CN111457953A - Automatic calibration detection system and method for rotary encoder - Google Patents
Automatic calibration detection system and method for rotary encoder Download PDFInfo
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Abstract
The invention discloses an automatic calibration detection system and method for a rotary encoder, the system comprises a standard motor (4), a servo control unit (7), an induced electromotive force sampling unit (8) and a detection control unit (9), the detection control unit (9) is used for sending a control signal to the servo control unit (7) to control the movement of the standard motor (4), carrying out precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected, and carrying out magnetic pole position zeroing processing according to the induced electromotive force and the angular position of the encoder to be detected, after the rotary encoder is installed on the motor to be detected, the invention can automatically complete the precision detection and calibration of the rotary encoder and the zeroing of the magnetic pole position, thereby greatly improving the reliability and the consistency of products and reducing the production cost, the production efficiency is improved.
Description
Technical Field
The invention relates to the field of motor rotary encoders, in particular to an automatic calibration detection system and method for a rotary encoder.
Background
The rotary encoder is a sensor device for feeding back the angular position of a motor rotor in real time in the servo motor, and the servo driver controls the servo motor in real time through position parameters fed back by the rotary encoder. The high-precision rotary encoder has important significance for servo control. In the actual servo motor production process, can assemble the rotary encoder of apolegamy in motor spindle rear end, because in the installation, there are circumstances such as mechanical deviation, can influence rotary encoder's precision, especially split type rotary encoder, for example: the mounting structure of split type magnetic rotary encoder is generally that, the magnet that produces the magnetic field is installed on servo motor rear end main shaft, and the magnetic encoder circuit board passes through support or pedestal frame on annular magnet, and such mounting means is simple, and is with low costs, but can cause very big precision deviation for rotary encoder because the deviation of structure, the concentricity of installation, altitude control and electron device itself. Therefore, there is a need for a servo motor that can perform precision detection and compensation data writing after installation of a rotary encoder for each servo motor with the rotary encoder installed in the production process of the servo motor, so as to increase the absolute positioning precision of the rotary encoder and reduce the fraction defective of products.
In addition, for the method of zeroing the magnetic pole positions of the rotary encoder and the servo motor, a common manual zeroing mode is that a current smaller than the rated current of the motor is applied to a three-phase winding of the servo motor to lock a rotor of the motor, the position displayed by the rotary encoder is the position of the magnetic pole, and then the rotary encoder is subjected to absolute position resetting operation. This method can find the magnetic pole position, but the magnetic pole position deviation is large.
The precision compensation and the magnetic pole position detection of the rotary encoder are the work which must be completed in the production and installation process of the servo motor, and usually, the precision detection of the rotary encoder is firstly carried out and then the magnetic pole position detection is carried out.
Disclosure of Invention
The invention aims to solve the technical problems that the precision of a rotary encoder cannot be guaranteed after the rotary encoder of a servo motor in the prior art is installed, no effective method is available for production detection to detect key parameters of the rotary encoder, zero setting of the magnetic pole position is needed after the rotary encoder is installed on the servo motor, the traditional magnetic pole zero setting method needs manual operation, the motor can be damaged under the condition of misoperation, and the magnetic pole position error of the manual zero setting is large, and provides an efficient and accurate automatic calibration detection system and method for the rotary encoder, so that the calibration accuracy, the detection efficiency and the convenience are improved, the system can automatically complete the detection and the calibration of the precision of the rotary encoder and the zero setting of the magnetic pole position after the motor to be detected is installed, the production efficiency is greatly improved, the production cost is saved.
The technical scheme adopted by the invention for solving the technical problems is as follows: construct a rotary encoder automatic calibration detecting system, including standard motor, servo control unit, induced electromotive force sampling unit, detection control unit, wherein:
the standard motor is used for being connected with a motor to be tested so as to drive the motor to be tested to synchronously act, a standard encoder is installed on the standard motor, and a coder to be tested is installed on the motor to be tested;
the servo control unit is connected with the standard motor and the standard encoder and is used for driving the standard motor and acquiring the angle position of the standard encoder;
the induced electromotive force sampling unit is used for sampling induced electromotive force generated by the motor to be tested in the rotating process;
the detection control unit is respectively connected with the induced electromotive force sampling unit, the servo control unit and the encoder to be detected and is used for sending a control signal to the servo control unit to control the motion of the standard motor, performing precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected and performing magnetic pole position zeroing processing according to the induced electromotive force and the angular position of the encoder to be detected.
