Acceleration dynamic measurement system for pulley under high-speed operation condition

Abstract

The application relates to the technical field of acceleration measurement, and discloses an acceleration dynamic measurement system under high-speed operation conditions of a belt pulley, which comprises a main base module, an inertia decoupling module, a magnetic coupling module, a signal sensing module and an oscillation suppression module; the inertia decoupling module is embedded with the main base module through an inclined conical surface interface; centrifugal force generated by high-speed rotation is used to drive the inertia decoupling module to expand radially, and the radial expansion is converted into normal approaching displacement through geometric constraints of the inclined conical surface interface, so as to compress a magnetic gap and offset magnetic flux density attenuation; the signal sensing module senses magnetic flux transients when the inertia decoupling module produces angular deviation relative to the main base module, and outputs induced voltage data; and the oscillation suppression module uses eddy current to generate an electromagnetic torque to suppress mechanical oscillation. The application realizes air gap self-compensation through a physical mechanism, maintains a constant physical transfer function in a wide rotating speed range, effectively avoids the amplification effect of mathematical derivation on high-frequency noise, and ensures collection accuracy.

Description

Technical Field

[0001] This invention relates to a dynamic acceleration measurement system for belt pulleys operating at high speeds, and belongs to the field of acceleration measurement technology. Background Technology

[0002] Currently, in the state monitoring and feedback control of power transmission systems, the angular acceleration of the pulley is the core physical parameter characterizing transmission slip, sudden load changes, and shaft torsional vibration. The mainstream technology in the industry currently uses photoelectric encoders or rotary transformers to collect angular displacement signals and uses microprocessors to calculate the acceleration based on discrete differential logic.

[0003] However, when the pulley is operating at high speed, high-frequency mechanical disturbances caused by manufacturing tolerances, dynamic changes in belt tension, and bearing clearance are superimposed on the speed signal as phase noise. Since the differential operator has high-pass characteristics in its mathematical nature, the operation process amplifies high-frequency noise, resulting in distortion of the output signal. To suppress noise, a common practice is to add a low-pass filter in the operation link. However, the filtering process will cause phase lag of the measured signal on the time axis, resulting in system response delay and inability to reflect transient physical processes in real time. This contradiction between relying on filtering accuracy and sacrificing the effectiveness of dynamic response is the fundamental constraint of the existing differential sampling system. Even if the sampling frequency is increased, it is difficult to eliminate the sensitivity of the mathematical differentiation mechanism to high-frequency disturbances from the physical source. In addition to the limitations of hardware acquisition logic, there are shortcomings at the algorithm control level. For example, Chinese invention patent with authorization announcement number CN109883712B discloses a method for measuring the rotational vibration of an engine cylinder block, which sets two triaxial acceleration sensors in the cylinder block and uses spatial vector cross product operation to solve angular acceleration.

[0004] Therefore, how to construct a measurement architecture that does not rely on discrete differential operations and directly captures the physical eigenvalues ​​of acceleration has become the technical problem to be solved by this invention. Summary of the Invention

[0005] To address the problems mentioned in the background art, the technical solution of the present invention is as follows: A dynamic acceleration measurement system for belt pulleys under high-speed operation conditions, comprising:

[0006] The main body module is connected to the inertial decoupling module through the air gap compensation module, which forms an inclined conical surface interface with a preset tilt angle.

[0007] The magnetic coupling module includes an inner magnetic pole unit and an outer magnetic pole unit respectively disposed on both sides of the inclined conical surface interface. A working air gap is provided between the inner magnetic pole unit and the outer magnetic pole unit to establish magnetic torsional constraints between the main body module and the inertial decoupling module.

[0008] The inertial decoupling module is used to generate radial elastic deformation by utilizing the centrifugal force generated by high-speed operation. The air gap compensation module is used to convert the radial elastic deformation into displacement along the normal direction of the inclined conical surface interface based on the geometric constraints of the interface, so as to compress the working air gap and offset the attenuation of magnetic induction intensity caused by the radial elastic deformation.

[0009] The signal sensing module is used to sense the transient magnetic flux when the inertial decoupling module shifts angularly relative to the main body module, and outputs induced voltage data characterizing the acceleration.

[0010] The oscillation suppression module includes a conductive unit fixed on the main base module. The conductive unit extends into the edge leakage magnetic field generated by the magnetic coupling module and is used to suppress the mechanical oscillation of the inertial decoupling module by using the braking torque generated by cutting the magnetic field lines.

