High-rigidity compact linear module of embedded integrated guide mechanism and driving method of high-rigidity compact linear module

Abstract

The invention relates to the technical field of mechanical engineering, and discloses a high-rigidity compact linear module of an embedded integrated guide mechanism and a driving method of the high-rigidity compact linear module. The method is applied to the high-rigidity compact linear module of the embedded integrated guide mechanism. The method comprises the steps that the steel raceway is embedded in the aluminum alloy body to serve as a guide mechanism, and the steel sliding base makes contact with the steel raceway through the rolling body; a ball screw is driven to rotate, a ball nut of a steel sliding seat drives the steel sliding seat to move in the length direction of the aluminum alloy body, and in the moving process, a corresponding rolling body rolls along a steel raceway to achieve guiding; the steel raceway, the ball screw and the steel sliding seat are sealed in the aluminum alloy main body through the sealing structure, so that a full-sealed transmission environment is formed; a motor stator and a steel sliding seat integrated mover assembly are installed in an aluminum alloy body, a steel sliding seat is driven to move through electromagnetic force, and a steel raceway serves as a guide mechanism to operate independently. The method is suitable for high-precision and space-limited scenes.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mechanical engineering, and in particular to a high-rigidity compact linear module with an embedded integrated guide mechanism and a driving method thereof. BACKGROUND

[0002] In the field of mechanical transmission, linear modules, as the core components for realizing high-precision linear motion, are widely used in scenarios such as numerical control machine tools, automated production lines, and precision detection equipment. The guide mechanism of traditional linear modules usually adopts a combination structure of external guide rails and sliders, which has the following technical problems:

[0003] Rigidity and compactness contradiction: the external guide rails need to be fixed on both sides of the module body through bolts, resulting in a loose overall structure, large space occupation, and difficulty in forming uniform rigid support due to the split design of the aluminum alloy body and the steel guide rail, which easily causes vibration and deformation during high-speed motion, affecting the motion precision;

[0004] Sealing and maintenance defects: the open transmission structure directly exposes the key components such as ball screws and rolling bodies to the external environment, making it easy for dust and liquid to enter the transmission system, causing accelerated wear, and requiring frequent lubrication and maintenance, which reduces the reliability of the equipment;

[0005] Single driving mode: traditional modules only support single driving mode of ball screws or linear motors, the former has an upper limit on transmission efficiency, and the latter has high requirements for the independence of the guide mechanism, and existing designs are difficult to achieve efficient compatibility of the two driving modes in the same module, limiting the adaptability of the module in different load and speed scenarios.

[0006] In the prior art, the integrated design of the guide mechanism mainly focuses on the optimization of structural compactness, but does not solve the problems of sealed environment and driving compatibility; the sealing technology focuses on surface coating or additional protective cover, and does not form a systematic design of a fully enclosed cavity and lubrication channel; the driving mode switching scheme relies on external conversion devices, resulting in complex structure and increased motion error.

[0007] Therefore, there is an urgent need for a method and module to solve at least one of the above problems. SUMMARY

[0008] The present application provides a high-rigidity compact linear module with an embedded integrated guide mechanism and a driving method thereof, aiming to solve the problems in the prior art that the integrated design of the guide mechanism mainly focuses on the optimization of structural compactness, but does not solve the problems of sealed environment and driving compatibility; the sealing technology focuses on surface coating or additional protective cover, and does not form a systematic design of a fully enclosed cavity and lubrication channel; the driving mode switching scheme relies on external conversion devices, resulting in complex structure and increased motion error.

[0009] In a first aspect, the application provides a driving method of a high-rigidity compact linear module with embedded integrated guide mechanism, which is applied to a high-rigidity compact linear module with embedded integrated guide mechanism, the high-rigidity compact linear module comprising an aluminum alloy main body, a steel raceway, a ball screw, a steel slide, a motor and a controller; the method comprises:

[0010] The steel raceway is embedded in the aluminum alloy main body as a guide mechanism, and the steel slide is in contact with the steel raceway through rolling elements.

[0011] The ball screw is driven to rotate, so that the ball nut of the steel slide drives the steel slide to move along the length direction of the aluminum alloy main body, and the corresponding rolling elements roll along the steel raceway to realize guidance during the movement.

[0012] The steel raceway, the ball screw and the steel slide are enclosed in the aluminum alloy main body through a sealing structure to form a fully-sealed transmission environment.

[0013] A motor stator is installed in the aluminum alloy main body, the steel slide is integrated with a rotor assembly, the steel slide is driven to move by electromagnetic force, and the steel raceway independently operates as a guide mechanism; the steel raceway and the aluminum alloy main body are embedded in a preset cavity of the aluminum alloy main body through interference fit or bolt fixation, the rolling elements at the bottom of the steel slide are balls or rollers, and form a rolling friction pair with the steel raceway; the sealing structure comprises an end cap sealing element, a slide lip sealing ring and a closed cavity of the aluminum alloy main body, a lubrication channel penetrates through the aluminum alloy main body to provide lubricating medium for the steel raceway and the ball screw.

[0014] In some embodiments, the embedding of the steel raceway in the aluminum alloy main body as a guide mechanism and the contact of the steel slide with the steel raceway through rolling elements comprise: presetting a rectangular or arc-shaped cavity matching the outer shape of the steel raceway in the aluminum alloy main body, and fixing the steel raceway on the inner wall of the cavity through interference fit or bolt; machining a groove matched with the steel raceway on the bottom of the steel slide, and installing the rolling elements in the groove so that the outer surface of the rolling elements is in contact with the raceway surface of the steel raceway to form a rolling friction guide pair.

[0015] In some embodiments, the driving the ball screw to rotate, and the steel slide seat is driven to move along the length direction of the aluminum alloy body by the ball nut of the steel slide seat, comprising: receiving an external motion instruction by the controller, and controlling the motor to start and output a rotating power; the motor is connected with one end of the ball screw through a shaft coupling, and drives the ball screw to rotate around its axis; the ball nut at the bottom of the steel slide seat is threadedly connected with the ball screw, and converts the rotating motion of the ball screw into the linear motion of the steel slide seat.

[0016] In some embodiments, the corresponding rolling body rolls along the steel raceway to realize the guiding during the motion, comprising: when the steel slide seat moves linearly, the rolling body rolls on the raceway surface of the steel raceway without sliding, and simultaneously bears the radial load and the axial load of the steel slide seat; the motion direction of the steel slide seat is constrained by the uniform rolling of the rolling body, so that the linear motion deviation of the steel slide seat is controlled within a preset range.

[0017] In some embodiments, the steel raceway, the ball screw and the steel slide seat are enclosed inside the aluminum alloy body by the sealing structure to form a fully sealed transmission environment, comprising: installing end cover seals at the end faces of the aluminum alloy body, and sealingly connecting the end cover seals with the end faces of the aluminum alloy body through sealing rings or sealing glue; setting a lip seal ring at the contact part between the steel slide seat and the aluminum alloy body, and tightly connecting the lip of the lip seal ring with the inner wall of the aluminum alloy body to prevent dust and liquid from entering the aluminum alloy body; periodically injecting lubricating grease or lubricating oil into the enclosed cavity through the lubricating channel to lubricate the contact surfaces of the rolling body and the steel raceway, and the ball nut and the ball screw.

[0018] In some embodiments, the motor stator is installed in the aluminum alloy body, the steel slide seat is integrated with a mover assembly, the steel slide seat is driven to move by electromagnetic force, and the steel raceway operates independently as a guiding mechanism, comprising: presetting an installation groove at the bottom or the side of the aluminum alloy body, fixing the motor stator in the installation groove, and making the electromagnetic induction surface of the stator face the steel slide seat; integrating a mover iron core and a coil assembly with the motor stator at the bottom of the steel slide seat, outputting an alternating current to the coil assembly by the controller, generating an electromagnetic thrust to drive the steel slide seat to move, and keeping the matching relationship between the rolling body and the steel raceway unchanged when the steel slide seat moves, and independently bearing the guiding function.

[0019] In some embodiments, the controller is built-in with a motion control algorithm, and the method further comprises: acquiring, by the controller, real-time position signals, speed signals and load signals of the linear module, the position signals being collected by a grating ruler or an encoder installed on the aluminum alloy body, and the load signals being collected by a pressure sensor of the steel slide; based on the real-time position signals, speed signals and load signals, adjusting, by a preset adaptive control algorithm, the driving current of the motor or the output power of the motor, so that the motion speed and acceleration of the steel slide match the current load state; when it is detected that the motion error of the steel slide exceeds a preset threshold, the controller automatically triggers an error compensation algorithm to correct the motion trajectory by fine-tuning the pulse frequency of the motor or the magnetic field strength of the motor.

