CN110986728A - Gear meter counting device and meter counting method - Google Patents
Gear meter counting device and meter counting method Download PDFInfo
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- CN110986728A CN110986728A CN201911312481.9A CN201911312481A CN110986728A CN 110986728 A CN110986728 A CN 110986728A CN 201911312481 A CN201911312481 A CN 201911312481A CN 110986728 A CN110986728 A CN 110986728A
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- gear
- inductive sensor
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B5/00—Measuring arrangements characterised by the use of mechanical techniques
- G01B5/02—Measuring arrangements characterised by the use of mechanical techniques for measuring length, width or thickness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
- G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Measurement Of Length, Angles, Or The Like Using Electric Or Magnetic Means (AREA)
Abstract
The invention relates to the technical field of sensors, in particular to a gear meter counting device which comprises an inductive sensor and a mounting plate used for mounting the inductive sensor, wherein the detection direction of the inductive sensor is parallel to the rotating surface of a gear and is intersected with the axis of the gear, and the detection range of the inductive sensor is larger than the distance from a signal transmitting end to the nearest tooth top and smaller than the distance from the signal transmitting end to the nearest tooth root. According to the invention, the teeth with uneven edges of the gear are utilized, the inductive sensor is adopted to calculate the pulse to meter the meter, the use is simple, the installation is convenient, the price is low, the detection precision can be effectively ensured, and the inductive sensor can only detect the signal of the tooth top but not the signal of the tooth root in the specific implementation process, so that the effective pulse number is obtained. Meanwhile, the invention also claims a gear meter counting method.
Description
Technical Field
The invention relates to the technical field of sensors, in particular to a gear meter counting device and a meter counting method.
Background
In the production process of the warp knitting machine, the number of meters of the fabric needs to be measured under different speeds and weft laying densities, and at present, an encoder is installed on a gear shaft, and the number of pulses is calculated by the encoder to count the meters, but the cost is high.
In view of the above problems, the present inventors have made extensive research and innovation based on practical experience and professional knowledge in engineering applications of such products for many years, and together with the application of theory, in order to create a gear meter-counting device and a meter-counting method, so that the gear meter-counting device and the meter-counting method are more practical.
Disclosure of Invention
The invention provides a gear meter counting device, so that the problems in the background technology are effectively solved. Meanwhile, the invention also claims a gear meter counting method.
In order to achieve the purpose, the invention adopts the technical scheme that: the method comprises the following steps:
a gear length measuring device comprises an inductive sensor and a mounting plate used for mounting the inductive sensor, wherein the detection direction of the inductive sensor is parallel to the rotation surface of a gear and intersected with the axis of the gear, and the detection range of the inductive sensor is larger than the distance from a signal transmitting end to the nearest tooth top and smaller than the distance from the signal transmitting end to the nearest tooth bottom.
Further, the inductive sensors are provided with at least two and simultaneously emit signals towards different positions of the gear.
Further, at least two of the inductive sensors transmit signals simultaneously toward adjacent teeth of the gear.
Further, the mounting plate has the same number of mounting surfaces as the gears, and each of the mounting surfaces is used for mounting each of the inductive sensors and is perpendicular to the detection direction of each of the inductive sensors.
A gear meter counting method comprises the following steps:
s1: installing an inductive sensor to ensure that the detection direction of the inductive sensor is parallel to the rotating surface of the gear and is intersected with the axis of the gear;
s2: adjusting the position of the inductive sensor in the detection direction, so that the detection range of the inductive sensor is larger than the distance from a signal transmitting end to the nearest tooth top and smaller than the distance from the transmitting end to the nearest tooth bottom;
s3: the inductive sensor continuously detects the pulse number and records the collected pulse number in a detection range;
s4: and converting the pulse number into a meter length according to the rotation time and the size of the gear.
Further, in the gear meter counting method, the average value of the pulse numbers collected by a plurality of inductive sensors working simultaneously is calculated.
Further, the self-learning process of the single pulse time comprises the following steps:
and after detecting the running signal of the warp knitting machine for 1-3 seconds, starting self-learning timing, delaying for 1-3 seconds after stopping detection, and stopping the machine, and calculating the single pulse time according to the self-learning timing time and the number of pulses detected in the period of time.
Further: the method also comprises the following steps: after the detected waveform is stabilized, the falling edge of the inductive sensor is detected, a timer is started when the falling edge is detected, in addition, the rising edge of the inductive sensor is detected, the timer is cleared when the rising edge is detected, and the final pulse number is determined by comparing the time detected by the timer with the standard single pulse time.
Further, the final number of pulses is determined by comparing the time detected by the timer with the standard single pulse time, specifically, when the time detected by the timer is greater than or equal to the single pulse time, the number of pulses is increased by 1, and when the time detected by the timer is less than the single pulse time, the number of pulses is disregarded.
