Batteryless multi-turn encoder

Abstract

A battery-free multi-turn encoder relates to the technical field of encoder, and aims to solve the problems of existing multi-turn encoder, such as battery dependence, complex structure or unstable operation. The encoder comprises an encoder body, the body has a moving disc, a static disc and a rotating shaft inside, a permanent magnet is fixed on the moving disc, and a mechanical switch is fixed on the static disc; the mechanical switch comprises a balance arm capable of rotating around a balance support seat and a magnetic conductor, the balance arm has a first switch contact at one end, the magnetic conductor has a corresponding second switch contact, the rotating track of the magnet overlaps with the projection of the magnetic conductor, and the contacts are electrically connected with lead wires. The structure can be optimized by setting a spring, a clamping piece or using a permanent magnet balance arm. The utility model does not need a battery, has a simple structure, accurate and stable counting, long service life, and is suitable for industrial control, precision instruments and other fields.

Description

Technical Field

[0001] This utility model relates to the field of encoder technology, and in particular to a battery-free multi-turn encoder. Background Technology

[0002] Regardless of whether it's a photoelectric, capacitive, permanent magnet, or inductive encoder, there are several ways to achieve multi-turn counting functionality:

[0003] 1. Mechanical type: Multi-turn counting can be achieved by physically meshing gears and setting appropriate meshing stages and gear ratios. This method has disadvantages such as large size, complex structure, complex algorithm, short lifespan, high requirements for gears in high-speed applications, and errors caused by meshing backlash.

[0004] 2. Battery-powered rotation counting function: By using an external battery, the encoder can maintain power supply and continuously monitor rotation when the main power is off, thus achieving multi-revolution counting. This method has disadvantages such as requiring an external battery, difficult setup, needing to replace the battery periodically, and difficulty in battery replacement.

[0005] 3. Wiegand effect sensor: This type of sensor uses energy collected through electromagnetic induction via the Wiegand effect when the encoder is not powered on to provide the encoder's multi-turn counting function. However, the electrical charge generated by the Wiegand effect in this method is very weak and its operation is uncontrollable, potentially leading to functional failure. Since the encoder cannot detect the anomaly, this could have serious consequences. Utility Model Content

[0006] In view of the above problems, the present invention provides a battery-free multi-turn encoder that overcomes or at least partially solves the above problems.

[0007] To address the aforementioned problems, this utility model discloses a battery-free multi-turn encoder, comprising: an encoder body, wherein the encoder body internally has a moving disk, a stationary disk, and a rotating shaft that drives the moving disk to rotate; and further comprising:

[0008] A magnet is fixedly mounted on the movable disk and rotates synchronously with the movable disk; the magnet is a permanent magnet.

[0009] A mechanical switch is fixedly installed on the stationary plate and is positioned corresponding to the magnet;

[0010] The mechanical switch includes a balance arm, a balance fulcrum, and a magnetic conductor;

[0011] The balance arm can rotate around the balance fulcrum seat, and one end of the balance arm is provided with a first switch contact; the magnetic conductor opposite to the first switch contact is provided with a second switch contact;

[0012] Furthermore, the rotation trajectory of the magnet overlaps with the projection of the magnetic conductor;

[0013] The first switch contact and the second switch contact are electrically connected by leads.

[0014] Optionally, a spring is also provided between the balance fulcrum seat and the balance arm, wherein the elastic force of the spring is weaker than the attraction force of the magnet on the balance arm through the magnetic conductor.

[0015] Optionally, the balance fulcrum seat is provided with a first engaging component;

[0016] The magnetic conductor is also provided with a second engaging component;

[0017] The first engaging component matches the second engaging component, and the engaging force between the two is less than the attraction force of the magnet on the balance arm through the magnetic conductor.

[0018] Optionally, the balance arm is a permanent magnet;

[0019] The attraction force of the balance arm to the magnetic conductor is less than the attraction force of the magnet to the balance arm through the magnetic conductor.

[0020] Optionally, the balance arm is a permanent magnet; and the elastic force of the spring is greater than the attraction force of the balance arm on the magnetic conductor, but less than the attraction force of the magnet on the balance arm through the magnetic conductor.

[0021] Optionally, the magnet is a neodymium magnet.