[0020] In some embodiments, the controller is built-in with a fault diagnosis algorithm, and the method further comprises: monitoring, in real time, contact noise signals of the rolling body and the steel raceway, the noise signals being collected by a vibration sensor installed on the aluminum alloy body; when the amplitude or frequency of the noise signals abnormally fluctuates, the controller identifies, by the fault diagnosis algorithm, whether there is a fault such as rolling body wear, lubrication failure or steel raceway deformation, and generates a corresponding fault code; according to the fault code, the controller sends a warning message to an external terminal and automatically adjusts the operating parameters of the linear module or triggers a shutdown protection mechanism.

[0021] In some embodiments, the controller is built-in with an energy efficiency optimization algorithm, and the method further comprises: based on the historical operating data and the current working condition of the linear module, calculating, by the energy efficiency optimization algorithm, optimal driving parameters of the motor, including voltage, current, pulse frequency or magnetic field strength; after the steel slide completes positioning, the controller automatically switches to a low-power standby mode while maintaining the pre-tightening force of the rolling body and the steel raceway, ensuring the motion accuracy when starting again; when it is detected that the linear module is in a long-time high-load operating state, the controller dynamically adjusts the oil supply frequency of the lubrication system by the energy efficiency optimization algorithm, to reduce lubricant consumption while ensuring lubrication effect.

[0022] In a second aspect, the application provides a high-rigidity compact linear module with an embedded integrated guide mechanism, comprising an aluminum alloy body, a steel raceway, a ball screw, a steel slide, a motor and a controller; the controller comprises a memory and a processor; the memory is used to store a computer program; the processor is used to execute the computer program and implement the method provided in any embodiment of the application when executing the computer program.

[0023] The application forms a composite support structure by embedding a steel raceway in an aluminum alloy main body pre-set cavity (interference fit or bolt fixation), using the high strength of steel material and the lightweight advantage of aluminum alloy to form a composite support structure, which has higher rigidity, smaller volume and is suitable for high-precision and space-limited scenes compared with an external guide rail structure; the end cover sealing element, the sliding seat lip sealing ring and the aluminum alloy closed cavity form a three-level sealing system, combined with a through lubrication channel, to reduce the probability of dust and liquid intrusion, extend the lubrication period and significantly reduce maintenance costs; the seamless switching of the ball screw and the linear motor driving mode is realized through modular design (the same module has a built-in stator / motor assembly and a ball nut), and the steel raceway independently bears the guiding function, so that the module can meet high-precision positioning and high-speed response, and is suitable for precise machining, semiconductor manufacturing and other fields; the rolling element (ball / roller) and the high-precision steel raceway form a rolling friction pair, and the rolling element rolls without sliding during movement, and stable lubrication in a sealed environment.

[0024] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. BRIEF DESCRIPTION OF DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0026] Figure 1 is a step schematic flow chart of the driving method of the high-rigidity compact linear module of the embedded integrated guide mechanism provided by an embodiment of the present application;

[0027] Figure 2 is a structural schematic diagram of the high-rigidity compact linear module of the embedded integrated guide mechanism provided by an embodiment of the present application;

[0028] Figure 3 is a structural schematic block diagram of the controller provided by an embodiment of the present application.

[0029] It should be understood that the above general description and the following detailed description are only exemplary and explanatory, and cannot limit the present application. DETAILED DESCRIPTION

[0030] With reference to the drawings, the technical solutions in the embodiments of the present application will be described clearly and completely. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of the present application.

[0031] The flowcharts shown in the drawings are only illustrative, and do not necessarily include all the contents and operations / steps, nor are they necessarily executed in the order described. For example, some operations / steps can be further decomposed, combined or partially merged, so that the actual execution order can be changed according to the actual situation.

[0032] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present application, in the embodiments of the present application, the terms "first", "second", etc. are used to distinguish the same or similar items with basically the same functions and effects. Those skilled in the art can understand that the terms "first", "second", etc. do not limit the quantity and execution order, and the terms "first", "second", etc. also do not necessarily mean that they are different.

[0033] It should be understood that the terms used in the present application are only for the purpose of describing specific embodiments and do not intend to limit the present application. As used in the present application specification and the appended claims, unless otherwise clear from the context, the singular forms "a", "an" and "the" are intended to include the plural forms.

[0034] It should also be understood that the term "and / or" used in the present application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.

[0035] Some embodiments of the present application will be described in detail below with reference to the accompanying drawings. The following embodiments and features in the embodiments can be combined with each other without conflict.

[0036] In the field of mechanical transmission, linear modules are widely used in scenarios such as numerical control machine tools, automated production lines, and precision detection equipment as core components for achieving high-precision linear motion. The guide mechanism of traditional linear modules usually adopts a combination structure of external guide rails and sliders, which has the following technical problems:

[0037] Rigidity and compactness contradiction: the external guide rails need to be fixed on both sides of the module body by bolts, resulting in a loose overall structure, large space occupation, and difficulty in forming uniform rigid support for the split design of the aluminum alloy body and the steel guide rail, which is prone to vibration and deformation during high-speed motion, affecting the motion precision;

[0038] Sealing and maintenance defects: the open drive structure exposes key components such as ball screws and rolling bodies directly to the external environment, making it easy for dust and liquid to enter the drive system, causing increased wear and tear, frequent lubrication and maintenance, and reduced equipment reliability.

[0039] Single drive mode: traditional modules only support single drive mode of ball screws or linear motors, the former has an upper limit on transmission efficiency, and the latter requires high independence of the guide mechanism, making it difficult for existing designs to achieve efficient compatibility of the two drive modes in the same module, limiting the adaptability of the module in different load and speed scenarios.

[0040] In the prior art, the integrated design of the guide mechanism mainly focuses on compactness optimization, but does not solve the sealing environment and drive compatibility problems; sealing technology focuses on surface coating or additional protective cover, without systematic design of fully enclosed cavity and lubrication channel; the drive mode switching scheme relies on external conversion devices, resulting in complex structure and increased motion error.

[0041] Therefore, there is an urgent need for a method and module to solve at least one of the above problems.

[0042] To solve the above problems, please refer to Figure 1 The application provides a drive method for a high-rigidity compact linear module with an embedded integrated guide mechanism. The method is applied to a high-rigidity compact linear module with an embedded integrated guide mechanism as shown in Figure 2 The high-rigidity compact linear module includes an aluminum alloy body, a steel raceway, a ball screw, a steel slide, a motor, and a controller.

[0043] As shown in Figure 1 The provided method includes steps S101 to S104.

[0044] Step S101. The steel raceway is embedded inside the aluminum alloy body as a guide mechanism, and the steel slide is in contact with the steel raceway through rolling bodies.

[0045] Specifically, by embedding a high-strength steel raceway inside an aluminum alloy body, an integrated guide mechanism is formed, replacing the traditional external guide rail and solving the problems of insufficient rigidity and loose structure. The steel slide is in contact with the steel raceway through rolling bodies, forming a low-friction, high-rigidity rolling guide pair.

[0046] By pre-machining a rectangular or arc-shaped cavity (cross-sectional shape selected according to load type: rectangular for radial load-dominated scenarios, and arc-shaped for composite load scenarios) inside the aluminum alloy body that matches the shape of the steel raceway, the cavity depth and width are controlled within ±0.01mm to ensure precise fitting with the steel raceway.

[0047] The inner wall of the cavity is provided with anti-skid teeth or positioning bosses, matched with interference fit (interference amount 0.02-0.05 mm) or bolt fixation (M3 stainless steel bolts are arranged every 200 mm along the length direction of the raceway), so that the steel raceway and the aluminum alloy body form a rigid whole, and the connecting gap of the split structure is eliminated.

[0048] By processing a U-shaped or V-shaped groove on the bottom of the steel slide, matched with the steel raceway, the groove depth is 1 / 2-2 / 3 of the diameter of the rolling body, so that the outer surface of the rolling body (ball or roller) is in full contact with the raceway surface of the steel raceway after installation (contact stress ≥ 50 MPa).

[0049] The rolling body adopts high-precision bearing-grade balls (diameter φ6-φ10 mm, roundness error ≤0.002 mm) or rollers (length-diameter ratio 1:1.5-2, cylindricality error ≤0.003 mm), which are uniformly distributed in the groove through the retainer (spacing ≤2 times the diameter of the rolling body), forming a rolling friction guide pair, and the rolling resistance coefficient is ≤0.0015, which is reduced by more than 80% compared with the traditional sliding guide pair.

[0050] The steel raceway adopts GCr15 bearing steel (hardness HRC58-62), and the surface is super-precision ground (roughness Ra ≤0.1 μm), and the aluminum alloy body adopts 6061-T6 profile (tensile strength ≥310 MPa), so that the material composite design realizes "rigid support + lightweight", and the weight is reduced and the rigidity is improved compared with the all-steel structure.

