Limit switch detection system
The limit switch detection system controlled by a microprocessor enables automated detection of limit switches, solving the problems of low detection efficiency and insufficient accuracy, improving detection efficiency and accuracy, and ensuring production quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGZHOU YILONG ELECTRONICS TECH CO LTD
- Filing Date
- 2025-07-07
- Publication Date
- 2026-08-04
AI Technical Summary
In the existing technology, the detection efficiency of limit switches is low and the accuracy is insufficient. Manual operation leads to generally unreliable detection results, which affects production quality.
The limit switch detection system, which is controlled by a microprocessor, includes a left-hand drive component, a right-hand drive component, a left-hand position sensor, a right-hand position sensor, and a signal acquisition circuit. It realizes the automated detection of limit switches. The microprocessor coordinates the operation of each component, and the position sensor provides real-time feedback of the angle position, while the signal acquisition circuit synchronously detects the electrical performance.
It significantly improves the detection efficiency and accuracy of limit switches, avoids human error, and improves production quality.
Smart Images
Figure CN224594781U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automation technology, and in particular to a limit switch detection system. Background Technology
[0002] A limit switch is an electrical component used to detect the position or travel of mechanical equipment. When the moving part reaches a preset position, it triggers a signal through mechanical contact or non-contact methods, thereby controlling the equipment to stop, reverse direction, or provide status feedback. Limit switches are widely used in industrial automation, elevators, machine tools, and other fields, providing safety protection and precise positioning for equipment operation. Rotary limit switches are specifically designed to detect the angular position of rotational movements, such as valve opening and closing, robotic arm rotation, or angle control of rotary platforms. They can trigger internal contacts through a rotating shaft or cam mechanism, generating corresponding electrical signals when the switch is connected to a circuit, making them suitable for applications requiring precise angle monitoring and control.
[0003] In related technologies, the performance of limit switches in production needs to be tested to determine the production quality. For rotary limit switches, manual operation is required to rotate them to the corresponding positions and test their mechanical and electrical performance one by one. This testing method is inefficient, and the accuracy of manual operation may be insufficient, resulting in generally unreliable test results, which can easily affect the production quality of limit switches.
[0004] In summary, the problems existing in the relevant technologies urgently need to be solved. Utility Model Content
[0005] The purpose of this utility model is to at least partially solve one of the technical problems existing in the related technologies.
[0006] Therefore, one objective of this utility model is to provide a limit switch detection system.
[0007] To achieve the above-mentioned technical objectives, the technical solution adopted by this utility model includes:
[0008] On one hand, this utility model embodiment provides a limit switch detection system, including:
[0009] Microprocessor, left-hand drive assembly, right-hand drive assembly, left-hand position sensor, right-hand position sensor, and signal acquisition circuit;
[0010] The microprocessor is connected to the left-hand drive assembly, the right-hand drive assembly, the left-hand position sensor, and the right-hand position sensor. The left-hand drive assembly drives the limit switch to be detected to rotate to the left, and the right-hand drive assembly drives the limit switch to rotate to the right. The left-hand position sensor feeds back a first position signal to the microprocessor when the limit switch rotates to the left to a first specified angle, and the right-hand position sensor feeds back a second position signal to the microprocessor when the limit switch rotates to the right to a second specified angle.
[0011] The signal acquisition circuit is used to access the limit switch, and the signal acquisition circuit is connected to the microprocessor.
[0012] In addition, the limit switch detection system according to the above embodiments of the present invention may also have the following additional technical features:
[0013] Furthermore, in one embodiment of this utility model, the limit switch detection system further includes a power supply, which is used to supply power to the microprocessor, the left-hand drive component, the right-hand drive component, the left-hand position sensor, the right-hand position sensor, and the signal acquisition circuit.
[0014] Furthermore, in one embodiment of this utility model, the limit switch detection system further includes a host computer and a communication converter, wherein the host computer is connected to the microprocessor through the communication converter.
