Position encoding device and monitoring system for vertical rotating machines

Abstract

This application provides a position encoding device and monitoring system suitable for vertically rotating machinery. The position encoding device includes a housing, an excitation assembly, and a magnetic sensing assembly. The housing rotates synchronously with the vertically rotating machinery around a first horizontal axis. The excitation assembly includes a rotating part rotatably disposed within the housing around a second horizontal axis, which is parallel to the first horizontal axis. A magnetic element is disposed on one side of the rotating part. The magnetic sensing assembly is disposed within the housing and includes multiple magnetic sensing units circumferentially spaced along the second horizontal axis. In response to the housing rotating with the target object, the magnetic element drives the rotating part to rotate relative to the housing under the action of gravity and remains directly below the second horizontal axis, sequentially triggering the multiple magnetic sensing units to generate a position encoding signal and an interrupt signal corresponding to the rotation angle of the housing.

Description

Technical Field

[0001] This application relates to the field of encoder technology, and more specifically, to a position encoding device and monitoring system suitable for vertically rotating machinery. Background Technology

[0002] When tunnel boring machines, mining machinery, and other vertically rotating machinery are in operation, multiple sensor modules are installed on rotating components (such as the cutterhead) for monitoring cutter wear and operating status. The sensor modules rotate with the components in a vertical plane. The operating environment is enclosed and complex, and an external host computer cannot obtain their position or control their working status. The sensors need to autonomously sense their position and switch modes.

[0003] The existing monitoring system uses an electronic position detection scheme, relying on a microcontroller for data processing and status control. The microcontroller needs to continuously collect data, eliminate strong vibration interference through filtering algorithms, and then perform position calculation and status judgment. Long-term high-load operation results in huge power consumption and significantly shortens battery life. At the same time, vibration can easily cause signal distortion, leading to problems such as module malfunction, data transmission timing disorder, and signal aliasing.

[0004] Therefore, there is an urgent need for a position encoding device suitable for vertically rotating machinery, which can acquire the rotational orientation during the operation of rotating machinery with low power consumption, thereby improving the endurance and operational stability of the monitoring system. Summary of the Invention

[0005] In view of this, this application provides a position encoding device and monitoring system suitable for vertically rotating machinery.

[0006] One embodiment of this application provides a position encoding device suitable for vertically rotating machinery, including a housing, an excitation assembly, and a magnetic sensing assembly. The housing rotates synchronously with the vertically rotating machinery about a first horizontal axis. The excitation assembly includes a rotating part and a magnetic element. The rotating part is rotatably disposed within the housing about a second horizontal axis, which is parallel to the first horizontal axis. The magnetic element is disposed on one side of the rotating part. The magnetic sensing assembly is disposed within the housing and includes a plurality of magnetic sensing units circumferentially spaced along the second horizontal axis. In response to the housing rotating with a target object, the magnetic element drives the rotating part to rotate relative to the housing under the action of gravity and keeps it directly below the second horizontal axis, sequentially triggering the plurality of magnetic sensing units, causing the magnetic sensing assembly to generate a position encoding signal and an interrupt signal corresponding to the rotation angle of the housing.

[0007] According to an embodiment of this application, the excitation assembly further includes a safety housing and a rotating shaft; a receiving cavity is formed inside the housing; the rotating shaft is fixed in the receiving cavity along the second horizontal axis; the rotating part is rotatably sleeved on the rotating shaft via a rolling bearing.

[0008] According to an embodiment of this application, a bearing mounting groove is formed on one side of the first end of the rotating part, and the rolling bearing is embedded in the bearing mounting groove.

[0009] According to an embodiment of this application, the inner wall of the bearing mounting groove opening side is provided with an annular limiting groove, and a limiting spring is embedded in the limiting groove. The limiting spring abuts against the rolling bearing to lock the rolling bearing axially.

[0010] According to an embodiment of this application, the second end of the rotating part opposite to the first end is provided with a magnet mounting groove, the magnetic component is embedded in the magnet mounting groove, and the magnetic poles are arranged facing the magnetic sensing unit. According to an embodiment of this application, a plurality of magnetic sensing units are distributed at equal angular intervals around the second horizontal axis at a preset angle.

[0011] According to an embodiment of this application, the plurality of magnetic sensing units include a reference sensing unit and a plurality of position sensing units; the magnetic sensing component is configured to: generate and output a first wake-up interrupt signal and a first position encoding signal in response to the triggering of the reference sensing unit; generate and output a second position encoding signal in response to the triggering of any of the position sensing units, and generate a second interrupt signal based on the outputs of the plurality of position sensing units.

[0012] According to an embodiment of this application, the mounting shell includes a first mounting shell and a second mounting shell that are fastened together, and the first mounting shell and the second mounting shell together form the receiving cavity.

