A multi-turn memory optical-magnetic encoder hybrid system

Abstract

This invention discloses a multi-turn memory optical-magnetic encoder hybrid system, belonging to the field of encoder technology for position and angle measurement. It aims to solve the problems of complex signal processing, long axial length, insufficient accuracy and stability, and easy loss of turn count and position information in existing optical-magnetic hybrid encoders. The system includes an optical encoder, a gallium arsenide magnetic signal acquisition sensor, multiple pairs of non-uniform magnetic rings, a processor, hardware circuitry, ultra-low power circuitry, and signal acquisition and processing modules. It integrates self-developed algorithms for magnetic angle analysis and turn count memory correction, and employs a dual-redundancy design and intelligent signal mode switching. It simplifies the signal processing flow, shortens the axial length, improves measurement accuracy and stability, enhances environmental adaptability and fault tolerance, and extends battery life, making it suitable for position and angle measurement in high-precision and harsh environments.

Description

Technical Field

[0001] This invention relates to the field of encoder technology for position and angle measurement, and more specifically to a multi-turn memory optical-magnetic encoder hybrid system. Background Technology

[0002] In the field of position and angle measurement, photoelectric encoders convert mechanical displacement into pulses or digital quantities through photoelectric conversion, offering advantages such as high measurement accuracy, fast response, and stable performance. However, they are susceptible to contamination and have poor anti-interference capabilities. Magnetic encoders, relying on magnetic induction devices, obtain the absolute position of the rotor by utilizing changes in the magnetic field. They are characterized by shock resistance, corrosion resistance, contamination resistance, and simple structure, but their accuracy is insufficient at high speeds. To combine the advantages of both, hybrid optical-magnetic encoders have emerged. They use optical and magnetic signals to collaboratively calculate position information, reducing the interference of contamination and vibration on the accuracy of position information to a certain extent.

[0003] However, existing optical-magnetic hybrid encoders still have many technical shortcomings: First, they typically require two types of magnetic sensing chips to determine the absolute position, resulting in complex signal processing and increased hardware costs and algorithmic difficulty. Second, they are mostly simple integrations of optical and magnetic encoders, leading to long axial lengths, which are not conducive to miniaturization and integrated applications. Third, in high-precision applications, their accuracy and stability are insufficient, making it difficult to meet the measurement needs in complex and harsh environments. Fourth, the lack of an effective collaborative mechanism between optical and magnetic encoders prevents them from fully leveraging their advantages, affecting the overall system performance and reliability. Fifth, multi-turn encoders have shortcomings in turn count memory and absolute position matching; inaccurate initial calibration value acquisition methods easily lead to turn count and position loss problems. Sixth, multi-turn counting correction devices have weak detection accuracy and anti-interference capabilities, and limitations in data processing and position calculation, making it difficult to meet the needs of efficient multi-turn data acquisition and calculation in complex scenarios. Therefore, this paper proposes a multi-turn memory optical-magnetic encoder hybrid system that can solve the above problems and achieve high precision, anti-pollution, simplified structure, and improved efficiency. Summary of the Invention

[0004] The present invention aims to solve the problems mentioned in the background art by providing a multi-turn memory optical-magnetic encoder hybrid system.

[0005] The specific technical solution is as follows:

[0006] A multi-turn memory optical-magnetic encoder hybrid system includes an optical encoder, a magnetic signal acquisition sensor, a processor, hardware circuitry, an ultra-low-power circuit, and integrated signal acquisition module, signal processing module, fault-tolerant correction module, low-power module, and angle resolution module. The processor is electrically connected to the hardware circuitry, ultra-low-power circuit, magnetic signal acquisition sensor, and optical encoder. The angle resolution module integrates a magnetic angle resolution algorithm to resolve the electrical signal output by the magnetic field change sensed by the magnetic signal acquisition sensor into an absolute position value. The signal processing module includes a turn count memory and correction algorithm for storing, retrieving, and automatically correcting the turn count memory value. The signal acquisition module synchronously acquires the optical signal output by the optical encoder and the magnetic signal output by the magnetic signal acquisition sensor, and transmits the acquired signals to the signal processing module. The fault-tolerant correction module verifies and corrects the acquired signals and the calculated position information. The low-power module controls the system's power consumption.

[0007] As a preferred embodiment of the present invention, the optical encoder includes a photoelectric conversion circuit, an operational single-ended output circuit, a comparator circuit, and a differential operation circuit; the photoelectric conversion circuit is used to convert the optical signal into an initial electrical signal, and the operational single-ended output circuit, the comparator circuit, and the differential operation circuit process the initial electrical signal in sequence, and the processed electrical signal is transmitted to the processor.

[0008] As a preferred embodiment of the present invention, the magnetic signal acquisition sensor is a gallium arsenide sensor, which is electrically connected to the signal acquisition module and is used to acquire external magnetic field signals and convert the magnetic field signals into electrical signals before transmitting them to the signal acquisition module.

[0009] As a preferred embodiment of the present invention, it further includes multiple pairs of non-uniform magnetic rings, which are configured in conjunction with a magnetic signal acquisition sensor to provide a coarse position detection reference; the signal processing module includes a coarse position decoding module, which identifies multiple position regions and outputs an n-bit coarse position code based on the magnetic signals of the multiple pairs of non-uniform magnetic rings acquired by the magnetic signal acquisition sensor through a binary encoder.

[0010] As a preferred embodiment of the present invention, the magnetic angle analysis algorithm of the angle analysis module includes an adaptive compensation algorithm, which includes a temperature compensation algorithm and an error self-calibration algorithm, used to perform temperature error compensation and real-time error calibration on the absolute position value obtained by analysis.

[0011] As a preferred embodiment of the present invention, the fault-tolerant correction module adopts a dual redundancy design, including dual sensor redundancy and dual storage redundancy; the dual sensor redundancy is that the optical encoder and the magnetic signal acquisition sensor back each other up, so that when one of the dual sensors fails, the other sensor continues to output a signal; the dual storage redundancy is to perform dual backup storage of important parameters in the system to avoid parameter loss.

[0012] As a preferred embodiment of the present invention, the low-power module includes functions such as configuring the processor to a low-power mode and intelligent power management; the intelligent power management function adjusts the power supply according to the system's operating status to extend the system's operating time when there is no external power supply.

[0013] As a preferred embodiment of the present invention, it also includes a built-in metal shielding layer. The metal shielding layer is made of permalloy and is disposed on the outside of the magnetic signal acquisition sensor to isolate magnetic field interference in the external environment and ensure the accuracy of the signal acquired by the magnetic signal acquisition sensor.

[0014] In a preferred embodiment of the present invention, the signal processing module has a signal mode switching function, including a photoelectric signal-dominated mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality assessment. In a clean environment, the system switches to the photoelectric signal-dominated mode, prioritizing the use of the signal output by the optical encoder for position calculation. In a polluted environment, the system switches to the magnetic signal backup mode, using the signal output by the magnetic signal acquisition sensor for position calculation. The intelligent dynamic weight adjustment algorithm dynamically adjusts the weights of the two signals in position calculation based on the quality assessment results of the optical and magnetic signals.

[0015] As a preferred embodiment of the present invention, the rotation count memory and correction algorithm of the signal processing module includes a position matching algorithm. The position matching algorithm includes a matching method between absolute position and rotation count memory value, and a dynamic update algorithm for reference position. The matching method between absolute position and rotation count memory value is used to associate and match the absolute position value obtained by the angle analysis module with the rotation count memory value. The dynamic update algorithm for reference position is used to update the reference position according to the real-time calculation result, thereby improving the position matching accuracy.

