Inductive angular displacement sensor and method of designing the same

Abstract

The application relates to an inductive angle displacement sensor and a design method thereof, and belongs to the technical field of angle displacement sensing. The method sequentially completes electromagnetic simulation modeling and winding parameter optimization, integrated anti-interference hardware integrated assembly, orthogonal magnetic coding sampling data two-part coarse positioning, segmented sampling channel dynamic switching, segmented nonlinear calibration and high-precision angle calculation, whole machine calibration and multi-environment performance verification. Through physical structure simulation optimization, shielding hardware integration and multi-level correction algorithm linkage, the application synchronously solves the defects of traditional potentiometers, Halls, photoelectric encoders and rotary transformers, such as wear, susceptibility to electromagnetic interference, large linear error, poor high-low temperature reliability, insufficient precision and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of angular displacement sensing, in particular to an inductive angular displacement sensor and a design method thereof. Background Art

[0002] An angular displacement sensor is a core component for realizing closed-loop position feedback in automatic control systems such as servo control, robot joint driving, precision pan-tilt adjustment and industrial valve positioning. It can collect angular information of a rotating mechanism in real time and convert it into standardized electrical signals, providing data support for accurate motion control of equipment. Currently, mainstream commercial angular displacement sensors on the market are mainly divided into four categories: potentiometer type, single-channel Hall magnetoelectric type, photoelectric encoder and traditional resolver. Limited by their own detection principles and structural forms, all types of products have unavoidable inherent defects, and it is difficult for them to simultaneously meet the comprehensive performance requirements such as high precision, wide temperature range adaptability, strong electromagnetic compatibility, impact and vibration resistance, and ultra-long service life.

[0003] With the technical iteration of high-end automation equipment, aviation supporting equipment and precision fluid control equipment, the industry has continuously improved the comprehensive performance indicators of angle detection components, and sensors matched with equipment need to simultaneously meet a number of stringent service conditions: both the full-range angle detection accuracy and repeated positioning accuracy are not less than 0.01°, completely covering the full rotation stroke from 0° to 360°; it can work continuously and stably in an ultra-wide temperature range from -55°C to 150°C, and no obvious signal drift occurs during temperature change; it can withstand high-level mechanical impact and continuous vibration, with the peak impact up to 10000g; high-power power devices are densely arranged around the equipment, and the interference intensity of electromagnetic radiation and alternating magnetic field is high, which requires the sensor to have excellent electromagnetic compatibility; meanwhile, the equipment operates continuously for a long time, which puts forward high standards for the mean time between failures and service life of the sensor.

[0004] Most of the existing conventional improvement solutions only adopt differential Hall sampling combined with a simple external magnetic shielding cover, which can only slightly weaken the local external magnetic field interference, and do not perform systematic optimization from the aspects of coil magnetic field distribution, winding space structure and sampling data operation logic. The full-range nonlinear error of the sensor cannot be fundamentally suppressed. Under the comprehensive working conditions of high and low temperature alternation, strong vibration and complex electromagnetic superposition, the problems of measurement data drift and accuracy attenuation are still prominent, and it cannot simultaneously meet multiple requirements such as ultra-high detection accuracy, wide temperature range adaptability, strong impact resistance and long service life. Therefore, there is an urgent need in the industry for a set of brand-new standardized sensor design methods, which perform simultaneous optimization from multiple dimensions of physical structure simulation optimization, hardware anti-interference integration and software segmented correction algorithm, to develop a high-precision inductive angular displacement sensor that can be adapted to various complex and harsh working conditions. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides an inductive angle displacement sensor and its design method. Through a complete design process combining electromagnetic simulation for pre-optimization of the winding structure, integrated metal shielding hardware, and multi-level segmented correction software algorithms, it achieves the complete development of an inductive angle displacement sensor with no mechanical wear, strong resistance to electromagnetic interference, ultra-wide temperature range, 10,000g-level shock resistance, and 0.01°-level high precision. This sensor is suitable for demanding operating conditions such as aerospace equipment, high-end industrial automation equipment, and precision servo control systems.

[0006] The technical solution adopted in this invention is as follows:

[0007] A design method for an inductive angular displacement sensor, comprising the following steps:

[0008] An electromagnetic simulation model was built, and multiple sets of comparative simulations were carried out on the coil shape and air gap spacing. Simulation data related to magnetic field and signal were collected, and the optimal coil structure and air gap size were selected to complete the finalization of the core physical structure of the sensor stator winding.

[0009] Build the sensing components corresponding to the simulation optimization parameters, integrate the signal processing circuit and lay out the metal shielding shell, install the fixing components and communication lines to complete the hardware construction of the whole machine with electromagnetic interference suppression capability.

[0010] Raw sampling data of rotor magnetic field is collected, and a binary search algorithm is used to complete coarse angle positioning, reducing the amount of data traversal and computation, and outputting angle interval data to provide a basic data source for subsequent segmented correction and accurate calculation.

[0011] By comparing the data difference between the two sampling chip intervals, the sampling data with better linear performance is selected as the basis for calculation, eliminating the segmented distortion caused by uneven magnetic field distribution, and outputting a continuously optimized sampling sequence.

[0012] Store the full-domain calibration sampling data, establish a piecewise interpolation solution model to convert accurate angles, build a multi-dimensional error evaluation model, and output standardized high-precision angle data after correction.

[0013] The sensor design was completed after secondary calibration was used to compensate for the measurement error across the entire range, various extreme environment reliability tests were conducted, and all accuracy indicators were verified.

[0014] Optionally, the core physical structure of the sensor stator winding is finalized, which specifically includes: constructing an electromagnetic simulation model, conducting multiple sets of comparative simulations on different coil shapes and air gap spacing parameters, collecting simulation data on induced electromotive force, magnetic field distribution, and waveform symmetry, and selecting coil configurations and optimal air gap spacing with high output signal strength, uniform magnetic field, and symmetrical waveform to finalize the core physical structure of the sensor stator winding, which provides basic structural parameter support for subsequent hardware circuit integration.

[0015] Optionally, complete the hardware construction of the whole machine with electromagnetic interference suppression capability, specifically including: processing stator and rotor components according to the coil and air gap parameters obtained from simulation, assembling bearings, rotor shafts and PCB signal processing circuit boards, integrating core detection circuits using SIP technology, assembling a fully enclosed magnetically conductive shell to build a magnetic shielding structure, laying communication cables and standard mounting fasteners, and completing the physical construction of the sensor hardware with electromagnetic interference resistance capability.

