Autonomous Shaft Revolution Counter with Signal Defect Detection
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Solution Overview
Problem
Existing systems for determining the number of revolutions of a rotationally mounted shaft suffer from high error rates, particularly when using Wiegand wires, due to issues with signal interpretation and potential defects or misalignments, which can lead to incorrect counting and malfunction detection.
Innovation Solution
A system that includes a permanent magnet connected to the shaft, a microgenerator (such as a Wiegand wire or pulse wire) with an energy buffer and memory device for storing revolution counts, and an angular sensor connected to a computer for monitoring and analyzing signal voltages, utilizing FRAM technology for long-term stability and statistical analysis of voltage pulses to detect defects and ensure accurate counting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a Wiegand wire is used as a microgenerator for revolution counting, then the system can operate without mechanical wear components, but signal interpretation errors occur leading to high error rates
Solution Approach 1:
The system continuously monitors the voltage signal from the Wiegand wire and compares it against expected characteristics. When deviations are detected (such as runt pulses or defective signals), the system generates warning messages and can trigger error signals, creating a feedback loop that maintains signal accuracy despite using wear-free Wiegand wire technology
Solution Approach 2:
The system analyzes multiple parameters of the voltage signal including amplitude, pulse width, and timing characteristics to distinguish between valid revolution signals and erroneous runt pulses. By monitoring these parameter changes, the system can filter out false signals while maintaining the benefits of Wiegand wire operation
2Use of energy by moving object
If the microgenerator operates autonomously without external power supply, then energy independence is achieved, but the ability to monitor and detect defects is reduced
Solution Approach 1:
The voltage signal from the Wiegand wire serves multiple functions simultaneously: it provides energy to the autonomous counter through the energy storage element, carries the revolution counting information, and enables defect detection through computer analysis. This multi-functionality allows the system to maintain energy autonomy while preserving monitoring capabilities
Solution Approach 2:
The voltage signal acts as an intermediary that transfers information between the autonomous microgenerator and the externally powered computer. The computer analyzes this intermediate signal to detect defects without requiring direct power from the autonomous counter, thus preserving energy independence while enabling monitoring
3Productivity
If signal pulses are counted without verification of their validity, then counting speed is maintained, but error rates increase due to runt pulses and defective signals
Solution Approach 1:
The system performs partial verification of signal pulses by checking key characteristics such as voltage amplitude and pulse timing. Rather than exhaustive analysis of every signal parameter, the system checks sufficient conditions to distinguish valid pulses from runt pulses, maintaining high counting speed while achieving adequate accuracy through selective verification
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system reduces error rates by enabling energy-autonomous revolution counting, detecting defects before malfunctions occur, and ensuring reliable monitoring and control of the shaft's rotation, with the ability to differentiate between valid and faulty signal pulses, thus enhancing the system's reliability and safety.
Implementation Method 1
the signal voltage generated by a micro-generator situated in an operative connection with the permanent magnet
Implementation Method 2
a permanent magnet is connected to the shaft in a torsionally fixed manner
Data Source
AI summary
System for ascertaining the number of revolutions of a rotationally mounted shaft, and method for ascertaining the number of revolutions of a rotationally mounted shaft, a permanent magnet being connected to the shaft in a torsionally fixed manner, the signal voltage generated by a microgenerator situated in an operative connection with the permanent magnet being supplied to an energy buffer, especially via a rectifier to a capacitor, a memory device for storing the number of revolutions being supplied from the energy buffer, the signal voltage of the microgenerator in particular being supplied to a counting logic device, which is supplied from the energy buffer and is connected to the memory device for reading out the respective old numerical value of the revolutions and for storing the respective newly ascertained numerical value of the revolutions.