Simulator of an integrated rotary encoder of an electric machine and associated simulation method
The integrated rotary encoder simulator with an improved brush assembly addresses the short lifespan issue by enabling fault detection and enhancing the durability of electric machines, thereby reducing replacement costs.
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- CHANGZHOU HUAXUAN SENSING TECH CO LTD
- Filing Date
- 2024-06-26
- Publication Date
- 2026-06-11
AI Technical Summary
Rotary encoders in electric machines have a short lifespan due to extreme rotational conditions, leading to frequent replacements and increased costs, and existing solutions complicate the operation by requiring direct connection to the encoder.
A simulator for an integrated rotary encoder system comprising a rotary encoder module and an electric machine module, with improved brush assembly, allows for signal comparison and fault detection, extending the service life and reducing testing costs.
The system provides extended service life and reduced testing costs by detecting faults in the rotary encoder circuit and improving the brush assembly, ensuring reliable operation.
Smart Images
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Abstract
Description
[0001] The present invention relates to the technical field of rotary encoders, specifically a simulator of an integrated rotary encoder of an electric machine and an associated simulation method.
[0002] A rotary encoder (resolver / transformer) is an electromagnetic sensor, also known as a synchro resolver. As an AC motor for angle measurement, a rotary encoder is used to measure the angular displacement and angular velocity of a rotating shaft of a rotating object and consists of a stator and a rotor. A stator winding serves as the primary side of a transformer and receives an excitation voltage. A rotor winding serves as the secondary side of the transformer and receives an induced voltage through electromagnetic coupling.
[0003] In current industrial production, rotary encoders are widely used for testing electric machine controls. A rotary encoder is mounted on an electric machine, and an electric machine controller receives a signal from the encoder, thus enabling direction reversal control of the electric machine. In this context, JP H09-201016 A relates to a brush holder for rotating electric machines with a first insulating plate on the brush head and a second insulating plate on the lower part of the holder box; the first plate moves with wear and locks against the second plate at the wear limit. In this context, US 10,389,281 B2 relates to a system and method for compensating offset and gain drift in position detectors of electric motors (encoders or resolvers).
[0004] Since the development of an electric motor control system uses an electric motor that is typically subjected to extreme rotational conditions, the electric motor has a short lifespan, and frequent replacement of the electric motor increases costs. Furthermore, an existing electric motor must be connected to a rotary encoder for use, which makes operation cumbersome.
[0005] Therefore, a simulator of an integrated rotary encoder of an electric machine is urgently needed to effectively extend the service life of the electric machine and avoid an increase in costs due to repeated replacement of the electric machine.
[0006] The present invention is based on the objective of providing a simulator of an integrated rotary encoder of an electric machine and an associated simulation method in order to solve the aforementioned technical problem in the prior art.
[0007] According to the invention, the problem is solved by a device and / or a method according to the independent claims. The dependent claims specify advantageous embodiments. It should be noted that the features of the claims can be combined with each other or with other aspects of the description. The description, particularly in conjunction with the figures, explains the invention and provides further exemplary embodiments.
[0008] A device for simulating a rotary encoder integrated into an electric machine is proposed, comprising a rotary encoder module and an electric machine module. An electric machine rotor of the electric machine module projects into a rotary encoder rotor of the rotary encoder module, which is provided with a first interface for connection to an external electric machine controller. The rotary encoder module is configured to receive rotation information from the electric machine module and transmit it to the electric machine controller. The electric machine module and the electric machine controller are connected via a second interface to adjust the rotational speed and direction of rotation of the electric machine module.
[0009] According to another aspect, a simulation method for an integrated rotary encoder of an electric machine is proposed, which includes the following: Using the above simulator of an integrated rotary encoder of an electric machine, and furthermore the following steps: - S1: Receiving an excitation signal that is output by a rotary encoder circuit of the electric machine control. - S2: Receiving a sine signal and a cosine signal from the rotary encoder module. - S3: Comparing the received excitation signal with the sine signal and the cosine signal to obtain a corresponding rotary encoder angle or rotary encoder speed. - S4: Compare the obtained rotary encoder angle or rotary encoder speed with a preset rotary encoder angle standard value or rotary encoder speed standard value. - S5: Determining the qualification status of the electrical machine control according to the comparison result.
[0010] The present invention is characterized in particular by the fact that, in the integrated rotary encoder of an electric machine and the associated simulation method according to the present invention, a current sine signal and a current cosine signal of the electric machine module are obtained by providing the rotary encoder module, and by comparing these signals with an excitation signal input by the electric machine control, it is determined whether a fault exists in a rotary encoder circuit of the electric machine control. Furthermore, by improving the brush assembly of the electric machine module, an extended service life of the electric machine module and reduced testing costs are achieved.
