Encoder counter wheel perimeter calibration structure and method

Abstract

The encoder counting wheel perimeter calibration structure comprises a supporting frame, a bottom plate is installed on one side of the upper portion of the supporting frame, a guide rail A is installed on the upper portion of the bottom plate, a sliding block A is installed on the guide rail A, a clamp fixing seat is installed on the upper portion of the sliding block A, a profile clamping clamp is movably installed in the clamp fixing seat, and the profile clamping clamp is movably installed on the lower portion of the supporting frame. A grating ruler parallel to the guide rail A is installed above the bottom plate and located on one side of the guide rail A. The principle utilized by the invention is basically consistent with that of manual calibration, and the difference is that the grating ruler is used for replacing the whole measurement process, a system program is used for replacing manual calculation and the whole calibration process, the whole measurement process can be fully automatically completed only by pressing a start button by a worker, manual participation is not needed in the process, the requirement on the technical capability of the worker is reduced, and the method is quicker, simpler and more convenient; and the grating ruler is used for surveying and mapping, which is more accurate than manual measurement with a tape measure, and the advancing distance of the material can be truly reflected.

Description

Technical Field

[0001] This invention relates to the field of profile feeding devices, and in particular to an encoder counting wheel circumference calibration structure and method. Background Technology

[0002] In encoder feedback feeding mechanisms, the circumference of the encoder counting wheel is the most critical parameter, directly affecting the accuracy of material feeding. Due to factors such as temperature, wear, and dirt, the actual circumference of the encoder counting wheel may change slightly. This slight change has a significant impact on the encoder's measurement of actual distance. Often, after a period of time, or when replacing the counting wheel, it is necessary to re-enter the circumference of the encoder counting wheel. This re-entry process requires re-detection and recalculation; this process is essentially a calibration process.

[0003] Current encoder counting wheel circumference calibration structures and methods on the market suffer from the following problems: Traditional calibration processes are done manually, resulting in low efficiency, high workload, and inaccuracy. This severely impacts production and the overall usability of the mechanism. The manual method involves feeding material, recording the initial position, and then recording the subsequent position after feeding a certain distance. The distance between these two positions is measured, and the number of encoder revolutions is calculated based on the previous encoder circumference. Dividing the distance by the number of revolutions gives the actual circumference of the counting wheel. This process requires mechanical actions such as sawing or drilling to mark the material, introduces significant measurement errors, requires two people, wastes materials, is inefficient, involves numerous steps, and requires workers to be familiar with the method and calculations, making it quite complex. Summary of the Invention

[0004] To address the shortcomings of the prior art, this invention provides an encoder counting wheel circumference calibration structure and method.

[0005] To address the aforementioned issues, this invention employs the following technical solution: an encoder counting wheel circumference calibration structure, comprising a support frame, a base plate mounted on one side of the support frame, a guide rail A mounted on the base plate, a slider A mounted on the guide rail A, a clamping seat mounted above the slider A, a profile clamping fixture movably mounted within the clamping seat, a grating ruler mounted on the base plate and parallel to the guide rail A on one side of the guide rail A, a grating ruler slider external to the grating ruler, and the grating ruler slider connected to the clamping fixture fixing seat via a connecting block, the support frame positioned on one side of the roller encoder feeding device, and an encoder counting wheel located on the side of the roller encoder feeding device.

[0006] As a further preferred embodiment of the present invention, the profile clamping fixture is machined with a groove to accommodate the profile, and the side of the profile clamping fixture is machined with a threaded hole for installing a tightening screw, and the tightening screw is movably installed inside the profile clamping fixture.

[0007] As a further preferred embodiment of the present invention, a horizontal slider mounting plate is mounted on the slider A, a horizontal guide rail is mounted on the horizontal slider mounting plate, a horizontal slider is mounted on the horizontal guide rail, a vertical slider mounting seat is mounted on the horizontal slider, a vertical guide rail is mounted on one side of the vertical slider mounting seat, a vertical slider is provided on the vertical guide rail, a clamp fixing seat is mounted on one side of the vertical slider, one end of the horizontal slider mounting plate is connected to the grating ruler slider through a grating ruler slider connecting block, and a reinforcing block is welded to the top of the horizontal slider mounting plate.

[0008] As a further preferred embodiment of the present invention, a stop block is installed on one side of the horizontal slider mounting plate, and springs are installed between the horizontal slider mounting plate and the stop block, as well as between the horizontal slider mounting plate and the connecting block.

[0009] As a further preferred embodiment of the present invention, a limiting block is installed at one end of the vertical slider mounting base, and a spring is installed between the limiting block and the vertical slider.

