Electrode moving position absolute value acquisition system and method

Abstract

The application discloses an electrode moving position absolute value collection system and method, relates to the technical field of industrial automation measurement and control, and comprises three encoders, three electrode moving position pulse signals are collected by the three encoders, and three electrode moving position pulse signals collected by the three encoders are transmitted in parallel; a CPU central processing module is electrically connected with the three encoders; a delay judgment and clearing module is integrated in the CPU central processing module and is used for monitoring the value change state of the encoder; when the value of the encoder remains unchanged within a preset delay time X seconds, the cumulative value of the encoder is automatically cleared; the three-encoder redundant collection architecture is adopted, the system can still work based on the remaining encoders when any encoder fails, and fault tolerance is realized through maximum / minimum / average value selection.

Description

Technical Field

[0001] This invention relates to the field of industrial automation measurement and control technology, specifically to a system and method for acquiring the absolute value of electrode movement position. Background Technology

[0002] In industrial production fields such as metallurgy and chemical engineering, accurate measurement and real-time monitoring of electrode positions are crucial for ensuring stable operation of production processes. Taking electric arc furnace steelmaking as an example, the raising and lowering position of the electrodes directly determines the arc length and input power, thus affecting smelting efficiency, energy consumption, and product quality. Traditional electrode position measurement methods mainly suffer from the following technical shortcomings: 1. Encoder Cumulative Error Problem: In existing technologies, encoders experience drift errors in their cumulative values ​​during long-term operation due to factors such as mechanical backlash and vibration interference. Even when the electrodes are stationary, the encoder may still output pulse signals due to weak vibrations, causing the cumulative value to continue to increase, severely affecting the accuracy of position measurement.

[0003] 2. Insufficient reliability of single encoder acquisition: Traditional solutions often use a single encoder for position acquisition. Once the encoder fails or the signal cable is damaged, the entire measurement system will fail, lacking a redundancy guarantee mechanism.

[0004] 3. Lack of multi-value selection function: In actual working conditions, the requirements for position data vary at different process stages—sometimes the peak position (maximum value) needs to be considered, sometimes the valley position (minimum value) needs to be considered, and sometimes the average position needs to be considered. Current technology lacks a flexible multi-value selection mechanism, preventing operators from switching output modes in real time according to working conditions. 4. Lack of forward and reverse motion judgment capability: Electrodes exhibit both upward and downward motion directions during actual operation. Current technology struggles to accurately distinguish the forward and reverse directions of encoder pulses, resulting in the cumulative value calculation failing to correctly reflect the actual motion trajectory of the electrode, thus affecting the accuracy of position control. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a system and method for acquiring the absolute value of electrode movement position, which solves the problems of large cumulative encoder error, insufficient reliability of single encoder acquisition, and lack of multi-value selection function in existing electrode position measurement schemes.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an absolute value acquisition system for electrode movement position, comprising: Three encoders are used to synchronously acquire electrode movement position pulse signals, and the three electrode movement position pulse signals acquired by the three encoders are transmitted in parallel. The CPU central processing module is electrically connected to the three encoders and is used to receive and process the three electrode movement position pulse signals. The delay judgment and clearing module is integrated into the CPU central processing module. It is used to monitor the encoder value change status. When the encoder value remains unchanged within a preset delay time of X seconds, the encoder cumulative value is automatically cleared to zero. An absolute value calculation module, which is integrated into the CPU central processing module, is used to perform absolute value calculation on the encoder's cumulative value. The three-stage selection switch includes an externally adjustable three-stage physical switch for switching between three output modes: maximum value, minimum value, and average value. The status signal of the externally adjustable three-stage physical switch is input to the CPU central processing module. A pulse and direction calculation module, which is integrated into the CPU central processing module, is used to count encoder pulses and determine the electrode movement direction by the A / B phase difference; The cumulative value output module is electrically connected to the CPU central processing module and is used to output the processed position cumulative absolute value to an external device.

[0007] In some embodiments, the three encoders are respectively installed on the motor shaft end, the reducer output shaft and the electrode arm guide wheel shaft of the electrode lifting transmission system, and the three encoders are used to synchronously acquire electrode movement pulse signals.

[0008] In some embodiments, the preset delay time X of the delay judgment and clearing module is an adjustable parameter, with a value range of 1-60 seconds; when the CPU central processing module detects that the values ​​of the three encoders have not changed within X seconds, it performs a clearing operation; if the value of any encoder changes, the cumulative value is kept unchanged.

[0009] In some embodiments, the operating modes of the three-segment selector switch include: maximum value mode, in which the CPU central processing module compares the absolute value outputs of the three encoders and takes the maximum value as the output; minimum value mode, in which the minimum value among the three is taken as the output; and average value mode, in which the arithmetic mean of the three is taken as the output.

[0010] In some embodiments, the pulse and direction calculation module determines the direction of motion by the phase relationship between the encoder A phase and the encoder B phase pulses. When the encoder A phase leads the encoder B phase by 90°, it is determined to be forward motion, and when the encoder B phase leads the encoder A phase by 90°, it is determined to be reverse motion. The cumulative value increases during forward motion and decreases during reverse motion.

[0011] In some embodiments, the CPU central processing module reads the encoder signal at a fixed sampling period T. Within each sampling period, it sequentially executes the processes of signal acquisition, delay judgment, zeroing, absolute value calculation, mode selection, direction calculation, and output processing, and executes them cyclically.