[0016] In a preferred embodiment of the present invention, the hardware circuit includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware. The core control hardware is a microcontroller unit integrating a dedicated computing unit for magnetic angle analysis algorithms. This microcontroller unit is connected to an optical encoder and a magnetic signal acquisition sensor via an SPI interface, and to an ultra-low power circuit via an I2C interface. The signal acquisition hardware includes a magnetic signal acquisition circuit containing a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit containing a photoelectric conversion circuit, a single-ended output circuit, a comparator circuit, and a differential operation circuit. The signal processing hardware includes a dual storage circuit composed of non-volatile memory and a coarse position decoding hardware module. The fault-tolerant and anti-interference hardware includes a permalloy metal shielding layer, a surge suppression circuit, and an electromagnetic compatibility filter circuit.

[0017] As a preferred embodiment of the present invention, the ultra-low power circuit includes a power management unit, a sleep / wake-up circuit, and a dynamic power consumption adjustment circuit; the power management unit is a low static current power management chip with multi-level output voltage adjustment function, which is connected to the microcontroller unit to receive power consumption control commands; the sleep / wake-up circuit includes a signal-triggered wake-up sub-circuit that detects signal changes and a timed wake-up sub-circuit composed of a low-power real-time clock; the dynamic power consumption adjustment circuit is linked with the signal acquisition module and can cut off the redundant power supply of the optical encoder and adjust the main frequency of the microcontroller unit according to the position change state.

[0018] The present invention has the following beneficial effects:

[0019] 1. Simplify signal processing and reduce system complexity: By combining multiple pairs of non-uniform magnetic rings with a coarse position decoding module, the position range can be quickly determined without additional zero-point searching, eliminating accumulated errors; the angle analysis module integrates a magnetic angle analysis algorithm, which only requires a processor to complete the analysis of the magnetic signal to the absolute position value, eliminating the need for two magnetic sensing chips, effectively simplifying the complex signal processing of existing optical-magnetic hybrid encoders, and reducing system hardware costs and algorithm difficulty.

[0020] 2. Optimize structural design to meet miniaturization and integration requirements: Abandon the existing optical-magnetic hybrid encoder's "simple integration of optical encoder and magnetic encoder" approach, and significantly shorten the axial length of the system through multi-module integrated design (integration of signal acquisition, processing, fault tolerance correction, and low-power modules within the system) and the compact cooperation of multiple pairs of non-uniform magnetic rings and magnetic signal acquisition sensors, making it more suitable for miniaturized and integrated application scenarios.

[0021] 3. Improved Position Measurement Accuracy and Stability: The optical encoder provides a high-resolution reference signal, while the magnetic encoder provides a reliable absolute position area and multi-turn memory; the two work together to solve the problem. The adaptive compensation algorithm of the angle analysis module (temperature compensation, error self-calibration) offsets the influence of temperature and real-time errors on the analysis results. The position matching algorithm corrects deviations by dynamically updating the reference position, ensuring position calculation accuracy from multiple dimensions. At the same time, dual sensor redundancy, dual storage redundancy, and anti-interference hardware (surge suppression circuit, electromagnetic compatibility filter circuit, permalloy metal shielding layer) reduce the impact of external interference and faults on the system, improve overall operational stability, and meet the measurement requirements in high-precision, complex, and harsh environments.

[0022] 4. Enhanced environmental adaptability and expanded application scenarios: The signal mode switching function based on environmental cleanliness (photoelectric signal dominant mode, magnetic signal backup mode) enables the system to achieve high-precision measurement in clean environments by relying on photoelectric signals, and to ensure measurement reliability in polluted environments by relying on magnetic signals; the intelligent dynamic weight adjustment algorithm optimizes the calculation based on signal quality, further improving the system's adaptability to different environments and breaking the limitation of poor environmental adaptability of existing optical-magnetic hybrid encoders.

[0023] 5. Optimize power consumption control and extend battery life: The processor's low-power mode and intelligent power management function of the low-power module, combined with the multi-level voltage adjustment, sleep-wake control, and dynamic power consumption adjustment (cutting off redundant power supply and adjusting the main frequency) of the ultra-low power circuit, greatly reduce the ineffective power consumption under non-high load conditions, effectively extend the system's running time in scenarios without external power supply, and improve the system's applicability in mobile devices and scenarios without external power supply.

[0024] 6. Enhance fault tolerance and ensure reliable system operation: Dual sensor redundancy avoids signal interruption caused by single sensor failure, dual storage redundancy prevents loss of important parameters, and anti-interference hardware reduces external electromagnetic and magnetic field interference. These multi-dimensional improvements enhance the system's fault tolerance, reduce the risk of position calculation interruption and errors caused by component failure or external interference, and ensure long-term reliable system operation. Attached Figure Description

[0025] Figure 1 A connection diagram of a multi-turn memory optical-magnetic encoder hybrid system provided in an embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of the structure of multiple pole-unequal magnetic rings in the multi-turn memory optical-magnetic encoder hybrid system provided in an embodiment of the present invention.

[0027] Figure 3 The waveform of the magnetic signal acquired by the multi-turn memory optical-magnetic encoder hybrid system provided in this embodiment of the invention;

[0028] Figure 4 An angle diagram calculated for the multi-turn memory optical-magnetic encoder hybrid system provided in this embodiment of the invention;

[0029] Figure 5 This is a schematic diagram of the structure of a single encoder provided in an embodiment of the present invention;

[0030] Figure 6 This is a schematic diagram of the structure of a dual encoder provided in an embodiment of the present invention.

[0031] The reference numerals are: 1. Optical encoder; 2. Magnetic signal acquisition sensor. Detailed Implementation

[0032] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0033] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0034] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0035] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0036] Example: The multi-turn memory optical-magnetic encoder hybrid system provided in this example, such as Figures 1-6As shown, the system includes an optical encoder 1, a magnetic signal acquisition sensor 2, a processor, hardware circuitry, an ultra-low-power circuit, and integrated signal acquisition module, signal processing module, fault-tolerant correction module, low-power module, and angle resolution module. The processor is electrically connected to the hardware circuitry, ultra-low-power circuit, magnetic signal acquisition sensor 2, and optical encoder 1. The angle resolution module integrates a magnetic angle resolution algorithm to resolve the electrical signal output by the magnetic field change sensed by magnetic signal acquisition sensor 2 into an absolute position value. The signal processing module includes a revolution count memory and correction algorithm to store, retrieve, and automatically correct the revolution count memory value. The signal acquisition module synchronously acquires the optical signal output by optical encoder 1 and the magnetic signal output by magnetic signal acquisition sensor 2, and transmits the acquired signals to the signal processing module. The fault-tolerant correction module verifies and corrects the acquired signals and the calculated position information. The low-power module controls the system's power consumption.

[0037] By configuring an optical encoder 1, a magnetic signal acquisition sensor 2, a processor, hardware circuitry, an ultra-low-power circuit, a signal acquisition module, a signal processing module (including a rotation memory and correction algorithm), a fault-tolerant correction module, a low-power module, and an angle analysis module (integrating a magnetic angle analysis algorithm), and with the processor electrically connected to the hardware circuitry, the ultra-low-power circuit, the magnetic signal acquisition sensor 2, and the optical encoder 1 respectively, the signal acquisition module synchronously acquires optical and magnetic signals and transmits them to the signal processing module, the angle analysis module analyzes the absolute position value, the fault-tolerant correction module verifies and corrects errors, and the low-power module controls the system's power consumption, this scheme achieves coordinated operation of optical and magnetic signals, simplifies the complex signal processing flow of existing optical-magnetic hybrid encoders, solves the problems of easy position loss and structural redundancy, improves the integrity and reliability of position calculation through fault-tolerant correction, and enhances the overall system performance by controlling the overall power consumption through the low-power module.

