Fault detection and processing method and system for dual-redundancy angle sensor
By performing multi-dimensional fault diagnosis and intelligent decision-making on dual-redundant angle sensors, the problems of abnormal dynamic output behavior and insufficient combination of working states of the sensors were solved, thus achieving high reliability of the sensors and safe and stable operation of the system.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-24
- Publication Date
- 2026-03-24
AI Technical Summary
Existing technologies have a relatively singular fault detection dimension, lack in-depth diagnosis of abnormal dynamic output behavior of sensors, and the detection logic fails to be closely integrated with the working state of the sensors, resulting in the inability to identify potential or intermittent faults in a timely manner, and the redundancy management and system response strategies are not comprehensive enough.
A dual-redundancy angle sensor is used to perform consistency detection during the power-on phase and dynamic behavior detection during the operation phase for the first and second redundancies, respectively. This includes multi-dimensional fault diagnosis such as data transmission interruption, data not updating, data jump, and data reverse change, and the system performs redundancy switching or system shutdown based on the detection results.
It enables comprehensive monitoring and anomaly identification of sensor operating status, improves the accuracy and real-time performance of fault detection, ensures seamless switching of the system in the event of a single redundancy failure, and ensures safe shutdown in the event of failure of both redundancies, thus significantly improving the reliability and stability of the system.
Smart Images
Figure CN121720360A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of sensor fault diagnosis, in particular to a fault detection and processing method and system of a dual-redundancy angle sensor. BACKGROUND
[0002] As a key measurement device for converting spatial angle into electrical signal, angle sensor is widely used in aerospace, industrial automation and automotive electronics due to its high precision and wide measurement range. In these applications, any error code or fault of the sensor may cause system malfunction, and even lead to serious accidents. The single-channel sensor design is difficult to meet the requirements of such high-reliability scenarios due to its inherent single-point failure risk. Therefore, the dual-redundancy (i.e. dual-channel) sensor design has become an important technical means to improve the overall reliability of the system through redundant backup.
[0003] The fault detection dimension of the prior art is relatively single, mainly focusing on the presence or absence of signals or static range over-limit, lacking in-depth diagnosis of abnormal dynamic output behavior of the sensor (such as data jump, reverse change, abnormal freezing, etc.), which leads to some potential or intermittent faults that cannot be identified in time and accurately. Secondly, the detection logic often fails to closely combine the working state of the sensor (such as whether it is in a motion state), affecting the accuracy of the judgment and possibly causing false positives or false negatives. Finally, the redundancy management and system response strategy after the fault occurs is relatively simple, lacking a complete and reliable processing flow from comprehensive detection to intelligent decision-making. SUMMARY
[0004] In view of the above-mentioned defects or deficiencies in the prior art, it is desirable to provide a fault detection and processing method and system of a dual-redundancy angle sensor.
[0005] The present application provides a fault detection and processing method of a dual-redundancy angle sensor, comprising: Performing fault detection on a first redundancy and a second redundancy of the dual-redundancy angle sensor, the fault detection including consistency detection in a power-on stage and dynamic behavior detection in a running stage; wherein the dynamic behavior detection in the running stage includes data transmission interruption detection, data non-update detection, data jump detection and data reverse change detection; Based on the fault detection result, performing redundancy switching or system stopping operation.
[0006] According to the fault detection and processing method of the dual-redundancy angle sensor provided by the present application, the consistency detection in the power-on stage comprises: Continuously reading the angle measurement values of the first redundancy and the second redundancy multiple times; Calculating the difference between the measurement values of the two redundancies at each reading; If the calculated difference is greater than the first preset threshold multiple times, it is determined that the dual-redundancy angle sensor has a fault of excessive power-on redundancy difference, and the control system enters a stop working state.
[0007] According to the fault detection and handling method of a dual-redundancy angle sensor provided by the present invention, the data transmission interruption detection includes: Set independent receiving timers for the first redundancy and the second redundancy respectively; Whenever angle data for any redundancy is received, the receiving timer for that redundancy is cleared to zero. If the value of the receive timer for any redundancy exceeds the second preset threshold, it is determined that there is a data transmission interruption fault in that redundancy.
