CN113091797B - Method and device for monitoring fault state of encoder - Google Patents
Method and device for monitoring fault state of encoder Download PDFInfo
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Abstract
The invention relates to the technical field of ferrous metallurgy automatic production, in particular to a method and a device for monitoring the fault state of an encoder, wherein the method comprises the following steps: acquiring a theoretical code value variable quantity and a first actual code value variable quantity of an encoder in a current program execution cycle and second actual code value variable quantities in a plurality of continuous program execution cycles; determining a followability of the encoder based on the theoretical code value variation and the first actual code value variation; determining a jump condition of the encoder based on a second actual code value variation of the plurality of continuous program execution cycles; based on the following performance and the jumping condition of the encoder, the fault state of the encoder is determined, and then the fault of the encoder can be found as early as possible, so that production accidents caused by the fault of the encoder are avoided.
Description
Technical Field
The invention relates to the technical field of automatic production of ferrous metallurgy, in particular to a method and a device for monitoring a fault state of an encoder.
Background
In the automatic production process of ferrous metallurgy, a large number of application incremental encoders and absolute value encoders are adopted on site to monitor the speed, angle, position and other state data of field equipment, along with the continuous improvement of the automation level of the ferrous metallurgy industry, the requirements on the detection precision and the fault rate of the field-mounted encoders are higher and higher, and the detection precision and the fault rate of the encoders are not only related to the quality of products, but also influenced by factors such as the surrounding environment, the mounting mode, the wiring mode, external force damage and the like. In the production process, stability problems such as encoder signal jumping, detection precision degradation, following abnormity and the like are difficult to find by detecting conventional points, routing inspection methods and the like. Often these just can be exposed under encoder breaks down and influences the condition that produces, then, go on corresponding processing again after confirming the fault reason through automated engineer's investigation analysis, consequently, not only can cause the production accident when the encoder breaks down, still often can produce longer outage and fault handling time, cause great loss to the economic benefits of enterprise.
Therefore, how to avoid production accidents and downtime caused by the failure of the encoder is a technical problem to be solved.
Disclosure of Invention
In view of the above, the present invention has been made to provide a method and apparatus for monitoring an encoder fault condition that overcomes or at least partially solves the above-mentioned problems.
In a first aspect, the present invention provides a method for monitoring a fault state of an encoder, comprising:
acquiring a theoretical code value variable quantity and a first actual code value variable quantity of an encoder in a current program execution cycle and second actual code value variable quantities in a plurality of continuous program execution cycles;
determining a followability of the encoder based on the theoretical code value delta and the first actual code value delta;
determining a jumping condition of the encoder based on second actual code value variation of the continuous program execution cycles;
and determining the fault state of the encoder based on the followability and the jumping condition of the encoder.
Preferably, before determining a transition situation of the encoder based on the actual code value variation and the first actual code value variation of the consecutive program execution cycles, the method further includes: acquiring the maximum code value variation corresponding to the maximum displacement speed of the encoder, including:
acquiring the maximum speed of the encoder;
obtaining a theoretical maximum displacement speed of the encoder based on the maximum speed of the encoder;
and obtaining the maximum code value variation corresponding to the theoretical maximum displacement speed of the encoder based on the theoretical maximum displacement speed.
Preferably, when there is an encoder, determining the followability of the encoder based on the theoretical code value variation and the first actual code value variation includes:
judging whether the deviation between the first actual code value variation and the theoretical code value variation exceeds a threshold deviation or not;
and if so, determining that the followability of the encoder is abnormal.
Preferably, when there are two encoders, determining the followability of the encoder based on the theoretical code value variation and the first actual code value variation includes:
acquiring first actual code value variable quantities of the two encoders in a current program execution cycle;
converting the first actual code value variable quantities corresponding to the two encoders into speed values of the same type;
judging whether the speed values corresponding to the two encoders meet preset conditions or not;
if not, determining that the following performance of the two encoders is abnormal.
