Rudder system monitoring system

Abstract

The utility model discloses a rudder system monitoring system, which belongs to the technical field of electric servo control, and comprises a data acquisition unit, an analog-to-digital conversion unit, a main control unit and a power supply turn-off unit which are connected in sequence, and the main control unit is also connected with a data storage unit; the data acquisition unit comprises a voltage acquisition module, a current acquisition module and a temperature acquisition module. By introducing the voltage acquisition module, the current acquisition module and the temperature acquisition module, the voltage, the current and the temperature in the working process of the rudder system can be monitored in real time, and when any parameter of the voltage, the current or the temperature exceeds a set threshold range, the main control unit judges that the working state of the rudder system is abnormal; the main control unit timely and rapidly cuts off the power supply of the rudder system through the power supply turn-off unit and stops continuously supplying power to the rudder system, so that the loss caused by wrong turn-off, wrong turn-off and not timely turn-off of the power supply of the rudder system due to inaccurate manual judgment is avoided, the whole process does not need manual intervention, and the automation degree is high.

Description

Technical Field

[0001] The utility model relates to the technical field of electric servo control, in particular to a rudder system monitoring system. Background Art

[0002] A rudder system is a mechanical system widely used to control rotational motion. It's commonly found in ships, aircraft, robots, and various automated equipment. Its core function is to control the direction and angle of the device. A rudder system consists of a servo controller, a steering gear, a motor, and a reducer. The servo controller outputs PWM waves to control the motor's rotational motion. The motor powers the servo's reducer, which in turn drives the servo's rotation.

[0003] The rudder system requires an external power supply, and the supply voltage must be manually configured. This can easily lead to errors, resulting in inaccurate voltage settings. These settings can exceed the system's maximum operating voltage or be too low. If the voltage exceeds the withstand voltage of internal components, these components can be damaged, causing the rudder system to malfunction. If the voltage is too low, the rudder system cannot start properly. Proper operation of the rudder system depends on hardware circuit design supplemented by software control. Circuit problems such as short circuits or short circuits can cause the rudder system's operating current to increase. Continued operation at high currents can cause the rudder system to operate abnormally, leading to complete damage. Rudder system temperature is a key indicator of concern. Excessively high temperatures indicate an abnormal rudder system operation. Therefore, abnormalities in voltage, current, and temperature during rudder system operation are often indicative of system failure. Failure to promptly power off the system can cause irreversible damage to the system, or even explosion and casualties. Generally, when these abnormalities occur, personnel assess the situation based on the actual situation and immediately shut off the power to minimize damage. This reliance on manual shutdown inevitably leads to problems such as inaccurate judgment by staff and untimely shutdown, resulting in certain human and economic losses. In summary, how to design a monitoring system to monitor the voltage, current, and temperature parameters of the rudder system in real time during operation and to promptly cut off the rudder system power supply when an abnormality occurs is a technical problem that needs to be solved urgently. Utility Model Content

[0004] The purpose of the utility model is to overcome the problems of the prior art and provide a rudder system monitoring system.

[0005] The purpose of the utility model is achieved through the following technical solutions: a rudder system monitoring system, the system includes a data acquisition unit, an analog-to-digital conversion unit, a main control unit and a power shutdown unit connected in sequence, the main control unit is connected to the data storage unit; the data acquisition unit includes a voltage acquisition module, a current acquisition module and a temperature acquisition module, and the output ends of the voltage acquisition module, the current acquisition module and the temperature acquisition module are all connected to the analog-to-digital conversion unit.

[0006] In one example, the voltage acquisition module includes an isolation operational amplifier and an operational amplifier connected in sequence, the isolation operational amplifier is connected to the rudder system power supply, and the output end of the operational amplifier is connected to the analog-to-digital conversion unit.

[0007] In one example, the current acquisition module is a current sensor, which is connected in series to the rudder system power supply circuit and / or the motor power supply circuit, and the output end of the current sensor is connected to the analog-to-digital conversion unit.