[0013] According to an embodiment of this application, the center of the inner wall of the first mounting shell extends along the second horizontal axis to form a first support platform, and the rotating shaft is integrally formed on the end face of the first support platform; the center of the inner wall of the second mounting shell extends along the second horizontal axis to form a second support platform opposite to the first support platform, and the end face of the second support platform forms a rotating shaft limiting groove for fixing the rotating shaft; wherein, the outer diameters of the first support platform and the second support platform are both larger than the outer diameter of the rotating shaft, which is suitable for axially limiting the rolling bearing.

[0014] Another embodiment of this application provides a monitoring system, including at least one sensor module; the position encoding device for vertically rotating machinery is disposed on the rotating component of the vertically rotating machinery and electrically connected to the sensor module, and is adapted to output the position encoding signal and the interrupt signal to the sensor module; the sensor module responds to the interrupt signal and identifies the corresponding rotation orientation according to the position encoding signal, and performs corresponding preset operations for data acquisition and data transmission.

[0015] According to an embodiment of this application, the rotation axis of the outer shell and the rotation axis of the rotating part are horizontal axes parallel to each other. Combined with a gravity-driven downward magnetic component and circumferentially arranged magnetic sensing units, a gravity-adaptive rotation structure achieves position encoding of the rotation angle and output of interrupt signals. This eliminates the need for a microcontroller to continuously collect, filter, and calculate position information, reducing system power consumption from the source. Simultaneously, the gravity-driven excitation structure can withstand strong vibration interference during tunnel boring machine operation, stably outputting reliable position signals, avoiding position distortion and chaotic operating states. This allows the monitoring module to automatically switch operating modes based on interruptions and encoding, significantly improving the endurance and operational stability of the vertical rotating machinery monitoring system. Attached Figure Description

[0016] The above and other objects, features and advantages of this application will become clearer from the following description of embodiments with reference to the accompanying drawings, in which:

[0017] Figure 1 A perspective view of the position encoding device of this application is shown;

[0018] Figure 2 A schematic diagram of the internal structure of the position encoding device of this application is shown;

[0019] Figure 3 A perspective view of the magnetic sensing component of this application is shown;

[0020] Figure 4 An exploded view of the rotating part of this application is shown;

[0021] Figure 5 A perspective view of the first mounting housing of this application is shown;

[0022] Figure 6 A perspective view of the second mounting housing of this application is shown;

[0023] Figure 7 An exploded view of the casing of this application is shown.

[0024] In the accompanying drawings, the meanings of the reference numerals are as follows:

[0025] 1. Outer shell; 11. Housing; 12. Flange; 13. Cover; 14. First fastener; 15. Sealing ring; 2. Excitation assembly; 21. Rotating part; 211. Bearing mounting groove; 212. Limiting slot; 213. Limiting snap ring; 214. Magnet mounting groove; 22. Mounting shell; 221. First mounting shell; 222. Second mounting shell; 223. First support platform; 224. Second support platform; 225. Shaft limiting groove; 23. Shaft; 24. Rolling bearing; 25. Second fastener; 26. Vibration damping pad; 3. Magnetic component; 4. Magnetic sensing assembly; 41. Support component; 42. Magnetic sensing unit; 43. Logic unit; 44. Third fastener; 5. Signal connector. Detailed Implementation

[0026] The embodiments of this application will now be described with reference to the accompanying drawings. However, it should be understood that these descriptions are exemplary only and are not intended to limit the scope of this application. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the embodiments of this application for ease of explanation. However, it will be apparent that one or more embodiments may be implemented without these specific details. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concepts of this application.

[0027] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or mechanisms, but do not exclude the presence or addition of one or more other features, steps, operations, or mechanisms.

[0028] All terms used herein (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0029] When using expressions such as "at least one of A, B and C", they should generally be interpreted in accordance with the meaning that is commonly understood by those skilled in the art (e.g., "a system having at least one of A, B and C" should include, but is not limited to, a system having A alone, a system having B alone, a system having C alone, a system having A and B, a system having A and C, a system having B and C, and / or a system having A, B and C, etc.).

[0030] Those skilled in the art will understand that the features described in the various embodiments of this application can be combined and / or combined in various ways, even if such combinations or combinations are not explicitly described in this application. In particular, the features described in the various embodiments of this application can be combined and / or combined in various ways without departing from the spirit and teachings of this application. All such combinations and / or combinations fall within the scope of this application.

[0031] Figure 1 A perspective view of the position encoding device of this application is shown; Figure 2 A schematic diagram of the internal structure of the position encoding device of this application is shown.

[0032] Embodiments of this application provide a position encoding device suitable for vertically rotating machinery, such as... Figure 1 and Figure 2 As shown, the device includes a housing 1, an excitation assembly 2, and a magnetic sensing assembly 4. The housing 1 rotates synchronously with the vertically rotating machinery around a first horizontal axis. The excitation assembly 2 includes a rotating part 21 and a magnetic element 3. The rotating part 21 is rotatably disposed inside the housing 1 around a second horizontal axis, which is parallel to the first horizontal axis. The magnetic element 3 is disposed on one side of the rotating part 21. The magnetic sensing assembly 4 is disposed inside the housing 1 and includes multiple magnetic sensing units 42 circumferentially spaced along the second horizontal axis. In response to the rotation of the housing 1 with the target object, the magnetic element 3 drives the rotating part 21 to rotate relative to the housing 1 under the action of gravity and remains directly below the second horizontal axis, sequentially triggering the multiple magnetic sensing units 42, causing the magnetic sensing assembly 4 to generate a position encoding signal and an interrupt signal corresponding to the rotation angle of the housing 1.