[0011] Preferably, the half-cone angle of the inclined conical surface interface of the air gap compensation module is configured such that, when the main base module is in operation, the amount of air gap compression caused by displacement is equal to the component of the radial deformation of the inertial decoupling module caused by centrifugal force in the normal direction of the inclined conical surface interface, so as to maintain the static torsional stiffness of the magnetic coupling module.

[0012] Preferably, the inner and outer magnetic pole units in the magnetic coupling module are arranged alternately along the circumferential direction to form a magnetic spring circuit between the main body module and the inertial decoupling module.

[0013] Preferably, the signal sensing module includes multiple sets of induction coil units distributed along the circumference of the main base module; the multiple sets of induction coil units are used to generate induced voltage data by sensing the change in magnetic flux caused by the relative angular displacement between the inner magnetic pole unit and the outer magnetic pole unit when the main base module generates angular acceleration.

[0014] Preferably, the multiple sets of induction coil units adopt a differential connection structure to cancel the radial runout interference signal generated by the main substrate module while superimposing the angular offset induction signal, so as to improve the signal-to-noise ratio of the induction voltage data.

[0015] Preferably, the real-time normal air gap δ at the air gap compensation module satisfies the following quantization relationship: ,in, Δr is the initial air gap length when the main base module is stationary, Δr is the radial displacement of the inertial decoupling module caused by centrifugal force, and θ is the semi-cone angle of the inclined conical surface interface relative to the rotation axis of the main base module.

[0016] Preferably, the conductive unit in the oscillation suppression module is made of a metal material with a conductivity of not less than 3.5E7S / m, and the axial thickness of the conductive unit is less than the axial gap where the edge leakage magnetic field is located.

[0017] Preferably, the inertial decoupling module uses a lightweight alloy material with an elastic modulus between 65 GPa and 80 GPa to generate linearly recoverable radial elastic deformation in the speed range of 0 to 6000 r / min.

[0018] Preferably, the output of the signal sensing module is electrically connected to a signal processing subsystem, which includes a preamplifier module and a low-pass filter module with a cutoff frequency of 500Hz, for extracting and outputting induced voltage data.

[0019] Preferably, the permanent magnet units in the magnetic coupling module are arranged in a Hellbeck array to enhance the magnetic flux density at the inclined conical interface and weaken the magnetic field distribution on the back side of the main substrate module, thereby improving the sensitivity of the signal sensing module.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. In the case of high-speed operation of the pulley, the physical differential characteristics of electromagnetic induction are utilized to reconstruct the traditional discrete sampling of angular position and mathematical differential operation logic into a physical intrinsic induction process in the spatial domain. Since the topological induction unit only generates induced voltage when the pulley generates angular acceleration, causing the secondary hysteresis magnetic field to undergo a spatial phase transient, the system filters out the constant speed base signal at the physical source, avoiding the exponential amplification effect of the mathematical differential operator on high-frequency mechanical noise. This allows the output analog voltage signal to directly characterize the transient value of angular acceleration, effectively improving the signal-to-noise ratio and response speed of dynamic acceleration acquisition under high-speed conditions.

[0022] 2. By constructing a self-cancelling structure of normal strain on a conical surface between the main body of the pulley and the inertial decoupling module, the radial elastic expansion generated by the inertial decoupling module driven by centrifugal force is transformed into a near displacement along the normal direction of the conical surface under the geometric constraints of the conical surface. This automatically compresses the working air gap of the magnetic coupling pair, compensates for the attenuation of magnetic flux density and the weakening of torsional stiffness caused by the increase of rotational speed or the increase of ambient temperature, and ensures that the measurement system maintains a constant acceleration to displacement mapping reference within a wide rotational speed envelope. This solves the problem of parasitic destruction of the physical transfer function by the centrifugal field of the base rotational speed in the field of dynamic measurement.

[0023] 3. A non-contact eddy current damping mechanism with repeated use of magnetic flux boundaries is adopted. A non-magnetic conductive energy-consuming disk is inserted into the edge magnetic flux return air gap of the magnetic coupling pair. When the inertial decoupling module generates high-frequency relative oscillation, it cuts the edge magnetic lines of force to generate a passive electromagnetic damping torque. This physical-level frequency adaptive suppression characteristic can suppress the mechanical overshoot of the system at its natural frequency without introducing additional friction pairs or viscous fluids. This allows the measurement system to maintain linear response characteristics under wideband excitation, balancing the contradiction between measurement sensitivity and operating condition adaptability. Attached Figure Description

[0024] Figure 1 This is a flowchart illustrating the working principle and data generation process of the belt pulley acceleration measurement system of the present invention.

