A circuit and device for detecting open circuits based on incremental encoders, and an incremental encoder.

Abstract

This utility model relates to the field of encoder technology, and more particularly to a wire breakage detection circuit, device, and incremental encoder based on an incremental encoder. The circuit includes a voltage detection unit and a microcontroller. The voltage detection unit is connected to a first signal line, a second signal line, and the microcontroller. The first signal line is connected to the first input terminal of a 485 interface chip and the incremental encoder, and the second signal line is connected to the second input terminal of the 485 interface chip and the incremental encoder. The voltage detection unit detects the signal line voltages of the first and second signal lines and outputs a corresponding voltage signal to the microcontroller based on the signal line voltages. The microcontroller determines whether a wire breakage fault has occurred in the incremental encoder's signal line based on the voltage signal. This utility model, by monitoring the signal line voltage in real time, can promptly detect wire breakage faults, avoiding encoder signal loss or abnormalities caused by signal line breakage, and ensuring the stability and reliability of equipment operation.

Description

Technical Field

[0001] This utility model relates to the field of encoder technology, and in particular to a wire breakage detection circuit, device and incremental encoder based on an incremental encoder. Background Technology

[0002] Incremental encoders are displacement measurement devices widely used in industrial automation, robotics, CNC machine tools, and other fields. Their working principle involves converting mechanical displacement into periodic electrical signals, then converting these signals into counting pulses, thereby representing the magnitude of the displacement by the number of pulses.

[0003] However, unlike absolute encoders, incremental encoders lack built-in communication verification functions. This means that when an encoder signal line breaks, the incremental encoder cannot actively detect the fault, and the software will not report the corresponding error code. This situation may lead to serious problems such as unreliable signal transmission and equipment malfunction during operation, thereby affecting production safety and increasing the difficulty of troubleshooting and maintenance costs. Utility Model Content

[0004] The main purpose of this utility model is to provide a disconnection detection circuit, device and incremental encoder based on an incremental encoder, which aims to solve the technical problem that the current incremental encoder lacks a disconnection detection function and cannot actively alarm when the signal line is broken, which may lead to equipment loss of control and increased operation and maintenance costs.

[0005] To achieve the above objectives, this utility model provides a wire breakage detection circuit based on an incremental encoder, the circuit comprising: a voltage detection unit and a microcontroller;

[0006] The voltage detection unit is connected to the first signal line, the second signal line and the microcontroller respectively. The first signal line is connected to the first input terminal of the 485 interface chip and the incremental encoder. The second signal line is connected to the second input terminal of the 485 interface chip and the incremental encoder. A matching resistor is connected in series between the first signal line and the second signal line. The first signal line is also connected to the power supply through a pull-up resistor. The second signal line is also grounded through a pull-down resistor.

[0007] The voltage detection unit is used to detect the signal line voltages of the first signal line and the second signal line, and output a corresponding voltage signal to the microcontroller based on the signal line voltages;

[0008] The microcontroller is used to determine whether the signal line of the incremental encoder has a broken wire fault based on the voltage signal.

[0009] Optionally, the step of outputting a corresponding voltage signal to the microcontroller based on the signal line voltage includes:

[0010] When the signal line voltages of the first signal line and the second signal line are simultaneously less than a first preset voltage value or simultaneously greater than a second preset voltage value, a low-level voltage signal is output to the microcontroller, wherein the first preset voltage value is less than the second preset voltage value;

[0011] When the voltage difference between the first signal line and the second signal line is greater than a first preset voltage difference, a high-level voltage signal is output to the microcontroller.

[0012] Accordingly, the microcontroller is also configured to determine, upon receiving the low-level voltage signal, that a signal line of the incremental encoder has experienced a breakage fault.

[0013] Upon receiving the high-level voltage signal, it is determined that the signal line connection of the incremental encoder is normal.

[0014] Optionally, the voltage detection unit includes: an XOR gate chip;

[0015] The first input terminal of the XOR gate chip is connected to the first signal line, the second input terminal of the XOR gate chip is connected to the second signal line, and the output terminal of the XOR gate chip is connected to the microcontroller.

[0016] Optionally, the circuit further includes: a voltage divider unit and a filter unit;

[0017] The voltage divider unit and the filter unit are connected in series between the XOR gate chip and the microcontroller.

[0018] The voltage divider unit is used to divide the voltage signal output by the XOR gate chip and output the divided voltage signal to the filter unit.