[0010] As a further preferred embodiment of the present invention, a drag chain mounting bracket upright plate and a drag chain mounting bracket horizontal plate are installed on one side of the connecting block, a drag chain is fixed on the drag chain mounting bracket horizontal plate, and a drag chain mounting plate is installed on the bottom surface of one side of the base plate, and a drag chain is fixedly connected to the drag chain mounting plate.

[0011] As a further preferred embodiment of the present invention, parallel blocks are respectively installed at both ends of the top surface of the drag chain mounting plate between the guide rail A and the grating ruler.

[0012] As a further preferred embodiment of the present invention, the invention also includes an electrical control section, including a host computer and a PLC section.

[0013] The calibration steps include the following:

[0014] S1. Install the profile into the opening of the profile clamping fixture and tighten it with the tightening screw. One end of the profile extends to a position that is in full contact with the encoder roller, and at the same time tighten the tightening screw located on the side of the fixture fixing seat.

[0015] S2, set the electrical control section to encoder calibration mode, and set the calibration parameters, speed, and length.

[0016] S3, Press the encoder calibration button, the roller feeding section clamping cylinder starts clamping, and feeding begins.

[0017] S4, Calibration Process: Before feeding begins, the encoder's coordinates on the controller are zeroed, and the actual position value of the grating ruler is also zeroed. After complete zeroing, the profile is fed in under the drive of the rollers until it reaches the set calibration length, at which point it stops. During this process, the encoder continuously sends pulses to the PLC, and the grating ruler also continuously sends pulses to the PLC. When the profile reaches the calibration endpoint, the controller system records the total number of pulses sent by the encoder and grating ruler, and calculates the actual circumference of the encoder based on this. Let: the number of encoder pulses Nb

[0018] The number of pulses Nq that the encoder can generate in one revolution

[0019] Number of pulses transmitted by the grating ruler (Ng)

[0020] The distance K corresponding to one pulse of the grating ruler

[0021] The actual perimeter of the encoder is L

[0022] L=Ng*K*Nq / Nb.

[0023] S5, the controller records the actual perimeter, which will be used as the effective perimeter of the encoder in the subsequent system.

[0024] As a further preferred embodiment of the present invention, in step S1, the mounting profile clamping fixture clamps the profile, and the use of tightening screws provides a fixing effect for the profile clamping fixture.

[0025] The principle of this invention is basically the same as that of manual calibration. The difference is that a grating ruler is used to replace the entire measurement process, and a system program is used to replace manual calculation. The entire calibration process can be completed automatically by the worker simply by pressing the start button. No human intervention is required during the process, which reduces the technical requirements for workers. It is faster and simpler. Moreover, the measurement with a grating ruler is more accurate than the measurement with a tape measure, which is more accurate and can truly reflect the distance the material has traveled. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0027] Figure 2 This is a schematic diagram of the cable chain mounting plate structure of the present invention;

[0028] Figure 3 This is a schematic diagram of the horizontal slider structure of the present invention;

[0029] Figure 4 For the present invention Figure 2 Enlarged diagram of part A in the middle.

[0030] The markings in the diagram are as follows: 1. Encoder counting wheel; 2. Roller encoder feeding device; 3. Support frame; 4. Base plate; 5. Guide rail A; 6. Grating ruler; 510. Slider A; 520. Horizontal slider mounting plate; 530. Horizontal slider; 531. Horizontal guide rail; 532. Stop block; 533. Spring; 534. Reinforcing block; 535. Connecting block; 536. Vertical slider mounting seat; 540. Vertical slider; 541. Vertical guide rail; 543. Profile clamping fixture; 544. Fixture fixing seat; 545. Tightening screw; 546. Limit block; 555. Parallel block; 610. Cable chain mounting bracket upright plate; 611. Cable chain mounting bracket horizontal plate; 612. Cable chain; 613. Cable chain mounting plate; 620. Grating ruler slider. Detailed Implementation

[0031] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0032] In the description of this invention, it should be understood that the terms "length", "vertical", "horizontal", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] The following disclosure provides many different embodiments or examples for implementing different structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0036] This invention provides a technical solution: such as Figure 1-4 As shown, an encoder counting wheel circumference calibration structure and method includes a support frame 3, a base plate 4 mounted on one side of the support frame 3, a guide rail A5 mounted on the base plate 4, and a slider A510 mounted on the guide rail A5.

[0037] A clamping base 544 is installed on the top, and a profile clamping fixture 543 is movably installed in the clamping base 544. A grating ruler 6 is installed on the top of the base plate 4 and on the side of the guide rail A5, parallel to the guide rail A5. A grating ruler slider 620 is provided on the outside of the grating ruler 6. The grating ruler slider 620 is connected to the clamping fixture fixing base 544 through a connecting block 535. The support frame 3 is arranged on one side of the roller encoder feeding device 2. An encoder counting wheel 1 is provided on the side of the roller encoder feeding device 2.