[0008] According to the fault detection and handling method of a dual-redundancy angle sensor provided by the present invention, the data non-update detection includes: The angle values of the first and second redundancies are periodically read, and the angle changes of the first and second redundancies are calculated respectively within a first preset time period; If the absolute value of the angle change of any redundancy is less than the third preset threshold, it is determined that the redundancy has a data update failure.
[0009] According to the fault detection and processing method of a dual-redundancy angle sensor provided by the present invention, the data jump detection includes: When the dual-redundancy angle sensor is in a unidirectional rotation state, the angle changes of the first and second redundancies are calculated respectively within a second preset time. If the absolute value of the angle change of any redundancy is greater than the fourth preset threshold, then the redundancy is determined to have a data jump fault.
[0010] According to the fault detection and processing method of a dual-redundancy angle sensor provided by the present invention, the data reverse change detection includes: When the dual-redundancy angle sensor is in a unidirectional rotation state, it monitors the real-time angle change direction of the first and second redundancies; If the angle change direction of any redundancy is detected to be opposite to the current rotation direction, and the angle change of any redundancy exceeds the fifth preset threshold, then it is determined that there is a data reverse change fault in that redundancy.
[0011] According to the fault detection and handling method of a dual-redundancy angle sensor provided by the present invention, the step of performing redundancy data selection or system protection operation includes: If the fault detection result indicates that the second redundancy is faulty, the system continues to use the data from the first redundancy. If the fault detection result indicates that there is a fault in the first redundancy, the system switches to using the data of the second redundancy; If the fault detection result indicates that both the first redundancy and the second redundancy are faulty, the control system will stop working.
[0012] A second aspect of the present invention provides a fault detection and processing system for a dual-redundancy angle sensor, comprising: The fault detection module is used to perform fault detection on the first redundancy and the second redundancy of the dual-redundancy angle sensor respectively. The fault detection includes consistency detection during the power-on phase and dynamic behavior detection during the operation phase. The dynamic behavior detection during the operation phase includes data transmission interruption detection, data non-update detection, data jump detection, and data reverse change detection. The execution control module is used to perform redundancy switching or system shutdown operations based on fault detection results.
[0013] A third aspect of the present invention provides a fault detection and processing device for a dual-redundancy angle sensor, comprising: A memory and at least one processor, wherein the memory stores instructions; At least one of the processors invokes the instructions in the memory to cause a fault detection and processing device for a dual-redundant angle sensor to perform a fault detection and processing method for a dual-redundant angle sensor as described in any of the preceding claims.
[0014] A fourth aspect of the present invention provides a computer-readable storage medium storing instructions that, when executed by a processor, implement a fault detection and processing method for a dual-redundancy angle sensor as described in any of the preceding claims.
[0015] This invention provides a fault detection and handling method for a dual-redundancy angle sensor. By performing multi-dimensional fault diagnosis on the sensor's first and second redundancies, including consistency detection during power-on and dynamic behavior detection during operation, comprehensive monitoring and anomaly identification of the sensor's operating status are achieved. Furthermore, based on the fault detection results, the redundancy where the fault occurred is intelligently determined, and corresponding redundancy or system shutdown operations are executed according to the determination result. This enables seamless switching in the event of a single redundancy fault and ensures safe system shutdown in the event of failure in both redundancies. This method integrates multiple detection mechanisms such as data transmission interruption, data non-update, data jump, and data reverse change, combined with adaptive thresholds and status judgment, significantly improving the accuracy, real-time performance, and reliability of fault detection. Attached Figure Description
[0016] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 A schematic flowchart illustrating a fault detection and handling method for a dual-redundancy angle sensor provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of a fault detection and processing system for a dual-redundant angle sensor provided in an embodiment of the present invention. Detailed Implementation
[0017] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.
[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.
[0019] As mentioned in the background section, this invention proposes a fault detection and handling method and system for a dual-redundant angle sensor.
