Laser non-contact valve core displacement measurement embedded system and operation method thereof

Abstract

The invention provides a laser non-contact type valve element displacement measurement embedded system and an operation method thereof, relates to the technical field of non-contact type displacement measurement and embedded control, and aims to solve the problems that contact type measurement is easy to wear, clamping errors exist, valve element movement is interfered, and measurement accuracy is high. And a non-contact scheme is poor in interface compatibility, single in function and difficult to meet the requirements of real-time performance and measurement-control integration of an industrial site. The laser displacement sensor, the real-time controller and the multi-channel I / O board card are integrated, LabVIEW software is matched, valve element displacement non-contact collection and analog / digital signal output and debugging are achieved, contact type measurement defects are avoided, and the requirements for industrial field measurement and control integration and high stability are met. According to laser non-contact measurement, contact abrasion, errors and valve element interference are avoided, and the measurement precision is improved; the integrated measurement and control function solves the problem of poor interface compatibility; modularization is easy to maintain and extensible, and the detection efficiency of the precision executing mechanism is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of non-contact displacement measurement and embedded control technology, in particular to a laser non-contact spool displacement measurement embedded system and a running method thereof. BACKGROUND

[0002] Spool displacement is an important index for performance evaluation and online detection of precision actuators such as hydraulic servo valves and proportional valves. Traditional displacement measurement mostly uses contact displacement sensors or mechanical limiters. Such contact schemes are prone to friction and wear, clamping errors and mechanical nonlinearities during long-term operation, and may interfere with the motion characteristics of the spool body, affecting the measurement accuracy and repeatability. In addition, traditional field test systems are usually composed of discrete devices and manual configuration, lacking unified real-time acquisition, synchronous triggering and industrial-grade signal isolation, making it difficult to meet the stability and maintainability requirements of high-precision, long-term online testing.

[0003] Existing non-contact measurement schemes (such as laser displacement sensors) have advantages in precision, but still face several problems in engineering applications: first, there are interface compatibility and synchronous sampling problems between the sensor and the upper data acquisition system; second, industrial sites often require analog and digital outputs / control to drive the measured mechanism, while existing demonstration software or examples often only implement single functions, lacking modular and expandable embedded acquisition and output platforms; third, when analog or pulse signals need to be output to external drivers for feedback comparison, real-time and low-latency processing are required, and ordinary PC solutions are difficult to meet the requirements of real-time, reliability and ease of use in industrial sites.

[0004] Based on the above technical problems, there is an urgent need for an integrated non-contact displacement measurement system for engineering applications: it can use the high-precision characteristics of laser sensors to complete real-time acquisition and recording of spool displacement, and provide industrial-grade embedded real-time control and multi-channel I / O (including analog output and digital pulse output) capabilities to realize measurement, debugging and subsequent closed-loop control expansion, thereby improving the efficiency and reliability of field testing. SUMMARY

[0005] The application provides a laser non-contact valve core displacement measurement embedded system and an operation method thereof.

[0006] A six-degree-of-freedom mechanical structure comprises a Z-axis shear type manual lifting platform, an adapter plate, an XYR three-axis displacement platform and an L-shaped mounting plate, and the L-shaped mounting plate, the XYR three-axis displacement platform, the adapter plate and the Z-axis shear type manual lifting platform are sequentially fixed and connected from top to bottom.

[0007] A laser non-contact valve core displacement measurement embedded system, characterized in that it comprises a laser displacement sensor, a sensor controller, a real-time controller, an analog input board card, an analog output board card, a digital I / O board card, a six-degree-of-freedom mechanical structure, a guide rail type switching power supply and an upper computer. The laser displacement sensor is fixedly connected with the six-degree-of-freedom mechanical structure through a threaded fastener, the signal output end of the laser displacement sensor is connected with the signal input end of the sensor controller through a special cable, and the analog output end of the sensor controller is connected with the signal input end of the analog input board card through a differential adaptive cable. The analog input board card, the analog output board card and the digital I / O board card are respectively connected with the board card interface of the real-time controller through slots. The power output end of the guide rail type switching power supply is connected with the power input end of the sensor controller and the power input end of the real-time controller through power supply cables. The communication port of the real-time controller is connected with the communication port of the upper computer through a communication cable. The common ground end of the guide rail type switching power supply, the common ground end of the sensor controller and the common ground end of the real-time controller are connected with each other through wires.

[0008] Further, the laser displacement sensor is used for non-contact acquisition of a valve core linear displacement physical signal. The sensor controller is used for receiving the valve core linear displacement physical signal output by the laser displacement sensor, amplifying, filtering and analog-digital conversion processing the valve core linear displacement physical signal, and outputting a standard analog displacement signal. The real-time controller is configured to receive signals transmitted by the analog input board card, output control instructions to the analog output board card and the digital I / O board card, and simultaneously realize industrial-grade real-time data processing and instruction response. The analog input board card is configured to receive standard analog displacement signals output by the sensor controller, convert the standard analog displacement signals into digital signals, and transmit the digital signals to the real-time controller. The analog output board card is configured to receive control instructions from the real-time controller, and output analog waveform signals of a preset type to drive external execution components. The digital I / O board card is configured to receive control instructions from the real-time controller, output digital pulse signals, or collect digital feedback signals from the external execution components and transmit the digital feedback signals to the real-time controller. The six-degree-of-freedom mechanical structure is configured to fix the laser displacement sensor, and precisely align the laser displacement sensor with a valve core measurement area through Z-axis height adjustment, X / Y-axis plane position fine adjustment, and R-axis angle fine adjustment. The guide rail type switching power supply is configured to provide stable industrial-grade power supply for the sensor controller and the real-time controller. The upper computer is configured to configure system working parameters, display collected data and output signal waveforms in real time, store measurement data, and realize system debugging operations.