[0012] In some embodiments, the cumulative value output module outputs the absolute position value, motion direction flag, and system status flag to the HMI display unit and the host computer system via an RS485 / Modbus RTU interface.

[0013] A method for acquiring the absolute value of electrode movement position includes the following steps: S1: The three encoders simultaneously acquire the electrode movement position pulse signal and transmit it in parallel to the CPU central processing module; S2: The CPU central processing module monitors the value change status of the three encoders in real time. When the values ​​of the three encoders remain unchanged within a preset delay time of X seconds, the cumulative value of the encoder is automatically cleared to zero. S3: The CPU central processing module performs absolute value calculation on the cumulative value of the encoder to obtain the absolute position values ​​P1, P2 and P3 of the three encoders; S4: Read the status of the external three-stage selection switch, and calculate the output value P_out according to the algorithm of selecting the maximum, minimum or average value according to the switch position; S5: The direction of electrode movement is determined by the phase difference between the A and B phases of the encoder. The cumulative value increases when moving in the forward direction and decreases when moving in the reverse direction. S6: Output the output value P_out, the direction of motion, and the system status to an external device.

[0014] In some embodiments, in step S2, the CPU central processing module reads the encoder value at a fixed sampling period T, compares the current period value with the previous period value, and if the difference between the three encoders is 0, the static timer is incremented. When the accumulated value of the timer reaches the delay threshold X seconds, it is cleared.

[0015] In some embodiments, in step S4, the gear switching of the three-stage selector switch takes effect in real time within each sampling period. The operator can switch the output mode at any time during system operation. The CPU central processing module automatically updates the output algorithm according to the current switch state to achieve seamless switching.

[0016] Beneficial effects A redundant acquisition architecture with three encoders is adopted. If any encoder fails, the system can still continue to work based on the remaining encoders. Fault tolerance is achieved by selecting the maximum / minimum / average value.

[0017] The delay-based zeroing module automatically zeroes the electrode after it has been stationary for more than X seconds, effectively eliminating the cumulative error of static drift caused by weak vibrations and mechanical gaps, and ensuring the long-term accuracy of position measurement.

[0018] The three-stage external adjustable switch allows operators to flexibly switch between maximum, minimum, or average output modes according to different process stages, adapting to various working conditions without modifying the program.

[0019] The forward and reverse motion of the electrodes is accurately determined by the phase difference between the A and B phases, and the cumulative value can truly reflect the net displacement of the electrodes, providing an accurate feedback signal for closed-loop control.

[0020] Absolute value calculation unifies the position representation in the positive and negative directions, and the cross-verification of the three encoders further reduces the measurement error of a single encoder, improving the overall accuracy by more than 30%.

[0021] The automatic zeroing mechanism reduces the frequency of manual calibration, the redundant architecture reduces downtime caused by single point of failure, and the overall system maintenance cost is reduced by more than 40%. Attached Figure Description

[0022] Figure 1 This is a block diagram of the overall architecture of the electrode movement position absolute value acquisition system of the present invention.

[0023] Figure 2 This is a flowchart of the delay judgment and clearing module of the present invention.

[0024] Figure 3 This is a schematic diagram of the three-stage selection switch logic of the present invention.

[0025] Figure 4 This is a schematic diagram of the pulse and direction calculation module of the present invention.

[0026] Figure 5 This is a flowchart of the CPU data processing of the present invention. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] like Figure 1As shown, the present invention provides a technical solution: an absolute value acquisition system for electrode movement position, comprising: three encoders, the three encoders being used to synchronously acquire electrode movement position pulse signals, and the three electrode movement position pulse signals acquired by the three encoders being transmitted in parallel; and a CPU central processing module, the CPU central processing module being electrically connected to the three encoders, and being used to receive and process the three electrode movement position pulse signals. The system includes: a delay-based zeroing module (integrated into the CPU), a three-stage selector switch (including an externally adjustable three-stage physical switch for switching between maximum, minimum, and average output modes, with the status signal of the externally adjustable three-stage physical switch input to the CPU), a pulse and direction calculation module (integrated into the CPU) for counting encoder pulses and determining the electrode movement direction based on the A / B phase difference), and a cumulative value output module (electrically connected to the CPU) for outputting the processed cumulative absolute value of the position to an external device.

[0029] This system is a three-channel incremental encoder signal acquisition, processing, data transmission, and control system. The entire system consists of a power supply module, multi-channel encoder sensors, a signal conditioning board, a CPU central processing module, external selection switches, a human-machine interface unit, and a data output and host computer monitoring system. It realizes three-axis position pulse signal acquisition, real-time processing, parameter switching, local display, and remote host computer communication monitoring. It is suitable for multi-axis mechanical position synchronous monitoring and displacement accumulation measurement scenarios. The entire system is powered by a 24VDC industrial standard power supply.

[0030] Functional description of each component 1. Sensor Input Unit (Three-Channel Encoder) The system receives three independent incremental encoder signals: Encoder #1: Acquires motor shaft speed / position signals (motor shaft end) Encoder #2: Acquires the position signal of the reducer output shaft (reducer output shaft) Encoder #3: Acquires guide wheel shaft position signal (guide wheel shaft). The three encoders synchronously acquire the original differential signal of each shaft pulse position as the data input source for the entire system.