[0038] The system has the ability to adapt to both single and dual encoders. The signal acquisition module can automatically identify the number (single / dual) and type (combination of optical encoder 1 and magnetic signal acquisition sensor 2) of encoders deployed. Without manually modifying the hardware circuit or core algorithm parameters, it can match the corresponding signal processing logic and adapt to motor operation scenarios with different accuracy requirements.

[0039] Specifically, in this embodiment, the optical encoder 1 includes a photoelectric conversion circuit, an operational single-ended output circuit, a comparator circuit, and a differential operation circuit. The photoelectric conversion circuit converts the optical signal into an initial electrical signal. The operational single-ended output circuit, the comparator circuit, and the differential operation circuit process the initial electrical signal sequentially, and the processed electrical signal is transmitted to the processor. The optical encoder 1 includes a photoelectric conversion circuit, an operational single-ended output circuit, a comparator circuit, and a differential operation circuit. After the photoelectric conversion circuit converts the optical signal into an initial electrical signal, the operational single-ended output circuit, the comparator circuit, and the differential operation circuit process and transmit it to the processor sequentially. In this scheme, the operational single-ended output circuit amplifies the initial electrical signal, the comparator circuit eliminates noise interference through threshold discrimination, and the differential operation circuit converts the single-ended signal into a differential signal with stronger anti-interference capability. This effectively reduces interference during the transmission process after the optical signal is converted into an electrical signal, improves the stability and accuracy of the electrical signal, and provides reliable optical signal data support for the processor's subsequent position calculation.

[0040] Specifically, in this embodiment, the magnetic signal acquisition sensor 2 is a gallium arsenide (GaAs) sensor. This GaAs sensor is electrically connected to the signal acquisition module and is used to acquire external magnetic field signals, convert them into electrical signals, and transmit them to the signal acquisition module. The GaAs sensor possesses high magnetic field sensitivity, accurately sensing changes in the magnetic field and stably converting them into electrical signals. This avoids the problem of insufficient signal acquisition accuracy in existing ordinary magnetic sensors, providing a high-quality magnetic signal source for the angle analysis module to analyze the absolute position value, thus improving the reliability of magnetic signal acquisition.

[0041] Specifically, in this embodiment, multiple pairs of non-uniform magnetic rings are also included. These non-uniform magnetic rings are configured in conjunction with the magnetic signal acquisition sensor 2 to provide a coarse position detection reference. The signal processing module includes a coarse position decoding module. This module, based on the magnetic signals from the non-uniform magnetic rings acquired by the magnetic signal acquisition sensor 2, identifies multiple position regions through a binary encoder and outputs an n-bit coarse position code. The system adds multiple pairs of non-uniform magnetic rings, which are configured in conjunction with the magnetic signal acquisition sensor 2. The signal processing module includes a coarse position decoding module that outputs an n-bit coarse position code through a binary encoder based on the magnetic signals acquired by the magnetic signal acquisition sensor 2. The non-uniform magnetic rings provide a clear coarse position detection reference. Unlike incremental encoders, the coarse position decoding module can quickly identify position regions and output coarse position codes without searching for a zero point. This allows for rapid determination of the absolute position range, elimination of accumulated errors, simplification of the initial position positioning process, and improvement of the efficiency and accuracy of position range determination.

[0042] Specifically, in this embodiment, the magnetic angle analysis algorithm of the angle analysis module includes an adaptive compensation algorithm, which comprises a temperature compensation algorithm and an error self-calibration algorithm. These algorithms are used to compensate for temperature errors and calibrate real-time errors in the analyzed absolute position value. The temperature compensation algorithm can offset the influence of temperature changes on magnetic signal analysis, while the error self-calibration algorithm can correct deviations in the analysis process in real time. This avoids the problem of existing analysis algorithms being greatly affected by ambient temperature and real-time errors, reduces the interference of temperature and real-time errors on the analysis of absolute position value, and improves the accuracy of the absolute position value output by the angle analysis module.

[0043] Specifically, in this embodiment, the fault-tolerant correction module adopts a dual redundancy design, including dual sensor redundancy and dual storage redundancy. Dual sensor redundancy involves the optical encoder 1 and magnetic signal acquisition sensor 2 backing each other up; when one sensor fails, the other continues to output a signal. Dual storage redundancy involves dual backup storage of important parameters within the system to prevent parameter loss. The dual sensor redundancy allows the other sensor to continue outputting a signal even if one sensor fails, preventing signal interruption due to sensor failure. Dual storage redundancy prevents the loss of important parameters, avoids the problem of poor fault tolerance in existing systems, improves the stability of the system in the event of sensor failure or abnormal parameter storage, and reduces the occurrence of position calculation interruptions or errors.

[0044] Specifically, in this embodiment, the low-power module's functions include configuring the processor to a low-power mode and intelligent power management. The intelligent power management function adjusts the power supply according to the system's operating state, extending the system's runtime without external power. The low-power module has the function of configuring the processor to a low-power mode and possesses intelligent power management functionality that adjusts the power supply according to the system's operating state. By configuring the processor to a low-power mode and adjusting the power supply according to the operating state, the system's power consumption under non-high load conditions can be reduced, avoiding the problems of high power consumption and poor battery life of existing encoders, extending the system's runtime without external power, and improving the system's applicability in scenarios without external power.

[0045] Specifically, in this embodiment, a built-in metal shielding layer is also included. This metal shielding layer, made of permalloy, is located on the outside of the magnetic signal acquisition sensor 2 to isolate magnetic field interference from the external environment, ensuring the accuracy of the signals acquired by the magnetic signal acquisition sensor 2. The system adds a built-in metal shielding layer, made of permalloy and located on the outside of the magnetic signal acquisition sensor 2. Permalloy possesses excellent magnetic shielding performance, effectively isolating magnetic field interference from the external environment, preventing external magnetic fields from affecting the magnetic field signals acquired by the magnetic signal acquisition sensor 2, preventing the existing problem of magnetic signals being easily interfered with by external magnetic fields, ensuring the accuracy of the output electrical signals of the magnetic signal acquisition sensor 2, and improving the reliability of magnetic signal acquisition.

[0046] Specifically, in this embodiment, the signal processing module has a signal mode switching function, including a photoelectric signal-dominated mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality assessment. In a clean environment, the system switches to the photoelectric signal-dominated mode, prioritizing the use of the signal output by the optical encoder 1 for position calculation. In a polluted environment, the system switches to the magnetic signal backup mode, using the signal output by the magnetic signal acquisition sensor 2 for position calculation. The intelligent dynamic weight adjustment algorithm dynamically adjusts the weights of the two signals in position calculation based on the quality assessment results of the optical and magnetic signals. The signal processing module features signal mode switching capabilities, including a photoelectric signal-dominated mode, a magnetic signal backup mode, and an intelligent dynamic weight adjustment algorithm based on signal quality assessment. In clean environments, the photoelectric signal-dominated mode is used, while in polluted environments, the magnetic signal backup mode is employed. The intelligent dynamic weight adjustment algorithm adjusts the weights of the two signals in position calculation based on signal quality. In clean environments, photoelectric signals offer high accuracy, and the photoelectric signal-dominated mode improves position calculation accuracy. In polluted environments, photoelectric signals are susceptible to contamination, and the magnetic signal backup mode ensures signal reliability. The intelligent dynamic weight adjustment algorithm combines the two signal qualities to select the optimal calculation method, avoiding the poor environmental adaptability issues of existing systems, improving the system's adaptability to different environments, and optimizing the accuracy and reliability of position calculation.