[0016] Optionally, raw sampling data of the rotor magnetic field is collected, specifically including: constructing a matching drive fixture to drive the sensor rotor to rotate continuously at a uniform speed along a full stroke from 0° to 360°; two orthogonal magnetic encoding chips inside the sensor synchronously and in real time collect the raw sampling values ​​corresponding to the changes in the magnetic field during the rotor rotation, with the two chips collecting data synchronously and in parallel to cover the non-uniform magnetic field region of the entire circumference. All the collected raw sampling data are uniformly written into the Flash storage unit on the PCB circuit board to form a complete sampling dataset with a total size of n.

[0017] Optionally, a binary search algorithm is used to complete the coarse angle positioning. Specifically, this includes: selecting an initial retrieval unit much smaller than the total data volume as a reference interval; comparing the sampled data within the reference interval with the current acquired value; if the current acquired value exceeds the boundary of the reference interval, doubling the retrieval range based on the current reference interval and proceeding to the next iteration; repeating the comparison between the sampled data within the reference interval and the current acquired value, as well as doubling the retrieval range, until the retrieval range completely covers the sampled data interval corresponding to the current rotor angle, thus completing the coarse positioning interval boundary locking.

[0018] Optionally, comparing the data difference between the two sampling chip intervals specifically includes: receiving the output rotor coarse positioning interval information, the main control unit synchronously retrieving the original sampling values ​​of consecutive adjacent sampling points of the two orthogonal magnetic encoder chips within the angle interval; performing difference calculations on the adjacent sampling data of the two chips respectively to obtain their respective sampling differences.

[0019] Optionally, the standardized high-precision angle data after correction is output, specifically including: solidifying the original data sampled by the two orthogonal chips into the storage unit, establishing a segmented interpolation solution model based on the circumferentially divided calibration interval, substituting the segmented effective sampled data to complete the accurate angle conversion, superimposing multi-dimensional error terms to construct the maximum error evaluation model of the whole machine, and outputting the corrected high-precision standardized angle output data.

[0020] Optionally, a secondary calibration is used to compensate for the full-range measurement error. Specifically, this includes: based on the full-range error distribution law output by the error model, dividing the full range of 0°-360° into independent intervals, matching a dedicated nonlinear compensation coefficient for each interval, and performing segmented correction on the Pout original angle data output by the solution to offset the segmented linear error and measurement offset caused by winding structure, mechanical assembly, and magnetic field inhomogeneity.

[0021] Optionally, the original sampling data PIn of the orthogonal chip is collected in real time. The main control program automatically retrieves the calibration array ori, determines that PIn falls within the interval formed by the adjacent calibration points ori[i] and ori[i+1], and substitutes it into the standardized angle output solution formula to complete the piecewise linear interpolation operation.

[0022] An inductive angle displacement sensor is obtained by the above-described design method. The inductive angle displacement sensor includes a rotor shaft, a support bearing, a stator assembly, a PCB signal processing circuit board, a fully enclosed magnetic housing, a communication cable, and multiple sets of standard mounting fasteners.

[0023] The PCB signal processing circuit board acquires the induced voltage signal generated by the coupling of the stator and rotor windings in real time, runs a complete set of built-in software algorithms to complete the entire process of sampling preprocessing, binary coarse positioning, segmented data switching, high-precision angle calculation, and global nonlinear correction, converts the original induced voltage signal into standardized high-precision angle data, and stores the global calibration sampling data.

[0024] This invention provides an inductive angular displacement sensor and its design method. The technical solution provided by the embodiments of this invention brings at least the following beneficial effects:

[0025] (1) The design method of this invention introduces an electromagnetic simulation pre-optimization step, and relies on multiple sets of simulation cloud maps to compare and select the optimal coil configuration and air gap distance. The core hardware parameters can be locked without multiple prototypes, shortening the R&D cycle and reducing the trial production cost, and suppressing measurement nonlinearity error from the source of physical structure.

[0026] (2) The hardware adopts SIP high integrated circuit with a full metal enclosed magnetic shell to form a full-domain magnetic shielding structure, which can effectively isolate external stray magnetic fields and electromagnetic radiation interference from motors, and is suitable for strong electromagnetic complex industrial conditions; the non-contact inductive coupling detection structure has no brushes or slip ring mechanical wear, which greatly extends the service life of the sensor.

[0027] (3) It is equipped with a multi-level software correction algorithm, and fully configured with a mathematical model for bisection angle positioning, segmented sampling selection, segmented interpolation angle calculation, and global error evaluation. It gradually reduces the amount of data computation, eliminates segmented distortion caused by uneven magnetic field distribution, and achieves ultra-high precision angle conversion at the 0.01° level. The output resolution can reach 16 bits.

[0028] (4) The whole machine is subjected to secondary segmented nonlinear calibration and compensation, and verified by full working condition environmental test. It can stably withstand the ultra-wide temperature range of -55℃~150℃ and 10000g high-level mechanical impact. Its environmental adaptability is far superior to potentiometers, ordinary Hall effect sensors, photoelectric encoders and traditional rotary transformers.

[0029] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a structural design diagram of an inductive angular displacement sensor.

[0032] Figure 2 This is a schematic diagram illustrating the principle of the electromagnetic simulation model.

[0033] Figure 3 This is a schematic diagram of the time-varying magnetic field distribution;

[0034] Figure 4 A schematic diagram showing the simulation results of the magnetic field distribution under different air gap spacings;

[0035] Figure 5 A flowchart illustrating the design method for an inductive angular displacement sensor.