Preferably, the system further comprises: go up backup pad, bottom suspension fagging, support column, shaft coupling, go up backup pad, bottom suspension fagging and just to setting up and pass through the support column is connected, standard motor sets up on the bottom suspension fagging, the motor setting that awaits measuring is in go up on the backup pad, standard motor passes through the coupling joint the motor that awaits measuring.
Preferably, the detection control unit includes a processing subunit and a communication control subunit, the processing subunit is responsible for processing the control signal and the data, and the communication control subunit is responsible for forwarding the control signal and the data.
Preferably, the communication control subunit includes:
one path of communication interface is connected with the encoder to be tested to read data of the encoder to be tested, and the other path of communication interface is connected with the processing subunit to perform data interaction with the processing subunit;
the servo control interface is connected with the servo control unit to send a control signal to the servo control unit so as to control the motion of the standard motor, and the servo control unit is used for acquiring the angular position of the standard encoder;
and the induced electromotive force signal detection interface is connected with the induced electromotive force sampling unit to acquire the induced electromotive force.
Preferably, the precision compensation process includes:
analyzing the angle position fed back by the encoder to be tested in the multi-turn rotating process of the standard motor to obtain the most value of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value;
when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result;
and when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
Preferably, after the precision compensation processing, the detection control unit performs the zero adjustment processing on the magnetic pole position when the integral nonlinearity and the differential nonlinearity of the encoder to be detected are respectively detected to meet the requirements in the static state and the rotating process of the motor to be detected.
Preferably, the magnetic pole position zeroing process includes:
determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time;
and after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
Preferably, the induced electromotive force sampling unit is configured to collect input signals of an U, V, W three-phase power line of the motor to be detected, and output the U, V-phase input signals after subtracting the W-phase input signals, respectively.
In another aspect of the present invention, an automatic calibration and detection method for a rotary encoder is further configured, and is implemented based on the system in any one of the foregoing embodiments, the method includes:
performing precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected;
and carrying out zero setting treatment on the magnetic pole position according to the induced electromotive force and the angular position of the encoder to be detected.
Preferably, the performing precision compensation processing on the encoder to be measured according to the obtained angular positions of the standard encoder and the encoder to be measured includes:
analyzing the angle position fed back by the encoder to be tested in the multi-turn rotating process of the standard motor to obtain the most value of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value;
when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result;
and when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
Preferably, the zero-setting processing of the magnetic pole position according to the induced electromotive force and the angular position of the encoder to be measured includes:
after the result of the precision compensation processing is verified to meet the requirement, determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time;
and after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
The automatic calibration and detection system and method for the rotary encoder have the following beneficial effects: after the rotary encoder is installed on the motor to be tested, the precision detection and calibration of the rotary encoder and the zero setting work of the magnetic pole position can be automatically completed, the reliability and consistency of products are greatly improved, the production cost is reduced, and the production efficiency is improved.
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 embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts:
FIG. 1 is a schematic diagram of the automatic calibration and detection system of the rotary encoder of the present invention;
FIG. 2 is a schematic diagram of a servo control interface;
FIG. 3 is a flow chart of the method of the present invention for automatic calibration detection of a rotary encoder;
FIG. 4 is a diagram illustrating a precision deviation curve measured before precision compensation processing is performed on an encoder to be measured in an exemplary embodiment;
FIG. 5 is a diagram illustrating a deviation curve of accuracy obtained by forward rotation testing after performing accuracy compensation on an encoder to be tested, according to an exemplary embodiment;
FIG. 6 is a diagram illustrating a precision deviation curve obtained by performing a reverse test after performing precision compensation on an encoder to be tested, as measured in an exemplary embodiment;
fig. 7 is a schematic view of a magnetic pole position detection curve in one embodiment.