Through the technical scheme, the invention has the beneficial effects that:
the gear meter counting device and the meter counting method utilize the uneven teeth on the edge of the gear, and the inductive sensor is adopted to calculate the pulse to count the meter, so that the gear meter counting device is simple to use and convenient to install, is low in price, and can ensure certain precision.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic structural view of a gear meter counter;
FIG. 2 is a schematic diagram of the distance A from the signal emitting end of the inductive sensor to the nearest tooth crest;
FIG. 3 is a schematic illustration of the distance B from the signal emitting end of the inductive sensor to the nearest tooth root;
FIG. 4 is a block diagram of a gear metering device control system;
FIG. 5 is a flow chart of a gear meter method;
FIG. 6 is a diagram of a self-learning sensed waveform;
fig. 7 and 8 are graphs of waveforms of actual operation of two inductive sensors, including jitter portions at start-up and stop, respectively.
Reference numerals: 1. the sensor comprises an inductive sensor, 2, a mounting plate and 3, a gear.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.
As shown in fig. 1 to 3, a gear meter counter device includes an inductive sensor 1 and a mounting plate 2 for mounting the inductive sensor 1, wherein a detection direction of the inductive sensor 1 is parallel to a rotation surface of the gear 3 and intersects with an axis of the gear 3, and a detection range of the inductive sensor 1 is greater than a distance from a signal transmitting end to a nearest tooth crest and is smaller than a distance from the signal transmitting end to a nearest tooth root.
In this embodiment, utilize 3 marginal unevenness's of gear teeth, adopt inductance type sensor 1 to calculate the pulse and come the meter rice, simple to use simple to operate, the low price, and can effectively guarantee to detect the precision. Fig. 2 shows a distance a from a signal emitting end of the inductive sensor 1 to a nearest tooth crest, and fig. 3 shows a distance B from the signal emitting end of the inductive sensor 1 to a nearest tooth root, wherein a detection range of the inductive sensor 1 is greater than a and smaller than B, so that the inductive sensor 1 can only detect a signal of the tooth crest but not a signal of the tooth root, thereby obtaining an effective pulse number.
In the specific implementation process, the control system is composed of an inductive sensor, a PLC and a configuration screen as shown in FIG. 4, the inductive sensor detects the metal object in a non-contact and abrasion-free mode, wherein the detection distance of the sensor is preferably 4-8 mm, and therefore the detection precision is guaranteed. The PLC is used to process the pulse signal from the inductive sensor 1, counting the meter length. In this embodiment, taking the example that the gear has 64 teeth, the transmission distance between the teeth is 12.7mm, and the detected pulse number is D, the formula for calculating the length L of the meter is as follows:
L=12.7*Dmm。
the meter length can be calculated by only calculating the number of pulses the gear passes and the size of the gear 3.
In order to further improve the accuracy of the detection, due to the relatively complex production environment in the field, it is preferable that the inductive sensor 1 is provided with at least two and simultaneously emits signals toward different positions of the gear 3.
Thus, a more accurate measurement result can be obtained by averaging a plurality of values, wherein, taking the example of using two inductive sensors 1 as an example, the pulse numbers detected by the two inductive sensors are respectively D1 and D2, the above formula is changed as follows:
L=12.7*(D1+D2)/2 mm。
in order to reduce the installation difficulty and simultaneously enable each inductive sensor 1 to obtain a closer detection environment, it is preferable that at least two inductive sensors 1 simultaneously transmit signals towards adjacent teeth of the gear 3.
In the actual installation process, the inductive sensor 1 can be directly installed through external threads on the external part of the inductive sensor, the installation method is simple and easy to implement, in order to synchronously finish accurate positioning of the detection direction of the inductive sensor 1 in the process, the installation plate 2 is provided with installation surfaces with the same number as the gears 3, and each installation surface is used for installing each inductive sensor 1 and is perpendicular to the detection direction of each inductive sensor 1. Through the mode, the sensors can be quickly installed and positioned, only the threaded holes are correspondingly formed in each installation surface, and the installation surfaces of the installation plate 2 can be obtained through bending, so that the cost is low.
As shown in fig. 5, a gear meter counting method includes the following steps:
s1: the inductive sensor 1 is installed, so that the detection direction of the inductive sensor 1 is parallel to the rotating surface of the gear 3 and is intersected with the axis of the gear 3;
s2: adjusting the position of the inductive sensor 1 in the detection direction to ensure that the detection range of the inductive sensor 1 is larger than the distance from the signal transmitting end to the nearest tooth top and smaller than the distance from the transmitting end to the nearest tooth root;
s3: the inductive sensor 1 continuously detects and records the number of collected pulses in a detection range;
s4: the length of the meter is converted from the number of pulses, and the rotation time and size of the gear 3.
The average value of the number of pulses collected by the plurality of inductive sensors 1 working simultaneously is calculated, so that more accurate calculation can be realized.
Since the speed and weft density of each warp knitting machine are different, resulting in different individual pulse times for each warp knitting machine, in the preferred embodiment, the individual pulse time interval T0 is self-learned during start-up. The PLC detects the running signal of the warp knitting machine for 2 seconds, then starts self-learning timing for 8 seconds (8000 ms, which can be adjusted according to actual conditions), delays for 2 seconds after stopping detection and stops the machine, wherein 2 seconds before and after starting aims to remove shaking of starting and stopping, and detects the pulse number D0 in the 8 seconds, as shown in FIG. 6, a self-learning detection waveform is shown.