[0025] Figure 2 This is a spatial architecture and signal processing link diagram of the internal modules of the measurement system of the present invention.

[0026] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0028] A dynamic acceleration measurement system for belt pulleys operating at high speeds includes:

[0029] The main body module is connected to the inertial decoupling module through the air gap compensation module, which forms an inclined conical surface interface with a preset tilt angle.

[0030] The magnetic coupling module includes an inner magnetic pole unit and an outer magnetic pole unit respectively disposed on both sides of the inclined conical surface interface. A working air gap is provided between the inner magnetic pole unit and the outer magnetic pole unit to establish magnetic torsional constraints between the main body module and the inertial decoupling module.

[0031] The inertial decoupling module is used to generate radial elastic deformation by utilizing the centrifugal force generated by high-speed operation. The air gap compensation module is used to convert the radial elastic deformation into displacement along the normal direction of the inclined conical surface interface based on the geometric constraints of the interface, so as to compress the working air gap and offset the attenuation of magnetic induction intensity caused by the radial elastic deformation.

[0032] The signal sensing module is used to sense the transient magnetic flux when the inertial decoupling module shifts angularly relative to the main body module, and outputs induced voltage data characterizing the acceleration.

[0033] The oscillation suppression module includes a conductive unit fixed on the main base module. The conductive unit extends into the edge leakage magnetic field generated by the magnetic coupling module and is used to suppress the mechanical oscillation of the inertial decoupling module by using the braking torque generated by cutting the magnetic field lines.

[0034] Preferably, the half-cone angle of the inclined conical surface interface of the air gap compensation module is configured such that, when the main base module is in operation, the amount of air gap compression caused by displacement is equal to the component of the radial deformation of the inertial decoupling module caused by centrifugal force in the normal direction of the inclined conical surface interface, so as to maintain the static torsional stiffness of the magnetic coupling module.

[0035] Preferably, the inner and outer magnetic pole units in the magnetic coupling module are arranged alternately along the circumferential direction to form a magnetic spring circuit between the main body module and the inertial decoupling module.

[0036] Preferably, the signal sensing module includes multiple sets of induction coil units distributed along the circumference of the main base module; the multiple sets of induction coil units are used to generate induced voltage data by sensing the change in magnetic flux caused by the relative angular displacement between the inner magnetic pole unit and the outer magnetic pole unit when the main base module generates angular acceleration.

[0037] Preferably, the multiple sets of induction coil units adopt a differential connection structure to cancel the radial runout interference signal generated by the main substrate module while superimposing the angular offset induction signal, so as to improve the signal-to-noise ratio of the induction voltage data.

[0038] Preferably, the real-time normal air gap δ at the air gap compensation module satisfies the following quantization relationship: ,in, Δr is the initial air gap length when the main base module is stationary, Δr is the radial displacement of the inertial decoupling module caused by centrifugal force, and θ is the semi-cone angle of the inclined conical surface interface relative to the rotation axis of the main base module.

[0039] Preferably, the conductive unit in the oscillation suppression module is made of a metal material with a conductivity of not less than 3.5E7S / m, and the axial thickness of the conductive unit is less than the axial gap where the edge leakage magnetic field is located.

[0040] Preferably, the inertial decoupling module uses a lightweight alloy material with an elastic modulus between 65 GPa and 80 GPa to generate linearly recoverable radial elastic deformation in the speed range of 0 to 6000 r / min.

[0041] Preferably, the output of the signal sensing module is electrically connected to a signal processing subsystem, which includes a preamplifier module and a low-pass filter module with a cutoff frequency of 500Hz, for extracting and outputting induced voltage data.

[0042] Preferably, the permanent magnet units in the magnetic coupling module are arranged in a Hellbeck array to enhance the magnetic flux density at the inclined conical interface and weaken the magnetic field distribution on the back side of the main substrate module, thereby improving the sensitivity of the signal sensing module.

[0043] Example 1: In a continuously operating wide-speed drive system, the main drive pulley needs to provide real-time transient angular acceleration measurement data characterizing transmission slip and load changes while maintaining a steady-state base speed of 6000 r / min. At this time, the system is subjected to centrifugal physical field induced by rotation and radial runout interference caused by manufacturing tolerances and bearing clearance. When using traditional discrete sampling and mathematical differentiation measurement methods to deal with speed signals containing high-frequency mechanical jitter, its differential operator has high-pass filtering characteristics. This characteristic amplifies high-frequency noise, thereby drowning out the true transient angular acceleration. If a post-processed digital filtering algorithm is used to purify the signal, phase lag will occur, causing the output acceleration signal to lose real-time performance. When using a conventional solid inertial measurement architecture, the peripheral inertial decoupling module undergoes radial elastic expansion under centrifugal force. This deformation widens the working air gap of the magnetic coupling module, causing the torsional stiffness of the system to decrease as the base speed increases. The above process destroys the mapping reference between relative angular displacement and angular acceleration, causing measurement distortion.