[0047] Specifically, in this embodiment, the revolution count memory and correction algorithm of the signal processing module includes a position matching algorithm. The position matching algorithm includes a method for matching the absolute position with the memoryd revolution count value, and a dynamic update algorithm for the reference position. The method for matching the absolute position with the memoryd revolution count value is used to correlate and match the absolute position value obtained by the angle analysis module with the memoryd revolution count value. The dynamic update algorithm for the reference position is used to update the reference position based on the real-time calculation results, improving the position matching accuracy. The correlation matching ensures the consistency between the absolute position value and the memoryd revolution count value, while the dynamic update algorithm for the reference position corrects deviations in the reference position, avoiding the problems of inaccurate revolution count and position matching and errors caused by a fixed reference position in existing multi-turn encoders, thus improving the accuracy of revolution count recording and position determination.

[0048] Specifically, in this embodiment, the hardware circuit includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware. The core control hardware is a microcontroller unit integrating a dedicated computing unit for magnetic angle analysis algorithms. This microcontroller unit is connected to the optical encoder 1 and the magnetic signal acquisition sensor 2 via an SPI interface, and to the ultra-low power circuit via an I2C interface. The signal acquisition hardware includes a magnetic signal acquisition circuit containing a gallium arsenide sensor and a signal conditioning circuit, as well as an optical signal acquisition circuit containing a photoelectric conversion circuit, an arithmetic single-ended output circuit, a comparator circuit, and a differential arithmetic circuit. The signal processing hardware includes a dual storage circuit composed of non-volatile memory and a coarse position decoding hardware module. The fault-tolerant and anti-interference hardware includes a permalloy metal shielding layer, a surge suppression circuit, and an electromagnetic compatibility filter circuit. The hardware circuitry includes core control hardware, signal acquisition hardware, signal processing hardware, and fault-tolerant and anti-interference hardware. The core control hardware is a microcontroller unit integrating a dedicated computational unit for magnetic angle resolution algorithms (connected to optical encoder 1 and magnetic signal acquisition sensor 2 via an SPI interface, and to an ultra-low-power circuit via an I2C interface). The signal acquisition hardware includes a magnetic signal acquisition circuit with a gallium arsenide sensor and signal conditioning circuitry, and an optical signal acquisition circuit with photoelectric conversion circuitry. The signal processing hardware includes a dual-memory circuit composed of non-volatile memory and a coarse position decoding hardware module. The fault-tolerant and anti-interference hardware includes a metal shielding layer, surge suppression circuitry, and electromagnetic compatibility filtering circuitry. The dedicated computational unit of the core control hardware improves magnetic angle resolution efficiency, and the interface connection ensures reliable data transmission. The signal conditioning circuit of the signal acquisition hardware optimizes the magnetic signal, and the optical signal acquisition circuit optimizes the optical signal. The dual-memory circuit and coarse position decoding hardware module of the signal processing hardware improve processing reliability and efficiency. The fault-tolerant and anti-interference hardware reduces the impact of external interference and component failures, avoiding the problems of low signal processing efficiency, poor anti-interference, and weak fault tolerance in existing hardware circuits, thus comprehensively improving the signal acquisition, processing, anti-interference, and fault tolerance capabilities at the hardware level.

[0049] Specifically, in this embodiment, the ultra-low power circuit includes a power management unit, a sleep / wake-up circuit, and a dynamic power consumption adjustment circuit. The power management unit is a low quiescent current power management chip with multi-level output voltage adjustment function. This chip is connected to the microcontroller unit to receive power consumption control commands. The sleep / wake-up circuit includes a signal-triggered wake-up sub-circuit that detects signal changes and a timed wake-up sub-circuit composed of a low-power real-time clock. The dynamic power consumption adjustment circuit is linked with the signal acquisition module and can cut off the redundant power supply of the optical encoder 1 and adjust the main frequency of the microcontroller unit according to the position change status. The ultra-low power circuit includes a power management unit, a sleep / wake-up circuit, and a dynamic power consumption adjustment circuit. The power management unit is a low quiescent current power management chip (connected to the microcontroller unit) with multi-level output voltage adjustment. The sleep / wake-up circuit includes a signal-triggered wake-up sub-circuit and a timed wake-up sub-circuit composed of a low-power real-time clock. The dynamic power consumption adjustment circuit is linked with the signal acquisition module (it can cut off the redundant power supply of the optical encoder 1 and adjust the operating frequency of the microcontroller unit). The multi-level voltage adjustment of the power management unit reduces static power consumption. The sleep / wake-up circuit allows the system to sleep when not in operation and wake up when needed to reduce ineffective power consumption. The dynamic power consumption adjustment circuit adjusts the power supply and operating frequency according to position changes to further optimize power consumption, avoiding the problems of imprecise power control and short battery life of existing ultra-low power circuits. This significantly reduces system power consumption, extends battery life, and ensures real-time performance during system operation.

[0050] Specifically, in this embodiment, the self-developed magnetic angle analysis algorithm includes an adaptive compensation algorithm, which in turn includes an adaptive compensation algorithm and an error self-calibration algorithm, wherein:

[0051] Temperature compensation algorithm: Real-time acquisition of ambient temperature data from temperature sensors (integrated into hardware circuits) within the system, establishing a correlation model between temperature and magnetic signal analysis error; When the ambient temperature changes, the algorithm automatically retrieves preset compensation parameters based on the model, corrects the deviation of the absolute position value corresponding to the output electrical signal of magnetic signal acquisition sensor 2 (gallium arsenide sensor), offsets the magnetic signal induction deviation caused by temperature changes, and ensures stable position analysis accuracy at different temperatures.

[0052] Error self-calibration algorithm: Based on the high-resolution signal output by optical encoder 1, the absolute value of the position resolved by the magnetic signal is periodically compared with the solution result of the optical signal; if the deviation between the two exceeds the preset threshold, the algorithm automatically calculates the deviation and generates calibration coefficients, updates the magnetic angle resolution parameters, and corrects the accumulated error in the magnetic signal resolution process in real time, maintaining the resolution accuracy without manual intervention.

[0053] Specifically, in this embodiment, the coarse position decoding algorithm is as follows: Based on the magnetic field signals of multiple pairs of non-uniform magnetic rings collected by the magnetic signal acquisition sensor 2, the algorithm first performs filtering and noise reduction processing on the magnetic signals to remove environmental interference signals; then, through binary encoder logic, it maps the multiple position regions divided by the multiple pairs of non-uniform magnetic rings to preset binary codes, identifies the position region to which the current magnetic field signal belongs, and outputs an n-bit coarse position code; this code directly defines the large area where the current mechanical angle is located, providing an initial range for subsequent precise position calculation, avoiding the process of incremental encoder searching for zero point, and shortening the position positioning time.

[0054] Specifically, in this embodiment, the lap count memory and correction algorithm is as follows:

[0055] 1. Lap count memory storage and retrieval: A dual storage circuit composed of non-volatile memory in the hardware circuit is used to synchronously store the lap count memory value calculated each time to two storage units; when retrieving, the data in the main storage unit is retrieved first. If the data in the main storage unit is abnormal, the backup storage unit data is automatically switched to be read to prevent the loss of lap count memory value.

[0056] 2. Dual signal source automatic rotation correction: The algorithm compares the rotation change calculated by the optical encoder 1 signal with the rotation change analyzed by the magnetic signal in real time. If the two are inconsistent and the deviation exceeds the allowable range, the algorithm judges the validity of the signal (prioritizing the photoelectric signal in a clean environment and the magnetic signal in a polluted environment as the benchmark), and corrects the rotation calculation result of the other signal based on the rotation number corresponding to the valid signal to ensure accurate rotation record.

