Non-contact guiding system based on electromagnetic dynamic compensation and control method

Abstract

The invention relates to the technical field of forging equipment, in particular to a non-contact guiding system based on electromagnetic dynamic compensation and a control method. Radial constraining force is generated through the eight sets of symmetrically-distributed exciting windings, non-contact guiding in the moving beam sliding block moving process is achieved, the sectional area of the stand column guiding mechanism is reduced, and the overall weight of forging equipment is directly reduced through the structural innovation. Secondly, the guide system is free of mechanical contact, so that the permanent magnet can be arranged in the stand column, a closed anti-interference structure is formed, and the positioning stability of the system in a vibration environment is improved. Laser gap measurement and stand column strain monitoring are fused into a parallel trigger condition, and a physical deviation-structural deformation two-dimensional sensing system is constructed. Through real-time cross validation of the two types of data, the trigger misjudgment rate is compensated. A double-layer control framework of PD fixed parameter + compensation force coefficient iteration is provided. The base layer adopts a fixed proportion-differential parameter to ensure quick response, and the optimization layer dynamically improves a compensation coefficient through closed-loop verification.

Description

Technical Field

[0001] This invention relates to the field of forging equipment technology, specifically a non-contact guiding system and control method based on electromagnetic dynamic compensation. Background Technology

[0002] Traditional high-speed forging mills generally employ mechanical guide rail systems. The core structure consists of copper- or steel-based sliding guide rails between the frame columns and the moving beam slider, relying on physical contact surfaces to maintain the slider's trajectory. However, during high-speed forging, massive impact loads (typically hundreds to thousands of tons) can cause elastic or plastic deformation of the frame columns, leading to abrupt changes in guide rail clearance or slider misalignment. This severely affects the dimensional accuracy of forgings, especially in aerospace precision forging, where such deviations can lead to component scrap. Traditional solutions often increase structural rigidity by enlarging the frame cross-section, but this results in a significant increase in equipment weight, raising material and foundation construction costs and limiting flexible layout within the factory space. Furthermore, mechanical guide rails require frequent maintenance due to long-term contact wear, and downtime for repairs leads to production losses. While some improvements attempt to introduce hydraulic servo compensation, its slow response speed and limited compensation force make it difficult to match the high-frequency impact conditions of 120 times per minute in high-speed forging mills. Additionally, hydraulic systems are prone to oil leaks, further increasing maintenance complexity. Summary of the Invention

[0003] The technical problem that this invention aims to solve is that existing racks often increase structural rigidity by increasing the cross-sectional dimensions of the rack when dealing with sudden changes in guide rail clearance or slider offset. However, this leads to a surge in equipment weight, which not only increases material and foundation construction costs but also limits the flexible layout of the equipment in the factory space.

[0004] To solve the aforementioned problem, the present invention provides the following specific solution: A non-contact guiding system based on electromagnetic dynamic compensation includes a high-speed forging machine, a dynamic compensation device, multiple electromagnetic guiding modules, and a multi-source sensing unit. The high-speed forging machine includes a machine body and a moving beam slider. Each electromagnetic guiding module is installed at each corner of the moving beam slider. A permanent magnet array that cooperates with each electromagnetic guiding module is installed on the machine body. Each multi-source sensing unit is installed at each corner of the machine body and the moving beam slider. The multi-source sensing unit is used to detect the gap between each corner of the moving beam slider and the machine body. The dynamic compensation device is used to distribute electrical energy to the electromagnetic guiding modules according to the gap data detected by the multi-source sensing unit.

[0005] As a preferred embodiment, a further technical solution of the present invention is: The main body of the machine includes an upper crossbeam, a lower crossbeam, and a column assembly. Each electromagnetic guide module is installed on each column of the column assembly. A main hydraulic cylinder is installed in the upper crossbeam, and a fixed worktable is installed on the lower crossbeam. The upper and lower crossbeams are respectively fixed to the upper and lower ends of the columns. The moving beam slider is connected to the output shaft of the main hydraulic cylinder, and the moving beam slider is driven to slide vertically in the middle of the column assembly through the output shaft of the main hydraulic cylinder.

[0006] The electromagnetic guidance module includes an excitation winding, which forms a non-contact force field with an array of permanent magnets fixed on a column, and the excitation winding is connected to a dynamic compensation device.

