WO2017080329A1 - 角度传感器及角度测量方法 - Google Patents

角度传感器及角度测量方法 Download PDF

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Publication number
WO2017080329A1
WO2017080329A1 PCT/CN2016/100802 CN2016100802W WO2017080329A1 WO 2017080329 A1 WO2017080329 A1 WO 2017080329A1 CN 2016100802 W CN2016100802 W CN 2016100802W WO 2017080329 A1 WO2017080329 A1 WO 2017080329A1
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Prior art keywords
angle
signal
gear
eddy current
current probe
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PCT/CN2016/100802
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English (en)
French (fr)
Inventor
耿继青
黄伟才
殷伟豪
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珠海格力电器股份有限公司
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Priority to US15/775,865 priority Critical patent/US10809102B2/en
Publication of WO2017080329A1 publication Critical patent/WO2017080329A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
    • G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
    • G01D5/245—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains using a variable number of pulses in a train
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/30—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring angles or tapers; for testing the alignment of axes
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
    • G01D5/14—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage
    • G01D5/20—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage by varying inductance, e.g. by a movable armature
    • G01D5/2006—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage by varying inductance, e.g. by a movable armature by influencing the self-induction of one or more coils
    • G01D5/202—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing the magnitude of a current or voltage by varying inductance, e.g. by a movable armature by influencing the self-induction of one or more coils by movable a non-ferromagnetic conductive element
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
    • G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
    • G01D5/245—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains using a variable number of pulses in a train
    • G01D5/2454—Encoders incorporating incremental and absolute signals
    • G01D5/2455—Encoders incorporating incremental and absolute signals with incremental and absolute tracks on the same encoder
    • G01D5/2457—Incremental encoders having reference marks

Definitions

  • the invention relates to an angle sensor and an angle measuring method, in particular to an eddy current based angle sensor and an angle measuring method.
  • the sensors for measuring the angle existing on the market can be divided into two types, one is a contact angle sensor, and the other is a non-contact angle sensor.
  • the contact angle sensor mainly relies on the structure for triggering.
  • Chinese Patent Application No. 201410074133.3 discloses an angle sensor mainly comprising 2N ball switches. By installing the 2N ball switches clockwise in the circumferential direction according to the trigger end in the front and the stabilizing end in the rear direction, or in the clockwise direction, the stabilizing end is in front and the trigger end is in the rear direction.
  • the ball switch is triggered to set an angle on each of the ball switches.
  • the rotary shaft rotates, which ball switch is triggered to output a corresponding angle, thereby obtaining a measurement result.
  • the angle sensor has low measurement accuracy, is easily damaged, is bulky, is cumbersome to maintain, and can only test the angle of low speed rotation.
  • the non-contact angle sensor differs according to the measurement principle, and mainly includes a photoelectric angle sensor and a Hall angle sensor.
  • the photoelectric angle sensor is tested by photoelectric effect, which is very demanding on the use environment. There is a little dust, a little vibration or slight deviation of the installation, which will cause the sensor to work normally, and need photoelectric emission and receiving device, large size and price. expensive.
  • the electromagnetic angle sensor is tested with a Hall element and consists mainly of a rotor and a stator. In operation, the coaxiality of the stator and rotor installation is very high. For example, the gap between the stator and the rotor is generally required to be less than 0.5 mm. Moreover, if the shaft is slightly deflected, the phenomenon of scratching and jamming may occur, and it is not applicable to the angle test with the deflection shaft.
  • the Chinese utility model patent ZL201420138818.5 discloses an angle sensor based on the eddy current effect.
  • the angle sensor includes a metal ring 51 that can be fixed to the rotating shaft, a first exciting coil group 52, and a second exciting coil group 53.
  • the first excitation coil group 52 and the second field coil group 53 are respectively connected to the hardware circuit 54.
  • the first excitation coil and the second excitation coil are directly connected to the hardware circuit through the circuit board.
  • the excitation coil senses the eddy current field generated by the metal ring 51 to change, and then uses the back end of the hardware circuit 54 or the like.
  • the processing device calculates the amount of change in the eddy current field to obtain the measured angle.
  • the angle sensor disclosed in the utility model has the following problems: First, it needs to fix the metal ring on the rotating shaft, and the shape of the metal ring is irregular, the mass distribution is uneven, and the rotational inertia of the rotating shaft is uneven. Therefore, the deflection of the rotating shaft occurs; secondly, the relative position of the exciting coil and the metal ring is strictly limited, the metal ring is fixed to the rotating shaft, and the exciting coil and the detecting coil are fixed to other structures, and when the deflection of the rotating shaft occurs, the inability cannot be completed. Accurate testing of the angle; third, two excitation coils and two detection coils are arranged on both sides of the metal ring, which are bulky and cumbersome to install. In addition, the angle sensor needs to be angle-calibrated before use, and the workload is large.