[0008] In one example, the temperature acquisition module is a temperature sensor, which is used to acquire the temperature of the servo drive circuit board and / or the motor, and the output end of the temperature sensor is connected to the analog-to-digital conversion unit.

[0009] In one example, the analog-to-digital conversion unit is an ADC chip.

[0010] In one example, the main control unit is one or more of FPGA, single chip microcomputer, DSP, ARM, and MCU.

[0011] In one example, the power shutdown unit is a transistor switch circuit, the base of the transistor is connected to the main control unit via a base resistor, the collector of the transistor is connected to the rudder system power supply via a collector resistor, and the emitter of the transistor is grounded.

[0012] In one example, the power shutdown unit also includes a MOS tube and an optocoupler, the source of the MOS tube is connected to the rudder system power supply, the drain of the MOS tube is connected to the rudder system, the gate of the MOS tube is connected to the optical receiver in the optocoupler, and the optical emitter in the optocoupler is connected to the collector of the transistor.

[0013] In one example, the data acquisition unit further includes a position detection module, and an output end of the position detection module is connected to the analog-to-digital conversion unit.

[0014] In one example, the data storage unit is an EEPROM memory.

[0015] It should be further explained that the technical features corresponding to the above system examples can be combined or replaced with each other to form a new technical solution.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. In one example, by introducing a voltage acquisition module, a current acquisition module, and a temperature acquisition module, the voltage, current, and temperature of the rudder system during operation can be monitored in real time. When any of the voltage, current, or temperature parameters exceeds a set threshold, the main control unit determines that the rudder system is operating abnormally. The main control unit promptly and quickly shuts off the rudder system power supply through the power shutoff unit, ceasing further power supply to the rudder system. This avoids losses caused by inaccurate manual judgment, such as mistaken shutdown, or failure to shut off the rudder system power in a timely manner. The entire process requires no human intervention, resulting in a high degree of automation. Furthermore, the voltage, current, and temperature information is stored in a data storage unit and read and analyzed by the main control unit. This allows for fault analysis even with the rudder system power off, preventing recurrence of the fault.

[0018] 2. In one example, the power shutdown unit further introduces a MOS tube based on the triode, so that the switching circuit has a higher switching speed, lower on-resistance and better thermal stability, thereby improving the overall efficiency and response speed of the switching circuit. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The specific implementation methods of the present invention are further described in detail below in conjunction with the accompanying drawings. The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The same reference numerals are used in these drawings to represent the same or similar parts. The schematic embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application.

[0020] Figure 1 A system block diagram provided as an example of the present utility model;

[0021] Figure 2 This is a schematic diagram of the isolated operational amplifier circuit in a voltage acquisition module provided as an example of the present utility model;

[0022] Figure 3 This is a schematic diagram of an operational amplifier circuit in a voltage acquisition module provided as an example of the present utility model;

[0023] Figure 4 A circuit diagram of a current acquisition module provided as an example of the present utility model;

[0024] Figure 5 A circuit diagram of a temperature acquisition module provided as an example of the present invention;

[0025] Figure 6 A circuit diagram of an analog-to-digital conversion unit provided as an example of the present utility model;

[0026] Figure 7A circuit schematic diagram of a main control unit provided as an example of the present utility model;

[0027] Figure 8 A circuit diagram of a power shutoff unit provided as an example of the present utility model;

[0028] Figure 9 This is a circuit block diagram of a power shutdown unit provided as an example of the present invention. DETAILED DESCRIPTION

[0029] The following is a clear and complete description of the technical solution of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the directions or positional relationships indicated by "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. are based on the directions or positional relationships described in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the use of ordinal numbers (for example, "first and second", "first to fourth", etc.) is for the purpose of distinguishing objects and is not limited to this order, and cannot be understood as indicating or implying relative importance.

[0031] In the description of this utility model, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections, electrical connections; direct connections, indirect connections through an intermediate medium, and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this utility model in specific contexts.

