Encoder Communication Circuit for Fault Location Identification
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Solution Overview
Problem
Current encoder communication systems face challenges in identifying the fault location during communication abnormalities, leading to prolonged restoration times and potential misidentification of the abnormality, which can result in unnecessary origin resets and safety hazards.
Innovation Solution
An encoder communication circuit with a communicator and data generator that outputs predetermined position or speed data and alarm information through a serial interface, including a pattern that indicates the encoder is not in an initial state and prevents servo motor operation, allowing for safe identification of fault locations without invalidating origin information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If another encoder is connected to the communication cable to check for abnormalities, then the fault location can be identified, but the origin information is invalidated requiring time-consuming origin reset operations
Solution Approach 1:
The patent creates a simplified copy of the encoder called an 'encoder communication circuit' that replicates only the communication functionality. This circuit can be connected to the communication cable to test for abnormalities without requiring a full encoder replacement, thus avoiding the invalidation of origin information while still enabling fault location identification.
Solution Approach 2:
The encoder system is segmented into two functional parts: the actual encoder that maintains origin information and the encoder communication circuit that handles communication testing. This segmentation allows communication tests to be performed independently without affecting the origin information stored by the main encoder.
2Reliability
If another encoder is connected to check communication, then communication abnormalities can be detected, but expensive replacement encoders are consumed for diagnostic purposes
Solution Approach 1:
The encoder communication circuit is designed as a low-cost, disposable diagnostic tool. Instead of using expensive replacement encoders for testing, this circuit provides the necessary communication functionality at minimal cost, making it economical to use for diagnostic purposes without concern for consuming valuable components.
Solution Approach 2:
A simplified copy of the encoder's communication interface is created that suffices for diagnostic purposes. This copy includes only the essential communication capabilities needed to test the communication cable and control apparatus, eliminating the need to use expensive full-featured replacement encoders.
3Loss of time
If another encoder is connected during abnormality checking, then the fault can be identified, but the machine may be mistakenly placed in operating state creating safety hazards
Solution Approach 1:
The encoder communication circuit is designed with built-in protective features that prevent the machine from being mistakenly placed in an operating state during diagnostic operations. The circuit includes mechanisms to ensure that communication tests cannot inadvertently trigger machine operation, thus eliminating safety hazards while maintaining diagnostic effectiveness.
4Productivity
If communication abnormalities are not quickly identified, then restoration time increases, but complex origin reset procedures are required when origin information is invalidated
Solution Approach 1:
The encoder communication circuit provides a communication interface that allows for quick diagnostic operations without affecting the main encoder's origin information. By separating the communication testing function from the main encoder, the system enables rapid fault identification while avoiding the need for complex origin reset procedures.
Data Source
AI summary
When a communication abnormality occurs between an encoder and communication circuit apparatus in a work apparatus feeding back data output from encoders for control by a control apparatus, an encoder communication circuit is used in place of the encoder to identify the location of occurrence of the abnormality. The encoder communication circuit outputs encoder data comprised position or speed data and alarm data to said control apparatus when connected to the control apparatus through a communication cable.