[0009] Further, the external execution components include a motor driver and a motor, the analog waveform signals output by the analog output board card are sine waves, square waves, triangular waves, sawtooth waves, or step waves, and are used to drive the motor driver to control the motor to run.

[0010] Further, the analog output board card supports two working mode switching: when the manual control function is turned on, step signals with adjustable voltage values are output; when the manual control function is turned off, sine waves, square waves, triangular waves, or sawtooth waves with adjustable frequency, amplitude, and duty cycle are output; and the 8-way bidirectional channels of the digital I / O board card are configured in groups of 4-bit increments by the upper computer, in which the first group of 4-way channels is configured in a digital output mode, and the second group of 4-way channels is configured in a digital input mode, and are used to output control pulses and collect feedback pulses, respectively.

[0011] Further, the real-time controller, the sensor controller, the analog input board card, the analog output board card, and the digital I / O board card are integrated in a cabinet made of cold-rolled steel, the cabinet has an IP20 protection level, and the surface of the cabinet is subjected to anti-corrosion and anti-rust treatment.

[0012] A running method of a laser non-contact valve core displacement measurement embedded system, based on the above laser non-contact valve core displacement measurement embedded system, includes the following steps: S1, turn on the guide rail type switching power supply, power supply for sensor controller and real-time controller, sensor controller first power on to enter the initial setting interface, complete the output polarity selection and analog output type configuration; S2, through the project program of LabVIEW graphical programming software running on the host computer, connect the real-time controller, configure the acquisition channel, sampling frequency and sampling point number of analog input board card, configure the waveform type and parameters of analog output board card, configure the pulse output / input mode of digital I / O board card; S3, the real-time controller receives the configuration instruction of the host computer, controls the analog input board card to collect the valve core displacement analog signal output by the sensor controller, and controls the analog output board card to output the preset analog waveform signal and the digital I / O board card to output the digital pulse signal to drive the external execution component; S4, the host computer displays the collected valve core displacement data, analog output waveform, frequency and duty cycle of digital pulse in real time through LabVIEW program, stores the collected voltage data as a specified format file, and monitors and adjusts the system running state through software debugging function.

[0013] Further, in S2, the waveform parameter configuration of the analog output board card includes frequency, amplitude and duty cycle, and the "manual control" and "automatic waveform output" modes are switched through the LabVIEW program: in the "manual control" mode, the output voltage value adjustable step signal, in the "automatic waveform output" mode, output sine wave, square wave, triangle wave or sawtooth wave; In S4, the specified format file stored by the host computer is TDMS format, and the voltage data stored needs to be multiplied by a preset proportion coefficient through the LabVIEW program to convert into valve core displacement value; at the same time, the LabVIEW program supports breakpoint setting, single step execution and animation display function of data and subprogram result, which is used for program debugging and fault troubleshooting in the system running process.

[0014] A storage medium, the storage medium has a computer program stored thereon, the computer program is executed by a processor to realize the operation method of the laser non-contact valve core displacement measurement embedded system described above.

[0015] A computer device, comprising: a memory, a processor and a computer program stored on the memory and executable on the processor, the processor executes the program to realize the operation method of the laser non-contact valve core displacement measurement embedded system described above.

[0016] Compared with existing technologies, the present invention achieves significant beneficial effects through the above-mentioned technical solutions: The laser non-contact valve core displacement measurement embedded system and its operation method of the present invention effectively avoid the problems of friction and wear, clamping errors, and valve core motion interference caused by traditional contact measurement by adopting a laser non-contact measurement method. Combining the triangulation measurement principle with a high-precision mechanical fine-tuning structure, the accuracy and repeatability of valve core displacement measurement are greatly improved. By integrating an embedded real-time controller, multi-channel I / O boards, and LabVIEW graphical software, an integrated industrial-grade solution of "measurement-control-interaction" is constructed. This not only solves the defects of poor interface compatibility and single function of existing non-contact solutions, but also realizes multi-functional integration such as parameter visualization configuration, real-time data display, analog / digital control signal output, and data storage, meeting the real-time and convenient debugging requirements of industrial sites. The modular design of the system not only facilitates on-site installation and maintenance, but also reserves a closed-loop control expansion interface, which can be quickly adapted to subsequent industrial automation closed-loop control scenarios. At the same time, through common ground design, industrial-grade power supply, and protective cabinet configuration, the operational stability and reliability in complex industrial environments are enhanced, significantly improving the efficiency and engineering practicality of precision actuator performance testing. Attached Figure Description

[0017] Figure 1 This is a system block diagram of an embedded system for laser non-contact valve core displacement measurement according to the present invention. Figure 2 This is a three-dimensional schematic diagram of a six-degree-of-freedom mechanical structure according to the present invention; Figure 3 Create an interface for the project; Figure 4 It provides a complete LabVIEW program interface for analog signal acquisition, analog signal output, digital pulse output, and digital pulse input.

[0018] Among them, 1 is a Z-axis scissor-type manual lifting platform; 2 is an adapter plate; 3 is an XYR three-axis displacement platform; and 4 is an L-shaped mounting plate. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Reference Figure 2As shown, a six-degree-of-freedom mechanical structure includes a Z-axis scissor-type manual lifting platform 1, a transition plate 2, an XYR three-axis displacement platform 3, and an L-shaped mounting plate 4. The L-shaped mounting plate 4, the XYR three-axis displacement platform 3, the transition plate 2, and the Z-axis scissor-type manual lifting platform 1 are fixedly connected from top to bottom.

[0021] Specifically, adapter plate 2 is fixed to the Z-axis scissor-type manual lifting platform 1, and XYR three-axis displacement platform 3 is fixed to adapter plate 2. An L-shaped mounting plate 4 is then installed on the XYR three-axis displacement platform 3 to achieve the fixation of the laser displacement sensor and high-precision fine-tuning of the six degrees of freedom. Adapter plate 2 is a 40 / 60 model adapter plate; the L-shaped mounting plate 4 is fixedly connected to the XYR three-axis displacement platform 3 using M3 screws, with the tightening torque controlled at 1.2 Nm (12 kgf-cm) or lower to avoid over-tightening and damage to components.