[0038] Example 1

[0039] This invention provides a technical solution: an encoder counting wheel circumference calibration structure, wherein a profile clamping fixture 543 is machined with a groove to accommodate the profile, and a threaded hole for installing a tightening screw 545 is machined on the side of the profile clamping fixture 543, and a tightening screw 545 is movably installed inside the profile clamping fixture 543.

[0040] The profile is installed in the opening of the profile clamping fixture 543 and tightened with the tightening screw 545. One end of the profile extends to a position that is in full contact with the encoder roller, and the tightening screw 545 located on the side of the fixture fixing seat 544 is tightened.

[0041] The profile clamping fixture 543 is used to clamp the profile, and the tightening screw 545 can provide a fixing effect for the profile clamping fixture 543.

[0042] Example 2

[0043] This invention provides a technical solution: an encoder counting wheel circumference calibration structure, wherein a horizontal slider mounting plate 520 is mounted on a slider A510, a horizontal guide rail 531 is mounted on the horizontal slider mounting plate 520, a horizontal slider 530 is mounted on the horizontal guide rail 531, a vertical slider mounting seat 536 is mounted on the horizontal slider 530, a vertical guide rail 541 is mounted on one side of the vertical slider mounting seat 536, a vertical slider 540 is provided on the vertical guide rail 541, a clamp fixing seat 544 is mounted on one side of the vertical slider 540, one end of the horizontal slider mounting plate 520 is connected to the grating ruler slider 620 through a connecting block 535, and a reinforcing block 534 is welded to the top of the horizontal slider mounting plate 520.

[0044] Set the electrical control section to encoder calibration mode and set the calibration parameters, speed, and length.

[0045] The electrical control section can provide parameter calibration for the grating ruler 6, making the position adjustment of the grating ruler 6 more accurate.

[0046] Example 3

[0047] This invention provides a technical solution: an encoder counting wheel circumference calibration structure, wherein a stop block 532 is installed on one side of the horizontal slider mounting plate 520, and springs 533 are installed between the horizontal slider mounting plate 520 and the stop block 532 and between the horizontal slider mounting plate 520 and the connecting block 535.

[0048] Press the encoder calibration button, and the roller feeding section clamping cylinder will begin to clamp and start feeding.

[0049] The roller feeding section can be started by pressing the encoder calibration button.

[0050] Example 4

[0051] This invention provides a technical solution: an encoder counting wheel circumference calibration structure, wherein a limit block 546 is installed at one end of a vertical slider mounting base 536, and a spring 533 is installed between the limit block 546 and the vertical slider 540.

[0052] Calibration process: Before feeding begins, the encoder's coordinates on the controller are zeroed, and the actual position value of the grating ruler 6 is also zeroed. After complete zeroing, the profile is fed in under the drive of the rollers until it reaches the set calibration length, at which point it stops. During this process, the encoder continuously sends pulses to the PLC, and the grating ruler 6 also continuously sends pulses to the PLC. When the profile reaches the calibration endpoint, the controller system records the total number of pulses sent by the encoder and the grating ruler 6, and uses this as a basis to calculate the actual circumference of the encoder. Let: the number of pulses sent by the encoder is Nb.

[0053] The number of pulses Nq that the encoder can generate in one revolution

[0054] Number of pulses transmitted by the grating ruler (Ng)

[0055] The distance K corresponding to one pulse of the grating ruler

[0056] The actual perimeter of the encoder is L

[0057] L=Ng*K*Nq / Nb

[0058] The encoder continuously sends pulses to the PLC, which controls the precise movement of the grating ruler 6.

[0059] Example 5

[0060] This invention provides a technical solution: an encoder counting wheel circumference calibration structure, wherein a drag chain mounting bracket upright plate 610 and a drag chain mounting bracket horizontal plate 611 are installed on one side of the connecting block 535, a drag chain 612 is fixed on the drag chain mounting bracket horizontal plate 611, a drag chain mounting plate 613 is installed on the bottom surface of one side of the base plate 4, the drag chain 612 is fixedly connected to the drag chain mounting plate 613, and parallel blocks 555 are respectively installed at both ends of the top surface of the drag chain mounting plate 613 between the guide rail A5 and the grating ruler 6.

[0061] The controller records the actual perimeter, which is used as the effective perimeter of the encoder in the subsequent system.

[0062] The controller can record the actual perimeter, providing data support for subsequent systems.

[0063] In summary, this invention replaces manual calculation with a system program, allowing the entire calibration process to be completed automatically simply by the worker pressing the start button. The encoder continuously sends pulses to the PLC, and the grating ruler 6 also continuously sends pulses to the PLC. By using the grating ruler 6 to replace the entire measurement process and the system program to replace manual calculation, the technical requirements for workers are reduced, making the process faster and simpler. Moreover, using the grating ruler for measurement is more accurate than using a tape measure or manual measurement, and can truly reflect the distance the material has traveled.