[0033] The position encoding device of this application is suitable for the position detection of rotating parts of vertical rotating machinery such as tunnel boring machines and mining machinery, and is especially suitable for the low-power position detection scenario of the tunnel boring machine cutterhead cutter wear monitoring system.

[0034] It should be noted that the first horizontal axis is the rotation center line of the rotating component of the vertical rotating machinery, and the second horizontal axis is the rotation center line of the rotating part 21. The parallel arrangement of the two ensures that the rotation plane of the rotating part 21 is completely coincident with the rotation plane of the vertical rotating machinery, avoiding deviation in the trigger position of the magnetic component 3 and the magnetic sensing unit 42 due to axis misalignment, thus ensuring the accuracy of position detection from a structural perspective.

[0035] Specifically, the outer shell 1 serves as the mounting base for the entire device, forming a sealed mounting chamber inside to encapsulate the excitation component 2 and the magnetic sensing component 4, isolating them from external contaminants and mechanical impacts. The magnetic component 3 is fixed to the free end of the rotating part 21 and maintains a vertically downward posture under the action of gravity. As the outer shell 1 rotates with the rotating component, the magnetic component 3 rotates relative to the outer shell 1, sequentially sweeping across each circumferentially arranged magnetic sensing unit 42. The magnetic sensing unit 42 is excited by the magnetic field and generates a trigger signal, which is then generated by the magnetic sensing component 4 to produce the corresponding position encoding signal and interrupt signal.

[0036] According to the above configuration, the gravity-driven rotating part 21 drives the magnetic component 3 to generate relative motion with the rotating outer shell 1. In conjunction with the circumferentially arranged magnetic sensing unit 42, the position encoding signal and interrupt signal are directly generated in pure hardware structure, which reduces the operating power consumption of the monitoring system from the source. At the same time, the gravity-adaptive rotating structure can effectively resist strong vibration interference during operation, ensuring the long-term stability and reliability of the output signal.

[0037] Figure 3 A perspective view of the magnetic sensing component of this application is shown.

[0038] In one illustrative embodiment, such as Figure 3 As shown, multiple magnetic sensing units 42 are distributed at equal angular intervals around the second horizontal axis at a preset angle.

[0039] Specifically, multiple magnetic sensing units 42 are distributed at equal angular intervals along the circumference, which ensures that during the rotation of the outer shell 1, the magnetic component 3 can trigger a magnetic sensing unit 42 every time it rotates by the same angle, thus achieving uniformity of angle detection and avoiding detection blind spots. At the same time, the equal-interval distribution also facilitates the setting and conversion of position codes, simplifying the subsequent signal processing logic. The preset angle can be flexibly set according to the accuracy requirements of position detection. The higher the detection accuracy requirement, the smaller the preset angle and the more magnetic sensing units 42 are deployed.

[0040] In some embodiments, the preset angle is 60°, and the number of magnetic sensing units 42 is 6, which completely covers the full angular range of one rotation, adapts to the conventional position detection requirements of the shield machine cutterhead cutter wear monitoring system, and can meet the position detection accuracy requirements of most scenarios.

[0041] In some embodiments, the preset angle is set to 30° and the number of magnetic sensing units 42 is 12, which can further improve the accuracy of position detection, adapt to the use requirements of high-precision detection conditions, and achieve more refined position recognition and control.

[0042] In one illustrative embodiment, a plurality of magnetic sensing units 42 are distributed at preset angular intervals around a second horizontal axis.

[0043] In one illustrative embodiment, such as Figure 3 As shown, the magnetic sensing component 4 also includes a support member 41 and a logic unit 43; the support member 41 is disposed inside the housing 1, and multiple magnetic sensing units 42 are arranged circumferentially on the side of the support member 41 facing the excitation component 2; the logic unit 43 is integrated on the support member 41 and is electrically connected to each magnetic sensing unit 42 respectively.

[0044] Specifically, the support component 41 provides a mounting base and electrical connection foundation for the magnetic sensing units 42 and the logic unit 43. Multiple magnetic sensing units 42 are welded and fixed to the support component 41, with their magnetic field sensing surfaces all facing the magnetic component 3. This maximizes the reception of magnetic field signals, improves the sensitivity and reliability of magnetic triggering, and avoids missed or false triggers. The logic unit 43 receives the trigger signals from each magnetic sensing unit 42, synthesizes them into corresponding interrupt signals through logical operations, and generates a binary position code signal matching the trigger position. This achieves hardware-level signal processing and encoding output, eliminating the need for an external microcontroller to perform additional acquisition, filtering, and computation operations.