[0022] Z-axis scissor-type manual lifting table 1 can be used for lifting and adjusting with large stroke, variable quantity, and large load. It has a multi-hole design on both the upper and lower sides, making it highly adaptable and suitable for mounting. The lifting stroke is 100mm, the lowering stroke is 10mm, and the total stroke is 110mm. Its performance indicators are as follows: table size 210mm×150mm, drive method is precision-ground lead screw drive, minimum adjustment amount is 10μm, load capacity is 30kg, and self-weight is 3.8kg.

[0023] The XYR three-axis displacement platform 3 is a high-precision displacement platform with accurate readings, convenient fine-tuning, and stable performance. Its performance indicators are as follows: platform size 40mm×40mm, weight 0.37kg, XY axis travel ±6.5mm, XY axis minimum scale 0.01mm, accuracy 0.02mm, R axis travel 360-degree coarse adjustment, ±5-degree fine adjustment, R axis minimum scale 10′ (angular minute), parallelism 0.02mm. Fine-tuning can ensure that the laser displacement sensor is aligned with the valve core measurement area.

[0024] Reference Figure 1 As shown, an embedded system for laser non-contact valve core displacement measurement is characterized by comprising: a laser displacement sensor, a sensor controller, a real-time controller, an analog input board, an analog output board, a digital I / O board, a six-degree-of-freedom mechanical structure, a rail-mounted switching power supply, and a host computer. The laser displacement sensor is fixedly connected to the six-degree-of-freedom mechanical structure via threaded fasteners. The signal output terminal of the laser displacement sensor is connected to the signal input terminal of the sensor controller via a dedicated cable. The analog output terminal of the sensor controller is connected to the signal input terminal of the analog input board via a differential adapter cable. Analog input boards, analog output boards, and digital I / O boards are connected to the real-time controller's board interface via slots. The power output terminal of the DIN rail type switching power supply is connected to the power input terminal of the sensor controller and the power input terminal of the real-time controller respectively via power supply cables. The communication port of the real-time controller is connected to the communication port of the host computer via a communication cable; The common ground terminals of the rail-mounted switching power supply, the sensor controller, and the real-time controller are interconnected by wires.

[0025] Specifically, this system designs an embedded system for laser non-contact valve core displacement measurement, including: a laser displacement sensor, a sensor controller, a real-time controller, an analog input board, an analog output board, a digital I / O board, a six-degree-of-freedom mechanical structure, a rail-mounted switching power supply, and a host computer. The system achieves stable acquisition of laser displacement signals, analog waveform output debugging (sine wave, square wave, triangle wave, etc.), and digital pulse output and input functions. The analog and digital outputs can be used to drive external actuator testing. Currently, it is in the open-loop testing phase; feedback acquisition and closed-loop control from external actuators are planned for future expansion. Using this system, modular and scalable industrial-grade real-time data acquisition and signal output can be achieved, facilitating on-site debugging and subsequent integrated closed-loop control. It has the advantages of easy integration, strong real-time performance, and high engineering feasibility. Connection of laser displacement sensor to six-degree-of-freedom mechanical structure: The laser displacement sensor is installed using a dedicated mounting structure (L-shaped mounting plate 4) for the six-degree-of-freedom mechanical structure. In this embodiment, the laser displacement sensor is IL-300, with a reference distance of 300mm, a measurement distance of 160~450mm, a sampling period selectable of 0.33 / 1 / 2 / 5ms, a repeatability of 30μm, a red semiconductor laser light source, and geometric dimensions of 50.7×66×27.2mm. It has high shock resistance and anti-interference capabilities, and is fully adapted to the high-precision measurement requirements of valve core displacement.

[0026] Connection between the laser displacement sensor and the sensor controller: Connect the laser displacement sensor and the sensor controller (in this embodiment, the sensor controller is IL-1000) using the OP-87056 dedicated cable. The connection steps are as follows: First, align the arrow on the dedicated cable connector with the laser displacement sensor probe cable connector and insert it, then tighten the threads on the connector; next, remove the locking cover of the sensor controller connector, insert the other end of the dedicated cable into the sensor controller connector until you hear a "click", and finally install the locking cover to fix the cable and ensure stable signal transmission.

[0027] Connection between the sensor controller and the analog input board: The analog output signal terminal (OUT+) and ground terminal (OUT-) of the sensor controller (IL-1000) are connected to the corresponding channel of the analog input board (NI9205 is used in this embodiment).

[0028] Connection of analog input board, analog output board, digital I / O board and real-time controller: The analog input board (NI9205) is a 32-channel single-ended or 16-channel differential analog input module with a sampling rate of 250kS / s per channel, 16-bit precision, and supports four programmable input ranges; the analog output board (NI9263 in this embodiment) is a ±10V, 16-bit analog voltage output module that can connect to 4 analog output channels and has overvoltage protection and short-circuit protection functions; the digital I / O board (NI9401 in this embodiment) is a 5V / TTL, 8-channel bidirectional digital I / O module with a digital signal update rate of 100ns, and can realize 4-bit incremental input or output; all three are supporting boards for the real-time controller (cRIO-9040 in this embodiment) and are connected to the real-time controller's board interface through slots. The real-time controller (cRIO-9040) features a built-in 1.30GHz dual-core CPU, 2GB DRAM, and 4GB storage. It has four slots, can operate normally in the range of -20~55℃, and has two Ethernet ports to support high-speed data transmission and programming communication.

