A load movement monitoring device, printer, cutting machine and robot

Abstract

The application provides a load motion monitoring device, a printer, a cutting machine and a robot. The load motion monitoring device comprises a motor, a sensor and a single-chip microcomputer. The sensor arranged on a driving part of the motor outputs a pulse signal, which reflects the motion state of the motor in real time. The single-chip microcomputer controls the driving part based on the pulse signal, so that the load state monitoring is realized. The complexity of the device structure is simplified, and the device maintenance cost is reduced.

Description

Technical Field

[0001] This application relates to the field of load motion monitoring technology, and in particular to a load motion monitoring device, printer, cutting machine and robot. Background Technology

[0002] The stable operation of automated equipment heavily relies on real-time monitoring of the load's motion status. Traditional solutions typically employ direct detection of load-side motion parameters by deploying multiple dedicated sensors at the load end. However, as equipment complexity increases, this direct detection approach leads to a more complex equipment structure. Each new load-side sensor requires an independent mechanical fixing structure and signal transmission lines, significantly increasing the internal layout density. This complex internal layout not only increases assembly difficulty but also increases the risk of sensor failure due to mechanical stress during long-term operation, thus raising maintenance costs. Utility Model Content

[0003] To overcome the aforementioned problems in the prior art, this specification provides a load motion monitoring device, a printer, a cutting machine, a robot, and related equipment.

[0004] To achieve the above objectives, one or more embodiments of this specification provide the following technical solutions:

[0005] According to a first aspect of the embodiments of this specification, a load motion monitoring device is provided, including a motor, a sensor, and a microcontroller;

[0006] The motor is equipped with a drive component, which is used to drive the load to move.

[0007] The sensor is mounted on the drive component to monitor the motion parameters of the motor and output a pulse signal, which is used to characterize whether the motion state of the motor is abnormal.

[0008] The microcontroller is electrically connected to the sensor and is used to control the drive component based on pulse signals.

[0009] According to a second aspect of the embodiments of this specification, a printer is provided, including a load motion monitoring device as described in the first aspect and a printer printhead as the load.

[0010] According to a third aspect of the embodiments of this specification, a cutting machine is provided, including a load motion monitoring device as described in the first aspect and a cutting tool as the load.

[0011] According to a fourth aspect of the embodiments of this specification, a robot is provided, including a load motion monitoring device as described in the first aspect and a robotic arm joint serving as the load.

[0012] According to a fifth aspect of the embodiments of this specification, an apparatus is provided, the apparatus comprising the load motion monitoring device as described in the first aspect and the load.

[0013] The technical solutions provided in the embodiments of this specification may include the following beneficial effects:

[0014] The embodiments in this specification use a sensor mounted on the drive component of the motor to output pulse signals, which reflect the motor's motion status in real time. A microcontroller controls the drive component based on the pulse signals to achieve load status monitoring. This eliminates the need for the traditional load-side sensor installation structure, simplifies the complexity of the equipment structure, and thus reduces equipment maintenance costs. Attached Figure Description

[0015] Figure 1 This is a schematic structural diagram of a load motion monitoring device shown in an exemplary embodiment of this application;

[0016] Figure 2 This is a schematic structural diagram of a load motion monitoring device shown in another exemplary embodiment of this application;

[0017] Figure 3 This is a schematic structural diagram of a printer shown in an exemplary embodiment of this application;

[0018] Figure 4 This is a schematic structural diagram of a cutting machine shown in an exemplary embodiment of this application;

[0019] Figure 5 This is a schematic structural diagram of a robot shown in an exemplary embodiment of this application;

[0020] Figure 6 This is a schematic structural diagram of a device shown in an exemplary embodiment of this application. Detailed Implementation

[0021] 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 denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0022] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms “a,” “the,” and “the” used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0023] It should be understood that although the terms first, second, third, etc., may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0024] In the field of modern automation equipment, the stable operation of equipment such as industrial printers, precision cutting machines, and robots highly depends on the real-time monitoring of the load's motion status. Current technologies generally acquire motion parameters by directly deploying sensors at the load end, such as installing position sensors along the load's movement path to detect displacement changes, or setting up dedicated detectors to capture abnormal vibrations. This approach is based on the inherent understanding that the actual motion state of the load must be directly obtained through measurement points on its own body to ensure reliability.