[0044] To obtain angular acceleration parameters, the acceleration dynamic measurement system relies on the nested structure of the main base module and the inertial decoupling module to intervene in this operating condition. The inertial decoupling module is suspended radially outside the main base module by four sets of symmetrically distributed circumferential metal flexible supports. The radial elastic modulus of the supports is set such that the radial displacement Δr of the inertial decoupling module is within the geometric constraint range of the inclined conical surface interface under the centrifugal force at the highest rated speed. The circumferential shear stiffness of the supports is less than one-tenth of the magnetic torsional stiffness of the magnetic coupling module, so that the inertial decoupling module has the circumferential rotational freedom relative to the main base module when it undergoes radial elastic deformation. The supports are made of 65Mn spring steel sheets with a thickness of 0.5mm and a width of 12mm. Its circumferential static stiffness is calibrated to 1.25Nm / rad by a step thrust of 100mN. Physical limit pins ensure that the radial travel of the supports under centrifugal force does not exceed 1.5m / rad. mm, thus maintaining the circumferential degree of freedom of the support under high-speed conditions, allowing the magnetic coupling module to capture relative angular displacement caused by angular acceleration and avoid mechanical friction resistance. When the pulley is subjected to alternating load and generates transient angular acceleration, the inertial decoupling module with rotational inertia generates an inertial torque that resists the change in rotational speed, causing the magnetic coupling module composed of inner and outer magnetic pole units to undergo torsional deflection, generating a relative angular displacement proportional to the angular acceleration. The inclined conical surface interface of the air gap compensation module establishes the measurement reference. When the base rotational speed causes the inertial decoupling module to elastically expand radially outward, the geometric constraint of the inclined conical surface interface converts this radial displacement into a near displacement along the normal direction of the conical surface. This normal near displacement compresses the working air gap of the magnetic coupling module. The system relies on the increase in magnetic flux density caused by the reduction in air gap to offset the attenuation of magnetic induction intensity caused by centrifugal deformation, thereby maintaining constant torsional stiffness within the rotational speed envelope.

[0045] Simultaneously, the conductive unit fixed to the main base module extends into the edge leakage magnetic field generated by the magnetic coupling module. When the inertial decoupling module is subjected to broadband excitation, inducing a high-frequency mechanical oscillation tendency, the conductive unit cuts the edge leakage magnetic field and excites induced eddy currents. The system generates an electromagnetic braking torque opposite to the direction of the relative angular velocity according to the Lorentz force law. An oscillation suppression mechanism is constructed using leakage magnetic energy. Multiple sets of induction coil units distributed in the circumferential direction of the main base module sense the change in magnetic flux excited when the inner and outer magnetic pole units are relatively displaced. The signal sensing module, in conjunction with its internal differential connection structure, simultaneously superimposes the circumferential acceleration signal in phase. Subtracting the common-mode interference flux of the same polarity caused by radial mechanical vibration, the signal sensing module generates induced voltage data representing the transient value of angular acceleration at its output. The induced voltage data output by the system is exempt from differential calculation and low-pass filtering and is directly used as an analog feedback source to be introduced into the downstream motor drive control closed loop. In the transmission condition where centrifugal force field and high-frequency mechanical vibration are intertwined, the system converts centrifugal expansion deformation into physical driving force for compressing the working air gap. At the same time, the system converts the common-mode radial vibration that causes signal distortion into the cancellation parameter inside the differential structure. The above structure forms a calculation link from inertial mechanical response to electromagnetic induction output.