[0045] In some embodiments, such as Figure 2 and Figure 3 As shown, the magnetic sensing component 4 is arranged inside the housing 1 around the excitation component 2. Specifically, the support member 41 is annular, such as an annular printed circuit board, with an inner diameter larger than the outer diameter of the excitation component 2. It is installed inside the housing 1 by multiple third fasteners 44. Multiple magnetic sensing units 42 are distributed at intervals along the annular circumference. The magnetic field sensing surface of each magnetic sensing unit 42 faces the excitation component 2 on the inner side and maintains a constant radial distance from the magnetic component 3 on the rotating part 21.

[0046] In some embodiments, the excitation assembly 2 and the magnetic sensing assembly 4 are axially spaced within the housing 1 along the second horizontal axis. Specifically, the rotation plane of the excitation assembly 2 is a vertical plane in which the rotating part 21 drives the magnetic element 3 to rotate. The support member 41 of the magnetic sensing assembly 4 is a circular plate with the same outer diameter as the excitation assembly 2 and a circular hole in the center. It is installed inside the housing 1 by fasteners parallel to the vertical plane in which the magnetic element 3 rotates. Multiple magnetic sensing units 42 are spaced around the second horizontal axis in a plane parallel to the rotation plane of the excitation assembly 2. The magnetic field sensing surface of each magnetic sensing unit 42 faces the excitation assembly 2 on one side and maintains a constant axial distance from the magnetic element 3 on the rotating part 21.

[0047] In one illustrative embodiment, the plurality of magnetic sensing units 42 include a reference sensing unit and a plurality of position sensing units; the magnetic sensing component 4 is configured to generate and output a first wake-up interrupt signal and a first position encoding signal in response to the triggering of the reference sensing unit; and to generate and output a second position encoding signal in response to the triggering of any position sensing unit, and to generate a second interrupt signal based on the outputs of the plurality of position sensing units.

[0048] Specifically, the reference sensing unit has an independent power supply and is always in a constant power supply operating state, while the other position sensing units and subsequent logic encoding circuits are normally in a de-energized state. When the rotating part of the tunnel boring machine starts to rotate, the outer shell 1 rotates with the rotating part to the reference position for the first time. When the magnetic component 3 triggers the reference sensing unit, the reference sensing unit outputs a first wake-up interrupt signal and a corresponding first position encoding signal. The first wake-up interrupt signal is used to connect the power supply to the other position sensing units and logic encoding circuits of this device, and at the same time wakes up the external sensor module, enabling this device and the sensor module to enter the working state. Meanwhile, the first position encoding signal serves as the reference zero point for position detection, for subsequent position determination. The reference is provided; when the sensor module and position encoding device enter the working state, when the reference sensing unit is triggered again, it only outputs the first position encoding signal and the first wake-up interrupt signal as the reference zero point, and no longer has the wake-up function until the shield machine rotating parts stop rotating and then rotate again; when the outer shell 1 continues to rotate, when the magnetic component 3 triggers each position sensing unit in sequence, the magnetic sensing component 4 generates the second position encoding signal of the corresponding position, and at the same time, it combines the trigger signals of multiple position sensing units into a second interrupt signal through logical operation, and outputs it to the matching sensor module. The sensor module responds to the second interrupt signal, reads the corresponding second position encoding signal, and can accurately identify the current rotation orientation.

[0049] Based on the above setup, the low-power design of independently and continuously powered reference sensing unit while the rest of the circuits and sensor modules are normally powered off, combined with hardware logic to directly generate interrupt signals and position encoding signals, eliminates the need for continuous acquisition, filtering and position calculation by the microcontroller, which can significantly reduce the overall power consumption of the monitoring system and extend the service life of the battery-powered system.

[0050] In some embodiments, the logic unit 43 synthesizes the trigger signals of each magnetic sensing unit 42 into an interrupt signal and generates a corresponding binary position encoding signal. Signal synthesis and encoding are implemented through hardware logic circuits, eliminating the need for software computation, resulting in faster response speed, stronger anti-interference capability, and higher operational stability.

[0051] In some embodiments, when the trigger signal output by the magnetic sensing unit 42 is a negative pulse, the logic encoding unit uses a logical AND operation to synthesize it into a second interrupt signal; when the trigger signal output by the magnetic sensing unit 42 is a positive pulse, the logic encoding unit uses a logical OR operation to synthesize it into a second interrupt signal. This configuration can adapt to the output characteristics of different types of magnetic sensing units, expanding the applicability of the device and improving its versatility.

[0052] In some embodiments, the position encoding signal adopts a 3-bit binary encoding format. The first position encoding signal corresponding to the reference sensing unit is 000, and the second position encoding signals corresponding to the other position sensing units are 001, 010, 011, 100, 101, etc., respectively. The encoding format is simple and clear, which makes it easy for the sensor module to read and identify directly, and reduces the development difficulty of the supporting system.