[0032] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0033] In one example, a rudder system monitoring system, such as Figure 1As shown, the system includes a data acquisition unit, an analog-to-digital conversion unit, a main control unit and a power shut-off unit connected in sequence. The main control unit is also connected to a data storage unit. The data storage unit preferably adopts an EEPROM memory, which is used to store real-time data such as voltage, temperature, and current. . Among them, the data acquisition unit includes a voltage acquisition module, a current acquisition module and a temperature acquisition module. The voltage acquisition module is used to collect the power supply voltage of the rudder system in real time. The current acquisition module is used to collect the power supply current of the rudder system and the power supply current of the motor. The temperature acquisition module is used to collect the temperature of the servo drive circuit board (the servo drive circuit board is integrated with the servo controller, motor drive circuit, etc., and the servo controller can be used as the main control unit of the present invention) and the motor. The output ends of the voltage acquisition module, the current acquisition module and the temperature acquisition module are all connected to the analog-to-digital conversion unit. The analog-to-digital conversion unit converts the collected real-time voltage signal, real-time current signal and real-time temperature signal from analog signals into signals that can be recognized by the main control unit. The main control unit determines whether any of the real-time voltage signal, real-time current signal, and real-time temperature signal exceeds the corresponding voltage threshold range, current threshold range, or temperature threshold range. If any of the real-time voltage signal, real-time current signal, and real-time temperature signal exceeds the corresponding voltage threshold range, current threshold range, or temperature threshold range, the main control unit determines that the rudder system is in an abnormal operating state and outputs the corresponding control level to the power shutdown unit, thereby shutting off the power supply to the rudder system. This avoids losses caused by inaccurate manual judgment, such as mistaken shutdown, or failure to shut off the rudder system power in a timely manner. The entire process requires no manual intervention and has a high degree of automation. Furthermore, the data storage unit stores the voltage, current, and temperature information, which the main control unit reads and analyzes. When the rudder system power is shut off, the main control unit can analyze the voltage, current, and other data at the time of the fault to complete fault analysis. The analysis results can be used and learned to prevent the recurrence of the fault. It should be noted that the voltage threshold range, current threshold range, or temperature threshold range are set based on the knowledge and experience of the technician. The data processing process of the above-mentioned main control unit (determining whether it is in an abnormal state) is a conventional technical means of those skilled in the art, is not a technical improvement of the present invention, and is not within the scope of protection requested by the present invention.

[0034] The monitoring system of the present invention takes parameters such as voltage, current, and temperature as input, which are input to the main control unit through the analog-to-digital conversion module. The main control unit determines whether the rudder system is in an abnormal working state and outputs an instruction on whether to shut down the power supply, thereby forming a complete closed-loop autonomous monitoring system. At the same time, it can complete servo fault diagnosis based on the feedback value of the external sensor (data acquisition module) and fault analysis based on the data storage unit. When a fault is diagnosed, measures such as cutting off the power supply can be taken in time to effectively ensure the safe operation of the rudder system, prevent damage to the rudder system, and extend the service life of the rudder system.

[0035] In one example, if Figure 2-3 As shown, the voltage acquisition module includes an isolated operational amplifier U1 and an operational amplifier U2. The input of isolated operational amplifier U1 is connected to the rudder system power supply VCC, and the output of isolated operational amplifier U1 (pin VOUTP and pin VOUTN) is connected to the input of operational amplifier U2. The output of operational amplifier U2 is connected to the analog-to-digital conversion unit. At this time, VCC is divided by resistors R1 and R2 and input into isolated operational amplifier U1, where it is isolated and converted into a differential signal. Operational amplifier U2 converts the differential signal into a voltage signal U. The analog-to-digital conversion unit converts the analog voltage signal U into a digital signal and transmits it to the main control unit for judgment. If the main control unit determines that the voltage exceeds the upper voltage threshold Umax (or is lower than the lower voltage threshold Umin), it sends a control level to the power shutdown unit, which shuts off the power supply VCC to prevent potential hazards.