[0015] Furthermore, in one embodiment of this utility model, the communication converter is an RS232 communication converter.
[0016] Furthermore, in one embodiment of this utility model, the limit switch detection system further includes a camera device, which is used to collect video data of the left-hand drive component and the right-hand drive component driving the limit switch; the camera device is communicatively connected to the host computer.
[0017] Furthermore, in one embodiment of the present invention, the left-hand drive assembly includes a solenoid valve and a rotating device, the rotating device being connected to the microprocessor via the solenoid valve.
[0018] Furthermore, in one embodiment of this utility model, the rotating device is a rotary cylinder or a servo motor.
[0019] Furthermore, in one embodiment of this utility model, the limit switch includes a reference contact, a first contact, and a second contact, wherein the first contact corresponds to the first specified angle, and the second contact corresponds to the second specified angle;
[0020] The signal acquisition circuit includes a first acquisition circuit and a second acquisition circuit. The first acquisition circuit is connected to the reference contact and the first contact, and its output is connected to the microprocessor. The second acquisition circuit is connected to the reference contact and the second contact, and its output is connected to the microprocessor.
[0021] Furthermore, in one embodiment of this utility model, the first acquisition circuit includes an optocoupler, a first resistor, a second resistor, a third resistor, a fourth resistor, and a fifth resistor; the collector of the optocoupler is connected to the microprocessor, the anode of the optocoupler is connected to the power supply through the fifth resistor, the cathode of the optocoupler is connected to the reference contact, the second contact is grounded through the fourth resistor, the second contact is also connected to the first end of the third resistor, the second end of the third resistor is grounded through the second resistor, and the second end of the third resistor is also connected to the microprocessor through the first resistor.
[0022] Furthermore, in one embodiment of this utility model, the optocoupler is model PC817.
[0023] The advantages and beneficial effects of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this invention:
[0024] This application discloses a limit switch detection system, comprising: a microprocessor, a left-hand drive component, a right-hand drive component, a left-hand position sensor, a right-hand position sensor, and a signal acquisition circuit; the microprocessor is connected to the left-hand drive component, the right-hand drive component, the left-hand position sensor, and the right-hand position sensor; the left-hand drive component drives the limit switch to be detected to rotate to the left, and the right-hand drive component drives the limit switch to rotate to the right; the left-hand position sensor feeds back a first position signal to the microprocessor when the limit switch rotates to the left to a first specified angle, and the right-hand position sensor feeds back a second position signal to the microprocessor when the limit switch rotates to the right to a second specified angle; the signal acquisition circuit is connected to the limit switch and is also connected to the microprocessor. This application uses a microprocessor to control a left / right rotation drive component to automatically rotate the limit switch to be tested, combined with a position sensor to provide real-time feedback of the angle position, and a signal acquisition circuit to synchronously detect the electrical performance, thereby achieving fully automated testing of the limit switch. This application can significantly improve the testing efficiency and accuracy of the limit switch, avoid human operation errors, and help improve the production quality of the limit switch. Attached Figure Description
[0025] Figure 1This paper shows a schematic diagram of the structure of a limit switch detection system provided in an embodiment of this application;
[0026] Figure 2 A schematic diagram of the circuit principle of a first acquisition circuit provided in an embodiment of this application is shown. Detailed Implementation
[0027] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.
[0028] In the description of this utility model, it should be understood that the terms "length," "upper," "lower," "front," "rear," "left," "right," "top," "inner," "outer," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0029] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0030] A limit switch is an electrical component used to detect the position or travel of mechanical equipment. When the moving part reaches a preset position, it triggers a signal through mechanical contact or non-contact methods, thereby controlling the equipment to stop, reverse direction, or provide status feedback. Limit switches are widely used in industrial automation, elevators, machine tools, and other fields, providing safety protection and precise positioning for equipment operation. Rotary limit switches are specifically designed to detect the angular position of rotational movements, such as valve opening and closing, robotic arm rotation, or angle control of rotary platforms. They can trigger internal contacts through a rotating shaft or cam mechanism, generating corresponding electrical signals when the switch is connected to a circuit, making them suitable for applications requiring precise angle monitoring and control.