[0046] Example 2: In the test conditions for evaluating the dynamic response characteristics of a high-speed belt pulley drive system, high-frequency transient angular acceleration data containing mechanical eccentricity interference exhibited physical reference drift. The test was conducted on a programmable dynamic torque loading platform consisting of an asynchronous drive motor with a rated speed of 10000 r / min and an eddy current dynamometer. This platform has a torque pulsation resolution of 0.1 N·m and a spindle radial runout tolerance of 0.2 mm, used to input wideband load abrupt changes and base speed fluctuation parameters. The half-cone angle of the inclined conical interface of the air gap compensation module is set in relation to the centrifugal compensation amount and axial sliding friction. When the value of this half-cone angle approaches 0°, the inclined conical surface transforms into a cylindrical surface, losing the normal compensation dimension. When the value of this half-cone angle is greater than the critical value, the normal component force generated by radial expansion causes axial normal pressure between the inner and outer modules, inducing frictional interference and hindering the generation of relative angular displacement. The system determines this angle based on the compensation amount balance formula, as follows: ,in, Δr represents the normal air gap compression, k represents the stiffness transfer coefficient of the coupling interface. The stiffness transfer coefficient is obtained by physical calibration after the system is assembled by applying a radial simulated load of 20N. The measured ratio of radial displacement to normal displacement is collected. This coefficient is cured to 0.94 at room temperature. Δr represents the radial expansion induced by centrifugal force, and θ represents the half-cone angle of the inclined conical surface interface. Based on this relationship, the magnetic flux attenuation rate of the existing magnetic circuit at the rated speed is matched, and the working range of the half-cone angle is determined to be 15° to 30°. 22.5° is selected as the parameter value for constructing the test specimen.

[0047] The experiment injected a continuous radial vibration disturbance with an amplitude of 0.15 mm and a frequency of 50 Hz into the spindle to introduce bearing clearance runout noise. Simultaneously, at a set gradient base speed, a step angular acceleration excitation with an amplitude of 150 rad / s² was instantaneously applied. Three independent sample groups were established: the sample group of this invention used a slanted conical surface interface with a half-cone angle of 22.5° and included a conductive unit; the missing control group used a cylindrical surface interface with a half-cone angle of 0° and no conductive unit; and the out-of-range control group used a slanted conical surface interface with a half-cone angle of 45° and included a conductive unit. The experiment collected the magnetic flux density deviation and the step response time of the output induced voltage for each sample group at four gradient base speeds: 2000 r / min, 4000 r / min, 6000 r / min, and 8000 r / min. The original output... The input signal shows that at the moment of step excitation triggering, all sample groups were subjected to the interference impact of 50Hz radial vibration. For the missing control group, when the base rotation speed reached 6000r / min, the centrifugal force caused the inertial decoupling module to produce a radial deformation of 0.12mm, which caused the working air gap to increase proportionally. The increase in air gap caused the magnetic flux density to decrease by 18.5%. After superimposed with 50Hz radial vibration, the induced voltage data output by the missing control group showed a high-frequency fluctuation with a peak-to-peak value of 32.4%, and the step response signal characteristics disappeared in the common-mode interference. For the out-of-range control group, at the same base rotation speed of 6000r / min, the normal approach generated by the 45° half-cone angle caused frictional hindrance between modules. The step response time of this sample group was extended to 48.6ms, and it could not output the real-time signal required for dynamic measurement.

[0048] For the prototype of this invention, under the condition of 6000 r / min, the 22.5° oblique conical interface converts the radial expansion of 0.12 mm into a normal approximation of 0.045 mm according to the aforementioned relationship. This normal approximation offsets the centrifugal attenuation, limiting the magnetic flux density deviation to within 1.2% of the initial static value. The eddy current braking torque excited in the edge leakage magnetic field of the conductive unit consumes the mechanical oscillation energy, suppressing the voltage fluctuation amplitude caused by 50 Hz vibration to 1.5%. In the speed gradient verification, the prototype of this invention maintains the output acceleration amplitude error within the range of 1.1% to 1.4% in the range of 2000 r / min to 6000 r / min. When the rotational speed climbs to 8000 r / min, the data curve shows a nonlinear inflection point. As the magnetic circuit material approaches the magnetic saturation limit, the incremental magnetic flux generated by the compression of the normal air gap decreases marginally. The output error of the sample group of this invention rises to 2.9%. When it is in this saturation degradation range, the measurement error of the sample group of this invention is still lower than the divergence error of 45.2% of the missing control group at the same rotational speed. The experimental data reflects the physical operation state of the interaction between spatial geometric constraints and electromagnetic energy. The inclined conical interface and the conductive unit suppress centrifugal deformation and high-frequency mechanical jitter within the determined parameter range, so that the measurement system maintains a stable physical transfer function within the rotational speed envelope spanning 8000 r / min.