[0022] This utility model has the following advantages: The encoder body contains a moving disk, a stationary disk, and a rotating shaft that drives the moving disk to rotate; it also includes: a magnet, fixedly mounted on the moving disk and rotating synchronously with it, the magnet being a permanent magnet; a mechanical switch, fixedly mounted on the stationary disk and corresponding to the magnet; the mechanical switch includes a balance arm, a balance fulcrum, and a magnetic conductor; the balance arm can rotate around the balance fulcrum, and one end of the balance arm is provided with a first switch contact; the magnetic conductor opposite the first switch contact is provided with a second switch contact; and the rotation trajectory of the magnet overlaps with the projection of the magnetic conductor; the first and second switch contacts are electrically connected by leads. Attached Figure Description

[0023] Fig. 1 This is a schematic diagram of the main body structure of an embodiment of a battery-free multi-turn encoder according to this utility model;

[0024] Fig. 2 This is a cross-sectional structural schematic diagram of an embodiment of a battery-free multi-turn encoder according to this utility model;

[0025] Fig. 3 This is a schematic diagram of the mechanical switch principle structure of an embodiment of a battery-free multi-turn encoder of this utility model;

[0026] Fig. 4 This is a schematic diagram of the switch-off state of an embodiment of a battery-free multi-turn encoder of this utility model;

[0027] Fig. 5 This is a schematic diagram of the switch-closed state of an embodiment of a battery-free multi-turn encoder according to this utility model. Detailed Implementation

[0028] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0029] This utility model provides an embodiment of a battery-free multi-turn encoder, such as... Figs. 1 to 5 As shown, the encoder body 1 may specifically include: an encoder body 1, which has a moving disk 103, a stationary disk 102, and a rotating shaft 101 that drives the moving disk 103 to rotate; it also includes: a magnet 104, which is fixedly mounted on the moving disk 103 and rotates synchronously with the moving disk 103, and the magnet 104 is a permanent magnet; a mechanical switch 105, which is fixedly mounted on the stationary disk 102 and is correspondingly arranged with the magnet 104; the mechanical switch 105 includes a balance arm 201, a balance fulcrum 202, and a magnetic conductor 151; the balance arm 201 can rotate around the balance fulcrum 202, and one end of the balance arm 201 is provided with a first switch contact 203; the magnetic conductor 151 opposite to the first switch contact 203 is provided with a second switch contact 152; and the rotation trajectory of the magnet 104 overlaps with the projection of the magnetic conductor 151; the first switch contact 203 and the second switch contact 152 are electrically connected by a lead wire. This application addresses the technical problems of existing mechanical multi-turn encoders, such as large size, complex structure and algorithm, and meshing hysteresis; encoders with batteries rely on batteries, are difficult to debug and replace; and Wiegand effect sensors have weak power, uncontrollable operation, and cannot detect anomalies. On one hand, the multi-turn encoder of this application does not require an external battery, avoiding battery-related troubles and the risk of data loss. On the other hand, the multi-turn encoder of this application has a simple structure, without complex gears, reducing size and cost, and eliminating meshing hysteresis, thus improving counting accuracy. Furthermore, the aforementioned multi-turn encoder operates stably, achieving counting through the cooperation of magnet 104 and mechanical switch 105, avoiding the defects of Wiegand effect sensors.

[0030] For applications requiring fewer than two revolutions, where the encoder detects more than one revolution, a multi-revolution counting function is essential. Addressing the shortcomings of current multi-revolution counting methods, this application calibrates different revolution counts by magnetically triggering the opening and closing of a mechanical switch 105 without requiring a power supply. When the encoder is powered on again, the open / closed state of the mechanical switch 105 is detected to determine the encoder's current multi-revolution position. This achieves reliable revolution counting without adding mechanical structures or requiring battery power. It eliminates bulky gear meshing structures or complex power supply systems, ensuring stability and reliability.

[0031] Furthermore, a spring is provided between the balance fulcrum 202 and the balance arm 201, wherein the spring force is weaker than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. This solves the technical problem of unreliable reset of the balance arm 201, which may lead to unstable switching and affect the accuracy of counting. By setting a spring, the spring force is used to achieve reliable reset of the balance arm, ensuring that the contacts can separate in time when the magnet 104 leaves the overlapping area of ​​the magnetic conductor, ensuring stable switching and further improving counting accuracy and reliability. For example, in the application scenario of speed detection of conveyor belt drive motor in automated production line, the magnet 104 in the encoder rotates to the overlapping area of ​​the magnetic conductor, and the attraction force overcomes the spring force to make the contacts contact for counting; after the magnet 104 leaves, the spring force quickly resets the balance arm and separates the contacts, avoiding counting errors caused by contact adhesion, ensuring accurate motor speed detection, and ensuring stable operation of the production line.

