Angle Sensor Correction for Step Motor Accuracy
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Solution Overview
Problem
Step motors using open-loop control lack feedback mechanisms, leading to potential lost steps and decreased accuracy, while angle sensors prone to wear and tear result in gradual deviation from ideal curves, reducing accuracy and requiring frequent maintenance.
Innovation Solution
A method and device for correcting an angle sensor by rotating the step motor by a preset angle, reading the sensor voltage, determining deviations from a preset voltage curve, recording offsets, and compensating for sensing angles, thereby extending sensor life and maintaining accuracy without additional devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an angle sensor is disposed on the rotating shaft to detect actual rotation angle, then the accuracy of controlling movement is improved, but the sensor is prone to wear and tear after long period use, leading to gradual deviation from ideal curve
Solution Approach 1:
The patent applies parameter changes by introducing offset correction parameters. The controller calculates offset values based on the difference between detected angles and expected angles, then applies these offset parameters to correct subsequent angle readings. This transforms the sensor's output parameters to compensate for wear-induced deviations, maintaining measurement precision without requiring sensor replacement.
2Measurement precision
If an encoder is added to control movement accuracy, then the endpoint error detection is improved, but it only detects endpoint error and cannot prevent lost steps during operation
Solution Approach 1:
The patent implements continuous feedback by constantly monitoring the angle sensor output during motor operation. The controller compares detected angles with expected angles at each step, calculates real-time offsets, and corrects the control signals accordingly. This continuous feedback mechanism prevents lost steps during operation, not just at endpoints, thereby improving reliability throughout the entire operation cycle.
3Device complexity
If open-loop control is adopted for step motor, then the device complexity is reduced, but there is no feedback mechanism to determine whether the motor has lost step
Solution Approach 1:
The patent enables the open-loop control system to self-correct by using the angle sensor feedback internally. The controller monitors the sensor output, calculates offsets, and adjusts control commands without requiring external intervention or complex closed-loop control architecture. This self-service approach maintains the simplicity of open-loop control while improving reliability through automated correction.
Data Source
AI summary
A method for correcting an angle sensor is applied to a step motor including an angle sensor, where the angle sensor rotates with the step motor, and the method for correcting an angle sensor includes the following steps: rotating the step motor by a preset angle to a first position; reading a first voltage of the angle sensor when the angle sensor is rotated to the first position; determining whether the first voltage deviates from a preset voltage curve; if yes, recording a first offset of the first voltage relative to the preset voltage curve; and compensating for a sensing angle of the angle sensor according to the first offset. A device for correcting an angle sensor is further provided.