Redundant Position Detection for Encoder Fault Motion Stops

Solution Overview

Problem

Existing encoder systems in automatic control devices lack reliable methods to detect final position output abnormalities, leading to potential device malfunctions and safety hazards due to inadequate detection of encoder faults.

Innovation Solution

A position detection component with two redundant channels, one using absolute and one using incremental detection methods, outputs three signals to determine abnormalities, ensuring timely and accurate motion control by isolating components to prevent fault propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single position detection channel is used, then the device complexity is low, but the reliability of fault detection is insufficient

Engineering Contradiction:

Improvefault detection reliabilityVSAvoidposition detection channel complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent creates a copy of the position detection function through a second position detection channel that mirrors the first channel. Both channels process position information independently, and their outputs are compared to detect faults. This copying approach enhances reliability without fundamentally changing the detection mechanism, as the second channel is essentially a redundant copy of the first.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent implements feedback by continuously comparing the position information from the first and second detection channels. The comparison result feeds back into the system to determine whether a fault has occurred. This feedback mechanism enables real-time fault detection by monitoring the consistency between the two independent detection pathways.

Inventive Principle:

Principle #23Feedback

2Reliability

If multiple position detection channels are used, then the fault detection capability is improved, but the device complexity increases

Engineering Contradiction:

Improveencoder fault detection capabilityVSAvoiddetection channel structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent makes the position detection component multi-functional by enabling it to perform both absolute position detection and incremental position detection through two different channels. The first channel provides absolute position information while the second channel provides incremental position information. This multi-functionality allows the same component to detect various types of encoder faults without requiring entirely separate detection systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a copy of the position detection function through a second position detection channel that mirrors the first channel. Both channels process position information independently, and their outputs are compared to detect faults. This copying approach enhances reliability without fundamentally changing the detection mechanism, as the second channel is essentially a redundant copy of the first.

Inventive Principle:

Principle #26Copying

3Loss of time

If redundant position detection channels are implemented, then the timeliness of abnormality detection is improved, but the processing complexity increases

Engineering Contradiction:

Improveabnormality detection timeVSAvoidsignal processing complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent creates a copy of the position detection function through a second position detection channel that mirrors the first channel. Both channels process position information independently, and their outputs are compared to detect faults. This copying approach enhances reliability without fundamentally changing the detection mechanism, as the second channel is essentially a redundant copy of the first.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent implements feedback by continuously comparing the position information from the first and second detection channels. The comparison result feeds back into the system to determine whether a fault has occurred. This feedback mechanism enables real-time fault detection by monitoring the consistency between the two independent detection pathways.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20250390103A1Motion control system, position detection assembly, and robot

Publication Date: 2025.12.25 BEIJING GEEKPLUS TECH CO LTD

AI summary

A motion control system includes: a position detection component, configured to output an absolute position signal, a first relative position signal and a second relative position signal, a driving component, configured to obtain the absolute position signal output by the position detection component, determine an abnormal situation of the position detection component based on the absolute position signal, and generate a motion stop command in case that the position detection component is determined to be abnormal; and a safety control component, configured to obtain the first relative position signal and the second relative position signal output by the position detection component, determine an abnormal situation of the position detection component based on the first relative position signal and the second relative position signal, and generate the motion stop command in case that the position detection component is determined to be abnormal.