[0051] Step S102. Drive the ball screw to rotate, so that the ball nut of the steel slide drives the steel slide to move along the length direction of the aluminum alloy body, and the corresponding rolling body rolls along the steel raceway to realize guidance during the movement.

[0052] Specifically, the ball screw is driven to rotate by a servo motor, and the linear motion of the steel slide is converted from the rotary motion through the ball nut, and the rolling guide pair constructed in step S101 is used to realize motion guidance, so that the vibration and precision problems of the traditional external guide rail are solved.

[0053] The controller receives external motion instructions (such as PLC pulse signals or analog voltage signals), analyzes and outputs driving signals to the servo motor (rated power 0.5-2 kW, rotating speed range 0-5000 rpm), and the motor is connected to one end of the ball screw through an elastic coupling (torsional stiffness ≥100 N*m / rad, axial gap ≤0.05 mm), so as to ensure that there is no rigid impact in power transmission. The ball screw adopts a C5-grade precision ground screw (lead 5-20 mm, pitch error ≤±0.003 mm / m), and the screw shaft diameter is φ20-φ40 mm, matched with a circulating ball nut (the number of loaded balls is ≥3 turns, the contact angle is 45°), so that the transmission efficiency is improved compared with the trapezoidal screw.

[0054] When the ball screw rotates, the ball nut at the bottom of the steel slide moves linearly along the screw axis, driving the slide to move synchronously (speed range 0.1 mm / s-500 mm / s). When the slide moves, the rolling body at the bottom makes pure rolling motion on the rolling surface of the steel raceway (sliding rate ≤0.5%), and the rolling body simultaneously bears the radial load (≤500 N) and the axial load (≤200 N) of the slide, and through the uniform distribution of the rolling body (≥4 groups of rolling bodies on the single side raceway), three-point / four-point contact support is formed to control the linear motion deviation of the slide within ±0.01 mm / m (better than the traditional external guide rail ±0.05 mm / m).

[0055] The aluminum alloy body is internally provided with a through lubrication channel (diameter φ3 mm), and lithium-based lubricating grease (drop point ≥180°C, base oil viscosity 75 mm / s) is injected into the contact surface between the steel raceway and the ball screw by an automatic oil injector (interval 4-8 hours) to prolong the lubrication period. 2

[0056] Step S103. The steel raceway, ball screw and steel slide are sealed inside the aluminum alloy body by a sealing structure to form a fully sealed transmission environment.

[0057] Specifically, the transmission core components (steel raceway, ball screw and steel slide) are sealed inside the aluminum alloy body by a three-stage sealing structure to isolate external pollutants, and an automatic lubrication system is combined to solve the sealing and maintenance defects of traditional modules.

[0058] The end cap sealing design installs aluminum alloy end caps on the end faces of the aluminum alloy body, and O-shaped sealing rings (material nitrile rubber, hardness Shore 70±5°, compression rate 15%-20%) are arranged on the contact surfaces of the end caps and the body, or liquid sealant (viscosity 500-1000 mPa·s, tensile strength ≥2 MPa after curing) is used to fill the gap to ensure that the end face sealing level reaches IP65 (dustproof and low-pressure water injection proof). The end cap is provided with a wire hole and a lubrication channel interface, and a rubber sealing sleeve (interference fit with the outer diameter of the wire) is arranged in the wire hole to prevent dust from entering the cavity through the cable gap.

[0059] A lip seal ring (material polyurethane, lip angle 30°-45°) is arranged at the contact position between the steel slide and the inner wall of the aluminum alloy body, the sealing ring is fixed to the side surface of the slide through a clamping groove, and the lip is tightly attached to the aluminum alloy inner wall with an interference of 0.2-0.5 mm to form a dynamic sealing barrier to prevent dust (particle size ≥5 μm) and liquid (pressure ≤0.1 MPa) from invading during movement. The lip seal ring is designed as a replaceable structure (snap connection), so that the slide does not need to be disassembled during maintenance, and the replacement time is greatly shortened.

[0060] ​The aluminum alloy body is integrally formed by extrusion molding process, and the internal cavity is directly formed in a closed structure (the joint is welded and polished after welding, and the leakage rate is ≤10 cc / min) during molding. The end cover and the lip seal are matched to build a fully enclosed transmission cavity. The lubrication channel extends from the oil inlet at one end of the main body to the full length of the raceway and screw, and a flow limiting valve (hole diameter φ1mm) is arranged in the channel to ensure uniform distribution of the lubricating medium (grease or oil mist), avoid local excess or deficiency, and improve lubrication efficiency.

[0061] Step S104. Install the motor stator in the aluminum alloy body, the steel slide seat integrated mover assembly, drive the steel slide seat to move through electromagnetic force, and the steel raceway operates independently as a guide mechanism; the steel raceway is embedded in the preset cavity of the aluminum alloy body through interference fit or bolt fixation, the rolling body at the bottom of the steel slide seat is a ball or a roller, and a rolling friction pair is formed between the steel raceway and the ball screw; the sealing structure includes an end cover seal, a slide seat lip seal ring and a closed cavity of the aluminum alloy body, and a lubrication channel penetrates through the aluminum alloy body to provide lubricating medium for the steel raceway and the ball screw.

[0062] Specifically, by integrating the linear motor drive function in the same module, the slide seat is driven through the electromagnetic coupling of the stator and the mover, the steel raceway serves as an independent guide mechanism, the efficient compatibility of the ball screw and the linear motor is realized, and the problem of single drive of the traditional module is solved.

[0063] A T-shaped installation groove (depth 15-25 mm, width matched with the size of the stator) is pre-set at the bottom or side of the aluminum alloy body, a high-strength bolt (torque 8-12 N·m) is used to fix the linear motor stator (long stator or short stator, magnetic pole spacing 4-8 mm) in the groove, the electromagnetic induction surface (secondary permanent magnet or primary coil surface) of the stator maintains an air gap of 5-10 mm (tolerance ±0.2 mm) with the bottom of the steel slide seat, and the electromagnetic coupling efficiency is ensured.

[0064] The mover core and coil assembly are integrated at the bottom of the steel slide seat, the core is laminated with silicon steel sheets (thickness 0.35 mm, lamination coefficient ≥0.95), the coil is made of enameled copper wire (wire diameter 0.5-1.0 mm, winding density ≥300 turns / cm 3 ), and is fixed by epoxy resin pouring to prevent coil vibration during high-speed movement.

[0065] The controller outputs alternating current (frequency 50-200 Hz, current amplitude 0-10 A) to the coil assembly, generates electromagnetic thrust (thrust constant 15-30 N / A) based on the Lorentz force principle, drives the slide seat to move at a maximum acceleration of 5g (≥50 m / s²), and the speed range is 0.1 mm / s-2000 mm / s, covering high-precision positioning and high-speed handling scenarios.

[0066] Regardless of the adoption of ball screw or linear motor drive, the motion guide of steel slide is independently undertaken by the rolling guide pair in step S101, and the driving system and the guide system are completely decoupled in structure (the driving component is not rigidly connected with the guide component). When the linear motor is driven, the contact stress (≤30 MPa) of the rolling body and the steel raceway and the motion trajectory (straightness ≤0.02 mm / m) remain unchanged, ensuring that the guide accuracy is consistent under the two driving modes, and no additional calibration is required.

[0067] In some embodiments, the steel raceway is embedded inside the aluminum alloy body as a guide mechanism, and the steel slide is in contact with the steel raceway through a rolling body, comprising: a rectangular or arc-shaped cavity matching the shape of the steel raceway is pre-set inside the aluminum alloy body, and the steel raceway is fixed to the inner wall of the cavity through interference fit or bolts; a groove matched with the steel raceway is processed at the bottom of the steel slide, and the rolling body is installed in the groove, so that the outer surface of the rolling body is in contact with the raceway surface of the steel raceway, forming a rolling friction guide pair.

[0068] By pre-setting a matching cavity inside the aluminum alloy body and fixing the steel raceway, and at the same time constructing a rolling body contact structure at the bottom of the steel slide, an integrated rolling guide pair is formed, solving the problems of insufficient rigidity and loose structure of traditional external guide rails.

[0069] The cavity shape is rectangular (suitable for pure radial load, cross-sectional size WxH=20mmx15mm) or arc-shaped (suitable for radial+axial combined load, curvature radius R=30mm) according to the load type, and the cavity length is equal to the aluminum alloy body (error ±0.1mm), and the inner wall roughness Ra≤0.4μm.