[0011] Further features and advantages of the invention are described in the following description, and some of them will be made obvious by the description or understood through the implementation of the invention.
[0012] To better understand the aforementioned tasks, features and advantages of the present invention, a more detailed description is given below with reference to the accompanying drawings and using preferred embodiments.
[0013] To better explain the specific embodiments according to the present invention or the configurations in the prior art, the accompanying drawings used in the exemplary embodiments or to describe the prior art are briefly described below, whereby it is understood that the following drawings only represent some embodiments of the invention and it is possible for persons skilled in the art in this field to obtain further drawings from such drawings without inventive activity.
[0014] It shows: Fig. 1 a three-dimensional representation of the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 2 a schematic structural sectional view of the internal structure of the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 3 a schematic three-dimensional structural view of the brush device in the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 4 a schematic front view of the brush holder in the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 5 a three-dimensional representation of the brush holder in the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 6 a three-dimensional representation of the brush arrangement in the simulator of an integrated rotary encoder of an electric machine according to the present invention; Fig. 7 an enlarged schematic structural view of location A according to Fig. 4 of the present invention; Fig. 8 a schematic flowchart of the simulation method for an integrated rotary encoder of an electric machine according to the present invention.
[0015] To better understand the problem, the embodiments and the advantages of the present invention, the embodiments of the exemplary embodiments of the present invention are explained completely and clearly below with reference to the accompanying drawings. It is understood that the described exemplary embodiments represent a part of the exemplary embodiments of the invention instead of all of them. All other exemplary embodiments that can be obtained by persons skilled in the art in this field from the exemplary embodiments of the invention without inventive steps are also within the scope of protection of the invention.
[0016] As in Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7 to Fig.As shown in Figure 8, the present invention provides a simulator of an integrated rotary encoder of an electric machine. It comprises a rotary encoder module 1 and an electric machine module 2; an electric machine rotor 22 of the electric machine module 2 projects into a rotary encoder rotor 13 of the rotary encoder module 1; a first interface 10 for connection to an external electric machine controller is provided on the rotary encoder module 1; the rotary encoder module 1 is configured to receive rotation information from the electric machine module 2 and transmit it to the electric machine controller; the electric machine module 2 and the electric machine controller are connected to each other via a second interface 20 in order to adjust the speed and direction of rotation of the electric machine module 2.
[0017] In the present embodiment, the rotary encoder module 1 provides a current sine signal and a current cosine signal from the electric motor module 2. By comparing these signals with an excitation signal input by the electric motor control, it is determined whether a fault exists in a rotary encoder circuit of the electric motor control. Furthermore, improving the brush assembly of the electric motor module 2 results in an extended service life for the module and reduced testing costs.
[0018] In the present embodiment, the rotary indicator module 1 comprises a transformer housing 11 and a rotary indicator stator 12; both the rotary indicator rotor 13 and the rotary indicator stator 12 are arranged in the transformer housing 11; the rotary indicator stator 12 is pushed onto the outer circumference of the rotary indicator rotor 13.
[0019] In the present embodiment, the electric machine module 2 comprises an electric machine housing 21 and an electric machine stator 23; both the electric machine stator 23 and the electric machine rotor 22 are arranged in the electric machine housing 21; the electric machine stator 23 is pushed onto the outer circumference of the electric machine rotor 22.
[0020] In the present embodiment, the electric machine module 2 further comprises a brush device 24; the brush device 24 is arranged in the electric machine housing 21 and is in contact with the electric machine rotor 22 in order to introduce an external current into the electric machine rotor 22.
[0021] In the present embodiment, the brush device 24 comprises a brush holder 241, a commutator 242 and a brush assembly 243; the brush holder 241 is arranged on the electric motor housing 21; the commutator 242 is pushed onto the electric motor rotor 22; and the brush assembly 243 is arranged on the brush holder 241 and is in contact with the commutator 242.
[0022] In the present embodiment, the brush assembly 243 provided on the brush holder 241 can come into contact with the commutator 242 by arranging the brush holder 241 on the electric motor housing 21. Thus, an external current is introduced into the commutator 242 via the brush assembly 243.
[0023] In the present embodiment, the brush arrangement 243 comprises a brush 2431 and a brush sleeve 2432; the brush sleeve 2432 is arranged on the brush holder 241 and the brush 2431 is inserted into the brush sleeve 2432; a limiting arrangement 244 for retaining and supporting the brush 2431 is also provided in the brush sleeve 2432.