  • the present invention has been made in view of the problems in the prior art, that is, the present invention provides an angle sensor based on the principle of eddy current testing, which includes only one induction coil, does not require other electronic components, and has good adaptability to the environment. It can be tested in many harsh environments such as high temperature, high pressure and oil pollution. Further, in the measurement process, the sensor only needs to detect the teeth and the slots, and there is no need to make excessive adjustments to the installation position, so that the relative position of the detection surface and the sensor is not strictly required.
  • the invention also provides an angle measuring method.
  • an angle sensor comprising: a gear structure, an eddy current probe, and a processing unit; wherein the gear structure is mounted on a gear fixed to an outer circumference of the rotating shaft or on an outer circumference of the rotating shaft Forming a gear, and providing a positioning structure for feature angle recognition on an outer circumferential side of the gear structure; the eddy current probe is positioned on the outer circumferential side of the gear structure, and the probe faces the gear teeth of the gear and a cogging; and the processing unit is coupled to the eddy current probe for signal processing and outputting an angle measurement signal.
  • the positioning structure is a zero degree positioning structure.
  • the positioning structure is a positioning groove, more preferably a positioning slot or a sharp groove that is disposed deeper than the tooth groove of the gear.
  • the teeth and the slots are evenly distributed.
  • the axial centerline of the eddy current probe intersects perpendicularly to the central axis of the shaft.
  • the output signal of the eddy current probe is a series of peaks and troughs corresponding to the slot and the teeth, and corresponding to the positioning slot for the feature angle identification, the eddy current probe output is higher than A spike corresponding to the peak of the cogging.
  • the processing unit comprises a signal acquisition module for receiving an output signal of the eddy current probe, and a signal processing module for calculating a signal output by the signal acquisition module to output an angle measurement signal.
  • an interface for communicating with the PC is set on the processing unit package to store and display the angle measurement signal on the PC.
  • an angle measuring method for performing angle measurement using an angle sensor as described above comprising:
  • S1 an original pulse signal input, and the processing unit receives an output signal of the eddy current probe;
  • S3 selecting an angle periodic signal, and the processing unit selects one or more periodic angle signals
  • an angle measurement signal operation that is, segmentation processing the selected periodic angle signal to obtain an angular interval of each segment and an angle value of each segment, and further using the angular interval and the angle value of each segment to obtain a characteristic angle An angle measurement signal of the measurement result;
  • step S5 outputting an angle signal, and outputting the measurement angle signal obtained in step S4.
  • step S4 comprises:
  • S41 segment processing the angle signal, performing an infinitely divided segmentation process on the selected periodic angle signal to obtain each segment angle value; and S42: synthesizing each segment angle signal, that is, using each of the above segment angle values The angle value in one cycle or all cycles is synthesized as a measurement angle signal.
  • step S41 the peak-to-valley signal segment obtained by each of the slots and teeth of the gear is defined as x 0 ⁇ x n , and the angle between the center line of the uniform tooth groove and the gear tooth is defined as K, the angular interval of each segment of the signal is:
  • step S42 the angle synthesis is performed using the following formula:
  • FIG. 1 is a schematic view showing the structure of an angle sensor according to a preferred embodiment of the present invention.
  • Fig. 2 is a schematic view showing the structure of an angle sensor of another preferred embodiment of the present invention for explaining a positioning structure.
  • Fig. 3 shows a signal curve of an eddy current probe output in the case where the positioning structure is the positioning groove.
  • FIG. 4 is a block diagram showing the structure of a processing module in accordance with a preferred embodiment of the present invention.
  • FIG. 5 is a flow chart of an angle measurement process according to a preferred embodiment of the present invention.
  • 6(a) and 6(b) are schematic structural views of a prior art angle sensor.
  • the angle sensor of the present invention is an angle sensor based on an eddy current effect.
  • 1 is a schematic view showing the structure of an angle sensor according to a preferred embodiment of the present invention.
  • the angle sensor includes a gear structure 1, an eddy current probe 2, and a processing unit 3.
  • the gear structure is a gear that is fixed to an outer circumference of the rotating shaft or is formed on the outer circumference of the rotating shaft to form a gear.
  • On the outer circumferential side of the gear structure for example, in the teeth and cogging of the gear, a positioning structure P for feature angle recognition, ie for angular positioning, is formed.
  • the positioning structure is preferably a zero-degree positioning structure, and may of course be a positioning structure of other angles.
  • the eddy current probe 2 is positioned on the outer circumferential side of the gear structure, and the probe faces the teeth and the slots to detect a change in eddy current when the gear structure rotates.
  • the processing unit 3 is connected to the eddy current probe 2 and used for signal processing and outputs an angle measurement signal.