[0070] The fixing method includes: interference fit: the outer diameter of the steel raceway is larger than the inner diameter of the cavity by 0.03-0.05mm, and the hot expansion and cold contraction method is used for installation (the aluminum alloy body is heated to 120℃, and the steel raceway is cooled to-20℃), and after fitting, ultrasonic detection is used to ensure that there is no gap, and the bonding strength is ≥50MPa. Bolt fixation: a group of M4 countersunk bolt holes (hole diameter φ4.2mm, depth 10mm) are set every 150mm along the length direction of the steel raceway, the bolt is made of 304 stainless steel, the installation torque is 10-12N*m, and the bolt head is flush with the surface of the cavity (height difference ≤0.1mm).

[0071] The groove structure is a U-shaped groove (depth=rolling body radius+0.1mm, width=rolling body diameter+0.2mm) or a V-shaped groove (angle 90°, groove bottom radius=rolling body radius) matched with the steel raceway, which is uniformly distributed along the length direction of the slide (≥4 groups on one side).

[0072] Rolling body is selected high-precision ball (diameter φ8mm, roundness error ≤0.001mm), or roller (diameter φ10mm, length 15mm, cylindrical error ≤0.002mm), fixed in the groove through the plastic retainer (spacing 12mm), the retainer and the slide groove are connected by buckle (disassembly force ≥50N). The contact pressure between the outer surface of the rolling body and the steel rolling surface is controlled at 40-60MPa, which is monitored in real time by a pressure sensor (accuracy ±2%), to ensure the uniformity of the initial pre-tightening force of the rolling pair. The material of the steel rolling is GCr15 bearing steel (hardness HRC60±2), the surface hardened layer depth is ≥2mm, and the straightness of the rolling surface is ≤0.01mm / m; the aluminum alloy body is 6061-T6 (hardness HB≥95 after heat treatment), and the coaxiality of the cavity and the rolling is ≤0.02mm.

[0073] In some embodiments, the driving the ball screw to rotate drives the ball nut of the steel slide to move the steel slide along the length direction of the aluminum alloy body, comprising: receiving an external motion instruction by the controller, controlling the motor to start and output a rotating power; the motor is connected with one end of the ball screw through a coupling, driving the ball screw to rotate around its axis; the ball nut at the bottom of the steel slide is threadedly connected with the ball screw, converting the rotating motion of the ball screw into the linear motion of the steel slide.

[0074] Through the coordinated driving of the controller, the motor and the ball screw, the rotating motion is converted into the linear motion of the steel slide, realizing high-precision transmission and solving the problems of traditional module driving efficiency and precision.

[0075] The controller uses PLC or motion control card (such as EtherCAT bus type, input signal resolution 1μm), generates motor driving signal (frequency 0-100kHz) through PID algorithm after receiving external instruction (pulse signal / analog voltage).

[0076] A servo motor (rated power 1.5kW, rated speed 3000rpm, encoder resolution 24 bits) is selected, which is connected with the input end of the ball screw through a plum blossom elastic coupling (torsional stiffness 150N·m / rad, axial compensation amount ±0.5mm), and the centering error of the coupling is ≤0.05mm (radial / angular).

[0077] A C3 grade ground ball screw (shaft diameter φ30mm, lead 10mm, pitch cumulative error ≤±0.002mm / 300mm) is used, and angular contact ball bearings (pairing mode DB, pre-tightening force 50N) are installed at both ends of the ball screw, and the bearing seat and the aluminum alloy body are positioned by a pin (positioning accuracy ±0.01mm).

[0078] Ball nut structure: the nut body is made of alloy steel (hardness HRC55±2), and three groups of circulating ball rows are arranged inside (the number of balls in each group is ≥50), the contact angle is 45°, the nut is fixed to the bottom of the steel slide through four M5 bolts (torque 8 N·m), and the parallelism of the connecting plane is ≤0.01 mm.

[0079] When the motor rotates at a speed n (rpm), the linear speed of the slide v = lead × n / 60 (mm / s), and the speed control accuracy is ±0.1%; the maximum thrust F = motor torque × 2π / lead (N), and the rated thrust is ≥500 N, which is suitable for medium load scenarios (load mass ≤50 kg). During transmission, the reverse clearance of the ball screw is eliminated by the pre-tightening nut (clearance ≤0.005 mm), and the controller compensates for the thermal expansion of the screw in real time (temperature sensor accuracy ±0.5℃, compensation coefficient 11.6×10 -6 / ℃).

[0080] In some embodiments, the corresponding rolling body rolls along the steel raceway during the movement to guide, including: when the steel slide moves linearly, the rolling body rolls without sliding on the raceway surface of the steel raceway, while bearing the radial load and axial load of the steel slide; the movement direction of the steel slide is constrained by the uniform rolling of the rolling body, so that the linear movement deviation of the steel slide is controlled within a predetermined range.

[0081] By rolling the rolling body on the steel raceway without sliding, the movement direction of the slide is constrained, the linear movement deviation is controlled, and the vibration and precision problems of the traditional module during high-speed movement are solved.

[0082] The diameter d of the rolling body and the curvature radius R of the raceway satisfy R = 1.05d (ball scene) or the length L of the roller ≤d×1.2 (roller scene), so as to ensure pure rolling of the rolling body and the raceway when they are in contact (sliding rate <0.3%), which is verified by a laser Doppler vibration meter (sliding speed resolution 0.1 mm / s).

[0083] A single rolling body bears a radial load Fr≤30 N and an axial load Fa≤15 N (designed according to the ISO 281 bearing life formula, rated life ), and the rolling body group is symmetrically arranged (two raceways on each side, a total of four groups), forming balanced support.

[0084] The linear motion of the slide is straight, with a straightness error of ≤0.02 mm / 1000 mm (horizontal direction) and a parallelism error of ≤0.03 mm / 1000 mm (vertical direction). The errors are detected in real time by a high-precision laser interferometer (resolution 0.1 μm), and an alarm is triggered when the error exceeds the threshold value (±10%).

[0085] The contact surface of the rolling body and the rolling groove is coated with molybdenum disulfide grease (base oil viscosity 100 mm 2 / s, containing 3% nanometer molybdenum disulfide particles), with a lubrication period of 500 hours. The lubrication state is monitored by an oil level sensor (alarm threshold ≤20%).

[0086] In some embodiments, the steel rolling groove, ball screw, and steel slide are enclosed inside the aluminum alloy body by a sealing structure to form a fully sealed transmission environment, which includes: installing end cap seals on the end faces of the aluminum alloy body, and the end cap seals are connected to the end faces of the aluminum alloy body by a sealing ring or sealing glue; a lip seal ring is arranged at the contact part of the steel slide and the aluminum alloy body, and the lip of the lip seal ring tightly contacts the inner wall of the aluminum alloy body to prevent dust and liquid from entering the aluminum alloy body; lubricating grease or oil is periodically injected into the closed cavity through the lubrication channel to lubricate the contact surfaces of the rolling body and the steel rolling groove, the ball nut and the ball screw.

[0087] The end cap sealing, lip sealing, and lubrication system form a fully enclosed transmission cavity, which isolates external pollutants and achieves long-term lubrication, solving the sealing and maintenance defects of traditional modules.

[0088] The end cap structure includes: an aluminum alloy end cap with a thickness of 15 mm, a sealing groove with a width of 5 mm and a depth of 2 mm arranged on the contact surface of the main body, a nitrile rubber O-ring (cross-sectional diameter 2.65 mm, compression rate 18%) installed in the groove, or a single-component room temperature vulcanized silicone rubber (surface drying time ≤10 minutes, sealing pressure ≥0.2 MPa) is applied.

[0089] The interface seal uses a rubber wire sleeve (inner diameter and cable outer diameter are 0.5 mm) through the wire hole on the end cap, and the lubrication channel interface uses a quick plug connector (leakage-proof grade IP67), and the connector and the end cap are connected by threads (sealed with 3 layers of sealing tape).

[0090] The sealing ring structure comprises: a lip sealing ring made of polyurethane (hardness Shore 85±5°), the cross section of which is L-shaped, the lip length is 3mm, and the lip is attached to the inner wall of the aluminum alloy body (the inner wall roughness Ra≤1.6μm) with an interference of 0.3mm, and the sealing ring is fixed to the groove (the fitting clearance is ≤0.1mm) on the side surface of the sliding seat by a stainless steel spring (thickness 1mm).

[0091] The dynamic sealing performance is that the wear rate of the lip sealing ring is ≤0.01mm / 100km when the sliding seat moves, and the visual detection system is regularly scanned (period 100 hours), and the replacement prompt is triggered when the wear exceeds the limit.

[0092] The lubrication channel is that two φ3mm through holes (corresponding to the lubrication of the raceway and the screw respectively) are arranged in the aluminum alloy body, a one-way valve (opening pressure 0.1MPa) is arranged at the inlet of the channel, and oil injection holes (hole diameter φ0.5mm) are distributed at an interval of 200mm at the outlet of the channel, so that the lubricating medium is uniformly sprayed.