[0024] In the present embodiment, the brush 2431 is fixed, held back and supported by the limiting arrangement 244, which is arranged in the brush sleeve 2432, thus effectively preventing the brush 2431 from wobbling and being damaged.
[0025] In the present embodiment, the limiting arrangement 244 comprises a dust protection plate 2441, which is slid onto the lowest part of the brush 2431, and a push block 2442, which is arranged on the inner wall of the brush holder 241; the lowest part of the dust protection plate 2441 is provided with a wire hole for leading out a wire of the brush 2431; a spring 245 is provided below the lowest part of the dust protection plate 2441 to push the brush 2431 upwards; the push block 2442 is designed to push the side wall of the brush 2431; when the brush 2431 moves upwards to its highest point, the push block 2442 is inserted into the dust protection plate 2441 to increase the thrust force on the side wall of the brush 2431.
[0026] Since the brush 2431 is to be connected to an external power supply via a power supply cable, it is typically provided with a copper wire at its lowest point to establish this connection. Because the brush 2431 is subject to constant wear, prior art designs utilize a spring 245 or a torsion spring to push the brush 2431 upwards, ensuring that its end face remains in constant contact with the commutator 242. However, conventional brushes 2431 are usually inserted directly into the brush sleeve 2432, resulting in misalignment when the brush 2431 moves upwards and uneven wear, which in turn damages the electric motor.Furthermore, carbon powder resulting from wear falls into a gap between the brush sleeve 2432 and the brush 2431, thus preventing the brush 2431 from moving.
[0027] In the present embodiment, the lowermost part of the brush 2431 is held back by the dust guard 2441, which is provided at the lowermost part of the brush 2431, and the side wall of the brush 2431 is pushed by the thrust block 2442. This ensures that the brush 2431 always moves in the vertical direction. Furthermore, compared to the prior art embodiment in which the brush 2431 is inserted directly into the brush sleeve 2432, the use of the dust guard 2441 and the thrust block 2442 prevents direct contact between the brush 2431 and the brush sleeve 2432. This prevents carbon powder that falls off during movement of the brush 2431, resulting from wear, from adhering to the inner area of the brush sleeve 2432, thus ensuring that the brush sleeve 2432 is always kept clean.
[0028] Furthermore, moving the brush 2431 upwards to its highest point corresponds to the end of its use (the brush 2431 is a consumable item and is not usually completely used up. Instead, a residual length is provided. Reaching this predetermined residual length is defined as the end of its use). A small portion of the brush 2431 now remains, which is why a thrust force applied to the brush 2431 by the commutator 242 causes it to wobble more. By inserting the sealing block 2442 into the dust cover 2441, the clamping force on the brush 2431 is further increased, thus preventing breakage. In this way, breakage of the brush 2431 can be effectively prevented when a small portion remains.
[0029] In the present embodiment, a through-hole 246 is formed in both the dust protection plate 2441 and the thrust block 2442; a vacuum adjustment plate 2443 is provided adjacent to the dust protection plate 2441; the uppermost area of the vacuum adjustment plate 2443 is provided with a locking block 2444 to engage in the through-hole 246 of the dust protection plate 2441. When the thrust block 2442 is inserted into the dust protection plate 2441, the locking block 2444 is separated from the dust protection plate 2441 and lowered, thereby generating an intake airflow and thus drawing in carbon powder resulting from the wear of the brush 2431.
[0030] In the present embodiment, the through-holes 246 formed in the push block 2442 and the dust shield 2441 serve to collect the carbon powder resulting from the wear of the brush 2431. Specifically, carbon powder resulting from the wear of the brush 2431 surface falls into the space between the brush 2431 and the brush sleeve 2432. The provided vacuum adjustment plate 2443 closes the through-holes 246 in the initial phase, thus preventing carbon powder from passing through the through-holes 246 under the dust shield 2441 and adhering to the copper conductor wire, which would cause a short circuit.When the thrust block 2442 is inserted into the dust shield 2441, that is, when a thrust rod provided below the through-hole 246 of the thrust block 2442 is inserted into the through-hole 246 of the dust shield 2441, a thrust plate, which is movably provided at the through-hole 246 of the dust shield 2441, is pressed towards the brush 2431, so that the through-holes 246 become larger and thus the vacuum adjustment plate 2443 is separated from the respective through-hole 246 and lowered. Now the vacuum adjustment plate 2443 resembles a rubber stopper in a syringe cylinder. Thus, a vacuum airflow is created, which draws in carbon powder located at the through-hole 246 of the dust shield 2441 so that it gets under the dust shield 2441.This prevents the brush from carrying out carbon powder after moving to the highest point, which then adheres to the commutator 242 and causes secondary contamination.
