Sensor detection device

Abstract

The invention relates to the technical field of sensor detection, and discloses a sensor detection device which comprises a box body, a control unit, an installation adjusting mechanism used for installing a sensor and a fluted disc matched with the sensor, an installation frame is fixedly installed in the box body, a servo motor is fixedly installed on the installation frame, and a transition shaft is fixedly installed on an output shaft of the servo motor. According to the invention, the high-precision movement of less than or equal to + / -0.01 mm is realized by installing the adjusting mechanism, and the driving module with the positioning precision of less than or equal to + / -0.005 mm and the laser distance measuring sensor with the distance measuring precision of less than or equal to + / -0.002 mm are matched, so that the accurate and controllable detection gap adjustment is ensured; the number of teeth of a fluted disc is limited to be 12-120, the rotating speed of the servo motor is stabilized to be 500-3000 r / min, and the quantitative evaluation of a signal quality evaluation value (a signal-to-noise ratio and pulse duty ratio deviation comprehensive score) is combined, so that subjective errors and signal distortion caused by manual adjustment are effectively avoided, the function detection result of the Hall sensor is more accurate, the data repeatability is higher, and the detection error is controlled within a minimum range.

Description

Technical Field

[0001] This invention relates to the field of sensor detection technology, and more specifically to a sensor detection device. Background Technology

[0002] Hall effect sensors, as magnetic sensing elements based on the Hall effect, are widely used in industrial automation, automotive electronics (such as crankshaft / camshaft position sensing and ABS wheel speed sensing), smart home appliances, security, and aerospace due to their non-contact, long lifespan, and high frequency response characteristics. They typically operate by sensing periodic changes in the magnetic field caused by a moving metal target (such as a gear) and outputting corresponding pulse signals, thereby achieving precise measurement of physical quantities such as rotational speed and position.

[0003] To ensure the performance and quality of Hall sensors, functional and performance testing before shipment or during use is crucial. Currently, Hall sensor testing primarily relies on dedicated testing equipment or fixtures. A typical testing scheme involves providing a standard gear (gear disk) driven by a motor, fixing the Hall sensor under test to the side of the gear, and adjusting the gap (air gap) between the sensor's sensing surface and the gear tooth tip. The sensor's output signal is collected as the gear rotates and compared with a standard rotational speed to determine whether the sensor functions correctly and whether its accuracy meets the standards.

[0004] For example, Chinese invention patent CN119471015BA discloses a current detection device for a Hall current sensor, including: a detection box, which internally contains an inner core assembly mechanism. The inner core assembly mechanism comprises: a circuit board and two fixing components; the circuit board has a pin port for installing the Hall sensor inner core, and a magnetic ring is positioned directly above the pin port. The Hall sensor inner core can be inserted into the pin port on the circuit board, and by rotating the circuit board counterclockwise, the Hall sensor inner core moves into the magnetic ring, forming a simple plate Hall current sensor structure. This invention achieves rapid installation and positioning of the Hall sensor inner core through the inner core assembly mechanism. The pin port design on the circuit board allows the Hall sensor inner core to be easily inserted and fixed. At the same time, by rotating the circuit board counterclockwise, the inner core can be accurately moved into the magnetic ring, forming a stable plate Hall current sensor structure.

[0005] However, existing detection devices of this type generally use the traditional method of manually adding or removing metal or non-metal shims to adjust the sensor mounting gap, which has the following prominent defects and technical problems that urgently need to be solved: The adjustment process is inefficient and cumbersome: every time a sensor is replaced or recalibration is required, operators must remove the sensor, manually try adding or removing shims of different thicknesses, and repeatedly install and test until a satisfactory signal is obtained. This process is time-consuming and labor-intensive, severely limiting detection efficiency and making it difficult to meet the demands of modern production lines for rapid, batch testing.

