Incremental encoder fault detection method and device

Abstract

The invention provides a fault detection method and device for an incremental encoder. The fault detection method for the incremental encoder comprises the following steps: acquiring a real-time signal value of the incremental encoder; discretizing the real-time signal value based on a preset time period to obtain a plurality of real-time discrete intervals; determining a real-time ratio of each real-time discrete interval according to the preset time period and the real-time discrete intervals; and diagnosing the fault of the incremental encoder according to the real-time ratio and the normal ratio. According to the method, the purpose of quickly discovering the hidden fault of the incremental encoder can be achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rolling production control, and in particular to a kind of incremental encoder fault detection method and device. BACKGROUND

[0002] Incremental encoder is an important detection element of rolling production equipment, when incremental encoder appears 0 value, fixed value, jump value etc., it will cause electrical transmission device to report fault or electrical transmission device action disorder.Especially when incremental encoder signal jumps due to external installation environment and body fault interaction, transmission device dynamic adjustment function is abnormally obvious in some speed section, such as transmission device fast fault shutdown.

[0003] Therefore, it is necessary to quickly find the hidden fault of incremental encoder. SUMMARY

[0004] The present application provides a kind of incremental encoder fault detection method and device, to solve the technical problem of how to quickly find the hidden fault of incremental encoder.

[0005] The present application provides a kind of incremental encoder fault detection method, the method comprises:

[0006] obtain the real-time signal value of incremental encoder;

[0007] The real-time signal value is dispersed based on preset time period, to obtain multiple real-time discrete intervals;

[0008] According to the preset time period and the real-time discrete interval, the real-time ratio of each real-time discrete interval is determined;

[0009] According to the real-time ratio and normal ratio, the fault of the incremental encoder is diagnosed.

[0010] In an embodiment of the present application, the real-time signal value is dispersed based on preset time period, to obtain multiple real-time discrete intervals, comprising:

[0011] Based on the real-time signal value, the real-time running speed of the incremental encoder is determined;

[0012] According to the real-time running speed, the real-time signal value is divided into acceleration section, uniform speed section and deceleration section;

[0013] The real-time signal value in the acceleration section, the uniform speed section and the deceleration section is dispersed according to preset time period, to obtain multiple real-time discrete intervals.

[0014] In an embodiment of the present application, the method further comprises:

[0015] obtaining a normal signal value of the incremental encoder in normal operation;

[0016] determining a normal running speed of the incremental encoder based on the normal signal value;

[0017] dividing the normal signal value into an acceleration section, a constant speed section and a deceleration section according to the normal running speed;

[0018] discretizing the normal signal value in the acceleration section, the constant speed section and the deceleration section into a plurality of normal discrete intervals based on the preset time period, and determining a normal ratio of each normal discrete interval;

[0019] comparing the normal ratios of the acceleration section, the constant speed section and the deceleration section to determine a minimum ratio, a maximum ratio and an average ratio of the normal ratios in each stage.

[0020] In an embodiment of the present application, the method further comprises:

[0021] if an increment of the subsequent real-time running speed compared with the previous real-time running speed is less than a first preset value, or an increment of the subsequent normal running speed compared with the previous normal running speed is less than the first preset value, it is determined that the incremental encoder enters the acceleration section;

[0022] if a decrement of the subsequent real-time running speed compared with the previous real-time running speed is greater than a second preset value, or a decrement of the subsequent normal running speed compared with the previous normal running speed is greater than the second preset value, it is determined that the incremental encoder enters the deceleration section.

[0023] In an embodiment of the present application, the diagnosing the fault of the incremental encoder according to the real-time ratio and the normal ratio comprises:

[0024] comparing the real-time ratio with the normal ratio to obtain a comparison result;

[0025] diagnosing the fault of the incremental encoder based on the comparison result.

[0026] In an embodiment of the present application, when the incremental encoder is in the acceleration section;

[0027] if the real-time ratio is within a preset range of the average ratio, it is determined that the incremental encoder is in normal operation;

[0028] if the real-time ratio is greater than the maximum ratio, a first difference between the two is determined;

[0029] if the first difference is greater than a first threshold of the average ratio, it is determined that the incremental encoder is in a first fault.