[0025] However, as equipment complexity increases, this direct detection mode leads to a more complex equipment structure. Each newly added load-side sensor requires an independent mechanical fixing structure and signal transmission line, significantly increasing the internal layout density of the equipment. This complex internal layout not only increases assembly difficulty but also increases the risk of failure due to mechanical stress during long-term operation, thus increasing maintenance costs.

[0026] Therefore, this application proposes a load motion monitoring device that monitors load status by placing sensors at the motor end, thereby simplifying the device layout and reducing maintenance costs.

[0027] The embodiments described in this specification will now be described in detail.

[0028] like Figure 1 As shown, Figure 1 This specification illustrates a load motion monitoring device 10 according to an exemplary embodiment, which includes a motor 11, a sensor 13, and a microcontroller 12;

[0029] The motor 11 is provided with a drive component 111, which is used to drive the load to move.

[0030] The sensor 13 is mounted on the drive component 111 and is used to monitor the motion parameters of the motor 11 and output a pulse signal. The pulse signal is used to characterize whether the motion state of the motor 11 is abnormal.

[0031] The microcontroller 12 is electrically connected to the sensor 13 and is used to control the drive component 111 based on pulse signals.

[0032] The load motion monitoring device 10 provided in this specification changes the monitoring logic of directly collecting load end motion parameters in the prior art. This specification embodiment is based on the coupling relationship between the motion state of the motor 11 and the load state, and collects the pulse signals corresponding to the motion parameters of the drive component 111 by installing a sensor 13 on the drive component 111 of the motor 11. Specifically, the drive component 111 is the output shaft of the motor 11, which is mechanically connected to the load through a rigid transmission mechanism such as gears and belts. When the motor 11 is running, the drive component 111 directly transmits rotational power to the load, driving it to perform linear or rotational motion.

[0033] Sensor 13 can be fixed to the surface of drive component 111 by a rigid connector, and its sensing end maintains a constant distance from drive component 111. When drive component 111 moves, sensor 13 converts the physical displacement of drive component 111 into an electrical pulse signal. The pulse frequency of the output pulse signal increases with the rotational speed, and the interruption of the pulse indicates that the rotation stops.

[0034] The microcontroller 12 establishes an electrical connection with the sensor 13 via wires or interface terminals to receive pulse signals in real time. Its internally integrated hardware comparison circuit continuously compares the pulse characteristics with a preset threshold. When abnormal frequency fluctuations or phase disturbances are detected, it directly outputs an electronic control command to the drive component 111 to trigger a protection action.

[0035] Accordingly, this embodiment of the specification places the sensor 13 directly on the drive component 111 of the motor 11, enabling the pulse signal output by the sensor 13 to reflect the motion state of the motor 11 in real time. A microcontroller 12 is electrically connected to the sensor 13 to achieve control of the drive component 111 based on the pulse signal. This embodiment of the specification achieves load status monitoring by placing the sensor 13 on the drive component 111 of the motor 11, eliminating the need for a traditional load-side sensor mounting structure, simplifying the complexity of the equipment structure, and thus reducing equipment maintenance costs.

[0036] In one or more embodiments of this specification, the microcontroller 12 is used to control the drive component 111 to perform abnormal processing when the pulse signal indicates that the motion state of the motor 11 is abnormal. The abnormal processing includes any of the following: controlling the drive component 111 to decelerate, stop, or reverse its motion.