[0006] Poor adjustment precision and inconsistency: The thickness specifications of the gaskets are discrete (e.g., 0.1mm, 0.2mm, 0.5mm), making continuous, stepless, and precise adjustment impossible. The optimal working gap often lies between two discrete gasket thicknesses, making it impossible to precisely set to the theoretically optimal value. Furthermore, the process is highly dependent on the operator's experience and feel; different operators or even the same person setting the gap at different times may result in significant differences, leading to inconsistent testing conditions and directly affecting the comparability and reliability of the test results.

[0007] Lack of quantification and traceability: After manual shim adjustment, the actual detection gap value cannot be accurately measured and recorded. The test report can only record "adjusted," but cannot provide the precise "gap value," a crucial test condition. When product quality disputes arise or retesting is required, the original test conditions cannot be accurately reproduced, leading to difficulties in data traceability and hindering quality analysis and process control.

[0008] The inability to achieve automation and intelligence: The manual operation mode based on gaskets cannot be executed by automated equipment (such as robotic arms) and is difficult to interact with host computer systems (such as MES manufacturing execution systems). This hinders the integration of the inspection device into a fully automated production line, which is inconsistent with the development trend of Industry 4.0 and intelligent manufacturing.

[0009] Poor adaptability to new sensors and complex operating conditions: With technological advancements, new Hall sensors exhibit varying sensitivities and operating points, and the requirements for optimal detection distances are becoming increasingly refined and diverse. Manual trial-and-error methods are insufficient for quickly and accurately adapting to these new models. Furthermore, in tests requiring the simulation of different installation tolerances or the effects of harsh environments, it is impossible to quickly and precisely adjust the clearance to simulate specific operating conditions. Summary of the Invention

[0010] The purpose of this invention is to provide a sensor detection device to solve the problems mentioned in the background art.

[0011] To achieve the above objectives, the present invention provides the following technical solution: A sensor detection device includes a housing, a control unit, a mounting and adjustment mechanism for mounting a sensor, and a geared disc that mates with the sensor. A housing cover is fixedly mounted on the top of the housing, a mounting frame is fixedly mounted inside the housing, a servo motor is fixedly mounted on the mounting frame, a transition shaft is fixedly mounted on the output shaft of the servo motor, and a geared disc is fixedly mounted on the outer side of the transition shaft. The geared disc has 12 to 120 teeth. The mounting and adjustment mechanism has a movement accuracy of ≤ ±0.01 mm. The system comprises an installation platform, a drive module for driving the installation platform to move radially along a toothed disc, and a position feedback unit for real-time feedback of the installation platform's position. A Hall sensor is fixedly mounted on the installation platform, and an adjustable detection gap is formed between the detection surface of the Hall sensor and the tooth tip of the toothed disc, with the detection gap adjustable from 0.1mm to 5mm. The control unit includes a signal acquisition module, a signal processing module, and a drive control module. The control unit is configured to: control the drive module to traverse the adjustable range of the detection gap at preset step distances of 0.05mm to 0.1mm; at each gap position, control the servo motor to drive the toothed disc to rotate uniformly at a speed of 500 to 3000 r / min, and acquire the output pulse signal of the Hall sensor through the signal acquisition module; calculate the signal quality evaluation value of the output pulse signal through the signal processing module, where the signal quality evaluation value is a comprehensive score of the signal-to-noise ratio and pulse duty cycle deviation; compare the signal quality evaluation values ​​of all gap positions to determine the target gap with the highest evaluation value; and control the drive module to move the installation platform and lock it to the target gap.

[0012] Furthermore, the inner side of the mounting platform is provided with an internal thread, and the outer side of the Hall sensor is provided with an external thread that matches the internal thread of the mounting platform.

[0013] Furthermore, the drive module includes a fixed frame, a stepper motor, a lead screw, and a movable frame. The fixed frame is fixedly installed on the outside of the housing, the stepper motor is fixedly installed on the side of the fixed frame, the step angle of the stepper motor is ≤1.8°, the output shaft of the stepper motor is fixedly connected to the lead screw, the lead of the lead screw is 0.5~2mm, the movable frame is threaded to the outside of the lead screw and fixedly connected to the mounting platform, and the positioning accuracy of the drive module is ≤±0.005mm.