Preferably, the determining a transition situation of the encoder based on a second actual code value variation of the encoder in a plurality of consecutive program execution cycles includes:
when the encoder is in a static state, acquiring a difference value of second actual code value variation of adjacent program execution periods in the continuous multiple program execution periods;
performing derivation operation on the sum of the difference values to obtain an operation result;
judging whether the operation result approaches to 0;
if not, determining that the encoder is abnormally jumped.
Preferably, the determining the skip condition of the encoder based on the second actual code value variation of the encoder in a plurality of consecutive program execution cycles includes:
when the encoder is in a constant-speed motion state, judging whether a differential result of the variation of the second actual code value in each program execution period is a fixed constant or not, or keeping fluctuation within a preset range above and below the fixed constant;
if not, determining that the encoder is abnormally jumped;
when the encoder is in a variable-speed motion state, judging whether the differentiation result of the second actual code value variation of each program execution period fluctuates beyond a preset value or not;
and if so, determining that the encoder is abnormal jumping.
Preferably, the determining the skip condition of the encoder based on the second actual code value variation of the encoder in a plurality of consecutive program execution cycles includes:
judging whether the second actual code value variation of any program execution cycle exceeds the maximum code value variation in the second actual code value variations of the continuous program execution cycles;
and if so, determining that the encoder is the hopping interference.
In a second aspect, the present invention further provides an apparatus for monitoring a fault state of an encoder, including:
the device comprises a first acquisition module, a second acquisition module and a third acquisition module, wherein the first acquisition module is used for acquiring theoretical code value variation and first actual code value variation of an encoder in a current program execution cycle and second actual code value variation in a plurality of continuous program execution cycles;
a first determining module, configured to determine a followability of the encoder based on the theoretical code value variation and the first actual code value variation;
a second determining module, configured to determine a jump condition of the encoder based on a second actual code value variation of the encoder in a plurality of consecutive program execution cycles;
and the third determining module is used for determining the fault state of the encoder based on the following performance and the jumping condition of the encoder.
In a third aspect, the present invention also provides a computer device comprising a memory, a processor and a computer program stored on the memory and executable on the processor, the processor implementing the above-mentioned method steps when executing the program.
In a fourth aspect, the present invention further provides a computer-readable storage medium, on which a computer program is stored, where the computer program is executed by a processor to implement the above-mentioned method steps.
One or more technical solutions in the embodiments of the present invention at least have the following technical effects or advantages:
the invention provides a method for monitoring the fault state of an encoder, which comprises the following steps: acquiring a theoretical code value variable quantity and a first actual code value variable quantity of an encoder in a current program execution cycle and second actual code value variable quantities in a plurality of continuous program execution cycles; determining the followability of the encoder based on the theoretical code value variation and the first actual code value variation; determining the jumping condition of the encoder based on the second actual code value variation of the encoder in a plurality of continuous program execution cycles; based on the following performance and the jumping condition of the encoder, the fault state of the encoder is determined, and then the fault of the encoder can be found as early as possible, so that production accidents caused by the fault of the encoder are avoided.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to refer to like parts throughout the drawings. In the drawings:
FIG. 1 is a flow chart illustrating the steps of a method of monitoring an encoder fault condition in an embodiment of the present invention;
FIG. 2 is a schematic diagram of an apparatus for monitoring the fault state of an encoder according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of an electronic device implementing the method for monitoring the encoder fault state according to the embodiment of the present invention.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
Example one
The first embodiment of the invention provides a method for monitoring the fault state of an encoder, which is applied to the detection process of the state of the encoder and has the characteristics of real-time detection, real-time analysis, high efficiency and accuracy.
The method comprises the following steps: s101, acquiring a theoretical code value variation and a first actual code value variation of an encoder in a current program execution cycle and code value variations of the encoder in a plurality of continuous program execution cycles.
And S102, determining the followability of the encoder based on the theoretical code value variable quantity and the first actual code value variable quantity.
And S103, determining the jumping situation of the encoder based on the second actual code value variation of the encoder in a plurality of continuous program execution periods.
And S104, determining the fault state of the encoder based on the following and jumping conditions of the encoder.
