A strain gauge signal line breakage detection system
Patent Information
- Application Number
- CN202522069330.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-25
- Publication Date
- 2026-09-25
- Estimated Expiration
- 2035-09-25
AI Technical Summary
但这些系统主要针对信号受到干扰或应变片本身性能下降等情况，在实际应用过程中，应变片的信号线可能会因为各种原因（如振动、老化、外力拉扯等）出现断线的情况，而现有技术对于信号线断线这一特定故障，缺乏有效的检测手段
[0012]本实用新型的有益效果在于：本实用新型中的应变片信号线断线检测系统包括：应变片和信号处理模块；所述应变片通过第一信号线、第二信号线、第三信号线和第四信号线与所述信号处理模块电性连接；所述信号处理模块中设置有上拉电阻、下拉电阻、模数转换器、数据处理器和电源；所述上拉电阻串联在所述第三信号线和所述电源之间，所述下拉电阻串联在所述第四信号线和接地线之间；所述模数转换器用于将所述应变片的输出信号转化为输出数值；所述数据处理器用于在检测到所述输出数值与预设目标数值相同时判断所述应变片信号线断线。通过上拉电阻和下拉电阻的作用，在信号线断线时能使模数转换器检测到特定的目标数字，无需复杂的算法分析，可快速判断出断线故障，大大提高了检测的及时性和准确性，且仅需添加两个电阻即可实现断线检测功能，无需额外的复杂电路模块，成本低，易于实现和集成到现有应变片信号检测系统中；此外利用电阻对信号电平的钳位作用，不受外界干扰的影响，即使在复杂的工业环境中，也能稳定地检测出断线故障，避免误判；最后，该系统可应用于各种采用模数转换器进行信号采集的应变片测量系统，具有较强的通用性。
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Abstract
Description
Technical Field
[0001] This utility model relates to the field of signal measurement technology, and more specifically to a strain gauge signal line breakage detection system. Background Technology
[0002] In numerous fields such as industrial measurement, mechanical engineering, and aerospace, strain gauges are widely used as a common sensing element to measure the strain of objects. When a strain gauge is working, the tiny signal it generates needs to be transmitted through signal lines to subsequent signal processing circuits (such as ADCs, Analog-to-Digital Converters) for processing and analysis to obtain the strain information of the object.
[0003] Currently, existing technologies for strain gauge signal detection mainly focus on signal amplification, filtering, and analog-to-digital conversion to improve measurement accuracy and stability. For example, some solutions use high-precision operational amplifiers to amplify the weak differential signal output by the strain gauge, then use low-pass filters to filter out high-frequency noise, and finally use an ADC to convert the analog signal into a digital signal for subsequent processor analysis.
[0004] In addition, some technologies monitor signal fluctuation range and trends to determine signal abnormalities. However, these systems primarily address situations where the signal is interfered with or the strain gauge itself experiences performance degradation. In practical applications, the strain gauge signal wire may break due to various reasons (such as vibration, aging, or external pulling). Existing technologies lack effective detection methods for this specific fault. Because the strain gauge output signal is relatively weak, when the signal wire breaks, the ADC input may be in a floating state, resulting in uncertain signal values. Existing technologies struggle to reliably distinguish this situation from normal signals, leading to significant deviations in measurement results and potentially affecting the normal operation and safety of the entire device or system. Therefore, a strain gauge signal wire breakage detection system that overcomes these shortcomings is urgently needed. Utility Model Content
[0005] The purpose of this invention is to provide a strain gauge signal line breakage detection system. This system utilizes pull-up and pull-down resistors to enable the analog-to-digital converter (ADC) to detect a specific target value when the signal line is broken. Without complex algorithm analysis, it can quickly identify the breakage fault, greatly improving the timeliness and accuracy of detection. Furthermore, the breakage detection function can be achieved by adding only two resistors, eliminating the need for additional complex circuit modules, resulting in low cost and easy implementation and integration into existing strain gauge signal detection systems. In addition, the clamping effect of the resistors on the signal level prevents interference from external factors, ensuring stable detection of breakage faults even in complex industrial environments and avoiding misjudgments. Finally, this system can be applied to various strain gauge measurement systems that use ADCs for signal acquisition, demonstrating strong versatility.
[0006] To achieve the above objectives, this utility model provides the following technical solution: In a first aspect, this utility model provides a strain gauge signal wire breakage detection system, the system comprising: Strain gauges and signal processing modules; The strain gauge is electrically connected to the signal processing module via a first signal line, a second signal line, a third signal line, and a fourth signal line; The signal processing module includes pull-up resistors, pull-down resistors, an analog-to-digital converter, a data processor, and a power supply. The pull-up resistor is connected in series between the third signal line and the power supply, and the pull-down resistor is connected in series between the fourth signal line and the ground line; The analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; The data processor is used to determine that the strain gauge signal line is broken when the output value is detected to be the same as the preset target value.
