Redundant measurement architecture, redundant long horn sensor, and measurement method

Abstract

The application relates to the technical field of composite sensing detection, and discloses a redundancy measurement architecture, a redundancy long-angle sensor and a measurement method, which comprise a planetary gear structure, a main plate, an angle sensor system, a plurality of independent angle position sensors for detecting the rotation angles of different gears in the planetary gear structure, an arctangent operation and cross verification for obtaining fused angle measurement values, and length redundancy on a mechanical transmission chain; an inclination sensor system, two independent inertial measurement units orthogonally arranged on the main plate, a vibration and attitude monitoring system for inclination redundancy, vibration attitude real-time monitoring of the planetary gear structure, and real-time compensation of dynamic errors in the mechanical transmission; vibration frequency spectrums detected by the two independent inclination sensors are used for correcting the fusion algorithm of the plurality of independent angle sensors, transmission errors generated by the different modulus meshing structures of the planetary gear structure are compensated through the redundancy measurement of the plurality of independent angle sensors.

Description

Technical Field

[0001] This invention relates to the field of composite sensing and detection technology, and in particular, to a redundant measurement architecture, a redundant long-angle sensor, and a measurement method. Background Technology

[0002] In the field of precision measurement, long-angle sensors, as a type of composite sensor, integrate the functions of rope displacement detection and tilt angle measurement, enabling simultaneous monitoring of an object's linear displacement and attitude changes. Traditional long-angle sensors drive a winding wheel to rotate via an internal spring tensioning mechanism, using a sensor to output an electrical signal proportional to the rope displacement, thus converting linear motion into an electrical signal. Simultaneously, its built-in tilt-sensitive element measures the tilt angle by sensing changes in the component of gravitational acceleration. These sensors exhibit advantages such as compact structure, large measuring range, and high accuracy in applications requiring simultaneous monitoring of position and attitude.

[0003] However, existing long-angle sensors still have the following technical problems in practical applications:

[0004] 1. Traditional sensors rely on a single angle or displacement detection module. Once a key sensing unit fails, the system will completely fail, making it difficult to meet the requirements of high reliability scenarios.

[0005] 2. In the mechanical transmission process, nonlinear factors such as gear meshing vibration and backlash can introduce measurement errors, and existing technologies lack a collaborative suppression mechanism for multi-source interference.

[0006] 3. When using multi-stage reduction gear sets, traditional single-sensor solutions cannot effectively distinguish between mechanical transmission errors and sensor signal drift, resulting in a decrease in the accuracy of absolute position calculation.

[0007] 4. The data from tilt and displacement sensors are usually processed independently, lacking a dynamic weight adjustment mechanism based on the vibration spectrum, making it difficult to adapt to the real-time compensation requirements under complex working conditions.

[0008] The aforementioned issues limit the application of long-angle sensors in high-precision, high-reliability scenarios (such as positioning of engineering machinery and joint control of robots). Summary of the Invention

[0009] This invention provides a redundant measurement architecture, a redundant long-angle sensor, and a measurement method. It integrates a redundant measurement architecture, dynamic error compensation, and a multi-sensor collaborative algorithm to improve the robustness and measurement accuracy of the system. This addresses the technical problem that the insufficient accuracy and reliability of existing long-angle sensors limit their use in high-precision and high-reliability scenarios.

[0010] According to one aspect of the present invention, a redundant measurement architecture is provided, comprising: a planetary gear structure for forming a three-stage reduction meshing system and ensuring the consistency of the measurement reference of the angle sensors; a main board, corresponding to the planetary gear structure, serving as a vibration monitoring platform and information processing center, and realizing the coordination of mechanical, electrical, and algorithmic aspects; an angle sensor system that detects the rotation angles of different gears in the planetary gear structure through multiple independent angle position sensors, and obtains the fused angle measurement value through arctangent calculation and cross-validation, thus forming length redundancy on the mechanical transmission chain; and a tilt sensor system that consists of two independent inertial measurement units orthogonally arranged on the main board, forming a tilt-redundant vibration and attitude monitoring system for real-time monitoring of the vibration attitude of the planetary gear structure and real-time compensation of dynamic errors in the mechanical transmission; the vibration spectrum detected by the two independent tilt sensors is used to correct the fusion algorithm of the multiple independent angle sensors, and the transmission error generated by the heterogeneous meshing structure of the planetary gear structure is compensated by the redundant measurement of the multiple independent angle sensors.

[0011] Furthermore, the planetary gear structure includes: a central gear serving as the main drive gear, a first side gear and a second side gear forming a three-stage reduction meshing structure with the central gear, and a third side gear that maintains the same module relationship with the central gear to ensure the consistency of the measurement reference of the angle sensor.

[0012] Furthermore, the central gear has 26 teeth, the first side gear has 30 teeth, the second side gear has 32 teeth, and the third side gear has 26 teeth.

[0013] Furthermore, the angle sensor system includes: a first angle position sensor chip, fixedly mounted on the rotating shaft end of the central gear, used to detect the absolute angular position of the central gear by detecting the module; a second angle position sensor chip, respectively fixedly mounted on the rotating shaft ends of the first and second side gears, used to detect the relative angular position of the third side gear by detecting the module; a third angle position sensor chip, fixedly mounted on the rotating shaft end of the third side gear, used to detect the relative angular position of the third side gear by detecting the module, and ensuring accurate measurement even when the first angle position sensor chip fails; the signal output terminals of the first and third angle position sensor chips are respectively connected to independent ADC conversion channels, forming a length redundancy measurement on the mechanical transmission chain; the angle position sensor chip adopts a Wheatstone bridge structure based on the GMR principle, and the output sine and cosine analog signals are converted by the ADC, and then subjected to arctangent operation and cross-validation by a digital signal processor (DSP) to obtain the fused angle measurement value.

[0014] Furthermore, the first angle position sensor chip, the second angle position sensor chip, and the third angle position sensor chip all use the MT6501 angle position sensor chip.

[0015] Furthermore, the MT6501 angle position sensor chip consists of two GMR sensing units, Vx and Vy. Each GMR sensing unit comprises four GMR resistors connected to a Wheatstone bridge circuit. Under the influence of the rotating magnetic field, the X-bridge and Y-bridge channels output a sinusoidal analog voltage signal sinA and a cosine analog voltage signal cosA, where A is the angle between the magnetic field direction and the X-axis. According to the principle of the Wheatstone bridge circuit, we can obtain:

[0016] ;

[0017] The sinusoidal analog voltage signal sinA and the cosine analog voltage signal cosA are amplified and filtered by the analog front-end circuit so that the analog voltage signals fall entirely within the unipolar positive voltage range supported by the analog-to-digital converter (ADC). The ADC then converts the continuous analog voltage signals into discrete digital signals, representing the voltage amplitude at the sampling time. The amplified and digitally quantized sine and cosine signals finally enter the digital signal processor (DSP) for compensation and calibration. After calibration, a unique angle value A is obtained through arctangent operation. The angle value is then output by the digital-to-analog converter (DAC).

[0018] Furthermore, the tilt sensor system includes a first IIM-42352 tilt chip and a second IIM-42352 tilt chip deployed on the motherboard. The first IIM-42352 tilt chip and the second IIM-42352 tilt chip are orthogonally arranged to form tilt redundancy, which is used to monitor the vibration attitude of the gear system in real time and to dynamically compensate the output signal with the measurement data of the angle sensor system.

[0019] According to another aspect of the present invention, a redundant long-angle sensor is also provided, including the aforementioned redundant measurement architecture.

[0020] Furthermore, it also includes an upper cover assembly, a lower cover assembly, a pull cord assembly, and a spring assembly; the main board is located between the upper cover assembly and the pull cord assembly; the spring assembly is located between the pull cord assembly and the lower cover assembly.