[0007] The multi-source sensing unit includes a laser rangefinder and strain gauges. The laser rangefinder is installed on the inner side of each corner of the moving beam slider to monitor the left and right gaps between the moving beam slider and each column in real time. The strain gauges are attached to the cross-section of the column to measure the bending deformation of the column.

[0008] The column assembly includes four columns. The permanent magnet array is installed on the two vertical sides of the columns and the moving beam slider. The four corners of the moving beam slider are provided with guide grooves that cooperate with each column. Excitation windings are installed on the two vertical sides inside the guide grooves.

[0009] To solve the aforementioned problem, the second specific solution of the present invention is as follows: A non-contact guidance control method based on electromagnetic dynamic compensation includes the following steps: Step 1: Real-time monitoring: The gap between each edge of the moving beam slider and its mating column is monitored by a laser rangefinder to obtain gap data. The laser rangefinder updates the gap data every 0.1ms. When the gap design difference exceeds 0.02mm, or the strain gauge shows that the column bending exceeds 0.2mm, the compensation mechanism is triggered. Step 2: Dynamic Calculation The dynamic compensation controller calculates the required compensation force based on the current gap difference Δ and the rate of change of each laser rangefinder using a proportional-derivative (PD) algorithm. Step 3: Current Regulation The compensation force is converted into a current command, the current value is calculated, and the excitation winding near the deformation area of ​​the column is activated first to avoid global overcompensation. Step 4: Closed-loop verification: After compensation, the gap between each moving beam slider and the column is re-checked. If the residual deviation is >0.03mm, the compensation coefficient is automatically increased by 10% for a second adjustment until the moving beam slider returns to the center line of the fast forging machine.

[0010] As a preferred embodiment, a further technical solution of the second embodiment of the present invention is: The specific operation of step one is as follows: the laser rangefinder performs zero-point calibration on the gap between the moving beam slider and the vertical plane of the column. At the same time, the test current is applied through the excitation winding to calibrate the square relationship between the electromagnetic force and the current, establish the compensation force reference model, and after initialization, enter the real-time monitoring state. The gap deviation value of the laser rangefinder and the bending deformation of the strain gauge are synchronously collected at a period of 20ms. The gap deviation value and bending deformation are filtered and then input into the dynamic compensation controller. When the absolute value of the gap deviation value of the laser rangefinder exceeds 0.02mm, or the bending amount of the column detected by the strain gauge exceeds 0.2mm, it is determined that the moving beam slider is neutrally unstable.

[0011] The specific operation of step two is as follows: The required electromagnetic correction force is calculated using the proportional-differential (PD) algorithm. F = 1.5Δ + 0.2dΔ / dt; Among them, the proportional term (1.5Δ) is used to quickly offset the current deviation, and the differential term (0.2dΔ / dt) suppresses the offset trend; The driving current is calculated in reverse based on the compensation force reference model: I = sqrt(F / k).

[0012] Compared with the prior art, the present invention, which adopts the above technical solution, has the following beneficial effects: This invention generates radial constraint force through eight symmetrically distributed excitation windings, achieving non-contact guidance during the movement of the moving beam and slider. Compared to the mechanical guide rail method that relies on contact friction, this design eliminates mechanical friction, extending the lifespan of key components, avoiding oil mist contamination during forging, and simultaneously reducing the cross-sectional area of ​​the column guide mechanism. This structural innovation directly reduces the overall weight of the forging equipment. Secondly, the absence of mechanical contact in the guide system allows the permanent magnet to be placed inside the column, forming a closed, anti-interference structure and improving the system's positioning stability under vibration. By integrating laser gap measurement and column strain monitoring as parallel triggering conditions, a dual-dimensional sensing system of "physical deviation-structural deformation" is constructed. Real-time cross-validation of both types of data compensates for the trigger misjudgment rate. A two-layer control architecture of "PD fixed parameters + compensation force coefficient iteration" is proposed. The basic layer uses fixed proportional-differential parameters (F=1.5Δ+0.2dΔ / dt) to ensure rapid response, while the optimization layer dynamically improves the compensation coefficient through closed-loop verification (maximum iterations of 3 times, coefficient increase ≤30%). This design balances algorithm stability and error convergence efficiency while avoiding system instability caused by parameter oscillations. This patent constructs a new paradigm for high-speed precision forging through three core technologies: non-contact guidance, sensor fusion, and intelligent control algorithms, making it suitable for widespread application. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall assembly of Embodiment 1 of the present invention; Figure 2 yes Figure 1 A magnified view of part A in the image; Figure 3 This is a schematic diagram showing the distribution of the moving beam slider, excitation winding, and laser rangefinder in Embodiment 1 of the present invention; Figure 4 yes Figure 3 A magnified view of part B in the image; Figure 5 This is a schematic diagram of the distribution of the column permanent magnet array and strain gauges in Embodiment 1 of the present invention; Figure 6 yes Figure 5 A magnified view of part C; Figure 7 This is a schematic diagram of the compensation force adjustment and correction according to Embodiment 1 of the present invention; In the picture: 1. Moving beam slider; 2. DC winding; 3. Excitation magnet core; 4. Laser rangefinder; 5. Column; 6. Permanent magnet; 7. Strain gauge; 8. Upper crossbeam; 9. Lower crossbeam; 10. Main hydraulic cylinder; 11. Worktable; 12. Prestressed tie rod. Detailed Implementation