[0053] In one illustrative embodiment, such as Figure 2 As shown, the excitation assembly 2 also includes a mounting housing 22 and a rotating shaft 23; a receiving cavity is formed inside the mounting housing 22; the rotating shaft 23 is fixed in the receiving cavity along the second horizontal axis; the rotating part 21 is rotatably sleeved on the rotating shaft 23 through a rolling bearing 24.

[0054] Specifically, the mounting shell 22 is the encapsulation base of the excitation assembly 2, which encapsulates the rotating shaft 23, rolling bearing 24 and rotating part 21 in a sealed cavity to prevent external impacts from acting directly on the moving mating surface, and also to prevent contaminants from entering the bearing mating gap, which would cause rotational jamming and increased wear.

[0055] According to the above configuration, the sealed encapsulation design of the mounting shell 22 provides a stable working environment for the swing of the rotating part 21. At the same time, the low friction design of the rolling bearing 24 ensures the response speed and swing accuracy of the gravity follow-up of the rotating part 21, avoiding problems such as rotation jamming, lag, and vibration interference, and further improving the accuracy of position detection and the environmental adaptability of the device.

[0056] In some embodiments, the inner ring of the rolling bearing 24 is interference-fitted with the rotating shaft 23, and the outer ring is fixedly connected to the rotating part 21, which can convert the sliding friction between the rotating part 21 and the rotating shaft 23 into rolling friction, greatly reducing the rotational resistance.

[0057] In some embodiments, the rolling bearing 24 is a miniature deep groove ball bearing, which is suitable for radial loads and small axial loads, and can ensure smooth rotation and stability; a self-lubricating oil-impregnated bearing can also be selected, which does not require additional grease, reduces daily maintenance needs, and extends the service life of the device.

[0058] In some embodiments, the mounting housing 22 is made of a plastic insulating material, which can effectively avoid the transmission of vibration signals caused by using rigid materials to assemble the bearing, and protect the bearing from damage.

[0059] In some embodiments, such as Figure 2 As shown, a vibration damping pad 26 made of rubber or other materials is provided between the outer wall of the mounting shell 22 and the inner wall of the outer shell 1, and the mounting shell 22 is installed inside the outer shell 1 through the vibration damping pad 26.

[0060] The above configuration can effectively buffer the severe vibrations generated during tunneling, prevent the vibrations from being transmitted to the rotating part and causing it to swing abnormally, and further improve the working stability of the device in a strong vibration environment.

[0061] Figure 4 An exploded view of the rotating part of this application is shown.

[0062] In one illustrative embodiment, such as Figure 4 As shown, a bearing mounting groove 211 is formed on one side of the first end of the rotating part 21, and the outer ring of the rolling bearing 24 is fitted into the bearing mounting groove 211.

[0063] Specifically, the bearing mounting groove 211 is a circular recessed groove that matches the outer ring dimensions of the rolling bearing 24. The groove depth is greater than the width of the rolling bearing 24. The outer ring of the rolling bearing 24 is interference-fitted with the inner wall of the bearing mounting groove 211 to achieve a clearance-free fixed connection between the rolling bearing 24 and the rotating part 21, ensuring synchronous rotation between the rotating part 21 and the outer ring of the rolling bearing 24. The bottom of the bearing mounting groove 211 is provided with a clearance through hole to avoid structural interference between the rotating shaft 23 and the rotating part 21, ensuring the flexibility of the rotating part 21's swing.

[0064] According to the above configuration, the precise fitting design of the bearing mounting groove 211 achieves stable assembly of the outer ring of the rolling bearing 24 and the rotating part 21, ensuring the synchronization of their movements.

[0065] In one illustrative embodiment, such as Figure 4 As shown, the inner wall of the opening side of the bearing mounting groove 211 is provided with an annular limiting groove 212, and a limiting spring 213 is embedded in the limiting groove 212. The limiting spring 213 abuts against the rolling bearing 24 and locks the rolling bearing 24 axially.

[0066] Specifically, the limiting groove 212 is an annular groove opened circumferentially along the inner wall of the bearing mounting groove 211, which is adapted to the outer dimensions of the limiting spring 213. The limiting spring 213 is a retaining ring with an elastic hole. After assembly, it can be stably embedded in the limiting groove 212, and its end face abuts against the end face of the outer ring of the rolling bearing 24. It provides bidirectional axial limiting for the outer ring of the rolling bearing 24 from both sides, completely restricting the axial movement of the outer ring of the rolling bearing 24.

[0067] In some embodiments, a locking nut can be used instead of a retaining circlip to achieve axial locking of the rolling bearing. This structure has a stronger axial locking force, is suitable for large-size and heavy-load applications, and can further improve the reliability of bearing assembly.

[0068] In one illustrative embodiment, such as Figure 4 As shown, the second end of the rotating part 21, which is opposite to the first end, is provided with a magnet mounting groove 214. The magnetic component 3 is embedded in the magnet mounting groove 214, and the magnetic pole is set towards the magnetic sensing unit 42.