[0014] Furthermore, a limiting rod is fixed to the inner wall of the fixed frame, the limiting rod is arranged parallel to the lead screw, and the movable frame is slidably connected to the limiting rod through a sliding seat, the sliding gap of the sliding seat being ≤0.01mm.

[0015] Furthermore, the position feedback unit includes an indicator plate, which is fixedly installed on the side of the movable frame away from the sliding seat, and an observation window is fixedly installed on the side of the fixed frame close to the indicator plate.

[0016] Furthermore, the position feedback unit also includes a laser ranging sensor with a ranging accuracy of ≤ ±0.002 mm. Its output signal is electrically connected to the signal processing module of the control unit to calibrate the actual value of the detection gap and correct the calculation deviation of the signal quality evaluation value.

[0017] Furthermore, a bearing seat is fixedly installed on the inner wall of the housing, and the bearing seat is rotatably connected to the transition shaft.

[0018] Furthermore, a buffer pad is bonded between the mounting bracket and the servo motor, and the buffer pad is made of an elastic material with a damping coefficient greater than 0.15.

[0019] Furthermore, the inner walls of the enclosure and the enclosure cover are provided with a copper mesh electromagnetic shielding layer, the signal acquisition module of the control unit uses shielded twisted pair cable to transmit signals, and the shielding effectiveness of the electromagnetic shielding layer is ≥40dB, which is used to suppress signal distortion caused by external electromagnetic interference.

[0020] A method for adaptive adjustment of sensor detection gap applied to the device according to any one of claims 1-9, characterized in that it includes the following steps: a. Initialization: The control unit drives the servo motor to run under no-load to calibrate the initial position of the gear plate; it drives the drive module of the installation adjustment mechanism to move the installation platform to the starting position of the detection gap; b. Gap Traversal and Signal Acquisition: The control drive module gradually adjusts the detection gap from the starting position to the ending position in a preset step size of 0.05mm; at each gap position, the control servo motor drives the gear plate to rotate at a constant speed of 1000r / min, continuously acquiring the output pulse signal of the Hall sensor under test, with an acquisition time of ≥100ms; c. Signal quality assessment: The signal quality evaluation value for each gap position is calculated by the signal processing module of the control unit: the evaluation value = ×60 + ×40, the evaluation value range is 0~100 points, and the higher the score, the better the signal quality; d. Target gap determination: Select the position with the highest evaluation value among all gap positions as the target gap. If multiple positions have the same evaluation value, select the gap with the smallest value as the target gap. e. Locking and Feedback: The control drive module moves the installation platform to the target gap, calibrates the actual gap value through the laser range sensor of the position feedback unit, locks the installation platform when the error is ≤ ±0.005mm, and feeds back the target gap value and signal quality evaluation value through the indicator module.

[0021] The beneficial effects of this invention are as follows: 1. This invention achieves high-precision movement of ≤±0.01mm through the installation of an adjustment mechanism. Combined with a drive module with positioning accuracy ≤±0.005mm and a laser rangefinder with ranging accuracy ≤±0.002mm, it ensures precise and controllable adjustment of the detection gap. The number of teeth on the gear plate is limited to 12 to 120, and the servo motor speed is stabilized at 500 to 3000 r / min. Combined with the quantitative evaluation of signal quality evaluation value (comprehensive score of signal-to-noise ratio and pulse duty cycle deviation), it effectively avoids subjective errors and signal distortion caused by manual adjustment, making the functional detection results of the Hall sensor more accurate, the data repeatability higher, and the detection error controlled within a very small range.

[0022] 2. The control unit of this invention can automatically traverse the detection gap range of 0.1mm to 5mm with a preset step size of 0.05mm to 0.1mm. It can lock the target gap with the best signal quality without repeated manual adjustments, which greatly shortens the detection preparation time. The signal acquisition time of a single gap position is only ≥100ms. The entire process is automated. Compared with the traditional manual adjustment method, the detection efficiency is improved by more than 50%, which is especially suitable for the rapid detection needs of sensors in mass production.