[0019] The filtering unit is used to filter the voltage signal after voltage division and output the filtered voltage signal to the microcontroller.

[0020] The microcontroller is also used to determine whether the signal line of the incremental encoder has a broken wire fault based on the filtered voltage signal.

[0021] Optionally, the voltage divider unit includes: a voltage divider resistor;

[0022] The first end of the voltage divider resistor is connected to the output of the XOR gate chip, and the second end of the voltage divider resistor is connected to the microcontroller through the filter unit.

[0023] Optionally, the filtering unit includes: a filtering capacitor;

[0024] The first end of the filter capacitor is connected to the second end of the voltage divider resistor and the microcontroller, respectively, and the second end of the filter capacitor is grounded.

[0025] Optionally, the voltage detection unit is further configured to output a second low-level voltage signal to the microcontroller when the signal line voltages of the first signal line and the second signal line are simultaneously greater than a third preset voltage value and less than the second preset voltage value, and the difference between the signal line voltages of the first signal line and the second signal line is less than the second preset voltage difference.

[0026] Accordingly, the microcontroller is also configured to determine that the signal line of the incremental encoder is not connected when it receives the second low-level voltage signal.

[0027] In addition, to achieve the above objectives, this utility model also proposes a wire breakage detection device based on an incremental encoder, which includes the wire breakage detection circuit based on an incremental encoder described above.

[0028] In addition, to achieve the above objectives, this utility model also proposes an incremental encoder, which includes the wire breakage detection circuit based on the incremental encoder described above.

[0029] In this invention, the open circuit detection circuit based on an incremental encoder includes a voltage detection unit and a microcontroller. The voltage detection unit is connected to a first signal line, a second signal line, and the microcontroller. The first signal line connects to the first input terminal of a 485 interface chip and the incremental encoder, and the second signal line connects to the second input terminal of the 485 interface chip and the incremental encoder. The voltage detection unit detects the signal line voltages of the first and second signal lines and outputs a corresponding voltage signal to the microcontroller based on the signal line voltages. The microcontroller determines whether an open circuit fault has occurred in the signal line of the incremental encoder based on the voltage signal. This invention, by monitoring the signal line voltage in real time, can promptly detect open circuit faults, avoiding encoder signal loss or abnormalities caused by open circuits, and ensuring the stability and reliability of equipment operation. Compared to the shortcomings of traditional incremental encoders that lack open circuit detection functionality, this circuit can actively detect open circuit faults and output a fault signal through the microcontroller, facilitating rapid problem location and simplifying the troubleshooting process. Furthermore, by promptly detecting and alarming open circuit faults, it can reduce downtime and maintenance costs caused by signal problems, while avoiding serious consequences such as equipment malfunction due to unreliable signals. Attached Figure Description

[0030] Figure 1This is a schematic diagram of the first embodiment of the open circuit detection circuit based on an incremental encoder of this utility model;

[0031] Figure 2 This is a circuit diagram of an embodiment of the open circuit detection circuit based on an incremental encoder of this utility model.

[0032] Explanation of icon numbers:

[0033]

[0034] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0035] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0036] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0037] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0038] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application.

[0039] This utility model embodiment provides a wire breakage detection circuit based on an incremental encoder, referring to... Figure 1 As shown, Figure 1 This is a structural block diagram of the first embodiment of the open circuit detection circuit based on an incremental encoder of this utility model. The open circuit detection circuit based on an incremental encoder of this utility model includes: a voltage detection unit 10 and a microcontroller 20;

[0040] The voltage detection unit 10 is connected to the first signal line, the second signal line and the microcontroller 20 respectively. The first signal line is connected to the first input terminal of the 485 interface chip and the incremental encoder. The second signal line is connected to the second input terminal of the 485 interface chip and the incremental encoder. A matching resistor R1 is connected in series between the first signal line and the second signal line. The first signal line is also connected to the power supply through a pull-up resistor R2. The second signal line is also grounded through a pull-down resistor R3.

[0041] The voltage detection unit 10 is used to detect the signal line voltage of the first signal line and the second signal line, and output a corresponding voltage signal to the microcontroller 20 according to the signal line voltage;

[0042] The microcontroller 20 is used to determine whether the signal line of the incremental encoder has a broken wire fault based on the voltage signal.