[0031] In related technologies, the performance of limit switches in production needs to be tested to determine the production quality. For rotary limit switches, manual operation is required to rotate them to the corresponding positions and test their mechanical and electrical performance one by one. This testing method is inefficient, and the accuracy of manual operation may be insufficient, resulting in generally unreliable test results, which can easily affect the production quality of limit switches.
[0032] In view of this, this application provides a limit switch detection system, including: a microprocessor, a left-hand drive component, a right-hand drive component, a left-hand position sensor, a right-hand position sensor, and a signal acquisition circuit; the microprocessor is connected to the left-hand drive component, the right-hand drive component, the left-hand position sensor, and the right-hand position sensor; the left-hand drive component is used to drive the limit switch to be detected to rotate to the left, and the right-hand drive component is used to drive the limit switch to rotate to the right; the left-hand position sensor is used to feed back a first position signal to the microprocessor when the limit switch rotates to the left to a first specified angle, and the right-hand position sensor is used to feed back a second position signal to the microprocessor when the limit switch rotates to the right to a second specified angle; the signal acquisition circuit is connected to the limit switch and is also connected to the microprocessor. This application uses a microprocessor to control a left / right rotation drive component to automatically rotate the limit switch to be tested, combined with a position sensor to provide real-time feedback of the angle position, and a signal acquisition circuit to synchronously detect the electrical performance, thereby achieving fully automated testing of the limit switch. This application can significantly improve the testing efficiency and accuracy of the limit switch, avoid human operation errors, and help improve the production quality of the limit switch.
[0033] The following is a detailed description of a limit switch detection system provided in the embodiments of this application, with reference to the specific accompanying drawings.
[0034] This application provides a limit switch detection system, specifically referring to... Figure 1The limit switch detection system provided in this application embodiment mainly includes:
[0035] Microprocessor, left-hand drive assembly, right-hand drive assembly, left-hand position sensor, right-hand position sensor, and signal acquisition circuit;
[0036] The microprocessor is connected to the left-hand drive assembly, the right-hand drive assembly, the left-hand position sensor, and the right-hand position sensor. The left-hand drive assembly drives the limit switch to be detected to rotate to the left, and the right-hand drive assembly drives the limit switch to rotate to the right. The left-hand position sensor feeds back a first position signal to the microprocessor when the limit switch rotates to the left to a first specified angle, and the right-hand position sensor feeds back a second position signal to the microprocessor when the limit switch rotates to the right to a second specified angle.
[0037] The signal acquisition circuit is used to access the limit switch, and the signal acquisition circuit is connected to the microprocessor.
[0038] The limit switch detection system provided in this embodiment mainly includes a microprocessor, a left-hand drive component, a right-hand drive component, a left-hand position sensor, a right-hand position sensor, and a signal acquisition circuit. The microprocessor, as the control core, coordinates the entire detection process and processes related data signals. The left-hand and right-hand drive components drive the limit switch to be detected to rotate to the left and right, respectively. The left-hand and right-hand position sensors employ high-precision position detection elements, feeding back a position signal to the microprocessor when the limit switch rotates to the corresponding specified angle. The signal acquisition circuit monitors the electrical parameters of the limit switch in real time at the corresponding rotational position when the limit switch rotates to the specified angle and transmits the acquired data to the microprocessor for analysis. These components work together to form a complete automated detection system, effectively improving the low efficiency and poor accuracy of traditional manual detection methods, thereby significantly enhancing the quality detection level of limit switches.