[0029] Power supply connection for DIN rail type switching power supply: The DIN rail type switching power supply is compatible with a wide voltage input of 100-240VAC 2.0A 50 / 60Hz, with an output of 24V 3.2A and a rated power of 75W. Its power output terminal is connected to the power input terminal of the sensor controller (IL-1000) and the power input terminal of the real-time controller (cRIO-9040) via power supply cables, respectively (the real-time controller requires an external power supply of 9V~30V), providing stable industrial-grade power to both. After filtering and conditioning the power supply, the real-time controller indirectly supplies power to the analog input board, analog output board, and digital I / O board, ensuring the voltage stability of each module.

[0030] Connection between the real-time controller and the host computer: The real-time controller (cRIO-9040) is connected to the host computer via an Ethernet cable. The host computer is an Advantech 610L industrial PC (Windows 10 Professional 64-bit operating system, Intel Core i7-8700@3.20GHz six-core processor, 8GB Apacer DDR4 2400MHz memory, and a 512GB solid-state drive). The host computer runs the LabVIEW-based project program "cRIO acquisition.lvproj". After opening the project file, right-click the device name "NI-cRIO-9040-021722CC" and execute the "connect" operation. After successful deployment, you can view the analog input board (NI9205), analog output board (NI9263), and digital I / O board (NI9401) in the real-time resource list. After confirming the recognition, click the vi program to open the interface and run it.

[0031] Rack Integration Details: The real-time controller, sensor controller, analog input board, analog output board, and digital I / O board are integrated into a cold-rolled steel rack. The rack measures 550mm (length) × 400mm (depth) × 600mm (height). It features side ventilation vents for natural heat dissipation. The rack has an IP20 protection rating and its surface is treated with anti-corrosion and anti-rust coatings, making it suitable for complex industrial environments with dust and mild corrosive gases, protecting internal components from external interference.

[0032] In this embodiment, the laser displacement sensor is IL-300, the sensor controller is IL-1000, the dedicated cable between the laser displacement sensor and the sensor controller is OP-87056, the real-time controller is cRIO-9040, the analog input board is NI9205, the analog output board is NI9263, and the digital I / O board is NI9401.

[0033] Furthermore, the laser displacement sensor is used for non-contact acquisition of the physical signal of the linear displacement of the valve core; The sensor controller is used to receive the physical signal of the valve core linear displacement output by the laser displacement sensor, and after amplifying, filtering and analog-to-digital conversion of the physical signal of the valve core linear displacement, output a standard analog displacement signal. The sensor controller (IL-1000) supports the configuration of analog output type, specifically including five options: OFF, 0-5V, -5-5V, 1-5V, and 4-20mA. It can be selected according to the input range of the analog input board and the observation requirements. In this embodiment, the -5-5V output type is selected.

[0034] The real-time controller is used to receive signals transmitted from the analog input board, output control commands to the analog output board and the digital I / O board, and simultaneously realize industrial-grade real-time data processing and command response. The analog input board (NI9205) is used to receive the standard analog displacement signal output by the sensor controller, convert it into a digital signal, and then transmit it to the real-time controller. It supports single-ended or differential input modes. The differential mode can effectively reduce noise interference in the industrial field and improve measurement accuracy.

[0035] The analog output board (NI9263) is used to receive control commands from the real-time controller and output preset type analog waveform signals to drive external actuators; it has overvoltage and short-circuit protection functions to prevent damage to the board caused by abnormal external actuators.

[0036] The digital I / O board (NI9401) is used to receive control commands from the real-time controller and output digital pulse signals, or to acquire digital feedback signals from external actuators and transmit them to the real-time controller; the 100ns signal update rate ensures accurate transmission and feedback acquisition of high-speed pulses.

[0037] The six-degree-of-freedom mechanical structure is used to fix the laser displacement sensor, and through Z-axis height adjustment (Z-axis scissor-type manual lifting platform with a total stroke of 110mm), X / Y-axis plane position fine adjustment (XYR three-axis displacement platform XY-axis stroke ±6.5mm, accuracy 0.02mm), and R-axis angle fine adjustment (XYR three-axis displacement platform R-axis ±5 degrees fine adjustment, minimum scale 10′), the laser displacement sensor is precisely aligned with the valve core measurement area. The rail-mounted switching power supply is used to provide stable industrial-grade power to the sensor controller and real-time controller; it has a wide input voltage range to adapt to different field power environments, and a stable 24V output voltage to meet the power supply requirements of various components. The host computer is used to configure system operating parameters, display the acquired data and output signal waveforms in real time, store measurement data, and perform system debugging operations; the built-in LabVIEW software supports graphical programming, which facilitates parameter configuration and program debugging.

[0038] Furthermore, the external execution components include a motor driver and a motor. The analog waveform signal output by the analog output board is a sine wave, square wave, triangle wave, sawtooth wave, or step wave, which is used to drive the motor driver and thus control the operation of the motor.

[0039] Specifically, in industrial field testing, the system's analog and digital outputs need to drive specific external actuators to complete valve core-related testing tasks. These external actuators include a motor driver and a motor. The motor driver, as a signal conversion and power amplification component, receives the analog waveform signal output from the analog output board, converts it into a drive signal adapted to the motor, and then controls the motor's operation. The motor, as the final actuator, drives the valve core or valve core-related testing mechanism to move through its own movement, simulating the dynamic working state of the valve core in actual industrial scenarios, and providing test conditions for the laser displacement sensor to collect "valve core displacement data under working conditions".

[0040] The analog output board can output various preset types of analog waveform signals, including sine waves, square waves, triangle waves, sawtooth waves, and step waves. The output of these waveform signals needs to match the signal requirements of the external actuator (motor driver): Sine waves, square waves, triangle waves, and sawtooth waves are mainly used to simulate the periodic motion of the valve core (such as the reciprocating uniform motion of the valve core of a hydraulic servo valve). By adjusting the frequency, amplitude, and duty cycle of the waveform, the valve core motion state at different speeds and strokes can be simulated to test the accuracy of the laser displacement sensor in acquiring dynamic displacement. Step waves are mainly used to simulate sudden displacement changes of the valve core (such as the rapid start and stop of the valve core and position switching) to test the system's response speed and acquisition stability to transient displacement signals. The above-mentioned analog waveform signals are transmitted to the control input terminal of the motor driver through the designated channel of the analog output board (such as the first group of analog output channels). The motor driver adjusts the output power according to the parameters of the waveform signal to drive the motor to run according to the preset law, and finally realizes the test link of "analog waveform output → motor drive → valve core movement → displacement acquisition".