  • the processing unit 3 is a hardware signal processing unit with an integrated algorithm package, an algorithm program built in, and the like.
  • the positioning structure P is further described below with reference to Figures 1 and 2.
  • the positioning structure is preferably formed at the position of the slot and deeper than the slot. The form of the slot.
  • the angle sensor can achieve highly accurate measurement results.
  • 2 is a schematic structural view of an angle sensor of another preferred embodiment of the present invention for explaining a positioning structure, which differs from the embodiment shown in FIG. 1 only in the number of teeth and slots of the gear and the form of the positioning structure. Therefore, the description of the same portions as those of FIG. 1 is omitted.
  • FIG. 2 in the gear structure, compared with the solution shown in FIG.
  • the number of teeth and the number of slots of the gear structure is small, for example, if n is less than 21, the positioning structure is preferably disposed to be formed at the position of the slot. And in the form of a sharp groove having a depth deeper than the tooth groove. At this time, since the number of cogs and teeth of the gear structure is relatively small, the measurement accuracy is relatively low.
  • the positioning structure can also be provided in other forms, for example in the form of protrusions that are higher or lower than the teeth of the gear. It should be noted that the positioning structure is capable of causing a change in the eddy current so that the eddy current probe 2 can recognize the structure so that angular positioning can be performed.
  • the angle sensor of the present invention will be described in more detail below by taking a fixed gear mounted on the outer circumference of the rotating shaft as an example.
  • a metal gear having n slots and teeth is fixed to the outer circumference of the shaft.
  • n the more accurate the measurement result is, so it can be selected according to the required measurement accuracy.
  • it is preferably 21 to 81 pieces.
  • the teeth and the slots of the gear are evenly distributed.
  • the positioning structure P for feature angle recognition is provided at a position of the gear teeth and/or the tooth groove for identification of zero angles or other feature angles in order to achieve angular positioning. Taking the case where the positioning structure P is a positioning groove deeper than the cogging groove, the characteristic angle is expressed on the output signal of the eddy current probe 2 as being higher than the output of the eddy current probe 2 corresponding to the tooth groove of the gear.
  • the voltage setting of the signal i.e., the cogging correspondingly outputs a peak
  • the output of the positioning slot has a larger peak than the peak.
  • the eddy current probe 2 is disposed on the outer circumferential side of the gear structure, and preferably, the axial center line of the probe perpendicularly intersects the central axis of the rotating shaft (the axis perpendicular to the paper surface in Fig. 1). At this time, the detection accuracy is the highest.
  • the eddy current probe 2 outputs a series of signal curves having n periods (or troughs) corresponding to n slots (teeth) in a cycle with a change in the cogging gap of the gear. .
  • Fig. 3 shows a signal curve outputted by the eddy current probe 2 in the case where the positioning structure is the positioning groove.
  • the output signal of the eddy current probe 2 is a series of peaks and troughs corresponding to the slots and teeth, and corresponds to the positioning groove for the feature angle recognition, and the eddy current probe 2
  • a spike PK shown in Figure 3 that is significantly higher than the other cogging waveforms is output.
  • the processing unit 3 is used for angle signal acquisition and processing.
  • 4 is a block diagram showing the structure of a processing unit in accordance with a preferred embodiment of the present invention.
  • the eddy current probe 2 outputs a detection signal to the processing unit 3.
  • the processing unit 3 preferably includes a signal acquisition module 31 that receives the detection signal output by the eddy current probe 2, and a signal processing module 32 that processes the acquired signal using a built-in algorithm program to obtain an angle signal characterizing the detection result and output.
  • the processing unit 3 comprises a display module 33, such as an LED display, for displaying an angle signal output from the signal processing module 32.
  • the processing unit 3 may set an interface for communicating with the PC when the hardware circuit is packaged, so that the display module 33 may be omitted, and the angle signal output by the signal processing module 32 may be displayed and stored by the PC.
  • the angle signal displayed on the display device may be a real-time graph characterizing the angle signal, or may be a graph of the angle signal within a predetermined period of time. At the same time, the measured angle signal can also be stored in the PC.
  • the processing unit 3 comprises a power supply module 34 for supplying power to the modules in the processing unit 3 and for supplying power to the eddy current probe.
  • a power supply module 34 for supplying power to the modules in the processing unit 3 and for supplying power to the eddy current probe.
  • an integrated power module can also be additionally provided to supply power to the above components.
  • FIG. 5 is a view of the present invention Angle measurement processing flow chart. As shown in FIG. 5, the angle measuring method includes the following steps:
  • Raw pulse signal input that is, the signal acquisition module 31 of the processing unit 3 transmits the output signal of the collected eddy current probe 2 to the signal processing module 32.
  • determining the angle feature signal that is, the signal processing module 32 identifies a positioning structure corresponding to the positioning structure for the feature angle recognition, such as a positioning slot, such as the spike pulse PK shown in FIG.