[0023] 3. The inner walls of the enclosure and cover of this invention are equipped with a copper mesh electromagnetic shielding layer (shielding effectiveness ≥40dB). The signal acquisition module uses shielded twisted-pair cable to transmit signals, which can effectively resist electromagnetic interference generated by equipment such as frequency converters and motors in industrial environments and reduce the risk of signal distortion. The buffer pad between the mounting bracket and the servo motor is made of elastic material with a damping coefficient greater than 0.15, which can weaken the impact of motor vibration on the rotation accuracy of the gear disk, further ensuring the stability of the detection signal, and enabling the device to work stably in complex scenarios with strong electromagnetic fields and multiple vibrations.

[0024] 4. The position feedback unit of this invention features an indicator plate and observation window design, which allows for real-time observation of the installation platform position; the target gap value and signal quality evaluation value are intuitively fed back through the indicator module, allowing operators to quickly grasp the detection results without professional skills; the core components of the device (servo motor, stepper motor, laser ranging sensor) are all selected from mature and reliable standardized components, with a high degree of modularity, convenient maintenance and replacement, and low long-term operating costs. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall structure of the present invention after the lid is removed; Figure 3 This is a cross-sectional structural diagram of the box body of the present invention; Figure 4 This is a schematic diagram of the structure of the driving module and feedback unit of the present invention; Figure 5 This is a schematic diagram of the installation platform and Hall sensor of the present invention.

[0026] Reference numerals: 1. Housing; 2. Housing cover; 3. Mounting bracket; 4. Servo motor; 5. Buffer pad; 6. Transition shaft; 7. Gear disc; 8. Bearing seat; 9. Control unit; 10. Mounting and adjustment mechanism; 101. Mounting platform; 102. Drive module; 1021. Fixing bracket; 1022. Stepper motor; 1023. Lead screw; 1024. Movable frame; 1025. Limiting rod; 1026. Sliding seat; 103. Position feedback unit; 1031. Indicator plate; 1032. Observation window; 1033. Laser rangefinder sensor; 11. Hall sensor. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0028] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0029] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0030] In the above description of the present invention, it should be noted that the terms "one side," "the other side," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is conventionally placed during use. These terms are used only for the convenience of describing the present invention and for 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, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0031] Furthermore, terms such as "identical" do not imply that components must be absolutely identical; minor differences are permissible. The term "perpendicular" simply means that the positional relationship between components is more perpendicular than "parallel," not that the structure must be perfectly perpendicular; a slight tilt is acceptable.

[0032] Figures 1-5 This is the preferred embodiment of the present invention, which is described below in conjunction with... Figures 1-5 The present invention will be further described below.

[0033] A sensor detection device includes a housing 1, a control unit 9, a mounting adjustment mechanism 10 for mounting the sensor, and a geared disc 7 that cooperates with the sensor. A housing cover 2 is fixedly mounted on the top of the housing 1. A mounting bracket 3 is fixedly mounted inside the housing 1. A servo motor 4 is fixedly mounted on the mounting bracket 3. A transition shaft 6 is fixedly mounted on the output shaft of the servo motor 4. A geared disc 7 with 12 to 120 teeth is fixedly mounted on the outer side of the transition shaft 6. The mounting adjustment mechanism 10 includes: a mounting platform 101 with a movement accuracy ≤ ±0.01 mm, a drive module 102 for driving the mounting platform 101 to move radially along the geared disc 7, and a mechanism for... The position feedback unit 103 provides real-time feedback on the position of the mounting platform 101. A Hall sensor 11 is fixedly mounted on the mounting platform 101. An adjustable detection gap is formed between the detection surface of the Hall sensor 11 and the tooth tip of the gear disk 7. The adjustment range of the detection gap is 0.1mm to 5mm. The control unit 9 includes a signal acquisition module, a signal processing module, and a drive control module. The control unit 9 is configured to: control the drive module 102 to traverse the adjustment range of the detection gap at a preset step size of 0.05mm to 0.1mm; at each gap position, control the servo motor 4 to drive the gear disk 7 to rotate at a constant speed of 500 to 3000 r / min, and acquire the output pulse signal of the Hall sensor 11 through the signal acquisition module; calculate the signal quality evaluation value of the output pulse signal through the signal processing module. The signal quality evaluation value is a comprehensive score of signal-to-noise ratio (SNR) ≥ 30dB and pulse duty cycle deviation ≤ 5%; compare the signal quality evaluation values ​​of all gap positions to determine the target gap with the highest evaluation value; and control the drive module 102 to move the mounting platform 101 and lock it to the target gap.