[0021] Furthermore, the pull rope assembly includes a spool, a lead outlet, a line guard assembly, and a gear seat. A central gear, a first side gear, a second side gear, and a third side gear are arranged on the gear seat. The rotation axis of the central gear is coaxially arranged with the rotation axis of the spool and connected to each other.

[0022] Furthermore, the top cover assembly is equipped with light guides, which are used to indicate whether the power is on.

[0023] Furthermore, the wire protection assembly includes a wire threading porcelain nozzle, a rubber sleeve, and a steel wire rope sleeve arranged in sequence. The steel wire rope on the wire reel passes through the wire threading porcelain nozzle and the rubber sleeve in sequence and is fixed to the steel wire rope sleeve.

[0024] According to another aspect of the present invention, a measurement method based on a redundant long-angle sensor is also provided. Employing the aforementioned redundant long-angle sensor, the method includes the following steps: S100, sensor data acquisition and preprocessing: acquiring raw signals from four magnetic angle position sensors, monitoring the rotation angles of the central gear and the side gear respectively, eliminating errors from the magnetic angle position sensors, mapping continuous angle values ​​to gear numbers, and determining the current gear meshing position; S200, comparison of the positions of the central gear and the side gear: extracting the angular deviation of the central gear, obtaining the subdivision position of the central gear within the current tooth groove, calculating the absolute angle of the side gear using the side gear sensor data, comparing it with the position of the central gear, calculating the offset, and locking the number of the side gear currently meshing with the central gear; S300, absolute position calculation: inputting the gear number of the central gear and the gear number of the meshing side gear, and using the discrete value of the gear number to inversely deduce the number of complete revolutions the central gear has made; S400, rope length conversion: calculating the real-time length value of the rope based on the absolute angle and number of revolutions of the planetary gear, combined with the transmission ratio of the rope assembly.

[0025] The present invention has the following beneficial effects:

[0026] 1. Improved reliability: By using the same module pairing design in the planetary gear structure (e.g., both the center tooth and the third side tooth have a module of 26) and the redundant configuration of the angle sensor system, a dual backup of mechanical and signal is formed; when a single angle sensor fails, the system can still maintain basic measurement functions through another sensor, overcoming the defect of the traditional long angle sensor's single-point failure causing system paralysis; the orthogonal arrangement of the tilt sensor system further provides spatial redundancy, ensuring the continuity of vibration monitoring.

[0027] 2. Dynamic Error Suppression: The nonlinear transmission error generated by the gear set with different module is significantly suppressed by multi-sensor data fusion and Chinese residual theorem calculation; the arctangent operation and cross-verification of the angle sensor system can separate the gear meshing error from the real displacement signal; the vibration spectrum monitored in real time by the tilt sensor dynamically adjusts the weight of the fusion algorithm to compensate for high-frequency vibration interference; the closed-loop correction mechanism solves the problem that traditional solutions cannot distinguish between mechanical error and signal noise.

[0028] 3. Measurement accuracy optimization: The motherboard acts as a collaborative processing center, aligning the gear position data from the angle sensor with the attitude data from the tilt sensor in time and space; by comparing the offset between the side teeth and the center teeth (rounding to determine the meshing tooth sequence), and combining the Chinese Remainder Theorem to restore the absolute number of turns, the cumulative error caused by multi-stage transmission of gears with different module numbers is eliminated; the final output rope length value integrates the redundant verification results of angle and displacement, and the accuracy is better than that of a single sensor output.

[0029] 4. Enhanced anti-interference capability: The orthogonal arrangement of the dual tilt sensors can capture omnidirectional vibration components, and the output vibration spectrum is used to correct the dynamic weight of the angle sensors; for example, when the vibration amplitude in a certain direction exceeds the threshold, the data weight of the corresponding sensor is reduced to avoid outliers from polluting the fusion results; significantly improving the stability of the system under complex working conditions (such as the strong vibration environment of engineering machinery).

[0030] 5. Functional Synergy: The planetary gear structure, mainboard, angle sensor system, and tilt sensor system form a multi-level synergy; mechanical synergy, with gears of the same module ensuring a unified measurement benchmark, and gears of different modules expanding the transmission ratio range; electrical synergy, with the mainboard integrating a signal processing link to achieve synchronous acquisition and low-latency transmission of sensor data; algorithmic synergy, with the Chinese Remainder Theorem resolving ambiguities in the number of revolutions for multiple modules, and dynamic weight allocation optimizing fusion accuracy; fault tolerance, with redundant design of each subsystem supporting degraded operation mode.

[0031] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0032] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0033] Figure 1 This is a schematic diagram of the structure of a redundant long-angle sensor according to a preferred embodiment of the present invention;

[0034] Figure 2 This is a schematic diagram of the planetary gear structure and angle sensor system according to a preferred embodiment of the present invention;

[0035] Figure 3 This is a schematic diagram of the wire protection assembly according to a preferred embodiment of the present invention;

[0036] Figure 4 This is a schematic diagram of the structure of the top cover assembly and the pull cord assembly according to a preferred embodiment of the present invention;

[0037] Figure 5This is a GMR Wheatstone bridge circuit diagram of a redundant long-angle sensor according to a preferred embodiment of the present invention;

[0038] Figure 6 This is an orthogonal vector decomposition diagram of a redundant long-angle sensor according to a preferred embodiment of the present invention;

[0039] Figure 7 This is a block diagram of a magnetic sensor system for a redundant long-angle sensor according to a preferred embodiment of the present invention;

[0040] Figure 8 This is a flowchart of the measurement method based on a redundant long-angle sensor according to a preferred embodiment of the present invention.

[0041] Legend:

[0042] 100. Planetary gear structure; 101. Central gear; 102. First side gear; 103. Second side gear; 104. Third side gear; 200. Main board; 300. Angle sensor system; 400. Tilt sensor system; 500. Top cover assembly; 501. Light guide column; 600. Bottom cover assembly; 700. Pull cord assembly; 701. Cable reel; 702. Cable outlet; 703. Cable protection assembly; 7031. Cable threading nozzle; 7032. Rubber sleeve; 7033. Steel wire rope sleeve; 704. Gear seat; 800. Spring assembly. Detailed Implementation

