Method and device capable of dynamically calibrating pedal controller

Abstract

The invention discloses a method and device capable of dynamically calibrating a pedal controller, and belongs to the technical field of man-machine interaction control. According to the method, Hall sensor digital values are collected at a fixed frequency, the change rate between adjacent collection values is calculated, and calibration values of a minimum stroke point and a maximum stroke point are dynamically calibrated based on the change rate. When the change rate is larger than the minimum change rate threshold value, it is judged that the minimum stroke point is reached, and the calibration value is updated; when the change rate is smaller than the maximum change rate threshold value, it is judged that the maximum stroke point is reached, and the calibration value is updated. The device comprises a pedal mechanism, a Hall sensor and a control module, the Hall sensor detects the pedal stroke and outputs a signal, and the control module executes dynamic calibration. According to the method, the change rate can be continuously monitored to recognize the pedal travel extreme point, calibration deviation caused by element aging or mechanical fatigue is effectively avoided, the method is suitable for a man-machine interaction system of an operation power device, and accurate control over the rotating speed or direction of an operation tool is achieved.

Description

Technical Field

[0001] This application relates to a method and apparatus for dynamically calibrating a foot pedal controller, belonging to the field of controller calibration technology. Background Technology

[0002] With the continuous development of medical technology, surgical power units have become indispensable equipment in modern operating rooms. Among these devices, the foot pedal controller serves as a crucial human-machine interface between the surgeon and the equipment, and its accuracy and reliability directly affect the safety and outcome of the surgery. Currently, most foot pedal controllers use Hall effect sensors to detect pedal travel and convert it into control signals to adjust the speed or direction of surgical instruments.

[0003] In existing technologies, Hall effect sensors are widely used in various stroke detection scenarios. For example, CN110057595B discloses a calibration method for brake-by-wire stroke. This method determines the maximum stroke value by judging whether the rate of change of the data collected by the Hall effect sensor within a preset time period is less than a preset value, thus realizing automatic calibration of the brake-by-wire stroke. CN202032999U proposes a pedal stroke measurement device for a driving simulator. It uses a data acquisition board with two Hall effect sensors, A and B, to collect pedal stroke information and transmits this information to a microcontroller for processing in the form of digital voltage pulses.

[0004] In the field of flow control, CN120253214A introduces a flow valve position calibration method based on a Hall matrix. This method determines the position calibration parameters by real-time acquisition of the voltage signal output by the Hall sensor array, differential signal noise reduction processing, and identification of slope abrupt change points. CN119022768A discloses a Hall coordinate zero-point calibration method, which determines the Hall zero-point calibration value by recording the Hall values ​​at different positions of the transmission mechanism and calculating the change in Hall values. Furthermore, CN111246108B proposes a Hall sensor calibration method that calibrates the zero drift value of the Hall sensor and calibrates the Hall sensor based on a preset distance and a reference distance.

[0005] However, existing Hall sensor calibration methods have significant shortcomings. First, most calibration methods employ static or fixed-cycle calibration, which cannot address dynamic parameter shifts caused by component aging and mechanical fatigue. Second, traditional calibration methods typically require specialized personnel using dedicated tools, increasing maintenance costs and downtime. Third, existing calibration methods lack precise identification mechanisms for extreme travel points, easily leading to inaccurate calibration parameters and consequently, problems such as false triggering or insensitive control. These issues can have serious consequences, especially in applications requiring extremely high precision, such as surgical power systems.

[0006] Furthermore, most existing calibration methods are designed for specific application scenarios and lack versatility and adaptability. When applied to foot pedal controllers of surgical power devices, these methods struggle to meet the stringent requirements of medical equipment for stability, reliability, and accuracy. Especially during long-term use, factors such as aging of electronic components and mechanical fatigue can cause the Hall effect value of the foot pedal controller to deviate. If timely and effective calibration is not performed, it can lead to inaccurate control and even safety accidents.

[0007] Therefore, there is an urgent need for a method that can dynamically calibrate the foot pedal controller to solve the problems existing in the current technology and improve the control accuracy and reliability of the surgical power device. Summary of the Invention

[0008] To address the technical problem that foot pedal controllers used in surgical power devices require recalibration due to the aging of electronic components and mechanical fatigue causing deviations in the Hall value of the travel pedal after a period of use, this invention provides a method and apparatus for dynamically calibrating foot pedal controllers. This achieves the technical benefits of dynamic calibration parameters during use, eliminating the need for recalibration, providing more precise control, and making use and maintenance more convenient.