[0069] Specifically, the magnet mounting groove 214 is a recessed groove that matches the outer dimensions of the magnetic component 3. The magnetic component 3 is interference-fitted into the magnet mounting groove 214 to ensure synchronous movement between the magnetic component 3 and the rotating part 21, and to prevent vibration from causing the magnetic component 3 to fall off or shift.

[0070] Furthermore, the magnetic poles of the magnetic component 3 are arranged radially along the second horizontal axis, that is, radially toward the magnetic sensing assembly 4 along the rotating part 21, so that the magnetic field of the magnetic component 3 can act on the magnetic sensing unit 42 at the corresponding position to the maximum extent, thereby improving the sensitivity of magnetic triggering.

[0071] According to the above configuration, the magnetic component 3 and the rotating part 21 are stably assembled through the adaptation design of the magnet mounting slot 214. At the same time, the sensitivity and reliability of the magnetic trigger are maximized through the optimized design of the magnetic pole orientation.

[0072] In some embodiments, when the excitation assembly 2 and the magnetic sensing assembly 4 are arranged axially spaced along the second horizontal axis, the magnetic poles of the magnetic element 3 are disposed toward the magnetic sensing assembly 4 along the axial direction of the second horizontal axis or inclined to the axial direction of the second horizontal axis.

[0073] In some embodiments, the magnetic component 3 is fixed to the magnet mounting groove 214 by structural adhesive, which can further improve the assembly firmness of the magnetic component.

[0074] In some embodiments, the magnetic component 3 is selected from neodymium iron boron permanent magnets, which have high energy product and high coercivity, and can maintain a stable magnetic field strength during long-term use, adapting to the long-term use requirements under harsh working conditions and ensuring the stability of magnetic triggering.

[0075] In some embodiments, the surface of the magnetic component 3 is covered with an epoxy resin protective layer, which can isolate external moisture and corrosive media, prevent the permanent magnet from oxidizing and demagnetizing, extend the service life of the magnetic component, and ensure the long-term stability of the magnetic field strength.

[0076] Figure 5 A perspective view of the first mounting housing of this application is shown; Figure 6A perspective view of the second mounting housing of this application is shown.

[0077] In one illustrative embodiment, such as Figure 2 , Figure 5 and Figure 6 As shown, the mounting shell 22 includes a first mounting shell 221 and a second mounting shell 222 that are fastened and fixed to each other, and the first mounting shell 221 and the second mounting shell 222 enclose each other to form an accommodating cavity.

[0078] In some embodiments, the first mounting shell 221 and the second mounting shell 222 are split structures that are detachably fixed together by a second fastener 25 to form a sealed accommodating cavity.

[0079] In some embodiments, the mating surfaces of the first mounting shell 221 and the second mounting shell 222 are provided with mutually compatible positioning stops, which can ensure the coaxiality and assembly accuracy of the two mating surfaces and avoid misalignment of the assembly causing the axis of the rotating shaft 23 to deviate.

[0080] In some embodiments, the first mounting shell 221 and the second mounting shell 222 are integrally injection molded, which has low processing cost, easy dimensional accuracy, and good insulation and vibration reduction performance, which can effectively isolate external vibration interference and improve the operational stability of the device.

[0081] In some embodiments, the mating surfaces of the first mounting shell 221 and the second mounting shell 222 are provided with an annular sealing groove, and a sealing ring is embedded in the annular sealing groove; the side wall of the first mounting shell 221 or the second mounting shell 222 is provided with a filling hole communicating with the accommodating cavity, and low viscosity anti-wear hydraulic oil can be injected into the accommodating cavity through the filling hole. The filling hole is sealed after the accommodating cavity is filled with liquid, so that the accommodating cavity forms a closed liquid-filled chamber, and the rotating part 21 completes the rotation in the hydraulic oil medium.

[0082] According to the above configuration, the hydraulic oil medium can provide uniform viscous damping, effectively suppressing the high-frequency swaying and random shaking of the rotating part 21 under strong vibration environment, making the gravity follow-up response of the rotating part 21 more stable and accurate, and avoiding the false triggering of the magnetic sensing unit 42 due to vibration.

[0083] In one illustrative embodiment, such as Figure 5 and Figure 6As shown, the center of the inner wall of the first mounting shell 221 extends along the second horizontal axis to form a first support platform 223, and the rotating shaft 23 is integrally formed on the end face of the first support platform 223; the center of the inner wall of the second mounting shell 222 extends along the second horizontal axis to form a second support platform 224 opposite to the first support platform 223, and the end face of the second support platform 224 forms a rotating shaft limiting groove 225 for fixing the rotating shaft 23; wherein, the outer diameters of the first support platform 223 and the second support platform 224 are both larger than the outer diameter of the rotating shaft 23, which is suitable for axially limiting the inner ring of the rolling bearing 24.

[0084] According to the above configuration, the coaxiality and positioning accuracy of the rotating shaft 23 are ensured by the integrated structure of the rotating shaft 23 and the support platform. At the same time, the design of the rotating shaft limiting groove 225 realizes the stable fixation of the inner ring of the rotating shaft 23. The axial limiting of the inner ring of the rolling bearing 24 is realized by the outer diameter difference of the support platform. The structure has high integration and good assembly accuracy, effectively avoiding problems such as rotating shaft offset and bearing movement, and further improving the operational stability of the device.