[0020] like Figure 1 As shown, the present invention provides a fault detection and handling method for a dual-redundancy angle sensor, comprising: S1. Fault detection is performed on the first and second redundancies of the dual-redundancy angle sensor. Fault detection includes consistency detection during power-on and dynamic behavior detection during operation. Dynamic behavior detection during operation includes data transmission interruption detection, data non-update detection, data jump detection, and data reverse change detection.
[0021] Regarding step S1: In some implementations, the conformance check during the power-on phase includes: Read the angle measurement values of the first redundancy and the second redundancy multiple times consecutively; Calculate the difference between the two redundancy measurements at each reading; If the difference calculated multiple times is greater than the first preset threshold, it is determined that the dual-redundancy angle sensor has a fault of excessive power-on redundancy difference, and the control system enters a stop working state.
[0022] In this invention, after the system is powered on, the control chip will continuously read the angle information output by the two redundancies (i.e., the first redundancy and the second redundancy) of the dual-redundancy angle sensor multiple times. After each read, the difference between the two redundancy measurements is calculated and compared with a preset first threshold. If the calculated difference exceeds the threshold multiple times consecutively, it is determined that the sensor has a hardware consistency fault of "excessive power-on redundancy difference". At this time, the system will directly enter a stop-work state, thereby avoiding subsequent control errors caused by abnormal initial state of the sensor itself, and ensuring the safety of the system from the initial stage.
[0023] In some implementations, data transmission interruption detection includes: Set independent receiving timers for the first and second redundancy respectively; Whenever angle data for any redundancy is received, the receiving timer for that redundancy is cleared to zero. If the value of the receive timer for any redundancy exceeds the second preset threshold, it is determined that there is a data transmission interruption fault in that redundancy.
[0024] In this invention, the control chip periodically receives angle data sent by the sensor via the CAN bus. To achieve detection, an independent software timer is configured for the first and second redundancies. Whenever a data packet from a redundancy is successfully received, the corresponding redundancy's timer is reset to zero. If, due to a communication line break, interface failure, or sensor transmitting component malfunction, no data is received from that redundancy within a set second preset threshold, its corresponding timer will time out. Once the receiving timer for any redundancy times out, it is determined that a data transmission interruption fault has occurred for that redundancy, ensuring real-time monitoring of the communication link reliability.
[0025] In some implementations, the data not-updated detection includes: The angle values of the first and second redundancies are periodically read, and the angle changes of the first and second redundancies within a first preset time period are calculated respectively. If the absolute value of the angle change of any redundancy is less than the third preset threshold, it is determined that there is a data update failure in that redundancy.
[0026] In this invention, the detection aims to identify faults such as "stuck" or stalled updates in sensor output values. The system periodically reads the angle value of the currently detected redundancy (first or second redundancy) and calculates its angle change over a first preset time period. Based on the sensor's working principle and actual application scenarios, a reasonable minimum angle change threshold (third preset threshold) can be set. If the absolute value of the calculated angle change is less than this threshold, it indicates that the sensor output has hardly changed during that time period, which does not conform to the expected behavior under motion conditions, and thus the redundancy is determined to have a "data not updating" fault. This method can effectively detect abnormal situations where the sensor's internal sampling or processing circuitry is frozen.
[0027] In some implementations, data transition detection includes: When the dual-redundancy angle sensor is in a unidirectional rotation state, the angle changes of the first and second redundancies are calculated respectively within a second preset time. If the absolute value of the angle change of any redundancy is greater than the fourth preset threshold, it is determined that there is a data jump fault in that redundancy.
[0028] In this invention, the detection targets sudden, non-physically predictable changes in sensor output. First, the system determines whether the dual-redundancy sensor is in a clearly defined unidirectional rotation state (e.g., determined by external motion commands or data from another redundancy). In this state, the angular change of the detected redundancy is calculated over a second preset time period. Based on the system's maximum physical angular velocity limit, a reasonable maximum angular change threshold (fourth preset threshold) is set. If the absolute value of the calculated angular change exceeds this threshold, it means that an impossible, drastic change in the angle value occurred within a very short time, indicating a "data jump" fault in the redundancy. This typically corresponds to situations such as strong interference with the sensor's internal signal or errors in the analog-to-digital conversion process.