[0014] The present invention will be further described below with reference to embodiments, which are intended only to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0015] This invention proposes a non-contact guiding system and control method based on electromagnetic dynamic compensation, breaking through the dependence of traditional mechanical structures on "absolute stiffness" and instead using real-time electromagnetic force to counteract the influence of frame deformation. Its core design involves: symmetrically arranging multiple sets of high-response electromagnets on both sides of the moving beam slider 1, forming a controllable repulsive force field with the array of permanent magnets 6 on the frame column 5; using a laser rangefinder 4 and strain gauges 7 to monitor the slider offset and column 5 deformation in real time, dynamically adjusting the electromagnet current to generate a reverse compensation force, ensuring the slider remains stable on its theoretical trajectory. This solution not only improves slider offset accuracy but also allows for a reduction in the cross-section of the frame column 5, lowering the weight of a single unit and foundation costs. Simultaneously, the non-contact design completely eliminates guide rail wear, resulting in a long theoretical lifespan and low maintenance costs. This technology provides a novel solution for lightweighting and intelligent upgrading in the forging industry. This invention, through real-time non-contact electromagnetic force to counteract the influence of frame deformation on the slider's motion trajectory, breaks through the excessive dependence of traditional mechanical guide rails on structural stiffness, achieving a synergistic improvement in equipment lightweighting and precision.

[0016] See appendix Figure 1-7Embodiment 1 of this invention discloses a non-contact guiding system based on electromagnetic dynamic compensation, including a high-speed forging machine, a dynamic compensation device, multiple electromagnetic guiding modules, and a multi-source sensing unit. The high-speed forging machine includes a machine body and a moving beam slider 1. Each electromagnetic guiding module is installed at each corner of the moving beam slider 1. An array of permanent magnets 6 that cooperate with each electromagnetic guiding module is installed on the machine body. Each multi-source sensing unit is installed on each corner of the machine body and the moving beam slider 1. The multi-source sensing unit is used to detect the gap between each corner of the moving beam slider 1 and the machine body. The dynamic compensation device is used to allocate electrical energy to the electromagnetic guiding modules according to the gap data detected by the multi-source sensing unit. The dynamic compensation device adopts a dynamic compensation controller. After receiving the data from the multi-source sensing unit, the dynamic compensation controller generates compensation instructions according to a preset algorithm. The control response time is ≤0.1ms, and it supports real-time closed-loop control at a forging frequency of 120 times / minute.

[0017] In this embodiment, the main body includes an upper crossbeam 8, a lower crossbeam 9, and a set of columns 5. Each electromagnetic guiding module is installed on each column 5 of the set of columns 5. A main hydraulic cylinder 10 is installed in the upper crossbeam 8, and a fixed workbench 11 is installed on the lower crossbeam 9. The upper crossbeam 8 and the lower crossbeam 9 are respectively fixed to the upper and lower ends of the columns 5 and are fastened together by a prestressed tie rod 12. The moving beam slider 1 is bolted to the output shaft of the main hydraulic cylinder 10. The output shaft of the main hydraulic cylinder 10 drives the moving beam slider 1 to slide vertically in the middle of the set of columns 5. The excitation windings around the moving beam slider 1 correspond to the permanent magnets 6 embedded in the columns 5 and maintain a certain gap. The laser rangefinder 4 is aimed at the vertical plane of the columns 5 and detects the relative distance between each corner of the moving beam slider 1 and the columns 5 in real time.

