Calculate the phase alarm threshold based on the basic parameters and standard pitch.

[0040] Furthermore, the basic parameters include the probe center-to-center distance and the elongation alarm threshold, and step 102 may include the following sub-steps: S11. Determine the remaining spacing by using the probe center spacing and the standard pitch.

[0041] Furthermore, S11 may include the following sub-steps: S111. The first ratio is obtained by calculating the ratio between the center distance of the probe and the standard pitch.

[0042] S112. Round down the first ratio to get the pitch number.

[0043] In the specific implementation, the above process S111-S112 is encapsulated into a formula, as follows:

[0044] In the formula, Indicates the pitch number, Indicates the center-to-center distance of the probes. Indicates the standard pitch.

[0045] It should be noted that the complete pitch number The center-to-center distance of the sensor probe In the middle, the chain pitch that can be fully accommodated The maximum number of integers.

[0046] S113. Multiply the pitch number by the standard pitch to obtain the first multiplication value.

[0047] S114. The remaining spacing is obtained by performing a difference calculation between the center spacing of the probes and the first multiplication value.

[0048] In the specific implementation, the above processes S113-S114 are encapsulated into formulas, as follows:

[0049] In the formula, This represents the remaining distance, specifically the length remaining after deducting the full pitch from the center distance between the two sensor probes.

[0050] S12. The first sum is obtained by using the elongation alarm threshold and the preset standard coefficient to perform a sum calculation.

[0051] In this embodiment of the invention, the elongation alarm threshold is the pre-set maximum allowable elongation ratio of the chain (e.g., 2%, i.e., 0.02), and the preset standard coefficient is 1 (because the actual pitch after the chain elongates is the sum of the standard pitch and the elongation, i.e., standard pitch × (1 + elongation alarm threshold)), so the first sum is the sum of 1 and the elongation alarm threshold (e.g., 1 + 0.02 = 1.02).

[0052] S13. Multiply the standard pitch with the first sum to obtain the second multiplier.

[0053] In the specific implementation, the above S12-S13 process is encapsulated into a formula, as follows:

[0054] In the formula, This represents the second multiplication value, specifically characterizing the actual pitch when the chain extends to the alarm threshold.

[0055] S14. The phase alarm threshold is obtained by performing a ratio calculation between the remaining spacing and the second multiplier.

[0056] In the specific implementation, the above process S14 is encapsulated into a formula, as follows:

[0057] In the formula, This indicates the phase alarm threshold, specifically representing the critical phase difference when the chain extends to the alarm threshold.

[0058] Step 103: Install the Hall proximity switch assembly at the detection position of the chain metal drive component, and calculate the real-time phase difference based on the detected running square wave signal.

[0059] Furthermore, the specific detection position of the chain metal transmission component is as follows: The detection area corresponding to the metal transmission component of the chain is positioned so that the probe of the Hall proximity switch group faces the metal transmission component perpendicular to the direction of chain movement, and the distance between the probe and the metal transmission component is within the preset effective sensing range.

[0060] In this embodiment of the invention, the side or top detection area corresponding to the metal transmission component of the chain, wherein the side detection area is the side of the chain, is such that the probe of the Hall proximity switch group is aligned with the pin end face in a direction perpendicular to the chain plate (i.e., perpendicular to the chain movement direction). Figure 3 Component 4 is a pin); the upper detection area is directly above the chain suspension section, so that the probe is aligned with the outer circumference of the sleeve and the sleeve gap in a direction perpendicular to the chain movement (e.g., Figure 4 The sleeve is a cylindrical component of the chain link; and the distance between the probe and the metal transmission component (pin end face or sleeve) is within the preset effective sensing range of 2mm to 3mm.

[0061] like Figure 3 and Figure 4 As shown, 4 is the pin and 5 is the chain plate.

