TWI786751B - System of analyzing and measuring distance sensor - Google Patents

Abstract

A system of analyzing and measuring distance sensor is disclosed in the present invention. The system includes a controller, a servo controller, a servo motor, an encoder, a ball screw, a fixing assembly, a testing plate, and a human machine interface. The system is utilized to electrically control at least one distance sensor to move and analyze and measure at least one measurement characteristics of the at least one distance sensor.

Description

Distance sensor measurement and analysis system

The invention relates to a system, in particular to a distance sensor measurement and analysis system.

A sensor is a detection device that can sense changes in the external environment and convert the received signal into an electrical signal or other forms of information output. Distance sensors are one of the most numerous and widely used types of sensors, which are used to sense distances, and are commonly used in processing, manufacturing, testing and other fields. Distance sensors have different working principles according to their usage, and can be roughly divided into contact distance sensors and non-contact distance sensors.

Each distance sensor has measurement characteristics, common measurement characteristics include: linearity, resolution, response time, etc. Please refer to the first figure, which shows a schematic diagram of a distance sensor testing device in the prior art. As shown in the figure, a distance sensor testing device PA1 is used to measure at least one measurement characteristic of a distance sensor PAS1, and includes a base PA11, a displacement platform PA12, a support frame PA13 and a tested board PA14, wherein the displacement platform PA12 includes a manual adjustment rod PA121.

The displacement platform PA12 is set on the base PA11. The support frame PA13 is disposed on the displacement platform PA12 for connecting the distance sensor PAS1 , wherein the distance sensor PAS1 is a non-contact distance sensor, such as an optical type, an eddy current type, and the like. The board under test PA14 is set on the base PA11 relative to the support frame PA13. The user can rotate the manual adjustment lever PA121 to adjust the distance between the distance sensor PAS1 and the tested board PA14 to perform at least one test operation. The user can use the distance between the distance sensor PAS1 and the board under test PA14 and the signal generated by the distance sensor PAS1 to obtain the measurement characteristics of the distance sensor PAS1 .

Among the common measurement characteristics, "linearity" refers to the relationship between the output signal of the distance sensor PAS1 and the distance moved, and the relationship between the two is calculated (regression line); "resolution" refers to the distance sense The minimum distance that can be sensed by the sensor PAS1; "response time" is the time when the distance sensor PAS1 moves a resolution at each specific time and the received output signal starts to change.

However, if the user manually adjusts the distance sensor testing device PA1 , measurement errors will be caused by the manual adjustment, and various problems will arise. The measurements are all at the micrometer level. Errors caused by manual adjustments may lead to errors in the relationship between linearity (regression line), resolution errors, and objects equal to the resolution cannot be detected. In addition, the distance sensor test device PA1 in the prior art cannot measure the "response time", and an additional device is required for measurement. Therefore, there is room for improvement in the prior art.

In view of the fact that in the prior art, there are various problems such as measurement error and its derived linearity relationship error, resolution error, and inability to measure response time in the manual adjustment. One of the main objectives of the present invention is to provide a distance sensor measurement and analysis system to solve at least one problem in the prior art.

In order to solve the problems of the prior art, the necessary technical means adopted by the present invention is to provide a distance sensor measurement and analysis system, which is used to measure at least one measurement characteristic of at least one distance sensor, including a host computer, a servo A driver, a servo motor, an encoder, a ball screw, a fixed component, a tested board and an operation display interface. The host is electrically connected to the distance sensor. The servo driver is electrically connected to the host computer and controlled by the host computer. The servo motor is electrically connected to the servo driver and driven by the servo driver. The encoder is electrically connected to the servo motor and the servo driver. The ball screw is arranged corresponding to the servo motor so as to be driven by the servo motor to move. The fixing component is connected with the ball screw to carry the distance sensor. The board under test is set corresponding to the fixed component, and is used for the distance sensor to perform at least one test operation. The operation display interface is electrically connected to the host and the distance sensor, and displays measurement characteristics.