[0031] 2. Signal conditioning board Core Functions: Optical isolation + differential signal reception. The differential pulse signals from the three encoders are first sent to the signal conditioning board to complete electrical isolation and signal shaping. Optical isolation: blocks industrial interference in the field, prevents strong electrical interference from entering the main control circuit, and improves the system's EMC anti-interference capability; Differential signal reception: Adapts to encoder differential level signals, converts raw differential pulses into standard pulse signals that can be recognized by the main control module; the standardized pulse signals after conditioning are sent to the CPU central processing module.

[0032] 3. CPU (Central Processing Unit) (Core Computing Unit of the System) As the core of this device, it integrates multiple functional sub-modules to complete pulse signal processing, logic operations, and data buffering: The delay judgment and clearing module has built-in timing judgment logic, which can realize the automatic clearing of the counter register after a delay according to the set conditions, and is used for periodic measurement and segmented cumulative reset.

[0033] The three-stage selector switch module (internal logic channel) works in conjunction with the external three-stage selector switch to achieve switching between three data acquisition and calculation modes: maximum value of level I, minimum value of level II, and average value of level III; it also works in conjunction with the zeroing logic control calculation channel.

[0034] The absolute value calculation module performs absolute value calculations on the encoder pulse position data to eliminate the influence of the positive and negative signs of the direction, and is used for absolute displacement length statistics.

[0035] The pulse and direction calculation module analyzes the A / B phase pulses of the incremental encoder, identifies the number of pulses and the direction of rotation, and calculates the displacement and position increments in real time.

[0036] The three independent hardware / logic registers (C1_cum, C2_cum, C3_cum) continuously buffer the cumulative position pulse values ​​of the three encoders to store long-term cumulative measurement data.

[0037] The output registers (P_out, DIR, FLAG_ZERO) buffer the final operation output results: position output value, rotation direction indicator, and clear status flag, serving as a data buffer for external communication.

[0038] 4. External three-position selector switch (externally adjustable) The external hardware switch for the human-machine interface sends mode commands to the CPU module, providing three operating modes for selection: Gear 1: Maximum value calculation mode Gear 2: Minimum Value Calculation Mode Gear III: Average value calculation mode enables switching between different algorithms for calculating data from the three encoders, meeting the monitoring needs of different working conditions.

[0039] 5. Cumulative value output module & RS485 Modbus-RTU communication link The CPU output register data is sent to the cumulative value output module, and after protocol encapsulation, it is transmitted externally through the RS485 interface using the Modbus RTU industrial standard protocol. Modbus RTU is a universal industrial bus protocol with good compatibility.

[0040] 6. HMI display unit (7-inch touchscreen) As a local human-computer interaction terminal: Real-time reading of the cumulative value, direction, and status flags of the three encoders on the RS485 bus; Local real-time display of location and cumulative metering parameters; It supports local parameter settings, status alarms, and data viewing, enabling on-site monitoring.

[0041] 7. Host computer monitoring system Remote monitoring is achieved by communicating with the system through the same RS485 Modbus bus: the host computer summarizes all collected data, completes data storage, historical curves, and remote parameter viewing, and realizes remote centralized monitoring and management.

[0042] 8. Power supply module (24VDC) The power supply unit provides 24VDC industrial power to all hardware units, including the signal conditioning board, CPU module, and touch screen, and is the energy supply for the entire system.

[0043] Complete data flow workflow Three-channel encoders acquire differential pulses of the original position of the three axes; The pulse enters the signal conditioning board, where it is optically isolated and the differential signal is shaped. Standardized pulses are sent to the CPU central processing module; The CPU analyzes the number of pulses and the direction of rotation, and performs absolute value calculations; it selects the operation mode (maximum / minimum / average) using an external three-segment switch; the delay clearing module controls the cumulative register reset logic. The results of the operation are stored in the cumulative register and the output register; Valid data enters the cumulative value output module, is encapsulated as ModbusRTU protocol, and outputs via RS485; Data is transmitted to the 7-inch touchscreen for real-time local display. Data is uploaded synchronously to the host computer monitoring system to achieve remote monitoring.

[0044] This system adopts a multi-module integrated architecture, relying on the integrated design of multi-channel synchronous acquisition, intelligent zeroing, multi-mode algorithm switching and accurate direction recognition. It effectively solves the problems of large single-channel acquisition error, static value drift, single output mode and inability to accurately adapt to different working conditions in traditional electrode position acquisition. The overall architecture has a high degree of modularity and strong compatibility, and can be adapted to high-precision position acquisition scenarios of various industrial electrode lifting equipment.

[0045] In some embodiments, three encoders are respectively installed on the motor shaft end, the reducer output shaft and the electrode arm guide wheel shaft of the electrode lifting transmission system. The three encoders are used to synchronously acquire electrode movement pulse signals.

[0046] By deploying encoders at the three key nodes of the electrode lifting transmission system—power input, transmission transfer, and execution output—the system can comprehensively capture the positional deviations caused by power loss, transmission gaps, and mechanical deformation during electrode transmission. Compared to traditional single-point acquisition methods, this completely avoids the acquisition distortion problems caused by mechanical wear and transmission lag at a single acquisition point. The synchronous acquisition and parallel transmission of three signals ensures the comprehensiveness and real-time nature of position data acquisition, providing sufficient and accurate raw data support for subsequent data comparison and algorithm calculation.

[0047] like Figure 2 As shown, in some embodiments, the preset delay time X of the delay judgment and clearing module is an adjustable parameter, with a value range of 1-60 seconds; when the CPU central processing module detects that the values ​​of the three encoders have not changed within X seconds, it performs a clearing operation; if the value of any encoder changes, the cumulative value is kept from being cleared.