[0037] Sensor 13 continuously transmits pulse signals to the input port of microcontroller 12. When the pulse signal output by sensor 13 indicates an abnormal motion state (e.g., the pulse frequency is continuously lower than a threshold indicating a sudden drop in speed), microcontroller 12 drives its internally integrated relay or power semiconductor device to control the drive component 111 to decelerate, stop, or reverse its movement. Specifically, controlling the drive component 111 to decelerate can be achieved by adjusting the voltage divider resistor network of the drive component 111's power supply voltage to reduce the input voltage of motor 11; controlling the drive component 111 to stop can be achieved by triggering a circuit breaker relay to cut off the power circuit of drive component 111; and controlling the drive component 111 to reverse its movement can be achieved by switching the conduction sequence of the field-effect transistors in the H-bridge circuit to reverse the current direction. For example, when the load suddenly jams, the torque of the drive component 111 of motor 11 increases sharply, causing an abnormal pulse frequency. Microcontroller 12 can quickly trigger power-off protection to avoid equipment damage.

[0038] In one or more embodiments of this specification, the motion parameters include at least one of rotational speed, direction, and angle.

[0039] Based on the aforementioned connection between sensor 13 and drive component 111, the rotational speed can be directly characterized by the pulse frequency due to the integrated sensing unit within sensor 13. Specifically, drive component 111 generates a fixed number of pulses per revolution, and the number of pulses per unit time corresponds to the real-time rotational speed. For directional motion parameters, the pulse signal output by sensor 13 can be a dual-path orthogonal pulse signal. The specific parameter value of the rotational direction can be calculated based on the phase difference between the dual-path orthogonal pulse signals. For example, the sensing unit of sensor 13 includes two sets of spatially orthogonal photoelectric gratings, denoted as phase A and phase B signal channels, respectively. When the phase A pulse leads phase B by 90 degrees, the comparator circuit outputs a forward rotation level signal; a phase reversal triggers a reversal marker. For angular motion parameters, since sensor 13 outputs pulses when drive component 111 rotates, each pulse corresponds to a fixed angular displacement. A pulse accumulation counter can be configured, and the accumulated value of the pulse accumulation counter directly reflects the rotational angle.

[0040] The embodiments in this specification can respond to at least one of rotational speed, direction, and angle through the output pulse signal of sensor 13. Based on the speed parameter, obvious faults such as load jamming can be identified; based on the direction signal, freewheeling caused by transmission mechanism slippage can be detected; and based on the angle parameter, positioning deviation accumulation problems can be diagnosed. The multiple parameters responded to by the pulse signal enable the microcontroller 12 to provide targeted control basis for the drive component 111.

[0041] like Figure 2 As shown, Figure 2This is a schematic structural diagram of a load motion monitoring device 10 according to another exemplary embodiment of this specification. In the load motion monitoring device 10, the microcontroller 12 includes a decision unit 121, which is used to determine whether the motion state of the motor 11 is abnormal based on the motion state output by the pulse signal.

[0042] The decision controller 121, as a hardware module within the microcontroller 12, directly receives the pulse signal transmitted from the sensor 13. The decision controller 121 presets a pulse signal reference range as the basis for judgment. When the characteristics of the input pulse signal continuously deviate from the pulse signal reference range, the decision controller 121 automatically outputs an electrical signal with a changing level to indicate an abnormal motion state of the motor 11. For example, when the pulse signal frequency is lower than the threshold of the set reference range, the output port of the decision controller 121 generates a low-to-high level transition; or, in unidirectional motion mode, the direction parameters of the motor 11 must strictly match the control system commands, and the output port of the decision controller 121 also generates a low-to-high level transition. It can be understood that the decision controller 121 can be configured with multiple output ports, each corresponding to a different type of motion state abnormality.

[0043] In one or more embodiments of this specification, the microcontroller 12 is further configured to send an alarm signal to the host computer when the pulse signal indicates an abnormal motion state of the motor 11.

[0044] When the pulse signal indicates an abnormal motion state of the motor 11, the microcontroller 12 sends an alarm signal to the host computer, enabling intelligent operation and maintenance and remote monitoring, forming a closed-loop response chain from local device diagnosis to global management. For example, the microcontroller 12 can transmit electrical signals to the host computer using UART (serial port) or CAN (industrial bus), and the transmitted alarm signal may include a device identifier, an abnormality type identifier, and a pulse signal indicating when the abnormality occurs.

