Dual encoder signal device

Abstract

The utility model discloses a kind of double-encoder signal devices, belong to signal acquisition technical field, the double-encoder signal device includes gyro wheel and two encoders, gyro wheel is contacted with linear motion line body, make gyro wheel rotate, transmission shaft is fixedly connected on gyro wheel, transmission shaft respectively extends to the outside of the both ends of gyro wheel, two encoders are located at the both ends of gyro wheel, input shaft is equipped on encoder, two input shafts are coaxially connected with transmission shaft, so that two encoders are synchronously obtained pulse signal, when line body jumps, two encoders can slide along first direction, to adapt the jumping displacement of line body.The utility model realizes the accurate, synchronous conversion of line body movement data to double-encoder pulse signal, the signal of double-encoder acquisition is highly consistent, provides high-precision, redundant check signal source for the multi-device collaborative control of automated production line, effectively improves the control precision of production process and product quality consistency.

Description

Technical Field

[0001] This utility model belongs to the field of signal acquisition technology, and in particular relates to a dual encoder signal device for use in industrial automated production lines. Background Technology

[0002] In modern industrial automated production lines (such as electronic component assembly lines, food packaging conveyor lines, and automotive parts assembly lines), the stable operation of the line and the accurate collection of operating data are the key foundations for achieving automated control of the production process and ensuring consistent product quality.

[0003] Traditional single-encoder signal acquisition schemes have significant drawbacks:

[0004] On the one hand, the data collected by a single encoder has a limited dimension, making it difficult to meet the needs of multi-device collaborative control in complex production scenarios for redundant data verification and synchronous access to multi-channel signals;

[0005] On the other hand, during actual operation, the production line is prone to jumping and shifting due to factors such as uneven material conveying, mechanical vibration of equipment, and deviation in the installation accuracy of the line itself. This can lead to gaps and slippage in the transmission connection between the encoder and the line, causing signal acquisition errors and even damaging the encoder hardware, thereby affecting the operational stability of the entire production line and the quality of product production.

[0006] While existing technologies have attempted to adopt multi-encoder solutions, they generally suffer from poor compatibility between encoders and production line drives, as well as weak resistance to interference from operating conditions. For example, they have not specifically addressed signal acquisition deviations caused by production line runout, nor the impact of equipment vibration on the long-term stable operation of encoders. Consequently, they cannot provide continuous, accurate, and reliable multi-encoder synchronization signals for automated production lines.

[0007] Therefore, there is an urgent need to design a dual encoder signal device to solve the problems mentioned above. Utility Model Content

[0008] The purpose of this invention is to provide a dual encoder signal device that has the advantages of being able to stably, accurately, and synchronously acquire dual encoder pulse signals in complex production environments, thus solving the problems mentioned in the background art.

[0009] To achieve the above objectives, the specific technical solution of this utility model for a dual encoder signal device is as follows:

[0010] A dual-encoder signal device includes a roller and two encoders. The roller contacts a linearly moving line, causing it to rotate. A drive shaft is fixedly connected to the roller, extending beyond both ends of the roller. The two encoders are located at both ends of the roller, and each encoder has an input shaft. The input shaft is coaxially connected to the drive shaft, enabling the two encoders to synchronously acquire pulse signals. When the line jumps, the two encoders can slide along a first direction to adapt to the jump displacement of the line.

[0011] Furthermore, a coupling assembly is provided between the input shaft and the transmission shaft. The two input shafts are respectively connected to the transmission shaft through the coupling assembly, so that the two input shafts and the transmission shaft can drive coaxially.

[0012] Furthermore, the coupling assembly includes a rigid coupling, with its two ends connected to the input shaft and the transmission shaft respectively, to ensure the coaxial transmission accuracy of the input shaft and the transmission shaft.

[0013] Furthermore, the coupling assembly includes a spring coupling, with its two ends connected to the input shaft and the drive shaft respectively, to absorb and buffer the vibration energy between the input shaft and the drive shaft.

[0014] Furthermore, this dual encoder signal device also includes a buffer assembly, which is connected to the two encoders. When the line bounces, the two encoders can slide along the first direction through the buffer assembly to adapt to the bounce displacement of the line and keep the encoder in contact with the line.

[0015] Furthermore, the buffer assembly includes a line connecting base, on which a support shaft is connected. The coupling assembly can slide along the support shaft in a first direction. A spring is sleeved on the support shaft. When the line jumps, the two encoders adapt to the jumping displacement of the line by the elastic compression or stretching of the spring.