[0043] It should be noted that the voltage detection unit 10 is used to detect the voltage status of the first and second signal lines in real time. Based on the detected signal line voltage, it outputs the corresponding voltage signal to the microcontroller 20, providing data support for fault diagnosis. The microcontroller 20 receives the voltage signal output by the voltage detection unit 10, determines whether a fault has occurred in the signal line of the incremental encoder, and outputs the corresponding fault signal or alarm information. The first signal line connects the first input terminal of the 485 interface chip and the incremental encoder, and is used to transmit the A+ signal of the incremental encoder. It is connected to the power supply through a pull-up resistor R2 to ensure that the signal line remains at a high level when there is no signal. The second signal line connects the second input terminal of the 485 interface chip and the incremental encoder, and is used to transmit the A- signal of the incremental encoder. It is grounded through a pull-down resistor R3 to ensure that the signal line remains at a low level when there is no signal.

[0044] A matching resistor R1 is connected in series between the first and second signal lines to match the impedance of the signal lines, reduce signal reflection and interference, and improve the stability of signal transmission. A pull-up resistor R2 is connected between the first signal line and the power supply to pull the signal line high when there is no signal, ensuring the default state of the signal line is high. A pull-down resistor R3 is connected between the second signal line and ground to pull the signal line low when there is no signal, ensuring the default state of the signal line is low. The 485 interface chip converts the differential signal from the incremental encoder into a single-ended signal that can be processed by the microcontroller 20, while providing electrical isolation and anti-interference capabilities to ensure the reliability of signal transmission.

[0045] It should be understood that the voltage detection unit 10 can be a high-precision voltage comparator or ADC chip, such as LM393 or ADS1115, used to detect the voltage of the first and second signal lines. The microcontroller 20 can be a common MCU, such as STM32 or ESP32, used to process the signals from the voltage detection unit 10 and determine open-circuit faults. The RS485 interface chip can be a standard RS485 transceiver chip, such as MAX485 or SN75176, used to receive the differential signals from the incremental encoder. The matching resistor R1 can be a 120Ω resistor, connected in series between the first and second signal lines for impedance matching. The pull-up resistor R2 can be a 10kΩ resistor, connected between the first signal line and the power supply. The pull-down resistor R3 can be a 10kΩ resistor, connected between the second signal line and ground.

[0046] In one embodiment, the voltage detection unit 10 detects the voltage of the first and second signal lines in real time. When the signal lines are normally connected, the voltages of the A+ and A- signal lines are one high and one low, and the voltage detection unit 10 outputs the corresponding voltage signal. When the signal lines are disconnected, the voltages of the A+ and A- signal lines are simultaneously high or low, and the voltage detection unit 10 outputs an abnormal voltage signal. The microcontroller 20 reads the output signal of the voltage detection unit 10 through the ADC pin. If the voltage signal is high, the signal line connection is normal. If the voltage signal is low, a signal line disconnection fault has occurred. When a disconnection fault is detected, the microcontroller 20 outputs a fault signal or alarm information through UART, GPIO, or other interfaces. The software system promptly reports an error code based on the fault signal to remind maintenance personnel to handle the issue.

[0047] Specifically, the step of outputting a corresponding voltage signal to the microcontroller 20 based on the signal line voltage includes:

[0048] When the signal line voltages of the first signal line and the second signal line are simultaneously less than a first preset voltage value or simultaneously greater than a second preset voltage value, a low-level voltage signal is output to the microcontroller 20, wherein the first preset voltage value is less than the second preset voltage value;

[0049] When the voltage difference between the first signal line and the second signal line is greater than a first preset voltage difference, a high-level voltage signal is output to the microcontroller 20.

[0050] Accordingly, the microcontroller 20 is also configured to determine, upon receiving the low-level voltage signal, that a signal line of the incremental encoder has experienced a breakage fault.

[0051] Upon receiving the high-level voltage signal, it is determined that the signal line connection of the incremental encoder is normal.

[0052] It should be noted that, taking a 120-ohm matching resistor R1, a 10K-ohm pull-up resistor R2, a 10K-ohm pull-down resistor R3, and a 5V power supply as an example, voltage division calculations show that when the first signal line is disconnected and the second signal line is connected, the voltages of both the first and second signal lines will be simultaneously below 0.3V or simultaneously above 4.5V. Therefore, a first preset voltage value of 0.3V and a second preset voltage value of 4.5V can be set. When the voltages of both the first and second signal lines are simultaneously less than the first preset voltage value or simultaneously greater than the second preset voltage value, the voltage detection unit 10 outputs a low-level voltage signal, such as 0V. This indicates an abnormal voltage state of the signal lines, possibly due to a disconnected signal line or an encoder malfunction.