[0062] Side mounting: Install the sensor assembly on the side of the chain, perpendicular to the chain plate, so that the sensor probe faces the end face of the pin, and maintains a small gap of 2-3 mm between it and the highest point of the pin (e.g., Figure 3 (As shown). When the chain is running, the Hall proximity switch will generate a square wave signal by alternately sensing the raised pin and the flatter chain plate.

[0063] Top mounting: Install the sensor assembly directly above the chain suspension section, ensuring the sensor probe is aligned with the chain sleeve and sleeve gap, maintaining a 2-3 mm gap from the highest point of the sleeve (e.g., Figure 4 (As shown). When the chain is running, the Hall proximity switch will generate a square wave signal by alternately sensing the gap between the sleeve and the sleeve.

[0064] It is worth mentioning that the dual-mode design of side mounting (probe perpendicular to the chain plate, facing the pin end face, maintaining a 2-3mm gap) and top mounting (probe above the suspension section, facing the sleeve and gap, maintaining a 2-3mm gap) avoids mechanical contact wear due to its non-contact characteristics, extending the life of the sensor and chain. The 2-3mm gap combined with the electromagnetic induction principle ensures that harsh environments such as oil, dust, and humidity cannot block the signal, unlike laser light path contamination, thus ensuring continuous monitoring. The dual mounting modes adapt to different equipment spaces (side mounting when there is sufficient chain side, top mounting when the suspension section layout is available), breaking through the bottleneck of installation space. The square wave signal generated by alternating sensing (protruding pin / sleeve vs. flat chain plate / gap) has steep edges and a stable period, providing high-fidelity data for the phase difference algorithm, ultimately achieving accurate, real-time, and low-loss monitoring of chain elongation in harsh scenarios.

[0065] Furthermore, step 103 may include the following sub-steps: S21. Perform edge detection on the detected running square wave signal to obtain the link edge time series of the Hall proximity switch group.

[0066] In this embodiment of the invention, two square wave signals output by Hall proximity switches A and B during chain operation are acquired, and the rising or falling edges are detected in real time. The timestamp of each edge is recorded to obtain the chain link edge time sequence of the Hall proximity switch group. The chain link edge time sequence includes the chain link edge timestamp sequence detected by Hall proximity switch A. The chain link edge timestamp sequence detected by Hall proximity switch B ,in, This represents the time elapsed since the beginning of the i-th link was A. This represents the time B elapsed before the i-th link.

[0067] S22. Calculate the single-path periodic sequence of the chain using the link edge time series.

[0068] In this embodiment of the invention, the single-path period refers to the time interval between the detection of the edges of two adjacent chain links by the same Hall proximity switch, reflecting the period of a single chain link passing through the sensor.

[0069] Taking Hall proximity switch A as an example, the single-path period of the i-th link is the time difference between two adjacent links passing through A:

[0070] in, This forms a single-path periodic sequence. .

[0071] Similarly, the edge time series of Hall proximity switch B can be used as a basis. Calculate a single-path periodic sequence In practical applications, one path (such as path A) can be selected as the benchmark, or the average of the two periodic sequences can be taken to improve stability.

[0072] S23. Calculate the time difference sequence of the chain using the chain link edge time series.

[0073] In this embodiment of the invention, edge timestamps of the same chain segment are paired using a time window matching rule: for the i-th chain segment, if It falls within a preset, physically reasonable range, which is derived from the sensor spacing and the maximum and minimum speeds of the chain, such as... ,in The distance between A and B is... If the upper and lower limits are the chain running speeds, then it is considered a valid pairing.

[0074] Based on the valid pairing results, calculate the time difference between the i-th link and A and B. This leads to the formation of a time difference sequence. (m is the number of valid paired links, m≤n).

[0075] S24. The ratio of the time difference sequence to the single-path periodic sequence is calculated to obtain the single-link continuous phase difference sequence.

[0076] In this embodiment of the invention, the phase difference between the two square waves when the chain is not elongated can be calculated based on the sensor spacing L and the pitch P of the monitored chain. :like (in (where the number of complete pitches between the two sensors is the total number of pitches), then the phase difference... As can be seen from the formula, the phase difference of the square wave is only related to the sensor spacing and chain pitch, and is independent of the chain running speed.