Detailed Description
The invention provides an efficient and accurate automatic calibration and detection system and method for a rotary encoder, aiming at solving the problems that in the prior art, the precision of the rotary encoder cannot be guaranteed after the rotary encoder of a servo motor is installed, no effective method is available for production detection to detect key parameters of the rotary encoder, zero adjustment of a magnetic pole position is needed after the rotary encoder of the servo motor is installed, the traditional magnetic pole zero adjustment method needs manual operation, the damage of the motor and other conditions can be caused under the condition of misoperation, and the error of the magnetic pole position of the manual zero adjustment is large. Therefore, the invention has the main idea that the automatic calibration detection system of the rotary encoder is designed to comprise a standard motor, a servo control unit, an induced electromotive force sampling unit, a communication control subunit and a processing subunit, wherein the standard motor is connected with a motor to be detected so as to drive the motor to be detected to synchronously act, the standard motor is driven by the servo control unit, the induced electromotive force generated in the rotation process of the motor to be detected is sampled by the induced electromotive force sampling unit, the detection control unit is respectively connected with the induced electromotive force sampling unit, the servo control unit and the encoder to be detected, the detection control unit can issue a control signal to the servo control unit to control the motion of the standard motor on one hand, and can perform precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected on the other hand, and carrying out zero setting treatment on the magnetic pole position according to the induced electromotive force and the angular position of the encoder to be detected. Therefore, the system can automatically complete the detection and calibration of the precision of the rotary encoder and the zero setting work of the magnetic pole position after the motor to be detected is installed, greatly improves the production efficiency and saves the production cost.
To facilitate an understanding of the invention, the invention will now be described more fully with reference to the accompanying drawings. Exemplary embodiments of the invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. It should be understood that the embodiments and specific features in the embodiments of the present invention are described in detail in the present application, but not limited to the present application, and the features in the embodiments and specific features in the embodiments of the present invention may be combined with each other without conflict.
Referring to fig. 1, in one aspect of the present invention, an automatic calibration and detection system for a rotary encoder is constructed, and includes a standard motor 4, a servo control unit 7, an induced electromotive force sampling unit 8, and a detection control unit 9. The servo control unit 7 is connected with the standard motor 4 and the standard encoder, and the detection control unit 9 is respectively connected with the induced electromotive force sampling unit 8, the servo control unit 7 and the encoder to be detected. And a standard encoder is installed on the standard motor 4, and a to-be-detected encoder is installed on the to-be-detected motor 5.
The standard motor 4 is used for being connected with a motor 5 to be tested so as to drive the motor 5 to be tested to synchronously act, and the servo control unit 7 is used for driving the standard motor 4, carrying out position control and rotating speed control on the standard motor 4 and acquiring angle position data of a standard encoder; the induced electromotive force sampling unit 8 is used for sampling the induced electromotive force generated by the motor 5 to be detected in the rotation process; the detection control unit 9 is used for issuing a control signal to the servo control unit 7 to control the motion of the standard motor 4, performing precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected, and performing magnetic pole position zeroing processing according to the induced electromotive force and the angular position of the encoder to be detected.
The test precision of the whole system is determined by the standard motor 4 and the servo control unit 7, the control precision of the servo control unit 7 selected by the invention reaches +/-0.004167 degrees, the standard encoder carried in the standard motor 4 is a high-precision photoelectric encoder, and the positioning precision reaches +/-15 arc seconds.
Preferably, in order to facilitate the installation of the motor 5 to be tested, the system further comprises: go up backup pad 1, bottom suspension fagging 2, support column 3, shaft coupling 6, go up backup pad 1, 2 level settings of bottom suspension fagging, just go up backup pad 1, bottom suspension fagging 2 from top to bottom just to setting up and passing through support column 3 connects, standard motor 4 sets up on the bottom suspension fagging 2, the motor 5 that awaits measuring sets up go up on the backup pad 1, standard motor 4 passes through shaft coupling 6 connects the motor 5 that awaits measuring. After the coupling 6 between the standard motor 4 and the motor 5 to be measured is locked, the motor 5 to be measured can rotate at a plurality of same angles when the standard motor 4 rotates at a plurality of angles.
The detection control unit 9 includes a processing subunit 92 and a communication control subunit 91, the processing subunit 92 is responsible for processing the control signal and the data, and the communication control subunit 91 is responsible for forwarding the control signal and the data. Specifically, the communication control subunit 91 includes: two-way communication interface, servo control interface, induced electromotive force signal detection interface.