[0036] In one example, if Figure 4 As shown, the current acquisition module is comprised of current sensors. At least two current sensors are connected in series to the rudder system's main line and the motor power supply circuit, respectively. The output terminals of the current sensors are connected to an analog-to-digital conversion unit. The current sensors collect the currents Izg and I flowing through the main line and motor, respectively, in real time. The analog-to-digital conversion unit converts these currents Izg and I into digital signals, which are then input to the main control unit. The main control unit then determines whether the current values ​​flowing through the main line and motor are abnormal. If the main line current is abnormal, the main control chip sends a control level to the power shutdown unit, disconnecting the main power supply. If the motor current is abnormal, the main control unit will no longer output PWM waves to drive the motor, thereby preventing more serious accidents and further losses.

[0037] In one example, if Figure 5As shown, the temperature acquisition module is a temperature sensor, specifically a thermistor in this example. At least two temperature acquisition modules are used to respectively acquire the temperature of the servo drive circuit board and the motor. The output of the temperature sensor is connected to the analog-to-digital conversion unit. In this case, the current sensor respectively acquires the real-time temperature of the servo drive circuit board and the motor. The analog-to-digital conversion unit converts the real-time temperature signal into a digital signal and inputs it to the main control unit. The main control unit determines whether the temperature of the drive circuit board and the motor is abnormal. If the temperature of the servo drive circuit board and the motor is determined to be too high, the main control unit reduces the temperature by reducing the PWM duty cycle. If the temperature continues to rise, the main control unit will not output the PWM wave and will no longer drive the motor to move, thereby reducing the motor temperature.

[0038] In one example, if Figure 6 As shown, the analog-to-digital conversion unit is an ADC chip, which is connected to the output ends of the operational amplifier U2, the current sensor, and the temperature sensor to receive the real-time voltage signal U, the real-time current signal I, Izg, and the real-time temperature signal Temp, and then convert the real-time voltage signal U, the real-time current signal I, Izg, and the real-time temperature signal Temp into digital signals and input them into the main control unit.

[0039] In one example, the main control unit is one or more of FPGA, single chip microcomputer, DSP, ARM, MCU, etc. Figure 7 As shown, the present invention preferably utilizes an FPGA, which has strong parallel processing capabilities and is suitable for control scenarios requiring fast response and complex logic. Optionally, the main control unit is connected to a host computer for transmitting the collected real-time voltage, current, and temperature signals to the host computer, which then plots the real-time voltage, current, and temperature curves.

[0040] In one example, if Figure 8-Figure 9 (The switch indicated in the oval dotted box in the figure is Figure 8 As shown in the power shutdown unit shown, the power shutdown unit includes a transistor Q2, a MOS transistor Q1, and an optocoupler U1. The base of transistor Q2 is connected to the main control unit via base resistor R17. A grounding resistor R18 is provided between resistor R17 and the base of the transistor. The collector of the transistor is connected to the optical emitter (pin 2) in the optocoupler MOS driver U1, and the emitter of the transistor is grounded. The source of MOS transistor Q1 is connected to the rudder system power supply VCC, and the drain of the MOS transistor is connected to power supply VCC1, which is connected to the rudder system (power supply VCC1 and power supply VCC have equal voltage and can be considered the same power supply). The gate of the MOS transistor is connected to the optical receiver (pin 4) in the optocoupler MOS driver U1. The main control unit sends a low level to the power shutdown unit, thereby lowering the level of Uen (the connection point between resistor R17 and the main control unit), thereby shutting off power supply VCC.