[0057] Specifically, in this embodiment, the location matching algorithm is as follows:

[0058] 1. Matching absolute position with lap count memory value: The absolute position value output by the angle analysis module is associated with the lap count memory value to establish a "lap count - absolute position" correspondence. After each calculation, the algorithm verifies whether the current absolute position value is within the preset position range of the corresponding lap count. If it exceeds the range, the lap count memory value is automatically adjusted or the absolute position value is corrected to ensure that the two match.

[0059] 2. Dynamic update of reference position: Based on the accurate position results of multiple consecutive calculations, the algorithm calculates the position change trend in real time; when the position calculation result is detected to be stable (fluctuation is less than the preset value), the current position is automatically updated to a new reference position to replace the initial reference position, so as to avoid the initial reference position deviation from accumulating over time and affecting the accuracy of subsequent calculations.

[0060] Specifically, in this embodiment, the intelligent dynamic weight adjustment algorithm: evaluates the quality of optical and magnetic signals in real time (such as the signal-to-noise ratio of optical signals and the stability of magnetic signals), and assigns weight coefficients to the two signals respectively; in a clean environment, the quality of optical signals is high, so the algorithm increases the weight of optical signals (accounting for more than 50%), and prioritizes the use of optical signals to solve the position; in a polluted environment, the quality of magnetic signals is better, so the algorithm increases the weight of magnetic signals; if the quality of the two signals is similar, the weights are assigned according to a preset ratio, and the solution results of the two are merged to balance accuracy and reliability.

[0061] In addition, such as Figures 5-6 As shown, the system's single / dual encoder adaptive configuration specifically includes the following two application modes:

[0062] Single encoder adaptive application configuration: Only one encoder needs to be deployed at the motor end (optical encoder 1 or magnetic signal acquisition sensor 2 combined with multi-pole unequal magnetic rings, or a combination of one multi-pole unequal magnetic ring and one optical encoder 1) to meet the basic operating requirements of the motor; after the signal acquisition module automatically detects the signal of a single encoder, it does not need to start the dual-signal collaborative solution logic, but directly calls the signal processing flow of the corresponding type of encoder (optical encoder 1 calls the photoelectric conversion-differential operation link, magnetic signal acquisition sensor 2 combination or multi-pole unequal magnetic ring and optical encoder 1 combination calls the coarse position decoding-magnetic angle analysis link), and at the same time enables the single sensor fault warning function of the fault tolerance correction module to ensure stability and low power consumption in the basic operating scenario; this mode is suitable for ordinary motor drive scenarios without high precision requirements, such as small conveying equipment, ordinary drive motors, etc.

[0063] Dual encoder adaptive application configuration: Dual encoders are deployed at the high-speed and low-speed ends of the motor. They can be used independently or collaboratively to achieve high-precision position calculation. A typical configuration involves deploying encoders at the high-speed and low-speed ends of the motor (optical encoder 1 at the high-speed end and magnetic signal acquisition sensor 2 with a combination of multiple pairs of non-uniform magnetic rings at the low-speed end, or vice versa), adapting to the high-precision motor operation requirements (such as high-precision transmission scenarios of frameless torque motors paired with precision harmonic reducers). After the signal acquisition module detects the signals from both encoders, it automatically starts the dual-signal collaborative calculation logic, utilizing the intelligent dynamic weight adjustment algorithm of the signal processing module. The encoder signals at both high and low speeds are evaluated for quality and weighted accordingly (e.g., when the motor is running at high speed, the weight of the high-speed optical encoder 1 is increased to ensure dynamic accuracy; when the load at low speed is stable, the weight of the low-speed magnetic signal is increased to ensure absolute position accuracy). Simultaneously, the dual-sensor redundancy function of the fault-tolerant correction module is fully activated, allowing the high-speed and low-speed encoders to back each other up. If either encoder fails, the system automatically switches to the signal processing of the other encoder, ensuring continuous and reliable operation in high-precision scenarios. This mode is suitable for high-precision control applications, such as joint motors in industrial robots, spindle motors in precision machine tools, and drive motors in medical equipment.

[0064] Specifically, in this embodiment, the environmental cleanliness detection mechanism of this system relies on the signal characteristics of the optical encoder 1 and the signal quality assessment capability of the signal processing module. The logic is "optical signal quality inversely inferring environmental cleanliness"—because the optical encoder 1 is easily affected by dust, oil, and other contaminants, a decrease in environmental cleanliness will directly lead to optical signal attenuation and increased noise. Therefore, the current environmental cleanliness status can be accurately determined through the optical signal quality assessment algorithm. The specific implementation process and related design are as follows:

[0065] 1. Acquisition of key optical signal parameters: The signal acquisition module synchronously acquires the core parameters of the optical signal output by the optical encoder 1 after processing, including the optical signal-to-noise ratio (the ratio of effective signal to noise in the output signal of the photoelectric conversion circuit), signal amplitude stability (the fluctuation amplitude of the output voltage of the single-ended output circuit), and signal edge sharpness (the steepness of the rising / falling edge of the square wave signal output by the comparator circuit). The above parameters are transmitted to the signal processing module through the differential operation circuit of the optical encoder 1 to ensure the anti-interference of the acquired data.

[0066] 2. Signal quality assessment threshold setting: The signal processing module has a built-in optical signal quality assessment threshold, which is based on the signal parameters of the optical encoder 1 in a standard clean environment (such as setting the signal-to-noise ratio ≥30dB, signal amplitude fluctuation ≤5%, and edge rise time ≤100ns as the clean environment judgment benchmark); the threshold judgment logic works in conjunction with the threshold discrimination function of the comparator circuit to avoid misjudgment caused by a single parameter abnormality.

[0067] 3. Environmental cleanliness algorithm judgment: The signal processing module runs an optical signal quality assessment algorithm to analyze the collected parameters in real time.

[0068] (1) If all parameters meet the clean environment threshold, the current environment is determined to be clean, and the "photoelectric signal-dominated mode" is triggered. The signal processing module increases the weight of the optical signal in the position calculation and prioritizes the use of the high-resolution signal of the optical encoder 1 for calculation, giving full play to its accuracy advantage.

[0069] (2) If any parameter exceeds the threshold (e.g., signal-to-noise ratio < 30dB, amplitude fluctuation > 5%), it is determined that the environmental cleanliness has decreased (pollution exists). The algorithm further analyzes the signal degradation trend: if the parameter briefly exceeds the threshold, it is determined to be temporary interference. The photoelectric signal-dominated mode is maintained and noise filtering is strengthened through the comparator circuit. If the parameter exceeds the threshold for three consecutive sampling cycles, it is determined to be continuous environmental pollution. The "magnetic signal backup mode" is triggered, and the signal processing module automatically switches to the solution mode based on the output signal of the magnetic signal acquisition sensor 2 (gallium arsenide sensor) to avoid the impact of pollution on the optical signal.

[0070] 4. Synergistic Integration with System Modules: This detection mechanism works in deep collaboration with the "intelligent dynamic weight adjustment algorithm" of the signal processing module. When the environmental cleanliness is at a critical state (parameters are close to the threshold), the algorithm dynamically adjusts the calculation weights of the optical and magnetic signals (e.g., the optical signal weight decreases from 70% to 50%, and the magnetic signal weight increases from 30% to 50%) to achieve a smooth transition between the two signals. At the same time, the fault-tolerant correction module records abnormal optical signal quality. If continuous pollution causes the optical signal to be unable to recover for a long time, the system issues a calibration prompt through the status interface of the hardware circuit, reminding maintenance personnel to clean the optical encoder 1, ensuring that the detection mechanism is consistent with the existing fault-tolerant and maintenance logic.

