A speed sensor detection system

Abstract

This invention discloses a speed sensor detection system, relating to the field of sensor detection technology. The system includes a main control unit, a drive unit, and a signal acquisition unit. The main control unit sends a rotation speed command, the drive unit drives the speed sensor under test to rotate at the target rotation speed, and the signal acquisition unit acquires electrical signals. The main control unit extracts voltage amplitude and frequency characteristics from the signals and compares them with preset benchmark values ​​to calculate performance indicators such as linearity and sensitivity. The system is also equipped with a dual-motor module including a first servo motor and a second servo motor, which can automatically match high and low speed drive sources according to the test task. Furthermore, the system has built-in performance testing and durability testing modules, with the durability test having a power-off memory function. This invention achieves full automation of the speed sensor detection process, is compatible with multiple sensor models, and effectively solves the problems of low detection efficiency, poor versatility, and easy loss of long-cycle test data in existing technologies.

Description

Technical Field

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

[0002] Speed ​​sensors, as core components for measuring the rotational speed of rotating equipment, are widely used in aviation, aerospace, rail transportation, automotive, and industrial automation. The linearity and sensitivity of speed sensors are key indicators of their performance, directly affecting the speed control accuracy and operational safety of the measured equipment. Therefore, a comprehensive and accurate performance test must be performed on speed sensors before they leave the factory or during regular maintenance.

[0003] Currently, existing speed sensor detection methods have the following shortcomings: First, traditional testing methods rely on manual adjustment of drive speed, manual recording of instrument readings, and offline calculation, resulting in low testing efficiency and easy introduction of human reading and calculation errors. Second, existing automated testing equipment has poor versatility and can usually only be adapted to a single type or narrow speed range of sensors, making it difficult to meet the full coverage testing needs of multiple types of sensors with different ranges in both military and civilian fields. Third, in long-term durability tests, existing equipment has poor fault tolerance to abnormal power outages. Test data is lost after a power outage, and the test must be started from scratch, which increases testing costs and time.

[0004] Therefore, there is an urgent need to develop a speed sensor detection system that is highly automated, highly compatible, has power failure memory protection, and can automatically generate multi-dimensional performance reports. Summary of the Invention

[0005] The purpose of this invention is to provide a speed sensor detection system to solve the technical problems of low efficiency of manual detection, poor equipment compatibility, and data loss during power outages in durability tests in the prior art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a speed sensor detection system, comprising: The main control unit is used to send speed control commands and process and analyze the received signal data. The drive unit is communicatively connected to the main control unit and is used to drive the measured speed sensor to rotate at a specified target speed according to the speed control command. A signal acquisition unit, connected to the output terminal of the speed sensor under test, is used to acquire the electrical signal generated by the speed sensor under test due to rotation under the control of the main control unit; the electrical signal includes a sine wave signal. The main control unit is configured to: extract voltage amplitude features and frequency features from the electrical signal; compare and calculate the extracted voltage amplitude features and frequency features with a preset reference value corresponding to the target rotational speed to determine the performance indicators of the speed sensor under test, wherein the performance indicators include at least linearity and sensitivity.

[0007] Furthermore, the main control unit includes a host computer, and the drive unit includes a servo driver and one or more servo motors; the host computer is connected to the servo driver through an industrial communication protocol, and the servo driver drives the corresponding servo motor to operate according to the speed control command, so as to drive the measured speed sensor to rotate.

[0008] Furthermore, the servo motor includes a first servo motor and a second servo motor, wherein the rated maximum speed and speed range of the first servo motor are both higher than those of the second servo motor; the main control unit is further configured to automatically select and control the first servo motor or the second servo motor to work according to the test task requirements, so as to match the detection speed range of different models of speed sensors under test.

[0009] Furthermore, the signal acquisition unit includes a multi-functional data acquisition board, and the host computer integrates measurement and control software developed based on a graphical programming environment; the measurement and control software interacts with the servo driver through a configuration software interface to send the speed control command and monitor the status of the drive unit.

[0010] Furthermore, the main control unit is also equipped with a performance testing module and a durability testing module; the performance testing module is configured to: automatically control the drive unit to run according to a preset speed curve sequence, trigger data acquisition at each target speed point, and automatically generate a performance test report including linearity, sensitivity, and repeatability indicators; the durability testing module is configured to: control the drive unit to drive the speed sensor under test to run continuously at a set speed, accumulate working time or number of cycles in real time, and have a power failure memory function, so that it can resume and continue to accumulate records when the system is powered on again after a power failure.

