WO2019184136A1 - 一种数字式位移传感器及其位移测量方法 - Google Patents

一种数字式位移传感器及其位移测量方法 Download PDF

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WO2019184136A1
WO2019184136A1 PCT/CN2018/094934 CN2018094934W WO2019184136A1 WO 2019184136 A1 WO2019184136 A1 WO 2019184136A1 CN 2018094934 W CN2018094934 W CN 2018094934W WO 2019184136 A1 WO2019184136 A1 WO 2019184136A1
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signal
processing unit
waveform
sensor
displacement sensor
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PCT/CN2018/094934
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English (en)
French (fr)
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梁磊
夏晴
吴炜杰
郁春雷
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磐石电气（常州）有限公司
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Priority to US16/083,903 priority Critical patent/US10890432B2/en
Priority to EP18912184.1A priority patent/EP3748284B1/en
Publication of WO2019184136A1 publication Critical patent/WO2019184136A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/04—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving
    • G01B11/043—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving for measuring length
    • 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
    • G01D5/26—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
    • G01D5/32—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light
    • G01D5/34—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells
    • G01D5/347—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
    • G01D5/34776—Absolute encoders with analogue or digital scales
    • G01D5/34792—Absolute encoders with analogue or digital scales with only digital scales or both digital and incremental scales
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
    • G01P3/00—Measuring linear or angular speed; Measuring differences of linear or angular speeds
    • G01P3/42—Devices characterised by the use of electric or magnetic means
    • G01P3/44—Devices characterised by the use of electric or magnetic means for measuring angular speed
    • G01P3/48—Devices characterised by the use of electric or magnetic means for measuring angular speed by measuring frequency of generated current or voltage
    • G01P3/481—Devices characterised by the use of electric or magnetic means for measuring angular speed by measuring frequency of generated current or voltage of pulse signals
    • G01P3/486—Devices characterised by the use of electric or magnetic means for measuring angular speed by measuring frequency of generated current or voltage of pulse signals delivered by photo-electric detectors
    • 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
    • G01D5/24428—Error prevention
    • G01D5/24433—Error prevention by mechanical means
    • G01D5/24438—Special design of the sensing element or scale
    • 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
    • G01D5/24471—Error correction
    • G01D5/24485—Error correction using other sensors
    • 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
    • G01D5/26—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
    • G01D5/32—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light
    • G01D5/34—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells
    • G01D5/347—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 characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light with attenuation or whole or partial obturation of beams of light the beams of light being detected by photocells using displacement encoding scales
    • G01D5/34746—Linear encoders

Definitions

  • the invention belongs to the technical field of displacement sensors, and in particular relates to a digital displacement sensor and a displacement measuring method thereof.
  • Displacement is a relatively common physical quantity to be measured in production and life.
  • Sensors commonly used for displacement measurement include grating scales, tolerance scales, resistance scales, or angular encoders that have been mechanically extended (such as rope encoders, angular displacement line shifts), etc., and are widely used.
  • technologies such as gratings and capacitive barriers exist in the form of integral equipment components. For example, when measuring, the entire scale is integrated into semi-automatic or automated equipment. This method has strong requirements on the structure of the automation equipment and is costly.
  • the sensor itself is gradually transitioning from analog-like sensing components to digital signal acquisition modules.
  • the digital signal acquisition module is more and more widely used due to its own operation compensation function and easy system integration.
  • the process of converting the sinusoidal signal into a square wave signal by the sensor is a necessary part of the signal processing; but the photoelectric sensor is very sensitive to the change of the distance a, as shown in Fig. 1, the measured object 11 is far from the traditional
  • the change of the distance of the sensor 12 has a great influence on the generated sensor signal.
  • a change of 0.5 mm will result in a signal change of more than 20%.
  • the signal of the light sensor is weak, when the distance a is small.
  • the signal of the light sensor is strong.
  • a conventional sinusoidal signal converts a square wave signal by inputting a sinusoidal signal and a DC signal of a given voltage to a voltage comparator to generate a square wave.
  • the sinusoidal signal also changes.
  • the sensor signal is at the peak, if the distance becomes smaller, the signal waveform moves down, and the peak voltage of the sensor may be less than a given fixed voltage.
  • the sensor is at the bottom, if the distance becomes larger.
  • the valley voltage of the sensor may be greater than a given fixed voltage.
  • the above factors cause the sensor to not generate a stable square wave signal, resulting in a final measurement error.
  • the traditional solution is to signal the signal generated by a sensor to obtain a valid signal. Since the signal generated by the sensor is affected by many factors in practical applications, for example, the influence of the distance a in FIG. 1, for example, the influence of the moving speed of the measured object, for example, the influence of temperature and humidity, such as the brightness of ambient light, etc. Wait. These effects can cause the signal generated by the sensor itself to be unstable. Since the conventional scheme only processes the unstable signal itself, the processed effective signal cannot be stably generated, and an error may occur.
