Linear module fault diagnosis sensor

Abstract

The utility model relates to the technical field of sensors, in particular to a linear module fault diagnosis sensor, which is characterized in that a circuit board, a battery and a cover body are sequentially arranged in an inner cavity of a shell, and the battery is used for supplying power to the circuit board; an accelerometer sensor used for monitoring the motion state of the linear module in real time, a microprocessor used for receiving signals of the accelerometer sensor and processing and analyzing the signals and a warning assembly used for sending out warning signals are integrated on the circuit board, and a control button is arranged on the shell. Through the design that the accelerometer sensor, the microprocessor and the warning assembly are integrated on the circuit board, the problem that early slight damage of the linear module is not easy to find can be effectively avoided, it is guaranteed that maintenance personnel conduct maintenance in time through warning information, the service life of the linear module is greatly prolonged, and the stability of the linear module is greatly improved; moreover, due to the design of the battery, it is ensured that the device can be used while being installed, and meanwhile, the stability during use is also ensured.

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, specifically to a linear module fault diagnosis sensor. Background Technology

[0002] In the field of industrial automation, electrically driven linear motion mechanisms are widely used in manufacturing, with linear modules accounting for a large proportion, effectively promoting efficient and high-quality production. However, during the commissioning and operation phases of linear modules, human error, control system malfunctions, and other factors often cause the slider to collide with the body limit block or the slider to bear a load exceeding its rated weight. This not only reduces the service life of the linear module but may even cause it to be damaged.

[0003] Currently, the traditional method for detecting whether a linear module slider has collided with the main body limit block relies primarily on the imprint inspection method, which determines whether a one-time injury has occurred. However, this detection method is inefficient, highly susceptible to subjective factors, resulting in inaccurate inspection results, and it also fails to detect potential safety hazards in the linear module in advance.

[0004] Meanwhile, it is understood that the market is currently almost entirely lacking in real-time fault diagnosis devices for linear modules. During the operation of linear modules, due to the lack of effective real-time diagnostic methods, minor damage occurring in the early stages is difficult to detect in time. By the time maintenance personnel discover the abnormality, the linear module has often suffered serious damage, or even become irreparable. This not only directly interferes with the normal operation of the entire machine, but also forces companies to face equipment replacement costs, production downtime losses, and potential order delay compensation, resulting in certain economic losses for the company. Utility Model Content

[0005] This invention provides a fault diagnosis sensor for linear modules to solve the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0007] A fault diagnosis sensor for a linear module is provided for installation at a predetermined position on the linear module. The sensor includes a housing, and a circuit board, a battery, and a cover are sequentially arranged inside the housing. The battery powers the circuit board, and the circuit board integrates an accelerometer sensor for real-time monitoring of the linear module's motion state, a microprocessor for receiving and analyzing the accelerometer sensor signal, and a warning component for issuing a warning signal. The housing also has a control button.

[0008] Preferably, the microprocessor includes a threshold module for setting a threshold, a judgment module for judging the accelerometer sensor signal, and a storage module for storing the accelerometer sensor signal data.

[0009] Preferably, the warning component includes an indicator light and a transparent protection zone, wherein at least one indicator light is provided, and the transparent protection zone corresponds to the indicator light.

[0010] Preferably, the warning component includes a UV lamp and a color-changing label area, wherein at least two UV lamps are provided, and the color-changing label area corresponds to the UV lamp.

[0011] Preferably, a recessed groove is provided at one end of the housing, the cover is disposed in the recessed groove, and the cover is adapted to the recessed groove.

[0012] Preferably, the inner cavity of the housing is further provided with a filler for protecting the circuit board.

[0013] Preferably, the housing is made of metal or plastic.

[0014] Preferably, the cover is made of metal or plastic.