[0036] Figure descriptions: 1-Rotor, 2-Stator, 3-3 M3 set screw, 4-3 M2 bolts, 5-3 Stator mounting fixture, 6-communication cable, 7-rotor shaft, 8-stator mounting end face. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0038] Before describing the technical solution of the present invention in detail, the technical background and technical terms involved in the technical solution will be explained first:

[0039] Gradient air gap spacing: Air gap spacing refers to the air isolation gap between the stator excitation winding and the rotor induction winding. It is the thickness of the air layer through which the magnetic field passes in the magnetic circuit, directly determining the magnetic reluctance, induced electromotive force, and magnetic field uniformity. In this invention, the aforementioned gradient does not refer to a gradual change in magnetic field strength along space, but rather to the artificial division of the air gap thickness into multiple gradient levels, forming an ordered sequence of parameters. This is a variable setting method for simulation experiments. In the electromagnetic simulation process of this invention, keeping other simulation conditions such as coil excitation, winding structure, and motion stroke unchanged, only the air isolation gap between the stator excitation winding and the rotor induction winding is set to multiple discrete thickness values ​​that increase in an ordered manner. The graded air gap thicknesses of each group constitute the gradient air gap spacing. By comparing the induced electromotive force and magnetic field distribution uniformity under different gaps through step-by-step simulation, the optimal air gap size for the entire assembly is selected.

[0040] On the one hand, this invention provides a design method for an inductive angular displacement sensor. Figure 5 A flowchart illustrating the design method for an inductive angular displacement sensor. The method includes the following steps:

[0041] Step S101: Build an electromagnetic simulation model, conduct multiple sets of comparative simulations on coil shape and air gap spacing, collect simulation data related to magnetic field and signal, select the best coil structure and air gap size, and complete the finalization of the core physical structure of the sensor stator winding.

[0042] The above steps constitute the electromagnetic simulation modeling and coil and air gap structure parameter optimization steps. An electromagnetic simulation model is constructed, and multiple sets of comparative simulations are conducted across different coil shapes and air gap spacing parameters. Simulation data on induced electromotive force, magnetic field distribution, and waveform symmetry are collected. The coil configuration and optimal air gap spacing with high output signal strength, uniform magnetic field, and symmetrical waveform are selected, completing the core physical structure design of the sensor stator winding. This provides basic structural parameter support for subsequent hardware circuit integration. Specifically, it includes the following sub-steps:

[0043] Sub-step S101-1: Build the basic electromagnetic simulation model.

[0044] Ansoft Maxwell electromagnetic simulation software was used to build a coupled simulation model of the excitation winding and the induction winding. The model structure is as follows: Figure 2As shown, this model is used to establish the spatial coordinate coupling relationship between the excitation winding and the induction winding, providing a basic model for subsequent magnetic field distribution and induction signal simulation. The model includes two sets of orthogonally distributed planar windings, winding α and winding β, arranged at a distance of 5a along the X-axis. Winding α is the excitation winding, and winding β is the other excitation winding; together, they construct a spatial alternating magnetic field. The four sides of winding α are labeled A'A, B'B, C'C, and D'D, and their spatial coordinates in the three-dimensional Cartesian coordinate system are defined as: A'(-a,b,0), A(-a,b,-c), B'(a,b,0), B(a,b,-c), C'(a,-b,0), C(a,-b,-c), D'(-a,-b,0), D(-a,-b,-c), with each side parallel to the coordinate axes. Two sinusoidal excitation currents with a 90° phase difference, I1=sin(ωt) and I2=cos(ωt), are passed through winding α to generate a time-varying alternating magnetic field in the winding space. Winding β is structurally symmetrical with winding α and is passed through with an excitation current in the same phase as winding α to construct orthogonal magnetic field components.

[0045] In the electromagnetic simulation model, an arbitrary field point P(m,n,k) is defined. Angles θ, θ1, θ2, and distance H between the field point and each side of the winding are established through geometric relationships for subsequent calculation of the magnetic induction intensity at the field point. By controlling the winding dimensions, air gap spacing (distance between windings in the Z-axis direction), and excitation current parameters, the magnetic field distribution and induced electromotive force variation under different rotor rotation angles can be simulated, providing a theoretical simulation basis for optimizing coil configuration and air gap parameters.

[0046] Sub-step S101-2: Comparison and simulation of the shapes of multiple types of coils.

[0047] Unified simulation conditions were set: a sinusoidal excitation signal with an amplitude of 0.1A and a frequency of 10kHz was applied to the rectangular excitation coil, controlling the induction coil to move 8.2mm unidirectionally along the positive half-axis of the X-axis. Independent simulation models of three types of induction coils—rectangular, triangular, and semi-sinusoidal—were established. The output after running the simulation was determined. Figure 3 The time-varying magnetic field distribution cloud map and the corresponding induced electromotive force values ​​of each group of coils are shown, including three-dimensional surface plots and two-dimensional contour plots, which are used to compare the magnetic field uniformity and signal output characteristics of different coil shapes.

[0048] Simulation results show that the induced voltage amplitude of the rectangular coil is ±240mV, the induced voltage amplitude of the half-sine coil is ±220mV, and the induced voltage amplitude of the triangular coil is only ±170mV. Regarding waveform symmetry, the standing wave curves of the rectangular and half-sine coils are perfectly symmetrical around the E=0mV baseline. The standing wave peak of the triangular coil shows a significant deviation in amplitude, indicating poor waveform symmetry and a tendency to introduce nonlinear distortion when synthesizing traveling waves. Considering both the output strength of the induced signal and the waveform symmetry, this invention uniformly uses a sinusoidal induction coil as the basic configuration for both stator and rotor windings. This improves the amplitude of the induced signal from a physical structural perspective and reduces measurement errors caused by waveform asymmetry.

[0049] Sub-step S101-3: Simulation of magnetic field of multi-gradient air gap spacing.

[0050] Using the controlled variable method, only the air gap distance d between the excitation winding and the induction winding was adjusted. Four sets of gradient parameters were set: d=0.25mm, d=0.45mm, d=0.65mm, and d=0.85mm. The magnetic field distribution under each air gap condition was simulated in MATLAB software, and the output was... Figure 4 Magnetic field intensity distribution cloud map under four independent XY coordinate systems.

[0051] The peak values ​​of the induced electromotive force corresponding to each air gap are 19mV, 41mV, 17mV, and 2mV, respectively. The magnetic field distribution patterns show significant differences: when d=0.25mm, the winding gap is too small, the magnetic fields of adjacent windings interfere with each other, and the middle area of ​​the magnetic field distribution cloud map is obviously concave; when d=0.45mm, the winding gap is optimally matched, the magnetic field distribution is flat and uniform, forming an approximately ideal uniform alternating magnetic field; when d=0.65mm, the winding spacing is too large, and the middle area of ​​the magnetic field distribution is slightly convex upward; when d=0.85mm, the winding spacing is too large, the magnetic field induction intensity is greatly reduced, and the cloud map shows significant convex distortion.