  • the object of the present invention is to provide a digital displacement sensor and a displacement measuring method thereof, which solve the deficiencies of the conventional technology.
  • the present invention adopts the following technical solutions:
  • a digital displacement sensor includes a signal acquisition module, the signal acquisition module includes at least two photoelectric sensors, and the two photoelectric sensors are configured to respectively acquire a first signal and a second signal, and send the signal to a signal processing unit, where The first signal has a peak and a valley and is periodically distributed, the second signal is the same as the waveform of the first signal, and the peak of the first signal corresponds to the valley of the second signal in the same clock cycle;
  • a signal processing unit configured to generate a third signal, and generate a falling waveform of the third signal at the first intersection of the waveforms of the first signal and the second signal in the same clock cycle, the first signal and the second signal A rising waveform of the third signal is generated at the second intersection of the waveform to form a waveform of the third signal in one clock cycle.
  • the data processing unit is configured to count the rising waveform and the falling waveform of the third signal to digitize the length measurement result.
  • the signal acquisition module of the present invention is configured with an analog front end circuit, the signal acquisition module and the analog front end circuit constitute a signal acquisition unit, and the signal processing unit is a comparator;
  • the analog front-end circuit includes an amplifier and its peripheral circuits.
  • the two photoelectric sensors are respectively connected to the input ends of an analog front-end circuit, and the outputs of the two analog front-end circuits are respectively connected to the positive input terminal and the negative input terminal of the comparator.
  • the output of the comparator is connected to the data processing unit.
  • the invention further includes a housing and a circuit board, the housing is provided with a window and an opening, the circuit board is disposed in the housing, and the data processing unit, the signal processing unit and the signal acquisition unit are integrated on the circuit board, and the data processing
  • the signal output interface of the unit is connected to a communication cable, and the communication cable protrudes through the opening through the opening.
  • Both of the photosensors of the present invention are reflective photointerrupters.
  • the digital displacement sensor of the present invention is configured to detect the length of the object to be measured, and the measuring object is provided with a measuring coating, and the measuring coating comprises two stripes with different reflection efficiency, and the two stripe widths are the same, and the photoelectricity during detection The sensor obtains a signal by sensing the measurement coating.
  • the detection signals of the two photoelectric sensors of the present invention are sinusoidal signals, and the signals output by the comparators are square wave signals, and the phase difference of the sinusoidal signals of the two photosensors is 180 degrees when detecting.
  • the present invention also provides a displacement measuring method using the above-described digital displacement sensor comprising the following steps:
  • the first signal and the second signal are respectively sent to the signal processing unit, wherein the first signal has peaks and troughs and is periodically distributed, the second signal
  • the waveform of the first signal is the same as the waveform of the first signal, and the peak of the first signal corresponds to the valley of the second signal in the same clock cycle;
  • the signal processing unit obtains a third signal according to the first signal and the second signal, and generates a third signal at a first intersection of waveforms of the first signal and the second signal in the same clock cycle a falling waveform, a rising waveform of the third signal at a second intersection of the waveforms of the first signal and the second signal, thereby forming a waveform of the third signal in one clock cycle;
  • the data processing unit counts the rising waveform and the falling waveform of the third signal and determines the displacement direction, thereby digitizing the length measurement result.
  • the two photoelectric sensors of the present invention are all reflective optical interrupters, the signal processing unit is a comparator, the data processing unit is an ARM controller, and the first signal and the second signal obtained by the two photoelectric sensors are All of the sinusoidal signals are generated, and the third signal generated by the comparator is a square wave signal, and the rising edge and the falling edge of the square wave signal of the ARM controller are counted to digitize the length measurement result.
  • the phase difference between the first signal and the second signal is 180 degrees.
  • the digital displacement sensor of the present invention obtains a square wave signal by two complementary signals, and the measurement is more reliable because the third signal is generated based on the intersection of the waveforms of the first signal and the second signal, and the first The intersection of the waveform of the signal and the second signal depends on the width and distance of the bright and dark layers on the measurement coating.
  • the width and distance are artificially designed and constant, so the third signal is not in the same clock cycle.
  • Will be affected by the change of the distance a if the distance a changes as shown in Figure 1, the amplitudes of the waveforms of the first signal and the second signal will change simultaneously, but the intersection of the two waveforms will not change, so the third signal itself will not affected.
  • the digital displacement sensor of the present invention is also not affected by factors such as the moving speed of the object to be measured, the temperature and humidity, and the brightness of the ambient light.
  • a digital displacement sensor and a displacement measuring method thereof according to the present invention realize a displacement sensor capable of flexibly selecting a fixed sensor or a fixed object to be measured according to a structure, and only need to move relative to each other to perform measurement.