[0039] Specifically, the microprocessor in the limit switch detection system is responsible for coordinating the workflow of each component and processing sensor signals and data fed back from the signal acquisition circuit. Exemplarily, in some embodiments, the microprocessor may be an ARM Cortex-M series chip with multi-channel ADC and PWM output, or an STM series microcontroller chip; this application does not impose any limitations on this.
[0040] The left-hand and right-hand drive components constitute the mechanical actuators of the limit switch detection system. They can employ precision rotary cylinders or servo motors as the rotating devices, and incorporate solenoid valves. These rotating devices are connected to a microprocessor via the solenoid valves. Thus, the microprocessor can control the operating state of the rotating devices through the solenoid valves to drive the limit switch to rotate in the relevant direction, thereby achieving performance detection. Exemplarily, in some embodiments, overload protection circuits can also be included in the left-hand and right-hand drive components. When abnormal resistance is detected, operation is immediately stopped and an alarm is triggered to prevent damage to the limit switch under test.
[0041] In this embodiment, the left-hand and right-hand position sensors serve as position detection components and can be non-contact photoelectric sensors or high-precision Hall effect sensors. The left-hand position sensor is installed at a detection position at a first specified angle. When the limit switch rotates to this angle, the left-hand position sensor sends a position signal to the microprocessor via an interrupt, triggering the electrical performance test process. In this embodiment, this is recorded as the first position signal. It is understood that the specific first specified angle can be set according to the actual setting standard of the limit switch, and this application does not limit its size. Similarly, the right-hand position sensor adopts the same working principle as the left-hand position sensor. When it detects that the limit switch has rotated to the right to a second specified angle, it generates a corresponding second position signal. In this embodiment, the first and second position signals can serve as signals to trigger the measurement of the electrical performance of the limit switch. When the microprocessor receives the first or second position signal, it can acquire the corresponding circuit parameters of the limit switch through the signal acquisition circuit, thereby determining its electrical performance.
[0042] In this embodiment, the signal acquisition circuit is used to detect the circuit parameters corresponding to the limit switch when it rotates to different positions. It is understood that for a limit switch, there will be multiple contacts corresponding to different rotation angles. When rotated to a certain specified angle, the contacts of the limit switch will be connected to the circuit. The signal acquisition circuit can be equipped with corresponding acquisition channels, each channel can be used to acquire the circuit parameters corresponding to the limit switch at the corresponding contact. These circuit parameters can be voltage parameters or current parameters; this application does not impose any limitations on this.
[0043] In this embodiment of the application, in order to conveniently and efficiently detect each limit switch, quick-connect clamps can be used to connect the contacts of the limit switches to the signal acquisition circuit. After the current limit switch is measured, the next limit switch can be easily replaced for testing.
[0044] It is understood that the limit switch detection system provided in this application embodiment automatically rotates the limit switch to be detected by controlling the left / right rotation drive component through a microprocessor, combined with the real-time feedback of the angle position by the position sensor, and the electrical performance is detected synchronously by the signal acquisition circuit, so as to realize the fully automated detection of the limit switch. This application can significantly improve the detection efficiency and accuracy of the limit switch, avoid human operation errors, and help improve the production quality of the limit switch.
[0045] Specifically, in some embodiments, the limit switch detection system further includes a power supply for powering the microprocessor, the left-hand drive assembly, the right-hand drive assembly, the left-hand position sensor, the right-hand position sensor, and the signal acquisition circuit. This application does not limit the voltage level that the power supply can provide; for example, it may include 220V, 24V, or 12V, etc.
[0046] Specifically, in some embodiments, the limit switch detection system further includes a host computer and a communication converter, with the host computer connected to the microprocessor via the communication converter. The host computer can be a computer device, which can connect to the microprocessor and collect the measured detection data. The data can then be conveniently displayed and analyzed on the computer device. Furthermore, the host computer can effectively store detection data collected from multiple locations, facilitating subsequent data traceability. In this embodiment, the communication converter is used to realize communication transmission between the microprocessor and the host computer. In some embodiments, it can be an RS232 communication converter, but it is not limited to this.