[0052] Through simulation comparison of four sets of gradient air gaps, the influence of air gap spacing on the uniformity of magnetic field distribution and magnetic induction intensity can be clearly defined. Thus, d=0.45mm was selected as the optimal assembly air gap for stator and rotor windings, providing key dimensional basis for sensor hardware processing. At the same time, it effectively avoids the problems of magnetic field crosstalk due to excessively small air gaps and signal attenuation due to excessively large air gaps.

[0053] Sub-step S101-4: Summarize simulation data and finalize physical structure parameters.

[0054] The system compiles all simulated magnetic field distribution cloud maps, induced electromotive force amplitude, and waveform symmetry data for two sets of simulations, including coil shape and air gap spacing. It then selects the optimal sinusoidal coil configuration and the standard air gap spacing of 0.45mm as the reference parameters for stator and rotor winding machining, outputs the core dimension indicators of the hardware machining drawings, and completes the preliminary design of the sensor's physical structure.

[0055] Step S102: Build the sensing components corresponding to the simulation optimization parameters, integrate the signal processing circuit and lay out the metal shielding shell, install the fixing components and communication lines to complete the hardware construction of the whole machine with electromagnetic interference suppression capability.

[0056] The above steps are the assembly of the integrated hardware structure and the deployment of the shielding shell. Based on the coil and air gap parameters obtained from the simulation, the stator and rotor components are processed, the bearings, rotor shaft, and PCB signal processing circuit board are assembled, the core detection circuit is integrated using SIP technology, the magnetic shielding structure is built by assembling a fully enclosed magnetically conductive shell, and the communication cables and standard mounting fasteners are laid out to complete the physical hardware construction of the sensor with anti-electromagnetic interference capability.

[0057] Sub-step S102-1: Machining of windings, rotor, and stator assemblies.

[0058] Based on the sinusoidal coil configuration and optimal air gap spacing parameters obtained from the electromagnetic simulation in step S101, the windings and mechanical structures are fabricated. Both the stator excitation winding and the rotor induction winding are sinusoidal coils manufactured using PCB technology. The coil routing strictly follows the geometric dimensions of the simulation model to ensure that the spatial distribution of the windings is completely consistent with the electromagnetic simulation conditions. During processing, the parallelism between the rotor winding and the stator winding must be strictly controlled to ensure that they maintain the set standard air gap spacing after assembly. The rotor shaft, stator base, and support bearings are machined simultaneously. The rotor shaft and stator base are made of high-rigidity metal materials to ensure structural stability and impact resistance. The stator base has 3×M3 set screw mounting holes, 3×M2 bolt fixing holes, and 3 sets of stator mounting fixture assembly positions, providing a unified positioning reference for subsequent assembly of the entire machine and ensuring the positional accuracy between components.

[0059] Sub-step S102-2: Core circuit SIP integration and circuit board assembly.

[0060] The orthogonal magnetic encoder chip, signal acquisition circuit, real-time signal processing circuit, CAN bus communication circuit, and PWM analog output circuit are highly integrated using SIP (System-in-Package) technology to form an integrated functional module. This integrated module is soldered onto a PCB signal processing circuit board, which also houses a Flash memory unit for storing the raw sampling data of the rotor's full-domain magnetic field, calibration parameters, and error compensation coefficients. The PCB adopts a multi-layer design with a large area of ​​grounded copper foil on the inner layer to suppress high-frequency signal interference. During the soldering process, impedance matching and isolation are performed on key signal lines to reduce signal crosstalk and ensure the purity and stability of the sampled data. After soldering and testing, the circuit board achieves integrated signal acquisition, real-time algorithm calculation, and multi-mode signal output functions, providing a reliable hardware platform for subsequent overall system debugging.

[0061] Sub-step S102-3: Mechanical assembly of the whole machine.

[0062] by Figure 1 Based on the structural layout shown, the mechanical assembly of the entire machine is completed sequentially. First, the support bearing is press-fitted into the bearing hole of the stator base, and then the rotor shaft is inserted into the bearing, ensuring that the rotor shaft can rotate smoothly without friction. Next, the machined stator excitation winding is fixed to the inner wall of the stator base, and the rotor induction winding is fixed to the outer wall of the rotor shaft. During the assembly process, special tooling is used to control the parallelism and coaxiality between the stator and rotor windings, ensuring that the air gap between them is strictly equal to the optimal air gap parameter determined in step S101. Subsequently, the integrated PCB signal processing circuit board is fixed to the stator mounting end face with 3×M2 bolts, and 3×M3 set screws are used to axially limit the rotor shaft and the circuit board to prevent axial displacement under high impact and vibration conditions. Afterward, one end of the communication cable is plugged into the communication output interface of the circuit board, and the other end is reserved to extend to the outside of the housing as the external signal transmission channel of the entire machine. Finally, the stator, rotor, circuit board and related components are installed into a fully enclosed magnetically conductive metal housing. The two ends of the housing are sealed with end caps to form a closed, full-area magnetically shielded cavity, which completely encloses all internal components to isolate external stray magnetic fields and electromagnetic radiation interference.

[0063] Sub-step S102-4: Pre-test of overall hardware functions.

[0064] After the entire machine is assembled, a comprehensive functional pre-test of the hardware system is performed. First, a power-on test is conducted to check whether the rotor induction winding can output a stable alternating induction signal after the stator excitation winding is supplied with excitation current, verifying the normal electromagnetic coupling between the windings. Second, the function of the PCB signal processing circuit board is tested, checking whether the signal acquisition circuit can read the induction signal normally, whether the CAN bus and PWM communication interfaces can send and receive data normally, and whether the Flash storage unit can read and write data normally. Simultaneously, the magnetic shielding effectiveness of the all-metal magnetic housing is tested by applying an interference magnetic field using an external magnetic field simulation device to check for abnormal fluctuations or drift in the sensor output signal. In addition, the mechanical assembly quality is checked to confirm that the rotor shaft rotates smoothly without jamming, all fasteners are secure, and the air gap spacing is within tolerance. Through these pre-tests, hardware defects such as magnetic field crosstalk, communication interruptions, and loose components are eliminated. Only after confirming that the entire hardware system is fault-free can the subsequent software algorithm debugging process begin.