[0034] The mounting platform 101 has an internal thread on its inner side, and the Hall sensor 11 has an external thread on its outer side that matches the internal thread of the mounting platform 101. Specifically, the threaded connection design enables quick disassembly and initial positioning of the Hall sensor 11, which is convenient to operate and has a stable connection, avoiding signal deviation caused by sensor loosening during the detection process. With the high-precision drive of the mounting adjustment mechanism 10, the initial posture of the sensor can be finely adjusted by the thread before automatically adjusting the target gap, further improving the accuracy of gap adjustment and detection stability.

[0035] The drive module 102 includes a fixed frame 1021, a stepper motor 1022, a lead screw 1023, and a movable frame 1024. The fixed frame 1021 is fixedly installed on the outside of the housing 1. The stepper motor 1022 is fixedly installed on the side of the fixed frame 1021. The step angle of the stepper motor 1022 is ≤1.8°. The output shaft of the stepper motor 1022 is fixedly connected to the lead screw 1023, and the lead of the lead screw 1023 is 0.5~2mm. The movable frame 1024 is threaded to the outside of the lead screw 1023 and fixedly connected to the mounting platform 101. The positioning accuracy of the drive module 102 is ≤±0.005mm. Specifically, it adopts a transmission combination of stepper motor 1022 + lead screw 1023, with a step angle of ≤1.8° and a lead of 0.5~2mm. The adaptable lead design enables smooth and precise driving of the installation platform 101, with a positioning accuracy of ±0.005mm, providing a reliable guarantee for high-precision adjustment of the detection gap; the modular assembly structure of the fixed frame 1021 and the movable frame 1024 not only ensures stable installation and high transmission efficiency, but also has strong component versatility, making maintenance and replacement convenient and effectively reducing the operation and maintenance cost of the device.

[0036] A limiting rod 1025 is fixed to the inner wall of the fixed frame 1021. The limiting rod 1025 is arranged parallel to the lead screw 1023. The movable frame 1024 is slidably connected to the limiting rod 1025 through a sliding seat 1026. The sliding gap of the sliding seat 1026 is ≤0.01mm. Specifically, the limiting rod 1025 is arranged parallel to the lead screw 1023. With the sliding seat 1026 having a sliding gap of ≤0.01mm, the movement trajectory of the movable frame 1024 can be precisely limited, effectively avoiding deviation and shaking during the transmission of the lead screw 1023, and ensuring that the installation platform 101 moves smoothly along the radial direction of the gear plate 7. The rigid guide structure design further improves the positioning stability of the drive module 102 and forms a synergy with the high-precision transmission components, providing double protection for the precise adjustment of the detection gap and indirectly improving the reliability of the sensor detection data.

[0037] The position feedback unit 103 includes an indicator plate 1031, which is fixedly installed on the side of the movable frame 1024 away from the sliding seat 1026. An observation window 1032 is fixedly installed on the side of the fixed frame 1021 near the indicator plate 1031. Specifically, the indicator plate 1031 moves synchronously with the movable frame 1024. With the observation window 1032 on the fixed frame 1021, the position status of the installation platform 101 can be observed intuitively in real time without additional disassembly or the aid of instruments. The operation is convenient and the gap adjustment dynamics can be quickly obtained.

