Centralized loading servo controller

Abstract

The invention provides a centralized loading servo controller which is applied to the technical field of servo controllers, and the centralized loading servo controller highly integrates a main control module, a signal input module, a signal output module, a communication module and a conditioning amplification module, so that when the centralized loading servo controller is applied to different scenes, the loading precision of the servo controller is greatly improved. Complex installation in combination with conditioning and amplification equipment of an application scene is not needed, use is more convenient, and universality is higher. In addition, the centralized loading servo controller provided by the invention highly integrates each module, and the whole equipment is small in size, small in occupied area and more convenient to carry and use.

Description

Technical Field

[0001] The present invention relates to the technical field of servo controllers, and in particular to a centralized loading servo controller. Background Art

[0002] With the development of science and technology, servo controllers are widely used in the fields of industrial automation and precision control, such as machine tool processing, industrial robots, automated production lines, and loading tests. In these applications, servo controllers can accurately control the rotation speed and position of the motor to achieve high-precision positioning and transmission control.

[0003] The inventors have found that current servo controllers are usually based on the hardware form of standard rack-mounted industrial computers and built-in related input and output boards, combined with peripheral power supply junction boxes and conditioning and amplification junction boxes for different application scenarios, and installed on standard cabinets. The installation process is relatively complicated, and when used in different application scenarios, it takes time for complex installation. Traditional servo controllers have poor versatility. Summary of the invention

[0004] In view of this, an embodiment of the present application provides a centralized loading servo controller in which each module is highly integrated and does not require complicated installation in conjunction with peripheral conditioning, amplification and junction boxes in different application scenarios, thereby improving the versatility of the centralized loading servo controller.

[0005] To achieve the above objectives, the present application provides the following technical solutions:

[0006] A centralized loading servo controller, comprising:

[0007] Main control module, signal input module, signal output module, communication module and conditioning and amplification module;

[0008] The signal input module is used to collect the position signal, the encoder signal, the external control signal and the load signal amplified by the conditioning and amplification module, and send the position signal, the load signal, the encoder signal and the external control signal as input signals to the main control module;

[0009] The main control module is used to obtain the control configuration information of the host computer through the communication module and receive the input signal collected by the signal input module, and process the input signal based on the control configuration information to output a control signal for controlling the servo drive device;

[0010] The signal output module is used to receive the control signal output by the main control module and send the control signal to the servo drive device.

[0011] The centralized loading servo controller mentioned above, optionally, the signal input module comprises:

[0012] Analog quantity acquisition module, encoder acquisition module and digital quantity input module;

[0013] The analog quantity acquisition module is used to acquire the position signal of the displacement sensor and the load signal amplified by the load amplification module in the conditioning and amplification module;

[0014] The encoder acquisition module is used to acquire the encoder signal of the encoder;

[0015] The digital quantity input module is used to receive an external control signal of an external device.

[0016] In the above-mentioned centralized loading servo controller, optionally, the analog quantity acquisition module is also used to receive analog quantity instructions.

[0017] The above-mentioned centralized loading servo controller, optionally, the signal output module includes:

[0018] Digital output module and analog output module;

[0019] The digital quantity output module is used to send a digital quantity signal in the control signal for controlling the enabling state of the servo drive device to the switch module in the conditioning and amplification module, so that the switch module sends an enabling signal to the servo drive device according to the digital quantity signal;

[0020] The analog output module is used to send the voltage control signal in the control signal output by the main control module to the servo drive device, and to send the current control signal in the control signal to the servo amplifier module in the conditioning and amplifier module, so that the servo amplifier module amplifies the current control signal and sends it to the servo drive device.

[0021] The above-mentioned centralized loading servo controller, optionally, the analog output module is also used to output an analog load signal to the outside.

[0022] The centralized loading servo controller mentioned above, optionally, the communication module includes:

[0023] Ethernet communication module;

[0024] The Ethernet communication module is used to support the main control module in receiving the control configuration data of the host computer.

[0025] The above-mentioned centralized loading servo controller, optionally, the communication module further comprises: a clock synchronization module and a reflective memory module;

[0026] The reflective memory module is used to realize data cross-linking between the centralized loading servo controller and an external system;

[0027] The clock synchronization module is used to achieve clock synchronization between the centralized loading servo controller and an external system.

[0028] The centralized loading servo controller mentioned above may optionally further include:

[0029] Heat dissipation module, switch button module, display module, buzzer and DC power supply module;

[0030] The heat dissipation module is used to dissipate heat for the centralized loading servo controller;

[0031] The switch button module is used to provide control operations for the centralized loading servo controller;

[0032] The display module includes a plurality of status indicator lights for displaying the operating status of the centralized loading servo controller;

[0033] The buzzer is used to issue an alarm when the state of the centralized loading servo controller is abnormal;

[0034] The DC power supply module is used to provide DC power to the centralized loading servo controller.

[0035] The above-mentioned centralized loading servo controller may optionally further include: a box;

[0036] The main control module, signal input module, signal output module, communication module, conditioning and amplification module, heat dissipation module, switch button module, display module, buzzer, and DC power supply module in the centralized loading servo controller are all integrated in the box;

[0037] The front panel of the box is provided with a control module panel, a power module panel, a buzzer reset button, an emergency stop button and a cooling fan;

[0038] The rear panel of the box is provided with the input and output signal interfaces of each channel of the centralized loading servo controller, an external control interface, an analog input and output interface, a power supply interface, a system interface, a buzzer, an external power supply interface and a fan outlet.

[0039] The centralized loading servo controller mentioned above, optionally, the main control module further includes:

[0040] Self-check module and thread execution module;

[0041] The self-check module is used to perform a self-check on the centralized loading servo controller based on a preset self-check strategy when the centralized loading servo controller is started;

[0042] The thread execution module is used to execute each preset thread.