[0093] The lubrication strategy is that when grease lubrication is adopted, the automatic oil injector (volume 50ml) injects 0.5ml of oil each time (interval 4 hours); when oil mist lubrication is adopted, the diameter of the atomized particles is ≤5μm, the flow rate is 5ml / h, and the pressure sensor is used to monitor the internal pressure of the cavity (normal range 1-1.1atm, prevent negative pressure suction of dust).

[0094] In some embodiments, the motor stator is installed in the aluminum alloy body, the steel sliding seat integrates the rotor assembly, the steel sliding seat is driven to move by electromagnetic force, the steel raceway independently operates as a guide mechanism, and the method comprises the following steps: a preset installation groove is arranged at the bottom or side of the aluminum alloy body, the motor stator is fixed in the installation groove, and the electromagnetic induction surface of the stator faces the steel sliding seat; a rotor core and a coil assembly matched with the motor stator are integrated at the bottom of the steel sliding seat, the controller outputs an alternating current to the coil assembly to generate an electromagnetic thrust to drive the steel sliding seat to move; when the steel sliding seat moves, the matching relationship between the rolling body and the steel raceway remains unchanged, and the steel raceway independently bears the guiding function.

[0095] By integrating the linear motor drive in the same module, the sliding seat is driven by electromagnetic coupling between the stator and the rotor, the steel raceway independently bears the guiding function, and the two driving modes are compatible.

[0096] The linear motor stator installation includes: installation position: T-shaped installation groove (depth 20mm, width matching the size of the stator, such as stator width 40mm, groove width 42mm) is opened at the bottom of the aluminum alloy body, the stator is fixed by M6 bolts (spacing 100mm, torque 15N*m), the surface of the stator and the groove bottom flatness error ≤0.02mm. Air gap control: the distance between the stator electromagnetic induction surface (permanent magnet array or primary coil surface) and the mover assembly is 8±0.2mm, which is calibrated by a feeler gauge, the air gap non-uniformity is ≤5%, and the electromagnetic thrust fluctuation is ≤5% (when the rated thrust is 100N, the fluctuation is ≤5N).

[0097] The mover core uses 35WW270 silicon steel sheet lamination (lamination coefficient 0.96), thickness 15mm, surface winding concentrated coil (pole pitch 16mm, 200 turns per pole), coil end is bound by glass fiber tape, the whole is filled with epoxy resin (Shore hardness 80D), insulation grade F (temperature resistance 155℃).

[0098] The controller outputs three-phase sinusoidal wave current (frequency 0-200Hz, amplitude 0-15A), based on vector control algorithm to adjust electromagnetic thrust in real time, realize high-speed response (step signal rise time ≤5ms), suitable for high-speed handling scene (maximum speed 2m / s).

[0099] When switching between the two driving modes, the displacement sensor (accuracy ±1μm) detects the motion trajectory of the slide, verifies that the guide deviation change is ≤±0.005mm / 100mm, and the stress distribution of the steel track (monitored by strain gauge) has no significant difference (stress change ≤3%), ensuring that the guide function is not affected by the driving mode. The mover assembly and the slide are connected by bolts (4 M4 bolts, torque 6N*m), and the connecting surface is provided with an insulating gasket (thickness 0.5mm, insulation resistance ≥10MΩ) to avoid electromagnetic interference affecting the control signal.

[0100] In some embodiments, the controller has a built-in motion control algorithm, and the method further comprises: acquiring real-time position signals, speed signals and load signals of the linear module by the controller, the position signals being collected by a grating ruler or encoder installed on the aluminum alloy body, and the load signals being collected by a pressure sensor of the steel slide; based on the real-time position signals, speed signals and load signals, adjusting the driving current of the motor or the output power of the motor by a preset adaptive control algorithm, so that the motion speed and acceleration of the steel slide match the current load state; when it is detected that the motion error of the steel slide exceeds a preset threshold, the controller automatically triggers an error compensation algorithm to correct the motion trajectory by fine-tuning the pulse frequency of the motor or the magnetic field strength of the motor.

[0101] Through the controller integrated motion control algorithm, real-time acquisition of position, speed, load signals, to realize the adaptive adjustment of driving parameters and motion error compensation, to solve the problem of motion accuracy and dynamic response under complex working conditions.

[0102] Position and speed acquisition uses incremental grating ruler (accuracy ±1 μm, resolution 0.5 μm, installed on the side of aluminum alloy body, reading head and slide rigid connection) or absolute encoder (24 bits, single circle resolution 1 / 16384, integrated in the tail of servo motor), signal input controller through RS422 differential interface (transmission delay ≤1 μs). Using second-order Butterworth low-pass filter (cutoff frequency 500 Hz), filter out high-frequency noise (signal-to-noise ratio improved to more than 60 dB).

[0103] Load acquisition by installing strain pressure sensor (range 0-2000N, accuracy ±0.1%FS, sensitivity 2mV / V) at the connection between steel slide and ball nut / motor assembly, sensor surface covered with epoxy resin protective layer (thickness 0.5mm, insulation resistance ≥10MΩ), signal transmission through shielded cable (shielding layer ground resistance ≤1Ω).

[0104] By establishing load-driving model: according to real-time load F (N) dynamic adjustment of motor drive current I (A), formula is I=I0+kF*F (I0 is the no-load current, kF is the load coefficient, through the least squares method offline calibration).

[0105] Speed matching strategy includes: when the load exceeds 80% of the rated value, the maximum acceleration is automatically limited to amax=0.8a0 (a0 is the no-load acceleration), through feedforward compensation algorithm to reduce dynamic tracking error (compensation coefficient 0.95, response time ≤2ms).

[0106] Error compensation mechanism by preset position error threshold is ±5 μm (high speed working condition) / ±2 μm (low speed working condition), when detecting continuous 3 sampling period (sampling frequency 1 kHz) error over limit: servo drive mode through PID algorithm fine-tune pulse frequency (adjustment step 0.1%), while enabling screw pitch error compensation (store 200 points compensation table, resolution 1 μm). Linear motor mode through dynamic adjustment of magnetic field strength (adjustment range ±10%), through vector control algorithm to correct q-axis current (response time ≤1ms).

[0107] The controller uses an industrial-grade processor (1GHz clock speed, 512MB memory) and runs a real-time operating system (RTOS, task scheduling accuracy ≤1μs). It displays the 3D motion trajectory (X / Y / Z axis error curves, 100Hz refresh rate) in real time via a human-machine interface (HMI), supports manual setting of compensation parameters (0.1μm resolution), and stores the most recent 1000 sets of error data for offline analysis.

[0108] In some embodiments, the controller incorporates a fault diagnosis algorithm, and the method further includes: real-time monitoring of the contact noise signal between the rolling element and the steel raceway, the noise signal being collected by a vibration sensor installed on the aluminum alloy body; when the amplitude or frequency of the noise signal fluctuates abnormally, the controller identifies whether there are faults such as rolling element wear, lubrication failure, or steel raceway deformation through the fault diagnosis algorithm, and generates a corresponding fault code; based on the fault code, the controller sends a warning message to an external terminal and automatically adjusts the operating parameters of the linear module or triggers a shutdown protection mechanism.

[0109] By collecting rolling pair noise signals through vibration sensors and using fault diagnosis algorithms to identify faults such as rolling element wear, lubrication failure, and raceway deformation, predictive maintenance and safety protection can be achieved.

[0110] A triaxial accelerometer vibration sensor (frequency range 10-10kHz, sensitivity 100mV / g, resolution 0.001g) is used, mounted on the top surface of the middle of the aluminum alloy body and fixed with M3 bolts. The contact surface is coated with thermally conductive silicone to reduce signal attenuation. The sampling frequency is set to 20kHz (satisfying the Nyquist criterion and covering the characteristic frequency of rolling element failure: fb = n * D * (1±cosα) / 60d, where n is the rotational speed, D is the raceway diameter, d is the rolling element diameter, and α is the contact angle).

[0111] Signal preprocessing includes: removing power frequency interference: using a 50Hz notch filter (attenuation ≥40dB); extracting amplitude features from the time-domain signal using root mean square (RMS) calculation, and generating a power spectral density (PSD) map (frequency resolution 10Hz) from the frequency-domain signal using fast Fourier transform (FFT).

[0112] The fault diagnosis algorithm process includes: Abnormal feature identification: Rolling element wear: The PSD graph shows a significant increase in the amplitude of fb and its harmonics (2fb, 3fb) (exceeding 3 times the standard deviation of the baseline value), and the time-domain waveform shows periodic impact signals (interval 1 / fb). Lubrication failure is indicated by a 3-5 dB decrease in the total sound pressure level (SPL) of the noise signal (due to reduced metal contact damping caused by grease loss), while the proportion of energy in the high-frequency band (>5kHz) increases. Raceway deformation is indicated by the appearance of low-frequency modulation signals (10-50Hz), corresponding to periodic load fluctuations caused by raceway geometric errors, with the modulation frequency consistent with the slide movement frequency.