[0065] The aforementioned hardware system (hereinafter referred to as the system) is a combination of hardware circuits (including the microcontroller unit MCU integrated on the PCB signal processing circuit board, the orthogonal magnetic encoder chip interface circuit, the data bus and the on-chip Flash storage unit) and embedded algorithms (embedded programs embedded in the MCU), which will be described in detail later.

[0066] Step S103: Collect the original sampling data of the rotor magnetic field, use the binary search algorithm to complete the coarse angle positioning, reduce the amount of data traversal and calculation, and output the angle interval data to provide a basic data source for subsequent segmented correction and accurate calculation.

[0067] The above steps are the preprocessing of sampling data from the orthogonal magnetic coding chip and the coarse angle positioning steps using the bisection method. The orthogonal magnetic coding chip is used to collect the original magnetic field sampling data generated by the rotor rotation. The bisection angle position judgment algorithm is used to traverse the sampling dataset to complete the coarse angle positioning, reducing the amount of computation in traversing the original sampling data and outputting the coarse positioning angle interval data, providing the original data for interval division for piecewise linear correction and accurate angle calculation.

[0068] Sub-step S103-1: Acquisition of raw data of the global magnetic field.

[0069] After completing the hardware pre-inspection, a matching drive fixture is assembled to drive the sensor rotor to rotate continuously and uniformly along its full stroke from 0° to 360°. Two orthogonal magnetic encoder chips inside the sensor synchronously and in real-time acquire the raw sampling values ​​corresponding to the magnetic field changes during rotor rotation. The two chips acquire data in parallel to cover the entire circumferential non-uniform magnetic field region. All acquired raw sampling data is written to the Flash storage unit on the PCB circuit board, forming a complete sampling dataset of size n. Because the magnetic field distribution along the circumference of the magnetic ring is non-uniform, if a traditional polling traversal method is used to retrieve the dataset for angle positioning, the controller needs to traverse a large number of sampling points for each positioning operation, which will consume a significant amount of MCU computing resources and slow down the real-time signal response speed. Therefore, a dedicated positioning optimization algorithm is needed to process the raw sampling data.

[0070] Sub-step S103-2: Deployment of the binary angle position determination algorithm.

[0071] An interval doubling retrieval algorithm is deployed in the circuit board's built-in arithmetic control unit to perform coarse rotor angle positioning. This algorithm optimizes the time complexity of a single angle positioning to O(logn), and the corresponding recursive operation relationship is as follows:

[0072] ;

[0073] Where T(n) represents the total computation time required for a single angle positioning operation when the total amount of the sampled dataset is n; The recursive form of the algorithm indicates that the search coverage is doubled in each iteration based on the initial search unit; O(1) refers to the constant-level computational overhead required for a single boundary comparison judgment.

[0074] The algorithm operates as follows: First, an initial retrieval unit much smaller than the total data volume is selected as the baseline interval. The sampled data within this baseline interval is compared with the current acquired value. If the current acquired value exceeds the boundary of the baseline interval, the retrieval range is doubled based on the current baseline interval, and the next iteration begins. This process of comparing the sampled data within the baseline interval with the current acquired value and doubling the retrieval range is repeated until the retrieval range completely covers the sampled data interval corresponding to the rotor's current angle, thus completing the coarse positioning interval boundary locking. This algorithm gradually expands the retrieval coverage with constant-level computational overhead, avoiding the indiscriminate traversal of the entire data range by traditional polling algorithms. It keeps the computational load of the coarse positioning process at a logarithmic level, significantly reducing the real-time operating load of the MCU, while providing a clear basis for subsequent segmented data switching and precise angle calculation.

[0075] Step S104: Compare the data difference between the two sampling chip intervals, select the sampling data with better linear performance as the basis for calculation, eliminate the segmented distortion caused by uneven magnetic field distribution, and output a continuously optimized sampling sequence.

[0076] The above steps are dynamic switching steps for segmented data of orthogonal chips based on sampling differences. By comparing the differences between adjacent sampling points of two orthogonal magnetic encoder chips, the chip segmented sampling data with a larger difference and better linearity is selected as the effective calculation data source. This eliminates the segmented linear distortion problem caused by uneven distribution of the whole-cycle magnetic field and outputs a continuous effective sampling data sequence after segment optimization.

[0077] Sub-step S104-1: Real-time calculation of segmented sampling difference.

[0078] Upon receiving the rotor coarse positioning interval information output in step S103, the main control unit synchronously retrieves the original sampling values ​​of consecutive adjacent sampling points of the two orthogonal magnetic encoder chips (chip1 and chip2) within the angular interval. It then performs a difference calculation on the adjacent sampling data of the two chips to obtain their respective sampling differences. This difference directly characterizes the variation of the magnetic field lines with the rotation angle within the current interval. A larger difference indicates better linearity of the sampling curve and lower measurement distortion in that interval; conversely, a smaller difference indicates more significant linear distortion and insufficient reliability of the sampling data. The system continuously calculates the difference between the two chips in real time, providing a quantitative basis for selecting the optimal sampling channel.

[0079] Sub-step S104-2: Calculation of optimal sampling channel selection.

[0080] The system executes the formula for calculating the number of valid sampling points in segments:

[0081] ;

[0082] Where m represents the number of optimal effective sampling points within the current coarse positioning interval; chip1 is the numerical difference between adjacent sampling points of the first orthogonal magnetic encoder chip; chip2 is the numerical difference between adjacent sampling points of the second orthogonal magnetic encoder chip; max() is the maximum value operation function.

[0083] The program compares the differences calculated by the two chips in real time and automatically selects the orthogonal magnetic encoder chip with the larger difference as the main sampling channel for the current angle interval, thus completing the dynamic switching of the segmented data source. This mechanism can avoid the piecewise linear distortion problem caused by the uneven distribution of the magnetic field around the entire circumference of the magnetic ring, integrate the effective sampling information of the high linearity intervals of the two chips, and splice and output a continuous and complete effective sampling data sequence after segment optimization, providing a higher quality raw calculation data source for subsequent high-precision angle calculation.

[0084] Step S105: Store the full-domain calibration sampling data, establish a piecewise interpolation solution model to convert the accurate angle, build a multi-dimensional error evaluation model, and output the standardized high-precision angle data after correction.

