Encoder Wiring Fault Localization With Dual Detection Circuits
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Solution Overview
Problem
Existing fault detection methods for encoder wiring in systems with encoders and controllers are inadequate, requiring extensive visual inspection and prolonged downtime to identify fault locations, especially in long encoder wiring configurations.
Innovation Solution
A fault detection device with dual detection circuits for encoder wiring, one for signals from the encoder to the controller and another for signals from the controller to the encoder, integrated with an interface part and a processor, allowing for easy identification of fault locations using a combination of receivers and drivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fault detection circuits are used, then fault detection capability is provided, but fault location identification requires extensive visual inspection and prolonged downtime
Solution Approach 1:
The encoder wiring is divided into multiple sections with detection circuits placed at specific locations (controller side and encoder side). This segmentation allows the system to identify which specific section contains the fault, transforming the fault detection from a binary state to a localized identification problem, thereby reducing inspection time.
Solution Approach 2:
Detection circuits are introduced as intermediary components between the controller and encoder. These circuits include detection input terminals connected to the encoder wiring and detection output terminals that provide fault information. The intermediary detection circuits enable automated fault location identification without requiring visual inspection of the entire wiring system.
2Length of moving object
If encoder wiring length is increased to cover larger system areas, then system coverage is improved, but fault location identification becomes more difficult and time-consuming
Solution Approach 1:
The long encoder wiring is segmented into multiple sections by placing detection circuits at intermediate locations. This divides the extensive wiring into manageable segments, each with its own detection capability. When a fault occurs in a long wiring configuration, the system can identify which segment contains the fault, making fault location identification as easy as checking the segmented sections rather than inspecting the entire long wiring run.
3Measurement precision
If dual detection circuits are implemented for bidirectional signal detection, then fault detection accuracy and location identification are improved, but device complexity increases
Solution Approach 1:
The detection circuits are designed with multi-functionality to handle both signal transmission directions. Each detection circuit can detect faults in both the encoder-to-controller signal path and the controller-to-encoder signal path. This universal design allows a single detection circuit configuration to serve multiple detection purposes, reducing the need for separate dedicated circuits for each direction and thereby limiting the increase in device complexity.
Data Source
AI summary
A fault detection device is provided which detects a fault having occurred in encoder wiring in a system including a controlled apparatus having an encoder and a controller controlling the controlled apparatus and, in the system, the encoder and the controller are connected with each other through the encoder wiring. In a case that a signal which is transmitted from the encoder to the controller is defined as a first signal, and a signal which is transmitted from the controller to the encoder is defined as a second signal, the fault detection device includes a first detection circuit which detects a fault in the encoder wiring through which the first signal is transmitted, and a second detection circuit which detects a fault in the encoder wiring through which the second signal is transmitted.