  • the material of the object to be tested is not limited, and materials such as steel strip, aluminum plate, plastic, etc. can be flexibly used. Only the surface is coated with corresponding stripes, and the sensor itself is digitally processed, which can digitally compensate for environmental errors, and the sensor does not touch the object to be measured.
  • the utility model has the advantages of no mechanical wear and long service life, and the invention has the advantages of simple structure and low cost, and the sensor precision can be adjusted by placing a plurality of sets of sensing elements, thereby greatly reducing the requirement for the stability of the signal quantity of the sensor.
  • Figure 1 is a drawing of the background art
  • Figure 2 is a schematic view of the structure of the present invention.
  • FIG. 3 is a circuit diagram of a signal acquisition module of the present invention.
  • Figure 4 is a mathematical model diagram of calculating the spacing between photosensors of the present invention.
  • Figure 5 is a waveform diagram of the first signal, the second signal, and the third signal of the present invention.
  • photosensor 1 housing 2, circuit board 3, communication cable 4, measuring coating 5, window 6, opening 7, object to be tested 11, conventional sensor 12.
  • a digital displacement sensor as shown in Figures 2-4 includes a signal acquisition module, a signal processing unit, and a data processing unit.
  • the signal acquisition module includes at least two photoelectric sensors for respectively acquiring the first signal and the second signal and transmitting to the signal processing unit, wherein the first signal has peaks and troughs and is periodically distributed, and second The signal is the same as the waveform of the first signal, and the peak of the first signal corresponds to the valley of the second signal in the same clock cycle;
  • the signal processing unit is configured to generate a third signal, and generate a falling waveform of the third signal, a waveform of the first signal and the second signal at a first intersection of the waveforms of the first signal and the second signal in the same clock cycle A rising waveform of the third signal is generated at the second intersection point, thereby forming a waveform of the third signal in one clock cycle.
  • the first signal and the first signal may also be implemented by a software method or a combination of software and hardware.
  • a rising waveform of the third signal is generated at a first intersection of the waveforms of the two signals, and a falling waveform of the third signal is generated at a second intersection of the waveforms of the first signal and the second signal, thereby forming a clock cycle The waveform of the third signal.
  • the data processing unit is configured to count the rising waveform and the falling waveform of the third signal to digitize the length measurement result.
  • the signal acquisition module is configured with an analog front end circuit, the signal acquisition module and the analog front end circuit constitute a signal acquisition unit, and the signal processing unit is a comparator.
  • the signal processing unit of the embodiment includes but is not limited to a comparator, and the like. Modules that implement comparator functions through software or both hardware and software are included, and no restrictions are imposed on them;
  • the analog front end circuit comprises an amplifier and its peripheral circuit, two photoelectric sensors are respectively connected to the input end of an analog front end circuit, and the output ends of the two analog front end circuits are respectively connected to the positive input terminal and the negative input end of the comparator, the comparator The output end is connected to the data processing unit.
  • the two photosensors are the first photosensor U1 and the second photosensor U2, respectively; the output ends of the first photosensor U1 and the second photosensor U2 respectively pass through
  • the amplifier is connected to the positive input terminal and the negative input terminal of the comparator IC1, and the output terminal of the comparator IC1 is connected to the signal output interface.
  • the digital displacement sensor of this embodiment further includes a casing 2 and a circuit board 3.
  • the casing 2 is provided with a window 6 and an opening 7.
  • the circuit board 3 is disposed in the casing 2, and the circuit board 3 is integrated with a data processing unit, a signal processing unit, and The signal acquisition unit, the signal output interface of the data processing unit is connected to a communication cable 4, and the communication cable 4 extends out of the casing 2 through the opening 7.
  • the data processing unit of this embodiment is an ARM controller, and both photosensors are reflective photointerrupters.
  • the digital displacement sensor of the present embodiment is configured to detect the length of the object to be measured.
  • the measurement object 5 is provided with a measurement coating 5, and the measurement coating 5 includes two stripes of different reflection efficiencies, and two The stripe width is the same.
  • the photosensor measures the coating 5 by induction to obtain a signal.
  • the signal acquisition module is spaced from the object 11 to be measured by a distance of 0.1 mm to 5 mm.
  • the measurement coating 5 includes a bright layer and a dark layer. The layer, the bright layer is printed on the object to be measured using bright pigment, and the dark layer is printed on the object to be measured using dark pigment.
  • the photoelectric sensor senses the bright layer and the dark layer on the object to be measured, and of course, the measurement of the coating 5 is performed.
  • the method and coating employed are not limited thereto.
  • the detection signals of the two photoelectric sensors of the embodiment are sinusoidal signals, and the signals output by the comparators are square wave signals.