[0009] The technical solution adopted by this invention to solve its technical problem is: On one hand, the present invention provides a method for dynamically calibrating a foot pedal controller, comprising: The digital values ​​of the Hall sensor are acquired at a fixed frequency, and the digital values ​​are proportional to the pedal travel of the foot pedal controller; Calculate the rate of change between the currently acquired Hall value and the previously acquired Hall value; Based on the rate of change, the minimum travel point calibration value and the maximum travel point calibration value are dynamically calibrated, wherein the calibration includes: updating the minimum travel point calibration value when the rate of change meets a first condition; and updating the maximum travel point calibration value when the rate of change meets a second condition.

[0010] In one embodiment of the present invention, the dynamic calibration minimum travel point calibration value includes: When the rate of change is greater than the minimum rate of change threshold, it is determined that the minimum travel point has been reached, and the corresponding Hall value is obtained; The Hall value is processed using a sliding window filter to generate a filtered value; The minimum travel point calibration value is updated using the filtered value.

[0011] In one embodiment of the present invention, the dynamic calibration of the maximum travel point calibration value includes: When the rate of change is less than the maximum rate of change threshold, it is determined that the maximum travel point has been reached, and the corresponding Hall value is obtained; The Hall value is processed using a sliding window filter to generate a filtered value; The maximum travel point calibration value is updated using the filtered value.

[0012] In one embodiment of the present invention, the rate of change is calculated using the formula... Implementation, in which The currently collected Hall value. This is the Hall value collected previously.

[0013] In one embodiment of the present invention, the method further includes: continuously monitoring the rate of change during the calibration process to identify the extreme points of the pedal travel, thereby avoiding calibration deviations caused by component aging or mechanical fatigue.

[0014] On the other hand, the present invention also provides a device for dynamically calibrating a foot pedal controller, comprising: The pedal mechanism is used to receive user foot pedal input and generate mechanical displacement; A Hall sensor, mechanically connected to the pedal mechanism, is used to detect pedal travel and output a Hall signal; A control module, communicatively connected to the Hall sensor, is configured to perform the method as described in any one of the above descriptions to dynamically calibrate the calibration parameters.

[0015] In one embodiment of the present invention, the control module includes a processor and a memory, the memory storing instructions that, when executed by the processor, implement the dynamic calibration method.

[0016] In one embodiment of the present invention, the Hall sensor is a linear Hall element, and its output signal is linearly related to the pedal travel.

[0017] In one embodiment of the present invention, the device is applied to the human-computer interaction system of a surgical power device for precisely controlling the rotational speed or direction of surgical tools.

[0018] In one embodiment of the present invention, the pedal mechanism includes a return spring for automatically returning to the initial position after the foot pedal is released; Preferably, the device further includes a communication interface for transmitting the calibrated calibration parameters to an external monitoring system.

[0019] The beneficial effects that this application can produce include: This application achieves dynamic calibration of the minimum and maximum travel points of the foot pedal controller by real-time acquisition of Hall sensor digital values ​​and calculation of their rate of change, combined with sliding window filtering technology. Compared with existing technologies, this invention automatically adapts to Hall value shifts caused by aging of electronic components and mechanical fatigue during use without manual intervention, avoiding the cumbersome recalibration steps required by traditional methods. This dynamic calibration mechanism ensures that the foot pedal controller maintains accurate control output throughout long-term use, making it particularly suitable for medical equipment with high precision requirements, such as surgical power units. It significantly improves the reliability and ease of use of the equipment, and reduces maintenance costs and operational risks. Attached Figure Description

[0020] Figure 1 This is a schematic diagram illustrating the failure of the foot pedal calibration in one embodiment of this application; Figure 2 This is a schematic diagram of the foot pedal travel in one embodiment of this application; Figure 3 This is a flowchart of the dynamic calibration process in one embodiment of this application. Detailed Implementation

[0021] Please refer to the following. Figure 1-3 The present application is described in detail with reference to the embodiments, but the present application is not limited to these embodiments.

[0022] Example 1 This embodiment provides a method for dynamically calibrating a foot pedal controller. The method improves control accuracy and stability by acquiring digital values ​​from a Hall sensor at a fixed frequency and dynamically calibrating the minimum and maximum travel points of the foot pedal controller based on the rate of change of these digital values.