[0043] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0044] like Figure 1As shown, the redundant measurement architecture of this embodiment includes: a planetary gear structure 100, used to form a three-stage reduction meshing system and ensure the consistency of the measurement reference of the angle sensors; a main board 200, corresponding to the planetary gear structure 100, used as a vibration monitoring platform and information processing center, and to realize the coordination of mechanical, electrical and algorithmic aspects; an angle sensor system 300, which uses multiple independent angle position sensors to detect the rotation angle of different gears in the planetary gear structure 100, and obtains the fused angle measurement value through arctangent operation and cross-validation, thus forming length redundancy on the mechanical transmission chain; and a tilt sensor system 400, which uses two independent inertial measurement units orthogonally arranged on the main board 200 to form a tilt-redundant vibration and attitude monitoring system, used to monitor the vibration attitude of the planetary gear structure 100 in real time and compensate for dynamic errors in the mechanical transmission in real time; the vibration spectrum detected by the two independent tilt sensors is used to correct the fusion algorithm of multiple independent angle sensors, and the transmission error generated by the heterogeneous meshing structure of the planetary gear structure 100 is compensated by the redundant measurement of multiple independent angle sensors. This invention presents a redundant measurement architecture that utilizes the matching design of the same module in the planetary gear structure (e.g., both the center tooth and the third edge tooth have a module of 26) and the redundant configuration of the angle sensor system to form a dual backup for both mechanical and signal aspects. When a single angle sensor fails, the system can still maintain basic measurement functions through another sensor, overcoming the deficiency of traditional long-angle sensors where single-point failure leads to system paralysis. The orthogonal arrangement of the tilt sensor system further provides spatial redundancy, ensuring the continuity of vibration monitoring. The nonlinear transmission error generated by the gear set with different module numbers is significantly suppressed through multi-sensor data fusion and Chinese residual theorem calculation. The arctangent operation and cross-validation of the angle sensor system can separate gear meshing error from the actual displacement signal. The vibration spectrum monitored in real time by the tilt sensor dynamically adjusts the weights of the fusion algorithm to specifically compensate for high-frequency vibration interference. The closed-loop correction mechanism solves the problem that traditional solutions cannot distinguish between mechanical errors and signal noise. The motherboard, acting as the collaborative processing center, spatiotemporally aligns the gear position data from the angle sensor with the attitude data from the tilt sensor. By comparing the offset between the side teeth and the center teeth (rounding to determine the meshing tooth sequence) and using the Chinese Remainder Theorem to restore the absolute number of turns, it eliminates the cumulative error caused by multi-stage transmission of gears with different module numbers. The final output of the rope length value incorporates redundant verification results of angle and displacement, achieving higher accuracy than the output of a single sensor. The orthogonal arrangement of the dual tilt sensors captures omnidirectional vibration components, and their output vibration spectrum is used to correct the dynamic weights of the angle sensors. For example, when the vibration amplitude in a certain direction exceeds a threshold, the data weight of the corresponding sensor is reduced to avoid outliers contaminating the fusion result. This significantly improves the system's stability under complex working conditions (such as the strong vibration environment of construction machinery).The planetary gear structure, mainboard, angle sensor system, and tilt sensor system form a multi-level collaborative system; mechanical collaboration, with gears of the same module ensuring a unified measurement benchmark, and gears of different modules expanding the transmission ratio range; electrical collaboration, with the mainboard integrating a signal processing link to achieve synchronous acquisition and low-latency transmission of sensor data; algorithmic collaboration, with the Chinese Remainder Theorem resolving ambiguities in the number of revolutions for multiple modules, and dynamic weight allocation optimizing fusion accuracy; and fault tolerance, with redundant design of each subsystem supporting degraded operation mode.

[0045] The goal of the fusion algorithm is to utilize mechanical and sensor redundancy, through a series of algorithmic processes, to suppress nonlinear errors in heterogeneous gear transmissions, compensate for vibration interference, maintain system functionality even when a single sensor fails, and ultimately output a high-precision, high-reliability absolute position (rope length) value. Specifically, this includes:

[0046] 1. Algorithm for calculating absolute circle count based on the Chinese Remainder Theorem (CRT)

[0047] Input: Instantaneous angle values ​​of each gear (θ_center, θ_planet1, θ_planet2, ...) detected by multiple magnetic angle sensors and calculated by arctangent.

[0048] process:

[0049] 1.1 Gear number determination: Discretize the continuous angle values ​​and determine which specific side gear (meshing tooth number) is currently meshing with the center gear by "comparing the offset between the side teeth and the center teeth and rounding".

[0050] 1.2 CRT Solution: The "tooth number of the center gear" (a smaller module) and the "tooth number of the meshing planetary gear" (a larger module) are used as inputs to a set of "congruence equations".

[0051] 1.3 The Chinese Remainder Theorem guarantees that this set of inputs can uniquely determine the absolute number of revolutions of the central gear, thereby expanding the measurement range from a single revolution to multiple revolutions and eliminating cumulative errors.

[0052] Output: High-precision, unambiguous absolute mechanical angle values ​​(including the number of turns and the angle within the turns).

[0053] 2. Transmission error compensation algorithm based on redundant measurement

[0054] Input: Raw data from all magnetic angle sensors.

[0055] process:

[0056] 2.1 Cross-validation: Since multiple sensors measure the motion at different points on the same mechanical transmission chain (length redundancy), their readings are correlated through a physical model (gear ratio). By comparing the consistency of the results calculated from the readings of each sensor, outliers or potential faults can be identified.

[0057] 2.2 Error Separation and Compensation:

[0058] Offline modeling: The system pre-establishes a "gear meshing error model" through calibration learning. This model describes the inherent transmission error of gear pairs with different modules at different positions.

[0059] Online compensation: The system compares the readings of multiple sensors with the error model in real time to separate the gear meshing error from the actual displacement signal. The estimated error component is then subtracted from the original readings.

[0060] Output: A cleaner gear angle signal after nonlinear transmission error compensation.

[0061] 3. Dynamic weight allocation algorithm based on vibration spectrum

[0062] Input: Vibration spectrum monitored in real time by two orthogonally arranged tilt sensors (IMUs) (obtained through frequency domain analysis such as FFT).

[0063] process:

[0064] 3.1 Vibration Analysis: Real-time calculation of the dominant frequency and amplitude of vibration.

[0065] 3.2 Weight Adjustment: This is the core of the algorithm. The system has a dynamic weight allocation table. For example, "when the vibration amplitude in the X direction exceeds a threshold, the weight of the data from the angle sensor that primarily reflects X-direction motion is reduced in the fusion process." Conversely, if the vibration environment of a certain sensor is very small, its data weight will be increased.

[0066] 3.3 Targeted Compensation: The algorithm dynamically adjusts the weights of the fusion algorithm to avoid outliers caused by vibration from contaminating the final fusion result.

[0067] Output: A set of sensor data weighting coefficients that are dynamically optimized according to the vibration environment.

[0068] 4. Multi-rate Kalman filtering and spatiotemporal alignment algorithm

[0069] Input: Low-frequency, high-precision absolute angle data (from the angle sensor system) after compensation by Algorithm 2 (transmission error compensation algorithm based on redundant measurement).

[0070] The high-frequency, high-dynamic vibration and attitude change quantities (from the tilt sensor system) are weighted by Algorithm 3 (dynamic weight allocation algorithm based on vibration spectrum).

[0071] process:

[0072] 4.1 Spatiotemporal Alignment: The motherboard acts as the processing center, stamping all sensor data with a unified timestamp and transforming it to the same coordinate system, thus solving the problems caused by different sampling rates and physical locations of different sensors.

[0073] 4.2 Sensor Fusion: A Kalman filter is used as the master state estimator.

[0074] Prediction: Utilize high-frequency data from the IMU to predict the system's next state (angle, angular velocity).

[0075] Update: When low-frequency, high-precision absolute angle data arrives, it is used to correct the prediction state and eliminate IMU drift.

[0076] In this process, the dynamic weights output by Algorithm 3 (dynamic weight allocation algorithm based on vibration spectrum) directly affect the measurement noise covariance matrix of the Kalman filter, thus determining which sensor's data it "trusts" more.

[0077] Output: An optimally estimated absolute angle value that incorporates all information.

[0078] 5. Fault diagnosis and degradation operation algorithm

[0079] Input: Data and status from all sensors.

[0080] Process: Continuous cross-validation is performed. If data from a certain angle sensor is found to be consistently abnormal (inconsistent with the results from other sensors and inconsistent with the trend predicted by the IMU), then that sensor is considered faulty.

[0081] In the event of a failure, the system automatically triggers a degraded operating mode: discarding data from the faulty sensor and relying solely on data from the remaining sensors (dual backup of mechanical and signal processing) and the IMU to continue fusion calculations. Although accuracy may decrease slightly, this overcomes the drawback of a single point of failure causing system paralysis.

[0082] Output: The fusion result of system health status indication and degraded operation mode.