In a specific embodiment, a drum type flying shear is generally installed on a thin strip hot rolling production line and is used for shearing the head and the tail of the strip, and the actual speed and the angle of a drum during shearing are detected by a code installed on a motor and a reduction box.
In the actual production process, the detection state of the encoder is divided into a static state and a motion state.
The failure states regarding the encoder mainly include: followability and jump situations.
Different analyses are performed for the stationary state and the moving state of the encoder.
The following detection principle is that theoretical code value variation of the corresponding encoder in the current motion state in one program execution cycle is obtained based on mechanical characteristic parameters and control characteristic parameters of the encoder, and therefore theoretical code value variation of the encoder in different motion states in one program execution cycle is determined. Wherein the mechanical property parameters, such as diameter, tooth ratio, maximum speed, maximum position, etc.; the control characteristic parameters include, for example, a target angle, a target position, a target speed, a set speed during movement, acceleration, and the like.
The different motion states of the encoder include: the flying shear rotary drum is in a constant speed rotation state and the flying shear rotary drum is in a variable speed rotation state.
And determining that the flying shear drum is in a constant-speed rotation state when a set value in the control characteristic parameter of the encoder is not changed and is not equal to zero. When the flying shear drum is in a constant-speed rotation state, the code value variation of the encoder in one rotation is obtained based on the set speed, the drum diameter, the gear ratio, the resolution and the code value variation of the encoder in one rotation, and the encoder is executed in the current programPeriodic theoretical code value variation C 1 。
According to a formula:
C 1 ＝(RPM 1 /60)×Ratio×T scan ×V Ec thus obtaining the product.
Wherein the RPM 1 To set speed, ratio is the gear Ratio, T scan For program execution cycle, V ec The actual code value variation corresponding to one rotation of the encoder.
Changing the theoretical code value of the encoder into C under the condition that the flying shear drum is in a constant-speed rotation state 1 And the first actual code value variation C 0 The deviation therebetween is compared to a threshold deviation, and when the threshold deviation is exceeded, a follow-up anomaly of the encoder is determined. The threshold deviation is in the range of 5% to 30%, with a preferred threshold deviation of 10%.
When the set value in the control characteristic parameter of the encoder changes, the flying shear drum is determined to be in a variable speed rotation state. When the flying shear drum is in a variable speed rotation state, a theoretical acceleration time or a theoretical deceleration time is obtained based on an acceleration set value of the motor, and then, an integral operation, that is, a speed variation of each program execution period is performed based on the theoretical acceleration time or the theoretical deceleration time, that is, the speed variation is calculated
t is acceleration time, v is real-time speed, and the real-time speed is added with an original speed set value to obtain a theoretical real-time speed in the variable speed rotation state; thereby obtaining the theoretical code value variation amount for each program execution cycle.
When the flying shear drum is in a variable speed rotation state, the theoretical code value variation and the first actual code value variation C of each program execution cycle are compared 0 The deviation between the two is compared with a threshold deviation, and when the preset deviation is exceeded, the following abnormity of the encoder is determined. The threshold deviation ranges from 5% to 30%, with a preferred threshold deviation of 15%.
The first actual code value variation C 0 Are measured directly and are not limited herein.
Through the following determination, the problems of vibration, mounting connection looseness and the like of the encoder can be accurately and effectively judged, and the method can be applied to real-time online detection of the encoder.
The above is an analysis of the case where there is only one encoder. For the detection system that the rotary drum flying shear has two encoders, namely one encoder is arranged at the tail part of the motor and used for detecting the rotating speed of the motor, and the other encoder is arranged at the reduction gearbox and used for detecting the rotating speed angle, the working states of the two encoders can be detected and diagnosed on line in real time in a mode that the two encoders are mutually checked. By adopting the detection system with the two encoders, when one encoder fails, the requirement of real-time emergency production can be met through automatic switching.
Specifically, first actual code value variations of two encoders in a current program execution cycle are obtained; then, the first actual code value variation amounts corresponding to the two encoders are converted into the same type of speed value. Then, judging whether the speed values corresponding to the two encoders respectively meet a preset condition; if not, determining that the following performance of the two encoders is abnormal.