The two paths of communication interfaces are respectively a 485 communication interface and a USB communication interface. And the 485 communication interface is connected with the encoder to be tested so as to read the data of the encoder to be tested. The USB communication interface is connected to the processing subunit 92 for data interaction with the processing subunit 92. The processing subunit 92 sends a corresponding control signal (instruction) to the communication control subunit 91 through the USB communication interface, and the communication control subunit 91 executes a corresponding action after receiving the control signal, where the control signal contains: turning on/off a power supply of the encoder to be tested, reading/writing data of the encoder to be tested, turning on/off a power supply of the standard motor 4, shifting the standard motor 4 for a plurality of distances, and the like.
And the induced electromotive force signal detection interface is connected with the induced electromotive force sampling unit 8 to acquire the induced electromotive force.
The communication control subunit 91 reads the angular position of the standard encoder, specifically, determines the angular position by counting the pulse signals in an incremental form received by the servo control interface, as shown in fig. 2, the servo control units 7 (also called servo controllers) of general motors are all configured with a DI/DO (input/output) interface connected with the outside, the communication control subunit 91 is provided with corresponding control signals (commands) to communicate with the servo control unit 7, wherein P L S,/P2S is a pulse command input terminal SIGN,/SIGN command input terminal C L R,/C L R is a position deviation clearing input terminal Z,/Z is an encoder frequency dividing pulse output terminal, i _ coi is a positioning completion output terminal i-y _ i is a position deviation clearing input terminal, Z is an encoder frequency dividing pulse output terminal, i _ coi is a positioning completion output terminal, B is a-B is a position deviation clearing input terminal, B is a signal output terminal, B is a signal output terminal B is a signal, B signal is generated, a signal is a signal, B signal is a signal, a signal is generated, a signal is transmitted to an alarm signal, a signal is generated, a signal is output terminal, a signal is output signal, a signal is generated, a signal is output signal, a signal is generated, a signal is output signal is generated, a signal output signal is output signal, a signal is output signal.
The induced electromotive force sampling unit 8 is configured to collect input signals of the U, V, W three-phase power line of the motor 5 to be measured, and output the U, V-phase input signals after subtracting the W-phase input signals, respectively.
The following describes in detail the specific procedures of the precision compensation process and the magnetic pole position zeroing process of the present system. After the precision compensation processing, the invention carries out the zero setting processing of the magnetic pole position, and the specific process is as follows:
1) analyzing the angle position fed back by the encoder to be tested in the process of rotating the standard motor 4 for multiple circles to obtain the most value (the maximum value and the minimum value) of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value.
On one hand, the processing subunit 92 sends an instruction to the communication control subunit 91, and after the communication control subunit 91 correctly receives the instruction, the communication control subunit sends a control signal (instruction) to the servo control unit 7 through the servo control interface, where the sent instruction includes: the method comprises the steps of turning ON a power supply instruction of an encoder, turning ON an SV _ ON instruction, setting a motor rotation direction instruction, setting a rotation speed instruction, setting a motor rotation N-turn instruction, reading an RAM address data instruction of the encoder to be detected, and setting a motor rotation stopping instruction. The angular position generated by N turns of the encoder is stored in the RAM of the encoder. On the other hand, the data of the angular position of the encoder to be measured is sent to the communication control subunit 91 through the 485 communication interface, and then is handed to the processing subunit 92 for data analysis to implement the precision compensation processing.
Specifically, the angular position is an original signal generated by the encoder, which is a sine and cosine signal, and the mathematical expressions are respectively: x is AX×cosα+OX，Y＝AY×sinα+OYWherein, X represents a cosine signal, and Y represents a sine signal; a. theXAnd AYRepresenting an amplitude value; o isXAnd OYRepresenting the bias, then:
wherein, XmaxRepresenting the maximum, X, of the sinusoidal signal in the acquired angular position dataminRepresenting collected angular position dataMinimum value of the sinusoidal signal in (1), YmaxRepresenting the maximum value, Y, of the cosine signal in the acquired angular position dataminRepresents the minimum value of the cosine signal in the collected angular position data.
