Computational Encoder Relay for Filtering Vibration-Distorted Image Triggers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current machine vision systems using rotary encoders for locomotives suffer from mechanical play and vibrations, leading to uneven trigger signals that cause distorted images, especially at high speeds, and existing solutions require costly maintenance and installation.
Innovation Solution
A signal filter controller that determines the average pulse frequency of the trigger signal, applies frequency restrictions, and outputs a PWM signal with evenly spaced pulses to synchronize the image capturing device, minimizing the impact of mechanical play and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary encoder is synchronized to the wheel rotation to trigger image capturing, then the image capture timing is synchronized with wheel position, but mechanical play and vibrations cause uneven trigger signals leading to distorted images
Solution Approach 1:
The patent replaces the mechanical rotary encoder with a virtual encoder implemented through software algorithms. The virtual encoder calculates wheel position and speed based on GPS data, inertial measurements from accelerometers/gyroscopes, and odometer readings, rather than relying on mechanical components that suffer from play and vibration. This substitution eliminates the mechanical source of trigger signal unevenness while maintaining synchronized image capture timing.
Solution Approach 2:
The patent introduces multiple intermediary systems between the wheel rotation and image capture trigger: GPS satellite signals provide position data, inertial sensors provide motion data, and software algorithms process these inputs to generate a virtual encoder output. These intermediaries filter out the direct mechanical vibrations and play that would otherwise cause trigger signal distortion, while still maintaining accurate position-based triggering.
2Measurement precision
If mechanical devices are installed to minimize free motion of the encoder, then mechanical play is reduced, but installation requires maintenance shop visits resulting in additional expenses and time loss
Solution Approach 1:
The patent eliminates the need for physical encoder installation by replacing the mechanical device with a virtual encoder implemented in software. The virtual encoder uses data from existing sensors (GPS, accelerometers, gyroscopes, odometer) that are already part of the locomotive's standard equipment. This substitution removes the requirement for maintenance shop visits to install or calibrate mechanical encoders, eliminating both the installation time loss and the associated maintenance costs.
Solution Approach 2:
The virtual encoder system is self-configuring and automatically adapts to different wheel diameters and locomotive configurations through software parameters. The system uses readily available data from existing sensors without requiring manual calibration or mechanical adjustment, enabling the system to serve itself without external maintenance intervention.
3Productivity
If the rotary encoder outputs high frequency triggering signals at high speeds, then image capture frequency increases, but mechanical vibrations cause excess triggers manifesting as distorted images
Solution Approach 1:
The patent replaces the mechanical rotary encoder that generates trigger signals with a virtual encoder implemented through software. The virtual encoder calculates the appropriate trigger frequency based on GPS position changes, inertial sensor data, and odometer readings, rather than relying on mechanical rotation detection. This substitution maintains high capture rates at high speeds while eliminating the mechanical vibrations and play that cause spurious trigger signals and image distortion.
Solution Approach 2:
The virtual encoder system continuously receives feedback from multiple sensors (GPS position updates, accelerometer measurements, gyroscope data, odometer readings) to dynamically adjust the trigger signal frequency. This feedback mechanism ensures that the image capture rate accurately reflects the actual wheel rotation speed without being contaminated by mechanical vibrations, maintaining both high productivity and image quality at varying speeds.
Data Source
AI summary
Methods and systems for filtering a trigger signal from an encoder for triggering an image capturing device. In embodiments, a trigger signal may be received as an input signal from an encoder including a sequence of pulses for triggering the image capturing device. In embodiments, an average pulse frequency of the trigger signal over a period of time may be determined based on sampling a number of pulses in the trigger signal over the period of time, and frequency restrictions may be applied to the average pulse frequency to generate a trigger frequency. In embodiments, an output frequency may be determined based on the trigger frequency, and a pulse width modulation (PWM) signal having a frequency based on the output frequency may be determined for triggering the image capturing device.