[0041] During system design, the output parameters of the analog output board must match the input specifications of the motor driver: the output voltage range of the analog output board is ±10V, which can cover the analog control signal input range of most industrial-grade motor drivers; at the same time, the parameters of the analog waveform (frequency, amplitude, duty cycle) can be adjusted in real time through the graphical programming software (LabVIEW) on the host computer, thereby flexibly controlling the motor speed, direction, and stroke to meet the testing requirements of different valve core models; in addition, during the debugging phase, the waveform output accuracy of the analog output board and the stability of the motor drive link can be verified by observing the actual motion state of the motor and the displacement data collected by the laser displacement sensor, ensuring the reliability of the test data.

[0042] Furthermore, the analog output board supports two working modes: when the manual control function is enabled, it outputs an adjustable step signal with adjustable voltage; when the manual control function is disabled, it outputs a sine wave, square wave, triangle wave, or sawtooth wave with adjustable frequency, amplitude, and duty cycle. The eight bidirectional channels of the digital I / O board are configured in 4-bit incremental groups by the host computer, wherein the first group of four channels is configured as digital output mode and the second group of four channels is configured as digital input mode, used to output control pulses and acquisition feedback pulses respectively.

[0043] Specifically, the analog output board supports two working modes: "manual control" and "automatic waveform output." Mode switching is achieved through the "manual control" function button in the graphical programming software (LabVIEW) interface of the host computer. The specific logic is as follows: "Manual Control" Mode: When the "Manual Control" function is enabled, the analog output board no longer outputs preset periodic waveforms (such as sine waves and triangular waves), but instead outputs a step signal with an adjustable voltage value. The operator can directly set the voltage value of the step signal through the host computer interface. The voltage adjustment range matches the output specifications of the analog output board (±10V). This mode is mainly used to test the response characteristics of external actuators (such as motor drivers) to fixed voltage signals, or to perform fixed position dwell tests on valve cores.

[0044] "Automatic Waveform Output" Mode: When the "Manual Control" function is turned off, the analog output board switches to automatic output mode, which can output sine waves, square waves, triangle waves, or sawtooth waves according to the parameters configured by the host computer. The frequency, amplitude, and duty cycle of the waveform can be adjusted in real time through the host computer interface. After the parameters are adjusted, the analog output board will immediately update the output waveform without restarting the system. This mode is mainly used to simulate the periodic movement of the valve core in actual working conditions and to test the continuous acquisition capability of the laser displacement sensor for dynamic displacement.

[0045] The digital I / O board has 8 bidirectional channels. The channel configuration is set in groups according to the "4-bit incremental" rule through the graphical programming software (LabVIEW) on the host computer. The specific configuration method and functions are as follows: Grouping rules: Divide the 8 bidirectional channels into two groups, each containing 4 channels; grouping configuration requires no hardware changes and can be completed only through software parameter settings. After configuration, the input / output attributes of the channels are fixed until the next reconfiguration.

[0046] The first group of 4 channels (digital output mode): This group of channels is configured in digital output mode. Its core function is to receive control commands issued by the real-time controller and output digital pulse signals. The output digital pulse signals can be directly transmitted to the pulse input terminal of the external actuator (such as the pulse control terminal of the motor driver) to realize the stepping motion control of the external actuator (such as the precise angle control of the motor). In this embodiment, the commonly used parameter configuration is a pulse frequency of 100Hz and a duty cycle of 0.5.

[0047] The second group of 4 channels (digital input mode): This group of channels is configured in digital input mode and is mainly used to collect digital signals fed back by external actuators (such as motor running status signals and fault alarm signals). The collected digital feedback signals are transmitted to the real-time controller in real time. The real-time controller judges the working status of the external actuators based on the feedback signals. If an abnormality is found (such as the motor stopping), the output command can be adjusted in time to ensure the safety and stability of the system testing process.

[0048] Furthermore, the real-time controller, sensor controller, analog input board, analog output board, and digital I / O board are integrated into a cabinet made of cold-rolled steel plate. The cabinet has an IP20 protection rating and its surface is treated with anti-corrosion and anti-rust treatment.

[0049] Specifically, to ensure the safe and stable operation of the real-time controller, sensor controller, analog input board, analog output board, and digital I / O board in an industrial environment, these components need to be integrated into a dedicated cabinet. The design and integration logic of the cabinet is as follows: The cabinet of this invention is made of cold-rolled steel plate with a smooth and flat surface after special treatment. It has anti-corrosion and anti-rust functions and can adapt to complex environments such as dust and slightly corrosive gases that may exist in industrial sites. At the same time, the cabinet has an IP20 protection level, which can effectively block the intrusion of solid foreign objects and protect the internal electrical components from interference from external foreign objects, thus meeting the basic protection requirements of industrial equipment.

[0050] The cabinet has heat dissipation vents on the side to dissipate internal heat through natural ventilation. This design ensures that the heat generated by the real-time controller, various boards and other components during operation is dissipated in a timely manner, avoiding performance degradation or failure of components due to high temperature, and ensuring the stability of the system during long-term operation in industrial sites (compatible with the operating temperature range of the real-time controller from -20 to 55℃).

[0051] The cabinet measures 550mm in length, 400mm in depth, and 600mm in height. Its internal space can accommodate the installation layout of real-time controllers, sensor controllers, analog input boards, analog output boards, and digital I / O boards. During integration, the installation sequence must be planned according to the size and interface position of each component to ensure that the wiring between components (such as the connection between the board and the slot of the real-time controller, and the power supply connection between the sensor controller and the power supply) is neat and orderly. At the same time, sufficient operating space should be reserved to facilitate subsequent system maintenance and board replacement.