[0083] The fusion algorithm integrates classical number theory (CRT), modern control theory (Kalman filtering), signal processing (FFT), and artificial intelligence (dynamic weight allocation) into a closed-loop intelligent system. It uses the absolute number of cycles calculated using the Chinese Remainder Theorem as a framework, employs redundant cross-validation and offline error models for static error compensation, and uses vibration spectrum analysis for dynamic weight adjustment. Finally, it achieves optimal fusion of all information through a multi-rate Kalman filter, and a fault diagnosis algorithm ensures the system's reliability throughout the process. This solves the problem of traditional solutions being unable to distinguish between mechanical errors and signal noise, transforming the entire redundant architecture from a hardware-intensive system into an intelligent system.

[0084] like Figure 1 and Figure 2 As shown, in this embodiment, the planetary gear structure 100 includes: a central gear 101 serving as the main transmission gear; a first side gear 102 and a second side gear 103 forming a three-stage reduction meshing structure with the central gear 101; and a third side gear 104 maintaining the same module relationship with the central gear 101 to ensure the consistency of the measurement reference of the angle sensor. Multi-stage speed change is achieved through the three-stage reduction meshing structure of the central gear 101, the first side gear 102, and the second side gear 103. Simultaneously, the same module pairing design of the central gear 101 and the third side gear 104 (e.g., both the central gear 101 and the third side gear 104 have a module of 26) ensures the consistency of the measurement reference of the two angle sensors. The error of traditional single-stage transmission is distributed to the three-stage meshing links, and the reference alignment function of the same module gears suppresses accumulated errors. The same module relationship between the third gear 104 and the center gear 101 ensures they have the same pitch angle resolution. When the angle sensor detects the absolute position of the center gear 101 and the relative position of the third gear 104, the output signals of the angle sensor can be directly compared without additional scaling transformation, solving the signal conversion complexity problem caused by gear sets with different module numbers. The different module design of the first gear 102 (e.g., module 30) and the second gear 103 (e.g., module 32) disperses the meshing contact points between different transmission stages through differentiated tooth profile distribution, reducing the probability of single-tooth surface wear. Compared with gear sets with the same module number, this can extend gear life. The characteristic vibration spectrum generated by the three-stage meshing structure can be captured by a dual tilt sensor. When abnormal wear occurs in a certain stage of gear, its corresponding vibration frequency component will be significantly enhanced, allowing the system to locate the fault level, which traditional single-stage transmissions cannot provide. The coaxial or parallel arrangement of the third gear 104 and the center gear 101 achieves a compact installation layout.

[0085] like Figure 1 and Figure 2As shown, in this embodiment, the central gear 101 has 26 teeth, the first side gear 102 has 30 teeth, the second side gear 103 has 32 teeth, and the third side gear 104 has 26 teeth. The identical tooth count design of the central gear 101 (26 teeth) and the third side gear 104 (26 teeth) ensures that the pulse signals detected by the dual-angle sensors have the same periodicity. The two angle signals can be directly compared in phase, eliminating the signal scaling conversion step required for gear sets with different tooth counts and avoiding the introduction of quantization errors during the conversion process. The 26:30:32 three-stage transmission with different tooth counts disperses the transmission error to different meshing frequency points through differentiated tooth profile distribution, breaking the condition of periodic error accumulation. Combined with the redundant verification of the reference gear with the same tooth count, an error suppression closed loop is formed. The non-integer transmission ratio (26 / 30≈0.867, 30 / 32≈0.938) generates a non-repetitive meshing sequence, reducing the risk of resonance and improving the dynamic response stability of the system. Specific combinations of tooth counts create distinguishable characteristic frequencies: a 26-tooth gear corresponds to a 26-fold frequency characteristic, a 30-tooth gear to a 30-fold frequency characteristic, and a 32-tooth gear to a 32-fold frequency characteristic, providing a clear basis for fault location in vibration spectrum analysis. The design of the small-tooth-count reference gear (26 teeth) reduces the mounting envelope size of the third-side gear 104, optimizes sensor placement space, and improves system integration.

[0086] like Figure 7As shown, in this embodiment, the angle sensor system 300 includes: a first angle position sensor chip, fixedly installed on the rotating shaft end of the central gear 101, used to detect the absolute angular position of the central gear 101 by detecting the modulus; a second angle position sensor chip, fixedly installed on the rotating shaft ends of the first side gear 102 and the second side gear 103 respectively, used to detect the relative angular position of the third side gear 104 by detecting the modulus; and a third angle position sensor chip, fixedly installed on the rotating shaft end of the third side gear 104, used to detect the relative angular position of the third side gear 104 by detecting the modulus, and to ensure accurate measurement even when the first angle position sensor chip fails; the signal output terminals of the first angle position sensor chip and the third angle position sensor chip are respectively connected to independent ADC (analog-to-digital converter) conversion channels, forming a length redundancy measurement on the mechanical transmission chain; the angle position sensor chip adopts a Wheatstone bridge structure based on the GMR (giant magnetoresistance) principle, and the output sine and cosine analog signals are converted by the ADC, and then subjected to arctangent operation and cross-validation by the digital signal processor (DSP) to obtain the fused angle measurement value. A primary and backup dual measurement channel is constructed using a first angle sensor (center gear 101) and a third angle sensor (third side gear 104) to ensure continuous system operation even in the event of a single sensor failure. A second angle sensor, detecting the first side gear 102 and the second side gear 103, forms an intermediate verification node, providing transmission chain status monitoring. A sensor chip based on a GMR Wheatstone bridge structure provides high-precision sine and cosine analog signals; an independent ADC channel avoids signal crosstalk and maintains the integrity of the original signal; the arctangent operation of the DSP eliminates the influence of signal amplitude fluctuations; and cross-validation of multi-sensor data reduces random errors. A matching design with the same module (26-tooth center gear 101 and 26-tooth third side gear 104) ensures a unified measurement benchmark; transmission errors in gear sets with different modules (26 / 30 / 32) are compensated for through multi-sensor data fusion; real-time cross-validation can identify and correct measurement deviations caused by abnormal gear meshing. Fault detection is achieved by comparing the output differences of the primary and backup sensors (first and third angle sensors). The system can automatically identify sensor failures and switch to the backup measurement channel. The second angle sensor provides transmission chain status verification, assisting in fault location. The analog signal processing link from GMR to ADC to DSP balances anti-interference capability and processing accuracy; the fusion algorithm of the digital signal processor achieves optimal weighting of multi-source data; the system can dynamically adjust the weights of each sensor according to the vibration spectrum.

[0087] In this embodiment, the first, second, and third angle position sensor chips all use the MT6501 angle position sensor chip. Using the same sensor model (MT6501) ensures that the two measurement channels have identical sensitivity characteristics, matched temperature drift coefficients, and consistent signal output formats, eliminating the system calibration complexity caused by mixing different sensors. Chip-level parameter consistency allows for direct comparison of primary and backup sensor outputs, more accurate fault diagnosis threshold settings, and eliminates the need for recalibration during switching. The same GMR Wheatstone bridge structure provides compatible ADC conversion parameter configurations and standardized arctangent operation inputs. The unified MT6501 chip enables interchangeable spare parts management, simplified maintenance processes, and consistent lifespan expectations.