[0016] Furthermore, a fixed seat is fixedly connected to the line connecting base, and the support shaft can be inserted into the fixed seat. Screw holes are opened on the fixed seat and the support shaft. After the support shaft is inserted into the fixed seat, the support shaft is connected and fixed to the line connecting base by tightening the nut into the screw hole.

[0017] Furthermore, this dual encoder signal device also includes a connecting component, which is fixedly connected to the two encoders. The connecting component is provided with a limiting cavity, and the coupling component is located in the limiting cavity. The input shaft and the transmission shaft both extend into the limiting cavity and are connected to the coupling component. The connecting component is connected to the buffer component.

[0018] Furthermore, the connecting assembly includes a connecting frame and a connecting plate. The roller is located inside the connecting frame, and a support rod is fixedly connected to the connecting frame. The end of the support rod away from the connecting frame is fixedly connected to the connecting plate, and the connecting plate is fixedly connected to the encoder. The connecting frame, the support rod, and the connecting plate form a limiting cavity. A sliding groove is provided on the connecting frame, and the connecting frame is slidably connected to the support shaft through the sliding groove.

[0019] Furthermore, both the connecting frame and the connecting plate are provided with rotating holes. The drive shaft is connected to the rotating hole on the connecting frame through a rotating bearing, and the input shaft is connected to the rotating hole on the connecting plate through a rotating bearing. Both the drive shaft and the input shaft extend into the limiting cavity through the rotating holes and are connected to the coupling assembly.

[0020] This invention has the following advantages: it realizes the accurate and synchronous conversion of line motion data into dual encoder pulse signals, and the signals collected by the dual encoders are highly consistent, providing a high-precision, redundantly verified signal source for multi-device collaborative control of automated production lines, effectively improving the control accuracy of the production process and the consistency of product quality. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the dual encoder signal device of this utility model. Figure 1 ;

[0022] Figure 2 This is a schematic diagram of the overall structure of the dual encoder signal device of this utility model. Figure 2 ;

[0023] Figure 3 This is a schematic diagram of the connection structure of the roller, encoder and coupling assembly of this utility model;

[0024] Figure 4 This is a schematic diagram of the structure of the connecting component, roller, encoder and coupling assembly of this utility model;

[0025] Figure 5 This is a schematic diagram of the structure of the connecting component of this utility model;

[0026] Figure 6 This is a schematic diagram of the structure of the buffer assembly of this utility model;

[0027] The markings in the diagram are as follows: 1. Roller; 11. Drive shaft; 2. Encoder; 21. Input shaft; 3. Coupling assembly; 4. Connecting assembly; 41. Connecting frame; 42. Connecting plate; 43. Support rod; 5. Buffer assembly; 51. Line connecting base; 52. Support shaft; 53. Spring; 54. Fixing seat. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0029] Those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of this invention and form different embodiments. For example, in the claims, any of the claimed embodiments can be used in any combination.

[0030] The following is a reference to the appendix. Figure 1 To be continued Figure 6 This invention describes a dual encoder signal device.

[0031] In existing technologies, multi-encoder solutions generally suffer from poor compatibility between encoders and production line drives, as well as weak resistance to interference from operating conditions. For example, they do not specifically address signal acquisition deviations caused by production line runout, nor do they address the impact of equipment vibration on the long-term stable operation of encoders. Consequently, they cannot provide continuous, accurate, and reliable multi-encoder synchronization signals for automated production lines.

[0032] Therefore, this dual encoder signal device includes a roller 1 and two encoders 2. The roller 1 contacts the linearly moving line, causing the roller 1 to rotate. A drive shaft 11 is fixedly connected to the roller 1, and the drive shaft 11 extends beyond both ends of the roller 1. The two encoders 2 are located at both ends of the roller 1. The encoders 2 are provided with input shafts 21, and the two input shafts 21 are coaxially connected to the drive shaft 11, so that the two encoders 2 synchronously acquire pulse signals. When the line jumps, the two encoders 2 can slide along the first direction A to adapt to the jumping displacement of the line.

[0033] Preferably, roller 1 is made of PU (polyurethane) material with a diameter of 40mm and a width of 40mm. High-precision bearings are integrated inside roller 1. The external dimensions of the PU roller have been strictly calculated and tested. The 40mm width ensures sufficient contact area when in contact with the production line (such as belt conveyor, chain conveyor, etc.), which can effectively disperse the contact pressure on the surface of the production line. The internal bearing adopts a model with low friction coefficient and high load-bearing capacity to ensure the smooth rotation of roller 1. In addition, PU material has good wear resistance, oil resistance and anti-aging properties, which can adapt to the complex environment in industrial production (such as oil, dust, temperature changes, etc.) and extend the service life of roller 1. In other embodiments of this utility model, rollers of other models and materials can also be selected according to the actual situation.