[0041] In one example, if Figure 9 As shown, the data acquisition unit also includes a position detection module, specifically a position sensor in this example, which is used to collect the real-time position signal of the servo and transmit it to the main control unit after analog-to-digital conversion. Specifically, the data output pin of the position sensor is connected to the data input pin of the analog-to-digital conversion unit, and the data output pin of the analog-to-digital conversion unit is connected to the input pin of the main control unit. The main control unit compares the feedback real-time position signal with the expected position signal to see if there is a difference, namely the deviation e. If the deviation is greater than a threshold, the main control unit determines that a fault has occurred and reduces the PWM duty cycle or controls the power shutdown unit to cut off the power supply to reduce the losses and damage caused by the fault.

[0042] Optionally, the data acquisition unit also includes a vibration sensor for collecting the vibration signal of the motor and feeding it back to the main control unit through the analog-to-digital conversion unit. The main control chip compares the real-time vibration signal with the vibration threshold to determine whether the motor is in an abnormal working state.

[0043] Combining the above examples to obtain a preferred embodiment of the present invention, the system comprises a data acquisition unit, an analog-to-digital conversion unit, a main control unit, and a power shutoff unit, connected in sequence. The main control unit is also connected to a data storage unit. The data acquisition unit comprises a voltage acquisition module, a current acquisition module, a temperature acquisition module, and a position acquisition module. The voltage acquisition module comprises an isolated operational amplifier and an operational amplifier, connected in sequence. The isolated operational amplifier is connected to the rudder system power supply, and the output of the operational amplifier is connected to the analog-to-digital conversion unit. The current acquisition module is a Hall effect current sensor, connected in series to the rudder system power supply circuit and the motor power supply circuit, and the output of the current sensor is connected to the analog-to-digital conversion unit. The temperature acquisition module is a temperature sensor used to collect the temperature of the servo drive circuit board and the motor, and the output of the temperature sensor is connected to the analog-to-digital conversion unit. The position acquisition module is a position sensor, such as a Hall effect sensor. Furthermore, the analog-to-digital conversion unit is an ADC chip, and the main control unit is an FPGA. The power shutdown unit includes a transistor and a MOS transistor. The base of the transistor is connected to the main control unit via a base resistor, the collector of the transistor is connected to the rudder system power supply via a collector resistor, and the emitter of the transistor is grounded. The source of the MOS transistor is connected to the rudder system power supply, the drain of the MOS transistor is connected to the power supply VCC1, and the gate of the MOS transistor is grounded via a diode. At this time, the working principle of the system is as follows:

[0044] The voltage acquisition module, current acquisition module, temperature acquisition module, and position acquisition module are applied to the input circuit of the rudder system (in this case, the independent control circuit installed on the monitoring board serves as the main control unit of the monitoring system) to provide real-time and accurate monitoring of the rudder system input. Specifically, in this example, the current acquisition module, composed of a high-performance Hall effect current sensor, inputs the collected current to the FPGA of the main control unit. The FPGA then determines the current value. If the current value is not within the specified range, the FPGA issues a command to automatically control the power supply to prevent damage to the components of the rudder system. Similarly, the voltage acquisition module, temperature acquisition module, and position acquisition module respectively convert the collected voltage, temperature, and position values ​​into appropriate supply voltage values ​​for the FPGA through a conversion chip. The FPGA then determines whether the rudder system is in an abnormal operating state. If the rudder system input parameters such as voltage, current, temperature, and position are abnormal, that is, if they do not meet the rudder system input conditions, the power supply can be promptly and accurately cut off, thereby protecting the normal operation of the rudder system.

[0045] The FPGA in this monitoring system features a fault diagnosis function, capable of diagnosing common steering gear faults and storing them in memory (the FPGA is connected to the memory), enabling traceability and alarming. During operation, the steering gear may experience faults such as overtravel, jitter, and twitching. To ensure the steering gear continues to operate within the desired state, corresponding thresholds can be set for its operating parameters. When the steering gear feedback value exceeds the corresponding threshold, the steering gear will experience an overtravel fault. This utility model uses an external sensor to compare the feedback value with the threshold to diagnose process faults. If the feedback value exceeds the threshold, the PWM duty cycle can be reduced or the power supply can be cut off. Twitching faults can occur when the steering gear frequently moves forward and backward. Fault diagnosis is performed based on whether the number of times the feedback curve crosses the mean line exceeds a preset number of pulses. If a fault is detected, the power supply can be promptly cut off. When the deviation e exceeds the set threshold, the speed v should be at the preset full speed. If it is not at full speed, a twitching fault will occur. Feedback from the deviation e and speed v can be used to determine whether the steering gear has experienced a twitching fault. If this fault is present, the power supply should be promptly cut off. In summary, the present invention has a fault diagnosis capability and can timely reduce the PWM duty cycle or cut off the power supply when a fault occurs, thereby reducing the losses and harms caused by the fault.