Among them, the distance sensor measurement and analysis system uses the host computer and the servo driver to electronically control the servo motor to drive the fixed component to move, so as to make the distance sensor perform the test operation, and use the encoder to record at least one group corresponding to the test operation process. The position information, and then the host uses the position information to measure the measurement characteristic of the distance sensor, wherein the measurement characteristic is at least one of a linearity, a resolution and a response time.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the distance sensor measurement and analysis system further include a backlash-free coupling, which connects the servo motor and the ball The screw is used to make the ball screw move synchronously when driven by the servo motor.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the fixed component in the distance sensor measurement and analysis system include a carrying board, which is used for placing the distance sensor.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the fixing component in the distance sensor measurement and analysis system include a fixing seat and a locking element. The fixing seat is set corresponding to the tested board. The locking element is used for locking the distance sensor to the fixing seat.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host computer in the distance sensor measurement and analysis system include a control unit, and the control unit is electrically connected to the servo driver to control the servo drive. driver.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host in the distance sensor measurement and analysis system further include a processing unit, and the processing unit is electrically connected to the control unit for using the test Work and location information, process and measure measurement characteristics.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host in the distance sensor measurement and analysis system further include a storage unit, which is electrically connected to the processing unit for receiving and Store measurement properties.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host in the distance sensor measurement and analysis system further include a communication unit, the communication unit is electrically connected to the processing unit and the operation display interface, It is used to transmit the measured characteristics to the operation display interface.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host in the distance sensor measurement and analysis system further include a receiving unit, which is electrically connected to the distance sensor for At least one test signal generated by the distance sensor during the test operation is received.

On the basis of the above-mentioned necessary technical means, an auxiliary technical means derived from the present invention is to make the host in the distance sensor measurement and analysis system further include an analog-to-digital conversion unit, which is electrically connected to the receiving unit and The processing unit is used for converting the test signal from the analog format into the digital format and sending it to the processing unit.

Based on the above, the distance sensor measurement and analysis system provided by the present invention uses a host, a servo driver, a servo motor, an encoder, a ball screw, a fixing component, a measured board, and an operation display interface to measure distance The measurement characteristics of the sensor, compared with the manual adjustment of the prior art, the present invention uses an electronic control method to move the distance sensor, so there will be no error of manual adjustment, so there will be no human error in the prior art Derived problems, for example: lead to linearity relationship (regression line) error, cause resolution error and cause objects equal to the resolution to be unable to be detected. In addition, the present invention can also achieve the effect of measuring response time that cannot be achieved in the prior art.

The specific implementation manner of the present invention will be described in more detail below with reference to schematic diagrams. The advantages and features of the present invention will be more clear from the following description and claims. It should be noted that all the drawings are in very simplified form and use imprecise scales, which are only used to facilitate and clearly assist the purpose of illustrating the embodiments of the present invention.

Please refer to the second figure to the fourth figure, wherein the second figure shows the block diagram of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; the third figure shows the preferred embodiment of the present invention. The schematic diagram of the distance sensor measurement and analysis system provided; and, the fourth figure shows the side view of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention. As shown in the figure, a distance sensor measurement and analysis system 1 is used to measure at least one measurement characteristic of at least one distance sensor, and includes a host 11, a servo driver 12, a servo motor 13, and an encoder device 14 , a backlash-free coupling 15 , a ball screw 16 , a fixing component 17 , a tested board 18 and an operation display interface 19 . Wherein, in this embodiment, the figure draws two distance sensors S1 and S2 to illustrate, and the measurement characteristic is at least one of a linearity, a resolution and a response time.

The host 11 is used to control the servo driver 12 and includes a control unit 111 , a processing unit 112 , a receiving unit 113 , an analog-to-digital conversion unit 114 , a communication unit 115 and a storage unit 116 .

The servo driver 12 is electrically connected to the host 11 , the servo motor 13 and the encoder 14 for driving the servo motor 13 under the control of the host 11 . The encoder 14 is also electrically connected to the servo motor 13 . In this embodiment, the backlash-free coupling 15 connects the servo motor 13 and the ball screw 16 so that the ball screw 16 moves synchronously when the servo driver drives the servo motor 13 .

The fixing component 17 is connected with the ball screw 16 to carry the distance sensors S1 and S2. The tested plate 18 is set corresponding to the fixed component 17, usually made of aluminum, S45C medium carbon steel and other metal materials, but not limited thereto, and can also be used for the distance sensors S1, S2 to measure the above measurements characteristic material. According to different distance sensors S1 and S2 , the fixing component 17 further includes a bearing plate 171 , a fixing base 172 and a locking element 173 . Part of the distance sensors can be directly locked on the carrier board 171 , such as the distance sensor S2 as shown in the figure. When some distance sensors cannot be directly locked on the bearing plate 171 , or when they are locked on the bearing plate 171 and the test operation on the tested board 18 cannot be performed, the fixing seat 172 and the locking element 173 need to be used. As shown in the figure, the fixing base 172 is fixed on the bearing plate 171, and the locking element 173 is to lock the distance sensor S1 on the fixing base 172, so that the distance sensor S1 can test the board under test 18 Operation.