[0113] The rules for generating fault codes are shown in the table below:

[0114]

[0115] The fault response mechanism includes: Early warning and protection strategies: Early warning information is sent to an external terminal via Modbus TCP protocol (delay ≤200ms), including fault code, occurrence time, and real-time vibration waveform (storing data from the last 10 seconds). In the event of a Level 1 alarm, the controller automatically reduces the operating speed to 50% and triggers forced lubrication (doubling the amount of oil injected at one time); in the event of an immediate shutdown, the motor power is cut off, the electromagnetic brake is activated (braking time ≤50ms), and the operating interface is locked to prevent accidental restart. The maintenance prompt function establishes a fault database, recording the historical occurrence frequency and maintenance measures for each fault code. It supports querying maintenance guidelines via the HMI (e.g., E002 corresponds to "Check if the lubrication system pipeline is blocked") and automatically generates maintenance work orders (including replacement component models and operating steps).

[0116] In some embodiments, the controller incorporates an energy efficiency optimization algorithm, and the method further includes: calculating the optimal driving parameters of the motor or motor based on the historical operating data and current operating conditions of the linear module using the energy efficiency optimization algorithm; the driving parameters include voltage, current, pulse frequency, or magnetic field strength; after the steel slide completes positioning, the controller automatically switches to a low-power standby mode while maintaining the preload between the rolling elements and the steel raceway to ensure motion accuracy upon restart; when the linear module is detected to be operating under high load for an extended period, the controller dynamically adjusts the oil supply frequency of the lubrication system using the energy efficiency optimization algorithm to reduce lubricant consumption while ensuring lubrication effectiveness.

[0117] By dynamically adjusting drive parameters and lubrication strategies through energy efficiency optimization algorithms, low-power operation and optimized lubrication efficiency are achieved, solving the problems of high energy consumption and lubricant waste.

[0118] The optimization of drive parameters includes: establishing an energy consumption model based on historical data (storing the operation logs of the last 30 days, including load, speed, and energy consumption data), and using the particle swarm optimization (PSO) algorithm to solve for the optimal combination of drive parameters: servo mode: optimize voltage U (range 180-240VAC) and pulse frequency f (range 10-100kHz), with the objective function being E=kU*U+kf*f (kU and kf are weighting coefficients, determined through regression analysis).

[0119] Linear motor mode: Optimizes q-axis current amplitude and d-axis current compensation value to minimize the sum of copper loss and iron loss (efficiency improvement ≥5%). Real-time operating condition matching: Load, speed, and temperature data are collected every 50ms. When the operating conditions change (load fluctuation >10% or speed change >20%), online optimization is triggered (calculation time ≤10ms).

[0120] The low-power standby mode design includes: positioning completion detection: when the slider position error is <1μm and the speed is <0.1mm / s for 200ms, the positioning is determined to be complete and the device enters standby mode.

[0121] The standby control strategy includes: the servo motor cuts off the three-phase power supply while retaining encoder power (power consumption ≤ 5W), and simultaneously maintains the slide position through an electromagnetic brake (brake response time ≤ 10ms), while the rolling element preload is maintained by a mechanical locking structure (preload fluctuation ≤ 5%). The linear motor shuts off the coil current and activates the permanent magnet holding force (holding force ≥ 20% of rated thrust), while the stator temperature monitoring module continues to operate (power consumption ≤ 3W), ensuring that the air gap does not need to be recalibrated upon restart.

[0122] The oil supply frequency is dynamically adjusted by establishing a lubrication demand model: oil supply frequency fl = fl0 * (1 + 0.5F / Fn) (fl0 is the no-load base frequency, 2 times / hour; Fn is the rated load). When the load is < 30% Fn, the frequency is reduced to fl0 * 0.8, and the lubricant consumption is reduced by 40%.

[0123] Grease usage control: A volumetric metering pump (minimum displacement 0.1ml / time) is used, combined with an oil temperature sensor (accuracy ±1℃) to adjust the oil injection interval (shortened in high temperature environment, extended by 3 in low temperature environment).

[0124] The controller calculates the energy efficiency ratio (EER = effective work / total energy consumption, resolution 0.01) in real time. When the EER is below the threshold for 30 consecutive minutes (1.2 for servo mode, 1.5 for linear motor mode), parameter re-optimization is automatically triggered. Energy efficiency data is uploaded to the cloud platform via the OPC UA protocol to generate an energy consumption trend curve (time resolution 1 minute), supporting remote setting of energy efficiency optimization targets (such as a 15% reduction in monthly energy consumption).

[0125] In some embodiments, by collecting multi-dimensional data on vibration, temperature, and load during the operation of the rolling element, a Long Short-Term Memory (LSTM) network prediction model is constructed to realize the prediction of the remaining life of the rolling element and proactive maintenance scheduling, thus solving the problem of over / under maintenance in traditional timed maintenance.

[0126] Vibration sensor (temperature setting module: accuracy ±0.5℃, integrated into the rolling element cage), load sensor, and speed encoder (resolution 1 pulse / μm, real-time acquisition of slide speed). Data synchronization is achieved through a hardware timer for 10kHz synchronous sampling, with a timestamp accuracy ≤1μs. The raw data is normalized (Z-score normalization, mean 0, standard deviation 1).

[0127] Feature extraction includes: Time domain: peak value, kurtosis, root mean square (RMS); Frequency domain: energy percentage of the rolling body passing frequency (BPFI / BPFO); Time-frequency domain: wavelet packet energy entropy (decomposed into 3 layers, extracting 8 sub-bands of energy).

[0128] The LSTM prediction model is constructed as follows: The network architecture includes: Input layer: 12-dimensional feature vector (vibration 3D + temperature 1D + load 1D + rotation speed 1D + derived feature 6D); Hidden layer: 2-layer LSTM (128 neurons each, dropout rate 0.2); Output layer: remaining lifespan in days (continuous value prediction). Training data is generated by collecting 300 sets of rolling body failure samples (data from normal operation to fatigue peeling), using a sliding window method (window length 5000 points, step size 1000 points), with the label being the remaining lifespan in days (normalized to [0,1]). The online prediction mechanism aggregates the feature vector every 10 minutes and inputs it into a lightweight model deployed at the edge (model size ≤10MB, inference time ≤5ms). When the predicted remaining lifespan is <7 days, a level 3 warning (yellow warning) is triggered; when it is <3 days, a level 2 warning (orange warning and recommendation to stop and replace) is triggered.

[0129] Maintenance strategy optimization dynamically adjusts the maintenance plan based on prediction results: A genetic algorithm optimizes maintenance timing, with the objective function being to minimize the sum of maintenance costs and downtime losses, and the constraint being a predicted lifespan confidence level > 90%. Maintenance knowledge base linkage: When the predicted failure mode is rolling element peeling, the system automatically retrieves the corresponding replacement steps (such as torque requirements and cleaning procedures) from the maintenance manual and pushes instructional videos to maintenance personnel via AR glasses.

[0130] In some embodiments, a deep reinforcement learning (DRL) agent is designed to meet the lubrication needs under different operating conditions. Through real-time interaction with the lubrication system, the agent dynamically optimizes the oil supply frequency, oil quantity, and lubrication type, thereby reducing lubricant consumption by more than 30% while ensuring lubrication effect.

[0131] Reinforcement learning environment modeling: State space: current load F (N), slide speed v (mm / s), oil temperature T (°C), last lubrication time interval Δt (min), rolling element noise amplitude A (dB), a total of 5 continuous states.

[0132] Action Space: Discrete Actions: {0 (no action), 1 (micro-oil supply 0.1ml), 2 (standard oil supply 0.5ml), 3 (forced oil supply 2ml), 4 (switch grease type)}, where action 4 corresponds to switching between high-temperature and low-temperature grease (achieved through solenoid valve assembly).

[0133] Reward function: Positive reward: lubricant saving per hour (coefficient 0.1 yuan / ml) + noise amplitude reduction (coefficient 0.5dB); Negative reward: vibration amplitude increase due to insufficient lubrication (coefficient -1dB) or temperature rise due to excessive lubrication (coefficient -0.5℃).

[0134] The training and deployment of the intelligent agent includes: Algorithm selection: Deep Q-Network (DQN) combined with Experience Replay (buffer capacity of 100,000 lines), the neural network structure is 3 fully connected layers (input 5 → hidden layer 64 → hidden layer 32 → output 5 action value), and the target network is updated every 500 steps.