[0045] In one or more embodiments of this specification, the sensor 13 is an coded sensor. A coded sensor is a precision measuring device that converts mechanical displacement into digital signals. Exemplarily, the coded sensor includes a grating disk, a detection unit, and a signal conditioning circuit. The grating disk is a disc-shaped component mounted on the end of a rotating shaft, with equally spaced light-transmitting slits etched on its surface. The detection unit includes a transmitting light source and a receiving phototransistor symmetrically arranged on both sides of the grating disk. The signal conditioning circuit converts the signal output by the phototransistor into a regular square wave pulse. In this embodiment, the coded sensor 13 is mounted on the driving component 111 of the motor 11. When the driving shaft of the motor 11 rotates, the grating disk rotates synchronously, and the light-transmitting slits periodically pass between the transmitter and receiver, causing the light to alternate between bright and dark, thereby causing the phototransistor to output a continuous sinusoidal current signal. The signal conditioning circuit can be a Schmitt trigger circuit, which converts the sinusoidal current signal output by the phototransistor into a rectangular pulse signal based on a preset voltage threshold.

[0046] This instruction manual also provides Figure 3 The diagram shows a schematic structure of a printer 30. The printer 30 includes the features described above. Figure 1 The provided load motion monitoring device 10 and the printer printhead 31 as the load.

[0047] In printer 30, the printhead 31, as the core load, needs to perform high-precision, high-frequency reciprocating motion along the guide rail during printing, and its motion state directly affects print quality. Traditional solutions require installing a position sensor 13 at the printhead load end to monitor displacement, but this increases wiring complexity and potential failure points. This solution, however, monitors the motion state of the motor 11 driving the printhead and uses the sensor 13 to capture the motion parameters of the drive shaft that drives the printhead 31, mapping pulse signal anomalies to actual printhead load faults (such as jamming or positioning misalignment). The microcontroller 12 dynamically controls the motor 11's movement based on real-time data, significantly simplifying the printer 30's structure while ensuring printing accuracy.

[0048] For example, after the printer 30 is powered on, the motor 11 in the load motion monitoring device 10 drives the printer nozzle 31 to move towards the mechanical zero point. During the movement, the sensor 13 fixed on the drive shaft of the motor 11 continuously outputs pulse signals. The counter built into the microcontroller 12 accumulates the pulse signals. When the nozzle touches the mechanical limit block, the total number of pulses accumulated is compared with the preset zero point pulse signal threshold (that is, the aforementioned preset pulse signal reference range is set as a threshold). If the total number of pulses is greater than the zero point pulse signal threshold and the motor 11 is still moving, a "positioning failure" alarm is triggered.

[0049] This instruction manual also provides Figure 4The diagram shows a schematic structure of a cutting machine 40. The cutting machine 40 includes the above-described components. Figure 1 The provided load motion monitoring device 10 and the cutting tool 41 serving as the load.

[0050] In the cutting machine 40, the cutting tool 41, as the core load, needs to maintain stable cutting torque and axial feed accuracy during high-speed operation. Its motion state directly determines the machining quality and equipment safety. Traditional solutions rely on installing vibration sensors or strain gauges at the load end of the cutting tool 41 to monitor the cutting state, but the splashing of cutting debris and the corrosion of coolant significantly increase the risk of sensor failure. This solution utilizes a sensor 13 rigidly fixed to the drive shaft of the motor 11 to capture the motion parameters at the rotational power output end, enabling precise mapping of pulse signals to the actual working conditions of the cutting tool 41 load (such as jamming of hard materials or chipping of the cutting edge). The microcontroller 12 dynamically adjusts the output of the motor 11 in real time, simplifying the structure of the cutting tool 41 load end of the cutting machine 40 while ensuring cutting accuracy.

[0051] This instruction manual also provides Figure 5 The diagram shows a schematic structure of a robot 50. The robot 50 includes the aforementioned... Figure 1 The provided load motion monitoring device 10 and the robotic arm joint 51 serving as the load.