[0015] By adopting the above technical solution, the beneficial effects achieved by this utility model are as follows:

[0016] In this invention, by integrating an accelerometer sensor, a microprocessor, and an alarm component on a circuit board, the accelerometer sensor can detect the acceleration generated by the linear module at the moment of impact in real time and output an electrical signal for the microprocessor to process and analyze. When the analyzed signal reaches a threshold, the microprocessor can permanently store the acceleration value and simultaneously issue an alarm through the alarm component. This avoids the problem of early minor damage to the linear module being difficult to detect, and ensures that maintenance personnel can perform timely maintenance based on alarm information, greatly extending the service life and stability of the linear module and reducing certain economic losses.

[0017] In this invention, by placing the battery inside the housing to supply power to the circuit board, the fault diagnosis sensor can work normally without an external power supply, effectively avoiding the risks of signal interference and poor contact caused by external power cables. This ensures that the fault diagnosis sensor can still operate stably in complex environments and high-frequency vibration conditions, making it quite practical. At the same time, it achieves immediate use after installation, ensuring the flexibility of this invention. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0019] Figure 2 This is a schematic diagram of the exploded structure of this utility model.

[0020] Figure 3 This is a schematic diagram of the circuit board structure of this utility model.

[0021] Figure 4 This is a schematic diagram of the threshold module, judgment module and storage module of this utility model.

[0022] In the diagram: 1. Housing; 2. Circuit board; 3. Battery; 4. Cover; 5. Accelerometer sensor; 6. Microprocessor; 7. Warning component; 8. Control button; 9. Threshold module; 10. Judgment module; 11. Storage module; 12. Sinking tank. Detailed Implementation

[0023] To better understand the above-mentioned objectives, features, and advantages of this utility model, the present utility model will be further described below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0024] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the present invention is not limited to the specific embodiments disclosed in the following specification.

[0025] like Figures 1-4 As shown, this utility model provides a fault diagnosis sensor for a linear module, which is installed at a predetermined position on the linear module. It includes a housing 1, and a circuit board 2, a battery 3, and a cover 4 are sequentially arranged inside the housing 1. The battery 3 is used to power the circuit board 2. The circuit board 2 integrates an accelerometer sensor 5 for real-time monitoring of the linear module's motion status, a microprocessor 6 for receiving and processing the signals from the accelerometer sensor 5, and an alarm component 7 for issuing alarm signals. The circuit board 2 is also provided with peripheral circuitry, which is used to boost, buck, and filter the battery 3. It is worth emphasizing that the boost, buck, and filtering methods are technologies well known to those skilled in the art and can be set and applied by professional technicians. This article will not describe them in detail. The housing 1 is provided with control buttons 8.

[0026] As a further step, the accelerometer sensor 5 is used to output analog data electrical transmission signals in real time, and the accelerometer sensor 5 is also a vibration sensor.

[0027] Microprocessor 6 is responsible for receiving all electrical signals output by accelerometer sensor 5, processing and analyzing the signals, and outputting the results after meeting certain conditions.

[0028] The microprocessor 6 reads data signals in real time through the chip and amplifies the data signals for reading (conventional technology and operation in the field).

[0029] The microprocessor 6 includes a threshold module 9 for setting thresholds, a judgment module 10 for judging the signals of the accelerometer sensor 5, and a storage module 11 for storing the signal data of the accelerometer sensor 5. Specifically, the judgment module 10 can read the electrical transmission signal in real time and judge the read data signal based on the judgment logic and threshold: if the threshold is not reached, the acceleration value will not be output in real time; if the threshold is reached, the storage module 11 will permanently store the acceleration value and start an alarm.

[0030] In the first implementation, the microprocessor 6 can be configured to: issue a warning when the warning threshold (low threshold) is reached, and continue reading data after the warning; and issue an alarm when the alarm threshold (high threshold) is reached; wherein the warning and alarm thresholds are set differently (dual threshold concept).

[0031] In the second implementation, the microprocessor 6 can be configured to: set an alarm threshold, continue to acquire new data when the threshold is reached, and then continue running; read and permanently save any acceleration values ​​that exceed the threshold, and record the number of times the threshold is exceeded; the more times the collision occurs, the more serious the problem with the operating environment.