[0038] The position feedback unit 103 also includes a laser rangefinder 1033. The laser rangefinder 1033 has a ranging accuracy of ≤±0.002mm. Its output signal is electrically connected to the signal processing module of the control unit 9 to calibrate the actual value of the detection gap and correct the calculation deviation of the signal quality evaluation value. Specifically, the laser rangefinder 1033 calibrates the actual value of the detection gap in real time with an ultra-high ranging accuracy of ≤±0.002mm, effectively correcting mechanical transmission errors and signal calculation deviations, and providing core data support for the accurate locking of the target gap. It is linked with the signal processing module of the control unit 9 to form a closed-loop control of "transmission adjustment + real-time calibration", which greatly improves the adjustment accuracy of the detection gap and the accuracy of the signal quality evaluation, and further enhances the overall detection reliability of the device.

[0039] A bearing seat 8 is fixedly installed on the inner wall of the housing 1. The bearing seat 8 is rotatably connected to the transition shaft 6. Specifically, the bearing seat 8 provides stable support for the transition shaft 6, greatly reducing the frictional resistance during its rotation, ensuring that the gear disk 7 rotates at a constant speed of 500~3000r / min, and avoiding speed fluctuations from affecting the accuracy of sensor signal acquisition.

[0040] A buffer pad 5 is bonded between the mounting bracket 3 and the servo motor 4. The buffer pad 5 is made of an elastic material with a damping coefficient greater than 0.15. Specifically, the buffer pad 5, made of an elastic material with a damping coefficient greater than 0.15, can efficiently absorb the vibration generated by the servo motor 4 during operation, greatly reduce the transmission of vibration to the mounting bracket 3 and the housing 1, and avoid vibration causing the gear plate 7 to rotate eccentrically or the sensor signal to be distorted.

[0041] The inner walls of the enclosure 1 and the cover 2 are equipped with a copper mesh electromagnetic shielding layer. The signal acquisition module of the control unit 9 uses shielded twisted-pair cable to transmit signals. The shielding effectiveness of the electromagnetic shielding layer is ≥40dB, which is used to suppress signal distortion caused by external electromagnetic interference. Specifically, the copper mesh electromagnetic shielding layer (shielding effectiveness ≥40dB) and the shielded twisted-pair cable form a double anti-interference protection, which can effectively block electromagnetic signals generated by equipment such as frequency converters and motors in the industrial environment, suppressing signal distortion at the source and ensuring the accuracy of the test data. This design does not require additional complex anti-interference equipment, has a simple structure and strong compatibility, allowing the device to stably adapt to industrial scenarios with strong electromagnetic interference, while not affecting the normal operation of the core detection function, thus improving the environmental adaptability and practicality of the device.

[0042] Working principle and usage process of this invention: I. Preliminary Preparations Open the box cover 2 and install the Hall sensor 11 to be tested on the mounting platform 101 through the threaded connection. Manually fine-tune the initial posture of the sensor to ensure that the detection surface faces the tooth tip of the toothed disc 7 to complete the initial positioning.

[0043] Close and lock the cover 2, check the connection status of each component of the device (such as whether the wiring of the servo motor 4, stepper motor 1022, and laser range sensor 1033 is secure), and turn on the power.

[0044] II. Parameter Initialization Start the control unit 9, and the system automatically completes initialization: drive the servo motor 4 to run under no-load and calibrate the initial position of the gear disk 7; drive the module 102 to move the mounting platform 101 to the starting position (0.1mm) of the detection gap, and the laser range sensor 1033 completes the initial gap calibration.

[0045] Operators can preset detection parameters through control unit 9 (such as servo motor 4 speed 500~3000r / min, gap adjustment step 0.05mm~0.1mm), the default parameters are speed 1000r / min and step 0.05mm.

[0046] III. Automatic Interval Traversal and Signal Acquisition The control unit 9 issues a command to drive the stepper motor 1022 of the drive module 102 to rotate the lead screw 1023, and pull the installation platform 101 through the movable frame 1024 to gradually traverse the detection gap range of 0.1mm to 5mm according to the preset step distance.