[0032] The balance fulcrum 202 is provided with a first engaging component; the magnetic conductor 151 is also provided with a second engaging component; the first engaging component and the second engaging component are matched (not shown in the figure), and the engaging force between them is less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. This solves the technical problem that the balance arm is prone to malfunction due to vibration and other factors when there is no external force assistance, resulting in incorrect switching and counting errors. Through the engaging action of the first engaging component and the second engaging component, the position of the balance arm is fixed when there is no magnet 104 attraction, preventing it from malfunctioning due to vibration, ensuring that the switch is turned on and off only when the magnet 104 is attracted, reducing counting errors and improving the encoder's anti-interference capability.

[0033] Furthermore, the balance arm 201 is a permanent magnet; the attraction force of the balance arm 201 on the magnetic conductor 151 is less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. This solves the technical problem of unstable force exerted by the balance arm 201 on the magnetic conductor 151, which may lead to inconsistent switch on / off thresholds and affect counting consistency. By making the balance arm 201 a permanent magnet, its attraction force on the magnetic conductor 151 is stable and controllable, and this attraction force is less than the attraction force of the magnet 104 through the magnetic conductor 151, ensuring a fixed switch on / off threshold, good counting consistency, and improved encoder measurement stability. Especially in the detection of the rotational position of a turntable in precision instruments, where high counting consistency is required, the encoder's balance arm 201, being a permanent magnet, has a stable attraction force on the magnetic conductor. Only when the turntable drives the magnet 104 to rotate to a specific position does the superimposed attraction force cause the contacts to make contact, ensuring consistent counting conditions each time, accurately detecting the turntable's rotational position, and guaranteeing the operational accuracy of precision instruments.

[0034] Furthermore, the balance arm 201 is a permanent magnet; and the spring force is greater than the attraction force of the balance arm 201 on the magnetic conductor 151, but less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. This solves the technical problem that improper matching between the spring force and the attraction force of the balance arm 201 may lead to untimely reset or malfunction of the balance arm 201. By precisely setting the spring force to be greater than the attraction force of the balance arm 201 itself and less than the attraction force of the magnet 104 through the magnetic conductor, it is ensured that when there is no magnet 104 attraction, the spring can overcome the attraction force of the balance arm 201 to reset it, and when there is magnet 104 attraction, the contacts can reliably make contact, further optimizing the switching performance and improving the counting reliability.

[0035] Furthermore, the magnet 104 is a neodymium magnet. This solves the technical problem that insufficient magnetism of magnet 104 may lead to insufficient attraction force to the balance arm 201, resulting in unreliable switching. Neodymium magnets are preferred because their strong magnetism provides sufficient attraction force to ensure reliable attraction to the balance arm 201, ensuring contact and reliable switching, and improving the encoder's adaptability under different operating conditions. For example, in motor speed detection under high-temperature environments, the magnetism of ordinary magnets may weaken due to temperature, while neodymium magnets, with their strong magnetism and good high-temperature resistance, can still provide sufficient attraction force to reliably switch on and off, ensuring the encoder operates normally under high-temperature conditions and accurately detects motor speed.

[0036] It should be noted that neodymium magnets, also known as neodymium iron boron magnets (NdFeB magnets), are tetragonal crystals formed by neodymium, iron, and boron (Nd2Fe14B).

[0037] This application addresses applications requiring fewer than two revolutions for encoder counting, where the encoder detects more than one revolution, necessitating multi-revolution counting functionality. Addressing the shortcomings of current multi-revolution counting methods, this invention uses magnetic induction to trigger the opening and closing of a mechanical switch 105 without requiring a power supply. This calibrates different revolution counts, and upon power-up, the encoder's current multi-revolution position is determined by detecting the open / closed state of the mechanical switch 105. This achieves reliable revolution counting without adding mechanical structures or requiring battery power. It eliminates bulky gear meshing structures or complex power supply systems, ensuring stability and reliability.

[0038] Through a special design of the magnet 104 and the mechanical switch 105, when the magnet 104 follows the encoder moving plate 103 clockwise and passes the mechanical switch 105, the mechanical switch 105 enters a state (open or closed). When the magnet 104 follows the encoder moving plate 103 counterclockwise and passes the mechanical switch 105, the mechanical switch 105 enters the opposite state. Regardless of the movement of the magnet 104 or the number of times it passes the mechanical switch 105, each time the magnet 104 passes the mechanical switch 105, the mechanical switch 105 will be in a known, definite state. When the encoder is powered on again, by detecting the open / closed state of the mechanical switch 105, the position of the magnet 104 of the encoder moving plate 103—whether it is on the clockwise or counterclockwise side of the mechanical switch 105—can be determined. The number of revolutions is then calculated using appropriate software, thus achieving multi-revolution functionality. Because the mechanical encoder only has two states, this invention is only suitable for multi-revolution counting applications with fewer than two revolutions.