[0032] As a third implementation, the microprocessor 6 can be configured to: issue a reminder when the reminder threshold (low threshold) is reached, and continue reading data after the reminder; issue an alarm when the alarm threshold (high threshold) is reached; and record the number of alarms.

[0033] As a further step, when installing the housing 1, it can be fixed by using an ear seat and a fixing bolt, or by using double-sided adhesive tape to install the housing 1 on the slider of the linear module, so as to ensure the normal use of this utility model and ensure that the fault diagnosis sensor can perform real-time motion monitoring on the linear module.

[0034] As a further step, a recessed groove 12 is provided at one end of the housing 1, and the cover 4 is placed in the recessed groove 12. The cover 4 is adapted to the recessed groove 12, which can ensure the integrity of the fault diagnosis sensor and the stability during installation. Specifically, when the cover 4 is placed in the recessed groove 12, its bottom surface is on the same horizontal plane as the bottom surface of the mounting base 12.

[0035] As a further step, the inner cavity of the housing 1 is also provided with filler for protecting the circuit board 2 and the battery 3. The filler is used to ensure the stability of the circuit board 2 and the battery 3 when installed in the housing 1, and the filler includes, but is not limited to, glue and resin.

[0036] As a further step, the shell 1 and the cover 4 are made of metal or plastic, respectively.

[0037] It is worth noting that the use of battery 3, unlike the external power cable, ensures stability during use and allows for immediate use and flexible operation.

[0038] In one implementation, the warning component 7 includes an indicator light and a transparent protection zone. At least one indicator light is provided. When using a single indicator light, it is a dual-color LED indicator, enabling the warning function to be achieved with just one dual-color LED indicator. The transparent protection zone corresponds to the indicator light, which is also an LED indicator. A yellow LED indicates a warning, while a red LED indicates damage.

[0039] In a preferred embodiment, the warning component 7 includes indicator lights and a transparent protection zone. Two indicator lights are provided, both of which are LED indicators. When one LED indicator light is illuminated, it visually indicates that the linear module is in a warning state, meaning that there may be a potential risk in the equipment's operation and further inspection by relevant personnel is required. When the other LED indicator light is illuminated, it clearly indicates that the linear module is damaged and requires immediate shutdown and maintenance to prevent the fault from escalating and causing more serious impact on production.

[0040] In another implementation, the warning component 7 includes a UV lamp and a color-changing label area. A color-changing label is provided in the color-changing label area, and at least two UV lamps are provided, with the color-changing label area corresponding to a UV lamp. The UV lamps are designed so that when the UV lamps illuminate the color-changing labels in the color-changing label area, the labels undergo an irreversible color change, serving as a permanent indication. Two color-changing labels are provided, each corresponding to a UV lamp; when one label turns red, it indicates a warning, and when the other label turns red, it indicates damage.

[0041] As another implementation method, the warning component 7 can also be in other ways. It can use electrochromic ink dots, which can be activated by an electrical signal to change the color of the ink to achieve a visual alarm; it can also use a surface-mount fuse with an observable melting point, which will blow when the circuit is abnormally overloaded, and its melting state will intuitively present the fault signal; or it can use a thermochromic label, which will change color immediately when the temperature is abnormal, so as to achieve a rapid warning of temperature abnormality; or it can use an electromagnetic flip indicator, which uses an electromagnetic drive mechanism to flip and display a specific label when the alarm is triggered, so as to clearly convey the alarm information.

[0042] It should be emphasized that the microprocessor 6 in this invention determines whether the reminder threshold or alarm threshold has been reached based on the data transmission signal from the accelerometer sensor 5. This is a logical judgment in the prior art, and this invention does not involve the improvement of the algorithm, so it will not be described in detail.