[0011] Furthermore, the main control unit is also equipped with a manual test module, which is configured to: control the start, stop and speed of the drive unit according to user operation instructions; display the waveform and historical trend curve of the electrical signal acquired by the signal acquisition unit in real time, and provide data and curve saving functions.

[0012] Furthermore, it also includes a safety protection module, which includes: an over-temperature detection unit connected to the servo motor thermal element in the drive unit, and an audible and visual alarm unit connected to the main control unit; when the over-temperature detection unit detects that the temperature of the servo motor exceeds a preset safety threshold, it triggers the audible and visual alarm unit to issue an alarm, and controls the drive unit to perform shutdown protection through the main control unit.

[0013] Furthermore, it also includes an adjustable power supply module for providing the operating voltage required for testing the speed sensor under test; the main control unit is communicatively connected to the adjustable power supply module to remotely set and adjust the output voltage and current parameters of each channel of the adjustable power supply module.

[0014] Furthermore, the main control unit is also configured to perform a preprocessing operation on the electrical signal before performing the comparison calculation, the preprocessing operation including at least filtering and amplitude normalization.

[0015] Furthermore, the preset reference value includes: a theoretically calculated value corresponding to the target rotational speed, or a measured characteristic value-rotational speed curve obtained in advance by calibrating a standard speed sensor.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention achieves fully automated operation from speed application and signal acquisition to data analysis and report generation through closed-loop control of the main control unit, drive unit and signal acquisition unit, which greatly improves detection accuracy and efficiency.

[0017] 2. By configuring servo motor sets with different speed ranges, the system can automatically switch the drive source according to the model of the sensor being tested, and is compatible with the performance testing and life test of multiple models of high and low speed sensors for military and civilian use, realizing full model coverage testing.

[0018] 3. By setting up a durability test module with power failure memory function, the industry pain point of losing long-term test data due to power failure is effectively solved, ensuring the continuity of the test and the integrity of the data. Attached Figure Description

[0019] Figure 1 This is a block diagram showing the structural composition of the speed sensor detection system of the present invention; Figure 2 This is a flowchart of the automated detection process of the present invention; In the diagram, 1-main control unit, 2-drive unit, 3-signal acquisition unit, 4-adjustable power supply module, 5-safety protection module, 6-measured speed sensor, 11-measurement and control software, 21-servo driver, 22-first servo motor, 23-second servo motor, 51-over-temperature detection unit, 52-audio-visual alarm unit, 53-emergency stop button. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0021] Example: Please see Figures 1 to 2 The present invention provides a technical solution: a speed sensor detection system, which mainly consists of a main control unit 1, a drive unit 2, a signal acquisition unit 3, an adjustable power supply module 4, and a safety protection module 5.

[0022] I. Main Control Unit 1.

[0023] In this embodiment, the main control unit 1 is specifically an industrial control computer (host computer). The host computer runs measurement and control software 11 developed based on the LabVIEW graphical programming environment. This measurement and control software 11 interacts with the lower-level control hardware through the NI-OPC configuration software interface. The main control unit 1, as the system's control core and data processing center, is responsible for sending speed commands, managing the test process, executing data analysis algorithms, and generating test reports.

[0024] II. Drive Unit 2.

[0025] The drive unit 2 includes a servo driver 21 and a dual-motor drive module consisting of a first servo motor 22 and a second servo motor 23. The host computer communicates with the servo driver 21 via the industrial Ethernet protocol.

[0026] Specifically, the first servo motor 22 is a high-speed motor with an adjustable speed range of 0 to 20,000 r / min, and is capable of continuous and stable operation for 24 hours at 18,000 r / min; the second servo motor 23 is a low-speed motor with an adjustable speed range of 0 to 3,600 r / min, and is capable of continuous and stable operation for 24 hours at 3,600 r / min.

[0027] Before the test begins, the main control unit 1 will automatically call the corresponding test configuration file based on the model information of the speed sensor 6 under test input by the user, and automatically select the corresponding servo motor for transmission connection control, without the need for manual replacement of the mechanical connection shaft.