[0047] Specifically, in some embodiments, the limit switch detection system further includes a camera device for acquiring video data of the left-hand drive component and the right-hand drive component driving the limit switch; the camera device is communicatively connected to the host computer. By setting up the camera device, video data of the left-hand drive component and the right-hand drive component during rotation can be acquired. This allows for verification of potential quality issues with the limit switch during subsequent analysis, particularly regarding whether a problem arose with the driving of the left-hand drive component or the right-hand drive component during the detection process. This facilitates accurate problem tracing and verification.
[0048] Specifically, in some embodiments, the limit switch includes a reference contact, a first contact, and a second contact, wherein the first contact corresponds to a first specified angle, and the second contact corresponds to a second specified angle;
[0049] The signal acquisition circuit includes a first acquisition circuit and a second acquisition circuit. The first acquisition circuit is connected to the reference contact and the first contact, and its output is connected to the microprocessor. The second acquisition circuit is connected to the reference contact and the second contact, and its output is connected to the microprocessor.
[0050] In this embodiment, the limit switch may include three contacts, denoted as a reference contact, a first contact, and a second contact. During use, the reference contact is connected to the circuit, while the first and second contacts are connected differently depending on the rotation of the limit switch. Specifically, when the limit switch rotates counterclockwise to a first specified angle, the first contact is connected to the circuit; when the limit switch rotates clockwise to a second specified angle, the second contact is connected to the circuit.
[0051] The signal acquisition circuit can include a first acquisition circuit and a second acquisition circuit. The first acquisition circuit can be connected to a reference contact and a first contact, and the second acquisition circuit can be connected to both the reference contact and a second contact. The outputs of both acquisition circuits are connected to a microprocessor. Thus, when testing the circuit parameters of the limit switch when it is rotated counterclockwise to a first specified angle, data detection and transmission can be achieved through the first acquisition circuit; when testing the circuit parameters of the limit switch when it is rotated clockwise to a second specified angle, data detection and transmission can be achieved through the second acquisition circuit.
[0052] For example, please refer to Figure 2 , Figure 2 A schematic diagram of the circuit principle of a first acquisition circuit provided in an embodiment of this application is shown. Figure 2 As shown in the embodiments of this application, the first acquisition circuit may include:
[0053] The system comprises an optocoupler 5U2, a first resistor R1, a second resistor R2, a third resistor R3, a fourth resistor R4, and a fifth resistor R5. The collector of the optocoupler 5U2 is connected to the microprocessor. The anode of the optocoupler 5U2 is connected to the power supply VCC through the fifth resistor R5. The cathode of the optocoupler 5U2 is connected to the reference contact. The second contact is grounded through the fourth resistor R4. The second contact is also connected to the first end of the third resistor R3. The second end of the third resistor R3 is grounded through the second resistor R2. The second end of the third resistor R3 is also connected to the microprocessor through the first resistor R1.
[0054] In this embodiment, the first acquisition circuit can employ a design combining optocoupler isolation and resistor voltage divider. The optocoupler can be a PC817 device, with its collector connected to the microprocessor's input pin, its anode connected to the power supply via a fifth resistor, and its cathode forming a loop via a limit switch and several resistors. The microprocessor can control the optocoupler's conduction state. When the microprocessor outputs a control signal, the optocoupler conducts, and the limit switch is connected to the circuit, forming a loop. The first acquisition circuit can use a voltage divider circuit composed of a first resistor, a second resistor, and a third resistor to generate a voltage value at the first resistor. This voltage value corresponds to the voltage value at the second contact of the limit switch, allowing the inference of the limit switch's switching resistance. Therefore, in this embodiment, the voltage value at the first resistor can be output to the microprocessor as a circuit parameter for detecting the limit switch. This circuit parameter accurately determines the limit switch's switching resistance, thereby analyzing whether the limit switch performs its pre-set circuit function.