[0047] At each gap position, the servo motor 4 drives the gear disk 7 to rotate at a constant speed, and the signal acquisition module continuously acquires the output pulse signal of the Hall sensor 11 (acquisition time ≥ 100ms). At the same time, the laser range sensor 1033 acquires the actual value of the current gap in real time and transmits it to the signal processing module.

[0048] IV. Signal Quality Assessment and Target Gap Locking The signal processing module combines the calibrated gap value to calculate the signal quality evaluation value for each position (evaluation value = (signal-to-noise ratio SNR / 30dB) × 60 + (1 - pulse duty cycle deviation / 5%) × 40), and feeds it back to the control unit 9 in real time.

[0049] Control unit 9 compares the evaluation values ​​of all gap positions and selects the position with the highest evaluation value as the target gap; if there are multiple positions with the same highest evaluation value, the smallest gap is selected as the target gap.

[0050] The drive module 102 receives the instruction and moves the installation platform 101 precisely to the target gap. The laser range sensor 1033 performs a secondary calibration of the actual gap value. When the error is ≤ ±0.005mm, the installation platform 101 is locked.

[0051] V. Test Result Feedback and Follow-up Operations The indicator panel 1031 displays the target gap value and the corresponding signal quality evaluation value in real time. Operators can view it intuitively through the observation window 1032 or export the test data through the output interface of the control unit 9.

[0052] After the test is completed, turn off the servo motor 4 and drive module 102, disconnect the power, open the cover 2, and remove the Hall sensor 11 under test by thread to complete a single test.

[0053] If batch testing is required, simply repeat steps one through five. The device can run continuously without additional debugging.

[0054] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A sensor detection device, comprising a housing (1), a control unit (9), a mounting and adjusting mechanism (10) for mounting a sensor, and a geared disc (7) cooperating with the sensor, characterized in that: A cover (2) is fixedly installed on the top of the box (1), a mounting bracket (3) is fixedly installed inside the box (1), a servo motor (4) is fixedly installed on the mounting bracket (3), a transition shaft (6) is fixedly installed on the output shaft of the servo motor (4), and a gear plate (7) is fixedly installed on the outside of the transition shaft (6). The number of teeth on the gear plate (7) is 12 to 120. The installation adjustment mechanism (10) includes: an installation platform (101) with a movement accuracy of ≤ ±0.01mm, a drive module (102) for driving the installation platform (101) to move radially along the toothed disk, and a position feedback unit (103) for real-time feedback of the position of the installation platform (101). A Hall sensor (11) is fixedly installed on the installation platform (101). An adjustable detection gap is formed between the detection surface of the Hall sensor (11) and the tooth tip of the toothed disk (7). The adjustment range of the detection gap is 0.1mm to 5mm. The control unit (9) includes a signal acquisition module, a signal processing module, and a drive control module. The control unit (9) is configured as follows: The drive module (102) is controlled to traverse the adjustment range of the detection gap in a preset step distance of 0.05mm to 0.1mm; At each gap position, the servo motor (4) is controlled to drive the gear disk (7) to rotate at a constant speed of 500~3000r / min, and the output pulse signal of the Hall sensor (11) is collected through the signal acquisition module; The signal quality evaluation value of the output pulse signal is calculated by the signal processing module. The signal quality evaluation value is a comprehensive score of signal-to-noise ratio (SNR≥30dB) and pulse duty cycle deviation (≤5%). Compare the signal quality evaluation values ​​at all gap locations and determine the target gap with the highest evaluation value; The control drive module (102) moves the mounting platform (101) and locks it into the target gap.

2. The sensor detection device according to claim 1, characterized in that: The mounting platform (101) has an internal thread on its inner side, and the Hall sensor (11) has an external thread on its outer side that is compatible with the internal thread of the mounting platform (101).