  • S3 Select an angular period signal, that is, select one or more periodic angle signals.
  • the gear structure rotates one week, corresponding to one cycle signal.
  • one or more periodic angle signals can be automatically selected by the spike pulse PK described above and by the built-in algorithm program to determine the characteristic angle signal at the spike.
  • an angle measurement signal operation that is, segmentation processing the selected periodic angle signal to obtain an angular interval of each segment and an angle value of each segment, and further using the angular interval and the angle value of each segment to obtain a characteristic angle The angle measurement signal of the measurement result.
  • segment processing the angle signal that is, using the infinite segmentation idea for the selected periodic angle signal (ie, the selected data signal segment is composed of multiple data sampling points, fine to each adjacent two data samples Segmentation is performed by dividing the angular interval between points.
  • the selected data signal segment is composed of multiple data sampling points, fine to each adjacent two data samples Segmentation is performed by dividing the angular interval between points.
  • the peak-to-valley signal segment obtained by each tooth groove and tooth of the gear is defined as x 0 ⁇ x n
  • the angle between the center line of the uniform tooth groove and the gear tooth is defined as K
  • the angular interval of each data signal segment is:
  • the angle value of each segment is:
  • S42 synthesize each segment of the angle signal, that is, use the above-mentioned angle value of each segment to synthesize the angle value in one cycle or all cycles. Specifically, the following formula:
  • step S5 outputting the angle measurement signal, that is, obtaining a period or all period angle values in step S4, displaying on the display module 33 of the processing unit 3 or displaying and saving on the PC.
  • the angle sensor and angle measuring method of the present invention have been described above.
  • the angle sensor and the angle measuring method according to the present invention can be applied to an environment of high temperature, high pressure, high speed, dust, refrigerant, water immersion, oil immersion, and partial electromagnetic interference, and the application is wide, and there are no environmental restrictions.