[0030] In an embodiment of the present application, the incremental encoder is in a uniform speed section;

[0031] If the real-time ratio is within a preset range of the average ratio, it is determined that the incremental encoder is in normal operation;

[0032] If the real-time ratio is greater than the maximum value, a second difference between the two is determined;

[0033] If the second difference is greater than a second threshold value of the average ratio, a counter is started;

[0034] When the counter detects that the incremental encoder is sampled for a preset sampling period, if the second difference is still greater than the second threshold value of the average ratio, the counter counts the number of occurrences of the second difference;

[0035] If the number of occurrences is greater than a third preset value, it is determined that the incremental encoder is in a second fault;

[0036] If the number of occurrences is less than the third preset value, it is determined that the incremental encoder is in a third fault.

[0037] In an embodiment of the present application, the incremental encoder is in a deceleration section;

[0038] If the real-time ratio is within a preset range of the average ratio, it is determined that the incremental encoder is in normal operation;

[0039] If the real-time ratio is opposite in sign, it is determined that the incremental encoder is in a third fault.

[0040] The present application also provides an incremental encoder fault detection device for implementing the incremental encoder fault detection method as described in any one of the above embodiments, comprising:

[0041] An acquisition module is configured to acquire a real-time signal value of an incremental encoder;

[0042] A discretization module is configured to discretize the real-time signal value based on a preset time period to obtain a plurality of real-time discrete intervals;

[0043] A ratio module is configured to determine a real-time ratio of each of the real-time discrete intervals according to the preset time period and the real-time discrete intervals;

[0044] A fault detection module is configured to diagnose a fault of the incremental encoder according to the real-time ratio and a normal ratio.

[0045] The present application provides a kind of incremental encoder fault detection method and device, by obtaining the real-time signal value of incremental encoder, and based on the preset time period discrete real-time signal value, to obtain a plurality of real-time discrete intervals, subsequently according to the preset time period and real-time discrete interval, determine the real-time ratio of each real-time discrete interval, and according to real-time ratio and normal ratio, diagnose the fault of incremental encoder, to realize the purpose of quickly finding the hidden fault of incremental encoder. BRIEF DESCRIPTION OF DRAWINGS

[0046] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments consistent with the present application and, together with the description, further serve to explain the principles of the application. It is to be expressly understood that the drawings are included solely for purposes of illustration and are not to be construed as a limitation of the present application. It is to be understood that the description and drawings included herein are intended to be exemplary, illustrative, and not limiting of the various aspects of the present application. Those skilled in the art will readily appreciate that other embodiments of the present application can be used without departing from the spirit and scope of the present application.

[0047] In the drawings:

[0048] Figure 1 The flow chart of the incremental encoder fault detection method provided by an embodiment of the present application is shown in the figure;

[0049] Figure 2 The block diagram of the incremental encoder fault detection device provided by an embodiment of the present application is shown in the figure. DETAILED DESCRIPTION

[0050] The present application is described herein with reference to particular embodiments for a purpose of clarity and understanding. Those of ordinary skill in the art will readily appreciate the other advantages and objects of the present application upon study of the description herein. The present application can be practiced with other embodiments and in other subsystems without departing from the spirit and essential characteristics of the present application. The embodiments described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each embodiment should typically be considered as available for combination with features or aspects of the other embodiments.

[0051] It should be noted that the drawings provided in the following embodiments only schematically illustrate the basic concept of the present application, and the drawings only show the components related to the present application, not the number, shape and size of the components when actually implemented. The actual implementation of each component can be randomly changed, and the component layout pattern can be more complex.

[0052] In the following description, a large number of details are discussed in order to provide a more thorough explanation of embodiments of the application, however, it will be readily apparent to those skilled in the art that the embodiments of the present application can be practiced without these specific details, in other embodiments, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the embodiments of the present application.

[0053] Referring to Figure 1 In an embodiment, the method for detecting the failure of the incremental encoder can include steps S110-S140, which are described in detail as follows.

[0054] In step S110, a real-time signal value of the incremental encoder is obtained.

[0055] In some embodiments, during rotation of the incremental encoder, the controller counts the number of pulses of the incremental encoder and converts the number of pulses into an electrical signal, thereby obtaining the real-time signal value of the incremental encoder.