  • the phase difference of the sinusoidal signals of the two photoelectric sensors is 180 degrees. It should be noted that the sine wave Signal and square wave signals are just one implementation.
  • the width of the stripe, x is a natural number, and its physical meaning is the number of cycles.
  • the two stripes of the bright layer and the dark layer allow the photosensor to obtain a periodic sine wave waveform, and the length of the half cycle is h.
  • the formula can determine that the distance between the center points of the two photosensors is (2 ⁇ x+1)h, that is, when the distance between the center points of the two photosensors is an odd multiple of the length of the half cycle, two signals can be guaranteed.
  • the phase difference is 180 degrees.
  • the embodiment may adopt multiple data acquisition units for data acquisition, and then obtain multiple square wave signals and generate final results.
  • the digital displacement sensor of the present invention obtains a square wave signal by two complementary signals, and the measurement is more reliable, see FIG. 5, because the third signal is generated based on the intersection of the waveforms of the first signal and the second signal. And the intersection of the waveforms of the first signal and the second signal depends on the width of the two stripes on the measurement coating 5 and the distance thereof, which can be artificially designed and confined, so that in the same clock cycle, The third signal is not affected by the change of the distance a. If the distance a changes in FIG. 1, the amplitudes of the waveforms of the first signal and the second signal will change simultaneously, but the intersection positions of the two waveforms will not change, so the third The signal itself is not affected. By the same token, the digital displacement sensor of the present invention is also not affected by factors such as the moving speed of the object to be measured, the temperature and humidity, and the brightness of the ambient light.
  • the embodiment further provides a displacement measuring method, which uses the above digital displacement sensor, and includes the following steps:
  • the two photoelectric sensors respectively obtain the first signal and the second signal and send to the signal processing unit, wherein the first signal has a peak and a valley and is periodically distributed, and the second signal has the same waveform as the first signal. And the peak of the first signal corresponds to the valley of the second signal in the same clock cycle;
  • the signal processing unit obtains a third signal according to the first signal and the second signal, and generates a falling signal of the third signal at the first intersection of the waveforms of the first signal and the second signal in the same clock cycle, Generating a rising waveform of the third signal at a second intersection of the waveforms of the one signal and the second signal, thereby forming a waveform of the third signal in one clock cycle;
  • the data processing unit counts the rising waveform and the falling waveform of the third signal to digitize the length measurement result.
  • the digital displacement sensor When in use, the digital displacement sensor has no contact with the object being measured and remains at a fixed distance.
  • the surface of the object to be measured is evenly coated with two or more stripes or patterns of different reflection efficiency, such as black and white stripes.
  • the stripe moves relative to the signal acquisition module, and the optical signal emitted by the signal acquisition module changes, thereby detecting the pulse signal or the sinusoidal signal, and then passing through the signal processing unit and the digital processing.
  • the unit analyzes the direction of motion and the amount of displacement perpendicular to the direction of the stripe.
  • the amount of linear displacement measured by the sensor is the relative displacement between the sensor body and the measured object, that is, whether the fixed sensor body or the fixed object is measured, the displacement can be measured as long as there is relative displacement.
  • the invention constitutes a signal acquisition module by using two photoelectric sensors 1 as a group, that is, the first photoelectric sensor U1 and the second photoelectric sensor U2, and the sinusoidal signals generated by them are directly used as the input of the voltage comparator IC1, and can be generated in this way.
  • Stable Square Wave Signal When the distance a in Figure 1 changes, the two inputs of the comparator IC1 change simultaneously. Maintain a certain degree of synchronization. Therefore, this method can well compensate for the effect of distance. When the distance a changes, the voltage signals generated by the two photosensors 1 move up or down at the same time.
  • the two photosensors 1 are 180 degrees out of phase.
  • the voltage signal generated by the first photosensor U1 is at a peak
  • the voltage signal generated by the second photosensor U2 is at a valley value
  • the voltage signal generated by the first photosensor U1 must be greater than that generated by the second photosensor U2.
  • a voltage signal and when the voltage signal generated by the first photosensor U1 is at a bottom value, the voltage signal generated by the second photosensor U2 is at a peak, so the voltage signal generated by the first photosensor U1 must be smaller than the second photosensor U2.
  • the voltage signal so that the sinusoidal signals obtained by the two photoelectric sensors will periodically intersect, and the stable square wave signal can be generated according to the characteristics of the periodic intersection.
  • multiple signal acquisition modules can be used to generate more The square wave signal produces the final result.
