Encoder Abnormality Detection via Dual Circuit Segmentation
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Solution Overview
Problem
Existing encoder systems face difficulties in distinguishing between abnormalities in the encoder and communication path issues, making it challenging to determine the cause of motor or table control malfunctions.
Innovation Solution
An encoder system with a positional data generation circuit, magnetic pole data generation circuit, first data abnormality detection circuit, and communication abnormality detector, which outputs alarm signals to differentiate between encoder and communication path abnormalities based on positional and magnetic pole data comparisons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If encoder output monitoring is performed by comparing parameters with feedback data, then abnormality detection capability is improved, but the ability to distinguish between encoder abnormalities and communication path abnormalities deteriorates
Solution Approach 1:
The abnormality detection function is segmented into two independent detection circuits: a first detection circuit in the encoder that generates first alarm signals, and a second detection circuit in the controller that generates second alarm signals. This segmentation allows independent verification at different locations, enabling distinction between encoder abnormalities (when only second circuit detects) and communication path abnormalities (when both circuits detect).
Solution Approach 2:
Alarm signals serve as intermediary indicators that carry abnormality information from the encoder to the controller. The first alarm signal from the encoder's detection circuit and the second alarm signal from the controller's detection circuit act as mediators that, when compared, reveal the source of the abnormality without requiring direct analysis of the encoded data itself.
2Loss of information
If dual detection circuits are implemented in encoder and controller, then abnormality source identification capability is improved, but device complexity increases
Solution Approach 1:
The detection circuits in both the encoder and controller perform multiple functions: they monitor encoder output abnormalities, verify communication integrity, and generate alarm signals for system-level diagnostics. This multi-functionality justifies the added complexity by providing comprehensive system monitoring and precise fault localization.
Solution Approach 2:
The system implements feedback through alarm signals that are transmitted from the encoder to the controller and compared with the controller's own detection results. This feedback mechanism enables the controller to determine the abnormality source based on the correspondence between first and second alarm signals, making the additional detection circuits worthwhile.
Data Source
AI summary
An encoder system includes an encoder for outputting positional data and magnetic pole data of an output axis of a motor; and a controller for communicating with the encoder. The encoder includes a positional data generation circuit; a magnetic pole data generation circuit; a first data abnormality detection circuit for detecting an abnormality based on the positional data and the magnetic pole data, and outputting a first alarm signal; and a parallel-to-serial conversion circuit for outputting the positional data, the magnetic pole data, and the first alarm signal to the controller. The controller includes a second data abnormality detection circuit for detecting an abnormality based on the positional data and the magnetic pole data, and outputting a second alarm signal; and a communication abnormality detector for detecting an abnormality in a communication path based on the first and second alarm signals.