2) And when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result.
AX、AY、OX、OYA limited value is preset, and if the corresponding limit value is not exceeded, the requirement can be considered to be met, such as the lower limit value<AX<The upper limit value is considered to be AXMeets the requirements. If the requirements are not met, the calibration is considered to fail.
The plurality of detection positions in one rotation period are suggested to be equidistantly spaced, i.e., the angular distance between any two adjacent detection positions is the same. After dividing a rotation period into a plurality of detection positions, the processing subunit (92) compares the angle positions fed back by the standard encoder and the encoder to be detected at each detection position, takes the difference value of the two as the precision deviation on the corresponding detection position, and if the detection position is taken as the abscissa and the precision deviation is taken as the ordinate, a precision deviation curve is formed.
In order to obtain a precision deviation curve through data analysis, on one hand, the processing subunit 92 sends an instruction to the communication control subunit 91 to send a displacement signal through a servo control interface P L S and/P L S to control the motor to move, on the other hand, the processing subunit 92 sends an instruction to the communication control subunit 91 to read the angle position fed back by the encoder to be detected and the standard encoder at each detection position, the communication control subunit 91 specifically feeds back the actually rotating pulse count through the servo control interfaces a, B and/B to determine the angle position data of the standard encoder at each detection position, the angle position data of the encoder to be detected at each detection position is obtained through a 485 communication interface, and after the processing subunit 92 reads the angle position data of the encoder to be detected and the standard encoder at each detection position within a circle, the precision deviation of the encoder to be detected at each detection position can be analyzed through comparing the angle positions fed back by the encoder to the standard encoder to form the precision deviation curve.
3) And when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
For example, if the accuracy deviation does not exceed the maximum allowable error, the accuracy deviation is considered to be satisfactory. When the precision deviation of all the detection positions meets the requirement, the precision deviation of each detection position can be directly written into the encoder to be detected, and the encoder to be detected can carry out precision compensation according to the precision deviation.
4) After the precision compensation processing, whether the integral nonlinearity and the differential nonlinearity of the encoder to be detected meet the requirement is detected respectively in the static state and the rotating (forward rotation or reverse rotation) process of the motor 5 to be detected, if the integral nonlinearity and the differential nonlinearity meet the requirement, the calibration is determined to be unqualified, and the subsequent zero setting processing of the magnetic pole position is performed only if the requirement is met.
The integral nonlinearity of the encoder to be detected in the static state and the rotation (forward rotation or reverse rotation) process of the motor 5 to be detected can be detected in the same manner as in the step 2), namely, under the static state and the rotation (forward rotation or reverse rotation) condition of the motor 5 to be detected, the angular positions of the encoder to be detected and the standard encoder are collected and compared to obtain the precision deviation, and if the precision deviation meets the requirement, the integral nonlinearity is considered to be qualified. The differential nonlinearity is to detect the floating range of the data of the encoder to be detected at each detection position, for example, at the same detection position, obtain data of a plurality of angle positions, compare the maximum value with the minimum value to obtain the floating value of the detection position, and if the floating values of all the detection positions meet the requirement, the differential nonlinearity is considered to be qualified.
5) And determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time.
For example, the processing subunit 92 sends a command to the communication control subunit 91, and the communication control subunit 91 allows the servo control unit 7 to rotate at a rotation speed of 500RPM according to the correctly received command content, at which the permanent magnet on the rotor and the winding coil inside the motor 5 to be measured act to generate induced electromotive force. The signal is conditioned by the induced electromotive force sampling unit 8 and then input to the communication control subunit 91.
The induced electromotive force can output four pulse edges (a four-pole motor) in one rotation period, the pulse edges are the motor phase change time, and the angular position of the encoder to be detected is read and recorded at the motor phase change time.
6) And after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
Specifically, assuming that the number of pole pairs of the motor to be measured is M and the rotation period is L, data of the angular position M × L is recorded, and the calculation method of the magnetic pole position is as follows:
wherein, XiIndicating the recorded angular position, K the known multiplied coefficient, R the resolution of the encoder to be measured and S the magnetic pole position. If the size of the magnetic pole position is within the threshold range, the magnetic pole position can be considered to meet the requirement and can be written into the encoder to be tested.