  • the digital displacement sensor and the displacement measuring method thereof of the invention realize that the fixed sensor or the fixed object to be measured can be flexibly selected according to the structure, and the relative movement between the two can be used for measurement, the material of the measured object, etc. Unrestricted, flexible use of materials such as steel strip, aluminum sheet, plastic, etc., only need to apply the corresponding stripe on the surface, the sensor itself is digitally processed, digitally compensates for environmental errors, the sensor does not touch the object to be measured, no mechanical wear, service life
  • the invention has the advantages of simple structure and low cost, and the sensor precision can be adjusted by placing a plurality of sets of sensing elements, thereby greatly reducing the requirement for the stability of the signal amount of the sensor.

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  • General Physics & Mathematics (AREA)
  • Length Measuring Devices By Optical Means (AREA)
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Abstract

一种数字式位移传感器及其位移测量方法，数字式位移传感器包括外壳(2)和线路板(3)，线路板(3)设于外壳(2)内，外壳(2)设有窗口(6)和开孔(7)，线路板(3)上设有信号采集模块、模拟前端电路，数字补偿电路和信号输出接口。数字式位移传感器通过灵活选择固定传感器或固定被测物体，可测量传感器和被测物体之间的相对移动，被测物体的材料不受限制，可使用如钢带，铝板，塑料等材质，仅需表面涂敷相应条纹，传感器本身数字化处理，可数字补偿环境误差，传感器与被测物体不接触，无机械磨损，使用寿命长。数字式位移传感器结构简单，成本低，传感器精度可通过放置多组传感元件调节，极大地降低了对传感器信号稳定性的要求。

Description

一种数字式位移传感器及其位移测量方法 技术领域
本发明属于位移传感器技术领域，特别涉及一种数字式位移传感器及其位移测量方法。
背景技术
位移量是生产生活中比较常见的一种需被测量的物理量。通常做为位移测量的传感器包括光栅尺，容栅尺，电阻尺，或经过机械式扩展后的角度编码器(如拉绳编码器，角位移转线位移)等，且被广泛应用。在大多数应用场合，光栅、容栅等技术是以整体装备组件的型制存在的。例如测量时，需将整套光栅尺集成于半自动或自动化设备中。此种方式对自动化设备的结构有较强要求，且成本很高。
随着信息化，数字化的进程。传感器本身正逐渐从模拟类传感元件向数字化信号采集模块过渡。数字式的信号采集模块由于自身的运算补偿功能，且易于进行系统集成，应用越来越广泛。
在硬件设计上，将传感器获取到正弦信号转换为方波信号的过程是信号处理中必要的一个环节；但是光电传感器对于距离a的变化非常敏感，如图1所示，被测物体11距离传统传感器12的距离的变化对于产生的传感器信号影响极大，在最大信号区间，变化0.5mm将导致信号变化20％以上，当距离a较大时，光传感器的信号较弱，当距离a较小时，光传感器的信号较强。
传统的正弦信号转换方波信号的方法是将正弦信号和给定电压的直流信号输入到电压比较器来产生方波。但是由于距离的变化，正弦信号也会发生变化，当传感器信号处于峰值时，如果距离变小，信号波形下移，传感器的峰值电压可能会小于给定的固定电压。而当传感器处于谷值时，如果距离变大。信号波形上移，传感器的谷值电压可能会大于给定的固定电压。而且由于被测物体移动的速度比较快，无法快速，精准的自动调整一个合适的固定电压，以上因素导致传感器无法产生一个稳定的方波信号，从而导致了最终测量错误。