[0028] The specific automatic selection logic is as follows: The main control unit 1 internally stores a sensor model-speed range lookup table, or reads the test speed sequence input by the user through the measurement and control software 11. When the maximum value of the target speed is greater than or equal to the rated upper limit (e.g., 3600 r / min) of the low-speed motor (second servo motor 23), the main control unit 1 automatically controls the switching device (such as an electromagnetic clutch or relay) to drive the first servo motor 22 to the sensor under test 6; otherwise, the second servo motor 23 is selected. During the switching process, the measurement and control software 11 synchronously updates the parameter configuration of the servo driver 21 to ensure that the drive control matches the selected motor.

[0029] III. Signal Acquisition Unit 3.

[0030] Signal acquisition unit 3 uses the NI PCIe-6351 multi-function data acquisition board. This board features a sampling rate of 1.25 MS / s and 8 differential acquisition channels, strong anti-interference capabilities, and can accurately capture the weak electrical signals output by the speed sensor 6 during its rotation. After converting the analog signal into a digital signal, the acquisition board transmits it at high speed to the host computer's memory via the PCIe bus for use by the data processing module.

[0031] IV. Adjustable power supply module 4.

[0032] This system is equipped with an AC / DC adjustable power supply, supporting 0 to 32V voltage output and 3A current output, and has 3 independent output channels. The power supply communicates with the host computer, allowing testers to remotely set the excitation voltage supplied to the sensor under test via the measurement and control software interface, eliminating the need for manual adjustment of the knobs.

[0033] V. Safety Protection Module 5.

[0034] To ensure the safety of long-term durability testing, the system is equipped with a safety protection module 5. This module includes a thermistor temperature detection circuit embedded in the servo motor, as well as an emergency stop button 53 and an audible and visual alarm mounted on the operation panel. When the main control unit 1 detects that the motor winding temperature exceeds a preset threshold (such as 85°C) through the over-temperature detection unit 51, it will immediately trigger an audible and visual alarm and send an emergency stop command to the servo driver 21 to cut off the power output.

[0035] VI. System Workflow and Data Processing Mechanism.

[0036] Reference Figure 2 The automated detection workflow of the speed sensor detection system of the present invention includes the following steps: Step S1 (Initialization): Install the speed sensor 6 to be measured on the corresponding servo motor fixture, connect the sensor output signal line to the acquisition board, and connect the power supply line.

[0037] Step S2 (Parameter Configuration): Select the sensor model through the measurement and control software 11, or manually input the test parameters (including target speed sequence, power supply voltage, etc.).

[0038] Step S3 (System Configuration): The system automatically calls the corresponding test configuration file, automatically selects the first servo motor 22 or the second servo motor 23 according to the speed range, and establishes communication with the servo driver 21.

[0039] Step S4 (Speed ​​Control): The main control unit 1 sends a speed control command to the drive unit 2, and the drive unit 2 drives the measured speed sensor 6 to rotate at the specified target speed.

[0040] Step S5 (Signal Acquisition): The signal acquisition unit 3 acquires the electrical signal generated by the rotation of the speed sensor 6 under test in real time.

[0041] Step S6 (Signal Preprocessing): The main control unit 1 performs preprocessing operations on the acquired signal, including: digital bandpass filtering (filtering out power frequency interference and high frequency noise), and amplitude normalization processing (eliminating the interference of power supply fluctuations on amplitude calculation).

[0042] Step S7 (Amplitude Feature Extraction): Extract voltage amplitude features (peak-to-peak value) from the preprocessed waveform.

[0043] Step S8 (Frequency Feature Extraction): Extract frequency features from the preprocessed waveform (obtained by Fast Fourier Transform (FFT) or period counting method).

[0044] Step S9 (calling the reference value): The main control unit 1 calls the preset reference value stored in the database. The reference value can be the theoretical calculated value at the speed, or it can be the pre-calibrated standard sensor measured amplitude-speed curve.