[0049] Example 3: Addressing the physical phenomena of residual resonance generated by the inertial decoupling module under sudden load excitation in the drive system, and residual common-mode interference during signal extraction, the system establishes engineering operating procedures for oscillation suppression parameters and signal processing. The parameter setting of the conductive unit in the oscillation suppression module faces physical constraints of underdamping and overdamping. If the electromagnetic damping coefficient is too low, the mechanical oscillation decay time is too long; if the electromagnetic damping coefficient is too high, excessive electromagnetic braking torque hinders the inertial decoupling module's response to transient angular acceleration. The system determines the physical parameters of the conductive unit based on critical damping matching logic. The conductive unit of the oscillation suppression module uses a hard aluminum alloy disk with a conductivity of not less than 3.5E7S / m and a thickness of 1.8mm. The edge of the conductive unit extends axially into the leakage magnetic field region of the permanent magnet unit, with an axial air gap width of 2.3mm in the leakage magnetic field region, providing a damping ratio of not less than 0.85. The system withstands an amplitude of 150rad / s. Under a step angular acceleration load, the conductive unit cuts the magnetic field lines to generate induced eddy currents, which interact with the edge leakage magnetic field to generate an electromagnetic braking torque. This causes the residual mechanical oscillation of the inertial decoupling module to decay to less than 5% of the initial amplitude within 12ms. Without introducing viscous damping fluid to smooth the system's transient overshoot and maintain the linearity of the output induced voltage data, the conductive unit is constructed using non-magnetic metal materials. Under a given edge leakage magnetic field strength, the eddy current braking torque is positively correlated with the thickness and conductivity of the conductive unit. The test platform injects a sweep frequency vibration excitation with a bandwidth of 10Hz to 500Hz into the spindle. The system continuously monitors the torsional amplitude decay time of the inertial decoupling module relative to the main base module. When an aluminum-based alloy with a resistivity of 0.028μΩ·m is selected and its thickness is set to 1.85mm, the torsional amplitude decays to 5.2% of the initial excitation peak within 12.4ms after the system is subjected to a step disturbance with an amplitude of 150rad / s². This parameter combination constrains the eddy current braking torque within the critical damping window and suppresses high-frequency mechanical jitter.

[0050] The process of acquiring magnetic flux transient data by the signal sensing module does not involve digital sampling intervention. Multiple sets of induction coil units distributed along the circumference of the main base module are arranged in spatial anti-phase series to form a differential connection structure. When the inner magnetic pole unit and the outer magnetic pole unit undergo relative angular displacement, the circumferentially arranged induction coil unit group synchronously cuts the magnetic field lines and generates an induced electromotive force. The system directly inputs this set of analog electrical signals into a pure hardware analog subtractor circuit via wires. The analog subtractor outputs a signal according to the differential ratio relationship, which is as follows: ,in, This represents the output induced voltage data, where G represents the inherent gain coefficient of the analog subtractor. This represents the first induced electromotive force collected by the counterclockwise coil unit. The second induced electromotive force collected by the clockwise coil unit is represented by a gain coefficient of 24.5 in the experiment. This hardware differential structure superimposes the circumferential acceleration signal in phase while subtracting the common-mode interference flux of the same polarity caused by radial mechanical runout using the physical inverting input of the analog subtractor. The aforementioned conductive unit with specific thickness and resistivity parameters, combined with the differential signal sensing module in the pure analog domain, enables the acceleration measurement system to operate without digital low-pass filtering. The system converts the torsional deflection displacement containing eccentric noise into an analog voltage signal characterizing transient angular acceleration, with an output delay time of less than 0.8ms, maintaining the real-time dynamic response in the transmission condition.

[0051] Example 4: When the system faces the initial assembly condition of a brand-new belt-driven shaft system, due to the objective existence of machining tolerances and the initial static clearance of the bearings, the initial working air gap between the inner and outer magnetic pole units deviates from the theoretical design median value. The system establishes a pre-baseline calibration procedure, and the axial relative position of the inclined conical surface interface is adjusted by the static reference calibration of the air gap compensation module. When the main base module is stationary, the normal initial air gap is set by increasing or decreasing the thickness of the axial compensation shims of the inner and outer magnetic pole units. The thickness is 0.6 mm. Under dynamic operating conditions, the static magnetic flux density reference value output by the monitoring signal sensing module is used to correct the half-cone angle θ of the inclined conical interface. The half-cone angle θ is the angle between the inclined surface of the inclined conical interface and the axis of rotation. An angle value of 15° to 30° is selected to achieve a physical balance between the normal air gap compression Δg caused by radial expansion and the magnetic permeability decay caused by the temperature rise of the magnetic circuit material. The magnetic induction intensity fluctuation amplitude at 6000 r / min speed is maintained within 1.5% of the initial static value. When the drive motor is de-energized and the spindle is in a free and stationary state, the test bench applies a gradient static torque to the main drive pulley until it reaches 10% of the rated load to eliminate the mechanical doubling of the transmission chain. At this time, the current detection circuit inside the signal sensing module continuously reads the static background induced electromotive force of the counterclockwise side coil unit and the clockwise side coil unit. The system adjusts the zero-point bias potential of the analog subtractor according to the difference amplitude of the dual-side background electromotive force to physically clamp the reference output voltage to the 0V reference reference plane under the state of no dynamic angular acceleration.