传统的方案是对一个传感器产生的信号进行信号处理，得出一个有效的信号。由于传感器产生的信号受到实际应用中很多因素的影响， 例如，图1中距离a的影响，例如，相对被测物的移动速度的影响，例如，温湿度的影响，例如环境光的亮度，等等。这些影响会导致传感器产生的信号本身不稳定，由于传统的方案只对这个不稳定的信号本身进行处理，因而处理后的有效信号不能稳定的产生，从而可能会发生错误。
发明内容
本发明的目的是提供一种数字式位移传感器及其位移测量方法，解决了传统技术的不足。
为实现上述目的，本发明采用以下技术方案：
一种数字式位移传感器包括信号采集模块，该信号采集模块包括至少两个光电传感器，两个所述光电传感器用于分别获取第一信号和第二信号，并发送给信号处理单元，其中，所述第一信号具有波峰和波谷且呈周期性分布，所述第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
信号处理单元，用于产生第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形。
数据处理单元，用于对第三信号的上升波形和下降波形进行计数实现长度测量结果的数字化。
本发明所述信号采集模块配置有模拟前端电路，所述信号采集模块和模拟前端电路构成信号采集单元，所述信号处理单元为比较器；
其中，所述模拟前端电路包括放大器及其外围电路，两个光电传感器分别连接一个模拟前端电路的输入端，两个模拟前端电路的输出端分别连接到比较器的正输入端和负输入端，比较器的输出端连接数据处理单元。
本发明还包括外壳和线路板，外壳设有窗口和开孔，所述线路板设于外壳内，所述线路板上集成所述数据处理单元、信号处理单元和信号采集单元，所述数据处理单元的信号输出接口连接一根通信线缆，通信线缆通过开孔伸出外壳。
本发明两个所述光电传感器均为反射式光遮断器。
本发明所述数字式位移传感器被配置以检测被测物体的长度，被测物体上设有测量涂层，测量涂层包括两种不同反射效率的条纹，且两种条纹宽度相同，检测时光电传感器通过感应所述测量涂层以获得信号。
本发明两个所述光电传感器的检测信号为正弦波信号，所述比较器输出的信号为方波信号，检测时两个所述光电传感器的正弦波信号的相位差为180度。
本发明还提供一种位移测量方法，使用上述的一种数字式位移传感器包括以下步骤：
1)测量时两个所述光电传感器分别得到第一信号和第二信号并发送给所述信号处理单元，其中，所述第一信号具有波峰和波谷且呈周期性分布，所述第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
2)所述信号处理单元根据所述第一信号和第二信号得到第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形；
3)数据处理单元对第三信号的上升波形和下降波形进行计数并判断位移方向，实现长度测量结果的数字化。
本发明两个所述光电传感器均为反射式光遮断器，所述信号处理单元为比较器，所述数据处理单元为ARM控制器，两个所述光电传感器得到的第一信号和第二信号均为正弦波信号，所述比较器产生的第三信号为方波信号，所述ARM控制器对方波信号的上升沿和下降沿进行计数实现长度测量结果的数字化。
本发明测量时所述第一信号和第二信号之间的相位差为180度。
本发明的数字式位移传感器是通过两个互补的信号得到方波信号，测量更可靠，因为在测量时第三信号的产生是基于第一信号和第二信号的波形相交产生的，而第一信号和第二信号的波形相交位置取决于测量涂层上的亮层和暗层的宽度和距离，该宽度和距离是可以人为设计且具有恒定性，因此在同一时钟周期内，第三信号不会受到距离a 变化的影响，假如图1中距离a产生变化，第一信号和第二信号的波形的振幅会同时变化，但是两个波形的相交位置不会变，因此第三信号本身不会受到影响。同样的道理，本发明的数字式位移传感器也不会受到被测物的移动速度、温湿度、环境光的亮度等因素的影响。
本发明所述的一种数字式位移传感器及其位移测量方法，实现一种根据结构可灵活选择固定传感器或固定被测物体，只需二者之间的相对移动即可进行测量的位移传感器，对被测物体材料等不限制，可灵活使用如钢带，铝板，塑料等材质，仅需表面涂敷相应条纹，传感器本身数字化处理，可数字补偿环境误差，传感器与被测物体件不接触，无机械磨损，使用寿命长，本发明的结构简单，成本低，传感器精度可通过放置多组传感元件调节，极大的降低了对传感器信号量稳定性的要求。
附图说明
图1是背景技术的附图；
图2是本发明的结构示意图；
图3是本发明的信号采集模块的电路图；
图4是本发明的计算光电传感器之间间距的数学模型图；
图5是本发明的第一信号、第二信号和第三信号的波形示意图。
图中：光电传感器1、外壳2、线路板3、通信线缆4、测量涂层5、窗口6、开孔7、被测物体11、传统传感器12。
具体实施方式
如图2-4所示的一种数字式位移传感器包括信号采集模块、信号处理单元和数据处理单元。
该信号采集模块包括至少两个光电传感器，两个光电传感器用于分别获取第一信号和第二信号并发送给信号处理单元，其中，第一信号具有波峰和波谷且呈周期性分布，第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