[0077] The single-link phase difference is defined as the ratio of the time difference between the same link passing through points A and B to the single-path period of that link, reflecting the phase relationship of the links during the motion process.

[0078] It should be noted that the sensor spacing L is the time difference between the two sensors for the same link to pass through. The time it takes for a single link to pass through a sensor , Given the current real-time pitch, therefore, the phase difference Therefore, it can be concluded that the square wave phase difference is only related to the sensor spacing and chain pitch, and is not related to the chain running speed.

[0079] The ratio of the time difference between the same link passing through A and B to the single-path period of that link is essentially a conversion of the "spatial proportion" of the same link between the two sensors into a time proportion. In specific calculations, it is necessary to ensure that the time difference and the period correspond to the same link. For the i-th effectively paired link, its phase difference... When the chain is not extended, the current real-time pitch is equal to the standard pitch P. When the chain stretches, the actual length of the chain links increases. The difference will decrease accordingly. By calculating the difference sequentially for all valid links, the final single-link continuous phase difference sequence is obtained. , where m is the number of valid links.

[0080] S25. The sliding window averaging method is used to perform mean calculation on the continuous phase difference sequence of single-link segments to obtain the real-time phase difference.

[0081] In this embodiment of the invention, the purpose of using the sliding window averaging method is to suppress transient interference in the single-link phase difference sequence and ensure that the output real-time phase difference is stable and reliable.

[0082] In the specific implementation, the sliding window size k is set and selected according to the stability of the chain operation on site. It is usually 3 to 5 consecutive links to ensure that noise can be smoothed without lagging behind the real-time changes in phase difference.

[0083] When the new single-link phase difference When adding a sequence, the window slides along the sequence direction: if i single-link phase differences have been acquired (i≥k), then the window contains the k most recent phase differences. If i < k, it means that the number of links in the initial stage is insufficient for the window size, and the window contains all the phase differences of the single links that have been acquired.

[0084] Calculate the arithmetic mean of the phase differences within the window, i.e., the real-time phase difference corresponding to the i-th link. (When i < k, the denominator is the actual number of chain segments), and the final real-time phase difference is obtained. .

[0085] Step 104: Compare the real-time phase difference with the phase alarm threshold to generate the detection result.

[0086] Furthermore, step 104 may include the following sub-steps: S31. Compare the real-time phase difference with the phase alarm threshold.

[0087] In this embodiment of the invention, the phase alarm threshold is the critical phase value when the chain extends to the preset alarm threshold, and the real-time phase difference is the actual phase value when the chain is running. By comparing the two values, it can be directly reflected whether the current extension state of the chain has reached the alarm boundary.

[0088] S32. When the real-time phase difference is greater than the phase alarm threshold, it is determined that the chain elongation exceeds the limit.

[0089] In this embodiment of the invention, when the real-time phase difference is greater than the phase alarm threshold, it indicates that the actual pitch of the current chain is less than the chain elongation required to reach the alarm threshold, meaning the chain elongation has not reached the alarm threshold. This is determined to be an over-limit chain elongation, at which point the system immediately triggers an alarm and reports the detection result, as shown in the following example. Figure 5 As shown, Figure 5 The diagram above shows the phase difference between the two square waves before the chain is stretched. Figure 5 The diagram below shows the phase difference between the two square waves after the chain is stretched. The phase difference between the two square waves changes significantly after the chain is stretched.

[0090] S33. When the real-time phase difference is less than or equal to the phase alarm threshold, the chain is determined to be in normal condition, and the process jumps to the step of obtaining the basic parameters of the Hall proximity switch group and the standard pitch of the chain.

[0091] In this embodiment of the invention, when the real-time phase difference is less than or equal to the phase alarm threshold, the chain is determined to be in normal condition, and the process jumps to the step of obtaining the basic parameters of the Hall proximity switch group and the standard pitch of the chain.