[0039] It should be noted that, in practical applications, the magnetic field strength of the aforementioned magnet 104 is determined according to the design, the distance, and the design of the mechanical switch 105. The aforementioned magnet 104 includes, but is not limited to, circular magnets. For example... Figs. 3 to 5 As shown, the N pole of magnet 104 can be used to attract the S pole of balance arm 201. Alternatively, the magnetic poles of the two can be reversed, that is, the S pole of magnet 104 can be used to attract the N pole of balance arm 201.

[0040] For example, a battery-free multi-turn encoder includes an encoder body 1, which has a moving disk 103, a stationary disk 102, and a rotating shaft 101 that drives the moving disk 103 to rotate. It also includes a magnet 104 and a mechanical switch 105. The magnet 104 is a neodymium magnet, which is fixedly mounted on the moving disk 103 and rotates synchronously with the moving disk 103. The mechanical switch 105 is fixedly mounted on the stationary disk 102 and is configured correspondingly to the magnet 104.

[0041] The mechanical switch 105 includes a balance arm 201, a balance fulcrum 202, and a magnetic conductor 151. The balance arm 201 can rotate around the balance fulcrum 202. One end of the balance arm 201 is provided with a first switch contact 203. The magnetic conductor 151 opposite to the first switch contact 203 is provided with a second switch contact 152. The rotation trajectory of the magnet 104 overlaps with the projection of the magnetic conductor 151. The first switch contact 203 and the second switch contact 152 are electrically connected by leads for transmitting the switch on / off signal to an external counting circuit.

[0042] A spring is provided between the balance fulcrum 202 and the balance arm 201. The spring force is weaker than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. When the rotating shaft 101 drives the rotating disk 103 and the magnet 104 to rotate, when the magnet 104 rotates to the area overlapping with the projection of the magnetic conductor 151, the magnet 104 generates an attraction force on the balance arm 201 through the magnetic conductor 151. This attraction force overcomes the spring force, causing the balance arm 201 to rotate around the balance fulcrum 202. The first switch contact 203 contacts the second switch contact 152, the switch closes, and the external counting circuit receives the closing signal, completing one count. When the magnet 104 rotates away from the overlapping area, the attraction force disappears, the spring force causes the balance arm 201 to reset, the first switch contact 203 separates from the second switch contact 152, the switch opens, and it waits for the next count.

[0043] In some embodiments of this application, the difference is that, as in the example above, the balance fulcrum seat 202 is provided with a first engaging member, and the magnetic conductor 151 is provided with a second engaging member. The first engaging member and the second engaging member are matched, and the engaging force between them is less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151.

[0044] When the magnet 104 is not rotated to the overlapping area, the first engaging member engages with the second engaging member, keeping the first switch contact 203 and the second switch contact 152 separated; when the magnet 104 rotates to the overlapping area, the attraction force overcomes the engaging force, the balance arm 201 rotates, and the contacts make contact to achieve counting; after the magnet 104 leaves, the engaging member resets, and the contacts separate.

[0045] In some embodiments of this application, the balance arm 201 is a permanent magnet, and the attraction force of the balance arm 201 on the magnetic conductor 151 is less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. When there is no magnet 104 adsorption, the attraction force of the balance arm 201 itself on the magnetic conductor 151 is small and insufficient to make the contacts make contact; when the magnet 104 rotates to the overlapping area, the superimposed attraction force makes the balance arm 201 rotate, and the contact count is counted; after the magnet 104 leaves, the attraction force of the balance arm 201 itself cannot maintain the contact, and it resets under its own gravity or a slight external force.

[0046] In some embodiments of this application, the balance arm 201 is a permanent magnet, and a spring is provided between the balance fulcrum seat 202 and the balance arm 201. The spring force is greater than the attraction force of the balance arm 201 relative to the magnetic conductor 151, but less than the attraction force of the magnet 104 on the balance arm 201 through the magnetic conductor 151. When there is no magnet 104 adsorption, the spring force overcomes the attraction force of the balance arm 201 itself, causing the contacts to separate; when the magnet 104 rotates to the overlapping area, the attraction force overcomes the spring force, and the contact count is completed; after the magnet 104 leaves, the spring force causes the balance arm 201 to reset, and the contacts separate.