[0088] like Figure 5 and Figure 6 As shown, in this embodiment, the MT6501 angle position sensor chip consists of two GMR sensing units, Vx and Vy. Each GMR sensing unit is composed of four GMR resistors connected to a Wheatstone bridge circuit. Under the action of the rotating magnetic field, the X-bridge channel and the Y-bridge channel output a sinusoidal analog voltage signal sinA and a cosine analog voltage signal cosA, where A is the angle between the magnetic field direction and the X-axis. According to the principle of the Wheatstone bridge circuit, we can obtain:

[0089] ;

[0090] Among them, V x and V y These are the output voltages of the X-bridge channel and the Y-bridge channel, respectively, V. x+ and V x- These are the positive and negative voltages of the X-bridge channel, V. y+ and V y- These are the positive and negative voltages of the Y-bridge channel, V. DD R1, R2, R3, R4, R5, R6, R7, and R8 are the resistance values ​​in the Wheatstone bridge circuit.

[0091] The sinusoidal analog voltage signal sinA and the cosine analog voltage signal cosA are amplified and filtered by the analog front-end circuit, ensuring that the analog voltage signals fall entirely within the unipolar positive voltage range supported by the analog-to-digital converter (ADC). The ADC then converts the continuous analog voltage signals into discrete digital signals, representing the voltage amplitude at the sampling time. The amplified and digitally quantized sine and cosine signals ultimately enter a digital signal processor (DSP) for compensation and calibration. After calibration, a unique angle value A is obtained through arctangent calculation, and the angle value is then output via a digital-to-analog converter (DAC). The sinA and cosA analog signals output from the X-bridge and Y-bridge channels constitute a complete magnetic field angle representation. The arctangent calculation performed by the DSP achieves 360° blind-zone-free detection. The V of the Wheatstone bridge... x+ With V x- The differential output structure effectively suppresses common-mode interference. Amplification and filtering of the original GMR signal ensures the signal amplitude matches the ADC input range, and out-of-band noise is filtered out (anti-aliasing filtering). ADC conversion eliminates analog signal transmission loss, DSP digital compensation calibrates nonlinear errors, and the digital-to-analog conversion output maintains signal integrity. Matching with planetary gears ensures the sine / cosine signal period precisely corresponds to the physical angular displacement of the gear teeth (e.g., 26 teeth). Digital signal processing capabilities meet the real-time requirements of multi-sensor data fusion. Signal phase consistency is maintained during multi-chip synchronous sampling. A unified signal processing flow simplifies system integration. Open / short circuit faults can be detected by disrupting the symmetry of resistors R1-R8; signal validity is verified through the mathematical relationship sin²A + cos²A. ADC conversion range monitoring and DSP calculation result rationality verification ensure the monitoring of the processing chain.

[0092] In this embodiment, the tilt sensor system 400 includes a first IIM-42352 tilt chip and a second IIM-42352 tilt chip mounted on the motherboard 200. The first and second IIM-42352 tilt chips are orthogonally arranged to form tilt redundancy, which is used to monitor the vibration attitude of the gear system in real time and to dynamically compensate the output signal with the measurement data of the angle sensor system 300. The first IIM-42352 tilt chip (X-axis) and the second IIM-42352 tilt chip (Y-axis) are orthogonally arranged at 90° to realize the decomposition and detection of three-dimensional spatial vibration vectors. The dual-chip collaborative operation can completely acquire the vibration spectrum of the gear system in axial vibration (gear meshing direction), radial vibration (bearing rotation direction), and torsional vibration (transmission torque fluctuation). The tilt sensor output is synchronously processed in the time domain with the MT6501 angle signal.

[0093] ;

[0094] in, The corrected angle, The angle signal output by the MT6501 sensor. ω is the angular velocity detected by the tilt chip, k is the compensation coefficient, and t is the time variable; Represents the angular velocity from time 0 to the current time t. The integral, i.e., angular displacement; this formula describes how the angle is corrected by time-domain synchronization processing of the tilt sensor output and the MT6501 angle signal. Specifically, this is done by subtracting an integral term related to the angular velocity detected by the tilt chip from the angle output by the MT6501 sensor (multiplied by a compensation coefficient). k The calibration is achieved by using a method that aims to eliminate or reduce angle measurement deviations caused by sensor errors, environmental factors, or other reasons. High-frequency vibrations of gear meshing and low-frequency deformation of the mechanical structure are distinguished by vibration frequency characteristics. The orthogonally arranged dual chips can detect single-chip failures (abnormal signal amplitude), loose installations (baseline drift), and environmental interference (sudden increase in signal noise) through the correlation of their output signals. When a single chip fails, the system can automatically switch to the single-axis mode of the healthy chip and reconstruct missing axial information based on historical data. In conjunction with the MT6501, the tilt chip provides a vibration phase reference, assisting the DSP in identifying interference components in the MT6501 signal. The transmission error spectrum of gears with different module numbers (26 / 30 / 32) can be used as a basis for matching the vibration feature library. The system is integrated on the mainboard, sharing a clock synchronization signal, unified power supply filtering design, and coordinated heat dissipation management.

[0095] like Figure 1 As shown, the redundant long-angle sensor in this embodiment includes the aforementioned redundant measurement architecture.

[0096] like Figure 1 , Figure 2 and Figure 3As shown, this embodiment also includes an upper cover assembly 500, a lower cover assembly 600, a pull cord assembly 700, and a spring assembly 800; the main board 200 is disposed between the upper cover assembly 500 and the pull cord assembly 700; the spring assembly 800 is disposed between the pull cord assembly 700 and the lower cover assembly 600. A closed force transmission chain is formed by a stacked structure of upper cover assembly 500, main board 200, pull rope assembly 700, spring assembly 800, and lower cover assembly 600. The physical isolation between the main board 200 and the moving parts reduces vibration transmission; the axial balance of the pull rope tension eliminates radial off-center loading; the linear transmission of the spring preload ensures consistent displacement detection; the upper cover assembly 500 provides electromagnetic shielding and dust protection, while the sealed structure of the lower cover assembly 600 prevents oil contamination from entering the spring assembly 800; the elastic connection between the main board 200 and the pull rope assembly 700 (e.g., through a silicone pad) filters high-frequency vibrations and improves sealing; the stiffness parameters of the spring assembly 800 are mismatched with the natural frequency of the gear system to avoid resonance; in conjunction with the redundant measurement architecture, the central placement of the main board 200 shortens the connection distance with each sensor, reducing signal attenuation; the closed-loop detection chain of pull rope displacement, gear rotation angle, and main board 200 processing has small errors; the detachable design of the upper cover assembly 500 and / or the lower cover assembly 600 facilitates maintenance of internal components such as the main board 200.

[0097] like Figure 1 and Figure 4As shown, in this embodiment, the rope assembly 700 includes a spool 701, a cable outlet 702, a cable guard assembly 703, and a gear seat 704. A central gear 101, a first side gear 102, a second side gear 103, and a third side gear 104 are mounted on the gear seat 704. The rotation axis of the central gear 101 is coaxially mounted with and connected to the rotation axis of the spool 701. The coaxial connection between the central gear 101 and the spool 701 enables direct conversion between linear displacement and rotational angle, eliminating the cosine error caused by traditional eccentric structures. The coaxial structure reduces the moment of inertia of rotating components, improving the system's response speed to changes in rope speed. The integrated layout of the gear seat 704 maintains a constant meshing center distance between each gear level (central gear 101, first side gear 102, second side gear 103, and third side gear 104), suppressing the accumulation of backlash in multi-stage transmissions. The rotational motion of the spool 701 directly drives the central gear 101 through the coaxial connection, avoiding interference from intermediate transmission chains. The gear seat 704 provides a rigid support platform for the planetary gear system, ensuring a stable meshing relationship between the gears (26 teeth, 30 teeth, and 32 teeth); the coordinated design of the cable guard assembly 703 and the cable outlet 702 ensures the stability of the cable exit direction; the integrated structure of the gear seat 704 avoids relative displacement of the gear assembly, extending the service life of the gears; the coaxial arrangement of the center gear 101 and the cable reel 701 ensures that the gear position detected by the angle sensor strictly corresponds to the cable displacement; the mounting reference surface of the gear seat 704 provides a stable vibration monitoring platform for the tilt sensor.