[0048] like Figure 2 The diagram shows the automatic zeroing control logic for three encoders that remain stationary for an extended period. It continuously monitors the position values ​​of the three encoders. When all three encoders remain stationary for a set time, the accumulated values ​​of all encoders are automatically reset to zero, and a zeroing flag is output. If any encoder moves, the stationary timer is immediately reset, and the judgment process restarts. The entire logic operates in a periodic loop.

[0049] The steps are analyzed segment by segment. The program enters the loop process and starts a round of logical operations.

[0050] Read the current values ​​C1, C2, and C3 of the three encoders to collect the real-time position readings of the three encoders, and record the encoder values ​​at the sampling time.

[0051] Calculate the difference \(\DeltaC=|C(n)-C(n-1)|\)\(C(n)\) : the encoder value sampled in the current round; \(C(n-1)\) : the value sampled in the previous round. Calculate the absolute difference to determine if the encoder has changed position. The difference is calculated independently for each of the three encoders.

[0052] Judgment condition: The difference between the three encoders is 0? [Yes]: All three encoders showed no positional change, indicating that the equipment was in a stationary state; [No]: At least one encoder generates displacement, indicating that the device is in motion.

[0053] Branch (No): The static timer is cleared, and then the loop returns directly to the beginning to reread the encoder values. Static Branch (All Encoder Differences = 0): The static timer = timer + TT represents the sampling period of a single loop; for each round of sampling that determines static, the timer is incremented by one sampling period.

[0054] Judgment condition: timer≥X seconds (X×T sampling times) According to the sampling period T, the cumulative number of sampling times reaches \(X / T\) times, which is equivalent to the continuous static duration ≥ the set X seconds.

[0055] [No]: If the static time does not meet the standard, return directly to the loop start point and continuously monitor the encoder in a loop; [Yes]: If the continuous static time meets the threshold, the zeroing process is executed. All encoder cumulative values ​​are cleared, and the cumulative position values ​​inside encoders C1, C2, and C3 are reset to zero.

[0056] When the output is cleared, the flag FLAG_ZERO=1 is set to output a signal to inform the host computer / external system that the encoder has performed a static timeout clearing action.

[0057] After the timer reset completes one clearing operation, the timing variable is reset to avoid repeated clearing.

[0058] Returning to the beginning of the loop, the encoder value is read again, and the next cycle monitoring begins.

[0059] This adjustable delay parameter design can flexibly adapt to different working conditions of electrode equipment. It can accurately match the zeroing logic for different working states such as short-term start-stop, intermittent operation, and long-term static placement. At the same time, it adopts the judgment mechanism of "zeroing only when three-channel values ​​are synchronously stationary", which can effectively avoid the problem of false zeroing caused by single-channel signal interference, mechanical micro-vibration, and electromagnetic interference. It can not only eliminate the detection error caused by encoder cumulative value drift and zero position offset when the electrode is static for a long time, but also ensure the continuity and accuracy of position data during the dynamic operation of the electrode, which can greatly improve the anti-interference capability and detection stability of the system.

[0060] like Figure 3 As shown, in some embodiments, the operating modes of the three-stage selector switch include: maximum value mode, where the CPU central processing module compares the absolute value outputs of the three encoders and takes the maximum value as the output; minimum value mode, where the minimum value among the three is taken as the output; and average value mode, where the arithmetic mean of the three is taken as the output.

[0061] like Figure 3 The diagram shown is a block diagram of a three-stage selector switch system with three encoders for signal processing. The overall signal flow is from the left input, through the arithmetic selection module, and finally output to the right.

[0062] 1. Input branches (three parallel inputs on the left) There are a total of 3 encoder signal channels: Encoder #1 outputs the cumulative value C1_cum, which is then used to obtain P1=|C1_cum| through absolute value calculation; Encoder #2 outputs the cumulative value C2_cum, which is then used to calculate P2 = |C2_cum| using absolute value operation. Encoder #3 outputs a cumulative value C3_cum, which is then processed by absolute value calculation to obtain P3=|C3_cum|. The processed P1, P2, and P3 signals are then sent to the three-stage selection switch in the intermediate core module.

[0063] 2. Core Module: Three-position selector switch Internally integrated with three-way computing functions, the operating mode is selected by switching knob: Gear I (maximum value): Max(P1,P2,P3) Gear II (Minimum): Min(P1,P2,P3) Gear Level III (Average): Avg(P1,P2,P3) The knob can switch between three settings, selecting the corresponding calculation result as the output and transmitting it to the next stage.

[0064] 3. Output link (right side) The output signal of the three-stage selector switch is sent to the output register P_out; the register is finally connected to the RS485 interface and output to the HMI human-machine interface.

[0065] 4. The text formula below defines three gear shift algorithms. Gear I (maximum value): \(\boldsymbol{P_{out}=Max(|P1|,|P2|,|P3|)}\), selects the maximum value of the absolute values ​​of the three encoders; Gear II (Minimum): \(\boldsymbol{P_{out}=Min(|P1|,|P2|,|P3|)}\), selects the minimum absolute value of the three encoders; Gear III (average value): \(\boldsymbol{P_{out}=(|P1|+|P2|+|P3|) / 3}\), calculate the arithmetic mean of the absolute values ​​of the three encoders.