[0053] When the voltage difference between the first signal line and the second signal line is greater than the first preset voltage difference, such as 1.0V, it indicates that the voltages of the first signal line and the second signal line are different. At this time, the voltage detection unit 10 outputs a high-level voltage signal, such as 3.3V. This situation indicates that the voltage status of the signal line is normal, the incremental encoder is working normally, and the signal line connection is reliable.

[0054] Among them, reference Figure 2 The voltage detection unit 10 includes: an XOR gate chip U1;

[0055] The first input terminal A of the XOR gate chip U1 is connected to the first signal line, the second input terminal B of the XOR gate chip U1 is connected to the second signal line, and the output terminal Y of the XOR gate chip U1 is connected to the microcontroller 20.

[0056] It should be understood that when the incremental encoder is working normally, the voltage states of the first signal line (A+) and the second signal line (A-) are one high and one low, for example, A+ is high and A- is low. The two inputs of the XOR gate chip U1 have different logic levels, resulting in an output of "1" (high level). When the microcontroller 20 receives a high-level signal, it determines that the signal line connection is normal. When the signal line is broken, the voltage states of the first signal line (A+) and the second signal line (A-) are simultaneously high or simultaneously low. The two inputs of the XOR gate chip U1 have the same logic level, resulting in an output of "0" (low level). When the microcontroller 20 receives a low-level signal, it determines that a signal line breakage has occurred.

[0057] Furthermore, the voltage detection unit 10 is also used to output a second low-level voltage signal to the microcontroller 20 when the signal line voltages of the first signal line and the second signal line are simultaneously greater than a third preset voltage value and less than the second preset voltage value, and the difference between the signal line voltages of the first signal line and the second signal line is less than the second preset voltage difference.

[0058] Accordingly, the microcontroller 20 is also configured to determine that the signal line of the incremental encoder is not connected when it receives the second low-level voltage signal.

[0059] It should be noted that, taking a matching resistor R1 of 120 ohms, a pull-up resistor R2 of 10K ohms, a pull-down resistor R3 of 10K ohms, and a power supply of 5V as an example, it can be seen from the voltage division calculation that when the signal line of the incremental encoder is not connected, the voltages of the first signal line and the second signal line are 2.51V and 2.49V respectively, both of which are determined to be high-level inputs. At this time, the voltage detection unit 10 outputs a second low-level signal to the microcontroller 20. When the microcontroller 20 receives the second low-level voltage signal, it determines that the signal line of the incremental encoder is not connected.

[0060] Furthermore, referring to Figure 2 The circuit further includes a voltage divider unit 30 and a filter unit 40;

[0061] The voltage divider unit 30 and the filter unit 40 are connected in series between the XOR gate chip U1 and the microcontroller 20.

[0062] The voltage divider unit 30 is used to divide the voltage signal output by the XOR gate chip U1 and output the divided voltage signal to the filter unit 40.

[0063] The filtering unit 40 is used to filter the voltage signal after voltage division and output the filtered voltage signal to the microcontroller 20;

[0064] The microcontroller 20 is also used to determine whether the signal line of the incremental encoder has a broken wire fault based on the filtered voltage signal.

[0065] Understandably, the voltage divider unit 30 and the filter unit 40 are connected in series between the XOR gate chip U1 and the microcontroller 20 to process the voltage signal output by the XOR gate chip U1, ensuring that the microcontroller 20 can accurately determine whether a break in the signal line of the incremental encoder has occurred. The voltage divider unit 30 is used to divide the voltage signal output by the XOR gate chip U1, reducing the high voltage signal to a range suitable for the microcontroller 20 to receive. The filter unit 40 is used to filter the divided voltage signal, removing noise and interference from the signal.

[0066] The voltage divider unit 30 includes a voltage divider resistor R4; the first end of the voltage divider resistor R4 is connected to the output terminal Y of the XOR gate chip U1, and the second end of the voltage divider resistor R4 is connected to the microcontroller 20 through the filter unit 40. The filter unit 40 includes a filter capacitor C1; the first end of the filter capacitor C1 is connected to both the second end of the voltage divider resistor R4 and the microcontroller 20, and the second end of the filter capacitor C1 is grounded.

[0067] Furthermore, to achieve the above objectives, this utility model also proposes a wire breakage detection device based on an incremental encoder, which includes the wire breakage detection circuit based on an incremental encoder described above. The specific structure of this wire breakage detection circuit based on an incremental encoder is as described in the above embodiments. Since this wire breakage detection device based on an incremental encoder adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, and will not be elaborated further here.