[0052] After establishing the static electrical reference, the system needs to match the extreme response range limits of the specific application scenario to set the inherent gain coefficient in the aforementioned differential proportional relationship. The test bench injects a standard step angular acceleration calibration signal with a preset amplitude of 100 rad / s² into the spindle. The induction coil unit groups distributed in the circumferential direction of the main base module synchronously collect the transient differential mode magnetic flux change parameters. The system uses a 12-bit analog-to-digital converter with a sampling frequency of 15 kHz to store the analog voltage generated by the induction coil in a 32-byte circular buffer. By comparing the difference between two adjacent sampling periods, when the voltage change exceeds the trigger threshold of 5 mV, it is determined to be an angular acceleration step response. The system measures the analog subtractor output at this time. The first transient induced voltage peak generated at the output terminal is used to calculate the compensation multiplier based on the ratio of the upper limit of the full-scale voltage of the target range to the first transient induced voltage peak. The inherent gain coefficient is locked at this ratio level by adjusting the resistance of the hardware potentiometer of the analog subtractor preamplifier stage. After the hardware of this parameter is fixed, the signal sensing module operates directly according to this fixed parameter in normal measurement conditions and outputs analog induced voltage data representing the transient value of angular acceleration. A second-order Butterworth active filter circuit is cascaded at the analog signal output terminal, and its cutoff frequency is set to 500Hz. The group delay time generated by the hardware circuit is calibrated to 0.72ms in the full frequency band. This delay is canceled out by the lead compensation operator in the back-end drive algorithm.

[0053] Example 5: In the deployment of a rotating test bench equipped with laser interferometric ranging, the system executes a steady-state measurement procedure to establish a true stiffness transfer benchmark for a specific assembly. Under a constant ambient temperature of 25°C, the test bench drives the main substrate module to operate steadily within a 1000 r / min step increment range from 1000 r / min to 8000 r / min. At each steady-state speed node, the laser interferometric rangefinder synchronously collects the radial deformation expansion of the inertial decoupling module and the normal air gap compression between the inner and outer magnetic pole units. The system inputs the collected multiple sets of spatial coordinate data points into a multivariate linear regression calculation. The system performs fitting calculations and extracts the slope parameter of the obtained fitting curve as the true stiffness transfer coefficient characterizing the physical properties of the specific hardware assembly. The system uses an NTC thermistor embedded in the main body module to monitor the ambient temperature in real time and calls the preset compensation lookup table logic. When the shell temperature rises by 10 degrees Celsius, the stiffness transfer coefficient is automatically corrected downward by 1.5% to offset the 4.2% softening deviation of the elastic modulus of the lightweight alloy material caused by temperature rise. This coefficient data directly replaces the theoretical empirical constant in the system storage architecture and is solidified into the underlying calibration firmware of the signal sensing module, establishing the physical compensation baseline of the air gap compensation module before leaving the factory.

[0054] In online application conditions involving long-cycle operation and temperature fluctuations, the system executes a state reset procedure within the first 2 seconds after each power-on. This procedure injects a step test torque pulse with an amplitude of 5% of the rated load torque and a pulse width of 10ms into the drive motor control terminal. Simultaneously, the signal sensing module continuously acquires the attenuation envelope signal of the induced voltage excited by this pulse. The system extracts the time span from the peak value of this envelope signal to 10% of the peak value as the dynamic damping time constant. When the damping time constant is determined to be greater than the critical damping tolerance upper limit of 15ms, the system triggers the internal electrical compensation logic. The logic processor then sends a signal to the parallel-connected... The digital potentiometer in the feedback loop sends a serial pulse command to reduce the feedback resistance in 256-level adjustment steps. Each step corresponds to a 195 Ohm reduction in resistance, until the oscillation decay time of the induced voltage is detected to converge to the range of 12ms. The signal sensing module adjusts the compensation impedance network of the analog subtractor output circuit proportionally to the offset between the measured time constant and the reference value, and cyclically executes the self-test pulse test and impedance adjustment operation until the latest measured damping time constant converges within the reference window of 12ms to 13ms, thus physically counteracting the attenuation of the overall system damping characteristics caused by the drift of environmental parameters.