[0052] After the components are integrated into the cabinet, they form a modular embedded system unit, which not only reduces the direct impact of the external environment on the components, but also facilitates on-site handling and installation. In addition, the fully enclosed frame structure of the cabinet can reduce the impact of external electromagnetic interference on internal signals, further ensuring the accuracy of the analog input board's signal acquisition and the stability of the digital I / O board's signal transmission, meeting the anti-interference requirements of industrial-grade equipment.

[0053] Reference Figure 3 , Figure 4 As shown, an operation method for a laser non-contact valve core displacement measurement embedded system, based on the aforementioned laser non-contact valve core displacement measurement embedded system, includes the following steps: S1. Connect the rail-mounted switching power supply to power the sensor controller and the real-time controller. After the sensor controller is powered on for the first time, it enters the initial setting interface and completes the output polarity selection and analog output type configuration. Specifically, in S1, the rail-mounted switching power supply is connected. The output of this power supply powers the sensor controller (IL-1000) and the real-time controller (cRIO-9040) via power cables (the real-time controller requires an external power supply of 9V~30V; the rail-mounted switching power supply has an output voltage of 24V and an output current of 3.2A, which meets the power supply requirements). After the sensor controller is powered on for the first time, an initial setting interface will appear after a few seconds. Two core configurations need to be completed on this interface: First, select the polarity of the judgment output and edge detection output (the controller supports both NPN and PNP output modes, with NPN output polarity selected by default); Second, select the analog output type (the controller provides five output modes: OFF, 0-5V, -5-5V, 1-5V, and 4-20mA. Considering the allowable input range of the analog input board and the ease of observation, the -5-5V analog output type is usually selected). After the initial configuration is completed, the sensor controller enters standby mode and can receive and process signals from the laser displacement sensor.

[0054] S2. By running the project program of LabVIEW graphical programming software on the host computer, connect the real-time controller, configure the acquisition channel, sampling frequency and number of sampling points of the analog input board, configure the waveform type and parameters of the analog output board, and configure the pulse output / input mode of the digital I / O board. Specifically, in S2, the host computer runs the LabVIEW-based project program "cRIO acquisition.lvproj". Right-clicking the device name of the real-time controller (cRIO-9040) "NI-cRIO-9040-021722CC" and executing the "Connect" operation, after successful deployment, the host computer interface will display the rack resources of the real-time controller. Confirm that the analog input board (NI9205), analog output board (NI9263), and digital I / O board (NI9401) are all recognized. Then, configure the parameters: for the analog input board, select the acquisition channel (e.g., Mod1 / ai0, Mod1 / ai1, etc.) and set the sampling frequency (default 10). The configuration options are as follows: 1) Select the frequency (00Hz) and number of sampling points (default 1000 points), and configure the terminal block to the default adapter mode; for analog output boards, select the waveform output channel (e.g., Mod2 / ao0), set the waveform type (sine wave, square wave, triangle wave, sawtooth wave, or step wave) and corresponding parameters (common debugging frequency 10Hz, amplitude 1V, duty cycle 50%, which can be adjusted according to the requirements of external execution components); for digital I / O boards, select the pulse output / input mode (e.g., set the pulse output channel to Mod3 / PFI0, and the pulse input channel to Mod1 / PFI0); all parameter configurations are completed through the visual controls of the LabVIEW interface on the host computer, without the need to manually modify hardware parameters.

[0055] S3. The real-time controller receives configuration instructions from the host computer, controls the analog input board to collect the valve core displacement analog signal output by the sensor controller, and simultaneously controls the analog output board to output a preset analog waveform signal and the digital I / O board to output a digital pulse signal to drive external actuators. Specifically, in S3, after receiving the configuration command from the host computer, the real-time controller controls the analog input board (NI9205) to acquire the valve core displacement analog signal output by the sensor controller (IL-1000). The analog input board receives the signal through differential measurement configuration (which can improve accuracy and reduce noise), converts the analog signal into a digital signal, and transmits it to the real-time controller. On the other hand, according to the configuration command, the real-time controller controls the analog output board (NI9263) to output a preset type of analog waveform signal and controls the digital I / O board (NI9401) to output a digital pulse signal (such as 100Hz, 0.5 duty cycle). Both the analog waveform signal and the digital pulse signal are transmitted to external actuators (such as motor drivers) to drive the external actuators and provide a dynamic test scenario for valve core displacement measurement (the system is currently in the open-loop test stage and has not yet connected to the feedback signal of the external actuators).

[0056] S4. The host computer uses LabVIEW to display the collected valve core displacement data, analog output waveform, and frequency and duty cycle of digital pulses in real time. It stores the collected voltage data in a specified format file and monitors and adjusts the system operation status through software debugging functions.

[0057] Specifically, in S4, the data display includes: real-time display of the acquired valve core displacement data (presented as curves or numerical values) on the host computer interface, the output signal waveform of the analog output board, and the frequency and duty cycle of the digital pulses, facilitating intuitive observation of the system's operating status by operators; data storage: when the host computer stores the acquired data, the specified file format is TDMS. The storage operation must be completed in the "Sampling Record Settings" area of ​​the LabVIEW interface. After selecting "Record Mode," the system automatically writes the voltage data acquired by the analog input board into the TDMS file. The file path can be preset through interface controls for easy subsequent data retrieval and analysis; simultaneously, since the raw data acquired by the analog input board is voltage value, it needs to be converted into stored voltage values ​​using the LabVIEW program. The pressure data is multiplied by a preset proportional coefficient to convert it into a valve core displacement value. This proportional coefficient must match the signal characteristics of the laser displacement sensor (IL-300) (e.g., the sensor output -5-5V corresponds to a specific displacement range) to ensure accurate displacement value calculation. System debugging: Utilize LabVIEW's built-in debugging functions, including breakpoint setting (setting breakpoints at key nodes such as data acquisition and signal output to pause program execution and observe intermediate data), single-step execution (running the program step by step to troubleshoot logical errors), and animation display (showing the acquired data waveform, subroutine execution results such as waveform generation process, and signal transmission links in animated form), intuitively presenting the system's operating status and facilitating operators to quickly locate faults (such as unresponsive boards, interrupted data transmission, etc.).