[0056] In step S120, the real-time signal value is discretized based on a preset time period, thereby obtaining a plurality of real-time discrete intervals.

[0057] In some embodiments, the real-time signal value of the incremental encoder obtained within a unit time can be used to calculate the rotational speed of the rotational shaft of the incremental encoder, thereby obtaining the real-time running speed of the incremental encoder. According to the real-time running speed of the incremental encoder, the acceleration section, the constant speed section, and the deceleration section of the incremental encoder can be determined, that is, all the real-time signal values obtained are divided into the acceleration section, the constant speed section, and the deceleration section.

[0058] In an example, if the increment of the next real-time running speed compared to the previous real-time running speed is less than a first preset value, it is determined that the incremental encoder enters the acceleration section. For example, the first preset value can be that the increment of the next real-time running speed compared to the previous real-time running speed is 5%.

[0059] If the decrement of the next real-time running speed compared to the previous real-time running speed is greater than a second preset value, it is determined that the incremental encoder enters the deceleration section. For example, the second preset value can be that the decrement of the next real-time running speed compared to the previous real-time running speed is 10% or 15%. It should be noted that before the decrement of the next real-time running speed compared to the previous real-time running speed is greater than the second preset value, it is necessary to detect that the decrement of the next real-time running speed compared to the previous real-time running speed is 5%.

[0060] It should be noted that when the controller drives the incremental encoder to run, it is the start point of the incremental encoder. When the speed of the incremental encoder is zero, it is the stop point of the incremental encoder.

[0061] After the real-time signal values of the acceleration section, the constant speed section, and the deceleration section of the incremental encoder are determined, the real-time signal values in each section are discretized based on a preset time period, thereby obtaining a plurality of real-time discrete intervals in each section.

[0062] At step S130, the real-time ratio of each real-time discrete interval is determined according to the preset time period and the real-time discrete interval.

[0063] In some embodiments, the real-time signal difference value of each real-time discrete interval is determined according to the real-time signal values at the beginning and the end of each real-time discrete interval, i.e., the slope value of each real-time discrete interval is determined, and the ratio of the real-time signal difference value to the preset time period is calculated to obtain the real-time ratio of each real-time discrete interval.

[0064] At step S140, the fault of the incremental encoder is diagnosed according to the real-time ratio and the normal ratio.

[0065] In some embodiments, the normal ratio of the incremental encoder in normal operation needs to be determined before the incremental encoder is formally put into production. The normal signal value of the incremental encoder in normal operation is obtained, and the normal operation speed of the incremental encoder is determined according to the normal signal value. Subsequently, the normal signal value of the incremental encoder is divided into an acceleration segment, a constant speed segment, and a deceleration segment according to the normal operation speed of the incremental encoder.

[0066] In an example, if the increment of the subsequent normal operation speed compared to the previous normal operation speed is less than a first preset value, it is determined that the incremental encoder enters the acceleration segment. For example, the first preset value can be that the increment of the subsequent normal operation speed compared to the previous normal operation speed is 5%.

[0067] If the decrement of the subsequent normal operation speed compared to the previous normal operation speed is greater than a second preset value, it is determined that the incremental encoder enters the deceleration segment. For example, the second preset value can be that the decrement of the subsequent normal operation speed compared to the previous normal operation speed is 10% or 15%. It should be noted that before the decrement of the subsequent normal operation speed compared to the previous normal operation speed is greater than the second preset value, it is necessary to detect that the decrement of the subsequent normal operation speed compared to the previous normal operation speed is 5%.

[0068] It should be noted that when the controller drives the incremental encoder to run, it is the start point of the incremental encoder. When the speed of the incremental encoder is zero, it is the stop point of the incremental encoder.

[0069] The plurality of normal signal values in the acceleration segment, the constant speed segment, and the deceleration segment are discretized based on the preset time period to obtain a plurality of normal discrete intervals. The normal signal difference value of each normal discrete interval is determined according to the normal signal values at the beginning and the end of each normal discrete interval. Subsequently, the normal ratio of each normal discrete interval is determined based on the normal signal difference value and the preset time period.

[0070] Subsequently, the normal ratios in the acceleration section, the constant speed section, and the deceleration section are compared to determine the minimum ratio, the maximum ratio, and the average ratio in each section.