[0034] When the conveyor belt is running, thanks to the excellent frictional properties of PU material (compared to metal and ordinary rubber, PU material can maintain a high and stable coefficient of friction in both dry and wet friction environments), combined with the large contact area provided by its 40mm width, stable frictional force transmission can be achieved between roller 1 and the conveyor belt, effectively preventing slippage. The linear motion of the conveyor belt is converted into the rotational motion of roller 1 through friction. Furthermore, due to the sufficient contact area and stable friction, the rotational speed of roller 1 can accurately synchronize with the running speed of the conveyor belt, laying a stable motion input foundation for the subsequent signal acquisition by encoder 2.

[0035] Preferably, the drive shaft 11 is made of a high-strength alloy material (P20 heat treatment), which has good rigidity and straightness. In other embodiments of this utility model, the drive shaft 11 may also be made of other materials.

[0036] Roller 1 is coaxially connected to drive shaft 11. The rotation of roller 1 drives drive shaft 11 to rotate synchronously. Based on the rigid transmission characteristics of drive shaft 11, the rotational motion converted from the line speed is accurately and synchronously transmitted to the two encoders 2. The two encoders 2 simultaneously acquire the rotational pulse signal of drive shaft 11. Due to the coaxial transmission of drive shaft 11, the effect of "one-line line motion - dual encoder synchronous acquisition" is achieved, making the pulse signals acquired by the two encoders 2 completely synchronized. This can be used for subsequent multi-channel data verification, multi-device collaborative control, and other scenarios. The coaxial connection between drive shaft 11 and input shaft 21 ensures a high degree of synchronization in the signal acquisition of the two encoders 2, avoiding control errors caused by signal delay or asynchrony. The cooperation between high-strength drive shaft 11 and coupling assembly 3 ensures the accuracy and reliability of power transmission, providing stable and consistent motion input for the two encoders 2.

[0037] A coupling assembly 3 is provided between the input shaft 21 and the transmission shaft 11. The two input shafts 21 are respectively connected to the corresponding transmission shafts 11 through the coupling assembly 3, so that the two input shafts 21 and the transmission shafts 11 are coaxially driven.

[0038] In the first embodiment of the coupling assembly 3, the coupling assembly 3 includes a rigid coupling. The two ends of the rigid coupling are respectively connected to the input shaft 21 and the transmission shaft 11 to ensure the coaxial transmission accuracy of the input shaft 21 and the transmission shaft 11, and to have the buffering performance of movement. Preferably, a plum blossom coupling can be used. In other embodiments of this utility model, other rigid couplings can also be used, as long as the coaxial transmission accuracy of the input shaft 21 and the transmission shaft 11 can be guaranteed.

[0039] Regarding the second embodiment of the coupling assembly 3, the coupling assembly 3 includes a spring coupling. The two ends of the spring coupling are respectively connected to the input shaft 21 and the transmission shaft 11 to absorb and buffer the vibration energy between the input shaft 21 and the transmission shaft 11. Specifically, the spring coupling includes an elastic element and a half-coupling part. The two ends of the elastic element are connected to the half-coupling part, and the two half-coupling parts are respectively connected to the input shaft 21 and the transmission shaft 11. The elastic element is a helical spring made of alloy steel spring wire. The diameter, pitch, number of turns and other parameters of the helical spring are optimized according to the maximum vibration load and torque transmission requirements during the operation of the device.

[0040] When the equipment generates mechanical vibrations (such as motor vibrations from peripheral equipment or impact vibrations from material conveying on the production line), the spring coupling utilizes the elastic deformation of the helical spring to absorb and buffer the vibration energy, minimizing the impact of vibration on the rigid connection between the spring coupling and the drive shaft 11. Simultaneously, the elastic restoring force of the helical spring allows the spring coupling to quickly return to its initial state after the vibration load disappears, ensuring the transmission stability between the encoder 2 input shaft 21 and the drive shaft 11. This significantly improves the equipment's durability and vibration resistance, effectively reducing the risk of loosening or damage to internal components of the encoder 2 due to continuous vibration. The elastic buffering characteristics of the spring coupling enhance the resilience of the device, ensuring stable and long-term operation of the encoder 2 and maintaining signal acquisition accuracy even under harsh operating conditions with frequent vibrations.

[0041] This dual encoder signal device also includes a connecting component 4, which is fixedly connected to the two encoders 2. The connecting component 4 is provided with a limiting cavity, and the coupling component 3 is located in the limiting cavity. The input shaft 21 and the transmission shaft 11 both extend into the limiting cavity and are connected to the coupling component 3. The connecting component 4 is connected to the buffer component 5.