[0031] In the present embodiment, a preferred configuration for moving the dust protection plate 2441 and the vacuum adjustment plate 2443 is provided that the lowest areas of both components are each equipped with a spring 245. The difference lies in the fact that in the initial state, the spring 245 at the lowest area of the dust protection plate 2441 is compressed, while in the initial state, the spring 245 at the lowest area of the vacuum adjustment plate 2443 is in its normal state.
[0032] According to another aspect, the present invention further provides a simulation method for an integrated rotary encoder of an electric machine, comprising the use of the above simulator of an integrated rotary encoder of an electric machine and further comprising the following steps: Step S1: Receiving an excitation signal, which is output by a rotary encoder circuit of the electric machine control; Step S2: Receiving a sine signal and a cosine signal from the rotary encoder module 1; Step S3: Comparing the received excitation signal with the sine signal and the cosine signal to obtain a corresponding rotary encoder angle or rotary encoder speed; Step S4: Comparing the obtained rotary encoder angle or rotary encoder speed with a preset rotary encoder angle standard value or rotary encoder speed standard value; Step S5. Determining the qualification status of the electrical machine control according to the comparison result.
[0033] In summary, the integrated rotary encoder of an electric machine and the associated simulation method according to the present invention provide a current sine signal and a current cosine signal from the electric machine module 2 by means of the rotary encoder module 1. By comparing these signals with an excitation signal input by the electric machine control, it is determined whether a fault exists in the rotary encoder circuit of the electric machine control. Furthermore, by improving the brush assembly 24 of the electric machine module 2, an extended service life of the electric machine module 2 and reduced testing costs are achieved.
[0034] Individual components (parts whose specific structure is not further explained) used in the present application are standard parts or parts known to those skilled in the art. Their structures and principles can be learned by those skilled in the art from technical manuals or by conventional experimental methods. Furthermore, the software programs to which the present application relates are prior art, and the application does not relate to any improvement of these software programs.
[0035] In the present invention, the terms "attach," "connected," "join," or the like are to be understood in a broad sense unless expressly stated otherwise. Thus, they can refer, for example, to a permanent, detachable, or one-piece connection, as well as a mechanical or electrical connection. Furthermore, direct connections, indirect connections, connections made via an intermediate piece, and internal connections between two elements are also conceivable. Those skilled in the art in this field can use the circumstances as a basis to determine the intended meaning of the aforementioned terms according to the present invention.
[0036] In the description of the present invention, it should be noted that the terms "center," "top," "bottom," "left," "right," "vertical," "horizontal," "inside," "outside," etc., are used in relation to the directional or positional relationship shown in the respective drawing, solely to describe the invention and, where necessary, to simplify the description. In other words, these terms do not implicitly or explicitly refer to the positioning, design, or operation of the device or element in question in a predetermined position, so that there is no limitation of the invention in this respect either. Furthermore, it should be noted that the terms "first," "second," and "third" are not to be understood as an implicit or explicit indication of relative importance. Rather, they serve only for descriptive purposes.
[0037] In the embodiments described in this application, it is understood that the system, device, and method disclosed herein could be implemented in other ways. The aforementioned embodiments of the device have been described only schematically. For example, the units are categorized solely according to their logical functions. In practical implementation, the categorization can be carried out differently. For instance, several units or assemblies can be combined with one another or integrated into a different system. Alternatively, some features can be omitted or need not be implemented.Furthermore, a coupling or direct coupling or communication connection between displayed or discussed objects can be an indirect coupling and communication connection or an electrical, mechanical or other connection via some interfaces, devices or modules.
[0038] Units described as separate parts may, but do not necessarily, be physically separate. A component depicted as a single unit may, but does not necessarily, be a single physical unit. This means that both a single location and a distribution across multiple network units are conceivable. Depending on the actual requirements, some or all of these units can be selected to achieve the task of implementing the exemplary embodiments.
[0039] Furthermore, in the embodiments of the application, individual functional units can be integrated into a processing unit, or alternatively, be physically separate, or be integrated in pairs or more into a unit.