[0058] Furthermore, in S2, the waveform parameters of the analog output board can be configured, including frequency, amplitude and duty cycle, and the two modes of "manual control" and "automatic waveform output" can be switched through the LabVIEW program: in the "manual control" mode, the output voltage value is an adjustable step signal, and in the "automatic waveform output" mode, the output is a sine wave, square wave, triangle wave or sawtooth wave. In S4, the specified format file stored by the host computer is TDMS format, and the stored voltage data needs to be multiplied by a preset scaling factor through the LabVIEW program to convert it into valve core displacement value; at the same time, the LabVIEW program supports breakpoint setting, single-step execution and animation display of data and subroutine results, which are used for program debugging and troubleshooting during system operation.

[0059] Specifically, in S2, when configuring the analog output board parameters through the LabVIEW program on the host computer, the waveform parameters need to be configured with frequency, amplitude, and duty cycle, and these parameters must match the hardware specifications of the analog output board (NI9263) (output voltage range ±10V). The "Manual Control" button in the LabVIEW program interface allows switching between "Manual Control" and "Automatic Waveform Output" modes without requiring a system restart: When "Manual Control" mode is enabled, the analog output board stops outputting periodic waveforms and instead outputs an adjustable step signal. The voltage value is set directly through the "Manual Voltage Control" control on the host computer interface. The adjustment range is adapted to the output specifications of the board. It is mainly used to verify whether the response of the external actuator to the fixed voltage signal is normal. When the "Automatic Waveform Output" mode is turned on (i.e. "Manual Control" is turned off), the analog output board outputs sine waves, square waves, triangle waves or sawtooth waves according to the configuration. Before outputting, the waveform type must be selected in the "Waveform Output Settings" area of ​​the LabVIEW interface, and the corresponding frequency, amplitude and duty cycle parameters must be entered. After the parameters are confirmed, the board immediately outputs the preset waveform to simulate the dynamic movement of the valve core.

[0060] In S4, the host computer completes data processing and system debugging through LabVIEW programs. The data storage format is TDMS, which facilitates subsequent data analysis. When converting voltage data into displacement values, a proportional coefficient needs to be preset based on the signal characteristics of the laser displacement sensor to ensure conversion accuracy. LabVIEW's debugging function can efficiently troubleshoot system malfunctions and ensure the stability of the testing process.

[0061] A storage medium storing a computer program, which, when executed by a processor, implements the above-described operation method of the laser non-contact valve core displacement measurement embedded system.

[0062] Specifically, the storage medium of this invention stores a computer program capable of executing the above-described operating method, enabling the stable solidification and convenient reuse of the operating logic of the laser non-contact valve core displacement measurement embedded system. This avoids errors and efficiency losses caused by repeated program writing, and ensures that the complete process of "system power-on initialization - host computer parameter configuration - displacement acquisition and signal output - data processing and interaction" can be accurately reproduced when deployed on different compatible computer devices. It also includes detailed functions such as mode switching of the analog output board in step S2, voltage data to displacement value conversion, TDMS format storage, and LabVIEW debugging in step S4. Furthermore, it ensures that the system can always avoid the wear and interference problems of traditional contact measurement in a non-contact manner, stably realizing integrated industrial-grade applications of "measurement-control-interaction," improving the consistency, maintainability, and reliability of field testing, reducing the risk of test failures due to program instability, and providing a stable program carrier for high-precision valve core displacement measurement and external actuator drive control.

[0063] A computer device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the above-described method for operating the laser non-contact valve core displacement measurement embedded system.

[0064] Specifically, the computer device of this invention uses a memory to store the corresponding program and a processor to execute the program to realize the above-mentioned system operation method, providing a stable and efficient hardware operating platform for the laser non-contact valve core displacement measurement embedded system. The processor's computing power can ensure the real-time performance of the entire process of "system power-on initialization - parameter configuration - displacement acquisition - data processing", avoiding signal distortion or control command lag caused by computing delay, and ensuring accurate response of functions such as analog output board mode switching and digital I / O board pulse output / input. The memory can stably store the program and the acquired data, preventing program loss or damage, and can also cooperate with TDMS. The formatted data storage and voltage-displacement conversion logic ensure the secure retention of historical data and subsequent traceability analysis. Simultaneously, the device fully supports LabVIEW program debugging functions such as breakpoint setting and single-step execution, facilitating quick troubleshooting by operators and further improving system maintenance efficiency. Ultimately, through hardware and program collaboration, this computer device can continuously and stably reproduce the advantages of non-contact displacement measurement, avoiding the wear and interference problems of traditional contact measurement. This ensures the reliable implementation of the integrated "measurement-control-interaction" function, providing long-term, stable hardware support for high-precision valve core displacement testing and reducing the risk of failure and maintenance costs in industrial field testing.

[0065] The embodiments of the present invention disclosed above are merely illustrative of the invention. These embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention.

Claims

1. A six-degree-of-freedom mechanical structure, comprising a Z-axis scissor-type manual lifting platform (1), a transition plate (2), an XYR three-axis displacement platform (3), and an L-shaped mounting plate (4), characterized in that, The L-shaped mounting plate (4), the XYR three-axis displacement platform (3), the adapter plate (2), and the Z-axis scissor-type manual lifting platform (1) are fixedly connected from top to bottom.