The real-time angular velocity is calculated by using a mutual calibration method, for example, a real-time angular value detected by an angular detection encoder, and then the real-time angular velocity is converted into a real-time rotating speed of the motor according to mechanical characteristic parameters, and then the real-time rotating speed of the motor is compared with a rotating speed detected by a speed encoder installed at the tail part of the motor. The same comparison is also made after converting the speed encoder to a real-time angle.
In the specific comparison process, three conditions can be distinguished, wherein when the rotary drum is in a static state, the speed encoder and the angle encoder are subjected to real-time interchange comparison; one is that when the rotary drum is in angle control, a speed encoder is used for checking the angle encoder; one is to use an angle encoder to verify the speed encoder while the drum is under speed control.
For a system with two encoders of the same type, the comparison check can be directly performed.
Whether the speed values corresponding to the two encoders meet preset conditions or not is judged, namely, the deviation of the comparison result of the two encoders is compared with a preset value, if the deviation is smaller than the preset value, the following performance of the encoders is determined to be normal, and if the deviation is smaller than the preset value, the condition that the deviation is within 2% comprises that the speed values corresponding to the two encoders are consistent, otherwise, the following performance is considered to be abnormal.
When the following performance of the encoder is monitored by adopting the mutual checking mode, the encoder can detect more accurately in a motion state.
The transition situation of the encoder is analyzed as follows.
When the encoder is in a static state, firstly, acquiring a difference value of second actual code value variation of adjacent program execution periods in a plurality of continuous program execution periods; then, the sum of the differences is subjected to a derivative operation to obtain an operation result. Judging whether the operation result approaches to 0; and if not, determining that the encoder is abnormally jumped.
The jump code value is filtered by the filter, so that the output code value can be ensured to be smooth and can be used for emergency production.
When the encoder is in a moving state and the flying shear drum is in a constant-speed moving state, judging whether the differential result of the second actual code value variation of each program execution period is a fixed constant or meets the fluctuation within a preset range above and below the fixed constant; if not, the encoder has abnormal jump.
If the flying shear drum is in a variable speed motion state, judging whether the differential result of the variation of the code value of the encoder in each program execution period fluctuates beyond a preset value or not; if yes, the encoder is considered to have an abnormal jumping phenomenon, or the controlled equipment has an oscillation overshoot phenomenon.
Before determining the jumping situation of the encoder based on the second actual code value variation of the encoder in a plurality of continuous program execution cycles, the method further comprises the following steps: acquiring a maximum code value variation corresponding to a maximum displacement speed of an encoder, wherein acquiring the maximum code value variation corresponding to the maximum displacement speed of the encoder comprises:
acquiring the maximum speed of an encoder;
obtaining a theoretical maximum displacement speed of the encoder based on the maximum speed of the encoder;
and obtaining the maximum code value variation corresponding to the theoretical maximum displacement speed of the encoder based on the theoretical maximum displacement speed.
Specifically, the maximum code value variation of each program execution cycle of the rotary drum at the maximum displacement speed is obtained according to the maximum rotation speed of the motor, the gear ratio, the resolution and the code value variation of one rotation of the encoder.
Specifically, the maximum code value variation C of each program execution cycle is obtained according to the following formula max ：
C max ＝(RPM MAX /60)×Ratio×T scan ×V Ec
Wherein the RPM MAX For maximum allowable speed of the apparatus, ratio is gear Ratio, T scan For program execution cycle, V ec And changing the actual code value corresponding to one rotation of the encoder.
After the maximum code value change amount corresponding to the maximum displacement speed of the encoder is obtained, it is determined whether the second actual code value change amount of any program execution cycle in the second actual code value change amounts of consecutive program execution cycles of the encoder exceeds the maximum code value change amount.
And if so, determining that the encoder is the hopping interference.
For the analysis of the jump frequency, the working state of the encoder is qualitatively analyzed by counting the jump times in a quantitative time span, wherein, an alarm is given when the low-frequency jump occurs, and a fault is output when the high-frequency jump occurs.