[0071] Working principle: This system operates primarily based on the logic of "coordinated acquisition of optical and magnetic signals - multi-module linkage processing - fault tolerance and low power consumption control." The various components and modules collaborate according to the following process:

[0072] 1. Signal Acquisition Stage: The optical encoder 1 converts the optical signal into an initial electrical signal through its internal photoelectric conversion circuit. After being amplified by the single-ended output circuit, denoised by the threshold discrimination of the comparator circuit, and converted into an anti-interference differential signal by the differential operation circuit, the signal is transmitted to the signal acquisition module. The magnetic signal acquisition sensor 2 (gallium arsenide sensor) acquires the magnetic field signal generated by the interaction with multiple pairs of non-uniform magnetic rings, converts it into an electrical signal, and also transmits it to the signal acquisition module. The signal acquisition module simultaneously receives the two signals and transmits them to the signal processing module.

[0073] 2. Signal Processing and Position Calculation Stage: The coarse position decoding module within the signal processing module, based on magnetic signals, identifies the position region through a binary encoder and outputs an n-bit coarse position code to quickly determine the position range. The angle analysis module, relying on an integrated magnetic angle analysis algorithm, analyzes the electrical signal corresponding to the magnetic signal into an absolute position value. The adaptive compensation algorithm (including a temperature compensation algorithm and an error self-calibration algorithm) in the algorithm will compensate for temperature errors and correct real-time deviations in the absolute position value. At the same time, the rotation memory and correction algorithm of the signal processing module realizes the storage and retrieval of the rotation memory value. Its included position matching algorithm associates and matches the absolute position value output by the angle analysis module with the rotation memory value, and corrects the reference position based on the real-time calculation result through a reference position dynamic update algorithm, ultimately completing the accurate position calculation.

[0074] 3. Fault Tolerance and Power Consumption Control Stage: The fault tolerance correction module ensures system stability through a dual redundancy design—dual sensor redundancy allows the optical encoder 1 and magnetic signal acquisition sensor 2 to back each other up, so that the other sensor can continue to output a signal if either sensor fails; dual storage redundancy stores important system parameters in dual backups to avoid parameter loss; surge suppression circuits, electromagnetic compatibility filtering circuits, and permalloy metal shielding layers on the outside of magnetic signal acquisition sensor 2 in the hardware circuit further reduce external electromagnetic and magnetic field interference. The low-power module achieves power consumption control by configuring the processor to a low-power mode and using intelligent power management functions to adjust the power supply according to the working status; the ultra-low power circuit's power management unit (low quiescent current, multi-level voltage adjustment), sleep / wake-up circuit (signal-triggered wake-up sub-circuit and low-power real-time clock timed wake-up sub-circuit), and dynamic power consumption adjustment circuit (linked with the signal acquisition module, cutting off the redundant power supply to the optical encoder 1 and adjusting the processor's main frequency according to position changes) further optimize power consumption control.

[0075] 4. Environment Adaptation Phase: The signal processing module's signal mode switching function dynamically adjusts the working mode according to the environmental conditions—in a clean environment, it switches to the photoelectric signal-dominated mode, prioritizing the use of high-precision photoelectric signals to calculate the position; in a polluted environment, it switches to the magnetic signal backup mode, relying on the anti-pollution characteristics of magnetic signals to ensure signal reliability; based on the intelligent dynamic weight adjustment algorithm of signal quality assessment, it dynamically adjusts the weights of optical and magnetic signals in position calculation according to their quality, ensuring the accuracy and reliability of position calculation in different environments.

[0076] How to use:

[0077] 1. Environmental Adaptation and Mode Selection: After deploying the system in the target measurement scenario, the system automatically detects the cleanliness of the environment. If the environment is clean (without obvious dust, oil, or other pollution), the signal processing module automatically switches to the photoelectric signal-dominated mode, prioritizing the signal output by the optical encoder 1 as the core basis for position calculation. If the environment is polluted (dust, oil, or other factors that may affect the photoelectric signal), the system automatically switches to the magnetic signal backup mode, using the signal collected by the magnetic signal acquisition sensor 2 as the primary basis for position calculation. Regardless of the environment, the intelligent dynamic weight adjustment algorithm will evaluate the quality of the optical and magnetic signals in real time and dynamically adjust their weights in the calculation to ensure the optimal calculation result.

[0078] 2. Power-on Initialization and Position Calibration: After the system is powered on, the signal acquisition module synchronously acquires the initial signals from the optical encoder 1 and the magnetic signal acquisition sensor 2. The coarse position decoding module of the signal processing module outputs an n-bit coarse position code based on the multi-pair non-uniform magnetic ring signals acquired by the magnetic signal acquisition sensor 2, quickly determining the approximate range of the current position without the need for additional zero-point search operations like incremental encoders. The angle analysis module analyzes the absolute value of the initial position through a magnetic angle analysis algorithm, and the adaptive compensation algorithm simultaneously performs temperature error compensation and real-time error calibration. The position matching algorithm associates and matches the absolute value of the initial position with the memory value of the number of revolutions to complete the initial position calibration.

[0079] 3. Normal Operation and Data Processing: After calibration, the system enters normal measurement mode. The signal acquisition module continuously and synchronously acquires optical and magnetic signals and transmits them to the signal processing module. The signal processing module processes the signals according to its working mode, and combines the rotation count memory and correction algorithm to realize the real-time update and storage of the rotation count memory value. It dynamically updates the reference position through the position matching algorithm to ensure the accuracy of the position calculation. The processor receives the processed signal and the calculation result, and outputs the final position and angle measurement data. The fault tolerance correction module verifies the acquired signal and the calculation result in real time. If a sensor failure or parameter abnormality is found, dual redundancy backup is immediately activated (switching to the backup sensor or calling the backup parameters) to ensure uninterrupted system operation.

[0080] 4. Low-power control and battery life management: When the signal acquisition module detects that the encoder is stationary (no position change), the low-power module automatically configures the processor to low-power mode. The dynamic power consumption adjustment circuit of the ultra-low-power circuit cuts off the redundant power supply of the optical encoder 1 and reduces the processor's main frequency. If there is no position change for a long time, the low-power real-time clock of the sleep-wake circuit wakes up the processor periodically according to a preset period (e.g., adjustable from 10ms to 1s) to perform short-term signal acquisition. After the acquisition is completed, the processor is immediately controlled to return to sleep mode. When the signal acquisition module detects a position change, the system quickly restores the full power supply of the optical encoder 1 and the normal main frequency of the processor to ensure real-time calculation when the position changes.

[0081] 5. Fault Handling and Maintenance: If the system experiences signal interruption or computational anomaly, the fault-tolerant correction module will automatically check the sensor status and parameter storage status. If the optical encoder 1 fails, it will immediately switch to the magnetic signal acquisition sensor 2 to output the signal alone. If the magnetic signal acquisition sensor 2 fails, it will switch to the optical encoder 1 to output the signal alone. If the parameters are lost, it will call the backup parameters in the dual storage redundancy to restore system operation. During routine maintenance, the working status of each hardware unit (such as the power management unit, processor, and sensors) can be viewed through the hardware circuit status detection interface, and basic fault diagnosis can be completed without disassembling the system.

[0082] In summary, the multi-turn memory optical-magnetic encoder hybrid system provided in this embodiment has the following advantages:

[0083] 1. Simplify signal processing and reduce system complexity: By combining multiple pairs of non-uniform magnetic rings with a coarse position decoding module, the position range can be quickly determined without additional zero-point searching, eliminating accumulated errors; the angle analysis module integrates a magnetic angle analysis algorithm, which only requires a processor to complete the analysis of the magnetic signal to the absolute position value, eliminating the need for two magnetic sensing chips, effectively simplifying the complex signal processing of existing optical-magnetic hybrid encoders, and reducing system hardware costs and algorithm difficulty.