  • the algorithm program utilized by the solution of the invention can realize automatic recognition of the angle zero degree, automatic calculation and output of each time angle, the precision is up to ⁇ 0.1°, and calibration is not required.
  • the distance between the eddy current probe and the rotating shaft can be flexibly adjusted according to the probe range.
  • the machined gear teeth can be directly fixed to the rotating shaft, or directly processed into a gear tooth shape at a certain position of the rotating shaft, and only one eddy current probe needs to be installed on the side of the rotating shaft, and the structure design is simple and small. Easy to install and operate.
  • the processing unit for realizing the angle signal output includes a signal acquisition module and a signal processing module, and the two modules can be integrally integrated and packaged, and the algorithm is built in the signal processing module.
  • the package module has an interface for communication with the PC, which can display the current real-time angle value or the angle curve of the time period on the PC very intuitively, and can also conveniently store the historical angle data.

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  • Measurement Of Length, Angles, Or The Like Using Electric Or Magnetic Means (AREA)

Abstract

一种角度传感器，包括齿轮结构（1）、电涡流探头（2）以及处理单元（3）；其中，齿轮结构（1）为安装固定于转轴的外圆周上的齿轮或者在转轴的外圆周上加工形成齿轮，且在齿轮结构（1）的外圆周侧上设置用于特征角度识别的定位结构（P）；电涡流探头（2）定位在齿轮结构(1)的所述外圆周侧，且电涡流探头(2)面对齿轮的轮齿和齿槽；处理单元（3）连接于电涡流探头（2），用于信号处理，并输出角度测量信号。还公开了一种角度测量方法。

Description

角度传感器及角度测量方法
本申请要求于2015年11月13日提交中国专利局、申请号为201510785432.2、发明名称为“角度传感器及角度测量方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及一种角度传感器及角度测量方法，尤其涉及一种基于电涡流的角度传感器及角度测量方法。
背景技术
在根据传感器与待测对象是否接触，可以将目前市场上存在的测量角度的传感器分为两种，一种是接触式角度传感器，另一种是非接触式角度传感器。
其中，接触式角度传感器主要依靠结构进行触发。例如，中国发明专利第201410074133.3号申请公开了一种角度传感器，主要包括2N个滚珠开关。通过将2N个滚珠开关顺时针依次沿圆周按照触发端在前、稳定端在后的方向安装，或者是采用顺时针依次沿圆周按照稳定端在前、触发端在后的方向安装。在进行角度测量时，利用触发所述滚珠开关，在每个滚珠开关上设定好角度，当旋转轴旋转时，触发到哪个滚珠开关就输出相对应的角度，从而得到测量结果。然而，该角度传感器测量精度低、易损坏，体积大、维护繁琐且只能测试低速旋转的角度。
另一方面，非接触式角度传感器根据测量原理不同，主要包括光电式角度传感器和霍尔角度传感器。其中，光电式角度传感器利用光电效应进行测试，对使用环境要求非常苛刻，有少许粉尘、少许振动或者安装稍有偏差均会导致传感器不能正常工作，且需要光电发射与接收装置，体积大、价格昂贵。电磁式角度传感器利用霍尔元件进行测试，主要由转子和定子组成。在工作中，对定子与转子安装的同轴度要求非常高，例如，定子、转子之间的间隙一般要求小于0.5mm。并且，转轴稍有挠度即出现刮擦卡死等现象，无法适用于有挠度转轴的角度测试。
中国实用新型专利ZL201420138818.5公开了一种基于电涡流效应的角度传感器。如图6(a)、6(b)所示，该角度传感器包括：可固定于转轴上的金属环51、第一励磁线圈组52和第二励磁线圈组53。其中，第一励磁线圈组 52和第二励磁线圈组53分别与硬件电路54相连接。其中，第一励磁线圈与第二励磁线圈需通过电路板直接连接到硬件电路上，当转轴55旋转时，励磁线圈感应到金属环51产生的涡流场发生变化，然后利用硬件电路54等后端的处理设备对涡流场变化量进行计算，得出所测量的角度。