[0098] like Figure 3 As shown, in this embodiment, the upper cover assembly 500 is provided with a light guide post 501, which is used to indicate whether the power is on.

[0099] like Figure 4 As shown, in this embodiment, the wire protection assembly 703 includes a wire threading ceramic nozzle 7031, a rubber sleeve 7032, and a steel wire rope sleeve 7033 arranged in sequence. The steel wire rope on the wire reel 701 passes through the wire threading ceramic nozzle 7031 and the rubber sleeve 7032 in sequence and is fixed on the steel wire rope sleeve 7033.

[0100] like Figure 8As shown, the measurement method based on a redundant long-angle sensor in this embodiment uses the aforementioned redundant long-angle sensor and includes the following steps: S100, sensor (angle sensor system 300 and tilt sensor system 400) data acquisition and preprocessing, acquiring the raw signals of four magnetic angle position sensors (angle position sensor chip MT6501), monitoring the rotation angles of the center gear 101 and the side gears (first side gear 102, second side gear 103, and third side gear 104) respectively, eliminating the error of the magnetic angle position sensors, mapping continuous angle values ​​to gear numbers, and determining the current gear meshing position; S200, comparing the positions of the center gear 101 and the side gears (first side gear 102, second side gear 103, and third side gear 104) to extract... The angle deviation of the central gear 101 is used to obtain the subdivision position of the central gear 101 within the current tooth groove. The absolute angle of the side gear is calculated using data from the side gear sensor (angle position sensor chip MT6501) and compared with the position of the central gear 101 to calculate the offset and lock the number of the side gear currently meshing with the central gear 101. S300, Absolute position calculation: Input the gear number of the central gear 101 and the gear numbers of the meshing side gears (first side gear 102, second side gear 103, third side gear 104). The discrete value of the gear number is used to inversely calculate the number of complete revolutions of the central gear 101. S400, Pull rope length conversion: Calculate the real-time length value of the pull rope based on the absolute angle and number of revolutions of the planetary gears and the transmission ratio of the pull rope assembly 700. By synchronously acquiring and cross-validating data from four magnetic angle sensors, random errors in single-sensor measurements are eliminated. The gear sequence mapping algorithm discretizes continuous angles, establishing a precise correspondence with the physical tooth positions of planetary gears. Real-time position comparison between the center gear and the side gears identifies the offset caused by gear meshing backlash. The side tooth number locking algorithm effectively distinguishes between mechanical transmission errors and sensor signal drift. The rotation count back-calculation method based on the discrete values ​​of gear sequence avoids the overflow risk of the traditional cumulative counting method. The module differences of multi-stage gears (26 teeth, 30 teeth, 32 teeth) provide a natural congruence relationship, supporting highly reliable calculations. The fully closed-loop conversion process from gear angle to rope length ensures the uniformity of physical quantities for angle measurement and displacement detection, and the strict matching of transmission ratio calculation with the mechanical structure. The offset calculation in step S200 can monitor abnormal gear wear in real time. The rotation count calculation in step S300 has an automatic error correction mechanism to prevent the spread of cumulative errors.

[0101] More specifically, such as Figure 8 As shown, the entire process can be divided into three main stages: 1. Data acquisition and preprocessing; 2. Logical judgment and calculation; 3. Final result output.

[0102] Phase 1: Data Acquisition and Preprocessing

[0103] The system reads raw, continuous sine and cosine voltage signals from four magnetic angle position sensors (such as MT6501) installed at key locations to obtain raw data reflecting the instantaneous angle of the gear. Preprocessing may include signal filtering, amplification, etc., to ensure signal quality.

[0104] The raw values ​​of the four magnetic angle position sensors are calibrated to eliminate the inherent zero-point error and gain error of each sensor, ensuring that all sensor data are on the same high-precision reference, which is the basis for subsequent accurate calculations.

[0105] Phase Two: Logical Judgment and Calculation (Core Algorithm)

[0106] The raw values ​​of the continuous magnetic angle position sensor are discretized into gear numbers. The calibrated continuous angle values ​​are converted into a discrete tooth number based on the known number of gear teeth (for example, if there are 36 teeth in a 360-degree circle, then each 10-degree circle corresponds to a tooth number, thus coarsely positioning the continuous angle to a specific tooth).

[0107] Extract the deviation of the central gear number to obtain the position inside the central gear. Based on determining which tooth number the central gear is located in, calculate its precise small offset within that tooth range (i.e., the position inside the tooth). This combination of coarse positioning tooth number and fine positioning tooth position provides high-resolution position information for the central gear.

[0108] By comparing the absolute position of the edge tooth with the in-tooth position of the center tooth, the system compares the absolute position of one of the edge teeth (a continuous angular value) with the in-tooth position of the center tooth (a small offset).

[0109] Select the calculation formula based on the comparison result (if-else conditional logic):

[0110] If the absolute position of the edge tooth is greater than or equal to the inner position of the center tooth, execute the formula: Offset = Absolute position of edge tooth - Inner position of center tooth + Number of teeth / 2;

[0111] Otherwise, if the absolute position of the edge tooth is less than the inner position of the center tooth, the formula is: Offset = Absolute position of edge tooth - Inner position of center tooth - Number of teeth / 2;

[0112] By introducing an offset of ±(number of teeth / 2), the problem of the angle jump at the junction of 0° and 360° (i.e., the modular arithmetic problem) is solved, ensuring that the calculated offset is continuous and correct.

[0113] The offset is rounded to obtain the sequence number of the side gear currently meshing with the central gear. The calculated continuous offset values ​​are rounded to the nearest integer, which directly corresponds to which side gear is currently meshing with the central gear.

[0114] Based on the tooth numbers of the side gears meshing with the central gear and the central gear number, the number of revolutions the central gear has made is obtained using the Chinese Remainder Theorem. The system utilizes two pieces of information: 1) the tooth number of the central gear (a number that varies within a small range) and 2) the tooth numbers of the meshing planetary gears (a number that varies among several fixed values). The Chinese Remainder Theorem is a theorem in number theory that is very suitable for solving such one-to-many modular relationships. Through it, the number of complete revolutions the central gear has made can be uniquely determined, thus extending the measurement range from "within one revolution" to "multiple revolutions," achieving true absolute position measurement.

[0115] By combining the number of revolutions and the angle, the current absolute position of the planetary gear is obtained. The total number of revolutions calculated in the previous step is combined with the precise angle value within the current revolution obtained in the first stage to obtain a high-precision, multi-revolution absolute mechanical position value (e.g., 3 revolutions and 125.73 degrees).

[0116] Phase 3: Final Result Output

[0117] The absolute position of the planetary gear is converted into the length of the pull rope. Based on the reduction ratio of the planetary gear system and the transmission parameters of the pull rope mechanism (such as the diameter of the winding wheel), the rotation angle of the gear is linearly converted into the extension or retraction length of the pull rope, outputting the final, intuitive linear displacement required by the system.

[0118] This process perfectly solves the challenge of high-precision, large-range absolute position measurement. Through the fusion of four multi-sensor systems and a clever algorithm (the Chinese Remainder Theorem), it ensures extremely high measurement accuracy within a single rotation while achieving absolute position recording for an infinite number of rotations, avoiding errors that might arise from repeated counting. This process far surpasses simple single-sensor counting schemes, handling complex mechanical meshing relationships through logical judgment and mathematical theorems, resulting in extremely high stability and reliability, suitable for demanding industrial applications. The final output of the entire process system is a drawstring length, indicating that the sensor system likely provides the core measurement value for a high-precision drawstring displacement sensor. Internally, it utilizes a sophisticated gear mechanism to convert linear motion into rotational motion, and then calculates the absolute linear displacement through this process. This demonstrates the workflow of an efficient and reliable absolute position detection system, combining mechanical design, sensor technology, and algorithmic mathematics.