In this embodiment, the distance sensor measurement and analysis system 1 further includes a base 10, wherein, a servo motor 13, an encoder 14, a backlash-free coupling 15, a ball screw 16, a fixing assembly 17 and a tested board 18 will be set corresponding to the base 10.

The operation display interface 19 is electrically connected to the host 11 and the distance sensors S1, S2. The distance sensors S1 and S2 are non-contact distance sensors, such as optical distance sensors, eddy current distance sensors, and the like. In this embodiment, the distance sensor S1 is an eddy current distance sensor, and the distance sensor S2 is an optical distance sensor.

In more detail, a user can use the host computer 11 for electronic control and processing. The control unit 111 is electrically connected to the servo driver 12 for being operated by a user to electronically control the servo driver 12 to drive the servo motor 13 . In this embodiment, since the backlash-free coupling 15 connects the driving servo motor 13 and the ball screw 16 , the ball screw 16 can move synchronously when the servo motor 13 is driven, and no driving error occurs. The ball screw 16 moves along a first direction D1 or a second direction D2 to adjust a sensing distance d between the distance sensors S1 , S2 and the tested board 18 .

The user can directly operate the host computer 11 for electronic control, or further use the control unit 111 for electronic control by operating the operation display interface 19 to adjust the distance between the distance sensors S1, S2 and the tested board 18. Measure the distance d, and make the distance sensors S1, S2 perform at least one test operation on the tested board 18.

When the distance sensors S1 and S2 perform a test operation on the tested board 18 , the receiving unit 113 receives at least one test signal generated by the distance sensors S1 and S2 . In this embodiment, because the format of the test signal is an analog format, the analog-to-digital conversion unit 114 is electrically connected to the receiving unit 113 to receive the test signals from the distance sensors S1 and S2, and convert the format of the test signal from Conversion of analog format to digital format. At the same time, the encoder 14 records at least one set of position information of the distance sensors S1 and S2 respectively.

The processing unit 112 is electrically connected to the analog-to-digital conversion unit 114 and the control unit 111 for receiving test signals and position information. Since the control unit 111 electronically controls the servo driver 12 , the processing unit 112 can obtain position information through the control unit 111 . The processing unit 112 processes and measures the measurement characteristics of the distance sensors S1 and S2 according to the test signal and position information.

The communication unit 115 is electrically connected to the processing unit 112 and the operation display interface 19 for transmitting the measurement characteristics to the operation display interface 19 and displaying the measurement characteristics through the operation display interface 19 . The storage unit 116 is electrically connected to the processing unit 112 for receiving and storing the measured characteristics.

Finally, please refer to the second figure, the third figure and the fifth figure to the seventh figure together, wherein the fifth figure shows the operation display interface of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention Figure 6 is a schematic diagram showing the measurement characteristics of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; and Figure 7 is a schematic diagram showing the distance sense provided by the preferred embodiment of the present invention Schematic diagram of another measurement characteristic of the instrument measurement analysis system. As shown in the figure, the operation display interface 19 will display related information of the distance sensors S1 and S2, related information of the test operation, an interface for user operation, and the like.

As shown in the right half of FIG. 5 , the operation display interface 19 can be used to select and set the types of the distance sensors S1 and S2 , and also display the setting results, real-time information of the test operation, and the like. As shown in the figure, if the distance sensor S1 is an eddy current distance sensor, it will display "Eddy Current", and if the distance sensor S2 is an optical distance sensor, it will display "Laser"; "250" on the left half It is to display the moving distance of the ball screw 16 set by the distance sensors S1 and S2, and the unit is micrometer. In addition, the operation display interface 19 will also display a plurality of icons (icons) for the user to touch and operate, so as to achieve functions such as testing the electronically controlled servo driver 12 and the distance sensors S1 and S2 . The figure is only for illustration, and the operation and display interface 19 can also display waveform diagrams, real-time data, historical data and the like.

As shown in Figure 6, the line type L1 is the ideal feedback curve of the moving distance of the electronically controlled distance sensors S1 and S2, and the line type L2 is the actual measurement result of the moving distance of the electronically controlled distance sensors S1 and S2. From the figure, it can be seen that the line type L1 (ideal feedback curve) and the line type L2 (actual measurement results) will be slightly different. This difference is the influence of comprehensive factors such as "linearity", "resolution" and "response" the result of.

As shown in FIG. 7 , the above-mentioned line type L1 and line type L2 are combined to form a plurality of data points P1 . The line type L3 is a relational expression (regression line) calculated by using all the data points P1.