然而，该实用新型专利所公开的角度传感器存在如下问题：第一、其需要在转轴上固定所述金属环，且金属环的形状不规则，质量分布不均匀，容易造成转轴的转动惯量不均匀，使转轴出现挠度；第二，励磁线圈与金属环的相对位置有严格限制，金属环固定到转轴上，而励磁线圈与检测线圈固定到其它结构上，当转轴运动出现挠度时，则无法完成对角度的准确测试；第三、需要在所述金属环两侧布置2个励磁线圈、2个检测线圈，体积大、安装繁琐。此外，该角度传感器在使用前需进行角度标定，工作量大。
发明内容
本发明是鉴于现有技术中存在的问题而提出的，即本发明提供一种基于电涡流测试原理的角度传感器，该传感器仅包括一个感应线圈，无需其他电子元器件，对环境的适应性能良好，经测试可用于高温、高压、油污等多种恶劣环境中。进一步地，在测量过程中，该传感器只要检测到轮齿和齿槽即可，无需对其安装位置进行过多的调整，从而对检测面与传感器的相对位置无严格要求。本发明还提供一种角度测量方法。
根据本发明的第一方面，提供一种角度传感器，包括，齿轮结构、电涡流探头以及处理单元；其中，所述齿轮结构为安装固定于转轴的外圆周上的齿轮或者在转轴的外圆周上加工形成齿轮，且在齿轮结构的外圆周侧上设置用于特征角度识别的定位结构；所述电涡流探头定位在齿轮结构的所述外圆周侧，且探头面对所述齿轮的轮齿和齿槽；以及所述处理单元连接于电涡流探头，用于信号处理，并输出角度测量信号。
优选地，所述定位结构为零度定位结构。
优选地，所述定位结构为定位槽，更优选地，为设置得比所述齿轮的齿槽更深的定位齿槽或尖角槽。
优选地，所述轮齿和齿槽均匀分布。
优选地，所述电涡流探头的轴向中心线与所述转轴的中心轴线垂直相交。
进一步优选地，电涡流探头的输出信号为对应于所述齿槽、轮齿的一系列波峰、波谷，及对应于用于所述特征角度识别的所述定位槽，电涡流探头输出一个高于对应所述齿槽的波峰的尖峰脉冲。
优选地，所述处理单元包括用于接收电涡流探头的输出信号的信号采集模块，以及用于对信号采集模块输出的信号进行运算，以输出角度测量信号的信号处理模块。
优选地，在进行硬件电路封装时，在所述处理单元封装上设置与PC进行通信的接口，以在PC上存储和显示所述角度测量信号。
根据本发明的另一方面，提供一种角度测量方法，所述方法用如前所述的角度传感器进行角度测量，包括：
S1：原始脉冲信号输入，处理单元接收电涡流探头的输出信号；
S2：判断角度特征信号，处理单元识别对应于用于所述特征角度识别的定位结构的特征角度识别信号；
S3：选取角度周期信号，处理单元选取一个或多个周期角度信号；
S4：角度测量信号运算，即，对所选取的周期角度信号进行分段式处理，以获得每段的角度间隔及每段角度值，并进一步利用所述角度间隔和每段角度值获得表征角度测量结果的角度测量信号；以及
S5：输出角度信号，输出在步骤S4中得到的测量角度信号。
优选地，步骤S4包括：
S41：分段处理角度信号，对所选取的周期角度信号，对其进行无限分割式的分段式处理，得到每段角度值；以及S42：合成各段角度信号，即利用上述每段角度值合成一周期或所有周期内的角度值，作为测量角度信号。
优选地，在步骤S41中，定义由齿轮的每个齿槽和轮齿得到的峰谷点信号段为x0～xn，定义均布齿槽与轮齿两者中心线之间的角度为K，则每段信号段的角度间隔为：
Figure PCTCN2016100802-appb-000001
且每段角度值为：
1)x0～x1区间角度子数组
x0,x0+△x0,x0+2△x0,x0+3△x0,...,x1
2)x1～x2区间角度子数组
x1,x1+△x1,x1+2△x1,x1+3△x1,...,x2
…
n)xn-1～xn区间角度子数组
xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...,xn。
优选地，在步骤S42中，采用如下公式进行角度合成：
x0,x0+△x0,x0+2△x0,x0+3△x0,...x1,x1+△x1,x1+2△x1,x1+3△x1,...x2,...,xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...xn。
以下结合本发明的具体实施方式和附图对本发明的具体方案进行描述，本发明的有益效果将进一步明确。
附图说明
此处所说明的附图用来提供对本发明的进一步理解，构成本发明的一部分，用于解释本发明，并不构成对本发明的不当限定。
图1是本发明一优选实施例的角度传感器的结构示意图。
图2是用于说明定位结构的本发明另一优选实施例的角度传感器结构示意图。
图3示出了在所述定位结构为所述定位槽的情况下的电涡流探头输出的信号曲线。
图4为根据本发明一优选实施例的处理模块的结构示意图。
图5为本发明一优选实施例的角度测量处理流程图。
图6(a)、6(b)为现有技术的角度传感器的结构示意图。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚，下面将结合本发明具体实施例及相应的附图对本发明技术方案进行清楚、完整地描述。显然，所描述的实施例仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施 例，都属于本发明保护的范围。
本发明所述角度传感器是基于电涡流效应的角度传感器。图1是本发明一优选实施例的角度传感器的结构示意图。如图1所示，所述角度传感器包括齿轮结构1、电涡流探头2以及处理单元3。所述齿轮结构为安装固定于转轴的外圆周上的齿轮或者在转轴的外圆周上加工形成齿轮。在齿轮结构的外圆周侧上，例如，在所述齿轮的轮齿和齿槽中，形成用于特征角度识别，即用于角度定位的定位结构P。所述定位结构优选为零度定位结构，当然也可以是其他角度的定位结构。所述电涡流探头2定位在所述齿轮结构的所述外圆周侧，且探头面对所述轮齿和齿槽，以在所述齿轮结构旋转时检测涡电流的变化。所述处理单元3连接于电涡流探头2并用于信号处理，并输出角度测量信号。优选地，该处理单元3为一体化集成封装的、内置有算法程序等的硬件信号处理单元。