[0085] The above steps are the piecewise nonlinear calibration and high-precision angle position calculation steps. The original data sampled by the two orthogonal chips is stored in the storage unit. A piecewise interpolation calculation model is established based on the circumferentially divided calibration interval. The effective sampled data of the segments are substituted to complete the accurate angle conversion. Multi-dimensional error terms are superimposed to construct the maximum error evaluation model of the whole machine. The corrected high-precision standardized angle output data is output.

[0086] Sub-step S105-1: Calibration data solidification and calibration interval calculation.

[0087] A secondary global calibration method is used to drive the rotor to traverse the entire range of 0°-360°. Two orthogonal magnetic encoder chips synchronously collect raw sampling points throughout the entire stroke, and all calibration sampling data are stored in the flash memory of the circuit board to generate a calibration array ori. The total number of raw sampling points in the global range is denoted as n. Based on the 2π total radians of the circumference, the standard equally divided angle interval between two adjacent calibration points is calculated to be 2π / n radians. This establishes a calibration reference library covering the entire range, providing a unified data reference for piecewise interpolation calculations.

[0088] Sub-step S105-2: Precise angle position calculation.

[0089] During equipment operation, the original sampling data PIn from the orthogonal chip is collected in real time. The main control program automatically retrieves the calibration array ori, determines whether PIn falls within the interval formed by adjacent calibration points ori[i] and ori[i+1], and substitutes it into the standardized angle output solution formula to complete the piecewise linear interpolation operation.

[0090] ;

[0091] in The normalized output angle value after interpolation is expressed in radians; 2π represents the total radians of the complete circle; n is the total number of sampling points for global calibration; PIn is the raw sampling data acquired by the chip in real time; Ori[i] and Ori[i+1] are two adjacent sets of calibration reference sampling values, and i is the index of the calibration interval to which the current sampling data belongs. This formula is used to convert coarse sampling data into continuous high-precision angle values ​​and output the basic correction angle data.

[0092] Sub-step S105-3: Construction of the whole machine global error model.

[0093] By integrating all error sources from the sensors, a formula for evaluating the maximum measurement error of the entire instrument is established to predict the upper limit of the error across the entire measurement range, providing a basis for correction during secondary calibration and compensation.

[0094] ;

[0095] Where E is the maximum measurement error of the sensor across the entire range of 0°-360°; 2π is the total radian of the complete circle; n is the total number of original calibration sampling points across the entire range; min(m) is the minimum value of the optimal number of sampling points m for each segment of the entire stroke; Ev is the calibration system error introduced by the uneven rotation speed of the turntable; O(t) includes various time-varying random error terms such as timer clock jitter, dual-chip sampling timing deviation, and overall mechanical installation tolerance.

[0096] Step S106: Use secondary calibration to compensate for the measurement error across the entire range, conduct reliability tests in various extreme environments, verify all accuracy indicators, and complete the overall sensor design after confirming that the error meets the design requirements.

[0097] The above steps constitute the overall calibration, multi-environment testing, and error performance verification. A secondary calibration method is used to perform full-domain nonlinear compensation on the calculated output angle data. High and low temperature, mechanical shock, and electromagnetic compatibility full-condition environmental tests are completed. Full-domain displacement error curves are collected to verify measurement accuracy and repeatability. After confirming that the error meets the design threshold, the complete design of the inductive angle displacement sensor is finished.

[0098] Sub-step S106-1: Secondary global nonlinear calibration compensation.

[0099] Based on the global error distribution law output by the error model in step S105, the full range of 0°-360° is divided into independent intervals. A dedicated nonlinear compensation coefficient is matched for each interval, and the original angle data of Pout output is corrected in segments to offset the segmented linear error and measurement offset caused by winding structure, mechanical assembly and magnetic field inhomogeneity, and further reduce the full range angle measurement deviation.

[0100] Sub-step S106-2: Full-condition environmental reliability test.

[0101] The sensor prototype, after undergoing secondary calibration and compensation, was subjected to multiple sets of extreme operating condition reliability tests: a high and low temperature cycling test from -55℃ to 150℃ was performed to verify the signal output stability over a wide temperature range; a peak 10000g mechanical impact and continuous vibration test was conducted to verify the deformation resistance of the overall structure and the continuity of sampling data; and a strong electromagnetic radiation compatibility test was conducted to simulate interference scenarios from surrounding motors and frequency converters, verifying the anti-interference effect of the metal shielding shell. Sensor angle output data was recorded in real time throughout the process to troubleshoot faults such as data drift, communication interruption, and structural loosening.

[0102] Sub-step S106-3: Verification of accuracy indicators and error curves.

[0103] Collect measured angle values ​​from 0° to 360° across the entire range and compare them with theoretical ideal angle values. Calculate the difference between the two and plot a real-ideal displacement error curve. Verify each core design specification: detection accuracy ≤ 0.01°, repeatability ≤ 0.01°, complete coverage of the 0° to 360° measurement range, and signal output resolution of 16 bits. If the full-range measurement error is stably controlled within the 0.01° threshold, and there are no hardware damage, data distortion, or communication failures during any environmental testing, then all performance indicators of the sensor are deemed to meet the standards, completing the entire design process for the inductive angle displacement sensor.

[0104] Secondly, the present invention provides an overall structure for an inductive angle displacement sensor, which is designed using the above method. The overall structure of the inductive angle displacement sensor is as follows: Figure 1 As shown in the figure. The structural components shown in the figure include rotor 1, stator 2, and stator 3. M3 set screw 3, 3 M2 bolts 4, 3 5. Stator mounting fixture, 6. Communication cable, 7. Rotor shaft, 8. Stator mounting end face. Due to image area limitations, not all structural components are labeled. Detailed descriptions are as follows:

[0105] The inductive angle displacement sensor consists of seven core components: rotor shaft 7, support bearing, stator assembly, PCB signal processing circuit board, all-metal enclosed magnetic housing, communication cable 6, and multiple sets of standard mounting fasteners. The assembly and connection relationships, independent functions, and collaborative interaction logic between components are detailed below:

[0106] Rotor shaft and support bearing: The rotor shaft is the external angular rotation input actuator of the whole machine. The support bearing is fitted on the outer wall of the middle section of the rotor shaft, and the outer ring of the bearing is interference-fitted with the inner wall of the stator. The rotor induction winding is fixed on the outer wall of the rotor shaft. External drive devices such as servo motors and robot joints drive the rotor shaft to rotate synchronously. The rotor winding generates angular displacement synchronously with the rotor shaft, changing the relative spatial position with the stator excitation winding, so that the mutual inductance coefficient between the two sets of windings changes regularly, generating an alternating induced magnetic field signal. The support bearing realizes frictionless rotation support of the rotor shaft. The whole machine has no brushes, slip rings or other contact transmission structures, eliminating mechanical wear problems at the source.