[0084] 2. Optimize structural design to meet miniaturization and integration requirements: Abandon the existing optical-magnetic hybrid encoder's "simple integration of optical encoder 1 and magnetic encoder" approach, and significantly shorten the axial length of the system through multi-module integrated design (integration of signal acquisition, processing, fault tolerance correction, and low-power modules within the system) and the compact cooperation of multiple pairs of non-uniform magnetic rings and magnetic signal acquisition sensor 2, making it more suitable for miniaturized and integrated application scenarios.

[0085] 3. Improved position measurement accuracy and stability: The optical encoder 1 provides a high-resolution reference signal, while the magnetic encoder provides a reliable absolute position area and multi-turn memory, and the two work together to solve the problem; the adaptive compensation algorithm of the angle analysis module (temperature compensation, error self-calibration) offsets the influence of temperature and real-time error on the analysis results; the position matching algorithm corrects deviations by dynamically updating the reference position, ensuring the accuracy of position calculation from multiple dimensions; at the same time, dual sensor redundancy, dual storage redundancy, and anti-interference hardware (surge suppression circuit, electromagnetic compatibility filter circuit, permalloy metal shielding layer) reduce the impact of external interference and faults on the system, improve the overall operational stability, and meet the measurement requirements of high precision and complex and harsh environments.

[0086] 4. Enhanced environmental adaptability and expanded application scenarios: The signal mode switching function based on environmental cleanliness (photoelectric signal dominant mode, magnetic signal backup mode) enables the system to achieve high-precision measurement in clean environments by relying on photoelectric signals, and to ensure measurement reliability in polluted environments by relying on magnetic signals; the intelligent dynamic weight adjustment algorithm optimizes the calculation based on signal quality, further improving the system's adaptability to different environments and breaking the limitation of poor environmental adaptability of existing optical-magnetic hybrid encoders.

[0087] 5. Optimize power consumption control and extend battery life: The processor's low-power mode and intelligent power management function of the low-power module, combined with the multi-level voltage adjustment, sleep-wake control, and dynamic power consumption adjustment (cutting off redundant power supply and adjusting the main frequency) of the ultra-low power circuit, greatly reduce the ineffective power consumption under non-high load conditions, effectively extend the system's running time in scenarios without external power supply, and improve the system's applicability in mobile devices and scenarios without external power supply.

[0088] 6. Enhance fault tolerance and ensure reliable system operation: Dual sensor redundancy avoids signal interruption caused by single sensor failure, dual storage redundancy prevents loss of important parameters, and anti-interference hardware reduces external electromagnetic and magnetic field interference. These multi-dimensional improvements enhance the system's fault tolerance, reduce the risk of position calculation interruption and errors caused by component failure or external interference, and ensure long-term reliable system operation.

[0089] 7. Achieve adaptive single / dual encoder matching for flexible adaptation to various scenarios: Through the automatic identification function of the signal acquisition module, seamless switching between single encoder (basic accuracy) and dual encoder (high precision) scenarios can be achieved without modifying hardware or algorithm parameters; the single encoder mode reduces the hardware cost of basic scenarios, while the dual encoder mode improves the control stability of high precision scenarios through the collaborative signal of both ends, solving the problems of "poor scenario adaptability and complex configuration" of existing encoder systems, and broadening the application coverage of the system in the fields of general transmission and high precision control.

[0090] In summary, the multi-turn memory optical-magnetic encoder hybrid system of this embodiment simplifies signal processing, optimizes structural design, improves accuracy and stability, enhances environmental adaptability, optimizes power consumption control, and strengthens fault tolerance. At the same time, it achieves adaptive adaptation between single and dual encoders, solves the technical defects of existing optical-magnetic hybrid encoders, and takes into account both basic accuracy and high-precision scenario requirements, thus having broad application prospects.