[0045] This system supports obtaining preset benchmark values ​​through calibration using a standard speed sensor. The specific calibration steps are as follows: First, a standard speed sensor with known and qualified performance is installed on the system drive unit 2, and connected to the signal acquisition unit 3 and the adjustable power supply module 4. Then, in the measurement and control software 11 of the main control unit 1, the "benchmark calibration" mode is selected, and the calibration speed sequence is input (e.g., 0, 500, 1000, 2000, ..., upper limit speed, and the corresponding decreasing sequence). After starting the calibration process, the main control unit 1 automatically controls the drive unit 2 to operate sequentially to each target speed point. After the speed stabilizes, the signal acquisition unit 3 synchronously acquires the electrical signal output by the standard sensor, and the main control unit 1 extracts the voltage amplitude characteristics and frequency characteristics from the signal at each speed point. Finally, the system performs curve fitting (e.g., using the least squares method) on the characteristic values ​​corresponding to each speed point to generate a "characteristic value-speed" benchmark curve, which is stored in the system database. In actual testing, the main control unit 1 directly calls this benchmark curve as a comparison basis, without the need for repeated calibration. In addition, the system also supports directly inputting theoretically calculated values ​​as benchmarks.

[0046] Step S10 (Performance Comparison and Calculation): Compare the measured feature values ​​with the benchmark values, calculate the fitted straight line using the least squares method, and obtain the linearity and sensitivity parameters.

[0047] Step S11 (Output performance indicators): Output the performance indicators of the speed sensor 6 under test, including at least linearity, sensitivity and repeatability.

[0048] Step S12 (Loop Judgment): Determine whether the test of all preset target speed points has been completed. If not, return to step S4 and control drive unit 2 to switch to the next target speed point to continue testing; if completed, proceed to step S13.

[0049] Step S13 (Generate Report): Automatically generate a test report containing indicators such as linearity, sensitivity, and repeatability. The report format is Word or Excel, and it is automatically archived and saved to the specified path.

[0050] Step S14 (End): The detection process ends.

[0051] VII. Specific experimental mode description.

[0052] The measurement and control software 11 has three built-in core test modes: 1. Manual Test Mode: In this mode, operators can manually control the motor's start / stop and fine-tune its speed using the virtual knobs on the software interface. Simultaneously, the oscilloscope window in the center of the software interface displays the current sine wave and historical peak-to-peak trend charts in real time, suitable for troubleshooting and R&D debugging. Curve data can be exported to CSV or image format with one click.

[0053] 2. Performance Test Mode: This mode is used for factory testing. After the operator clicks "Start," the system automatically runs according to the preset speed curve sequence (e.g., 0→500→1000→2000→…→upper limit speed→…→0r / min). After stabilizing for 3 seconds at each target speed step, the system automatically collects 100 sets of data, calculates the average, and finally automatically generates a Word or Excel format test report containing three indicators: linearity, sensitivity, and repeatability. The report is then automatically archived and saved to the specified path.

[0054] 3. Durability Test Mode: This mode is used for lifespan testing. The system controls the motor to run continuously at a set speed. The cumulative timer on the screen ticks in real time. In the event of an unexpected power outage, the software writes the current cumulative value to the industrial computer's hard drive configuration file each time the timer value changes. When the system is powered on again, the measurement and control software 11 automatically reads the cumulative time value from the configuration file and restores the display and counting, realizing the power outage memory function. Simultaneously, the operation panel has a protected "Reset" button for providing a timer reset function.

[0055] The power-off memory function is implemented as follows: A timer is set in the measurement and control software 11 to trigger a data persistence event every 1 second or every 10 units (e.g., 0.1 hours). In this event, the software calls the Windows API function `WritePrivateProfileString` to write key parameters such as the current accumulated duration and number of cycles into the `config.ini` configuration file on the industrial computer's hard drive. Simultaneously, the software automatically backs up the test state in memory to another hidden file every 5 minutes. When the system unexpectedly loses power and is powered back on, the measurement and control software 11 first calls the `GetPrivateProfileInt` and `GetPrivateProfileString` functions to read the accumulated value from the configuration file and cross-checks it with the backup file. If they match, the display and count are directly restored; otherwise, the file data with the newer timestamp is used. Through this mechanism, the software can seamlessly continue the test from the point of power failure without manual intervention or starting from scratch.

[0056] In summary, by combining a modular hardware architecture with intelligent measurement and control software 11, this invention not only achieves high-precision automated measurement, but also significantly improves the versatility, reliability, and safety of long-cycle testing through the introduction of dual-motor modules and a power-off memory mechanism, thus possessing extremely high industrial practical value.