After the followability and the jump condition of the encoder are obtained, the fault state of the encoder can be determined.
One or more technical solutions in the embodiments of the present invention have at least the following technical effects or advantages:
the invention provides a method for monitoring the fault state of an encoder, which comprises the following steps: acquiring theoretical code value variation and first actual code value variation of an encoder in a current program execution cycle and second actual code value variation in a plurality of continuous program execution cycles; determining the followability of the encoder based on the theoretical code value variation and the first actual code value variation; determining the jumping situation of the encoder based on the second actual code value variation of the encoder in a plurality of continuous program execution periods; based on the following performance and the jumping condition of the encoder, the fault state of the encoder is determined, and then the fault of the encoder can be found as early as possible, so that production accidents caused by the fault of the encoder are avoided.
Example two
Based on the same inventive concept, an embodiment of the present invention provides an apparatus for monitoring a fault state of an encoder, as shown in fig. 2, including:
a first obtaining module 201, configured to obtain a theoretical code value variation and a first actual code value variation of an encoder in a current program execution cycle, and a second actual code value variation in consecutive program execution cycles;
a first determining module 202, configured to determine a followability of the encoder based on the theoretical code value variation and a first actual code value variation;
a second determining module 203, configured to determine a jump condition of the encoder based on a second actual code value variation of the encoder in a plurality of consecutive program execution cycles;
a third determining module 204, configured to determine a fault state of the encoder based on the followability and the transition situation of the encoder.
In an optional implementation manner, the method further includes a second obtaining module, including:
a first acquisition unit configured to acquire a maximum speed of the encoder;
a first obtaining unit configured to obtain a theoretical maximum displacement speed of the encoder based on a maximum speed of the encoder;
and the second obtaining unit is used for obtaining the maximum code value variation corresponding to the theoretical maximum displacement speed of the encoder based on the theoretical maximum displacement speed.
In an alternative embodiment, when there is an encoder, the first determining module 202 includes:
a first judging unit configured to judge whether a deviation between a first actual code value variation and the theoretical code value variation exceeds a threshold deviation;
a first determining unit, configured to determine that the followability of the encoder is abnormal if the following is abnormal.
In an alternative embodiment, when there are two encoders, the first determining module 202 includes:
the second acquisition unit is used for acquiring the first actual code value variable quantity of the two encoders respectively in the current execution period of executing a program;
the conversion unit is used for converting the first actual code value variable quantities corresponding to the two encoders into speed values of the same type;
the second judging unit is used for judging whether the speed values corresponding to the two encoders respectively meet a preset condition;
and the second determining unit is used for determining that the following performance of the two encoders is abnormal if the two encoders are not used for encoding.
In an alternative embodiment, the second determining module 203 includes:
a third acquiring unit, configured to acquire, when the encoder is in a stationary state, a difference value of a second actual code value variation of an adjacent program execution cycle in the consecutive program execution cycles;
a third obtaining unit, configured to perform a derivation operation on the sum of the difference values to obtain an operation result;
a third judging unit, configured to judge whether the operation result approaches to 0;
and the third determining unit is used for determining that the encoder is abnormally jumped if the encoder is not in the abnormal jumped state.
In an alternative embodiment, the second determining module 203 includes:
a third judging unit, configured to judge whether a differentiation result of a second actual code value variation for each program execution period is a fixed constant or meets fluctuation within a preset range above and below the fixed constant when the encoder is in a constant-speed motion state;
a fourth determining unit, configured to determine that the encoder is abnormally jumped if the encoder is not abnormally jumped;
a fourth judgment unit configured to judge whether or not a result of differentiating the amount of change in the encoder code value for each program execution cycle exhibits a fluctuation exceeding a threshold when the encoder is in a variable-speed motion state;
and a fifth determining unit, configured to determine that the encoder is abnormally jumped if the encoder is abnormally jumped.
In an alternative embodiment, the second determining module 203 includes:
a fifth judging unit operable to judge whether or not a second actual code value variation for any program execution cycle among second actual code value variations for successive program execution cycles of the encoder exceeds the maximum code value variation;
a sixth determining unit, configured to determine that the encoder is a hopping interference if the encoder is a hopping interference.