[0085] In some embodiments, the rotating shaft 23 adopts a split design, with its two ends respectively embedded in the limiting grooves of the first support platform 223 and the second support platform 224, which can adapt to different processing technology and assembly requirements, reduce processing difficulty, and improve production efficiency.

[0086] In some embodiments, such as Figure 2 As shown, the second fastener 25 passes through the first mounting shell 221, the second mounting shell 222 and the rotating shaft 23 in sequence, and is connected to the outer shell 1 to fix the mounting shell 22 to the outer shell 1.

[0087] Specifically, the first mounting shell 221, the second mounting shell 222, and the rotating shaft 23 are provided with coaxial through mounting holes at corresponding positions. The second fastener 25 is inserted from one side of the first mounting shell 221, passes through the first mounting shell 221, the rotating shaft 23, and the second mounting shell 222 in sequence, and then screws its end into the internal thread hole on the inner wall of the outer shell 1. The first mounting shell 221 and the second mounting shell 222 are locked together, the rotating shaft 23 is axially fixed, and the entire excitation assembly 2 is rigidly connected to the outer shell 1 by a single second fastener 25.

[0088] Figure 7 An exploded view of the casing of this application is shown.

[0089] In some embodiments, refer to Figure 7As shown, the outer casing 1 includes a shell 11, a flange 12, and a cover 13. The flange 12 is integrally formed on the first axial end of the shell 11 and is used for fixed connection with the rotating components of the vertically rotating machinery. The cover 13 is detachably fixed to the second axial end of the shell 11 by multiple first fasteners 14. An annular sealing groove is provided between the mating surfaces of the shell 11 and the cover 13, and a sealing ring 15 is embedded in the sealing groove. This effectively isolates the interior of the casing from harsh media such as high humidity, high dust, and pressurized mud in the soil chamber of the tunnel boring machine, preventing internal components from being contaminated or corroded and damaged, and ensuring the long-term stable operation of the device in complex operating environments.

[0090] In some embodiments, the shell 11, flange 12 and cover 13 of the outer casing 1 are all integrally formed of stainless steel, which has excellent structural strength, impact resistance and corrosion resistance, and can resist the severe mechanical impact during the tunneling process of the shield machine and the erosion of corrosive media in the soil chamber, effectively extending the overall service life of the device.

[0091] In some embodiments, such as Figure 2 As shown, the position encoding device also includes a signal connector 5, which is sealed and fixed to the side wall of the housing 1 and electrically connected to the magnetic sensing component 4.

[0092] Specifically, the side wall of the housing 1 has a mounting through hole that matches the external dimensions of the signal connector 5. The signal connector 5 is sealed and assembled in the mounting through hole. Its inner pins are electrically connected to the power supply circuit and signal circuit of the logic unit 43 and the magnetic sensing unit 42 on the support 41 through flexible wires. The outer interface is used to connect and communicate with the control terminal of the matching sensor module through a dedicated cable, so as to realize the power supply transmission, interrupt signal and position encoding signal stable output between the position encoding device and the sensor module.

[0093] Embodiments of this application also provide a monitoring system, including at least one sensor module disposed on a rotating component of a vertically rotating machine; and a position encoding device suitable for the vertically rotating machine, disposed on the rotating component of the vertically rotating machine, electrically connected to the sensor module, and adapted to output a position encoding signal and an interrupt signal to the sensor module; the sensor module responds to the interrupt signal and identifies the corresponding rotation orientation according to the position encoding signal, and performs corresponding preset operations for data acquisition and data transmission.

[0094] Specifically, the monitoring system is adapted to the scenario of monitoring cutterhead wear of tunnel boring machines (TBMs). Position encoding devices and sensor modules are configured one-to-one and installed inside the cutterhead box of the TBM, rotating synchronously with the cutterhead in the vertical plane. The position encoding device is electrically connected to the control terminal of the sensor module via signal connector 5, outputting interrupt signals and position encoding signals to the sensor module in real time. The sensor module is a cutterhead wear monitoring sensor module used to collect operational data such as cutterhead wear, temperature, and vibration. Normally, it is in a deep sleep state, with only the interrupt signal receiving circuit receiving power. When it receives the first wake-up interrupt signal output by the position encoding device, it wakes up and starts up, simultaneously reading the corresponding first position encoding signal and using it as the reference zero point for position detection. When it receives the second interrupt signal output by the position encoding device, it immediately reads the corresponding position encoding signal, identifies the current rotational orientation, and performs preset operations such as data acquisition and data transmission at the corresponding orientation according to the preset control program, achieving intelligent switching of working modes without the need for external host computer intervention.

[0095] In some embodiments, the monitoring system further includes a remote host computer. The sensor module transmits the collected monitoring data and location information to the host computer via wireless communication. The host computer can monitor the operating status of the vertical rotating machinery in real time and provide fault warnings based on the received data, thereby realizing remote intelligent management.