[0046] The system of the present invention can determine when to cut off the power supply without relying on human staff, and can independently diagnose faults such as overtravel, jitter, and movement. In summary, the present invention can free up labor, store the determined fault judgment in a memory, and can be backtracked and simultaneously serve as an alarm warning, so that the rudder system does not need to consume manpower when working, and can also keep an eye on the operation of the rudder system at all times; at the same time, it also avoids losses caused by inaccurate manual judgment, such as mistaken shutdown, wrong shutdown, and failure to shut down the rudder system power supply in time, effectively reducing the probability of increased losses caused by the rudder system not working properly.

[0047] The above specific implementation methods are detailed descriptions of the present invention. It cannot be determined that the specific implementation methods of the present invention are limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, they can make several simple deductions and substitutions without departing from the concept of the present invention, which should be regarded as falling within the scope of protection of the present invention.

Claims

1. A rudder system monitoring system, characterized by: It includes a data acquisition unit, an analog-to-digital conversion unit, a main control unit and a power shutdown unit connected in sequence. The main control unit is also connected to a data storage unit; the data acquisition unit includes a voltage acquisition module, a current acquisition module and a temperature acquisition module. The output ends of the voltage acquisition module, the current acquisition module and the temperature acquisition module are all connected to the analog-to-digital conversion unit.

2. The rudder system monitoring system according to claim 1, characterized in that: The voltage acquisition module includes an isolation operational amplifier and an operational amplifier connected in sequence, the isolation operational amplifier is connected to the rudder system power supply, and the output end of the operational amplifier is connected to the analog-to-digital conversion unit.

3. The rudder system monitoring system according to claim 1, characterized in that: The current acquisition module is a current sensor, which is connected in series to the rudder system power supply circuit and / or the motor power supply circuit, and the output end of the current sensor is connected to the analog-to-digital conversion unit.

4. The rudder system monitoring system according to claim 1, characterized in that: The temperature acquisition module is a temperature sensor, which is used to collect the temperature of the steering gear drive circuit board and / or the motor. The output end of the temperature sensor is connected to the analog-to-digital conversion unit.

5. The rudder system monitoring system according to claim 1, characterized in that: The analog-to-digital conversion unit is an ADC chip.

6. The rudder system monitoring system according to claim 1, characterized in that: The main control unit is one or more of FPGA, single chip microcomputer, DSP, ARM, and MCU.

7. The rudder system monitoring system according to claim 1, characterized in that: The power shutoff unit is a transistor switch circuit, the base of the transistor is connected to the main control unit via a base resistor, the collector of the transistor is connected to the rudder system power supply via a collector resistor, and the emitter of the transistor is grounded.

8. The rudder system monitoring system according to claim 7, characterized in that: The power shutdown unit also includes a MOS tube and an optocoupler, the source of the MOS tube is connected to the rudder system power supply, the drain of the MOS tube is connected to the rudder system, the gate of the MOS tube is connected to the optical receiver in the optocoupler, and the optical emitter in the optocoupler is connected to the collector of the transistor.

9. The rudder system monitoring system according to claim 1, characterized in that: The data acquisition unit further comprises a position detection module, and an output end of the position detection module is connected to the analog-to-digital conversion unit.

10. The rudder system monitoring system according to claim 1, characterized in that: The data storage unit is an EEPROM memory.

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