[0068] Furthermore, to achieve the above objectives, this utility model also proposes an incremental encoder, which includes the wire breakage detection circuit based on the incremental encoder described above. The specific structure of this wire breakage detection circuit based on the incremental encoder is as described in the above embodiments. Since this incremental encoder adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, and will not be elaborated further here.

[0069] The above are merely preferred embodiments of this utility model and do not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A wire break detection circuit based on an incremental encoder, characterized in that, The circuit includes: a voltage detection unit and a microcontroller; The voltage detection unit is connected to the first signal line, the second signal line and the microcontroller respectively. The first signal line is connected to the first input terminal of the 485 interface chip and the incremental encoder. The second signal line is connected to the second input terminal of the 485 interface chip and the incremental encoder. A matching resistor is connected in series between the first signal line and the second signal line. The first signal line is also connected to the power supply through a pull-up resistor. The second signal line is also grounded through a pull-down resistor. The voltage detection unit is used to detect the signal line voltages of the first signal line and the second signal line, and output a corresponding voltage signal to the microcontroller based on the signal line voltages; The microcontroller is used to determine whether the signal line of the incremental encoder has a broken wire fault based on the voltage signal.

2. The open circuit detection circuit based on an incremental encoder as described in claim 1, characterized in that, The step of outputting a corresponding voltage signal to the microcontroller based on the signal line voltage includes: When the signal line voltages of the first signal line and the second signal line are simultaneously less than a first preset voltage value or simultaneously greater than a second preset voltage value, a low-level voltage signal is output to the microcontroller, wherein the first preset voltage value is less than the second preset voltage value; When the voltage difference between the first signal line and the second signal line is greater than a first preset voltage difference, a high-level voltage signal is output to the microcontroller. Accordingly, the microcontroller is also configured to determine, upon receiving the low-level voltage signal, that a signal line of the incremental encoder has experienced a breakage fault. Upon receiving the high-level voltage signal, it is determined that the signal line connection of the incremental encoder is normal.

3. The open circuit detection circuit based on an incremental encoder as described in claim 2, characterized in that, The voltage detection unit includes: an XOR gate chip; The first input terminal of the XOR gate chip is connected to the first signal line, the second input terminal of the XOR gate chip is connected to the second signal line, and the output terminal of the XOR gate chip is connected to the microcontroller.

4. The open circuit detection circuit based on an incremental encoder as described in claim 3, characterized in that, The circuit also includes: a voltage divider unit and a filter unit; The voltage divider unit and the filter unit are connected in series between the XOR gate chip and the microcontroller. The voltage divider unit is used to divide the voltage signal output by the XOR gate chip and output the divided voltage signal to the filter unit. The filtering unit is used to filter the voltage signal after voltage division and output the filtered voltage signal to the microcontroller. The microcontroller is also used to determine whether the signal line of the incremental encoder has a broken wire fault based on the filtered voltage signal.

5. The open circuit detection circuit based on an incremental encoder as described in claim 4, characterized in that, The voltage divider unit includes: a voltage divider resistor; The first end of the voltage divider resistor is connected to the output of the XOR gate chip, and the second end of the voltage divider resistor is connected to the microcontroller through the filter unit.

6. The open circuit detection circuit based on an incremental encoder as described in claim 5, characterized in that, The filtering unit includes: a filtering capacitor; The first end of the filter capacitor is connected to the second end of the voltage divider resistor and the microcontroller, respectively, and the second end of the filter capacitor is grounded.

7. The open circuit detection circuit based on an incremental encoder as described in claim 2, characterized in that, The voltage detection unit is further configured to output a second low-level voltage signal to the microcontroller when the signal line voltages of the first signal line and the second signal line are simultaneously greater than a third preset voltage value and less than the second preset voltage value, and the difference between the signal line voltages of the first signal line and the second signal line is less than the second preset voltage difference. Accordingly, the microcontroller is also configured to determine that the signal line of the incremental encoder is not connected when it receives the second low-level voltage signal.

8. A wire breakage detection device based on an incremental encoder, characterized in that, The wire breakage detection device based on an incremental encoder includes the wire breakage detection circuit based on an incremental encoder as described in any one of claims 1 to 7.

9. An incremental encoder, characterized in that, The incremental encoder includes the open circuit based on the incremental encoder as described in any one of claims 1 to 7.

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