信号处理单元用于产生第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形，需要说明的是，也 可以通过软件方法或者软硬件结合的方式使得第一信号和第二信号的波形的第一个相交点处产生第三信号的上升波形，在第一信号和第二信号的波形的第二个相交点处产生第三信号的下降波形，从而形成一个时钟周期内的第三信号的波形。
数据处理单元用于对第三信号的上升波形和下降波形进行计数实现长度测量结果的数字化。
其中，信号采集模块配置有模拟前端电路，信号采集模块和模拟前端电路构成信号采集单元，信号处理单元为比较器，需要说明的是，本实施例的信号处理单元包括但不限于比较器，其他通过软件或软硬件结合实现比较器功能的模块都包含在内，对此不作限制；
其中，模拟前端电路包括放大器及其外围电路，两个光电传感器分别连接一个模拟前端电路的输入端，两个模拟前端电路的输出端分别连接到比较器的正输入端和负输入端，比较器的输出端连接数据处理单元，具体地，参见图3，两个光电传感器分别为第一光电传感器U1和第二光电传感器U2；第一光电传感器U1和第二光电传感器U2的输出端分别通过两个放大器连接比较器IC1的正输入端和负输入端，比较器IC1的输出端连接信号输出接口。
本实施例的数字式位移传感器还包括外壳2和线路板3，外壳2设有窗口6和开孔7，线路板3设于外壳2内，线路板3上集成数据处理单元、信号处理单元和信号采集单元，数据处理单元的信号输出接口连接一根通信线缆4，通信线缆4通过开孔7伸出外壳2。
本实施例的数据处理单元为ARM控制器，两个光电传感器均为反射式光遮断器。
本实施例的数字式位移传感器被配置以检测被测物体的长度，参见图2和4，被测物体上设有测量涂层5，测量涂层5包括两种不同反射效率的条纹，且两种条纹宽度相同，检测时光电传感器通过感应测量涂层5以获得信号，优选的，信号采集模块与被测物体11之间间隔0.1mm～5mm间距，例如，测量涂层5包括亮层和暗层，亮层使用亮色颜料印刷在被测物体上，暗层使用深色颜料印刷在被测物体上，光电传感器感应被测物体上的亮层和暗层得到信号，当然测量涂层5的制作方法和采用的涂层并不限于此。
本实施例的两个光电传感器的检测信号为正弦波信号，比较器输出的信号为方波信号，检测时两个光电传感器的正弦波信号的相位差为180度，需要说明的是，正弦波信号和方波信号仅是一种实施方式。
为了能够得到相应的180度相位差，本实施例的光电传感器的距离的设计方法如下：d＝h+x·2·h，其中，d为两个光电传感器的中心点的距离，h为单个条纹的宽度，x为自然数，其物理意义为周期数，结合图4可知，亮层和暗层两个条纹可以让光电传感器获得一个周期的正弦波波形，那么半个周期的长度为h，这样通过该公式可以确定两个光电传感器的中心点的距离为(2·x+1)h，即当两个光电传感器的中心点的距离为半周期长度的奇数倍时就可保证两个信号的相位差为180度。
为了提高测量精度，本实施例可采用多个数据采集单元进行数据采集，然后得到多个方波信号并产生最后的结果，具体设计方法如下：1、先确定测量精度，测量精度为D＝h/n，n为数据采集单元的个数，在数字式位移传感器的测量精度设定好之后，可以结合实际需要调整条纹的宽度和数据采集单元的个数，最终确定合理的条纹宽度以及数据采集单元的个数；2、确定数据采集单元的距离：d’＝h/n+x·2·h，其中，d’为两个数据采集单元的中心点的距离，h为单个条纹的宽度，x为自然数，其物理意义为周期数。
本发明的数字式位移传感器是通过两个互补的信号得到方波信号，测量更加可靠，参见图5，因为在测量时第三信号的产生是基于第一信号和第二信号的波形相交产生的，而第一信号和第二信号的波形相交位置取决于测量涂层5上的两种条纹的宽度以及其距离，该宽度和距离是可以人为设计且具有恒定性，因此在同一时钟周期内，第三信号不会受到距离a变化的影响，假如图1中距离a产生变化，第一信号和第二信号的波形的振幅会同时变化，但是两个波形的相交位置不会变，因此第三信号本身不会受到影响。同样的道理，本发明的数字式位移传感器也不会受到被测物的移动速度、温湿度、环境光的亮度等因素的影响。
参见图5，本实施例还提供一种位移测量方法，使用上述一种数字式位移传感器，包括以下步骤：
1、测量时两个光电传感器分别得到第一信号和第二信号并发送给信号处理单元，其中，第一信号具有波峰和波谷且呈周期性分布，第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
2、信号处理单元根据第一信号和第二信号得到第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形；
3、数据处理单元对第三信号的上升波形和下降波形进行计数实现长度测量结果的数字化。
使用时，数字式位移传感器与被测物体无接触，且保持固定距离。被测物体表面均匀涂敷两种或多种不同反射效率的条纹或图案，如黑白相间的条纹图案。当数字式位移传感器与被测物体之间产生相对位移时，条纹相对信号采集模块移动，信号采集模块发射的光信号产生变化，从而检测到脉冲信号或正弦信号，再通过信号处理单元和数字处理单元分析出运动方向及该垂直于条纹方向的位移量。
传感器所测量的线位移量为传感器本体与被测物体间的相对位移量，即无论固定传感器本体，还是固定被测物体，只要存在相对位移，即可测出位移量。