"Linearity" refers to the relationship between the output signals of the distance sensors S1 and S2 and the moving distance, and the relationship between the two (regression line) is calculated. As shown in the seventh figure, the line type L3 is the relational expression (regression line) of the distance sensors S1 and S2. Because the present invention is electronically controlled, there is no error in manual adjustment, so the present invention will not calculate the wrong relationship (regression line) like the prior art.

"Resolution" is the minimum distance that the distance sensors S1 and S2 can sense. For example, the resolution of the displacement platform PA12 is 0.1 micron (micrometer), the user rotates the manual adjustment lever PA121 to the grid number 5, and the signal changes at this time, it will be concluded that the resolution of the distance sensor PAS1 is 0.5 micron . However, because the number of divisions of the manual adjustment lever PA121 is not a gear, but a smooth rotation, there may be errors in manual adjustment, that is, the actual resolution of the distance sensor PAS1 may be 0.6 microns instead of The above measurements come out to 0.5 microns.

Resolution error will lead to a lot of problems. For scanning circuit boards, the smallest size of electronic components on the circuit board is 0.5 microns. The above-mentioned detection resolution is 0.5 microns but the actual distance sensor PAS1 is 0.6 microns. Electronic components of 0.5 microns cannot be detected. If the circuit boards are to be exported to foreign countries, there will be problems such as stopping production of the production line and facing huge compensation for breach of contract.

"Response time" is the time when the distance sensor moves a resolution at a specific time and the received output signal starts to change. For example, the specific time is 0.01 milliseconds (ms), and the resolution of the distance sensors S1 and S2 is 0.5 mm. When the distance sensors S1 and S2 move for five specific times, the test signal changes, and the distance The response time of the sensors S1, S2 is 0.05 milliseconds. Since the specific time is usually at the level of milliseconds or even microseconds, and the resolution is also at the level of millimeters, it is naturally impossible to measure the response time by manually adjusting the distance sensor testing device PA1 in the prior art.

In the present invention, the user can accurately move the distance sensors S1 and S2 by using the host 11 of the distance sensor measurement and analysis system 1 , the electronically controlled servo motor 13 and the ball screw 16 . In addition, the control unit 111 can be a programmable logic controller (Programmable Logic Controller; PLC), so in addition to controlling the movement of the distance sensors S1 and S2 , it can also control the movement of the distance sensors S1 and S2 within a specific time.

In practice, the control unit 111 will use steps such as "delayed start", "moving to absolute position", "delay", "return to origin", "data acquisition" and other steps to measure the response time; and use "delayed start Count the number of times”, “Move to the relative position”, “Wait for the servo to stabilize”, “Record data” and other steps to measure the linearity, etc. The above-mentioned steps of measuring the main measurement characteristics are comprehensible to those with ordinary knowledge in the technical field, so they are only briefly described without further explanation.

In addition, the measurement characteristics will have different nouns depending on the brand. For example, the "linearity" and "linear accuracy" of some brands are the above-mentioned "linearity"; the "resolution" and "resolution" are the It is the above-mentioned "resolution"; in addition, "response time" and "sampling cycle" are also expressions of "response time". The above response time is only one of the more common descriptions, because some manufacturers will additionally process the response time to obtain other measurement characteristics similar to response time, or the processed measurement characteristics are called Response time is hereby stated.

In addition, the common measurement characteristic is "repeat accuracy". "Repeat accuracy" means repeating a specific distance from the origin for a specific number of times, and dividing the difference between the maximum measurement value and the minimum measurement value by a specific distance is the repeat accuracy. For example: the specific distance is 10 microns, the specific number of times is 100, and the measurement results may be 9.97, 9.97, 10.03, 10.02...etc. When using manual control in the prior art, due to errors in manual operation and observation scales, it is impossible to accurately move a certain distance. However, the present invention uses electronic control to achieve precise movement, which will significantly improve the measurement repeatability.

To sum up, the distance sensor measurement and analysis system provided by the present invention uses a host, a servo driver, a servo motor, an encoder, a ball screw, a fixing component, a measured board, and an operation display interface to measure distance The measurement characteristics of the sensor, compared with the manual adjustment of the prior art, the present invention uses an electronic control method to move the distance sensor, so there will be no error of manual adjustment, so there will be no human error in the prior art Derived problems, for example: lead to linearity relationship (regression line) error, cause resolution error and cause objects equal to the resolution to be unable to be detected. In addition, the present invention can also achieve the effect of measuring response time that cannot be achieved in the prior art.

Through the above detailed description of the preferred embodiments, it is hoped that the characteristics and spirit of the present invention can be described more clearly, and the scope of the present invention is not limited by the preferred embodiments disclosed above. On the contrary, the intention is to cover various changes and equivalent arrangements within the scope of the patent application for the present invention.