[0071] In some embodiments, the incremental encoder compares the real-time ratio in the acceleration section, the constant speed section, and the deceleration section with the normal ratio during operation to obtain a comparison result. The comparison result is used to diagnose the fault of the incremental encoder.

[0072] In an example, when the incremental encoder is in the acceleration section, if the real-time ratio in the acceleration section is within a preset range of the average ratio in the acceleration section, it is determined that the incremental encoder is operating normally. For example, the preset range of the average ratio in the acceleration section can be ±5% of the average ratio in the acceleration section.

[0073] If the real-time ratio in the acceleration section is greater than the maximum ratio in the acceleration section, a first difference between the two is determined, and the first difference is compared with a first threshold of the average ratio in the acceleration section. If the first difference is greater than the first threshold of the average ratio in the acceleration section, it is determined that the incremental encoder has a first fault. For example, the first threshold of the average ratio in the acceleration section can be 2 times the average ratio in the acceleration section. The first fault can be a loose installation of the incremental encoder.

[0074] In an example, when the incremental encoder is in the constant speed section, if the real-time ratio in the constant speed section is within a preset range of the average ratio in the constant speed section, it is determined that the incremental encoder is operating normally. For example, the preset range of the average ratio in the constant speed section can be ±5% of the average ratio in the constant speed section.

[0075] If the real-time ratio in the constant speed section is greater than the maximum ratio in the constant speed section, a second difference between the two is calculated. If the second difference is greater than a second threshold of the average ratio in the constant speed section, a counter is started. For example, the second threshold of the average ratio in the constant speed section can be 1.1 times the average ratio in the constant speed section.

[0076] The counter counts the sampling period of the incremental encoder. When the sampling period of the incremental encoder reaches a preset sampling period, if the second difference is still greater than the second threshold of the average ratio in the constant speed section, the counter counts the number of occurrences of the second difference. For example, the preset sampling period can be set to 3 sampling periods.

[0077] If the number of occurrences of the second difference is greater than a third preset value, it is determined that the incremental encoder has a second fault. For example, the second fault of the incremental encoder is a cable fault of the incremental encoder. If the number of occurrences of the second difference is less than the third preset value, it is determined that the incremental encoder has a third fault. For example, the third fault of the incremental encoder is a body fault of the incremental encoder. For example, the third preset value can be set to 2 times.

[0078] In an example, when the incremental encoder is in the deceleration section, if the real-time ratio of the deceleration section is in a preset range of the average ratio of the deceleration section, it is determined that the incremental encoder is in normal operation. For example, the preset range of the average ratio of the deceleration section can be ±5% of the average ratio of the deceleration section.

[0079] If the sign of the real-time ratio of the deceleration section is opposite, that is, the direction of the speed change of the incremental encoder is suddenly opposite, it is determined that the incremental encoder is in the third fault. For example, the third fault of the incremental encoder is the body fault of the incremental encoder.

[0080] Referring to Figure 2 , an embodiment of the present application provides an incremental encoder fault detection device, which is used to implement the incremental encoder fault detection method described above. As shown in Figure 2 , the incremental encoder fault detection device 200 comprises:

[0081] The acquisition module 210 is configured to acquire a real-time signal value of the incremental encoder.

[0082] The discretization module 220 is configured to discretize the real-time signal value based on a preset time period to obtain a plurality of real-time discrete intervals.

[0083] The ratio module 230 is configured to determine a real-time ratio of each real-time discrete interval according to the preset time period and the real-time discrete interval.

[0084] The fault detection module 240 is configured to diagnose the fault of the incremental encoder according to the real-time ratio and the normal ratio.

[0085] The above-described embodiments are only illustrative of the principles and effects of the present application, and are not intended to limit the present application. Any person skilled in the art can modify or change the above-described embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes made by those skilled in the art without departing from the spirit and technical thought of the present application should be covered by the claims of the present application.

Claims

1. A fault detection method for an incremental encoder, characterized in that, The method includes: Obtain the real-time signal value of the incremental encoder; The real-time signal values ​​are discrete based on a preset time period to obtain multiple real-time discrete intervals; Based on the preset time period and the real-time discrete interval, determine the real-time ratio of each real-time discrete interval; The faults of the incremental encoder are diagnosed based on the real-time ratio and the normal ratio.