Single pulse time interval: t0 =8000/D0 ms.
The device will jitter on start and stop, as shown in fig. 7 and 8, which are pulse waveforms for start and stop of two inductive sensors 1, respectively, but the time interval of the jitter pulses is much smaller than the normal pulse interval, which in turn can be overcome by means of a suitable delay.
In the actual production process, it is difficult to ensure that in each detection process, an integral number of teeth are detected, and the undetected incomplete number of teeth may affect the measurement accuracy to some extent, and in the preferred embodiment, in order to overcome the above problem, the following processes are further included: after the detected waveform has stabilized, the falling edge of the inductive sensor 1 is detected, a timer is started when it is detected, and furthermore, the rising edge of the inductive sensor 1 is detected, the timer is cleared when it is detected, and the final pulse number is determined by comparing the time detected by the timer with the standard single pulse time.
Specifically, the final pulse number is determined by comparing the time detected by the timer with the standard single pulse time, wherein the pulse number is increased by 1 when the time detected by the timer is greater than or equal to the single pulse time, and the pulse number is not counted when the time detected by the timer is less than the single pulse time. In this way, the meter can be measured more accurately, wherein in the present embodiment, taking two inductive sensors 1 as an example, and continuing to refer to fig. 7 and 8, the program detecting the running signal starts counting during normal driving, the timers T1 and T2 are started when there is a falling edge, and the timers T1 and T2 are cleared when there is a rising edge. The timers T1 and T2 are then compared to T0,
The length L of the meter is calculated according to the pulse number of the two groups of sensors
L=12.7*(D1+D2)/2 mm。
It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. The gear length metering device is characterized by comprising an inductive sensor (1) and a mounting plate (2) used for mounting the inductive sensor (1), wherein the detection direction of the inductive sensor (1) is parallel to the rotation surface of a gear (3) and is intersected with the axis of the gear (3), and the detection range of the inductive sensor (1) is larger than the distance from a signal transmitting end to the nearest tooth crest and smaller than the distance from the signal transmitting end to the nearest tooth root.
2. Gear metering device according to claim 1, characterized in that the inductive sensor (1) is provided with at least two and simultaneously emits signals towards different positions of the gear (3).
3. Gear meter device according to claim 1, characterized in that at least two inductive sensors (1) are emitting signals simultaneously towards adjacent teeth of the gear wheel (3).
4. Gear metering device according to claim 2, characterized in that the mounting plate (2) has the same number of mounting faces as the gears (3), each mounting face being used for mounting the inductive sensor (1) respectively and being perpendicular to the detection direction of the inductive sensor (1).
5. A gear meter counting method is characterized by comprising the following steps:
s1: the inductive sensor (1) is installed, so that the detection direction of the inductive sensor (1) is parallel to the rotating surface of the gear (3) and is intersected with the axis of the gear (3);
s2: adjusting the position of the inductive sensor (1) in the detection direction, so that the detection range of the inductive sensor (1) is larger than the distance from a signal transmitting end to the nearest tooth top and smaller than the distance from the transmitting end to the nearest tooth bottom;
s3: the inductive sensor (1) continuously detects and records the number of acquired pulses in a detection range;
s4: the length of the meter is converted according to the number of pulses and the rotating time and size of the gear (3).
6. The gear meter counter method according to claim 5, wherein:
and calculating the average value of the pulse numbers collected by the inductive sensors (1) working simultaneously.
7. The gear meter counter method according to claim 5, wherein: the method also comprises the following steps in the self-learning process of the single pulse time:
and after detecting the running signal of the warp knitting machine for 1-3 seconds, starting self-learning timing, delaying for 1-3 seconds after stopping detection, and stopping the machine, and calculating the single pulse time according to the self-learning timing time and the number of pulses detected in the period of time.
8. The gear meter counting method according to any one of claims 5 to 7, wherein: the method also comprises the following steps: after the detected waveform is stabilized, the falling edge of the inductive sensor (1) is detected, a timer is started when the falling edge is detected, in addition, the rising edge of the inductive sensor (1) is detected, the timer is cleared when the rising edge is detected, and the final pulse number is determined by comparing the time detected by the timer with the standard single pulse time.
9. The gear meter counter method according to claim 8, wherein: the final pulse number is determined by comparing the time detected by the timer with the standard single pulse time, specifically, when the time detected by the timer is greater than or equal to the single pulse time, the pulse number is increased by 1, and when the time detected by the timer is less than the single pulse time, the pulse number is not counted.
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CN201911312481.9A CN110986728A (en) | 2019-12-18 | 2019-12-18 | Gear meter counting device and meter counting method |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN113233244A (en) * | 2021-05-27 | 2021-08-10 | 宏文科技(广东)有限公司 | Magnetic powder receiving and discharging automatic induction machine |
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