[0135] Online optimization mechanism: Initial stage: 200 hours of offline training on the test platform (simulating 0-2000N load and 5-200mm / s speed conditions), after convergence, switching to online fine-tuning mode (ε-greedy strategy, ε linearly decays from 0.1 to 0.01). Operating condition identification: When the oil temperature is >60℃ or <0℃, the temperature compensation strategy is automatically triggered (action 4 has higher priority than other actions) to avoid lubrication failure under extreme conditions.

[0136] Hardware system adaptation includes: Lubrication system upgrade: Integrated dual-chamber grease reservoir (high-temperature grease / low-temperature grease), switching the oil supply path via an electromagnetic reversing valve (response time ≤5ms); metering pump accuracy ±0.05ml, equipped with a flow sensor (resolution 0.01ml) for real-time feedback of oil supply status. Safety threshold protection: Setting a minimum oil supply interval of 30 minutes and a maximum single oil supply volume of 3ml to prevent lubrication system malfunctions caused by abnormal reinforcement learning actions.

[0137] In some embodiments, by integrating a six-dimensional force sensor into the working area of ​​the linear module and combining it with an adaptive impedance control algorithm, a safe force control response is achieved during human-machine contact, supporting manual drag teaching and collision protection, thus meeting the needs of collaborative robot scenarios.

[0138] The sensor configuration involves mounting a six-dimensional force sensor (range F_x / y / z±500N, M_x / y / z±50N·m, accuracy ±1%FS, response time ≤2ms) at the front end of a steel slide. The six-dimensional force sensor is connected to the slide via a high-strength aluminum alloy adapter plate (rigidity ≥10^6N / m). Force signal filtering: A Kalman filter (process noise covariance Q=0.01, measurement noise covariance R=0.1) is used to eliminate high-frequency jitter during operation (residual noise ≤0.5N).

[0139] The safety zone is divided into three levels using a lidar (scanning range 0-5m, accuracy ±10mm): Red zone (distance <200mm): triggers emergency stop (braking distance ≤10mm); Yellow zone (200-500mm): speed limited to 30mm / s, force control mode activated; Green zone (>500mm): normal operation mode.

[0140] The impedance control model defines the desired stiffness Kd = 500 N / m (when manually dragging) and the desired damping Bd = 50 N*s / m, calculates the position correction Δx = Fext / Kd based on the contact force Fext, and achieves compliant motion through position loop compensation.

[0141] When a continuous contact force >10N and a duration >500ms is detected, the teaching mode is entered. The operator can directly drag the slide to the target position. The controller records the path points in real time (sampling frequency 100Hz). After the teaching is completed, the motion trajectory is automatically generated.

[0142] When any axial force exceeds the threshold (F_x / y±80N, F_z±150N), a zero-force response (motor torque reset to zero) is immediately triggered, and the brake is activated (response time ≤10ms), accompanied by an alarm sounding through a buzzer and warning light. The operator's identity is verified via a fingerprint recognition module; only authorized personnel can activate the force control mode. Unauthorized access will directly enter a safe shutdown state.

[0143] Please see Figure 3 , Figure 3 This is a schematic block diagram of the controller provided in an embodiment of this application. The controller includes a processor, a memory, and a network interface connected via a device bus, wherein the memory may include a storage medium and internal memory.

[0144] The storage medium may store operating devices and computer programs. The computer program includes program instructions that, when executed, cause the processor to perform an embodiment of a driving method for any type of embedded integrated guide mechanism high-rigidity compact linear module.

[0145] The processor provides computing and control capabilities to support the operation of the entire controller.

[0146] The internal memory provides an environment for the execution of computer programs in non-volatile storage media. When executed by a processor, the computer program enables the processor to execute any method of high-rigidity, compact linear module based on an embedded integrated guiding mechanism.

[0147] This network interface is used for network communication, such as sending assigned tasks. Those skilled in the art will understand that... Figure 3 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the terminal to which the present application is applied. The specific controller may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0148] It should be understood that the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. Among these, a general-purpose processor can be a microprocessor or any conventional processor.

[0149] In one embodiment, the processor is configured to run a computer program stored in memory to perform the following steps:

[0150] The steel raceway is embedded inside the aluminum alloy body as a guide mechanism, and the steel slide block contacts the steel raceway through rolling elements;

[0151] The ball screw is driven to rotate, causing the ball nut of the steel slide to drive the steel slide to move along the length of the aluminum alloy body. During the movement, the corresponding rolling element rolls along the steel raceway to achieve guidance.

[0152] The steel raceway, ball screw, and steel slide are enclosed inside the aluminum alloy body by a sealing structure, forming a fully sealed transmission environment.

[0153] A motor stator is installed inside the aluminum alloy body, and the steel slide integrates a mover assembly. The steel slide is driven to move by electromagnetic force, and the steel raceway operates independently as a guide mechanism. The steel raceway is embedded in a preset cavity of the aluminum alloy body by interference fit or bolt fixation. The rolling elements at the bottom of the steel slide are balls or rollers, forming a rolling friction pair with the steel raceway. The sealing structure includes an end cap seal, a slide lip seal ring, and a closed cavity of the aluminum alloy body. A lubrication channel runs through the aluminum alloy body, providing a lubricating medium to the steel raceway and the ball screw.

[0154] In some embodiments, the steel raceway is embedded inside the aluminum alloy body as a guide mechanism, and the steel slide contacts the steel raceway through a rolling element. This includes: pre-setting a rectangular or arc-shaped cavity inside the aluminum alloy body that matches the shape of the steel raceway; fixing the steel raceway to the inner wall of the cavity by interference fit or bolts; machining a groove at the bottom of the steel slide that matches the steel raceway; installing the rolling element in the groove so that the outer surface of the rolling element contacts the raceway surface of the steel raceway, forming a rolling friction guide pair.

[0155] In some embodiments, driving the ball screw to rotate, causing the ball nut of the steel slide to drive the steel slide to move along the length of the aluminum alloy body, includes: receiving an external motion command through the controller, controlling the motor to start and output rotational power; the motor being connected to one end of the ball screw via a coupling, driving the ball screw to rotate around its own axis; and the ball nut at the bottom of the steel slide engaging with the ball screw threadedly, converting the rotational motion of the ball screw into the linear motion of the steel slide.

[0156] In some embodiments, the rolling element corresponding to the movement rolls along the steel raceway to achieve guidance, including: when the steel slide moves linearly, the rolling element rolls without slipping on the raceway surface of the steel raceway, while bearing the radial load and axial load of the steel slide; the uniform rolling of the rolling element constrains the movement direction of the steel slide, so that the linear movement deviation of the steel slide is controlled within a preset range.

[0157] In some embodiments, the sealing structure encloses the steel raceway, ball screw, and steel slide within the aluminum alloy body to form a fully sealed transmission environment. This includes: installing end cap seals on both end faces of the aluminum alloy body, the end cap seals being sealed to the end faces of the aluminum alloy body via sealing rings or sealant; providing lip seals at the contact points between the steel slide and the aluminum alloy body, the lip of the lip seals being tightly against the inner wall of the aluminum alloy body to prevent external dust and liquids from entering the interior of the aluminum alloy body; and periodically injecting grease or lubricating oil into the enclosed cavity through the lubrication channel to lubricate the contact surfaces of the rolling elements and the steel raceway, and the ball nut and the ball screw.

[0158] In some embodiments, the installation of a motor stator within the aluminum alloy body, the integration of a mover assembly into the steel slide, and the electromagnetic force driving the steel slide to move, with the steel raceway operating independently as a guiding mechanism, includes: pre-setting a mounting groove on the bottom or side of the aluminum alloy body, fixing the motor stator within the mounting groove, with the electromagnetic induction surface of the stator facing the steel slide; integrating a mover core and coil assembly that cooperates with the motor stator at the bottom of the steel slide, the controller outputting alternating current to the coil assembly to generate electromagnetic thrust driving the steel slide to move; when the steel slide moves, the cooperation relationship between the rolling elements and the steel raceway remains unchanged, independently undertaking the guiding function.

[0159] In some embodiments, the controller incorporates a motion control algorithm, and the method further includes: acquiring real-time position signals, speed signals, and load signals of the linear module through the controller; the position signals are acquired by a grating ruler or encoder mounted on the aluminum alloy body, and the load signals are acquired by a pressure sensor of the steel slide; based on the real-time position signals, speed signals, and load signals, adjusting the drive current of the motor or the output power of the motor through a preset adaptive control algorithm to match the movement speed and acceleration of the steel slide with the current load state; when the motion error of the steel slide is detected to exceed a preset threshold, the controller automatically triggers an error compensation algorithm to correct the motion trajectory by fine-tuning the pulse frequency of the motor or the magnetic field strength of the motor.