[0029] In some implementations, data reversal detection includes: When the dual-redundant angle sensor is in a unidirectional rotation state, it monitors the real-time angle change direction of the first and second redundancies; If the angle change direction of any redundancy is detected to be opposite to the current rotation direction, and the angle change of any redundancy exceeds the fifth preset threshold, then it is determined that there is a data reverse change fault in that redundancy.
[0030] In this invention, the detection is used to identify faults where the sensor output logic contradicts the physical direction of motion. Similarly, assuming the sensor is in a unidirectional rotation state, the angular change direction of the detected redundancy is monitored in real time. When physically rotating in one direction, the angle value output by the sensor should monotonically increase or decrease. If a change in the output value opposite to the current rotation direction is detected, and the magnitude of this reverse change exceeds a set fifth threshold (a fault-tolerance value), then the redundancy is determined to have a "data reverse change" fault. This fault may originate from reverse sensor installation, internal calculation program errors, or polarity errors in devices such as magnetic encoders.
[0031] S2. Based on the fault detection results, perform redundancy switching or system shutdown.
[0032] Regarding step S2: In some implementations, performing redundancy switching or system shutdown operations includes: If the fault detection result indicates that there is a fault in the second redundancy, the system will continue to use the data from the first redundancy. If the fault detection result indicates a fault in the first redundancy, the system switches to using data from the second redundancy. If the fault detection results indicate that both the first and second redundancies are faulty, the control system will stop working.
[0033] In this invention, the system defaults to using the data from redundancy 1 (first redundancy), which is detected as normal upon power-up, as the output. During operation: if redundancy 2 (second redundancy) is detected as faulty, the system continues to use the reliable data from redundancy 1; if redundancy 1 is detected as faulty, the system automatically switches the output to the still-normal redundancy 2, achieving primary / backup redundancy switching; if the worst-case scenario occurs, i.e., both redundancies are detected as faulty during operation, the system determines that all reliable angle information has been lost, and then controls the entire system to safely stop working, preventing dangerous actions guided by erroneous data. This entire logic constitutes a complete and clear fault response and system safety assurance mechanism.
[0034] like Figure 2 As shown, the present invention also provides a fault detection and processing system for a dual-redundancy angle sensor, comprising: The fault detection module 100 is used to perform fault detection on the first redundancy and the second redundancy of the dual-redundancy angle sensor respectively. The fault detection includes consistency detection during the power-on phase and dynamic behavior detection during the operation phase. The dynamic behavior detection during the operation phase includes data transmission interruption detection, data non-update detection, data jump detection, and data reverse change detection. The execution control module 200 is used to perform redundancy switching or system shutdown operations based on the results of fault detection.
[0035] The present invention also provides a fault detection and processing device for a dual-redundant angle sensor, comprising: a memory and at least one processor, wherein the memory stores instructions; at least one processor invokes the instructions in the memory to cause the fault detection and processing device for a dual-redundant angle sensor to perform a fault detection and processing method for a dual-redundant angle sensor as described in any of the preceding claims.
[0036] The present invention also provides a computer-readable storage medium storing instructions that, when executed by a processor, implement a fault detection and handling method for a dual-redundancy angle sensor as described in any of the preceding claims.
[0037] This invention constructs a two-layer fault detection architecture that combines consistency detection during the power-on phase with full-dimensional dynamic behavior detection during the operation phase. This architecture breaks through the limitations of traditional single-mode detection methods and comprehensively covers various faults that may occur in dual-redundant angle sensors at different operating stages.
[0038] During the power-on phase, multiple data comparisons and difference assessments are used to proactively identify potential issues with excessive initial redundancy deviations. For the operational phase, this invention designs dedicated detection logic and threshold judgment standards for core fault types such as data transmission interruptions, failure to update, jumps, and reverse changes. This enables accurate fault identification, rapid location, and timely warnings, significantly reducing the missed detection rate and false alarm rate. Furthermore, the differentiated processing strategy based on fault detection results combines flexibility and security: in the event of a single redundancy fault, seamless redundancy switching ensures the system can continuously acquire reliable angle data without shutdown, effectively guaranteeing the continuous and stable operation of related equipment or systems; in the event of failures in both redundancies, timely shutdown operations are triggered, mitigating the risk of equipment damage and functional abnormalities caused by data failure from the outset.
