直线舵机用磁编码器系统集成及多圈解算方法研究

Research on Magnetic Encoder System Integration and Multi-Turn Calculation Methods for Linear Servo Motors

摘要:

为满足直线舵机研制过程中对高集成度、高精度角度传感器的需求，设计了一种基于单圈绝对式磁编码器与小模数减速齿轮相结合的多圈角度解算方法；该方法通过设计齿轮传动机构与磁场检测装置，转化转子旋转角度信息为舵机线位移数据，将解算功能直接嵌入舵机控制器，从而降低系统硬件复杂度并提升控制精度；在算法设计方面，利用编码器输出计数与齿轮传动比之间的数学关系建立多圈解算模型，实现角度检测的连续性与单调性；在验证环节，开展了仿真计算与实物试验，实现最大 64 圈多圈计数，线位移定位误差不超过 0.3%；试验结果表明，该方法能够在常规硬件资源条件下覆盖直线舵机的全行程范围，且在角度解算过程中未出现圈数跳变或丢失现象，实现位移检测的准确性与实时性；该方法已应用于直线舵机工程研发项目，为直线舵设计提供了一种低成本、高分辨率和可扩展的设计参考。

Abstract:

In order to meet the requirement for highly integrated, high-precision angle sensors during the de-velopment of linear sero motors, a multi-turn angle calculation method was designed by combining a single-turn absolute magnetic encoder with a small-module reduction gear. This method converts rotor rotation angle information into servo linear displacement data by designing a gear transmission mechanism and magnetic field detection device. By embedding the calculation function directly into the servo controller, it effectively reduces system hardware complexity while enhancing control pre-cision. In algorithm design, a multi-turn calculation model is established using the mathematical relationship between encoder output counts and gear transmission ratios, ensuring continuous and monotonic angle detection. During validation, simulation calculations and physical testing were conducted, achieving multi-turn counting up to 64 revolutions with linear displacement positioning errors not exceeding 0.3%. Test results demonstrate that this method can cover the full travel range of linear servos under conventional hardware resource conditions. No revolution skipping or loss oc-curred during angle calculation, ensuring the accuracy and real-time performance of displacement detection. This method has been applied to the engineering development project of linear servo ac-tuators, providing a low-cost, high-resolution and scalable design reference for linear actuator design.