Referring to fig. 3, based on the same inventive concept, in another aspect of the present invention, an automatic calibration detection method for a rotary encoder is configured, and the method is implemented based on the above system, and includes:
s1: performing precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected;
s2: and carrying out zero setting treatment on the magnetic pole position according to the induced electromotive force and the angular position of the encoder to be detected.
Wherein, step S1 specifically includes:
s101: analyzing the angle position fed back by the encoder to be tested in the process of rotating the standard motor 4 for multiple circles to obtain the most value of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value;
on one hand, the processing subunit 92 sends an instruction to the communication control subunit 91, and after the communication control subunit 91 correctly receives the instruction, the communication control subunit sends a control signal (instruction) to the servo control unit 7 through the servo control interface, where the sent instruction includes: the method comprises the steps of turning ON a power supply instruction of an encoder, turning ON an SV _ ON instruction, setting a motor rotation direction instruction, setting a rotation speed instruction, setting a motor rotation N-turn instruction, reading an RAM address data instruction of the encoder to be detected, and setting a motor rotation stopping instruction. The angular position generated by N turns of the encoder is stored in the RAM of the encoder. On the other hand, the data of the angular position of the encoder to be measured is sent to the communication control subunit 91 through the 485 communication interface, and then is handed to the processing subunit 92 for data analysis to implement the precision compensation processing.
Specifically, the angular position is an original signal generated by the encoder, which is a sine and cosine signal, and the mathematical expressions are respectively: x is AX×cosα+OX，Y＝AY×sinα+OYWherein, X represents a cosine signal, and Y represents a sine signal; a. theXAnd AYRepresenting an amplitude value; o isXAnd OYRepresenting the bias, then:
wherein, XmaxRepresenting the maximum, X, of the sinusoidal signal in the acquired angular position dataminRepresenting the minimum value, Y, of the sinusoidal signal in the acquired angular position datamaxRepresenting the maximum value, Y, of the cosine signal in the acquired angular position dataminRepresents the minimum value of the cosine signal in the collected angular position data.
S102: when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result;
AX、AY、OX、OYa limited value is preset, and if the corresponding limit value is not exceeded, the requirement can be considered to be met, such as the lower limit value<AX<The upper limit value is considered to be AXMeets the requirements. If the requirements are not met, the calibration is considered to fail.
The plurality of detection positions in one rotation period are suggested to be equidistantly spaced, i.e., the angular distance between any two adjacent detection positions is the same. The processing subunit 92 divides a rotation period into a plurality of detection positions, compares the angle positions fed back by the standard encoder and the encoder to be detected at each detection position, and uses the difference between the two positions as the precision deviation on the corresponding detection position, and if the detection position is taken as the abscissa and the precision deviation is taken as the ordinate, a precision deviation curve is formed.
In order to obtain a precision deviation curve through data analysis, on one hand, the processing subunit 92 sends an instruction to the communication control subunit 91 to send a displacement signal through a servo control interface P L S and/P L S to control the motor to move, on the other hand, the processing subunit 92 sends an instruction to the communication control subunit 91 to read the angle position fed back by the encoder to be detected and the standard encoder at each detection position, the communication control subunit 91 specifically feeds back the actually rotating pulse count through the servo control interfaces a, B and/B to determine the angle position data of the standard encoder at each detection position, the angle position data of the encoder to be detected at each detection position is obtained through a 485 communication interface, and after the processing subunit 92 reads the angle position data of the encoder to be detected and the standard encoder at each detection position within a circle, the precision deviation of the encoder to be detected at each detection position can be analyzed through comparing the angle positions fed back by the encoder to the standard encoder to form the precision deviation curve.
S103: and when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
For example, if the accuracy deviation does not exceed the maximum allowable error, the accuracy deviation is considered to be satisfactory. When the precision deviation of all the detection positions meets the requirement, the precision deviation of each detection position can be directly written into the encoder to be detected, and the encoder to be detected can carry out precision compensation according to the precision deviation.