[0023] In this embodiment, the method includes the following steps: First, the digital values ​​from the Hall sensor are acquired at a fixed frequency. The Hall sensor, installed inside the pedal controller, detects the pedal position, and its output digital value is proportional to the pedal travel. The acquisition frequency can be set to 100Hz, meaning the Hall sensor's digital value is acquired every 10 milliseconds.

[0024] Next, the rate of change between the currently acquired Hall value and the previously acquired Hall value is calculated. The rate of change is calculated using the formula... Implementation, in which The currently collected Hall value. This is the Hall value from the previous acquisition. For example, if the current Hall value is 520 and the previous Hall value was 500, then the rate of change... =520-500=20.

[0025] Then, based on the calculated rate of change, the minimum and maximum travel point calibration values ​​are dynamically calibrated. The calibration process consists of two main parts: calibration of the minimum travel point and calibration of the maximum travel point.

[0026] For minimum travel point calibration, when the rate of change exceeds the minimum rate of change threshold, the minimum travel point is determined to have been reached, and the corresponding Hall value is acquired. The minimum rate of change threshold can be set to 15, meaning that when the Hall value increases by more than 15 units in two consecutive samples, the pedal is considered to be at the minimum travel point. After acquiring the Hall value, a sliding window filter is used to process it to eliminate possible noise interference. The sliding window size can be set to 5, that is, the Hall values ​​at the most recent 5 times the minimum travel point is reached are averaged to obtain the filtered value. Finally, this filtered value is used to update the minimum travel point calibration value. For example, if the filtered Hall value is 210, the minimum travel point calibration value is updated to 210.

[0027] For the calibration of the maximum travel point, when the rate of change is less than the maximum rate of change threshold, the maximum travel point is determined to have been reached, and the corresponding Hall value is acquired. The maximum rate of change threshold can be set to -15, meaning that when the Hall value decreases by more than 15 units in two consecutive samples, the pedal is considered to be at the maximum travel point. Similarly, after acquiring the Hall value, a sliding window filter is used to process it. The sliding window size can also be set to 5, averaging the Hall values ​​at the most recent 5 times the maximum travel point was reached to obtain the filtered value. Finally, this filtered value is used to update the maximum travel point calibration value. For example, if the filtered Hall value is 790, the maximum travel point calibration value is updated to 790.

[0028] Throughout the calibration process, the system continuously monitors the rate of change to identify extreme points in the pedal travel, thereby avoiding calibration deviations caused by component aging or mechanical fatigue. This continuous monitoring mechanism ensures that the system can adapt promptly to performance changes in the Hall sensor or mechanical structure, maintaining the accuracy of the calibration values. For example, when the output characteristics of the Hall sensor drift due to temperature changes, the system can automatically adjust the calibration values ​​to maintain control precision.

[0029] Through the above dynamic calibration method, the foot pedal controller can adaptively adjust the calibration value to ensure accurate control response in various operating environments, improve user experience, and extend equipment life.

[0030] Example 2 This embodiment provides a device for dynamically calibrating a foot pedal controller. The device detects pedal travel using a Hall effect sensor and employs a dynamic calibration method to adjust calibration parameters in real time, ensuring control accuracy and stability.

[0031] The device includes a pedal mechanism, a Hall sensor, and a control module. The pedal mechanism receives user foot input and generates mechanical displacement; when the user presses the pedal, the pedal mechanism produces a corresponding mechanical displacement. The Hall sensor is mechanically connected to the pedal mechanism to detect pedal travel and output a Hall signal. The control module is communicatively connected to the Hall sensor and configured to execute the dynamic calibration method described in Embodiment 1 to dynamically calibrate the calibration parameters.

[0032] The control module includes a processor and a memory. The memory stores instructions, which, when executed by the processor, implement the dynamic calibration method described in Embodiment 1. The processor can be a general-purpose microprocessor or a dedicated chip, and the memory can include various types such as ROM and RAM, used to store calibration algorithms and runtime data.

[0033] In this embodiment, the Hall sensor is a linear Hall element, whose output signal has a linear relationship with the pedal travel. This linear relationship makes the control more precise and facilitates the direct mapping of the Hall signal value to the pedal position. The output range of the linear Hall element is typically between 0-5V, and after analog-to-digital conversion, it generates a digital signal for the control module to process.