[0092] Furthermore, it also includes the following steps: Step 105: When the chain is running unloaded, calculate the unloaded phase difference based on the acquired running square wave signal.

[0093] In this embodiment of the invention, chain unloaded operation refers to the chain being in a state of no load and uniform motion (e.g., operating speed ≤ 0.5 m / s, to avoid inertial stretching interfering with the pitch). The time difference between the rising (or falling) edge of the signal is extracted by acquiring two square wave signals output from the Hall proximity switch group. Combined with square wave period (Based on standard pitch) P and no-load speed v calculate, Derivation of the no-load phase difference: .

[0094] Step 106: Calculate the initial phase value based on the basic parameters and standard pitch.

[0095] Furthermore, step 106 may include the following sub-steps: S41. Determine the remaining spacing by using the probe center spacing and the standard pitch.

[0096] In this embodiment of the invention, the calculation process is the same as that of S11, and will not be repeated here.

[0097] S42. The initial phase value is obtained by performing a ratio calculation between the remaining pitch and the standard pitch.

[0098] In this embodiment of the invention, the initial phase value is obtained by calculating the ratio between the remaining pitch and the standard pitch. .

[0099] Step 107: When the deviation between the initial phase value and the no-load phase difference is greater than the preset deviation threshold, the Hall proximity switch group is determined to be installed abnormally.

[0100] In this embodiment of the invention, the preset deviation threshold is typically set to 5%~10%, compatible with the Hall sensor's ±3% time measurement error and ±2% installation tolerance. If this occurs, it is determined that the Hall proximity switch assembly is installed abnormally.

[0101] Abnormal scenarios include: The gap between the probe and the metal transmission components deviates by 2~3mm (causing signal amplitude distortion and time difference calculation inaccuracy). The probe was not facing the target component in a direction perpendicular to the chain's movement (the square wave edge became gentler, and the time difference extraction error increased).

[0102] At this point, the system outputs an installation abnormality alarm and prompts for inspection of the sensor spacing, installation angle, and gap to ensure the validity of subsequent monitoring signals.

[0103] when If the Hall proximity switch assembly is found to be installed correctly, proceed to the step of calculating the real-time phase difference based on the detected operating square wave signal.

[0104] This invention has the following advantages: Hall effect proximity switch is used: The innovative use of Hall effect proximity switches for real-time monitoring of chain elongation allows for use in environments with oil, dust, smoke, and liquid contamination; it can also be used in environments with frost, dense fog, and large temperature fluctuations. Chain elongation is monitored by monitoring the square wave generated by the pin-chain plate: The Hall proximity switch is uniquely placed on the side of the chain plate, and the square wave is generated by the height difference between the pin and the chain plate, thereby realizing the monitoring of chain elongation. Chain elongation is obtained directly through the phase difference of two sensors: This innovative method directly obtains the chain elongation without relying on chain speed information.

[0105] Step 108: When the chain cannot run under no-load conditions, calculate the load phase difference based on the acquired running square wave signal; In this embodiment of the invention, the inability of the chain to run unloaded refers to scenarios such as continuous production line production and equipment structural constraints (e.g., the inability to unload the load during operation). By controlling the initial stage of the chain's operation under load, the two square wave signals output by the Hall proximity switch group are collected, the time difference of the rising edge (or falling edge) of the signal is extracted, and the load phase difference is derived by combining the square wave period. This step is similar to step 105 and will not be described again here.

[0106] Step 109: Calculate the load phase value based on the basic parameters and the theoretical pitch of the chain; S51. Determine the remaining spacing by using the center-to-center distance of the probes and the theoretical pitch of the chain.

[0107] In this embodiment of the invention, the calculation process is the same as that in S41, and will not be repeated here.

[0108] S52. The load phase value is obtained by calculating the ratio between the remaining gap and the theoretical pitch of the chain.

[0109] In this embodiment of the invention, the load phase value is obtained by calculating the ratio between the remaining spacing and the theoretical pitch of the chain.