[0055] It is understood that, in this embodiment of the application, when testing the limit switch, the microprocessor can control the left-hand drive component to rotate the limit switch to a first specified angle, measure a set of corresponding circuit parameters, and then control the right-hand drive component to rotate the limit switch to a second specified angle, and measure another set of corresponding circuit parameters. This allows for one round of performance testing. If it is necessary to test the lifespan of the limit switch, the above process can be repeated to obtain multiple sets of corresponding circuit parameters, facilitating analysis of when the limit switch might fail to achieve its expected circuit function. This application does not impose any limitations on this.
[0056] In the description of this specification, references to terms such as "one embodiment," "another embodiment," or "some embodiments," etc., indicate that a specific feature, structure, material, or characteristic described in connection with an embodiment or example is included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0057] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.
Claims
1. A limit switch detection system, characterized in that, include: Microprocessor, left-hand drive assembly, right-hand drive assembly, left-hand position sensor, right-hand position sensor, and signal acquisition circuit; The microprocessor is connected to the left-hand drive assembly, the right-hand drive assembly, the left-hand position sensor, and the right-hand position sensor. The left-hand drive assembly drives the limit switch to be detected to rotate to the left, and the right-hand drive assembly drives the limit switch to rotate to the right. The left-hand position sensor feeds back a first position signal to the microprocessor when the limit switch rotates to the left to a first specified angle, and the right-hand position sensor feeds back a second position signal to the microprocessor when the limit switch rotates to the right to a second specified angle. The signal acquisition circuit is used to access the limit switch, and the signal acquisition circuit is connected to the microprocessor.
2. The limit switch detection system according to claim 1, characterized in that, The limit switch detection system also includes a power supply, which supplies power to the microprocessor, the left-hand drive assembly, the right-hand drive assembly, the left-hand position sensor, the right-hand position sensor, and the signal acquisition circuit.
3. The limit switch detection system according to claim 1, characterized in that, The limit switch detection system also includes a host computer and a communication converter, wherein the host computer is connected to the microprocessor through the communication converter.
4. The limit switch detection system according to claim 3, characterized in that, The communication converter is an RS232 communication converter.
5. The limit switch detection system according to claim 3, characterized in that, The limit switch detection system also includes a camera device, which is used to collect video data of the left-hand drive component and the right-hand drive component driving the limit switch; the camera device is communicatively connected to the host computer.
6. The limit switch detection system according to claim 1, characterized in that, The left-hand drive assembly includes a solenoid valve and a rotating device, the rotating device being connected to the microprocessor via the solenoid valve.
7. The limit switch detection system according to claim 6, characterized in that, The rotating device uses a rotary cylinder or a servo motor.
8. The limit switch detection system according to claim 1, characterized in that, The limit switch includes a reference contact, a first contact, and a second contact. The first contact corresponds to the first specified angle, and the second contact corresponds to the second specified angle. The signal acquisition circuit includes a first acquisition circuit and a second acquisition circuit. The first acquisition circuit is connected to the reference contact and the first contact. The output terminal of the first acquisition circuit is connected to the microprocessor. The second acquisition circuit is connected to the reference contact and the second contact, and the output of the second acquisition circuit is connected to the microprocessor.
9. A limit switch detection system according to claim 8, characterized in that, The first acquisition circuit includes an optocoupler, a first resistor, a second resistor, a third resistor, a fourth resistor, and a fifth resistor. The collector of the optocoupler is connected to the microprocessor, the anode of the optocoupler is connected to the power supply through the fifth resistor, the cathode of the optocoupler is connected to the reference contact, the second contact is grounded through the fourth resistor, the second contact is also connected to the first end of the third resistor, the second end of the third resistor is grounded through the second resistor, and the second end of the third resistor is also connected to the microprocessor through the first resistor.
10. A limit switch detection system according to claim 9, characterized in that, The optocoupler is model PC817.