[0064] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0065] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A structure and method for calibrating the circumference of an encoder counting wheel, characterized in that: The device includes a support frame (3), a base plate (4) is installed on one side above the support frame (3), a guide rail A (5) is installed on the base plate (4), a slider A (510) is installed on the guide rail A (5), a clamping seat (544) is installed on the slider A (510), a profile clamping fixture (543) is movably installed in the clamping seat (544), a grating ruler (6) is installed on the base plate (4) and on one side of the guide rail A (5) parallel to the guide rail A (5), a grating ruler slider (620) is provided on the outside of the grating ruler (6), and the grating ruler slider (620) is connected to the clamping fixture fixing seat (544) through a connecting block (535). The support frame (3) is arranged on one side of the roller encoder feeding device (2), and an encoder counting wheel (1) is provided on the side of the roller encoder feeding device (2).

2. The encoder counter wheel circumference calibration structure of claim 1, wherein: The profile clamping fixture (543) is machined with a groove to accommodate the profile, and the profile clamping fixture (543) has a threaded hole on its side for installing a tightening screw (545). The tightening screw (545) is movably installed inside the profile clamping fixture (543).

3. The encoder counter wheel circumference calibration structure of claim 1, wherein: A horizontal slider mounting plate (520) is installed on the slider A (510). A horizontal guide rail (531) is installed on the horizontal slider mounting plate (520). A horizontal slider (530) is installed on the horizontal guide rail (531). A vertical slider mounting seat (536) is installed on the horizontal slider (530). A vertical guide rail (541) is installed on one side of the vertical slider mounting seat (536). A vertical slider (540) is provided on the vertical guide rail (541). A clamp fixing seat (544) is installed on one side of the vertical slider (540). One end of the horizontal slider mounting plate (520) is connected to the grating ruler slider (620) through a connecting block (535). A reinforcing block (534) is welded to the top of the horizontal slider mounting plate (520).

4. The encoder counter wheel circumference calibration structure of claim 1, wherein: A stop block (532) is installed on one side of the horizontal slider mounting plate (520), and springs (533) are installed between the horizontal slider mounting plate (520) and the stop block (532) and between the horizontal slider mounting plate (520) and the connecting block (535).

5. The encoder counter wheel circumference calibration structure of claim 1, wherein: A limiting block (546) is installed at one end of the vertical slider mounting base (536), and a spring (533) is installed between the limiting block (546) and the vertical slider (540).

6. The encoder counter wheel circumference calibration structure of claim 1, wherein: The connecting block (535) is equipped with a drag chain mounting bracket upright plate (610) and a drag chain mounting bracket horizontal plate (611) on one side. A drag chain (612) is fixed on the drag chain mounting bracket horizontal plate (611). A drag chain mounting plate (613) is installed on the bottom surface of one side of the base plate (4). A drag chain (612) is fixedly connected to the drag chain mounting plate (613).

7. The encoder counter wheel circumference calibration structure of claim 6, wherein: Parallel blocks (555) are installed at both ends of the top surface of the drag chain mounting plate (613) between the guide rail A (5) and the grating ruler (6).

8. The encoder counter wheel circumference calibration structure of claim 1, wherein: It also includes the electrical control section, including the host computer and PLC.

9. The encoder counting wheel circumference calibration structure according to any one of claims 1-8, characterized in that: The calibration steps include the following: S1, install the profile into the opening of the profile clamping fixture (543) and tighten it with the tightening screw (545). One end of the profile extends to a position that fully contacts the encoder roller, and at the same time tightens the tightening screw (545) located on the side of the fixture fixing seat (544). S2, Set the electrical control section to encoder calibration mode, and set the calibration parameters, speed, and length; S3, press the encoder calibration button, the roller feeding section clamping cylinder starts to clamp, and feeding begins; S4, Calibration process: Before feeding begins, the encoder coordinates on the controller are zeroed, and the actual position value of the grating ruler (6) is zeroed; After the zeroing is fully completed, the profile is fed in under the roller drive until it reaches the set calibration length and stops. During this process, the encoder continuously sends the generated pulses to the PLC, and the grating ruler (6) also continuously sends pulses to the PLC. When the profile reaches the calibration end point, the controller system records the total number of pulses sent by the encoder and the grating ruler (6) and calculates the actual circumference of the encoder based on this. Let Nb be the number of pulses transmitted by the encoder. The number of pulses Nq that the encoder can generate in one revolution Number of pulses transmitted by the grating ruler (Ng) The distance K corresponding to one pulse of the grating ruler The actual perimeter of the encoder is L L=Ng*K*Nq / Nb S5: The controller records the actual perimeter, which will be used as the effective perimeter of the encoder in the subsequent system.

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