[0119] In practice, a redundant long-angle sensor is provided, which achieves a synergistic breakthrough in reliability, accuracy and environmental adaptability through transmission topology reconstruction and key component innovation.

[0120] In terms of signal output format, this invention uses an absolute encoder, where each mechanical position within the 0-360° range maps to a unique angle value. There is no need to memorize the position, and any position can be used as the zero point, greatly reducing the difficulty of installation and debugging, and giving it a significant advantage in position control.

[0121] From the perspective of working principle, this invention selects a magnetoelectric encoder. Compared with photoelectric encoders, magnetoelectric encoders have a simple structure, no complicated process requirements, and are resistant to vibration, corrosion, pollution, and interference. They also have a wide temperature range and adopt a non-contact rotating structure, eliminating mechanical friction and providing a fast response speed. They can be applied to fields where traditional encoders are not applicable.

[0122] From the perspective of signal detection principle, this invention selects a magnetic encoder based on the Hall principle. The magnetic encoder based on magnetoresistive induction has higher sensitivity than the magnetic encoder based on the Hall principle, but the magnetic encoder based on magnetoresistive induction has high noise and is sensitive to magnetic fields, temperature and the surrounding electrical environment. The magnetic encoder based on the Hall principle is more stable and better meets the requirements.

[0123] The MT6501 angle position sensor chip selected in this invention uses the giant magnetoresistive (GMR) principle for angle detection. It consists of two GMR sensing units, Vx and Vy. Each sensing unit comprises four GMR resistors connected to a Wheatstone bridge circuit. Under the influence of the rotating magnetic field, the X-bridge and Y-bridge channels output a sinusoidal analog voltage signal sinA and a cosine analog voltage signal cosA, where A is the angle between the magnetic field direction and the X-axis. Based on the Wheatstone bridge circuit principle, we can obtain:

[0124] ;

[0125] The sinusoidal analog voltage signal sinA and the cosine analog voltage signal cosA are amplified and filtered by the analog front-end circuit, ensuring that the analog voltage signals fall entirely within the unipolar positive voltage range supported by the analog-to-digital converter (ADC). The ADC then converts the continuous analog voltage signals into discrete digital signals, representing the voltage amplitude at each sampling moment. The amplified and digitally quantized sine and cosine signals ultimately enter a digital signal processor (DSP) for compensation and calibration. After calibration, a unique angle value A is obtained through arctangent calculation. This angle value is then output via a digital-to-analog converter (DAC), as shown below. Figure 7 As shown.

[0126] This invention employs a planetary gear architecture, with the central gear 101 having a module of 26, the first side gear 102 having a module of 30, and the second side gear 103 having a module of 32. When the module combination is too small, for example, if the selected module combination is a central gear 101 module of 13, a first side gear 102 module of 15, and a second side gear 103 module of 16, the gap between the teeth is large when the central gear 101 and the side gears mesh, resulting in a large error.

[0127] The planetary gear architecture breaks through the limitations of traditional single-turn absolute encoders, extending the encoder to 240 turns, enabling large-range measurement in a small size, as shown in the table below:

[0128]

[0129] The control system can calculate the spindle angle information by adding the rotation number to the angle information within 360°. Assuming the rotation number is A, the current angle is B, and the total angle is C, then:

[0130] C = A ×360°+ B

[0131] To improve the reliability of the long-angle sensor, length redundancy and tilt redundancy functions were added. To achieve length redundancy, a third-side gear 104 (module 26, the same as the central gear 101) was added to the structural design. An angle position sensor chip MT6501 was added to the main board 200 of the long-angle sensor at the position corresponding to the third-side gear 104. With the structural design unchanged, if the angle position sensor chip MT6501 at the position corresponding to the central gear 101 (module 26) fails, the long-angle sensor can still accurately measure the length of the pull rope. To achieve tilt redundancy, two IIM-42352 tilt chips were placed on the main board 200 of the long-angle sensor. Both chips simultaneously acquire tilt information; if one chip fails, the long-angle sensor can still accurately measure the angle information.

[0132] The multi-turn absolute magnetoelectric encoder structure selected in this invention, based on the Hall effect principle, mainly consists of two parts: a mechanical reduction gearbox and a conditioning circuit. The reduction gearbox is a planetary gear mechanical structure composed of multiple meshing gears (center gear 101, first side gear 102, second side gear 103, and third side gear 104). It primarily reduces the high rotational speed of the main shaft through multi-stage reduction gears, decomposing the rotation angle information of the main shaft into rotation number information and angle information. The magnet is coaxial with the reduction gears. When the main shaft rotates, the magnet rotates at a proportionally reduced speed. Each angle position sensor chip MT6501 corresponds coaxially with the magnet, and the MT6501 senses the angle change of the gear through changes in the magnetic field. The conditioning circuit mainly uses a microcontroller to read the angle position of the magnet, calculate the angle position information, and realize communication with the control system.

[0133] The redundant long-angle sensor of this invention mainly includes an upper cover assembly 500, a main board 200, a pull cord assembly 700, a spring assembly 800 (spring seat, spiral spring), and a lower cover assembly 600. The pull cord assembly 700 internally includes a wire reel 701, a wire outlet 702, a wire protection assembly 703, and a gear seat 704. The gear seat 704 has four gears arranged on it, including a central gear 101 (26 teeth), a first side gear 102 (30 teeth), a second side gear 103 (32 teeth), and a third side gear 104 (26 teeth). The first side gear 102, second side gear 103, and third side gear 104 mesh only with the central gear 101. The central gear 101 and the third side gear 104 have the same number of teeth, which is used to achieve length redundancy.

[0134] Optionally, the top cover assembly 500 is equipped with an LED light guide (light guide 501) to indicate whether the long-angle redundant sensor is powered on.

[0135] Optionally, the wire protection assembly 703 includes a wire threading ceramic nozzle 7031, a rubber sleeve 7032, and a steel wire rope sleeve 7033.

[0136] Optionally, the motherboard 200 mainly includes four angle position sensor chips MT6501, two tilt chips IIM-42352, and one main control chip APM32E103RC, etc.

[0137] Optionally, O-rings are provided between the upper cover assembly 500 and the upper part of the pull cord assembly 700 of the long-angle redundant sensor, between the lower part of the pull cord assembly 700 and the upper part of the spring seat, and between the lower part of the spring seat and the lower cover assembly 600.

[0138] Optionally, the lower cover assembly 600 is fixed to the spring seat by bolts, the spring seat is fixed to the pull cord assembly 700 by bolts, and the upper cover assembly 500 is fixed to the pull cord assembly 700 by bolts.

[0139] Matters not covered in this invention are common knowledge.

