Shaft speed sensor with analog output

A 2-wire, loop-powered shaft rotational speed sensor device that outputs a 4-20 mA current in response to the shaft rotational speed. The device is comprised of a sensor (e.g., magnetic, optical) that senses an output from a sensor disk (e.g., magnetic, optical) and outputs a series of voltage pulses whose frequency varies with the shaft rotational speed. A microcontroller measures this pulse frequency and generates a digital code representative of that frequency. A digital-to-analog converter generates an analog waveform in response to the digital code. A loop-powered, voltage-to-current circuit generates the output current in response to the analog waveform.

BACKGROUND

I. Field of the Invention

The present invention relates generally to sensors and more particularly to shaft speed sensors.

II. Description of the Related Art

It is sometimes desirable, in systems that use rotating shafts in bearings, to monitor the rotational speed of the shafts. The monitoring can provide feedback to the system controller regarding the operational status of the shaft. The controller can then vary the speed of the shaft in order to produce the desired effect on the system.

Currently, an analog representation of rotating shaft speed can be generated only from a separate pulse-frequency-output sensor and a pulse-frequency-input to analog-output signal-conditioner module. However, it is desirable to monitor shaft speed using a minimum of components to reduce the size and price of the sensor. Accordingly, there is a need in the art for a self-contained sensor to monitor shaft rotational speed.

SUMMARY

The present invention encompasses a self-contained, loop-powered, 4-20 mA output shaft rotational-speed sensor. The device comprises a sensor that detects a shaft mounted target and outputs a voltage pulse frequency proportional to shaft rotational speed. A controller circuit, coupled to the sensor, generates a digital code representative of the angular speed. A digital-to-analog converter, coupled to the controller circuit, generates an analog voltage signal in response to the digital code. A voltage/current circuit, coupled to the digital-to-analog converter, generates an output current, within a predetermine range, in response to the analog voltage signal.

DETAILED DESCRIPTION

FIG. 1illustrates a circuit block diagram of one embodiment of the shaft speed sensor device100with analog output. The sensor is comprised of a magneto-resistive sensor101that detects magnetic pulses from embedded magnets in a shaft-mounted pulser target. An example of one such shaft-mounted pulser target is illustrated in the system ofFIG. 4that is discussed subsequently. Such a pulser target can be comprised of a plurality of magnets mounted equal distances apart on a disk that is coupled to the shaft being monitored. As a magnet rotates past the sensor the shaft speed sensor device100, the magneto-resistive sensor101outputs a voltage pulse. The voltage pulse frequency output by the sensor101is then directly proportional to the shaft RPM. The sensor thus detects shaft angle changes.

The present invention is not limited to using only a disk with magnets and a magnetic sensor. Other forms of detecting the shaft angle change of the shaft can be used including an optical disk that generates light pulses at predetermined intervals or a contact disk that generate electrical contact with the sensor101at predetermined intervals. Any means for generating input pulses spaced a predetermined distance apart can be used.

A controller102, such as a microcontroller circuit, is coupled to the magneto-resistive sensor101and monitors the sensor's output. The controller102measures the shaft angular speed and generates a digital code representation of that angular speed. This is accomplished by the controller102continuously receiving and timing the voltage pulse frequency using a crystal-based110timer that is internal to the controller. In one embodiment, the microcontroller determines the voltage pulse frequency and outputs a digital pulse frequency code, indicative of that frequency, every 8.192 ms. The frequency code is in a binary format. Alternate embodiments can use other number bases.

A digital-to-analog converter (DAC)104is coupled to the microcontroller102. The DAC104converts the digital code from the microcontroller102to an analog voltage signal.

A loop-powered voltage-to-current circuit (V/I)106is coupled to the DAC104. The DAC104is coupled to the voltage part of the V/I circuit which converts the analog voltage signal to a corresponding 4-20 mA current as used in a typical industrial analog signaling standard. The V/I circuit106is configured to perform multiple functions.

One function of the V/I circuit106is to supply power to the prior circuit elements101,102,104so that the shaft speed sensor device is self-powering. All of the circuitry together draws less than 4 mA and the V/I circuit is calibrated to draw a precise 4 mA “floor” current from which all circuit power is taken.

Another function of the V/I circuit106is to convert the DAC analog voltage signal to a 0-16 mA signal current that is added to the 4 mA floor current to give the 4-20 mA variable output current based on the input rotation speed of the shaft. The current flow is linearly proportional to the magnetic pulse frequency between the specified minimum and maximum pulse frequencies. In this 2-wire, loop-powered, 4-20 mA circuit, circuit power and analog signal are together in the same 4-20 mA current.

FIG. 2illustrates a circuit diagram of one embodiment of the shaft speed sensor device100of the present invention incorporated into a 4-20 mA current-loop circuit. A DC power supply (e.g., 24V) (+) terminal is coupled to the sensor (+) terminal. A current sense resistance201(e.g., 250 Ohm resistor) is coupled in series between the sensor (−) terminal and the DC power supply (−) terminal as shown. The resulting 1-5 volts across the resistor is an easily measurable representation of rotating shaft speed.

FIG. 3illustrates a graph of one embodiment of an input pulse frequency versus an output current. The graph shows that as the frequency along the x-axis increases, the current along the y-axis increases linearly.

FIG. 4illustrates one embodiment of a conveyor system400using the shaft speed sensor device100of the present invention. However, the present invention is not limited to any one type of system. Any system requiring monitoring of a shaft speed is encompassed by the present invention.

The illustrated embodiment uses a disk401with magnets, optics or some other means for generating a pulse frequency input to the sensor device100, mounted on a shaft402. The magnets are mounted a fixed distance apart around the periphery of the disk401. The speed of the shaft402sets the angular speed of the magnets and, thus, the magnetic pulse frequency detected by the sensor device100. The sensor device100, mounted close enough to detect the disk magnets, then outputs a current in the 4-20mA range as discussed previously. This signal can then be used by the system controller (not shown), connected to the sensor, to adjust the rotational speed of the shaft.