2. An embedded system for laser non-contact valve core displacement measurement, characterized in that, include: Laser displacement sensors, sensor controllers, real-time controllers, analog input boards, analog output boards, digital I / O boards, six-degree-of-freedom mechanical structures, DIN rail-mounted switching power supplies, and host computers. The laser displacement sensor is fixedly connected to the six-degree-of-freedom mechanical structure via threaded fasteners. The signal output terminal of the laser displacement sensor is connected to the signal input terminal of the sensor controller via a dedicated cable. The analog output terminal of the sensor controller is connected to the signal input terminal of the analog input board via a differential adapter cable. Analog input boards, analog output boards, and digital I / O boards are connected to the real-time controller's board interface via slots. The power output terminal of the DIN rail type switching power supply is connected to the power input terminal of the sensor controller and the power input terminal of the real-time controller respectively via power supply cables. The communication port of the real-time controller is connected to the communication port of the host computer via a communication cable; The common ground terminals of the rail-mounted switching power supply, the sensor controller, and the real-time controller are interconnected by wires.

3. The laser non-contact valve core displacement measurement embedded system according to claim 2, characterized in that, The laser displacement sensor is used for non-contact acquisition of the physical signal of the linear displacement of the valve core; The sensor controller is used to receive the physical signal of the valve core linear displacement output by the laser displacement sensor, and after amplifying, filtering and analog-to-digital conversion of the physical signal of the valve core linear displacement, output a standard analog displacement signal. The real-time controller is used to receive signals transmitted from the analog input board, output control commands to the analog output board and the digital I / O board, and simultaneously realize industrial-grade real-time data processing and command response. The analog input board is used to receive the standard analog displacement signal output by the sensor controller, convert it into a digital signal, and then transmit it to the real-time controller. The analog output board is used to receive control commands from the real-time controller and output analog waveform signals of a preset type to drive external execution components. The digital I / O board is used to receive control commands from the real-time controller and output digital pulse signals, or to collect digital feedback signals from external actuators and transmit them to the real-time controller. The six-degree-of-freedom mechanical structure is used to fix the laser displacement sensor, and through Z-axis height adjustment, X / Y-axis plane position fine adjustment and R-axis angle fine adjustment, the laser displacement sensor is precisely aligned with the valve core measurement area. The rail-mounted switching power supply is used to provide stable industrial-grade power to the sensor controller and the real-time controller. The host computer is used to configure system operating parameters, display the acquired data and output signal waveforms in real time, store measurement data, and perform system debugging operations.

4. The laser non-contact valve core displacement measurement embedded system according to claim 3, characterized in that, The external execution components include a motor driver and a motor. The analog waveform signal output by the analog output board is a sine wave, square wave, triangle wave, sawtooth wave or step wave, which is used to drive the motor driver and thus control the operation of the motor.

5. The laser non-contact valve core displacement measurement embedded system according to claim 4, characterized in that, The analog output board supports two working modes: when the manual control function is enabled, it outputs an adjustable step signal with adjustable voltage; when the manual control function is disabled, it outputs a sine wave, square wave, triangle wave, or sawtooth wave with adjustable frequency, amplitude, and duty cycle. The eight bidirectional channels of the digital I / O board are configured in 4-bit incremental groups by the host computer. The first group of four channels is configured as digital output mode, and the second group of four channels is configured as digital input mode, used to output control pulses and acquisition feedback pulses respectively.

6. The laser non-contact valve core displacement measurement embedded system according to claim 5, characterized in that, The real-time controller, sensor controller, analog input board, analog output board, and digital I / O board are integrated in a cold-rolled steel cabinet. The cabinet has an IP20 protection rating and its surface is treated with anti-corrosion and anti-rust treatment.

7. A method for operating a laser non-contact valve core displacement measurement embedded system, based on the laser non-contact valve core displacement measurement embedded system according to any one of claims 2-6, characterized in that, Includes the following steps: S1. Connect the rail-mounted switching power supply to power the sensor controller and the real-time controller. After the sensor controller is powered on for the first time, it enters the initial setting interface and completes the output polarity selection and analog output type configuration. S2. By running the project program of LabVIEW graphical programming software on the host computer, connect the real-time controller, configure the acquisition channel, sampling frequency and number of sampling points of the analog input board, configure the waveform type and parameters of the analog output board, and configure the pulse output / input mode of the digital I / O board. S3. The real-time controller receives configuration instructions from the host computer, controls the analog input board to collect the valve core displacement analog signal output by the sensor controller, and simultaneously controls the analog output board to output a preset analog waveform signal and the digital I / O board to output a digital pulse signal to drive external actuators. S4. The host computer uses LabVIEW to display the collected valve core displacement data, analog output waveform, and frequency and duty cycle of digital pulses in real time. It stores the collected voltage data in a specified format file and monitors and adjusts the system operation status through software debugging functions.

8. The operating method of the laser non-contact valve core displacement measurement embedded system according to claim 7, characterized in that, In S2, the waveform parameters of the analog output board can be configured, including frequency, amplitude and duty cycle. The LabVIEW program can switch between two modes: "manual control" and "automatic waveform output". In "manual control" mode, the output voltage value is an adjustable step signal. In "automatic waveform output" mode, the output is a sine wave, square wave, triangle wave or sawtooth wave. In S4, the specified format file stored by the host computer is TDMS format, and the stored voltage data needs to be multiplied by a preset scaling factor through the LabVIEW program to convert it into valve core displacement value; at the same time, the LabVIEW program supports breakpoint setting, single-step execution and animation display of data and subroutine results, which are used for program debugging and troubleshooting during system operation.

9. A storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the operation method of the laser non-contact valve core displacement measurement embedded system according to any one of claims 7-8.

10. A computer device, characterized in that, include: A memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement the operation method of the laser non-contact valve core displacement measurement embedded system according to any one of claims 7-8.

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