本发明以两个光电传感器1为一组构成信号采集模块，即第一光电传感器U1和第二光电传感器U2，将它们产生的正弦信号直接作为电压比较器IC1的输入，通过这种方式可以产生稳定的方波信号：当图1中的距离a发生变化时，比较器IC1的两个输入会同时变化。保持一定的同步性。因此这种方式可以很好的对距离产生的作用进行补偿。当距离a发生变化时，两个光电传感器1产生的电压信号会同时上移或者下移。
由于两个光电传感器1相差180度的相位。当第一光电传感器U1产生的电压信号处于峰值时，第二光电传感器U2产生的电压信号是处于谷值的，所以第一光电传感器U1产生的电压信号一定会大于第二光电传感器U2的产生的电压信号，而当第一光电传感器U1产生的电压信号处于谷值时，第二光电传感器U2产生的电压信号处于峰 值，所以第一光电传感器U1产生的电压信号一定会小于第二光电传感器U2产生的电压信号，这样两个光电传感器获得的正弦波信号会产生周期性的相交，根据周期性相交的特征可以产生稳定的方波信号，为了进一步提高精度，可以采用多个信号采集模块产生的多个方波信号产生最后的结果。
本发明的一种数字式位移传感器及其位移测量方法，实现了根据结构可灵活选择固定传感器或固定被测物体，只需二者之间的相对移动即可进行测量，对被测物体材料等不限制，可灵活使用如钢带，铝板，塑料等材质，仅需表面涂敷相应条纹，传感器本身数字化处理，可数字补偿环境误差，传感器与被测物体件不接触，无机械磨损，使用寿命长，本发明的结构简单，成本低，传感器精度可通过放置多组传感元件调节，极大的降低了对传感器信号量稳定性的要求。

Claims (9)

  1. 一种数字式位移传感器，其特征在于：包括：
    信号采集模块，该信号采集模块包括至少两个光电传感器，两个所述光电传感器用于分别获取第一信号和第二信号并发送给所述信号处理单元，其中，所述第一信号具有波峰和波谷且呈周期性分布，所述第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
    信号处理单元，用于产生第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形。
    数据处理单元，用于对第三信号的上升波形和下降波形进行计数实现长度测量结果的数字化。
  2. 如权利要求1所述的一种数字式位移传感器，其特征在于：所述信号采集模块配置有模拟前端电路，所述信号采集模块和模拟前端电路构成信号采集单元，所述信号处理单元为比较器；
    其中，所述模拟前端电路包括放大器及其外围电路，两个光电传感器分别连接一个模拟前端电路的输入端，两个模拟前端电路的输出端分别连接到比较器的正输入端和负输入端，比较器的输出端连接数据处理单元。
  3. 如权利要求1所述的一种数字式位移传感器，其特征在于：还包括外壳(2)和线路板(3)，外壳(2)设有窗口(6)和开孔(7)，所述线路板(3)设于外壳(2)内，所述线路板(3)上集成所述数据处理单元、信号处理单元和信号采集单元，所述数据处理单元的信号输出接口连接一根通信线缆(4)，通信线缆(4)通过开孔(7)伸出外壳(2)。
  4. 如权利要求1所述的一种数字式位移传感器，其特征在于：两个所述光电传感器均为反射式光遮断器。
  5. 如权利要求2所述的一种数字式位移传感器，其特征在于：所述数字式位移传感器被配置以检测被测物体的长度，被测物体上设有测量涂层(5)，测量涂层(5)包括两种不同反射效率的条纹，且两种条纹宽度相同，检测时光电传感器通过感应所述测量涂层(5)以获 得信号。
  6. 如权利要求5所述的一种数字式位移传感器，其特征在于：两个所述光电传感器的检测信号为正弦波信号，所述比较器输出的信号为方波信号，检测时两个所述光电传感器的正弦波信号的相位差为180度。
  7. 一种位移测量方法，使用如权利要求1所述的一种数字式位移传感器，其特征在于：包括以下步骤：
    1)测量时两个所述光电传感器分别得到第一信号和第二信号，并发送给所述信号处理单元，其中，所述第一信号具有波峰和波谷且呈周期性分布，所述第二信号与第一信号的波形相同，且在同一个时钟周期内第一信号的波峰对应第二信号的波谷；
    2)所述信号处理单元根据所述第一信号和第二信号得到第三信号，在同一个时钟周期内，第一信号和第二信号的波形的第一个相交点处产生第三信号的下降波形，第一信号和第二信号的波形的第二个相交点处产生第三信号的上升波形，从而形成一个时钟周期内的第三信号的波形；
    3)数据处理单元对第三信号的上升波形和下降波形进行计数实现长度测量结果的数字化。
  8. 如权利要求7所述的一种位移测量方法，其特征在于：两个所述光电传感器均为反射式光遮断器，所述信号处理单元为比较器，所述数据处理单元为ARM控制器，两个所述光电传感器得到的第一信号和第二信号均为正弦波信号，所述比较器产生的第三信号为方波信号，所述ARM控制器对方波信号的上升沿和下降沿进行计数实现长度测量结果的数字化。
  9. 如权利要求7或8所述的一种位移测量方法，其特征在于：测量时所述第一信号和第二信号之间的相位差为180度。
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