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Measuring/calculating shaft speed from a counter card

Oct. 21, 2024

I have been working on accurately measuring the shaft speed using a 120-tooth speed wheel, a bi-directional powered pickup, and a -HSC/B counter card. My setup involves controlling an eddy current coupling with an AC drive system, aiming to regulate the output shaft speed of the coupling. A brake is applied on the output side of the eddy current coupling, and the client requires that the brake speed remains within a limit of 5 rpm during its operation.

Initially, I utilized the encoder x4 mode via the Totalizer field to attain frequency measurements; however, the signal was only updating approximately every millisecond. Currently, I have switched to using the encoder x4 mode on Channel 0 for detecting direction, and I am employing Period/Rate mode on Channel 1 for frequency measurement. This adjustment has resulted in significantly faster updates in Period/Rate mode. Nonetheless, as the speed increases, the recorded frequency begins to exhibit spikes with lower values.

Additionally, I attempted to apply the encoder x4 mode for calculating the pulse difference over a span of 100 milliseconds; however, something appeared to be misconfigured, leading to inconsistent results. I am reaching out to see if anyone can provide recommendations or share sample code that outlines the standard approach for effectively measuring shaft speed in situations like this.

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