[0018] In this embodiment, the electromagnetic guiding module includes an excitation winding. The excitation winding and the array of permanent magnets 6 fixed on the column 5 form a non-contact force field. By adjusting the current of the excitation winding, a bidirectional repulsive force is generated, covering the deformation range of the high-speed forging machine under all working conditions. The excitation winding is connected to a dynamic compensation device.

[0019] In this embodiment, the multi-source sensing unit includes a laser rangefinder 4 and a strain gauge 7. The laser rangefinder 4 is installed on the inner side of each corner of the moving beam slider 1 to monitor the left and right gaps between the moving beam slider 1 and each column 5 in real time. The strain gauge 7 is attached to the cross section of the column 5 to measure the bending deformation of the column 5.

[0020] In this embodiment, the column group 5 includes four columns 5. The columns 5 of the fast forging machine are provided with grooves at the vertical guide positions to install permanent magnets 6. The N poles are uniformly facing outward to form an array of permanent magnets 6. Strain gauges 7 are installed at equal intervals near the array of permanent magnets 6 on the columns 5. The four corners of the moving beam slider 1 are provided with guide grooves that cooperate with each column 5. Excitation windings are installed on the two vertical sides inside the guide grooves. The DC windings 2 of the excitation windings are tightly wound in a ring along the excitation core 3 of the excitation windings and installed in the guide grooves. The electromagnetic forces generated by the permanent magnets 6 and the excitation windings repel each other. When the moving beam slider 1 moves vertically, if the feedback gap of the laser rangefinder 4 is inconsistent, for example, wider at the top and narrower at the bottom, the dynamic compensation controller controls the excitation winding at the upper end to weaken the electromagnetic force, while increasing the electromagnetic force for the excitation winding at the lower end, thereby correcting the guide gap. Two laser rangefinders 4 are vertically installed at each of the eight vertices of the moving beam slider 1.

[0021] Embodiment 2 of the present invention discloses a non-contact guidance control method based on electromagnetic dynamic compensation, comprising the following steps: Step 1: Real-time monitoring: The gap between each corner of the moving beam slider 1 and its mating column 5 is monitored by the laser rangefinder 4 to obtain gap data. The laser rangefinder 4 updates the gap data every 0.1ms. When the gap design difference exceeds 0.02mm, or the strain gauge 7 shows that the bending amount of the column 5 exceeds 0.2mm, the compensation mechanism is triggered. Step 2: Dynamic Calculation The dynamic compensation controller calculates the required compensation force based on the gap difference Δ and the rate of change of each laser rangefinder 4 using a proportional-derivative (PD) algorithm, ensuring a balance between rapid response and stability. Step 3: Current Regulation The compensation force calculation result is converted into a current signal by the DAC module. The current value is calculated, and the excitation winding is driven to generate a reverse compensation force within 5ms. The excitation winding closest to the deformation area of ​​column 5 is activated first, pushing the mold back to the preset centering position. During this process, the PD parameters remain at a fixed value to avoid system oscillation caused by frequent adjustments and to avoid global overcompensation. Step 4: Closed-loop verification: After compensation, the laser rangefinder 4 immediately re-detects the gap deviation Δnew between each moving beam slider 1 and column 5. If Δnew ≤ 0.03mm, the compensation is considered successful, and the system returns to the monitoring state; if the residual deviation > 0.03mm, the original PD parameters are maintained, but the compensation force coefficient is increased by 10%, the current is recalculated, and secondary compensation is performed. This design, through a "single PD calculation + coefficient iteration" strategy, converges the residual error to within 0.01mm while ensuring stability. The entire process, from triggering to verification completion, takes ≤ 30ms and can adapt to a high-speed forging rhythm of up to 120 times / minute.