[0055] 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 present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A dynamic acceleration measurement system for belt pulleys operating at high speeds, characterized in that, include: The main body module is connected to the inertial decoupling module through the air gap compensation module, which forms an inclined conical surface interface with a preset tilt angle. The magnetic coupling module includes an inner magnetic pole unit and an outer magnetic pole unit respectively disposed on both sides of the inclined conical surface interface. A working air gap is provided between the inner magnetic pole unit and the outer magnetic pole unit to establish magnetic torsional constraints between the main body module and the inertial decoupling module. The inertial decoupling module utilizes the centrifugal force generated by high-speed operation to produce radial elastic deformation. The air gap compensation module, based on the geometric constraints of the inclined conical interface, converts the radial elastic deformation into displacement along the normal direction of the inclined conical interface to compress the working air gap and offset the attenuation of magnetic induction intensity caused by the radial elastic deformation. The half-cone angle of the inclined conical interface of the air gap compensation module is configured such that, during the operation of the main base module, the air gap compression caused by displacement is equal to the component of the radial deformation of the inertial decoupling module caused by centrifugal force along the normal direction of the inclined conical interface, thus maintaining the static torsional stiffness of the magnetic coupling module. The real-time normal air gap δ at the air gap compensation module satisfies the following quantification relationship: ,in, Δr is the initial air gap length when the main base module is stationary, Δr is the radial displacement of the inertial decoupling module caused by centrifugal force, and θ is the semi-cone angle of the inclined conical surface interface relative to the rotation axis of the main base module. The signal sensing module is used to sense the transient magnetic flux when the inertial decoupling module shifts angularly relative to the main body module, and outputs induced voltage data characterizing the acceleration. The oscillation suppression module includes a conductive unit fixed on the main base module. The conductive unit extends into the edge leakage magnetic field generated by the magnetic coupling module and is used to suppress the mechanical oscillation of the inertial decoupling module by using the braking torque generated by cutting the magnetic field lines.

2. The acceleration dynamic measurement system for a pulley under high-speed operation as described in claim 1, characterized in that, In the magnetic coupling module, the inner and outer magnetic pole units are arranged alternately along the circumferential direction to form a magnetic spring circuit between the main body module and the inertial decoupling module.

3. The acceleration dynamic measurement system under high-speed operation of a pulley according to claim 1, characterized in that, The signal sensing module includes multiple sets of induction coil units distributed along the circumference of the main base module. These multiple sets of induction coil units are used to generate induced voltage data by sensing the change in magnetic flux caused by the relative angular displacement between the inner and outer magnetic pole units when the main base module generates angular acceleration.

4. The acceleration dynamic measurement system under high-speed operation of a pulley according to claim 3, characterized in that, Multiple sets of induction coil units adopt a differential connection structure to cancel the radial runout interference signal generated by the main substrate module while superimposing the angular offset induction signal, so as to improve the signal-to-noise ratio of the induction voltage data.

5. The acceleration dynamic measurement system for a pulley under high-speed operation as described in claim 1, characterized in that, The conductive unit in the oscillation suppression module is made of a metal material with a conductivity of not less than 3.5E7S / m, and the axial thickness of the conductive unit is less than the axial gap where the edge leakage magnetic field is located.

6. The acceleration dynamic measurement system for a pulley under high-speed operation as described in claim 1, characterized in that, The inertial decoupling module uses a lightweight alloy material with an elastic modulus between 65 GPa and 80 GPa to generate linearly recoverable radial elastic deformation in the speed range of 0 to 6000 r / min.

7. The acceleration dynamic measurement system for a pulley under high-speed operation as described in claim 1, characterized in that, The output of the signal sensing module is electrically connected to a signal processing subsystem, which includes a preamplifier module and a low-pass filter module with a cutoff frequency of 500Hz, used to extract and output induced voltage data.

8. The acceleration dynamic measurement system for a pulley under high-speed operation as described in claim 1, characterized in that, The permanent magnet units in the magnetic coupling module are arranged in a Helbeck array to enhance the magnetic flux density at the inclined conical interface and weaken the magnetic field distribution on the back side of the main substrate module, thereby improving the sensitivity of the signal sensing module.

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