[0040] The description so far has been based on preferred embodiments of the present invention, and with the help of the above description, a person skilled in the art can make various modifications and adaptations without deviating from the scope of the technical ideas of the invention. The technical scope of the present invention is in no way limited to the content of the description and should rather be determined according to the scope of the claims. REFERENCE MARK LIST 1 rotary indicator module 10 first interface 11 Transformer housings 12 Rotary signal stator 13 Rotary indicator rotor 2 Electric machine module 20 second interface 21 Electric machine housings 22 Electric machine rotor 23 Electric machine stator 24 brush device 241 brush holders 242 Commutator 243 Brush arrangement 2431 brush 2432 Brush sleeve 244 Limitation order 2441 Dust protection plate 2442 Push block 2443 Vacuum adjustment plate 2444 Rastblock 245 spring 246 Through hole
Claims
Device for simulating a rotary encoder integrated into an electric machine, the device comprising a rotary encoder module (1) and an electric machine module (2); wherein an electric machine rotor (22) of the electric machine module (2) is connected to a rotary encoder rotor (13) of the rotary encoder module (1); wherein the rotary encoder module (1) is provided with a first interface (10) for connection to an external electric machine controller; wherein the rotary encoder module (1) is configured to receive rotation information from the electric machine module (2) and transmit it to the electric machine controller; and the electric machine module (2) and the electric machine controller are connected to each other via a second interface (20) to adjust the rotational speed and direction of rotation of the electric machine module (2); the rotary encoder module (1) comprises a transformer housing (11) and a rotary encoder stator (12);wherein both the rotary encoder rotor (13) and the rotary encoder stator (12) are arranged in the transformer housing (11); wherein the rotary encoder stator (12) is pushed onto the outer circumference of the rotary encoder rotor (13); the electric machine module (2) comprises an electric machine housing (21) and an electric machine stator (23); wherein both the electric machine stator (23) and the electric machine rotor (22) are arranged in the electric machine housing (21); wherein the electric machine stator (23) is pushed onto the outer circumference of the electric machine rotor (22); the electric machine module (2) further comprises a brush device (24); the brush device (24) is arranged in the electric machine housing (21) and is in contact with the electric machine rotor (22) to introduce an external current into the electric machine rotor (22); the brush device (24) comprises a brush holder (241), a commutator (242) and a brush assembly (243);wherein the brush holder (241) is arranged on the electric motor housing (21); the commutator (242) is slid onto the electric motor rotor (22); and the brush assembly (243) is arranged on the brush holder (241) and is in contact with the commutator (242); wherein the brush assembly (243) comprises a brush (2431) and a brush sleeve (2432); wherein the brush sleeve (2432) is arranged on the brush holder (241) and the brush (2431) is inserted into the brush sleeve (2432); wherein the brush sleeve (2432) further includes a limiting arrangement (244) for retaining and supporting the brush (2431); the limiting arrangement (244) comprises a dust protection plate (2441) which is pushed onto the lowest area of the brush (2431) and a thrust block (2442) which is arranged on the inner wall of the brush sleeve (2432);wherein the lowest area of the dust guard plate (2441) is provided with a wire hole for leading out a wire of the brush (2431); wherein a spring is provided below the lowest area of the dust guard plate (2441) to push the brush (2431) upwards; wherein the push block (2442) is arranged to push the side wall of the brush (2431); and wherein, when the brush (2431) moves upwards to its highest point, the push block (2442) is inserted into the dust guard plate (2441) to increase the thrust force on the side wall of the brush (2431). Device according to claim 1, characterized in that a through-hole (246) is formed in both the dust protection plate (2441) and the push block (2442); wherein a vacuum adjustment plate (2443) is provided adjoining the dust protection plate (2441); wherein the uppermost area of the vacuum adjustment plate (2443) is provided with a locking block (2444) to engage in the through-hole (246) of the dust protection plate (2441), wherein the locking block (2444) is separated from the dust protection plate (2441) and lowered when the push block is inserted into the dust protection plate (2441), thereby generating an intake airflow and thus drawing in carbon powder resulting from the wear of the brush (2431). Simulation method for an integrated rotary encoder of an electric machine, wherein the simulation method comprises: using the device according to one of claims 1 to 2 and further comprising the following steps: Step S1: Receiving an excitation signal output by a rotary encoder circuit of the electric machine control; Step S2: Receiving a sine signal and a cosine signal from the rotary encoder module (1); Step S3: Comparing the received excitation signal with the sine signal and the cosine signal to obtain a corresponding rotary encoder angle or rotary encoder speed; Step S4: Comparing the obtained rotary encoder angle or rotary encoder speed with a preset rotary encoder angle standard value or with a rotary encoder speed standard value; Step S5: Determining the qualification state of the electric machine control according to the comparison result.