[0047] The advantages of this application include the ability to achieve multi-turn counting without battery power or additional mechanical structures, greatly simplifying system design. It offers high reliability, as the combination of magnetic transmission and mechanical switches reliably records multi-turn counts even after power loss. It is also cost-effective, eliminating the need for complex gear designs, cumbersome battery power systems, and expensive sensors.

[0048] It should be noted that the aforementioned magnetic conductor 151 can also be replaced by a metal capable of attracting magnets; the aforementioned magnet can also be implemented using an electromagnet composed of a coil and a magnetic core. While the structure of an electromagnet is more complex, the principle of encoding via magnetic attraction remains the same. All metals capable of attracting magnets are "magnetic conductors," but not all "magnetic conductors" are strongly attracted by magnets. In this application, a magnetic conductor refers to an object capable of effectively conducting magnetic force. Furthermore, the aforementioned first and second switch contacts are electrically connected by leads. One end of the lead is welded to the first and second switch contacts respectively or connected via a terminal, while the other end is connected to the signal input terminal of an external counting circuit. When the contacts are in contact, a circuit is formed, and the counting circuit receives a high-level (or low-level) signal to perform counting. When the contacts separate, the circuit is broken, and the counting circuit receives an opposite level signal. Since the connection of the contact lines is a conventional technique in this field, it will not be described in detail. The aforementioned magnetic conductor can be made of materials with good magnetic conductivity, such as electrical pure iron or silicon steel sheets, to ensure that the magnetic field of the magnet is effectively transmitted to the balance arm, making the attraction force reliable. Those skilled in the art can select appropriate materials according to actual needs. To prevent excessive rotation of the balance arm, which could damage components or cause unreliable contact, limiting structures, such as limit blocks or limit grooves, can be installed on the balance fulcrum or stationary plate to restrict the maximum rotation angle of the balance arm. This ensures that the balance arm rotates within a reasonable range, improving the encoder's lifespan and reliability. Since these limiting structures are standard features, they will not be detailed here.

[0049] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention.

[0050] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0051] The present invention provides a detailed description of a battery-free multi-turn encoder. Specific examples have been used to illustrate the principle and implementation of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A battery-free multi-turn encoder, characterized in that, include: The encoder body (1) includes a moving disk (103), a stationary disk (102), and a rotating shaft (101) that drives the moving disk (103) to rotate; it also includes: A magnet (104) is fixedly mounted on the moving disk (103) and rotates synchronously with the moving disk (103). The magnet (104) is a permanent magnet. A mechanical switch 105 (105) is fixedly installed on the stationary plate (102) and is arranged correspondingly to the magnet (104); The mechanical (105) switch includes a balance arm (201), a balance fulcrum seat (202), and a magnetic conductor (151). The balance arm (201) can rotate around the balance fulcrum seat (202), and one end of the balance arm (201) is provided with a first switch contact (203); the magnetic conductor (151) opposite to the first switch contact (203) is provided with a second switch contact (152). Furthermore, the rotation trajectory of the magnet (104) overlaps with the projection of the magnetic conductor (151); The first switch contact (203) and the second switch contact (152) are electrically connected by leads.

2. The multi-turn encoder according to claim 1, characterized in that, A spring is also provided between the balance fulcrum seat (202) and the balance arm (201), wherein the elastic force of the spring is weaker than the attraction force of the magnet (104) on the balance arm (201) through the magnetic conductor (151).

3. The multi-turn encoder according to claim 1, characterized in that, The balance fulcrum seat (202) is provided with a first engaging component; The magnetic conductor (151) is also provided with a second engaging component; The first engaging component matches the second engaging component, and the engaging force between the two is less than the attraction force of the magnet (104) on the balance arm (201) through the magnetic conductor (151).

4. The multi-turn encoder according to claim 1, characterized in that, The balance arm (201) is a permanent magnet; The attraction force of the balance arm (201) to the magnetic conductor (151) is less than the attraction force of the magnet (104) to the balance arm (201) through the magnetic conductor (151).

5. The multi-turn encoder according to claim 2, characterized in that, The balance arm (201) is a permanent magnet; and the elastic force of the spring is greater than the attraction force of the balance arm (201) on the magnetic conductor (151), and less than the attraction force of the magnet (104) on the balance arm (201) through the magnetic conductor (151).

6. The multi-turn encoder according to claim 1, characterized in that, The magnet (104) is a neodymium magnet.

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