Wherein, step S2 specifically includes:
s201: after the result of the precision compensation processing is verified to meet the requirement, determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time;
the integral nonlinearity of the encoder to be detected in the static state and the rotation (forward rotation or reverse rotation) process of the motor 5 to be detected can be detected in the same manner as in the step S102, that is, in the static state and the rotation (forward rotation or reverse rotation) of the motor 5 to be detected, the angular positions of the encoder to be detected and the standard encoder are collected and compared to obtain the precision deviation, and if the precision deviation meets the requirement, the integral nonlinearity is considered to be qualified. The differential nonlinearity is to detect the floating range of the data of the encoder to be detected at each detection position, for example, at the same detection position, obtain data of a plurality of angle positions, compare the maximum value with the minimum value to obtain the floating value of the detection position, and if the floating values of all the detection positions meet the requirement, the differential nonlinearity is considered to be qualified.
After the result of the precision compensation process is verified to meet the requirement, the processing subunit 92 sends an instruction to the communication control subunit 91, the communication control subunit 91 allows the servo control unit 7 to rotate at a rotation speed of 500RPM according to the correctly received instruction content, and at the rotation speed, the internal winding coil of the motor 5 to be tested and the permanent magnet on the rotor act to generate induced electromotive force. The signal is conditioned by the induced electromotive force sampling unit 8 and then input to the communication control subunit 91.
The induced electromotive force can output four pulse edges (a four-pole motor) in one rotation period, the pulse edges are the motor phase change time, and the angular position of the encoder to be detected is read and recorded at the motor phase change time.
S202: and after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
Specifically, assuming that the number of pole pairs of the motor to be measured is M and the rotation period is L, data of the angular position M × L is recorded, and the calculation method of the magnetic pole position is as follows:
wherein, XiIndicating the recorded angular position, K the known multiplied coefficient, R the resolution of the encoder to be measured and S the magnetic pole position. If the size of the magnetic pole position is within the threshold range, the magnetic pole position can be considered to meet the requirement and can be written into the encoder to be tested.
Based on the above-described system and method, in one embodiment of the present invention, a circle is divided into 256 detection positions at equal distances, i.e., 360 ° is divided into 256 parts on average, each part having a size of 1.40625 °, and is represented by absolute value data of an encoder to be measured, i.e., 4096 pulses each. Referring to fig. 4, the ordinate in the figure represents the magnitude of the precision deviation of the encoder to be measured at each detection position, and it is shown from fig. 4 that the maximum deviation is 400digit @10bit, that is, the number of output bits of the encoder to be measured is 10 bits, and the maximum precision deviation reaches 400 pulses, which is equivalent to 0.137329 °. After the precision compensation processing, the precision error of the encoder to be detected can be effectively mentioned, as shown in fig. 5 and 6, the abscissa is each detection position of the encoder to be detected in one circle, the ordinate is the precision deviation of the encoder to be detected at each detection position, the maximum precision deviation is 30 pulses, and compared with the precision deviation of the encoder to be detected before the precision compensation processing in fig. 4, the precision of the encoder to be detected after the precision compensation processing is improved by about 10 times. After the precision compensation processing is qualified, the magnetic pole position zero adjustment processing is continued, the obtained magnetic pole position detection curve is as shown in fig. 7, the abscissa is the phase change time, and the ordinate is the recorded angle position, because the number of the motor pole pairs of the motor 5 to be detected in the embodiment is four pairs of poles, that is, four magnetic pole position zero points can be determined within one circle of the motor, each zero point is a specific encoder angle value, and P1, P2, P3 and P4 in fig. 7 are positions where the motor zero point of one circle is located.
It is noted that the term "coupled" or "connected," as used herein, includes not only a direct connection between two entities, but also an indirect connection through other entities with beneficial and improved effects. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (10)
1. The utility model provides a rotary encoder automatic calibration detecting system which characterized in that, includes standard motor (4), servo control unit (7), induced electromotive force sampling unit (8), detection control unit (9), wherein:
the standard motor (4) is used for being connected with a motor (5) to be tested so as to drive the motor (5) to be tested to synchronously act, a standard encoder is installed on the standard motor (4), and a coder to be tested is installed on the motor (5) to be tested;
the servo control unit (7) is connected with the standard motor (4) and the standard encoder and is used for driving the standard motor (4) and acquiring the angular position of the standard encoder;
the induced electromotive force sampling unit (8) is used for sampling induced electromotive force generated by the motor (5) to be tested in the rotating process;
detection control unit (9), with induced electromotive force sampling unit (8), servo control unit (7) and the encoder that awaits measuring are connected respectively for send control signal give servo control unit (7) are in order to control the motion of standard motor (4) to and according to the standard encoder that obtains and the angular position of the encoder that awaits measuring right the encoder that awaits measuring carries out the precision compensation and handles, and according the induced electromotive force carries out the magnetic pole position zero setting with the angular position of the encoder that awaits measuring and handles.