[0052] In the industrial robot 50, the robotic arm joint 51, as the core load, needs to maintain precise angular positioning and torque output during multi-degree-of-freedom coordinated motion. Its motion state directly determines the operational accuracy and system safety. Traditional solutions require installing angle and torque sensors at the joint load end to monitor posture changes, but the wiring bottleneck and electromagnetic interference within the sealed joint cavity significantly increase system complexity. This solution monitors the motion state of the servo motor 11 driving the joint. A sensor 13 rigidly coupled to the output shaft of the motor 11 captures the motion parameters of the core power transmission node, accurately mapping pulse signal anomalies to the actual working conditions of the joint load. The microcontroller 12 dynamically adjusts the torque output of the motor 11 based on real-time data, reconstructing the monitoring structure of the robot 50 while ensuring motion accuracy.

[0053] This instruction manual also provides Figure 6 The diagram shows a schematic structure of a device 60. The device 60 includes the aforementioned... Figure 1 The provided load motion monitoring device 10 and the load 61.

[0054] Besides the printer 30, cutter 40, and robot 50 mentioned above, the aforementioned load motion monitoring device 10 can be universally applied to various automated devices 60. Whether it's the placement head of a semiconductor packaging machine, the heat sealing blade of a food packaging machine, or the linear actuator of medical equipment, traditional solutions require adding dedicated sensors to the load end, resulting in bulky equipment structures and limited environmental adaptability. This solution monitors the motion state of the core motor 11 driving the load 61, using a sensor 13 integrated into the motor 11's shaft to capture the motion essence of the power source, mapping pulse signal anomalies to the actual operating conditions of various loads (such as transmission failure or actuator blockage). The microcontroller 12 dynamically adjusts the output of the motor 11 in the device based on real-time data, reconstructing the load-side structure of the automated device 60 while ensuring the monitoring effect, and has broad application prospects.

[0055] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0056] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0057] It should be noted that when a component is described as "fixed to," "set on," "fixed to," or "mounted on" another component, it can be directly on the other component or there may be an intervening component. When a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be an intervening component. Furthermore, when a component is considered to be "fixedly connected" to another component, the connection can be detachable or non-detachable, such as through socketing, snap-fitting, integral molding, welding, etc., which are achievable in conventional technologies and will not be elaborated upon here.

[0058] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0059] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A load motion monitoring device, characterized in that, Includes motors, sensors, and microcontrollers; The motor is provided with a drive component, which is the output shaft of the motor, and the drive component is used to drive the load to move; The sensor is fixed to the surface of the drive component and is used to monitor the motion parameters of the motor and output a pulse signal. The pulse signal is used to characterize whether the motion state of the motor is abnormal. The microcontroller is electrically connected to the sensor and is used to control the drive component based on pulse signals. The microcontroller includes a decision unit, which is used to determine whether the motor's motion state is abnormal based on the output of the pulse signal.

2. The load motion monitoring device according to claim 1, characterized in that, The microcontroller is used to control the drive component to perform abnormal processing when the pulse signal indicates that the motor's motion state is abnormal. The abnormal processing includes any of the following: controlling the drive component to decelerate, stop, or reverse its motion.

3. The load motion monitoring device according to claim 1, characterized in that, The motion parameters include at least one of rotational speed, direction, and angle.

4. The load motion monitoring device according to claim 1, characterized in that, The microcontroller is also used to send an alarm signal to the host computer when the pulse signal indicates that the motor's motion state is abnormal.

5. The load motion monitoring device according to claim 1, characterized in that, The sensor is an coded sensor.

6. A printer, characterized in that, Includes the load motion monitoring device as described in any one of claims 1-5 and the printer printhead as said load.

7. A cutting machine, characterized in that, Includes the load motion monitoring device as described in any one of claims 1-5 and the cutting tool as the load.

8. A robot, characterized in that, Includes the load motion monitoring device as described in any one of claims 1-5 and the robotic arm joint serving as the load.

9. A device, characterized in that, The device includes the load motion monitoring device as described in any one of claims 1-5 and the load.

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