3. The sensor detection device according to claim 1, characterized in that: The drive module (102) includes a fixed frame (1021), a stepper motor (1022), a lead screw (1023), and a movable frame (1024). The fixed frame (1021) is fixedly installed on the outside of the housing (1). The stepper motor (1022) is fixedly installed on the side of the fixed frame (1021). The step angle of the stepper motor (1022) is ≤1.8°. The output shaft of the stepper motor (1022) is fixedly connected to the lead screw (1023). The lead of the lead screw (1023) is 0.5~2mm. The movable frame (1024) is threaded to the outside of the lead screw (1023) and fixedly connected to the mounting platform (101). The positioning accuracy of the drive module (102) is ≤±0.005mm.

4. The sensor detection device according to claim 3, characterized in that: The inner wall of the fixed frame (1021) is fixed with a limiting rod (1025), the limiting rod (1025) is arranged parallel to the lead screw (1023), the movable frame (1024) is slidably connected to the limiting rod (1025) through a sliding seat (1026), and the sliding gap of the sliding seat (1026) is ≤0.01mm.

5. The sensor detection device according to claim 4, characterized in that: The position feedback unit (103) includes an indicator plate (1031), which is fixedly installed on the side of the movable frame (1024) away from the sliding seat (1026), and an observation window (1032) is fixedly installed on the side of the fixed frame (1021) close to the indicator plate (1031).

6. The sensor detection device according to claim 5, characterized in that: The position feedback unit (103) also includes a laser rangefinder (1033), the rangefinder (1033) has a rangefinder accuracy of ≤ ±0.002mm, and its output signal is electrically connected to the signal processing module of the control unit (9) to calibrate the actual value of the detection gap and correct the calculation deviation of the signal quality evaluation value.

7. The sensor detection device according to claim 1, characterized in that: The inner wall of the housing (1) is fixedly installed with a bearing seat (8), and the bearing seat (8) is rotatably connected to the transition shaft (6).

8. The sensor detection device according to claim 1, characterized in that: A buffer pad (5) is bonded between the mounting bracket (3) and the servo motor (4), and the buffer pad (5) is made of an elastic material with a damping coefficient greater than 0.

15.

9. A sensor detection device according to claim 1, characterized in that: The inner walls of the housing (1) and the cover (2) are provided with a copper mesh electromagnetic shielding layer. The signal acquisition module of the control unit (9) uses shielded twisted pair cable to transmit signals. The shielding effectiveness of the electromagnetic shielding layer is ≥40dB, which is used to suppress signal distortion caused by external electromagnetic interference.

10. A method for adaptive adjustment of the sensor detection gap applied to the device according to any one of claims 1-9, characterized in that, Includes the following steps: a. Initialization: The control unit (9) drives the servo motor (4) to run under no-load and calibrate the initial position of the gear plate (7); the drive module (102) of the installation adjustment mechanism (10) is driven to move the installation platform (101) to the starting position (0.1mm) of the detection gap. b. Gap traversal and signal acquisition: The control drive module (102) gradually adjusts the detection gap from the starting position to the ending position (5mm) in a preset step size of 0.05mm; at each gap position, the control servo motor (4) drives the gear plate (7) to rotate at a speed of 1000r / min, and continuously acquires the output pulse signal of the Hall sensor (11) under test, with an acquisition time of ≥100ms; c. Signal quality assessment: The signal quality evaluation value at each gap position is calculated by the signal processing module of the control unit (9): The evaluation value = (signal-to-noise ratio SNR / 30dB) × 60 + (1 - pulse duty cycle deviation / 5%) × 40, and the evaluation value range is 0~100 points. The higher the score, the better the signal quality. d. Target gap determination: Select the position with the highest evaluation value among all gap positions as the target gap. If multiple positions have the same evaluation value, select the gap with the smallest value as the target gap. e. Locking and Feedback: The control drive module (102) moves the installation platform (101) to the target gap, calibrates the actual gap value through the laser range sensor (1033) of the position feedback unit (103), locks the installation platform (101) when the error is ≤ ±0.005mm, and feeds back the target gap value and signal quality evaluation value through the indicator module.

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