[0140] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0141] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

[0142] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A redundant measurement architecture, characterized in that, include: The planetary gear structure (100) is used to form a three-stage reduction meshing system and ensure the consistency of the measurement reference of the angle sensor; The motherboard (200) is arranged in correspondence with the planetary gear structure (100) and is used as a vibration monitoring platform and information processing center to achieve synergy between mechanical, electrical and algorithmic components. An angle sensor system (300) detects the rotation angle of different gears in the planetary gear structure (100) through multiple independent angle position sensors. The fused angle measurement value is obtained through arctangent operation and cross-verification, forming a length redundancy on the mechanical transmission chain. The tilt sensor system (400) is orthogonally arranged on the main board (200) through two independent inertial measurement units to form a tilt-redundant vibration and attitude monitoring system, which is used to monitor the vibration attitude of the planetary gear structure (100) in real time and compensate for the dynamic error in the mechanical transmission in real time. The vibration spectrum detected by two independent tilt sensors is used to correct the fusion algorithm of multiple independent angle sensors. The transmission error generated by the heterogeneous meshing structure of the planetary gear structure (100) is compensated by redundant measurement of multiple independent angle sensors. The orthogonal arrangement of dual tilt sensors can capture omnidirectional vibration components, and the output vibration spectrum is used to correct the dynamic weights of the angle sensors. There is a dynamic weight allocation table in the system. When the vibration amplitude in a certain direction exceeds the threshold, the data weight of the corresponding sensor is reduced, thereby dynamically adjusting the weights of the fusion algorithm to avoid outliers from contaminating the fusion results. The nonlinear transmission error generated by the heterogeneous meshing structure of the planetary gear (100) is significantly suppressed by multi-sensor data fusion and Chinese residual theorem calculation; the arctangent operation and cross-verification of the angle sensor system can separate the gear meshing error from the real displacement signal; the vibration spectrum monitored in real time by the tilt sensor dynamically adjusts the weight of the fusion algorithm to compensate for high-frequency vibration interference.

2. The redundant measurement architecture according to claim 1, characterized in that, The planetary gear structure (100) includes: The central gear (101) serves as the main drive gear, the first side gear (102) and the second side gear (103) form a three-stage reduction meshing structure with the central gear (101), and the third side gear (104) maintains the same module relationship with the central gear (101) to ensure the consistency of the measurement reference of the angle sensor.

3. The redundant measurement architecture according to claim 2, characterized in that, The center gear (101) has 26 teeth, the first side gear (102) has 30 teeth, the second side gear (103) has 32 teeth, and the third side gear (104) has 26 teeth.

4. The redundant measurement architecture according to claim 2 or 3, characterized in that, The angle sensor system (300) includes: The first angle position sensor chip is fixedly installed on the rotating shaft end of the central gear (101) and is used to detect the absolute angle position of the central gear (101) by detecting the module. The second angle position sensor chip is fixedly installed on the rotating shaft end of the first side gear (102) and the rotating shaft end of the second side gear (103), respectively, and is used to detect the relative angle position of the third side gear (104) by detecting the module. The third angle position sensor chip is fixedly installed on the rotating shaft end of the third side gear (104) and is used to detect the relative angle position of the third side gear (104) by detecting the module, and to ensure that it can still measure accurately when the first angle position sensor chip fails. The signal output terminals of the first and third angle position sensor chips are respectively connected to independent ADC conversion channels, forming a length redundancy measurement on the mechanical transmission chain. The angle position sensor chip adopts a Wheatstone bridge structure based on the GMR principle. The output sine and cosine analog signals are converted by ADC and then subjected to arctangent operation and cross-verification by digital signal processor to obtain the fused angle measurement value.

5. The redundant measurement architecture according to claim 4, characterized in that, The first, second, and third angle position sensor chips all use the MT6501 angle position sensor chip.

6. The redundant measurement architecture according to claim 5, characterized in that, The MT6501 angle position sensor chip consists of two GMR sensing units, Vx and Vy. Each GMR sensing unit comprises four GMR resistors connected to a Wheatstone bridge circuit. Under the influence of the rotating magnetic field, the X-bridge and Y-bridge channels output a sinusoidal analog voltage signal sinA and a cosine analog voltage signal cosA, where A is the angle between the magnetic field direction and the X-axis. Based on the Wheatstone bridge circuit principle, we can derive: Among them, V x and V y These are the output voltages of the X-bridge channel and the Y-bridge channel, respectively, V. x+ and V x- These are the positive and negative voltages of the X-bridge channel, V. y+ and V y- These are the positive and negative voltages of the Y-bridge channel, V. DD R1, R2, R3, R4, R5, R6, R7, and R8 are the resistance values ​​in the Wheatstone bridge circuit. The sinusoidal analog voltage signal sinA and the cosine analog voltage signal cosA are amplified and filtered by the analog front-end circuit, so that the analog voltage signals fall entirely within the unipolar positive voltage range supported by the analog-to-digital converter (ADC). The ADC then converts the continuous analog voltage signals into discrete digital signals, representing the voltage amplitude at the sampling time. The amplified and digitally quantized sine and cosine signals finally enter the digital signal processor for compensation and calibration. After calibration, a unique angle value A is obtained through arctangent operation, and the angle value is then output by the digital-to-analog converter (DAC).

7. The redundant measurement architecture according to claim 1, characterized in that, The tilt sensor system (400) includes a first IIM-42352 tilt chip and a second IIM-42352 tilt chip arranged on the motherboard (200). The first IIM-42352 tilt chip and the second IIM-42352 tilt chip are arranged orthogonally to form tilt redundancy, which is used to monitor the vibration attitude of the gear system in real time and to dynamically compensate the output signal with the measurement data of the angle sensor system (300).

8. A redundant long-angle sensor, characterized in that, Includes the redundant measurement architecture according to any one of claims 1 to 7.

9. The redundant long-angle sensor according to claim 8, characterized in that, It also includes an upper cover assembly (500), a lower cover assembly (600), a pull cord assembly (700), and a spring assembly (800); The mainboard (200) is positioned between the top cover assembly (500) and the pull cord assembly (700); The spring assembly (800) is positioned between the pull cord assembly (700) and the lower cover assembly (600).

10. The redundant long-angle sensor according to claim 9, characterized in that, The pull rope assembly (700) includes a spool (701), a cable outlet (702), a cable guard assembly (703), and a gear seat (704). A central gear (101), a first side gear (102), a second side gear (103), and a third side gear (104) are arranged on the gear seat (704). The rotation axis of the central gear (101) is coaxially arranged with the rotation axis of the spool (701) and connected to each other.

11. The redundant long-angle sensor according to claim 9, characterized in that, The top cover assembly (500) is provided with a light guide post (501) for indicating whether the power is on.

12. The redundant long-angle sensor according to claim 10, characterized in that, The wire protection assembly (703) includes a wire threading porcelain nozzle (7031), a rubber sleeve (7032), and a wire rope sleeve (7033) arranged in sequence. The wire rope on the reel (701) passes through the wire threading porcelain nozzle (7031) and the rubber sleeve (7032) in sequence and is fixed on the wire rope sleeve (7033).

13. A measurement method based on a redundant long-angle sensor, employing the redundant long-angle sensor as described in any one of claims 8 to 12, characterized in that, Includes the following steps: S100, Sensor data acquisition and preprocessing: Acquire the raw signals of four magnetic angle position sensors, monitor the rotation angle of the center gear (101) and the side gear respectively, eliminate the error of the magnetic angle position sensors, map the continuous angle values ​​to the gear sequence number, and determine the current gear meshing position. S200, compare the positions of the center gear (101) and the side gear, extract the angle deviation of the center gear (101), obtain the subdivision position of the center gear (101) in the current tooth groove, calculate the absolute angle of the side gear through the side gear sensor data, compare it with the position of the center gear (101), calculate the offset, and lock the number of the side tooth currently meshing with the center gear (101). S300, Absolute position calculation: Input the gear number of the center gear (101) and the gear number of the meshing side gear, and use the discrete value of the gear number to deduce the number of complete revolutions of the center gear (101). S400, the pull rope length conversion is performed by calculating the real-time length of the pull rope based on the absolute angle and number of turns of the planetary gear and the transmission ratio of the pull rope assembly (700).

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