Encoder Anomaly Detection via Voltage and Pulse Analysis
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Solution Overview
Problem
Conventional anomaly detection technologies face challenges in reliably detecting anomalies in encoder and wiring systems, particularly when the motor is stopped, and are prone to erroneous judgments due to fast signal changes, leading to increased costs and complexity.
Innovation Solution
A multi-faceted anomaly monitoring device utilizing a microcomputer with voltage level, pulse number, and pulse width detection methods, which inputs encoder signals as analog and digital signals to detect anomalies based on voltage levels, pulse differences, and pulse widths, allowing for reliable detection during both motor operation and standstill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage level analysis is used for anomaly detection, then detection capability during motor stoppage is improved, but erroneous judgments during motor operation may occur
Solution Approach 1:
The patent implements dynamic anomaly detection by switching between voltage level analysis (when motor is stopped) and pulse number analysis (when motor is operating). This dynamic adaptation resolves the contradiction by using the appropriate detection method based on the motor's operational state, preventing erroneous judgments while maintaining detection capability.
Solution Approach 2:
The patent changes the detection parameter based on motor operation state: using voltage level as the detection parameter when the motor is stopped, and switching to pulse number as the detection parameter when the motor is operating. This parameter change resolves the contradiction between detection capability and measurement precision.
2Measurement precision
If pulse number analysis is used for anomaly detection, then detection accuracy during motor operation is improved, but detection capability during motor stoppage is reduced
Solution Approach 1:
The system dynamically selects the detection method based on motor state: pulse number analysis is activated when the motor is operating to ensure detection accuracy, while voltage level analysis is used when the motor is stopped to maintain detection capability. This dynamic selection resolves the contradiction.
Solution Approach 2:
The patent changes the detection parameter from pulse number (during operation) to voltage level (during stoppage), allowing the system to maintain both detection accuracy during operation and detection capability during stoppage, resolving the contradiction between these two requirements.
3Reliability
If multiple detection methods are implemented, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent implements multi-functionality by using a single control device that can perform both voltage level analysis and pulse number analysis. This universal approach improves system reliability through multiple detection methods while avoiding the complexity of separate dedicated detection systems for each method.
Solution Approach 2:
The patent merges voltage level analysis and pulse number analysis into a single integrated anomaly detection system. By combining these methods in one control device and switching between them based on motor state, the system achieves high reliability without the complexity of multiple independent detection systems.
4Reliability
If comprehensive anomaly detection is implemented, then detection coverage is improved, but cost increases
Solution Approach 1:
The patent achieves comprehensive anomaly detection coverage using a single multi-functional control device that can perform both voltage level analysis and pulse number analysis. This universal approach provides wide detection coverage (including both operating and stopped states) while avoiding the high costs associated with multiple separate detection systems.
Solution Approach 2:
The patent combines comprehensive anomaly detection capabilities into a single integrated system that switches between detection methods based on motor state. This merging provides extensive detection coverage (voltage-based detection during stoppage, pulse-based detection during operation) while maintaining cost-effectiveness by avoiding redundant hardware.
Data Source
AI summary
In an anomaly monitoring device, in which an output signal from an encoder is input as an analog input signal via a wiring system, for detecting anomalies in the encoder or the wiring system, provided are a voltage level based device, a pulse number based device and a pulse width based device. The voltage level based device detects anomalies when the voltage level of the analog input signal exists within a prescribed range. The pulse number based device detects anomalies when the difference in the numbers of pulses of digital signals corresponding to the analog input signals is equal to or greater than a prescribed threshold value. The pulse width based device detects anomalies when the pulse width of the digital signals, measured from a combined signal of the digital signals or each of the digital signals, is different from the pulse width in a past control period.