[0043] The working principle and usage process of this utility model are as follows: When in use, after fixing this utility model to the predetermined installation position of the linear module (i.e., on the linear module slider), the acceleration generated by the linear module impact can be detected in real time by the accelerometer sensor 5. Specifically, when the linear module slider impacts the limiting block of the linear module base, the impact force generated after the collision is transmitted to the slider. The accelerometer sensor 5 obtains acceleration data based on this transmitted impact force and outputs an analog data transmission signal. When the microprocessor 6 receives and processes this signal, it can permanently store the acceleration value that reaches the threshold and simultaneously trigger an alarm via the warning component 7. The alarm provides permanent indication information, strong stability, and is not affected by external interference. It can eliminate signals that do not cause damage to the module due to its own movement, ensuring that maintenance personnel can promptly perform maintenance based on the obtained target alarm signal, greatly extending the service life and stability of the linear module.

[0044] It is worth noting that the warning component 7 in this solution includes, but is not limited to, LED indicator lights and UV lamps, and can also be a buzzer. That is, when a buzzer is used, a short and rapid buzzer can be set to represent an emergency fault warning state, and a long and slow buzzer can represent an abnormal warning state.

[0045] It is important to emphasize that this utility model merely provides a physical architecture for a sensor that can realize fault diagnosis of linear modules, and does not involve the protection of data processing algorithms and logic methods. Furthermore, it is crucial to emphasize that although the algorithm is not described in detail herein, those skilled in the art can apply and implement it using the physical architecture of this solution based on their professional knowledge. The proposed processing algorithms and logic methods are merely supplementary explanations to demonstrate the feasibility and authenticity of this utility model, and this utility model does not seek protection for the algorithm technology.

[0046] In this invention, the term "plural" refers to two or more items unless otherwise expressly defined. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. The terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0047] It should be noted that when a component is referred to as being "assembled on," "mounted on," "fixed to," or "set on" another component, it can be directly on the other component or there may be an intermediate component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intermediate component present. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0048] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0049] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A fault diagnosis sensor for a linear module, used for installation at a predetermined position on a linear module, characterized in that, The device includes a housing (1), and the inner cavity of the housing (1) is provided with a circuit board (2), a battery (3) and a cover (4) in sequence. The battery (3) is used to power the circuit board (2), and the circuit board (2) integrates an accelerometer sensor (5) for real-time monitoring of the motion state of the linear module, a microprocessor (6) for receiving the signal from the accelerometer sensor (5) and processing and analyzing the signal, and a warning component (7) for issuing warning signals. The housing (1) is provided with a control button (8).

2. The linear module fault diagnosis sensor according to claim 1, characterized in that, The microprocessor (6) includes a threshold module (9) for setting a threshold, a judgment module (10) for judging the signal of the accelerometer sensor (5), and a storage module (11) for storing the signal data of the accelerometer sensor (5).

3. The linear module fault diagnosis sensor according to claim 1, characterized in that, The warning component (7) includes an indicator light and a transparent protection zone, wherein at least one indicator light is provided and the transparent protection zone corresponds to the indicator light.

4. A linear module fault diagnosis sensor according to claim 1, characterized in that, The warning component (7) includes a UV lamp and a color-changing label area, wherein at least two UV lamps are provided and the color-changing label area corresponds to the UV lamp.

5. A linear module fault diagnosis sensor according to claim 1, characterized in that, A sinkhole (12) is provided at one end of the housing (1), and the cover (4) is disposed in the sinkhole (12), and the cover (4) is adapted to the sinkhole (12).

6. A linear module fault diagnosis sensor according to claim 1, characterized in that, The inner cavity of the housing (1) is also provided with filler for protecting the circuit board (2) and the battery (3).

7. A linear module fault diagnosis sensor according to claim 1, characterized in that, The shell (1) is made of metal or plastic.

8. A linear module fault diagnosis sensor according to claim 1, characterized in that, The cover (4) is made of metal or plastic.

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