下面参照图1、2进一步描述所述定位结构P。如图1所示，当齿轮结构上的轮齿、齿槽数n超过预定范围，例如n大于21时，所述定位结构优选为形成在齿槽位置的、且深度比所述齿槽更深的槽的形式。此时，该角度传感器能够实现高精度的测量结果。图2为用于说明定位结构的本发明另一优选实施例角度传感器的结构示意图，与图1所示实施例不同之处仅在于齿轮的轮齿和齿槽的数量及所述定位结构的形式，因此省略与图1相同部分的说明。如图2所示，齿轮结构相比图1所示的方案中，齿轮结构的轮齿、齿槽数较少，例如n小于21，则所述定位结构优选设置为形成在齿槽位置的、且深度比所述齿槽更深的尖角槽的形式。此时，由于齿轮结构的齿槽、轮齿的数量相对少，其测量精度相对较低。
此外，定位结构还可以设置为其他形式，例如，比所述齿轮的轮齿更高或者更低的突起的形式。需要指出的是，定位结构以能引起电涡流变化，以使得所述电涡流探头2能够识别该结构，从而能够进行角度定位为准。
以下以在转轴外圆周上安装固定齿轮为例，对本发明的角度传感器进行更为详细的描述。
首先，在转轴的外圆周上安装固定具有n个齿槽和轮齿的金属齿轮。其中，n的取值越大测量结果显然越精确，因此可以根据所需的测量精度进行选取。本发明中，优选为21-81个。此外，优选地，该齿轮的轮齿和齿槽为均匀分布。 在轮齿和/或齿槽的某位置上设置进行特征角度识别的所述定位结构P，用于零角度或其他特征角度的识别，以便实现角度定位。以定位结构P为比所述齿槽深的定位槽的情况为例，则所述特征角度在电涡流探头2的输出信号上表现为高于对应于齿轮的齿槽的电涡流探头2的输出信号的电压定值，即例如齿槽对应地输出波峰，则定位槽的输出具有比该波峰更大的峰值。
其次，将电涡流探头2布置于齿轮结构的外圆周侧，且优选地，探头的轴向中心线与所述转轴的中心轴线(图1中垂直于纸面的轴线)垂直相交。此时，检测精度最高。当转轴旋转时，电涡流探头2随着所述齿轮的齿槽间隙变化输出一系列具有多个周期，且周期内具有对应于n个槽(齿)的n个波峰(或波谷)的信号曲线。
图3示出了在所述定位结构为所述定位槽的情况下的电涡流探头2输出的信号曲线。如图3所示，电涡流探头2的输出信号为对应于所述齿槽、轮齿的一系列波峰、波谷，而对应于用于所述特征角度识别的所述定位槽，电涡流探头2输出一个明显高于其它齿槽波形的尖峰脉冲PK(如图3所示)。
最后，利用处理单元3进行角度信号采集和处理。图4为根据本发明一优选实施例的处理单元的结构示意图。如图4所示，电涡流探头2输出检测信号给所述处理单元3。处理单元3优选包括接收电涡流探头2输出的检测信号的信号采集模块31，以及利用内置算法程序对采集到的信号进行处理，以得到表征检测结果的角度信号并输出的信号处理模块32。优选地，处理单元3包括显示模块33，例如LED显示器，用于显示从信号处理模块32输出的角度信号。可选择地，处理单元3可以在进行硬件电路封装时，设置与PC进行通信的接口，从而可以省略上述显示模块33，而利用PC显示、存储信号处理模块32输出的角度信号。上述在显示装置上显示的角度信号，可以是表征角度信号的实时的曲线图，也可以是预定时间段内的角度信号的曲线图。同时，还可将测量的角度信号存储在PC中。
此外，进一步优选地，处理单元3包括电源模块34，用于给处理单元3中的各模块供电，并可以给电涡流探头供电。当然，也可以另外设置集成电源模块，为上述各部件供电。
下面结合图5说明本发明的角度传感器的角度测量方法。图5为本发明的 角度测量处理流程图。如图5所示，所述角度测量方法包括如下步骤：
S1：原始脉冲信号输入，即处理单元3的信号采集模块31将采集到的电涡流探头2的输出信号传送到信号处理模块32。
S2：判断角度特征信号，即，信号处理模块32识别对应于用于所述特征角度识别的定位结构，例如定位槽的特征角度识别信号，例如图3所示的尖峰脉冲PK。
S3：选取角度周期信号，即，选取一个或多个周期角度信号。其中，齿轮结构旋转一周，对应一个周期信号。具体地，可通过上述的尖峰脉冲PK，并由内置算法程序判定尖峰脉冲处的特征角度信号自动选取一个或多个周期角度信号。
S4：角度测量信号运算，即，对所选取的周期角度信号进行分段式处理，以获得每段的角度间隔及每段角度值，并进一步利用所述角度间隔和每段角度值获得表征角度测量结果的角度测量信号。
具体地，
S41：分段处理角度信号，即，对所选取的周期角度信号，对其采用无限分割思想(即，所选取的数据信号段由多个数据采样点组成，精细到每相邻两个数据采样点之间划分角度间隔区间)进行分段式处理。以选取一个周期角度信号为例，对于有n个齿槽的齿轮来说，如图2所示，定义由齿轮的每个齿槽和轮齿得到的峰谷点信号段为x0～xn，定义均布齿槽与轮齿两者中心线之间的角度为K，则每段数据信号段的角度间隔为：
Figure PCTCN2016100802-appb-000002
每段角度值为：
1)x0～x1区间角度子数组
x0,x0+△x0,x0+2△x0,x0+3△x0,...,x1
2)x1～x2区间角度子数组
x1,x1+△x1,x1+2△x1,x1+3△x1,...,x2
…
n)xn-1～xn区间角度子数组
xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...,xn。
S42：合成各段角度信号，即利用上述每段角度值合成一周期或所有周期内的角度值。具体地，如下公式：
x0,x0+△x0,x0+2△x0,x0+3△x0,...x1,x1+△x1,x1+2△x1,x1+3△x1,...x2,...,xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...xn。