[0110] Step 110: When the deviation between the load phase value and the load phase difference is greater than the preset load deviation threshold, the Hall proximity switch group is determined to be installed abnormally.

[0111] In this embodiment of the invention, the preset load deviation threshold is typically set to 5% to 12%, which is compatible with the small elongation error of the chain (<1%) in the initial stage of load bearing, the time measurement error of the Hall sensor of ±3% and the installation tolerance of ±2%. When the deviation between the load phase value and the load phase difference is greater than the preset load deviation threshold, it is determined that the Hall proximity switch group is installed abnormally.

[0112] Abnormal scenarios include: The gap between the probe and the metal transmission components deviates by 2~3mm (causing signal amplitude distortion and time difference calculation inaccuracy). The probe was not facing the target component in a direction perpendicular to the chain's movement (the square wave edge became gentler, and the time difference extraction error increased).

[0113] At this time, the system outputs an installation abnormality alarm and prompts for inspection of the sensor spacing, installation angle and gap to ensure the validity of subsequent monitoring signals; When the deviation between the load phase value and the load phase difference is less than or equal to a preset load deviation threshold, it is determined that the Hall proximity switch group is installed correctly, and the process jumps to the step of calculating the real-time phase difference based on the monitored operating square wave signal.

[0114] Please see Figure 6 , Figure 6 This is a structural block diagram of a non-contact transmission chain elongation detection system based on a Hall proximity switch, provided in an embodiment of the present invention.

[0115] This invention provides a non-contact transmission chain elongation detection system based on a Hall effect proximity switch, comprising: The acquisition module 601 is used to acquire the basic parameters of the Hall proximity switch group and the standard pitch of the chain. Processing module 602 is used to calculate the phase alarm threshold based on basic parameters and standard pitch; Mounting module 603 is used to mount the Hall proximity switch group to the detection position of the chain metal drive component and calculate the real-time phase difference based on the detected running square wave signal. The detection module 604 is used to compare the real-time phase difference with the phase alarm threshold and generate the detection result.

[0116] Furthermore, the specific detection position of the chain metal transmission component is as follows: The detection area corresponding to the metal transmission component of the chain is positioned so that the probe of the Hall proximity switch group faces the metal transmission component perpendicular to the direction of chain movement, and the distance between the probe and the metal transmission component is within the preset effective sensing range.

[0117] Furthermore, the installation module 603 includes: The link edge time sequence submodule is used to perform edge detection on the detected running square wave signal to obtain the link edge time sequence of the Hall proximity switch group; The single-path periodic sequence submodule is used to calculate the single-path periodic sequence of the chain using the link edge time series; The time difference sequence submodule is used to calculate the time difference sequence of the chain using the link edge time series. The single-link continuous phase difference sequence submodule is used to perform a ratio operation between the time difference sequence and the single-path periodic sequence to obtain the single-link continuous phase difference sequence. The real-time phase difference submodule is used to perform mean calculation on the continuous phase difference sequence of a single link using the sliding window averaging method to obtain the real-time phase difference.

[0118] Furthermore, the detection module 604 includes: The comparison submodule is used to compare the real-time phase difference with the phase alarm threshold; The first determination submodule is used to determine that the chain elongation exceeds the limit when the real-time phase difference is greater than the phase alarm threshold. The second determination submodule is used to determine that the chain is in normal condition when the real-time phase difference is less than or equal to the phase alarm threshold, and then jump to the step of calculating the real-time phase difference based on the detected running square wave signal.

[0119] Furthermore, the basic parameters include the probe center-to-center distance and the elongation alarm threshold, and the processing module 602 includes: The remaining spacing submodule is used to determine the remaining spacing by comparing the probe center spacing with the standard pitch. The first sum value submodule is used to perform sum value calculation using the elongation alarm threshold and a preset standard coefficient to obtain the first sum value; The second multiplication submodule is used to perform a multiplication operation between the standard pitch and the first sum to obtain the second multiplication value; The phase alarm threshold submodule is used to calculate the phase alarm threshold by performing a ratio calculation between the remaining spacing and the second multiplier.