[0066] Three switchable output modes can accurately adapt to the differentiated detection and control needs in industrial production. The maximum value mode can accurately reflect the limit of electrode movement, avoiding equipment collisions and process abnormalities caused by electrode overtravel. The minimum value mode can effectively eliminate extreme value interference data caused by transmission gaps and mechanical vibrations, reflecting the effective working displacement of the electrode. The average value mode can balance the deviation of the three-channel data acquisition, offset single-point mechanical errors and signal errors, and obtain high-precision and high-stability position average data. Operators can flexibly switch according to different scenarios such as process debugging, operation monitoring, and fault detection, making it highly adaptable and practical.

[0067] like Figure 4 As shown, in some embodiments, the pulse and direction calculation module determines the direction of motion by the phase relationship between the encoder A phase and the encoder B phase pulses. When the encoder A phase leads the encoder B phase by 90°, it is determined to be forward motion, and when the encoder B phase leads the encoder A phase by 90°, it is determined to be reverse motion. The cumulative value increases during forward motion and decreases during reverse motion.

[0068] Figure 4 The working principle of the incremental orthogonal A / B phase encoder for position acquisition is divided into four main parts: waveform diagram, direction judgment logic block diagram, counting operation process, and text explanation of the principle at the bottom. 1. Top left: Encoder A / B phase pulse waveform (orthogonal encoding) The display shows the A-phase and B-phase square wave signals output by the incremental encoder, with a 90° phase difference (orthogonality) between the two signals. The A-phase and B-phase voltage levels are staggered, and the difference in their voltage levels is the basis for determining the direction of rotation / movement.

[0069] 2. Top right: Direction determination logic Core judgment rule: Only capture the rising edge of phase A and read the level of phase B at that time. When phase A rises, phase B is high – forward motion, direction indicator DIR=1. When phase A rises, phase B is low → reverse motion occurs, direction indicator DIR=0. 3. Below: Complete data stream of pulse counting Process sequence: Pulse counter: Detects the rising edge of phase A and generates a pulse count value N; Direction flag DIR: Receives the direction determination result, 1 = positive, 0 = negative; Cumulative value calculation DIR=1 (positive): Cumulative value C_cum = C_cum + N_step (accumulation) DIR=0 (reverse): Cumulative value C_cum = C_cum - N_step (decreasing) Cumulative value output: The final cumulative position value is output synchronously, representing the net displacement of the equipment.

[0070] 4. Bottom text: [Summary of Working Principle] The incremental encoder outputs two-phase square waves, A and B, with a 90° phase difference; the controller CPU rapidly acquires the rising edge of phase A and synchronously latches the level of phase B. A rising edge & B high level: positive motion; A rising edge & B low level: reverse movement; the cumulative value of forward displacement increases, the cumulative value of reverse displacement decreases, and the final cumulative value accurately reflects the net displacement of the mechanism.

[0071] Direction recognition is achieved by utilizing the phase difference characteristics of the quadrature pulses A and B of the encoder. This method offers high recognition accuracy and fast response speed, precisely capturing even minute vertical movements of the electrodes. It completely solves the problems of traditional acquisition systems failing to distinguish electrode movement direction and prone to erratic accumulated values. Through direction matching, the accumulated values ​​are updated, accurately reproducing the actual displacement trajectory of the electrodes in real time. This ensures a perfect match between the accumulated position data and the actual electrode movement state, providing reliable direction and displacement data support for precise electrode positioning and closed-loop control.

[0072] like Figure 5 As shown, in some embodiments, the CPU central processing module reads the encoder signal at a fixed sampling period T. Within each sampling period, it sequentially executes the processes of signal acquisition, delay judgment, zeroing processing, absolute value calculation, mode selection, direction calculation, and output processing, and executes them in a loop.

[0073] like Figure 5 As shown, this is the workflow of a multi-encoder acquisition and processing control system. After the system is powered on and initialized, it cyclically executes the entire process of signal acquisition, processing, judgment, and output. The overall operation is carried out in a loop.

[0074] S1 System Initialization (Light Green Start Module) CPU power-on initialization, clear registers, and read switch status.

[0075] S2 signal acquisition (light blue module) The A / B phase pulse signals of the three encoders are read synchronously at a 10ms cycle, and the process returns to this step at the end of the process for continuous periodic acquisition.

[0076] S3 Delay Detection (Light Blue Module) Compare encoder value changes: when the encoder value is static, the timer increments; when the value changes, the timer is reset to zero.

[0077] S4 Clearing Detection (Light Yellow Detection Module) Judgment condition: timer ≥ X seconds Condition met: Encoder cumulative value cleared to zero; If the condition is not met: maintain the original cumulative value.

[0078] S5 Absolute Value Calculation (Light Blue Module) Take the absolute value of the cumulative values ​​of the three encoders: \(\boldsymbol{P1=|C1|,P2=|C2|,P3=|C3|}\) S6 Mode Selection (Light Yellow Module) Read the three-segment switch status and select one of three calculation algorithms (Max, Min, or Avg) based on the switch signal.

[0079] S7 direction calculation (light blue module) The direction of motion is determined by the phase difference between the A and B phases of the encoder, and the cumulative value of net displacement is calculated at the same time.

[0080] S8 Output and Display (Light Green Ending Module) Output results: displacement output value (P_{out}}), direction signal DIR, and various flag bits; the data is transmitted to the HMI (Human Machine Interface) and the host computer via RS485 bus. After execution, the process loops back to the S2 signal acquisition step and runs continuously periodically.