[0096] In some embodiments, when the sensor module does not receive an interrupt signal from the position encoding device within a preset time period, it determines that the rotating components of the vertically rotating machinery have stopped rotating. The sensor module cuts off the power supply to unnecessary acquisition and transmission circuits and simultaneously sends a sleep command to the position encoding device, cutting off the power supply to all circuits except the reference sensing unit, thus entering a deep sleep mode. This reduces battery consumption, further extends the system's battery life, reduces the frequency of battery replacements, and lowers maintenance costs.

[0097] The embodiments of this application have been described above. However, these embodiments are merely illustrative and not intended to limit the scope of this application. Although various embodiments have been described above, this does not mean that the measures in the various embodiments cannot be used advantageously in combination. Without departing from the scope of this application, those skilled in the art can make various substitutions and modifications, all of which should fall within the scope of this application.

Claims

1. A position encoding device suitable for vertically rotating machinery, characterized in that, include: The outer casing (1) rotates synchronously around the first horizontal axis with the vertical rotating machinery; Excitation assembly (2), including: A rotating part (21) is rotatably disposed inside the outer casing (1) about a second horizontal axis, the second horizontal axis being parallel to the first horizontal axis; A magnetic component (3) is disposed on one side of the rotating part (21); The magnetic sensing assembly (4) is disposed inside the housing (1) and includes a plurality of magnetic sensing units (42) circumferentially spaced along the second horizontal axis. In response to the outer shell (1) rotating with the target object, the magnetic component (3) drives the rotating part (21) to rotate relative to the outer shell (1) under the action of gravity and keeps it directly below the second horizontal axis, thereby triggering multiple magnetic sensing units (42) in sequence, so that the magnetic sensing component (4) generates a position encoding signal and an interrupt signal corresponding to the rotation angle of the outer shell (1).

2. The location encoding device according to claim 1, characterized in that, The excitation assembly (2) also includes: The mounting shell (22) forms an internal accommodating cavity; The rotating shaft (23) is fixed in the accommodating cavity along the second horizontal axis; The rotating part (21) is rotatably mounted on the rotating shaft (23) via a rolling bearing (24).

3. The position encoding device according to claim 2, characterized in that, A bearing mounting groove (211) is formed on one side of the first end of the rotating part (21), and the rolling bearing (24) is fitted into the bearing mounting groove (211).

4. The position encoding device according to claim 3, characterized in that, The inner wall of the opening side of the bearing mounting groove (211) is provided with an annular limiting groove (212), and a limiting spring (213) is embedded in the limiting groove (212). The limiting spring (213) abuts against the rolling bearing (24) to lock the rolling bearing (24) axially.

5. The position encoding device according to claim 1, characterized in that, The rotating part (21) has a magnet mounting groove (214) at its second end opposite to the first end. The magnetic component (3) is embedded in the magnet mounting groove (214) and the magnetic pole is set towards the magnetic sensing unit (42).

6. The location encoding device according to claim 1, characterized in that, Multiple magnetic sensing units (42) are distributed at equal angular intervals around the second horizontal axis at a preset angle.

7. The position encoding device according to claim 1 or 6, characterized in that, The plurality of magnetic sensing units (42) include a reference sensing unit and a plurality of position sensing units; The magnetic sensing component (4) is configured as follows: In response to the triggering of the reference sensing unit, a first wake-up interrupt signal and a first position encoding signal are generated and output; In response to the triggering of any of the said position sensing units, a second position encoding signal is generated and output, and a second interrupt signal is generated based on the outputs of the plurality of said position sensing units.

8. The position encoding device according to claim 2, characterized in that, The mounting shell (22) includes a first mounting shell (221) and a second mounting shell (222) that are fastened together, and the first mounting shell (221) and the second mounting shell (222) together form the accommodating cavity.

9. The position encoding device according to claim 8, characterized in that, The center of the inner wall of the first mounting shell (221) extends along the second horizontal axis to form a first support platform (223), and the rotating shaft (23) is integrally formed on the end face of the first support platform (223); The inner wall center of the second mounting shell (222) extends along the second horizontal axis to form a second support platform (224) opposite to the first support platform (223), and the end face of the second support platform (224) forms a shaft limiting groove (225) for fixing the shaft (23). The outer diameters of the first support platform (223) and the second support platform (224) are both larger than the outer diameter of the rotating shaft (23), which is suitable for axially limiting the rolling bearing (24).

10. A monitoring system, characterized in that, include: At least one sensor module; The position encoding device for vertically rotating machinery according to any one of claims 1 to 9 is disposed on the rotating component of the vertically rotating machinery, electrically connected to the sensor module, and adapted to output the position encoding signal and the interrupt signal to the sensor module; The sensor module responds to the interrupt signal and identifies the corresponding rotation orientation based on the position encoding signal, and performs the corresponding preset operations for data acquisition and data transmission.

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