[0107] Stator Assembly: The stator assembly includes a stator base, a stator excitation winding, and three sets of stator mounting fixtures. The stator excitation winding adopts a simulated and optimized sinusoidal coil configuration. During assembly, the winding maintains a standard air gap distance of 0.45mm with the rotor winding. A flat stator mounting end face is reserved on the outer wall of the stator base. The three sets of stator mounting fixtures are fixed on the outside of the stator base, serving as the locking reference for the assembly of the entire machine with external equipment. A 10kHz sinusoidal excitation current is continuously supplied to the stator excitation winding to generate a stable alternating excitation magnetic field, which forms an electromagnetic coupling with the rotor winding. It is the core magnetic field generating carrier of the inductive angle detection principle.

[0108] PCB signal processing circuit board: The circuit board is fastened to the stator mounting end face with 3×M2 bolts. The circuit board adopts SIP high integration technology and integrates an orthogonal magnetic encoder chip, signal acquisition module, algorithm operation MCU, Flash storage unit, CAN bus and PWM dual-mode output drive circuit. The circuit board acquires the induced voltage signal generated by the coupling of stator and rotor windings in real time, and runs the built-in complete software algorithm to complete the entire process of sampling preprocessing, binary coarse positioning, segmented data switching, high-precision angle calculation, and global nonlinear correction. It converts the original induced voltage signal into standardized high-precision angle data, and stores the global calibration sampling data. The circuit board relies on 3×M3 set screws to achieve axial limit, resisting the circuit board displacement under high impact and strong vibration conditions, and avoiding circuit contact failure.

[0109] All-metal enclosed magnetic housing: The housing completely encloses all internal components of the stator, rotor, and PCB circuit board, forming a sealed, full-area magnetic shielding cavity; the housing is made of high magnetic permeability metal material, which can absorb stray magnetic fields from external equipment and electromagnetic radiation from motor operation, and block external interference magnetic fields from intruding into the winding coupling area, thereby reducing measurement errors caused by electromagnetic interference from the hardware structure level, and is suitable for high-end automated equipment operating conditions with strong electromagnetic interference.

[0110] Communication cable: One end of the communication cable is plugged into the communication output interface of the PCB circuit board, and the other end extends to the outside of the metal shell as the external signal transmission channel of the whole machine; the cable is compatible with both CAN bus and PWM output modes, and can be directly connected to mainstream controllers in the industry such as microcontrollers and DSPs to transmit 16-bit resolution standardized angle output data after algorithm correction.

[0111] Standard mounting fasteners: The fasteners include three types: 3×M3 set screws, 3×M2 bolts, and 3 sets of stator mounting clamps; the 3×M2 bolts are responsible for locking the PCB circuit board to the stator mounting end face; the 3×M3 set screws realize bidirectional axial limit of the circuit board and rotor shaft, avoiding component displacement under high impact and vibration conditions; the 3 sets of stator mounting clamps serve as the external mounting reference for the whole machine, which can quickly fix the sensor to the servo motor, precision gimbal, and industrial valve positioning equipment.

[0112] The functional interaction logic of each component is as follows: The rotor shaft drives the rotor winding to rotate, changing the mutual inductance parameters of the winding. The stator excitation winding outputs an alternating magnetic field to complete electromagnetic coupling and generate an induced electrical signal. The PCB circuit board collects the induced voltage in real time and completes sampling preprocessing, binary coarse positioning, segmented channel optimal switching, high-precision angle calculation, and full-domain error correction through built-in multi-level software algorithms. The standardized angle data after correction is transmitted to the outside via communication cable in CAN or PWM mode. The all-metal enclosed shell shields external electromagnetic interference throughout the process, and various fasteners ensure the stability of the whole machine structure under high impact and extreme high and low temperature environments. The non-contact inductive coupling structure eliminates mechanical wear. Combined with the secondary segmented calibration algorithm, it achieves high-precision measurement of ≤0.01° across the entire range. All components work together to enable the sensor to have the ability to detect angle displacement with a wide temperature range of -55℃ to 150℃, 10,000g-level impact resistance, strong electromagnetic compatibility, and ultra-long service life.

[0113] The software on the aforementioned PCB signal processing circuit board is an embedded program embedded in the onboard MCU. It serves as the algorithm execution carrier for the entire inductive angle displacement sensor design methodology. The entire design methodology, from physical structure simulation, hardware fabrication and assembly, data acquisition, interval retrieval, sampling channel optimization, angle calculation, error compensation to overall system performance verification, is progressively developed around the functional requirements of this software. The two are deeply integrated and support each other at every level. Each step of the entire design methodology is guided by the computation, acquisition, and output requirements of the PCB circuit board software: the initial simulation and hardware assembly provide the software with high-quality input signals and the necessary hardware foundation; the intermediate data acquisition, interval retrieval, segment optimization, and angle calculation are all implemented entirely through the software; and the final calibration, compensation, and environmental testing rely on the software for performance verification. The specific implementation methods have been detailed in the design methodology section and will not be repeated here.

[0114] Thirdly, the present invention provides an electronic device comprising: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, the instructions being executed by the at least one processor to enable the at least one processor to perform the above-described inductive angle displacement sensor design method.

[0115] Fourthly, the present invention provides a storage medium, which may be a computer-readable storage medium having computer-readable program instructions (i.e., a computer program) stored thereon, the computer-readable program instructions being used to execute the above-described inductive angle displacement sensor design method.

[0116] The computer-readable storage medium provided by this invention may be, for example, a USB flash drive, but is not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems or devices, or any combination thereof. More specific examples of a computer-readable storage medium may include, but are not limited to: an electrical connection having one or more wires, a portable computer disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof. In this embodiment, the computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system or device. The program code contained on the computer-readable storage medium may be transmitted using any suitable medium, including but not limited to: wires, optical cables, RF (Radio Frequency), etc., or any suitable combination thereof.

[0117] The specific embodiments described above do not constitute a limitation on the scope of protection of this disclosure. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this disclosure should be included within the scope of protection of this disclosure.

