Encoder Failure Detection via Multi-Cycle Signal Synthesis
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Solution Overview
Problem
Conventional encoder failure detection techniques have low accuracy due to the lower resolution of magnetic-pole position data and require additional position detection signals, which increase hardware and manufacturing costs.
Innovation Solution
An encoder that computes intra-rotation position using multiple position-detection-signal generation systems with different cycles, allowing for failure determination based on a comparison between two intra-rotation positions calculated from existing position detection signals without additional signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic-pole position data is used for failure detection, then failure detection function is provided, but detection accuracy is low due to lower resolution
Solution Approach 1:
The patent creates a virtual copy of position detection signals through mathematical synthesis. The synthesis unit generates synthesized position detection signals by combining outputs from multiple position-detection-signal generation systems, creating a virtual signal that replicates the characteristics of actual position detection signals without requiring additional physical sensors.
2Measurement precision
If additional position detection signals are provided for failure detection, then failure detection accuracy is improved, but hardware complexity and manufacturing cost increase
Solution Approach 1:
The patent makes existing position detection signals serve multiple functions. The same position detection signals are used both for normal position detection and for failure detection by feeding them into multiple position-detection-signal generation systems, eliminating the need for dedicated failure detection sensors.
Solution Approach 2:
The encoder performs self-diagnosis by using its own internal resources. The comparison unit compares the synthesized position detection signals with the actual position detection signals to detect failures, allowing the system to monitor itself without external assistance or additional dedicated detection hardware.
3Reliability
If additional position detection signals are provided for failure detection, then failure detection capability is enhanced, but manufacturing cost increases due to additional hardware and calibration requirements
Solution Approach 1:
The patent creates a virtual copy of position detection signals through mathematical synthesis. The synthesis unit generates synthesized position detection signals by combining outputs from multiple position-detection-signal generation systems, creating a virtual signal that replicates the characteristics of actual position detection signals without requiring additional physical sensors.
Data Source
AI summary
The encoder includes a plurality of position-detection-signal generation systems that generates electrical signals as position detection signals having different cycles, respectively; a first computing unit that calculates first position data based on the position detection signals generated by the position-detection-signal generation systems; a second computing unit that calculates second position data based on electrical signals generated by fewer ones of the position-detection-signal generation systems than in the first computing unit; and a failure determination unit that determines whether the encoder is defective based on a comparison between the first position data and the second position data.