[0022] As a preferred embodiment, a further technical solution of the second embodiment of the present invention is: The specific operation of step one is as follows: After the system starts, the initialization program is executed first. The laser rangefinder 4 performs zero-point calibration on the gap between the moving beam slider 1 and the vertical plane of the column 5, which is recorded as ΔL0 / ΔR0. ΔL0: the initial reference deviation value of the gap on the left side; ΔR0: the initial reference deviation value of the gap on the right side; subscript 0: represents the calibration value of "zero point" (initial state). Δ is the feedback variable of the control algorithm. It means that when the set value remains unchanged, the compensation force F = 0 and no correction is needed. When a displacement deviation occurs (Δ), the compensation force will not be equal to 0, and a correction adjustment will occur. Simultaneously, a test current is applied through the excitation winding. The compensation force is related to the square of the current, F = kI², where k is a proportionality constant representing the direct proportionality between the compensation force F and the square of the current I². A compensation force benchmark model is established. After initialization, the system enters real-time monitoring mode, synchronously acquiring the gap deviation value (ΔL / ΔR) of the laser rangefinder 4 and the bending deformation (ε) of the strain gauge 7 at 20ms intervals. The gap deviation value and bending deformation are filtered and uploaded to the control unit, then input to the dynamic compensation controller. When the absolute value of the gap deviation value of the laser rangefinder 4 exceeds 0.02mm, or the bending amount of the column 5 detected by the strain gauge 7 exceeds 0.2mm, the moving beam slider 1 is determined to be neutrally unstable. The compensation mechanism is triggered when either condition is met. The dual-trigger design combines direct deviation monitoring with indirect structural status perception, enabling rapid response to sudden offsets and preventing systematic errors caused by the cumulative deformation of column 5. Compared with the traditional single-threshold judgment method, the reliability is significantly improved.

[0023] The specific operation of step two is as follows: The required compensation force is calculated using the proportional-differential (PD) algorithm. F = 1.5Δ + 0.2dΔ / dt; Among them, the proportional term (1.5Δ) is used to quickly offset the current deviation, and the differential term (0.2dΔ / dt) suppresses the offset trend; The driving current is calculated in reverse based on the compensation force reference model: I = sqrt(F / k).

[0024] This invention innovatively replaces the traditional sliding guide rail with a fully electromagnetic levitation guidance system. Eight symmetrically distributed excitation windings generate radial constraint force, achieving non-contact guidance of the moving beam slider 1 during its movement. Compared to the contact friction-dependent guidance method of mechanical guide rails, this design eliminates mechanical friction, extending the lifespan of key components and avoiding oil mist contamination during forging. Simultaneously, it reduces the cross-sectional area of ​​the column 5 guiding mechanism, directly lowering the overall weight of the forging equipment. Furthermore, the absence of mechanical contact in the guiding system allows the permanent magnet 6 to be placed inside the column 5, forming a closed, anti-interference structure and improving the system's positioning stability under vibration. By integrating laser gap measurement and column 5 strain monitoring as parallel triggering conditions, a dual-dimensional sensing system of "physical deviation-structural deformation" is constructed. Real-time cross-validation of both types of data compensates for the trigger misjudgment rate. A two-layer control architecture of "PD fixed parameters + compensation force coefficient iteration" is proposed. The base layer employs a fixed proportional-differential parameter (F=1.5Δ+0.2dΔ / dt) to ensure rapid response, while the optimization layer dynamically improves the compensation coefficient through closed-loop verification (maximum 3 iterations, coefficient increase ≤30%). This design balances algorithm stability and error convergence efficiency while avoiding system instability caused by parameter oscillations. This patent constructs a new paradigm for high-speed precision forging through three core technologies: non-contact guidance, sensor fusion, and intelligent control algorithms, making it suitable for widespread application.

[0025] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A non-contact guidance system based on electromagnetic dynamic compensation, characterized in that: The system includes a high-speed forging machine, a dynamic compensation device, multiple electromagnetic guiding modules, and a multi-source sensing unit. The high-speed forging machine consists of a machine body and a moving beam slider. Each electromagnetic guiding module is installed at one of the corners of the moving beam slider. The machine body is equipped with a permanent magnet array that cooperates with each electromagnetic guiding module. Each multi-source sensing unit is installed at one of the corners of the machine body and the moving beam slider. The multi-source sensing unit is used to detect the gap between each corner of the moving beam slider and the machine body. The dynamic compensation device is used to distribute electrical energy to the electromagnetic guiding modules based on the gap data detected by the multi-source sensing unit.