Claims

1. A design method for an inductive angular displacement sensor, characterized in that, The method includes the following steps: An electromagnetic simulation model was built, and multiple sets of comparative simulations were carried out on the coil shape and air gap spacing. Simulation data related to magnetic field and signal were collected, and the optimal coil structure and air gap size were selected to complete the finalization of the core physical structure of the sensor stator winding. Build the sensing components corresponding to the simulation optimization parameters, integrate the signal processing circuit and lay out the metal shielding shell, install the fixing components and communication lines to complete the hardware construction of the whole machine with electromagnetic interference suppression capability. Raw sampling data of rotor magnetic field is collected, and a binary search algorithm is used to complete coarse angle positioning, reducing the amount of data traversal and computation, and outputting angle interval data to provide a basic data source for subsequent segmented correction and accurate calculation. By comparing the data difference between the two sampling chip intervals, the sampling data with better linear performance is selected as the basis for calculation, eliminating the segmented distortion caused by uneven magnetic field distribution, and outputting a continuously optimized sampling sequence. Store the full-domain calibration sampling data, establish a piecewise interpolation solution model to convert accurate angles, build a multi-dimensional error evaluation model, and output standardized high-precision angle data after correction. The sensor design was completed after secondary calibration was used to compensate for the measurement error across the entire range, various extreme environment reliability tests were conducted, and all accuracy indicators were verified.

2. The design method for an inductive angle displacement sensor according to claim 1, characterized in that, The core physical structure of the sensor stator winding was finalized, which specifically included: constructing an electromagnetic simulation model, conducting multiple sets of comparative simulations on different coil shapes and air gap spacing parameters, collecting simulation data on induced electromotive force, magnetic field distribution, and waveform symmetry, and selecting coil configurations and optimal air gap spacing with high output signal strength, uniform magnetic field, and symmetrical waveform. This finalized the core physical structure of the sensor stator winding, providing basic structural parameter support for subsequent hardware circuit integration.

3. The design method for an inductive angular displacement sensor according to claim 1, characterized in that, Complete the hardware construction of the sensor with electromagnetic interference suppression capability. Specifically, this includes: processing stator and rotor components based on the coil and air gap parameters obtained from simulation; assembling bearings, rotor shafts, and PCB signal processing circuit boards; integrating the core detection circuit using SIP technology; assembling a fully enclosed magnetically conductive shell to build a magnetic shielding structure; and laying communication cables and standard mounting fasteners. This completes the physical hardware construction of the sensor with electromagnetic interference resistance capability.

4. The design method for an inductive angle displacement sensor according to claim 1, characterized in that, The process of collecting raw sampling data of the rotor magnetic field includes: setting up a matching drive fixture to drive the sensor rotor to rotate continuously at a uniform speed along the complete stroke from 0° to 360°; two orthogonal magnetic encoding chips inside the sensor synchronously and in real time collect the raw sampling values ​​corresponding to the changes in the magnetic field during the rotor rotation, and the two chips collect data synchronously and in parallel to cover the non-uniform magnetic field area of ​​the entire circumference; all the raw sampling data collected are uniformly written into the Flash storage unit on the PCB circuit board to form a complete sampling dataset with a total size of n.

5. The design method for an inductive angular displacement sensor according to claim 1, characterized in that, A binary search algorithm is used to perform coarse angle localization. Specifically, it includes: selecting an initial retrieval unit much smaller than the total data volume as a reference interval; comparing the sampled data within the reference interval with the current acquired value; if the current acquired value exceeds the boundary of the reference interval, doubling the entire retrieval range based on the current reference interval and proceeding to the next iteration; repeating the comparison between the sampled data within the reference interval and the current acquired value, as well as doubling the entire retrieval range, until the retrieval range completely covers the sampled data interval corresponding to the current rotor angle, thus completing the coarse localization interval boundary locking.

6. The design method for an inductive angle displacement sensor according to claim 1, characterized in that, The comparison of the data difference between the two sampling chip intervals specifically includes: receiving the rotor coarse positioning interval information output by the main control unit, and synchronously retrieving the original sampling values ​​of consecutive adjacent sampling points of the two orthogonal magnetic encoder chips within the angle interval; performing difference calculations on the adjacent sampling data of the two chips respectively to obtain their respective sampling differences.

7. The design method for an inductive angle displacement sensor according to claim 1, characterized in that, The output is standardized high-precision angle data after correction. Specifically, it includes: solidifying the original data sampled by the two orthogonal chips into the storage unit, establishing a segmented interpolation solution model based on the circumference equally divided calibration interval, substituting the segmented effective sampled data to complete the accurate angle conversion, superimposing multi-dimensional error terms to construct the maximum error evaluation model of the whole machine, and outputting the corrected high-precision standardized angle output data.

8. The design method for an inductive angle displacement sensor according to claim 1, characterized in that, The method employs secondary calibration to compensate for full-range measurement errors. Specifically, it involves: based on the full-range error distribution law output by the error model, dividing the full range of 0°-360° into independent intervals, matching a dedicated nonlinear compensation coefficient for each interval, and performing segmented correction on the Pout original angle data output by the solution to offset the segmented linear errors and measurement offsets caused by winding structure, mechanical assembly, and magnetic field inhomogeneity.

9. The design method for an inductive angular displacement sensor according to claim 7, characterized in that, The original sampling data PIn of the orthogonal chip is collected in real time. The main control program automatically retrieves the calibration array ori and determines that PIn falls within the interval formed by the adjacent calibration points ori[i] and ori[i+1]. The standardized angle is then substituted into the output solution formula to complete the piecewise linear interpolation operation.

10. An inductive angular displacement sensor, wherein the inductive angular displacement sensor is obtained by the design method according to any one of claims 1 to 9, characterized in that, The inductive angular displacement sensor includes a rotor shaft, support bearing, stator assembly, PCB signal processing circuit board, all-metal enclosed magnetic housing, communication cable, and multiple sets of standard mounting fasteners. The PCB signal processing circuit board acquires the induced voltage signal generated by the coupling of the stator and rotor windings in real time, runs a complete set of built-in software algorithms to complete the entire process of sampling preprocessing, binary coarse positioning, segmented data switching, high-precision angle calculation, and global nonlinear correction, converts the original induced voltage signal into standardized high-precision angle data, and stores the global calibration sampling data.

Images