[0120] Furthermore, it also includes: The no-load operation module is used to calculate the no-load phase difference based on the acquired running square wave signal when the chain is running under no-load conditions. The initial phase value module is used to calculate the initial phase value based on the basic parameters and the standard pitch. The first anomaly detection module is used to determine that the Hall proximity switch group is installed abnormally when the deviation between the initial phase value and the no-load phase difference is greater than a preset deviation threshold. The load phase difference module is used to calculate the load phase difference based on the acquired running square wave signal when the chain cannot run unloaded. The load phase value module is used to calculate the load phase value based on the basic parameters and the theoretical pitch of the chain; The second abnormal module is used to determine that the Hall proximity switch group is installed abnormally when the deviation between the load phase value and the load phase difference is greater than a preset load deviation threshold.

[0121] Furthermore, the initial phase value module includes: The remaining spacing submodule is used to determine the remaining spacing by comparing the probe center spacing with the standard pitch. The ratio calculation submodule is used to perform a ratio calculation between the remaining pitch and the standard pitch to obtain the initial phase value.

[0122] Furthermore, the remaining spacing submodule includes: The first ratio unit is used to perform a ratio calculation between the probe center spacing and the standard pitch to obtain the first ratio. The pitch number unit is used to round down the first ratio to obtain the pitch number; The first multiplication unit is used to perform a multiplication operation between the pitch number and the standard pitch to obtain the first multiplication value; The difference calculation unit is used to perform a difference calculation between the probe center spacing and the first multiplication value to obtain the remaining spacing.

[0123] Please see Figure 7 , Figure 7 This is a structural block diagram of an electronic device provided in an embodiment of the present invention.

[0124] An electronic device according to an embodiment of the present invention includes: a memory 701 and a processor 702. The memory 701 stores a computer program. When the computer program is executed by the processor 702, the processor 702 performs a non-contact transmission chain elongation detection method based on a Hall proximity switch as described in any of the above embodiments.

[0125] Memory 701 may be an electronic memory such as flash memory, EEPROM (Electrically Erasable Programmable Read-Only Memory), EPROM, hard disk, or ROM. Memory 701 has storage space 703 for program code 713 for performing any of the method steps described above. For example, storage space 703 for program code may include various program codes 713 for implementing the various steps in the methods described above. These program codes may be read from or written to one or more computer program products. These computer program products include program code carriers such as hard disks, CDs, memory cards, or floppy disks. The program code may be compressed, for example, in a suitable form. When run by a computing processing device, this code causes the computing processing device to perform the various steps in the methods described above. These program codes may be read from or written to one or more computer program products. These computer program products include program code carriers such as hard disks, CDs, memory cards, or floppy disks. The program code may be compressed, for example, in a suitable form. When this code is run by a computing device, it causes the device to perform the various steps in the Hall proximity switch-based non-contact transmission chain elongation detection method described above.

[0126] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0127] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces, or indirect coupling or communication connection between apparatuses or units, and may be electrical, mechanical, or other forms.

[0128] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0129] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0130] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0131] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A non-contact transmission chain elongation detection method based on Hall effect proximity switches, characterized in that, include: Obtain the basic parameters of the Hall proximity switch assembly and the standard pitch of the chain; Calculate the phase alarm threshold based on the aforementioned basic parameters and the standard pitch; The Hall proximity switch assembly is installed at the detection position opposite to the chain metal drive component, and the real-time phase difference is calculated based on the detected running square wave signal. The detection result is generated by comparing the real-time phase difference with the phase alarm threshold.

2. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 1, characterized in that, The specific detection position of the chain metal transmission component is as follows: The detection area corresponding to the metal transmission component of the chain is such that the probe of the Hall proximity switch group is directly facing the metal transmission component along a direction perpendicular to the chain movement direction, and the distance between the probe and the metal transmission component is within a preset effective sensing range.

3. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 1, characterized in that, The calculation of the real-time phase difference based on the detected running square wave signal includes: Edge detection is performed on the detected running square wave signal to obtain the link edge time series of the Hall proximity switch group; The single-path periodic sequence of the chain is calculated using the link edge time series; The time difference sequence of the chain is calculated using the link edge time series; By performing a ratio calculation between the time difference sequence and the single-path periodic sequence, a single-link continuous phase difference sequence is obtained; The real-time phase difference is obtained by averaging the continuous phase difference sequence of the single-link segment using the sliding window averaging method.

4. The non-contact transmission chain elongation detection method based on Hall proximity switches according to any one of claims 1-3, characterized in that, The comparison of the real-time phase difference with the phase alarm threshold to generate a detection result includes: Compare the real-time phase difference with the phase alarm threshold; When the real-time phase difference is greater than the phase alarm threshold, it is determined that the chain elongation exceeds the limit; When the real-time phase difference is less than or equal to the phase alarm threshold, the chain is determined to be in normal condition, and the process jumps to the step of calculating the real-time phase difference based on the detected running square wave signal.

5. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 1, characterized in that, The basic parameters include the probe center-to-center distance and the elongation alarm threshold. The calculation of the phase alarm threshold based on the basic parameters and the standard pitch includes: The remaining spacing is determined by using the probe center-to-center distance and the standard pitch. The first sum is obtained by performing a summation operation using the elongation alarm threshold and a preset standard coefficient; The second multiplication value is obtained by multiplying the standard pitch with the first sum. The phase alarm threshold is obtained by performing a ratio calculation between the remaining spacing and the second multiplier.

6. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 5, characterized in that, Also includes: When the chain is running unloaded, the unloaded phase difference is calculated based on the acquired running square wave signal; Calculate the initial phase value based on the aforementioned basic parameters and the standard pitch; When the deviation between the initial phase value and the no-load phase difference is greater than a preset deviation threshold, the Hall proximity switch group is determined to be installed abnormally. When the chain cannot run under no-load conditions, the load phase difference is calculated based on the acquired running square wave signal. The load phase value is calculated based on the aforementioned basic parameters and the theoretical pitch of the chain; If the deviation between the load phase value and the load phase difference is greater than a preset load deviation threshold, the Hall proximity switch group is determined to be installed abnormally.

7. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 6, characterized in that, The calculation of the initial phase value based on the basic parameters and the standard pitch includes: The remaining spacing is determined by using the probe center-to-center distance and the standard pitch. The initial phase value is obtained by calculating the ratio between the remaining pitch and the standard pitch.

8. The non-contact transmission chain elongation detection method based on Hall proximity switches according to claim 5 or 7, characterized in that, The step of determining the remaining spacing using the probe center spacing and the standard pitch includes: The first ratio is obtained by calculating the ratio between the center-to-center distance of the probe and the standard pitch. Round the first ratio down to obtain the pitch number; The first multiplication value is obtained by multiplying the pitch number with the standard pitch. The remaining distance is obtained by performing a difference calculation between the center-to-center distance of the probe and the first multiplication value.

9. A non-contact transmission chain elongation detection system based on a Hall effect proximity switch, characterized in that, include: The acquisition module is used to acquire the basic parameters of the Hall proximity switch group and the standard pitch of the chain. The processing module is used to calculate the phase alarm threshold based on the basic parameters and the standard pitch; The mounting module is used to install the Hall proximity switch group on the detection position of the chain metal transmission component and calculate the real-time phase difference based on the detected running square wave signal. The detection module is used to compare the real-time phase difference with the phase alarm threshold and generate a detection result.

10. An electronic device, characterized in that, The device includes a memory and a processor. The memory stores a computer program, which, when executed by the processor, causes the processor to perform the steps of the non-contact transmission chain elongation detection method based on a Hall proximity switch as described in any one of claims 1-8.

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