EXAMPLE III
Based on the same inventive concept, the third embodiment of the present invention provides a computer device, as shown in fig. 3, including a memory 304, a processor 302, and a computer program stored on the memory 304 and executable on the processor 302, where the processor 302 executes the computer program to implement the steps of the method for monitoring the encoder fault state.
Wherein in fig. 3 a bus architecture (represented by bus 300), bus 300 may include any number of interconnected buses and bridges, bus 300 linking together various circuits including one or more processors, represented by processor 302, and memory, represented by memory 304. The bus 300 may also link together various other circuits such as peripherals, voltage regulators, power management circuits, and the like, which are well known in the art, and therefore, will not be described any further herein. A bus interface 306 provides an interface between the bus 300 and the receiver 301 and transmitter 303. The receiver 301 and the transmitter 303 may be one and the same element, i.e. a transceiver, providing a means for communicating with various other apparatus over a transmission medium. The processor 302 is responsible for managing the bus 300 and general processing, and the memory 304 may be used for storing data used by the processor 302 in performing operations.
Example four
Based on the same inventive concept, a computer-readable storage medium is provided in a fourth embodiment of the present invention, and a computer program is stored thereon, where the computer program is executed by a processor to implement the steps of the method for monitoring the encoder fault state.
The algorithms and displays presented herein are not inherently related to any particular computer, virtual machine, or other apparatus. Various general purpose systems may also be used with the teachings herein. The required structure for constructing such a system will be apparent from the description above. Moreover, the present invention is not directed to any particular programming language. It is appreciated that a variety of programming languages may be used to implement the teachings of the present invention as described herein, and any descriptions of specific languages are provided above to disclose the best mode of the invention.
In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In some instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
Similarly, it should be appreciated that in the foregoing description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. However, the disclosed method should not be interpreted as reflecting an intention that: that the invention as claimed requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.
Those skilled in the art will appreciate that the modules in the device in an embodiment may be adaptively changed and disposed in one or more devices different from the embodiment. The modules or units or components of the embodiments may be combined into one module or unit or component, and furthermore they may be divided into a plurality of sub-modules or sub-units or sub-components. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and all of the processes or elements of any method or apparatus so disclosed, may be combined in any combination, except combinations where at least some of such features and/or processes or elements are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise.
Furthermore, those skilled in the art will appreciate that while some embodiments herein include some features included in other embodiments, rather than other features, combinations of features of different embodiments are meant to be within the scope of the invention and form different embodiments. For example, in the following claims, any of the claimed embodiments may be used in any combination.
The various component embodiments of the invention may be implemented in hardware, or in software modules running on one or more processors, or in a combination thereof. It will be appreciated by those skilled in the art that a microprocessor or Digital Signal Processor (DSP) may be used in practice to implement some or all of the functions of some or all of the components of the apparatus, computer device, and/or device for monitoring encoder fault conditions in accordance with embodiments of the present invention. The present invention may also be embodied as apparatus or device programs (e.g., computer programs and computer program products) for performing a portion or all of the methods described herein. Such programs implementing the present invention may be stored on computer-readable media or may be in the form of one or more signals. Such a signal may be downloaded from an internet website or provided on a carrier signal or in any other form.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word "comprising" does not exclude the presence of elements or steps not listed in a claim. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the unit claims enumerating several means, several of these means may be embodied by one and the same item of hardware. The usage of the words first, second and third, etcetera do not indicate any ordering. These words may be interpreted as names.