[0042] The connecting assembly 4 includes a connecting frame 41 and a connecting plate 42. The roller 1 is located inside the connecting frame 41. A support rod 43 is fixedly connected to the connecting frame 41. The end of the support rod 43 away from the connecting frame 41 is fixedly connected to the connecting plate 42. The connecting plate 42 is fixedly connected to the encoder 2. The connecting frame 41, the support rod 43 and the connecting plate 42 form a limiting cavity. Both the connecting frame 41 and the connecting plate 42 are provided with rotating holes. The drive shaft 11 is connected to the rotating hole on the connecting frame 41 through a rotating bearing. The input shaft 21 is connected to the rotating hole on the connecting plate 42 through a rotating bearing. Both the drive shaft 11 and the input shaft 21 extend into the limiting cavity through the rotating holes and are connected to the coupling assembly 3.

[0043] This dual encoder signal device also includes a buffer component 5, which is connected to two encoders 2. When the production line body experiences axial position shift or vertical jump (maximum jump range up to 70mm) due to factors such as uneven material distribution or changes in line tension, the encoder 2 will generate vertical displacement requirements as the line body jumps. The two encoders 2 can slide along the first direction A through the buffer component 5 to adapt to the jump displacement of the line body, so that the encoder 2 is always in contact with the line body, avoiding gaps between the line body and the encoder 2 due to position shift, thereby preventing the encoder 2 from spinning idly and ensuring that the encoder 2 continuously and stably collects the line body speed signal.

[0044] The buffer component 5 enables the device to cope with complex operating deviations of the production line. Even under conditions of production line runout within a range of 70mm, it can still ensure that the encoder 2 stably acquires speed signals and outputs reliable pulse signals. The design of the buffer structure reduces the impact of production line deviations on the hardware and signal acquisition of the encoder 2, thereby improving the applicability and reliability of the device in actual production environments.

[0045] The first direction A is the setting direction of the support shaft 52, which can also be understood as... Figure 1 The vertical direction in the field of view.

[0046] Specifically, the buffer assembly 5 includes a line connecting base 51, on which a support shaft 52 is connected. The coupling assembly 3 can slide along the first direction A on the support shaft 52. A spring 53 is sleeved on the support shaft 52. When the line jumps, the two encoders 2 adapt to the jumping displacement of the line through the elastic compression or stretching of the spring 53. Specifically, a sliding groove is provided on the connecting frame 41. The connecting frame 41 is slidably connected to the support shaft 52 through the sliding groove, so that the connecting frame 41 can drive the coupling assembly 3 to slide along the first direction A on the support shaft 52. The two ends of the spring 53 are fixedly connected to the line connecting base 51 and the connecting frame 41 respectively. The support shaft 52 provides guidance for the sliding of the encoder 2. The spring 53 adapts to the jumping displacement of the line through elastic compression or stretching, so that the encoder 2 always keeps in contact with the line, thereby preventing the encoder 2 from spinning freely and ensuring that the encoder 2 continuously and stably collects the line speed signal.

[0047] A limit stop is fixedly connected to one end of the support shaft 52 away from the line connecting base 51. The limit stop restricts the sliding stroke of the connecting frame 41 and the coupling assembly 3, preventing the connecting frame 41 from separating from the support shaft 52.

[0048] Preferably, a fixing seat 54 is fixedly connected to the line connecting base 51, and the support shaft 52 can be inserted into the fixing seat 54. The fixing seat 54 and the support shaft 52 are provided with screw holes. After the support shaft 52 is inserted into the fixing seat 54, the support shaft 52 is connected and fixed to the line connecting base 51 by tightening the nut into the screw hole. In other embodiments of this utility model, the support shaft 52 can also be fixed to the line connecting base 51 by other structures.

[0049] This dual encoder signal device has the following advantages:

[0050] (1) Accuracy and synchronization of signal acquisition:

[0051] Through the stable transmission of PU roller 1 and the coaxial connection of two encoders 2, the line motion data is accurately and synchronously converted into pulse signals from the dual encoders. The signals collected by the dual encoders are highly consistent, providing a high-precision, redundant verification signal source for the collaborative control of multiple devices in automated production lines (such as precise robot grasping and synchronous processing at multiple workstations), effectively improving the control accuracy of the production process and the consistency of product quality.