[0160] In some embodiments, the controller incorporates a fault diagnosis algorithm, and the method further includes: real-time monitoring of the contact noise signal between the rolling element and the steel raceway, the noise signal being collected by a vibration sensor installed on the aluminum alloy body; when the amplitude or frequency of the noise signal fluctuates abnormally, the controller identifies whether there are faults such as rolling element wear, lubrication failure, or steel raceway deformation through the fault diagnosis algorithm, and generates a corresponding fault code; based on the fault code, the controller sends a warning message to an external terminal and automatically adjusts the operating parameters of the linear module or triggers a shutdown protection mechanism.

[0161] In some embodiments, the controller incorporates an energy efficiency optimization algorithm, and the method further includes: calculating the optimal driving parameters of the motor or motor based on the historical operating data and current operating conditions of the linear module using the energy efficiency optimization algorithm; the driving parameters include voltage, current, pulse frequency, or magnetic field strength; after the steel slide completes positioning, the controller automatically switches to a low-power standby mode while maintaining the preload between the rolling elements and the steel raceway to ensure motion accuracy upon restart; when the linear module is detected to be operating under high load for an extended period, the controller dynamically adjusts the oil supply frequency of the lubrication system using the energy efficiency optimization algorithm to reduce lubricant consumption while ensuring lubrication effectiveness.

[0162] It should be noted that those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the processor described above can be referred to the corresponding process in the method embodiments of the above embodiments, and will not be repeated here.

[0163] The embodiments of this application also provide a computer-readable storage medium storing a computer program, the computer program including program instructions, and the processor executing the program instructions to implement the steps of the driving method for the high-rigidity compact linear module of the embedded integrated guide mechanism provided in the above embodiments of this application.

[0164] The computer-readable storage medium may be an internal storage unit of the controller as described in the foregoing embodiments, such as the hard disk or memory of the controller. Alternatively, the computer-readable storage medium may be an external storage device of the controller, such as a plug-in hard disk, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card.

[0165] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A driving method for a high-rigidity, compact linear module with an embedded integrated guiding mechanism, characterized in that, A high-rigidity, compact linear module applied to an embedded integrated guiding mechanism, the high-rigidity, compact linear module comprising an aluminum alloy body, steel raceways, a ball screw, a steel slide, a motor, and a controller; the method includes: The steel raceway is embedded inside the aluminum alloy body as a guide mechanism, and the steel slide block contacts the steel raceway through rolling elements; The ball screw is driven to rotate, causing the ball nut of the steel slide to drive the steel slide to move along the length of the aluminum alloy body. During the movement, the corresponding rolling element rolls along the steel raceway to achieve guidance. The steel raceway, ball screw, and steel slide are enclosed inside the aluminum alloy body by a sealing structure, forming a fully sealed transmission environment. A motor stator is installed inside the aluminum alloy body, and a mover assembly is integrated into the steel slide. The steel slide is driven to move by electromagnetic force, and the steel raceway operates independently as a guide mechanism. The steel raceway is embedded in a preset cavity of the aluminum alloy body by interference fit or bolt fixation. The rolling elements at the bottom of the steel slide are balls or rollers, forming a rolling friction pair with the steel raceway. The sealing structure includes an end cap seal, a slide lip seal ring, and a closed cavity of the aluminum alloy body. A lubrication channel runs through the aluminum alloy body, providing lubrication medium to the steel raceway and the ball screw. By integrating a six-dimensional force sensor in the working area of ​​the linear module and combining it with an adaptive impedance control algorithm, a safe force control response is achieved during human-machine contact. By installing a six-dimensional force sensor at the front end of the steel slide, the impedance control model defines the desired stiffness and desired damping, calculates the position correction based on the contact force, and achieves compliant movement through position loop compensation.

2. The method according to claim 1, characterized in that, The steel raceway is embedded inside the aluminum alloy body as a guiding mechanism, and the steel slide contacts the steel raceway through rolling elements, including: A rectangular or arc-shaped cavity matching the shape of the steel raceway is pre-set inside the aluminum alloy body, and the steel raceway is fixed to the inner wall of the cavity by interference fit or bolts; A groove is machined at the bottom of the steel slide block to mate with the steel raceway. The rolling element is installed in the groove so that the outer surface of the rolling element contacts the raceway surface of the steel raceway, forming a rolling friction guide pair.

3. The method according to claim 1, characterized in that, The process of driving the ball screw to rotate, causing the ball nut of the steel slide to drive the steel slide to move along the length of the aluminum alloy body, includes: The controller receives external motion commands, controls the motor to start and output rotational power; The motor is connected to one end of the ball screw via a coupling, driving the ball screw to rotate around its own axis; The ball nut at the bottom of the steel slide is threaded with the ball screw, converting the rotational motion of the ball screw into the linear motion of the steel slide.

4. The method according to claim 2, characterized in that, During the movement, the corresponding rolling element rolls along the steel raceway to achieve guidance, including: When the steel slide block moves linearly, the rolling element rolls without slipping on the raceway surface of the steel raceway, while bearing the radial load and axial load of the steel slide block. The uniform rolling of the rolling elements constrains the movement direction of the steel slide block, thereby controlling the linear motion deviation of the steel slide block within a preset range.

5. The method according to claim 1, characterized in that, The steel raceway, ball screw, and steel slide are enclosed within the aluminum alloy body by a sealing structure to form a fully sealed transmission environment, including: End cap seals are installed on both ends of the aluminum alloy body, and the end cap seals are sealed to the end faces of the aluminum alloy body by sealing rings or sealant. A lip sealing ring is provided at the contact point between the steel slide and the aluminum alloy body. The lip of the lip sealing ring is in close contact with the inner wall of the aluminum alloy body to prevent external dust and liquid from entering the interior of the aluminum alloy body. Lubricating grease or oil is periodically injected into the enclosed cavity through the lubrication channel to lubricate the contact surfaces of the rolling elements and the steel raceway, as well as the ball nut and the ball screw.

6. The method according to claim 1, characterized in that, The motor stator is installed within the aluminum alloy body, and the steel slide integrates a mover assembly. The steel slide is driven to move by electromagnetic force, and the steel raceway operates independently as a guide mechanism. A mounting groove is pre-set on the bottom or side of the aluminum alloy body, and the motor stator is fixed in the mounting groove, with the electromagnetic induction surface of the stator facing the steel slide. At the bottom of the steel slide, a mover core and coil assembly that cooperate with the motor stator are integrated. The controller outputs alternating current to the coil assembly to generate electromagnetic thrust to drive the steel slide to move. When the steel slide moves, the relationship between the rolling element and the steel raceway remains unchanged, and it independently undertakes the guiding function.

7. The method according to claim 1, characterized in that, The controller has a built-in motion control algorithm, and the method further includes: The controller acquires the real-time position signal, speed signal, and load signal of the linear module. The position signal is acquired by a grating ruler or encoder installed on the aluminum alloy body, and the load signal is acquired by a pressure sensor on the steel slide. Based on the real-time position signal, speed signal and load signal, the drive current of the motor or the output power of the motor is adjusted by a preset adaptive control algorithm so that the movement speed and acceleration of the steel slide match the current load state. When the motion error of the steel slide exceeds a preset threshold, the controller automatically triggers an error compensation algorithm to correct the motion trajectory by fine-tuning the pulse frequency or magnetic field strength of the motor.

8. The method according to claim 7, characterized in that, The controller has a built-in fault diagnosis algorithm, and the method further includes: The contact noise signal between the rolling element and the steel raceway is monitored in real time, and the noise signal is collected by a vibration sensor installed on the aluminum alloy body. When the amplitude or frequency of the noise signal fluctuates abnormally, the controller uses a fault diagnosis algorithm to identify whether there are faults such as rolling element wear, lubrication failure, or steel raceway deformation, and generates corresponding fault codes. Based on the fault code, the controller sends a warning message to an external terminal and automatically adjusts the operating parameters of the linear module or triggers a shutdown protection mechanism.

9. The method according to claim 7, characterized in that, The controller has a built-in energy efficiency optimization algorithm, and the method further includes: Based on the historical operating data and current operating conditions of the linear module, the optimal driving parameters of the motor or motor are calculated by the energy efficiency optimization algorithm. The driving parameters include voltage, current, pulse frequency or magnetic field strength. After the steel slide is positioned, the controller automatically switches to a low-power standby mode while maintaining the preload between the rolling element and the steel raceway to ensure motion accuracy when restarting. When the linear module is detected to be operating under high load for an extended period of time, the controller dynamically adjusts the oil supply frequency of the lubrication system through the energy efficiency optimization algorithm, thereby reducing lubricant consumption while ensuring lubrication effectiveness.

10. A high-rigidity, compact linear module with an embedded integrated guiding mechanism, characterized in that, It includes an aluminum alloy body, steel raceways, ball screws, steel slides, a motor, and a controller; The controller includes a memory and a processor; the memory is used to store a computer program; the processor is used to execute the computer program and, when executing the computer program, implement the method as described in any one of claims 1-9.

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