2. The non-contact guidance system based on electromagnetic dynamic compensation according to claim 1, characterized in that: The main body of the machine includes an upper crossbeam, a lower crossbeam, and a column assembly. Each electromagnetic guide module is installed on each column of the column assembly. A main hydraulic cylinder is installed in the upper crossbeam, and a fixed worktable is installed on the lower crossbeam. The upper and lower crossbeams are respectively fixed to the upper and lower ends of the columns. The moving beam slider is connected to the output shaft of the main hydraulic cylinder, and the moving beam slider is driven to slide vertically in the middle of the column assembly through the output shaft of the main hydraulic cylinder.

3. The non-contact guidance system based on electromagnetic dynamic compensation according to claim 2, characterized in that: The electromagnetic guidance module includes an excitation winding, which forms a non-contact force field with an array of permanent magnets fixed on a column, and the excitation winding is connected to a dynamic compensation device.

4. The non-contact guidance system based on electromagnetic dynamic compensation according to claim 2, characterized in that: The multi-source sensing unit includes a laser rangefinder and strain gauges. The laser rangefinder is installed on the inner side of each corner of the moving beam slider to monitor the left and right gaps between the moving beam slider and each column in real time. The strain gauges are attached to the cross-section of the column to measure the bending deformation of the column.

5. The non-contact guidance system based on electromagnetic dynamic compensation according to claim 2, characterized in that: The column assembly includes four columns. The permanent magnet array is installed on the two vertical sides of the columns and the moving beam slider. The four corners of the moving beam slider are provided with guide grooves that cooperate with each column. Excitation windings are installed on the two vertical sides inside the guide grooves.

6. A non-contact guidance control method based on electromagnetic dynamic compensation, characterized in that, Includes the following steps: Step 1: Real-time monitoring: The gap between each edge of the moving beam slider and its mating column is monitored by a laser rangefinder to obtain gap data. The laser rangefinder updates the gap data every 0.1ms. When the gap design difference exceeds 0.02mm, or the strain gauge shows that the column bending exceeds 0.2mm, the compensation mechanism is triggered. Step 2, Dynamic Calculation: The dynamic compensation controller calculates the required compensation force based on the current gap difference Δ and the rate of change of each laser rangefinder using a proportional-derivative (PD) algorithm. Step 3: Current Regulation The compensation force is converted into a current command, the current value is calculated, and the excitation winding near the deformation area of ​​the column is activated to avoid global overcompensation. Step 4: Closed-loop verification: After compensation, re-inspect the gap between each moving beam slider and the column. If the residual deviation is >0.03mm, increase the compensation coefficient by 10% for a second adjustment until the moving beam slider returns to the center line of the fast forging machine.

7. The non-contact guidance control method based on electromagnetic dynamic compensation according to claim 5, characterized in that, The specific operation of step one is as follows: the laser rangefinder performs zero-point calibration on the gap between the moving beam slider and the vertical plane of the column. At the same time, the test current is applied through the excitation winding. The compensation force reference model is established by the square relationship between the compensation force and the current. After initialization, it enters the real-time monitoring state and synchronously collects the gap deviation value of the laser rangefinder and the bending deformation of the strain gauge at a period of 20ms. The gap deviation value and bending deformation are filtered and then input into the dynamic compensation controller. When the absolute value of the gap deviation value of the laser rangefinder exceeds 0.02mm, or the bending amount of the column detected by the strain gauge exceeds 0.2mm, it is determined that the moving beam slider is neutrally unstable.

8. The non-contact guidance control method based on electromagnetic dynamic compensation according to claim 5, characterized in that, The specific operation of step two is as follows: The required compensation force is calculated using the proportional-differential (PD) algorithm. F = 1.5Δ + 0.2dΔ / dt; Among them, the proportional term (1.5Δ) is used to quickly offset the current deviation, and the differential term (0.2dΔ / dt) suppresses the offset trend; The driving current is calculated in reverse based on the compensation force reference model: I = sqrt(F / k).

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