[0039] Overall, this invention not only significantly improves the reliability, fault tolerance, and operational stability of the dual-redundant angle sensor itself, but also enhances the operational safety and anti-interference capabilities of systems in aerospace, industrial control, and intelligent equipment fields that rely on this sensor. It has a wide range of applications, can adapt to complex and harsh working environments, and provides strong technical support for the high-quality development of related industries. It has extremely high practical value and promotion prospects.
[0040] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.
Claims
1. A fault detection and handling method for a dual-redundancy angle sensor, characterized in that, include: Fault detection is performed on the first and second redundancies of the dual-redundancy angle sensor. The fault detection includes consistency detection during the power-on phase and dynamic behavior detection during the operation phase. The dynamic behavior detection during the operation phase includes data transmission interruption detection, data non-update detection, data jump detection, and data reverse change detection. Based on the fault detection results, perform redundancy switching or system shutdown.
2. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The consistency check during the power-on phase includes: Read the angle measurement values of the first redundancy and the second redundancy multiple times consecutively; Calculate the difference between the first and second redundancy measurements at each readout; If the calculated difference is greater than the first preset threshold multiple times, it is determined that the dual-redundancy angle sensor has a fault of excessive power-on redundancy difference, and the control system enters a stop working state.
3. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The data transmission interruption detection includes: Set independent receiving timers for the first and second redundancy respectively; Whenever angle data for any redundancy is received, the receiving timer for that redundancy is cleared to zero. If the value of the receive timer for any redundancy exceeds the second preset threshold, it is determined that there is a data transmission interruption fault in the current redundancy.
4. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The data not updating detection includes: The angle values of the first redundancy and the second redundancy are periodically read, and the angle changes of the first redundancy and the second redundancy are calculated respectively within a first preset time. If the absolute value of the angle change of any redundancy is less than the third preset threshold, it is determined that there is a data update failure in the current redundancy.
5. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The data jump detection includes: When the dual-redundancy angle sensor is in a unidirectional rotation state, the angle change of the first redundancy and the second redundancy is calculated respectively within a second preset time. If the absolute value of the angle change of any redundancy is greater than the fourth preset threshold, it is determined that there is a data jump fault in the current redundancy.
6. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The data reverse change detection includes: When the dual-redundancy angle sensor is in a unidirectional rotation state, it monitors the real-time angle change direction of the first redundancy and the second redundancy. If the angle change direction of any redundancy is detected to be opposite to the current rotation direction, and the angle change of any redundancy exceeds the fifth preset threshold, then it is determined that there is a data reverse change fault in the current redundancy.
7. The fault detection and handling method for a dual-redundancy angle sensor according to claim 1, characterized in that, The execution redundancy switching or system shutdown operation includes: If the fault detection result indicates that the second redundancy has a fault, then the data of the first redundancy will continue to be used; If the fault detection result indicates that there is a fault in the first redundancy, then switch to using the data of the second redundancy; If the fault detection result indicates that both the first redundancy and the second redundancy are faulty, the control system will stop working.
8. A fault detection and handling system for a dual-redundancy angle sensor, characterized in that, include: The fault detection module is used to perform fault detection on the first redundancy and the second redundancy of the dual-redundancy angle sensor respectively. The fault detection includes consistency detection during the power-on phase and dynamic behavior detection during the operation phase. The dynamic behavior detection during the operation phase includes data transmission interruption detection, data non-update detection, data jump detection, and data reverse change detection. The execution control module is used to perform redundancy switching or system shutdown operations based on fault detection results.
9. A fault detection and processing device for a dual-redundancy angle sensor, characterized in that, include: A memory and at least one processor, wherein the memory stores instructions; At least one of the processors invokes the instructions in the memory to cause a fault detection and processing device for a dual-redundant angle sensor to perform a fault detection and processing method for a dual-redundant angle sensor as described in any one of claims 1 to 7.
10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores instructions that, when executed by a processor, implement a fault detection and handling method for a dual-redundancy angle sensor as described in any one of claims 1 to 7.