[0007] In some embodiments, when the first signal line and / or the second signal line is disconnected, the pull-up resistor is used to clamp the output signal of the first signal line at a level close to the power supply. The pull-down resistor is used to clamp the output signal of the second signal line to a level close to ground. The analog-to-digital converter is used to convert the output signal of the strain gauge into an output value that is the same as the preset target value; The data processor is used to determine that the strain gauge signal line is broken when an output value that is the same as the preset target value is detected.
[0008] In some embodiments, when neither the first signal line nor the second signal line is broken, the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; The data processor is used to process the output values to obtain the strain information of the strain gauge.
[0009] In some embodiments, the signal processing module is further provided with a signal amplifier; The signal amplifier is disposed between the strain gauge and the analog-to-digital converter; The signal amplifier is used to amplify the output signal of the strain gauge.
[0010] In some embodiments, the resistance values of the pull-up resistor and the pull-down resistor are adjusted according to the output signal range of the strain gauge, the power supply voltage, and the input characteristics of the analog-to-digital converter.
[0011] In some embodiments, the resistance values of the pull-up resistor and the pull-down resistor are adjustable within the range of 100kΩ-1000kΩ.
[0012] The beneficial effects of this utility model are as follows: The strain gauge signal line breakage detection system of this utility model includes: a strain gauge and a signal processing module; the strain gauge is electrically connected to the signal processing module through a first signal line, a second signal line, a third signal line, and a fourth signal line; the signal processing module is provided with a pull-up resistor, a pull-down resistor, an analog-to-digital converter, a data processor, and a power supply; the pull-up resistor is connected in series between the third signal line and the power supply, and the pull-down resistor is connected in series between the fourth signal line and the ground line; the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; the data processor is used to determine that the strain gauge signal line is broken when the output value is detected to be the same as a preset target value. By utilizing pull-up and pull-down resistors, the analog-to-digital converter (ADC) can detect specific target values when the signal line is broken. This eliminates the need for complex algorithm analysis, allowing for rapid fault detection and significantly improving timeliness and accuracy. Furthermore, the fault detection function requires only two resistors, eliminating the need for additional complex circuit modules, resulting in low cost and easy integration into existing strain gauge signal detection systems. Additionally, the resistors clamp the signal level, preventing interference from external factors and ensuring stable fault detection even in complex industrial environments, thus avoiding misjudgments. Finally, this system is applicable to various strain gauge measurement systems that use ADCs for signal acquisition, demonstrating strong versatility.
[0013] The above description is only an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, the preferred embodiments of this utility model are described in detail below with reference to the accompanying drawings. Attached Figure Description
[0014] Figure 1This is a schematic diagram of the strain gauge signal line breakage detection system according to an embodiment of the present invention; Figure 2 This is a circuit diagram of a strain gauge signal line breakage detection system according to an embodiment of the present invention. Detailed Implementation
[0015] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model. It should be noted that references to "an embodiment," "embodiment," "example embodiment," etc., in this specification refer to the described embodiment including specific features, structures, or characteristics; however, not every embodiment must include these specific features, structures, or characteristics. Furthermore, such expressions do not refer to the same embodiment. Moreover, when describing specific features, structures, or characteristics in conjunction with embodiments, whether or not explicitly described, it is indicated that incorporating such features, structures, or characteristics into other embodiments is within the knowledge scope of those skilled in the art.
[0016] Furthermore, the technical features involved in the different embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.
[0017] In some embodiments, such as Figure 1 The diagram shows a structural schematic of a strain gauge signal line breakage detection system. The system includes a strain gauge and a signal processing module. The strain gauge is electrically connected to the signal processing module via a first signal line, a second signal line, a third signal line, and a fourth signal line. The signal processing module includes a pull-up resistor, a pull-down resistor, an analog-to-digital converter (ADC), a data processor, and a power supply. The pull-up resistor is connected in series between the third signal line and the power supply, and the pull-down resistor is connected in series between the fourth signal line and a ground line. The ADC converts the output signal of the strain gauge into an output value. The data processor determines that the strain gauge signal line is broken when the detected output value matches a preset target value.
[0018] Optionally, when the first signal line and / or the second signal line is disconnected, the pull-up resistor is used to clamp the output signal of the first signal line to a level close to the power supply; the pull-down resistor is used to clamp the output signal of the second signal line to a level close to ground; the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value that is the same as the preset target value; and the data processor is used to determine that the strain gauge signal line is disconnected when an output value that is the same as the preset target value is detected.
[0019] Optionally, when neither the first signal line nor the second signal line is disconnected, the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; the data processor is used to process the output value to obtain the strain information of the strain gauge.
[0020] Optionally, the signal processing module further includes a signal amplifier; the signal amplifier is disposed between the strain gauge and the analog-to-digital converter; the signal amplifier is used to amplify the output signal of the strain gauge.
[0021] Optionally, the resistance values of the pull-up resistor and the pull-down resistor are adjusted according to the output signal range of the strain gauge, the power supply voltage, and the input characteristics of the analog-to-digital converter. The adjustment range of the resistance values of the pull-up resistor and the pull-down resistor is 100kΩ-1000kΩ.