[0057] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A speed sensor detection system, characterized in that, include: The main control unit (1) is used to send speed control commands and process and analyze the received signal data; The drive unit (2) is communicatively connected to the main control unit (1) and is used to drive the measured speed sensor (6) to rotate at a specified target speed according to the speed control command. The signal acquisition unit (3) is connected to the output terminal of the speed sensor (6) under test and is used to acquire the electrical signal generated by the speed sensor (6) under test due to rotation under the control of the main control unit (1); the electrical signal includes a sine wave signal. The main control unit (1) is configured as follows: Extract voltage amplitude and frequency features from the electrical signal; The extracted voltage amplitude and frequency characteristics are compared and calculated with a preset reference value corresponding to the target rotational speed to determine the performance index of the speed sensor (6) under test, wherein the performance index includes at least linearity and sensitivity.

2. The speed sensor detection system according to claim 1, characterized in that, The main control unit (1) includes a host computer, and the drive unit (2) includes a servo driver (21) and one or more servo motors; The host computer is connected to the servo driver (21) via an industrial communication protocol. The servo driver (21) drives the corresponding servo motor to operate according to the speed control command, so as to drive the measured speed sensor (6) to rotate.

3. The speed sensor detection system according to claim 2, characterized in that, The servo motor includes a first servo motor (22) and a second servo motor (23), wherein the rated maximum speed and speed range of the first servo motor (22) are both higher than those of the second servo motor (23). The main control unit (1) is further configured to automatically select and control the first servo motor (22) or the second servo motor (23) to work according to the test task requirements, so as to match the detection speed range of different models of speed sensors (6).

4. The speed sensor detection system according to claim 2, characterized in that, The signal acquisition unit (3) includes a multi-functional data acquisition board, and the host computer integrates measurement and control software (11) developed based on a graphical programming environment. The measurement and control software (11) interacts with the servo driver (21) through the configuration software interface to send the speed control command and monitor the status of the drive unit (2).

5. The speed sensor detection system according to claim 1, characterized in that, The main control unit (1) is also equipped with a performance test module and a durability test module; The performance test module is configured to: automatically control the drive unit (2) to run according to a preset speed curve sequence, trigger data acquisition at each target speed point, and automatically generate a performance test report containing linearity, sensitivity and repeatability indicators; The durability test module is configured to: control the drive unit (2) to drive the speed sensor (6) under test to run continuously at a set speed, accumulate working time or number of cycles in real time, and have a power failure memory function, so that it can be restored and continue to accumulate records when the system is powered on again after a power failure.

6. The speed sensor detection system according to claim 1, characterized in that, The main control unit (1) is also equipped with a manual testing module, which is configured as follows: According to the user's operation instructions, control the start / stop and speed of the drive unit (2); The waveform and historical trend curve of the electrical signal acquired by the signal acquisition unit (3) are displayed in real time, and the data and curve are saved.

7. The speed sensor detection system according to claim 1, characterized in that, It also includes a security protection module (5), which includes: The over-temperature detection unit (51) is connected to the servo motor thermal element in the drive unit (2), and the audible and visual alarm unit (52) is connected to the main control unit (1). When the over-temperature detection unit (51) detects that the temperature of the servo motor exceeds the preset safety threshold, it triggers the audible and visual alarm unit (52) to issue an alarm and controls the drive unit (2) to perform shutdown protection through the main control unit (1).

8. The speed sensor detection system according to claim 1, characterized in that, It also includes an adjustable power supply module (4) for providing the working voltage required for testing the speed sensor (6) under test; The main control unit (1) is communicatively connected to the adjustable power supply module (4) to remotely set and adjust the output voltage and current parameters of each channel of the adjustable power supply module (4).

9. The speed sensor detection system according to claim 1, characterized in that, The main control unit (1) is further configured to perform a preprocessing operation on the electrical signal before performing the comparison calculation, the preprocessing operation including at least filtering and amplitude normalization.

10. The speed sensor detection system according to claim 1, characterized in that, The preset reference value includes: a theoretically calculated value corresponding to the target rotational speed, or a measured characteristic value-rotational speed curve obtained in advance by calibrating a standard speed sensor.

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