Automatic detection system of fault code for small size absolute photoelectric encoder
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摘要: 在批量生产光电编码器时，对光电编码器是否存在误码进行检测是一个重要的环节。现有的检测方法采用二进制灯排手动转动编码器用肉眼进行观测，存在手动检测慢、肉眼观测误差较大、检测结果受转动速度影响等缺点。在大批量生产的光电编码器，采用传统方法进行误码检测费时费力。为解决编码器生产及使用过程中对光电编码器的自动误差检测，本文设计了小型光电编码器误码自动检测系统。首先，在参照大量光电编码器生产经验的基础上，分析了编码器误码产生的主要原因；然后，提出了基于微分算法实现对光电编码器是否存在误码进行判断的误码自动检测方法；最后，以FPGA为主控芯片，设计了小型光电编码器自动误码检测系统。该系统能够实现对光电编码器的高速数据采集、数据处理与误码判断，并将误码判断结果通过LCD液晶显示。同时，可以根据需要将数据传输到计算机中作进一步分析。检测实验表明：本文所设计的误码检测系统成功实现了对15位串/并口光电编码器在高速和低速下进行数据采集及误码判断。系统可用于批量生产下光电编码器的误码自动检测，减少了人工操作，提高了自动化程度。系统具有智能便捷，移动性强，适用于实验室及各种工作场合下的误码检测等优点，检测速度较以往检测方法提高了3~5倍。Abstract: Error detection is an important procedure during large quantity production of photoelectric encoder. At present, such error is mostly detected manually by judging sequences from binary LED arrays. This method is of low efficiency and extra error due to manual work, especially when large quantity is concerned. Given the defects of current methods, an auto-detection system for photoelectric encoder is designed in this paper. Firstly, the main reasons for the error are analyzed, and then an auto-detection method is proposed by adopting differential after referring to present works method. Lastly, an auto-detection system is established, utilizing a FPGA control chip. The system is capable of swift data acquisition and procession and its outcomes can be transported to a computer or displayed on a LCD. Experimental results show that the system is suitable for 15 bit series or parallel interface in different speeds. The system is intelligent, swift, portable and suitable for laboratory and other work situations, and the detection efficiency has been improved by 3-5 times.
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Key words:
- photoelectric encoder /
- fault code /
- automatic detection /
- FPGA
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图 1 光电编码器误码原因统计图
Figure 1. Statistical diagram of the reasons for errors of photoelectric encoder
图 7 工作正常编码器无误码下的速度曲线图
Figure 7. Diagram of velocity curve for good-working photoelectric encoder
图 8 对故障编码器进行的误码检测
Figure 8. Diagram of velocity curve for faulty photoelectric encoder
图 9 码盘污染时的误码检测结果
Figure 9. Diagram of fault code detection for faulty photoelectric encoder with polluted code disc
图 10 安装偏心下的误码检测结果
Figure 10. Diagram of fault code detection for faulty photoelectric encoder with code disc eccentricity
图 11 第10位发生误码的速度曲线
Figure 11. Diagram of velocity curve for faulty photoelectric encoder with malfunction of the 10th bit
图 12 第5位发生误码的速度曲线
Figure 12. Diagram of velocity curve for faulty photoelectric encoder with malfunction of the 5th bit
图 13 编码器发生误码速度曲线图
Figure 13. Diagram of velocity curve of faulty photoelectric encoder
表 1 3种转速下15台故障编码器的误检率
Table 1. False drop rate of 15 faulty photoelectric encoders under three different rotation speeds
实验分类 检测显示有误码(台) 检测显示无误码(台) 误检率/% v=80°/s 1 15 0 0 2 15 0 0 3 15 0 0 v=8 r/s 1 15 0 0 2 15 0 0 3 15 0 0 v=10 r/s 1 15 0 0 2 15 0 0 3 15 0 0 
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表 2 3种转速下15台工作正常编码器的误检率
Table 2. False drop rate of 15 good-working photoelectric encoders under three different rotation speeds
实验分类 检测显示有误码(台) 检测显示误码(台) 误检率/% v=80°/s 1 0 15 0 2 0 15 0 3 0 15 0 v=8 r/s 1 0 15 0 2 0 15 0 3 0 15 0 v=10 r/s 1 0 15 0 2 0 15 0 3 0 15 0
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