[0091] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-turn memory magneto-encoder hybrid system, characterized by, The system comprises an optical encoder, a magnetic signal acquisition sensor, a processor, a hardware circuit, an ultra-low power consumption circuit, and signal acquisition, signal processing, fault-tolerant correction, low power consumption and angle analysis modules integrated in the system. The processor is electrically connected with the hardware circuit, the ultra-low power consumption circuit, the magnetic signal acquisition sensor and the optical encoder, the angle analysis module is integrated with a magnetic angle analysis algorithm for analyzing the electric signal output by the magnetic signal acquisition sensor in response to the change of the magnetic field into an absolute position value; the signal processing module comprises a number of memory and correction algorithms for storing, reading and automatically correcting the memory value; the signal acquisition module is used for synchronously acquiring the optical signal output by the optical encoder and the magnetic signal output by the magnetic signal acquisition sensor and transmitting the acquired signals to the signal processing module; the fault-tolerant correction module is used for checking and correcting the acquired signals and the calculated position information, and the low power consumption module is used for controlling the power consumption of the system. The system further comprises a plurality of pairs of unequal magnetic rings which are arranged in cooperation with the magnetic signal acquisition sensor to provide a coarse position detection reference; the signal processing module is provided with a coarse position decoding module which identifies a plurality of position areas through a binary encoder based on the magnetic signals of the plurality of pairs of unequal magnetic rings acquired by the magnetic signal acquisition sensor and outputs an n-bit coarse position code; The magnetic angle analysis algorithm of the angle analysis module comprises an adaptive compensation algorithm which includes a temperature compensation algorithm and an error self-calibration algorithm for compensating the temperature error and correcting the real-time error of the absolute position value obtained through analysis; The fault-tolerant correction module adopts a double-redundancy design including double-sensor redundancy and double-storage redundancy; the double-sensor redundancy is a mutual backup of the optical encoder and the magnetic signal acquisition sensor, and when one of the two sensors fails, the other sensor continues to output signals; the double-storage redundancy is a double backup storage of important parameters in the system to avoid parameter loss; The signal processing module has a signal mode switching function including an optical signal dominant mode, a magnetic signal backup mode and an intelligent dynamic weight adjustment algorithm based on signal quality evaluation; in a clean environment, the system switches to the optical signal dominant mode and preferentially uses the signals output by the optical encoder for position calculation; in a polluted environment, the system switches to the magnetic signal backup mode and uses the signals output by the magnetic signal acquisition sensor for position calculation; the intelligent dynamic weight adjustment algorithm dynamically adjusts the weight of the two signals in position calculation according to the quality evaluation results of the optical signal and the magnetic signal; The number of memory and correction algorithms of the signal processing module comprises a position matching algorithm which includes an absolute position and number of memory value matching method and a reference position dynamic updating algorithm; the absolute position and number of memory value matching method is used for associating and matching the absolute position value obtained by the angle analysis module with the number of memory value, and the reference position dynamic updating algorithm is used for updating the reference position according to the real-time calculation result to improve the position matching accuracy. The functions of the low-power module include configuring the processor into a low-power mode, and a smart power management function; the smart power management function adjusts the power supply according to the working state of the system, prolonging the running time of the system without external power supply; The multi-turn memory optical-magnetic encoder hybrid system also comprises a built-in metal shielding layer made of permalloy and arranged outside the magnetic signal acquisition sensor, which is used to isolate the magnetic field interference in the external environment and ensure the accuracy of the signal acquisition of the magnetic signal acquisition sensor; The hardware circuit comprises core control hardware, signal acquisition hardware, signal processing hardware and fault-tolerant and anti-interference hardware; the core control hardware is a micro control unit integrating a special operation unit for magnetic angle analysis algorithm, which is connected with the optical encoder and the magnetic signal acquisition sensor through an SPI interface and connected with the ultra-low power circuit through an I2C interface; the signal acquisition hardware comprises a magnetic signal acquisition circuit comprising a gallium arsenide sensor and a signal conditioning circuit, and an optical signal acquisition circuit comprising an optical-electric conversion circuit, an operation single-ended output circuit, a comparator circuit and a differential operation circuit; the signal processing hardware comprises a double storage circuit composed of a non-volatile memory and a coarse position decoding hardware module; the fault-tolerant and anti-interference hardware comprises a metal shielding layer made of permalloy, a surge suppression circuit and an electromagnetic compatibility filter circuit; The working process of the multi-turn memory optical-magnetic encoder hybrid system is as follows: Step 1. Signal acquisition stage: the optical encoder converts the optical signal into an initial electric signal through an internal optical-electric conversion circuit, amplifies the signal through an operation single-ended output circuit, discriminates and removes noise through a comparator circuit threshold, converts the signal into an anti-interference differential signal through a differential operation circuit, and then transmits the signal to a signal acquisition module; the magnetic signal acquisition sensor acquires the magnetic field signal generated in cooperation with multiple pairs of uneven magnetic rings, converts the signal into an electric signal, and then transmits the signal to the signal acquisition module; the signal acquisition module synchronously receives the two signals and transmits them to a signal processing module; Step 2. Signal processing and position solving stage: the coarse position decoding module in the signal processing module identifies the position area based on the magnetic signal through a binary encoder and outputs an n-bit coarse position code to quickly determine the position range; the angle analysis module relies on the integrated magnetic angle analysis algorithm to analyze the electric signal corresponding to the magnetic signal into a position absolute value, and the adaptive compensation algorithm in the algorithm offsets the temperature error of the position absolute value and corrects the real-time deviation; at the same time, the turn number memory and correction algorithm of the signal processing module realizes the storage and reading of the turn number memory value, the position matching algorithm contained therein associates and matches the position absolute value output by the angle analysis module with the turn number memory value, and corrects the reference position according to the real-time solving result through the reference position dynamic updating algorithm, finally completing the accurate position solving; Step 3. Fault tolerance and power consumption control stage: The fault tolerance correction module ensures system stability through dual redundancy design. Dual sensor redundancy allows the optical encoder and magnetic signal acquisition sensor to back up each other, so that either sensor can continue to output signals when one fails. Dual storage redundancy provides double backup storage for important system parameters, preventing parameter loss. Surge suppression circuit, electromagnetic compatibility filter circuit, and permalloy metal shielding layer outside the magnetic signal acquisition sensor further reduce external electromagnetic and magnetic field interference. Low-power modules achieve power consumption control by configuring the processor to low-power mode and adjusting power supply power according to the working state through intelligent power management function. The power management unit, sleep wake-up circuit, and dynamic power adjustment circuit of the ultra-low power circuit further optimize power consumption control. Step 4. Environmental adaptation stage: The signal mode switching function of the signal processing module dynamically adjusts the working mode according to the environmental state. In a clean environment, it switches to the photoelectric signal dominant mode, which prioritizes high-precision photoelectric signal for position calculation. In a polluted environment, it switches to the magnetic signal backup mode, relying on the anti-pollution characteristics of magnetic signals to ensure signal reliability. The intelligent dynamic weight adjustment algorithm based on signal quality evaluation dynamically adjusts the weight of optical and magnetic signals in position calculation according to their quality, ensuring accuracy and reliability of position calculation in different environments. The self-developed magnetic angle analysis algorithm includes an adaptive compensation algorithm and an error self-calibration algorithm. The adaptive compensation algorithm includes a temperature compensation algorithm and a magnetic signal error compensation algorithm. Temperature compensation algorithm: Real-time collection of environmental temperature data from the system's temperature sensor, establishment of a temperature and magnetic signal analysis error correlation model. When the environmental temperature changes, the algorithm automatically retrieves the preset compensation parameters according to the model to correct the position absolute value corresponding to the output electrical signal of the magnetic signal acquisition sensor, offsetting the magnetic signal sensing deviation caused by temperature changes and ensuring stable position analysis accuracy at different temperatures. Error self-calibration algorithm: Using the high-resolution signal output by the optical encoder as a reference, periodically compare the position absolute value obtained by magnetic signal analysis with the optical signal calculation result. If the deviation exceeds the preset threshold, the algorithm automatically calculates the deviation and generates a calibration coefficient to update the magnetic angle analysis parameters and correct the cumulative error in the magnetic signal analysis process in real time without the need for manual intervention to maintain analysis accuracy.

2. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The optical encoder includes a photoelectric conversion circuit, an operation single-end output circuit, a comparator circuit, and a differential operation circuit. The photoelectric conversion circuit is used to convert optical signals into initial electrical signals. The operation single-end output circuit, the comparator circuit, and the differential operation circuit sequentially process the initial electrical signals, and the processed electrical signals are transmitted to the processor.

3. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The magnetic signal acquisition sensor is a gallium arsenide sensor. The gallium arsenide sensor is electrically connected with the signal acquisition module and is used to acquire external magnetic field signals and convert the magnetic field signals into electrical signals, which are then transmitted to the signal acquisition module.

4. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The ultra-low power circuit comprises a power management unit, a hibernation wake-up circuit and a dynamic power consumption adjustment circuit; the power management unit is a low static current power management chip with multi-grade output voltage adjustment function, which is connected with the micro control unit to receive power consumption control instructions; the hibernation wake-up circuit comprises a signal trigger wake-up sub-circuit for detecting signal changes and a timing wake-up sub-circuit composed of a low power real-time clock; the dynamic power consumption adjustment circuit is linked with the signal acquisition module, and can cut off the redundant power supply of the optical encoder and adjust the operating frequency of the micro control unit according to the position change state.

5. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The coarse position decoding algorithm is specifically as follows: based on the magnetic signal acquisition sensor, a plurality of pairs of magnetic ring magnetic field signals are collected; the algorithm first filters and denoises the magnetic signals to eliminate environmental interference signals; then, through a binary encoder logic, a plurality of position regions divided by the plurality of pairs of magnetic ring magnetic field signals are corresponded to preset binary codes, a current position region to which the magnetic field signal belongs is identified, and an n-bit coarse position code is outputted. The code directly defines a large region where the current mechanical angle is located, provides an initial range for subsequent accurate position calculation, avoids the process of searching for a zero point by an incremental encoder, and shortens the position positioning time.

6. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The number of laps memory and correction algorithm is specifically as follows: The number of laps memory value storage and reading: a double storage circuit composed of a non-volatile memory in a hardware circuit is used to synchronously store the number of laps memory value calculated each time to two storage units; when reading, the data in the main storage unit is preferentially called, and if the data in the main storage unit is abnormal, the data in the backup storage unit is automatically switched to read, so as to prevent the loss of the number of laps memory value; Double signal source lap automatic correction: the number of laps change quantity calculated by the optical encoder signal and the number of laps change quantity calculated by the magnetic signal are compared in real time; If the two are inconsistent and the deviation exceeds the allowed range, the algorithm judges the signal effectiveness, and the number of laps corresponding to the effective signal is used as the criterion to correct the number of laps calculation result of the other signal, so as to ensure the accuracy of the number of laps record.

7. The multi-turn memory magneto-encoder hybrid system of claim 1, wherein, The position matching algorithm is specifically as follows: Absolute position and number of laps memory value matching: the absolute value of the angle analysis module output is associated with the number of laps memory value, and a corresponding relationship between the number of laps and the absolute position is established; after each calculation, the algorithm verifies whether the current absolute position value is within the preset position range of the corresponding number of laps, and if it is out of range, the number of laps memory value or the absolute position value is automatically adjusted to ensure that the two are matched and consistent; Dynamic update of reference position: based on the accurate position results of multiple continuous calculations, the algorithm calculates the position change trend in real time; when it is detected that the position calculation result is stable, the current position is automatically updated as a new reference position to replace the initial reference position, so as to avoid the influence of the deviation of the initial reference position on the subsequent calculation accuracy.

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