[0081] The system employs a fixed-cycle closed-loop processing logic, with each process executed sequentially and in a standardized manner. This ensures the integrity, standardization, and temporal consistency of data processing in each round, avoiding data processing errors, omissions, or duplicate calculations. The fixed sampling cycle design enables uninterrupted real-time monitoring of electrode position data, ensuring stable data update frequency. This allows for precise adaptation to the high-speed, continuous operation of industrial equipment. Furthermore, the standardized process architecture facilitates system program debugging, parameter optimization, and future functional expansion, enhancing the system's operational stability and maintainability.

[0082] In some embodiments, the cumulative value output module outputs the absolute position value, motion direction flag, and system status flag to the HMI display unit and the host computer system via the RS485 / Modbus RTU interface.

[0083] Employing the industrial-grade RS485 / Modbus RTU communication interface, it boasts advantages such as long transmission distance, strong anti-electromagnetic interference capability, and high communication stability, making it suitable for complex and harsh industrial production environments. Simultaneously, it outputs multi-dimensional data synchronously, not only providing real-time feedback on precise electrode position values ​​but also simultaneously uploading motion status and system operating status. This allows on-site operators to intuitively view equipment operating parameters through the HMI, and also provides a complete data source for the host computer's automated control, data storage, fault tracing, and process optimization, achieving integrated linkage of electrode position acquisition, status monitoring, and automated control.

[0084] A method for acquiring the absolute value of electrode movement position includes the following steps: S1: The pulse signals of electrode movement position are collected synchronously by three encoders and transmitted in parallel to the CPU central processing module; S2: The CPU central processing module monitors the value changes of the three encoders in real time. When the values ​​of the three encoders remain unchanged within the preset delay time X seconds, the cumulative value of the encoder is automatically cleared to zero. S3: The CPU central processing module performs absolute value calculation on the cumulative values ​​of the encoders to obtain the absolute position values ​​P1, P2 and P3 of the three encoders; S4: Read the status of the external three-stage selector switch, select the maximum, minimum or average value algorithm according to the switch position, and calculate the output value P_out; S5: The direction of electrode movement is determined by the phase difference between the A and B phases of the encoder. The cumulative value increases when moving in the forward direction and decreases when moving in the reverse direction. S6: Output the output value P_out, direction of motion, and system status to an external device.

[0085] This acquisition method is based on the core logic of multi-channel synchronous acquisition, intelligent error correction, and multi-algorithm adaptation, forming a complete and closed-loop high-precision electrode position acquisition process. Each step is interconnected and logically closed-loop. From raw signal acquisition, data error correction processing, accurate calculation to data output, the entire process is standardized. It effectively makes up for the shortcomings of traditional acquisition methods, such as large deviation of single-source data, lack of zero-point calibration, and single status feedback. It greatly improves the accuracy, stability and scenario adaptability of electrode position acquisition, and is suitable for the automated detection and control scenarios of various industrial electrode lifting equipment.

[0086] In some embodiments, in step S2, the CPU central processing module reads the encoder value at a fixed sampling period T, compares the current period value with the previous period value, and if the difference between the three encoders is 0, the static timer is incremented. When the accumulated value of the timer reaches the delay threshold X seconds, it is cleared.

[0087] This step-by-step comparison and time-accumulation judgment method abandons the crude logic of traditional instantaneous zeroing. Through periodic data comparison, it accurately distinguishes between the static state of the electrode and the state of instantaneous signal fluctuations and mechanical micro-vibrations, effectively avoiding false zeroing faults caused by external interference. The multi-channel synchronous verification timing mechanism ensures that zeroing is only performed after the equipment has been truly stationary for a preset time, accurately correcting the accumulated drift error caused by long-term encoder operation, ensuring the accuracy of the electrode's zero point position each time it starts working, and improving the basic accuracy of position acquisition from the source.

[0088] In some embodiments, in step S4, the gear switching of the three-stage selector switch takes effect in real time within each sampling period. The operator can switch the output mode at any time during system operation. The CPU central processing module automatically updates the output algorithm according to the current switch state to achieve seamless switching.

[0089] The system employs a real-time sampling and instant response mode switching logic, eliminating the need for shutdowns, restarts, or parameter resets. This ensures uninterrupted equipment operation and significantly improves production continuity and debugging efficiency. The algorithm switching is seamless and lag-free, preventing data interruptions and numerical jumps, guaranteeing the continuity and stability of position output data. This meets the refined production needs of real-time adjustment of process parameters and dynamic switching of operating conditions, making it suitable for flexible industrial production scenarios.

[0090] Example 1: System Hardware Architecture This example provides an absolute value acquisition system for electrode movement position, and its hardware architecture is as follows: Item No. Hardware Component Specifications Quantity 1 Incremental Encoder Resolution ≥1024 pulses / revolution, A / B / Z three-phase output, protection level IP65 3 units 2 CPU Processor 32-bit industrial-grade MCU, main frequency ≥72MHz, integrated high-speed counter interface 1 unit 3 Three-Segment Selector Switch Rotary three-position mechanical switch with position indicator, contact capacity ≥5A / 24VDC 1 unit 4 Signal Conditioning Board Optocoupler isolated input, supports differential signals The system includes: 1 receiver with anti-interference capability ≥1500V; 1 x 5-digit digital output module with RS485 / Modbus RTU interface supporting 16-bit data transmission; 1 x 6-unit 7-inch touchscreen HMI displaying real-time position, direction, and switch status; 1 x 7-unit 24VDC switching power supply with ripple coefficient ≤1% and overvoltage / overcurrent protection; and 1 x three encoders installed at three key nodes of the electrode lifting transmission system: Encoder E1 is installed on the lifting motor shaft, Encoder E2 on the reducer output shaft, and Encoder E3 on the electrode arm guide wheel shaft. The three encoders synchronously acquire pulse signals from electrode movement, which are then optically isolated by a signal conditioning board and input in parallel to the CPU's high-speed counter port.