Claims (8)
1. A method of monitoring an encoder for a fault condition, comprising:
acquiring a theoretical code value variable quantity and a first actual code value variable quantity of an encoder in a current program execution cycle and second actual code value variable quantities in a plurality of continuous program execution cycles;
determining a followability of the encoder based on the theoretical code value delta and the first actual code value delta, comprising:
for a single encoder system, determining whether a deviation between the first actual code value variation and the theoretical code value variation exceeds a threshold deviation; if yes, determining that the following performance of the encoder is abnormal;
for a dual-encoder system, determining the followability of an encoder by adopting a mutual check mode of two encoders comprises the following steps: acquiring first actual code value variable quantities of two encoders in a current program execution cycle; converting the first actual code value variable quantities corresponding to the two encoders into speed values of the same type; judging whether the speed values corresponding to the two encoders meet a preset condition or not; if not, determining that the following performance of the two encoders is abnormal;
determining a jump condition of the encoder based on a second actual code value variation of the plurality of continuous program execution cycles;
determining a fault condition of the encoder based on the followability and the transition condition of the encoder.
2. The method of claim 1, wherein prior to determining a transition condition of the encoder based on actual code value variations and the first actual code value variation for the consecutive plurality of program execution cycles, further comprising: acquiring the maximum code value variation corresponding to the maximum displacement speed of the encoder, including:
acquiring the maximum speed of the encoder;
obtaining a theoretical maximum displacement speed of the encoder based on the maximum speed of the encoder;
and obtaining the maximum code value variation corresponding to the theoretical maximum displacement speed of the encoder based on the theoretical maximum displacement speed.
3. The method of claim 1, wherein determining the transition condition of the encoder based on a second actual code value change amount of the encoder over a plurality of consecutive program execution cycles comprises:
when the encoder is in a static state, acquiring a difference value of second actual code value variation of adjacent program execution periods in the continuous multiple program execution periods;
performing derivation operation on the sum of the difference values to obtain an operation result;
judging whether the operation result approaches to 0;
and if not, determining that the encoder is abnormally jumped.
4. The method of claim 1, wherein determining the transition condition of the encoder based on a second actual code value change amount of the encoder over a plurality of consecutive program execution cycles comprises:
when the encoder is in a constant-speed motion state, judging whether a differential result of the variation of the second actual code value in each program execution period is a fixed constant or not, or keeping fluctuation within a preset range above and below the fixed constant;
if not, determining that the encoder is abnormally jumped;
when the encoder is in a variable-speed motion state, judging whether the differentiation result of the second actual code value variation of each program execution period fluctuates beyond a preset value or not;
and if so, determining that the encoder is abnormally jumped.
5. The method of claim 2, wherein determining the transition condition of the encoder based on a second actual code value change amount of the encoder over a plurality of consecutive program execution cycles comprises:
judging whether the second actual code value variation of any program execution cycle exceeds the maximum code value variation in the second actual code value variations of the plurality of continuous program execution cycles;
and if so, determining that the encoder is the hopping interference.
6. An apparatus for monitoring a fault condition of an encoder, comprising:
the device comprises a first acquisition module, a second acquisition module and a third acquisition module, wherein the first acquisition module is used for acquiring the theoretical code value variation and the first actual code value variation of an encoder in the current program execution cycle and the second actual code value variation of the encoder in a plurality of continuous program execution cycles;
a first determining module for determining a followability of the encoder based on the theoretical code value variation and the first actual code value variation, comprising:
for a single encoder system, determining whether a deviation between the first actual code value variation and the theoretical code value variation exceeds a threshold deviation; if yes, determining that the following performance of the encoder is abnormal;
for a dual-encoder system, determining the followability of an encoder by adopting a mutual check mode of two encoders comprises the following steps: acquiring first actual code value variable quantities of two encoders in a current program execution cycle; converting the first actual code value variable quantities corresponding to the two encoders into speed values of the same type; judging whether the speed values corresponding to the two encoders meet a preset condition or not; if not, determining that the following performance of the two encoders is abnormal;
a second determining module, configured to determine a jump condition of the encoder based on a second actual code value variation of the encoder in a plurality of consecutive program execution cycles;
and the third determining module is used for determining the fault state of the encoder based on the following performance and the jumping condition of the encoder.
7. Computer arrangement comprising a memory, a processor and a computer program stored on the memory and executable on the processor, characterized in that the processor realizes the method steps of any of claims 1-5 when executing the program.
8. A computer-readable storage medium, on which a computer program is stored which, when being executed by a processor, carries out the method steps of any one of claims 1 to 5.
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