[0052] (2) Equipment operational stability and durability:

[0053] The application of spring couplings significantly enhances the vibration resistance of the device, buffers the impact of equipment operation vibration on encoder 2 and transmission components, reduces the probability of equipment failure, and extends the service life of the equipment. The buffer assembly 5 solves the problem of abnormal signal acquisition caused by line runout from a structural perspective, ensuring that the device can operate stably for a long time under complex working conditions, reducing the number of production line downtimes caused by equipment failure, and improving production efficiency.

[0054] (3) Adaptability to working conditions and scalability to various scenarios:

[0055] This device features systematic structural optimization and functional design to address complex operating conditions commonly encountered in industrial production lines, such as line speed fluctuations, equipment vibrations, and line runouts. It is widely adaptable to automated production lines in industries such as electronics, food, and automotive. Furthermore, the dual encoder signal output design provides expansion interfaces for intelligent upgrades of production lines (such as big data collection and analysis, and adaptive process parameter adjustment), helping enterprises achieve higher levels of production process control.

[0056] (4) Overall cost advantage:

[0057] From a long-term operational perspective, the high stability and durability of this device can reduce equipment maintenance and replacement costs. Precise signal acquisition and reliable equipment control help reduce product defect rates and improve production efficiency. Compared with traditional single encoder solutions, this invention, while ensuring production quality and efficiency, brings significant overall cost reduction benefits to enterprises through functional optimization and life extension.

[0058] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A dual encoder signal device, characterized in that, It includes a roller and two encoders. The roller contacts the linearly moving line, causing the roller to rotate. A drive shaft is fixedly connected to the roller, extending beyond both ends of the roller. The two encoders are located at both ends of the roller, and each encoder has an input shaft. The two input shafts are coaxially connected to the drive shaft, enabling the two encoders to synchronously acquire pulse signals. When the line jumps, the two encoders can slide along a first direction to adapt to the jump displacement of the line.

2. The dual encoder signal device according to claim 1, characterized in that, A coupling assembly is provided between the input shaft and the transmission shaft. The two input shafts are respectively connected to the transmission shaft through the coupling assembly, so that the two input shafts and the transmission shaft can drive coaxially.

3. The dual encoder signal device according to claim 2, characterized in that, The coupling assembly includes a rigid coupling, with its two ends connected to the input shaft and the drive shaft, respectively, to ensure the coaxial transmission accuracy of the input shaft and the drive shaft.

4. The dual encoder signal device according to claim 2, characterized in that, The coupling assembly includes a spring coupling, with its two ends connected to the input shaft and the drive shaft, respectively, to absorb and buffer the vibration energy between the input shaft and the drive shaft.

5. The dual encoder signal device according to claim 1, characterized in that, It also includes a buffer assembly, which is connected to two encoders. When the line bounces, the two encoders can slide along the first direction through the buffer assembly to adapt to the bounce displacement of the line and keep the encoders in contact with the line.

6. The dual encoder signal device according to claim 5, characterized in that, The buffer assembly includes a line connecting base, on which a support shaft is connected. The coupling assembly can slide along the support shaft in a first direction. A spring is sleeved on the support shaft. When the line jumps, the two encoders adapt to the jump displacement of the line by the elastic compression or stretching of the spring.

7. The dual encoder signal device according to claim 6, characterized in that, A fixed base is fixedly connected to the line connecting base, and the support shaft can be inserted into the fixed base. The fixed base and the support shaft are provided with screw holes. After the support shaft is inserted into the fixed base, the support shaft is connected and fixed to the line connecting base by tightening the nut into the screw hole.

8. The dual encoder signal device according to claim 6, characterized in that, It also includes a connecting assembly, which is fixedly connected to two encoders. The connecting assembly has a limiting cavity, and the coupling assembly is located in the limiting cavity. The input shaft and the transmission shaft both extend into the limiting cavity and are connected to the coupling assembly. The connecting assembly is connected to the buffer assembly.

9. The dual encoder signal device according to claim 8, characterized in that, The connecting assembly includes a connecting frame and a connecting plate. The roller is located inside the connecting frame. A support rod is fixedly connected to the connecting frame. The end of the support rod away from the connecting frame is fixedly connected to the connecting plate. The connecting plate is fixedly connected to the encoder. The connecting frame, support rod and connecting plate form a limiting cavity. A sliding groove is provided on the connecting frame. The connecting frame is slidably connected to the support shaft through the sliding groove.

10. The dual encoder signal device according to claim 9, characterized in that, Both the connecting frame and the connecting plate have rotating holes. The drive shaft is connected to the rotating hole on the connecting frame through a rotating bearing, and the input shaft is connected to the rotating hole on the connecting plate through a rotating bearing. Both the drive shaft and the input shaft extend into the limiting cavity through the rotating holes and are connected to the coupling assembly.

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