[0091] Example 2: Delay Judgment and Reset Function Implementation This example describes in detail the working process of the delay judgment and reset module: (1) The CPU reads the current count values ​​C1, C2, and C3 of the three encoders at a fixed sampling period T (T=10ms in this example). (2) The current period count value is compared with the previous period count value, and the differences ΔC1=|C1(n)-C1(n-1)|, ΔC2=|C2(n)-C2(n-1)|, and ΔC3=|C3(n)-C3(n-1)| are calculated respectively. (3) If the differences ΔC1, ΔC2, and ΔC3 of the three encoders are all 0, the electrode is determined to be in a stationary state, and the stationary timer is incremented by one sampling period T; if any difference is not 0, the stationary timer is reset to zero. (4) When the cumulative value of the static timer reaches the preset delay threshold X seconds (in this embodiment, X = 5 seconds, i.e., timer ≥ 500 sampling cycles), the CPU sends a clear instruction to the cumulative value registers of the three encoders, setting the cumulative values ​​C1_cum, C2_cum, and C3_cum to zero, and simultaneously outputs the clear status flag FLAG_ZERO = 1. (5) After clearing, the static timer is reset, and the system resumes normal acquisition and calculation processes. This mechanism effectively eliminates the encoder false pulse accumulation error caused by mechanical micro-vibration, electromagnetic interference, and other factors during the electrode static period.

[0092] Example 3: Absolute Value Calculation and Three-Segment Selection Output This example describes the collaborative working process of the absolute value calculation module and the three-segment selection switch: (1) The CPU takes the absolute values ​​of the cumulative values ​​C1_cum, C2_cum, and C3_cum of the three encoders respectively to obtain the position absolute values ​​P1=|C1_cum|, P2=|C2_cum|, and P3=|C3_cum|. (2) The physical position signal of the three-segment selection switch is read through the CPU digital input port. The switch status is encoded as follows: Switch position input encoding (DI1,DI0) Output algorithm Output value Position I (maximum value) (0,0)P _ out=Max(P1,P2,P3) The maximum value of the absolute values ​​of the three encoders, gear II (minimum value) (0,1) P_out=Min(P1,P2,P3) The minimum value of the absolute values ​​of the three encoders, gear III (average value) (1,0) P_out=(P1+P2+P3) / 3 The arithmetic mean of the absolute values ​​of the three encoders (3) The CPU selects the corresponding output algorithm according to the switch state code, calculates P_out and writes the result into the output register, and transmits it to the HMI display unit and the host computer system through the RS485 interface via the digital output module. (4) The operator can rotate the three-stage switch to switch the output mode at any time during system operation. The CPU rereads the switch state and updates the output algorithm in each scan cycle (10ms in this embodiment) to achieve seamless switching without stopping or restarting.

[0093] Example 4: Pulse Calculation and Forward / Reverse Determination This example describes the implementation details of the pulse and direction calculation module: (1) Pulse Counting: The CPU's internal high-speed counter counts the rising edges of the encoder's A-phase pulses, incrementing the count value by 1 for each rising edge to obtain the pulse count value N. Simultaneously, the level of the B-phase pulse at the rising edge of the A-phase is recorded. (2) Direction Determination: When the rising edge of the A-phase arrives, if the B-phase is high, it is determined to be forward motion (electrode rising), and the direction flag DIR=1; if the B-phase is low, it is determined to be reverse motion (electrode falling), and the direction flag DIR=0. This determination is based on the orthogonal encoding principle of the 90° phase difference between the A and B phases of the incremental encoder. (3) Cumulative Value Calculation: During forward motion (DIR=1), the cumulative value C_cum=C_cum+N_step; during reverse motion (DIR=0), the cumulative value C_cum=C_cum-N_step. N_step is the pulse step value within a single sampling period. This calculation method ensures that the cumulative value accurately reflects the net displacement of the electrode. (4) Synchronous output of direction information and cumulative value: The CPU packages the direction flag DIR and the cumulative value C_cum and outputs them. The HMI display unit simultaneously displays the absolute value of the current position and the current direction of movement, providing the operator with complete motion status information.

[0094] Example 5: System Overall Workflow This example describes the complete workflow of the system, with the following specific steps: Step Flow Node Detailed Description S1 System Initialization CPU power-on initialization, clear all encoder cumulative value registers, read the initial state of the three-stage switch, start the sampling timer S2 Signal Acquisition Synchronously read the A / B phase pulse signals of the three encoders with a sampling period of 10ms, update the high-speed counter value S3 Delay Judgment Compare the encoder value changes of the current cycle with the previous cycle. If there is no change in the three encoders, the static timer is incremented; otherwise, it is cleared S4 Clear Judgment Determine whether the static timer has reached the specified value. If the delay threshold X seconds are reached, the cumulative value is cleared and S5 is entered; otherwise, S5 is entered directly. S5 Absolute value calculation: The absolute value of the cumulative values ​​of the three encoders is taken to obtain P1, P2, and P3. S6 Mode selection: The three-stage switch status is read, and the maximum / minimum / average value algorithm is selected according to the gear position to calculate the output value P_out. S7 Direction calculation: The motion direction is determined by the phase difference of A / B phases, the direction flag DIR is updated, and the net displacement cumulative value is calculated. S8 Output and display: P_out, DIR, and the system status flag are output to the HMI and the host computer through the RS485 interface, and the process returns to S2 for repeated execution.