[0022] For example, taking the detection of a broken strain gauge signal wire as an example, the strain gauge signal wire breakage detection system in this application will be described in detail, such as... Figure 2 As shown, Figure 2This is a circuit diagram of a strain gauge signal line breakage detection system. When the signal line is not broken, the strain gauge output signal is transmitted to a signal amplifier via the first, second, third, and fourth signal lines. After amplification, the signal is transmitted to an analog-to-digital converter (ADC), which converts the strain gauge output signal into a digital signal. The data processor then processes the digital signal to obtain the strain information of the strain gauge. In this case, the pull-up resistor R41 (at position 1) and the pull-down resistor R42 (at position 2) have minimal impact on the strain gauge output signal and can be ignored. When the first signal line and / or the second signal line is broken, such as when the first signal line (signal line A) or the second signal line (signal line B) is broken, or when both signal lines are broken, the signal lines are in a floating state. At this time, the pull-up resistor R41 clamps the first signal line to a level close to the power supply VCC, and the pull-down resistor R42 clamps the second signal line to a level close to ground GND. The voltage level causes the difference between the differential signals to reach its maximum, far exceeding the reference voltage acquired by the analog-to-digital converter. When the difference between the differential signals reaches its maximum range, the digital signal value converted by the analog-to-digital converter will become the target value 0Xffff (hexadecimal). The data processor can determine whether the signal line is broken by judging whether the signal value detected by the analog-to-digital converter is 0Xffff.
[0023] The strain gauge signal line breakage detection system in the above embodiment includes: a strain gauge and a signal processing module; the strain gauge is electrically connected to the signal processing module via a first signal line, a second signal line, a third signal line, and a fourth signal line; the signal processing module includes a pull-up resistor, a pull-down resistor, an analog-to-digital converter, a data processor, and a power supply; the pull-up resistor is connected in series between the third signal line and the power supply, and the pull-down resistor is connected in series between the fourth signal line and the ground line; the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; the data processor is used to determine that the strain gauge signal line is broken when the output value is detected to be the same as a preset target value. By utilizing pull-up and pull-down resistors, the analog-to-digital converter (ADC) can detect specific target values when the signal line is broken. This eliminates the need for complex algorithm analysis, allowing for rapid fault detection and significantly improving timeliness and accuracy. Furthermore, the fault detection function requires only two resistors, eliminating the need for additional complex circuit modules, resulting in low cost and easy integration into existing strain gauge signal detection systems. Additionally, the resistors clamp the signal level, preventing interference from external factors and ensuring stable fault detection even in complex industrial environments, thus avoiding misjudgments. Finally, this system is applicable to various strain gauge measurement systems that use ADCs for signal acquisition, demonstrating strong versatility.
[0024] The technical features of the above embodiments can be arbitrarily integrated. For the sake of brevity, not all possible integrations of the technical features in the above embodiments are described. However, as long as the integration of these technical features does not contradict each other, they should be considered to be within the scope of this specification.
[0025] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.
Claims
1. A strain gauge signal wire breakage detection system, characterized in that, The system includes: Strain gauges and signal processing modules; The strain gauge is electrically connected to the signal processing module via a first signal line, a second signal line, a third signal line, and a fourth signal line; The signal processing module includes pull-up resistors, pull-down resistors, an analog-to-digital converter, a data processor, and a power supply. The pull-up resistor is connected in series between the third signal line and the power supply, and the pull-down resistor is connected in series between the fourth signal line and the ground line; The analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; The data processor is used to determine that the strain gauge signal line is broken when the output value is detected to be the same as the preset target value.
2. The strain gauge signal wire breakage detection system as described in claim 1, characterized in that, When the first signal line and / or the second signal line is disconnected, the pull-up resistor is used to clamp the output signal of the first signal line at a level close to the power supply. The pull-down resistor is used to clamp the output signal of the second signal line to a level close to ground. The analog-to-digital converter is used to convert the output signal of the strain gauge into an output value that is the same as the preset target value; The data processor is used to determine that the strain gauge signal line is broken when an output value that is the same as the preset target value is detected.
3. The strain gauge signal wire breakage detection system as described in claim 2, characterized in that, When neither the first signal line nor the second signal line is broken, the analog-to-digital converter is used to convert the output signal of the strain gauge into an output value; The data processor is used to process the output values to obtain the strain information of the strain gauge.
4. The strain gauge signal wire breakage detection system as described in claim 1, characterized in that, The signal processing module is also equipped with a signal amplifier; The signal amplifier is disposed between the strain gauge and the analog-to-digital converter; The signal amplifier is used to amplify the output signal of the strain gauge.
5. The strain gauge signal wire breakage detection system as described in claim 1, characterized in that, The resistance values of the pull-up resistor and the pull-down resistor are adjusted according to the output signal range of the strain gauge, the power supply voltage, and the input characteristics of the analog-to-digital converter.
6. The strain gauge signal wire breakage detection system as described in claim 5, characterized in that, The resistance values of the pull-up resistor and the pull-down resistor can be adjusted within the range of 100kΩ-1000kΩ.