[0034] The pedal mechanism includes a return spring to automatically return the pedal to its initial position after the foot is released. The spring force of the return spring is precisely calculated to ensure reliable pedal return without causing excessive strain on the operator. When the user releases the pedal, the return spring immediately generates a restoring force, returning the pedal to its initial position for easy operation next time.

[0035] The device also includes a communication interface for transmitting calibrated parameters to an external monitoring system. The communication interface can use various methods such as USB, Bluetooth, or Wi-Fi to exchange data with external systems. This allows the external monitoring system to monitor the foot pedal controller's calibration status in real time and perform necessary recording and analysis.

[0036] In a preferred embodiment, the device is applied to the human-machine interface system of a surgical power device for precise control of the rotational speed or direction of surgical tools. In the surgical environment, control precision is directly related to surgical safety and outcome; therefore, dynamic calibration is particularly important. The surgeon can precisely adjust the working state of the surgical tools, such as drill rotational speed, cutting speed, or suction power, using a foot pedal controller, while the device continuously calibrates using the method described in Embodiment 1, ensuring that control precision is unaffected by environmental changes or equipment aging.

[0037] Through the above design, the device with dynamic calibrating foot controller can maintain stable and reliable control performance in various operating environments, and is particularly suitable for applications in medical, industrial and other fields that require high-precision control.

[0038] The above description is merely a few embodiments of this application and is not intended to limit this application in any way. Although this application discloses preferred embodiments as described above, it is not intended to limit this application. Any changes or modifications made by those skilled in the art without departing from the scope of the technical solution of this application using the disclosed technical content are equivalent to equivalent implementation cases and fall within the scope of the technical solution.

Claims

1. A method for dynamically calibrating a foot pedal controller, characterized in that, include: The digital values ​​of the Hall sensor are acquired at a fixed frequency, and the digital values ​​are proportional to the pedal travel of the foot pedal controller; Calculate the rate of change between the currently acquired Hall value and the previously acquired Hall value; Based on the rate of change, the minimum travel point calibration value and the maximum travel point calibration value are dynamically calibrated, wherein the calibration includes: updating the minimum travel point calibration value when the rate of change meets a first condition; When the rate of change meets the second condition, update the maximum travel point calibration value.

2. The method according to claim 1, characterized in that, The dynamic calibration minimum travel point calibration value includes: When the rate of change is greater than the minimum rate of change threshold, it is determined that the minimum travel point has been reached, and the corresponding Hall value is obtained; The Hall value is processed using a sliding window filter to generate a filtered value; The minimum travel point calibration value is updated using the filtered value.

3. The method according to claim 1, characterized in that, The dynamic calibration maximum travel point calibration value includes: When the rate of change is less than the maximum rate of change threshold, it is determined that the maximum travel point has been reached, and the corresponding Hall value is obtained; The Hall value is processed using a sliding window filter to generate a filtered value; The maximum travel point calibration value is updated using the filtered value.

4. The method according to claim 1, characterized in that, The rate of change is calculated using the formula Implementation, in which The currently collected Hall value. This is the Hall value collected previously.

5. The method according to claim 1, characterized in that, The method also includes: continuously monitoring the rate of change during calibration to identify extreme points in the pedal travel, thereby avoiding calibration deviations caused by component aging or mechanical fatigue.

6. A device for dynamically calibrating a foot pedal controller, characterized in that, include: The pedal mechanism is used to receive user foot pedal input and generate mechanical displacement; A Hall sensor, mechanically connected to the pedal mechanism, is used to detect pedal travel and output a Hall signal; A control module, communicatively connected to the Hall sensor, is configured to perform the method as described in any one of claims 1-5 to dynamically calibrate calibration parameters.

7. The apparatus according to claim 6, characterized in that, The control module includes a processor and a memory. The memory stores instructions, which, when executed by the processor, implement the dynamic calibration method.

8. The apparatus according to claim 6, characterized in that, The Hall sensor is a linear Hall element, and its output signal is linearly related to the pedal travel.

9. The apparatus according to claim 6, characterized in that, The device is used in the human-computer interaction system of the surgical power device to precisely control the rotation speed or direction of the surgical tools.

10. The apparatus according to claim 6, characterized in that, The pedal mechanism includes a return spring for automatically returning to the initial position after the foot pedal is released; Preferably, the device further includes a communication interface for transmitting the calibrated calibration parameters to an external monitoring system.

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