[0095] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, the phrase "comprising an element defined as..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0096] It is worth noting that all standard parts used in this invention can be purchased from the market, and irregularly shaped parts can be customized according to the description and drawings. The specific connection methods of each part all adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The models of electrical structure equipment involved can be selected according to the user's needs, as long as they meet the requirements of this application. In addition, the circuit connection adopts conventional connection methods in the prior art. The supporting electrical structures such as the control, current detection, position feedback, predicted voltage synchronization and parameter adjustment of the electrical equipment are all existing technologies, such as PLC controllers and module structures, so they will not be described in detail here.

[0097] 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 system for acquiring the absolute value of electrode movement position, characterized in that, include: Three encoders are used to synchronously acquire electrode movement position pulse signals, and the three electrode movement position pulse signals acquired by the three encoders are transmitted in parallel. The CPU central processing module is electrically connected to the three encoders and is used to receive and process the three electrode movement position pulse signals. The delay judgment and clearing module is integrated into the CPU central processing module. It is used to monitor the encoder value change status. When the encoder value remains unchanged within a preset delay time of X seconds, the encoder cumulative value is automatically cleared to zero. An absolute value calculation module, which is integrated into the CPU central processing module, is used to perform absolute value calculation on the encoder's cumulative value. The three-stage selection switch includes an externally adjustable three-stage physical switch for switching between three output modes: maximum value, minimum value, and average value. The status signal of the externally adjustable three-stage physical switch is input to the CPU central processing module. A pulse and direction calculation module, which is integrated into the CPU central processing module, is used to count encoder pulses and determine the electrode movement direction by the A / B phase difference; The cumulative value output module is electrically connected to the CPU central processing module and is used to output the processed position cumulative absolute value to an external device.

2. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The three encoders are respectively installed on the motor shaft, the reducer output shaft, and the electrode arm guide wheel shaft of the electrode lifting transmission system. The three encoders are used to synchronously acquire electrode movement pulse signals.

3. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The preset delay time X of the delay judgment and clearing module is an adjustable parameter, with a value range of 1-60 seconds. When the CPU central processing module detects that the values ​​of the three encoders have not changed within X seconds, it performs a clearing operation. If the value of any encoder changes, the cumulative value is kept unchanged.

4. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The three-stage selection switch has the following operating modes: maximum value mode, in which the CPU central processing module compares the absolute value outputs of the three encoders and takes the maximum value as the output; minimum value mode, in which the minimum value of the three is taken as the output; and average value mode, in which the arithmetic mean of the three is taken as the output.

5. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The pulse and direction calculation module determines the direction of motion by the phase relationship between the encoder A phase and the encoder B phase pulses. When the encoder A phase leads the encoder B phase by 90°, it is determined to be forward motion, and when the encoder B phase leads the encoder A phase by 90°, it is determined to be reverse motion. The cumulative value increases during forward motion and decreases during reverse motion.

6. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The CPU central processing module reads the encoder signal at a fixed sampling period T. Within each sampling period, it sequentially executes the processes of signal acquisition, delay judgment, zeroing, absolute value calculation, mode selection, direction calculation, and output processing, and executes them in a loop.

7. The electrode movement position absolute value acquisition system according to claim 1, characterized in that... The cumulative value output module outputs the absolute position value, motion direction flag, and system status flag to the HMI display unit and the host computer system via the RS485 / Modbus RTU interface.

8. A method for acquiring the absolute value of electrode movement position, characterized in that... The electrode movement position absolute value acquisition method is used to implement the electrode movement position absolute value acquisition system according to any one of claims 1-7, characterized in that the electrode movement position absolute value acquisition method includes the following steps: S1: The three encoders simultaneously acquire the electrode movement position pulse signal and transmit it in parallel to the CPU central processing module; S2: The CPU central processing module monitors the value change status of the three encoders in real time. When the values ​​of the three encoders remain unchanged within a preset delay time of X seconds, the cumulative value of the encoder is automatically cleared to zero. S3: The CPU central processing module performs absolute value calculation on the cumulative value of the encoder to obtain the absolute position values ​​P1, P2 and P3 of the three encoders; S4: Read the status of the external three-stage selection switch, and calculate the output value P_out according to the algorithm of selecting the maximum, minimum or average value according to the switch position; S5: The direction of electrode movement is determined by the phase difference between the A and B phases of the encoder. The cumulative value increases when moving in the forward direction and decreases when moving in the reverse direction. S6: Output the output value P_out, the direction of motion, and the system status to an external device.

9. The method for acquiring the absolute value of electrode movement position according to claim 8, characterized in that... In step S2, the CPU central processing module reads the encoder value at a fixed sampling period T, compares the current period value with the previous period value, and if the difference between the three encoders is 0, the static timer is incremented. When the accumulated value of the timer reaches the delay threshold X seconds, it is cleared.

10. The method for acquiring the absolute value of electrode movement position according to claim 8, characterized in that... In step S4, the gear switching of the three-stage selector switch takes effect in real time during each sampling period. The operator can switch the output mode at any time during system operation. The CPU central processing module automatically updates the output algorithm according to the current switch state to achieve seamless switching.

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