此外，多个周期角度值同理可得。
S5：输出角度测量信号，即将在步骤S4中得到一周期或所有周期内角度值，在处理单元3的显示模块33上进行显示或在PC上进行显示与保存。
以上对本发明的角度传感器及角度测量方法进行了描述。根据本发明的角度传感器及角度测量方法，可应用在高温、高压、高速、粉尘、冷媒、浸水、浸油以及存在部分电磁干扰的环境中，应用场合广泛，无较多环境限制。本发明的方案利用的算法程序可实现角度零度自动识别、各时刻角度自动计算并输出，精度高达±0.1°，且无需标定。电涡流探头与转轴间的距离可根据探头量程灵活调整，即使转轴在高速运转下有一定的挠度，也可以实现准确高精度的角度输出，有效解决了业内长期存在的挠度影响角度精度的问题。此外，本发明中，可直接将加工的轮齿固定到转轴上，或者在转轴某位置上直接加工成轮齿状，仅需在转轴侧面安装一个电涡流探头即可，结构设计简易、体积小、安装操作方便。
同时，根据本发明的实现角度信号输出的处理单元包括信号采集模块、信号处理模块，两个模块可一体化集成封装，并将算法内置于信号处理模块中。封装模块留有与PC通信的接口，可非常直观的在PC显示当前实时角度值或一段时间的角度曲线，也可方便保存历史角度数据。
以上所述仅为本发明的实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的权利要求范围之内。

Claims (13)

  1. 一种角度传感器，其特征在于，包括：
    齿轮结构、电涡流探头以及处理单元；其中，
    所述齿轮结构为安装固定于转轴的外圆周上的齿轮或者在转轴的外圆周上加工形成齿轮，且在齿轮结构的外圆周侧上设置用于特征角度识别的定位结构；
    所述电涡流探头定位在齿轮结构的所述外圆周侧，且探头面对所述齿轮的轮齿和齿槽；以及
    所述处理单元连接于电涡流探头，用于信号处理，并输出角度测量信号。
  2. 如权利要求1所述的角度传感器，其特征在于，其中，
    所述定位结构为零度定位结构。
  3. 如权利要求1或2所述的角度传感器，其特征在于，其中，
    所述定位结构为定位槽。
  4. 如权利要求3所述的角度传感器，其特征在于，其中，
    所述定位槽为，设置在齿槽位置且深度比齿槽更深的定位齿槽或定位尖角槽。
  5. 如权利要求1或2所述的角度传感器，其特征在于，其中，
    所述轮齿和齿槽均匀分布。
  6. 如权利要求1或2所述的角度传感器，其特征在于，其中，
    所述电涡流探头的轴向中心线与所述转轴的中心轴线垂直相交。
  7. 如权利要求3所述的角度传感器，其特征在于，其中，
    电涡流探头的输出信号为对应于所述齿轮的所述齿槽、轮齿的一系列波峰、波谷，及对应于用于所述特征角度识别的所述定位槽，电涡流探头输出一个高于对应所述齿轮的齿槽的波峰的尖峰脉冲。
  8. 如权利要求1或2所述的角度传感器，其特征在于，其中，
    所述处理单元包括用于接收电涡流探头的输出信号的信号采集模块，以及用于对信号采集模块输出的信号进行运算，并输出角度测量信号的信号处理模块。
  9. 如权利要求8所述的角度传感器，其特征在于，其中，
    在进行硬件电路封装时，在所述处理单元封装上设置与PC进行通信的接口，以在PC上存储和显示所述角度测量信号。
  10. 一种用如权利要求1-9任一项所述的角度传感器进行角度测量的角度测量方法，其特征在于，所述方法包括：
    S1：原始脉冲信号输入步骤，接收电涡流探头的输出信号；
    S2：判断角度特征信号，基于所述输出信号识别对应于用于所述特征角度识别的定位结构的特征角度识别信号；
    S3：选取角度周期信号，从所述特征角度识别信号中选取一个或多个周期角度信号；
    S4：角度测量信号运算，对所选取的周期角度信号进行分段式处理，以获得每段的角度间隔及每段角度值，并利用所述角度间隔和每段角度值获得表征角度测量结果的角度测量信号；以及
    S5：输出角度测量信号，输出在步骤S4中得到的角度测量信号。
  11. 如权利要求10所述的方法，其特征在于，其中，
    步骤S4具体包括：
    S41：分段处理角度信号，对所选取的周期角度信号，对其进行无限分割式的分段式处理，得到每段角度值；以及
    S42：合成各段角度信号，利用上述每段角度值合成一周期或所有周期内的角度值，作为测量角度信号。
  12. 如权利要求11所述的方法，其特征在于，其中
    在步骤S41中，定义由齿轮的每个齿槽和轮齿得到的峰谷点信号段为x0～xn，定义均布齿槽与轮齿两者中心线之间的角度为K，则每段信号段的角度间隔为：
    Figure PCTCN2016100802-appb-100001
    且每段角度值为：
    1)x0～x1区间角度子数组
    x0,x0+△x0,x0+2△x0,x0+3△x0,...,x1
    2)x1～x2区间角度子数组
    x1,x1+△x1,x1+2△x1,x1+3△x1,...,x2
    …
    n)xn-1～xn区间角度子数组
    xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...,xn。
  13. 如权利要求12所述的方法，其特征在于，其中，
    在步骤S42中，采用如下公式进行角度合成：
    x0,x0+△x0,x0+2△x0,x0+3△x0,...x1,x1+△x1,x1+2△x1,x1+3△x1,...x2,...,xn-1,xn-1+△xn-1,xn-1+2△xn-1,xn-1+3△xn-1,...xn。
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