2. The incremental encoder fault detection method according to claim 1, characterized in that: The step of discretizing the real-time signal value based on a preset time period to obtain multiple real-time discrete intervals includes: Based on the real-time signal value, the real-time operating speed of the incremental encoder is determined; Based on the real-time operating speed, the real-time signal value is divided into an acceleration segment, a constant speed segment, and a deceleration segment; The real-time signal values ​​within the acceleration segment, the constant speed segment, and the deceleration segment are discretized according to a preset time period to obtain multiple real-time discrete intervals.

3. The incremental encoder fault detection method according to claim 2, characterized in that, The method further includes: Obtain the normal signal value of the incremental encoder when it is working properly; Based on the normal signal value, the normal operating speed of the incremental encoder is determined; Based on the normal operating speed, the normal signal value is divided into an acceleration segment, a constant speed segment, and a deceleration segment; The normal signal values ​​within the acceleration segment, the constant speed segment, and the deceleration segment are discretized based on the preset time period to obtain multiple normal discrete intervals, and the normal ratio value of each normal discrete interval is determined. By comparing multiple normal ratios of the acceleration phase, the constant speed phase, and the deceleration phase, the minimum ratio, the maximum ratio, and the average ratio of the normal ratio within each phase are determined.

4. The incremental encoder fault detection method according to claim 3, characterized in that, The method further includes: If the increment of the real-time operating speed described later compared to the real-time operating speed described earlier is less than a first preset value, or the increment of the normal operating speed described later compared to the normal operating speed described earlier is less than a first preset value, then it is determined that the incremental encoder has entered the acceleration phase. If the reduction in the real-time operating speed of the latter compared to the real-time operating speed of the former is greater than a second preset value, or the reduction in the normal operating speed of the latter compared to the normal operating speed of the former is greater than a second preset value, then the incremental encoder is determined to have entered the deceleration phase.

5. The incremental encoder fault detection method according to claim 3, characterized in that: The step of diagnosing faults in the incremental encoder based on the real-time ratio and the normal ratio includes: Compare the real-time ratio with the normal ratio to obtain the comparison result; Based on the comparison results, the fault of the incremental encoder is diagnosed.

6. The incremental encoder fault detection method according to claim 5, characterized in that: When the incremental encoder is in the acceleration phase; If the real-time ratio is within a preset range of the average ratio, then the incremental encoder is determined to be operating normally. If the real-time ratio is greater than the maximum ratio, then the first difference between the two is determined; If the first difference is greater than a first threshold of the average ratio, then the incremental encoder is determined to be a first fault.

7. The incremental encoder fault detection method according to claim 5, characterized in that: When the incremental encoder is in the constant speed range; If the real-time ratio is within a preset range of the average ratio, then the incremental encoder is determined to be operating normally. If the real-time ratio is greater than the maximum value, then a second difference between the two is determined; If the second difference is greater than the second threshold of the average ratio, then the counter is started; When the counter detects that the incremental encoder has been sampled for a preset sampling period, if the second difference is still greater than the second threshold of the average ratio, the counter counts the number of times the second difference occurs. If the number of occurrences exceeds a third preset value, then the incremental encoder is determined to be a second fault. If the number of occurrences is less than a third preset value, then the incremental encoder is determined to be a third fault.

8. The incremental encoder fault detection method according to claim 5, characterized in that, include: When the incremental encoder is in the deceleration phase; If the real-time ratio is within a preset range of the average ratio, then the incremental encoder is determined to be operating normally. If the signs of the real-time ratios are opposite, then the incremental encoder is determined to be a third fault.

9. A fault detection device for an incremental encoder, characterized in that, A method for implementing the incremental encoder fault detection method as described in any one of claims 1-8, comprising: The acquisition module is used to acquire the real-time signal value of the incremental encoder; The discrete module is used to discrete the real-time signal value based on a preset time period to obtain multiple real-time discrete intervals; The ratio module is used to determine the real-time ratio of each real-time discrete interval based on the preset time period and the real-time discrete interval. The fault detection module is used to diagnose faults in the incremental encoder based on the real-time ratio and the normal ratio.

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