2. The system of claim 1, further comprising: go up backup pad (1), bottom suspension fagging (2), support column (3), shaft coupling (6), go up backup pad (1), bottom suspension fagging (2) from top to bottom just to setting up and pass through support column (3) are connected, standard motor (4) set up on bottom suspension fagging (2), the motor (5) that awaits measuring set up go up on backup pad (1), standard motor (4) pass through shaft coupling (6) are connected motor (5) awaits measuring.
3. The system according to claim 1, characterized in that the detection control unit (9) comprises a processing subunit (92) and a communication control subunit (91), the processing subunit (92) being responsible for the processing of control signals and data, the communication control subunit (91) being responsible for the forwarding of control signals and data.
4. The system according to claim 3, wherein the communication control subunit (91) comprises:
one path of communication interface is connected with the encoder to be tested to read data of the encoder to be tested, and the other path of communication interface is connected with the processing subunit (92) to perform data interaction with the processing subunit (92);
the servo control interface is connected with the servo control unit (7) to send a control signal to the servo control unit (7) so as to control the motion of the standard motor (4), and the angular position of the standard encoder is acquired through the servo control unit (7);
and the induced electromotive force signal detection interface is connected with the induced electromotive force sampling unit (8) to acquire the induced electromotive force.
5. The system of claim 1, wherein the accuracy compensation process comprises:
analyzing the angle position fed back by the encoder to be tested in the process of rotating the standard motor (4) for multiple circles to obtain the most value of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value;
when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result;
and when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
6. The system according to claim 1, characterized in that the detection control unit (9) performs the zero adjustment of the magnetic pole position after the precision compensation process when the integral nonlinearity and the differential nonlinearity of the encoder to be measured are respectively measured to meet the requirements in the static state and the rotating process of the motor (5) to be measured.
7. The system of claim 1, wherein the pole position zeroing process comprises:
determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time;
and after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
8. An automatic calibration detection method for a rotary encoder, the method being implemented based on the system of any one of claims 1 to 7, the method comprising:
performing precision compensation processing on the encoder to be detected according to the obtained angular positions of the standard encoder and the encoder to be detected;
and carrying out zero setting treatment on the magnetic pole position according to the induced electromotive force and the angular position of the encoder to be detected.
9. The method according to claim 8, wherein the performing precision compensation processing on the encoder under test according to the obtained angular positions of the standard encoder and the encoder under test comprises:
analyzing the angle position fed back by the encoder to be tested in the process of rotating the standard motor (4) for multiple circles to obtain the most value of the angle position, and calculating the amplitude and the offset of the sine and cosine signal of the encoder to be tested according to the most value;
when the amplitude and the offset of the sine and cosine signals of the encoder to be detected are calculated by the maximum value and meet the requirements, comparing the angle positions fed back by the standard encoder and the encoder to be detected at a plurality of detection positions in a rotation period, and determining the precision offset of the encoder to be detected at each detection position according to the comparison result;
and when the precision deviation at each detection position meets the requirement, writing the precision deviation at each detection position into the encoder to be detected as a precision compensation value.
10. The method of claim 8, wherein the performing of the pole position zeroing process according to the induced electromotive force and the angular position of the encoder to be tested comprises:
after the result of the precision compensation processing is verified to meet the requirement, determining the phase change time of the motor according to the change of the induced electromotive force, and recording the angle position fed back by the encoder to be tested at the phase change time;
and after continuously recording the angle positions of a plurality of commutation moments, performing data processing calculation on all the recorded angle positions to obtain magnetic pole positions, and writing the magnetic pole positions into the encoder to be tested if the magnetic pole positions meet requirements.
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