PA1: distance sensor test device PAS1: distance sensor PA11: base PA12: Displacement Platform PA121: Manual adjustment lever PA13: support frame PA14: board under test 1: Distance sensor measurement and analysis system 11: Host 111: Control unit 112: Processing unit 113: Receiving unit 114: Analog-to-digital conversion unit 115: Communication unit 116: storage unit 12:Servo drive 13:Servo motor 14: Encoder 15: backlash free coupling 16: Ball screw 17: Fixed components 171: Loading board 172: fixed seat 173: locking element 18: Board under test 19: Operation display interface 10: Base D1: the first direction D2: Second direction d: Sensing distance L1: Line type L2: Line type L3: Line type P1: data point S1, S2: distance sensor

The first figure is a schematic diagram showing a distance sensor testing device in the prior art; The second figure shows the block diagram of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; The third figure is a schematic diagram showing the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; The fourth figure is a side view showing the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; The fifth figure is a schematic diagram showing the operation display interface of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; The sixth figure is a schematic diagram showing the measurement characteristics of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention; and The seventh figure is a schematic diagram showing another measurement characteristic of the distance sensor measurement and analysis system provided by the preferred embodiment of the present invention.

1: Distance sensor measurement and analysis system

11: Host

12:Servo drive

13:Servo motor

14: Encoder

15: backlash free coupling

16: Ball screw

17: Fixed components

171: Loading board

172: fixed seat

173: locking element

18: Board under test

19: Operation display interface

10: base

S1, S2: distance sensor

Claims (10)

A distance sensor measurement and analysis system is used to measure at least one measurement characteristic of at least one distance sensor, including: a host computer electrically connected to the at least one distance sensor; A servo driver is electrically connected to the host and controlled by the host; A servo motor is electrically connected to the servo driver and driven by the servo driver; an encoder electrically connected to the servo motor and the servo driver; a ball screw provided corresponding to the servo motor so as to be moved by the servo motor; A fixing component is connected with the ball screw to carry the at least one distance sensor; A board under test is arranged corresponding to the fixed component for at least one test operation for the at least one distance sensor; and an operation display interface, which is electrically connected to the host computer and the at least one distance sensor, and displays the at least one measurement characteristic; Wherein, the distance sensor measurement and analysis system uses the host computer and the servo driver to electronically control the servo motor to drive the fixed component to move, so as to enable the at least one distance sensor to perform the at least one test operation, and utilize the The encoder records at least one set of position information corresponding to the at least one test operation, so that the host uses the at least one set of position information to measure the at least one measurement characteristic of the at least one distance sensor, wherein, The at least one measurement characteristic is at least one of a linearity, a resolution and a response time. The distance sensor measurement and analysis system as described in claim 1 further includes a backlash-free coupling, which connects the servo motor and the ball screw, so that when the servo motor drives , so that the ball screw moves synchronously. The distance sensor measurement and analysis system according to claim 1, wherein the fixing component includes a loading plate, and the loading plate is used for placing the at least one distance sensor. The distance sensor measurement and analysis system as described in claim 1, wherein the fixed component includes: a fixed seat, which is set corresponding to the board to be tested; and A locking element is used to lock the at least one distance sensor to the fixing seat. The distance sensor measurement and analysis system as described in Claim 1, wherein the host computer includes a control unit, and the control unit is electrically connected to the servo driver for controlling the servo driver. The distance sensor measurement and analysis system as described in claim 5, wherein the host computer further includes a processing unit, the processing unit is electrically connected to the control unit, and is used to utilize the at least one test operation and the at least one group The location information is processed and measured to obtain the at least one measurement characteristic. The distance sensor measurement and analysis system as described in Claim 6, wherein the host computer further includes a storage unit electrically connected to the processing unit for receiving and storing the at least one measurement characteristic. The distance sensor measurement and analysis system as described in claim 6, wherein the host computer further includes a communication unit, the communication unit is electrically connected to the processing unit and the operation display interface for the at least one measurement The characteristics are sent to the operating display interface. The distance sensor measurement and analysis system as described in claim 6, wherein the host computer further includes a receiving unit, and the receiving unit is electrically connected to the at least one distance sensor for receiving the at least one distance sensor At least one test signal generated when the device performs at least one test operation. The distance sensor measurement and analysis system as described in claim item 9, wherein the host computer further includes an analog-to-digital conversion unit, and the analog-to-digital conversion unit is electrically connected to the receiving unit and the processing unit for at least A test signal is converted from analog format to digital format and sent to the processing unit.

Images