[0043] The present application provides a centralized loading servo controller, including: the centralized loading servo controller is highly integrated with a main control module, a signal input module, a signal output module, a communication module and a conditioning and amplification module; the signal input module is used to collect position signals, encoder signals, external control signals and load signals amplified by the conditioning and amplification module, and send the position signals, load signals, encoder signals and external control signals as input signals to the main control module; the main control module is used to obtain the control configuration information of the host computer through the communication module and receive the input signal collected by the signal input module, and process the input signal based on the control configuration information, and output a control signal for controlling the servo drive device; the signal output module is used to receive the control signal output by the main control module, and send the control signal to the servo drive device. The centralized loading servo controller of the present application is highly integrated with a main control module, a signal input module, a signal output module, a communication module and a conditioning and amplification module, so that when the centralized loading servo controller is applied in different scenarios, there is no need to carry out complex installation of conditioning and amplification equipment in combination with the application scenario, and it is more convenient to use and more versatile. Furthermore, the centralized loading servo controller provided in the present application highly integrates various modules, and the entire device is very small in size, occupies a small area, and is more convenient to carry and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0045] Figure 1 A schematic diagram of the structure of a centralized loading servo controller provided in an embodiment of the present application;

[0046] Figure 2 A hardware topology diagram of a centralized loading servo controller provided in an embodiment of the present application;

[0047] Figure 3 An example diagram of the appearance of a centralized loading servo controller including a box provided in an embodiment of the present application;

[0048] Figure 4 An example diagram of the layout of the front panel of the box of the centralized loading servo controller provided in an embodiment of the present application;

[0049] Figure 5An example diagram of the layout of the front panel of the box of the centralized loading servo controller provided in an embodiment of the present application;

[0050] Figure 6 An example diagram of the self-check process of the centralized loading servo controller provided in an embodiment of the present application;

[0051] Figure 7 An example diagram of a process for executing a configuration receiving thread provided in an embodiment of the present application;

[0052] Figure 8 An example diagram of a process for executing a servo control thread provided in an embodiment of the present application;

[0053] Fig. 9 A flowchart of a centralized loading servo controller executing a real-time data upload thread provided by an embodiment of the present application;

[0054] Fig.10 A flowchart of a centralized loading servo controller executing a security protection thread provided in an embodiment of the present application;

[0055] Fig.11 This is a structural example diagram of the loading control system provided in an embodiment of the present application. DETAILED DESCRIPTION

[0056] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0057] In this application, the terms "comprises", "comprising" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or device comprising the element.

[0058] As can be seen from the background technology, traditional servo controllers have poor versatility, and after installation, traditional servo controllers will undergo non-standard design and debugging. The non-standard design of traditional servo control makes the controller poor in controllability, and the development and debugging efficiency is low, and the reliability and stability are poor.

[0059] In order to solve the above-mentioned problems, the present application provides a centralized loading servo controller, which highly integrates the main control module, signal input module, signal output module, communication module and conditioning and amplification module. When used in different scenarios, there is no need for complicated installation, which reduces the difficulty of use. The centralized loading servo controller provided by the present application is more versatile and can be compatible with the loading control requirements of different scenarios. In addition, the centralized loading servo controller provided by the present application significantly reduces the size of the loading controller and saves application space by highly integrating the main control module, signal input module, signal output module, communication module and conditioning and amplification module.

[0060] Reference Figure 1 , is a schematic diagram of the structure of a centralized loading servo controller provided in an embodiment of the present application, and is specifically described as follows:

[0061] The centralized loading servo controller includes: a main control module 101 , a signal input module 102 , a signal output module 103 , a communication module 104 and a conditioning and amplification module 105 .

[0062] The signal input module 102 is used to collect the position signal, encoder signal, external control signal and the load signal amplified by the conditioning and amplification module 105, and send the position signal, load signal, encoder signal and external control signal as input signals to the main control module.

[0063] It should be noted that the signal input module is used to collect various signals required for the centralized loading servo controller to work, such as: position signal, encoder signal, load signal, encoder signal and external control signal; different signals have different contents, and different signals have different signal sources.

[0064] Preferably, the external control signal may include a signal for controlling the emergency stop of the centralized loading servo controller, a signal representing the closed state of each switch in the centralized loading servo controller, a number of digital signals of an external device or an external system, etc.

[0065] The main control module 101 is used to obtain the control configuration information of the host computer through the communication module and the input signal collected by the receiving signal input module, and processes the input signal based on the control configuration information to output a control signal for controlling the servo drive device.

[0066] The main control module is used to receive various signals. Different signals have different functions. The main control module controls the working state of the centralized loading servo controller according to the various signals. For example, when the main control module receives an emergency stop signal, it controls the centralized loading servo controller to emergency stop; when the main control module receives a signal to output a control servo drive device, it processes the various signals required to control the servo drive device, thereby outputting a control signal for controlling the servo drive device.

[0067] The signal output module 103 is used to receive the control signal output by the main control module and send the control signal to the servo drive device.

[0068] The signal output module is used to send the control signal output by the main control module to the servo drive device, thereby controlling the servo drive device.

[0069] The centralized loading servo controller provided in the embodiment of the present application highly integrates the main control module, signal input module, signal output module, communication module and conditioning and amplification module; the signal input module is used to collect position signals, encoder signals, external control signals and load signals amplified by the conditioning and amplification module, and send the position signals, load signals, encoder signals and external control signals as input signals to the main control module; the main control module is used to obtain the control configuration information of the host computer through the communication module and receive the input signal collected by the signal input module, and process the input signal based on the control configuration information, and output the control signal for controlling the servo drive device; the signal output module is used to receive the control signal output by the main control module, and send the control signal to the servo drive device. The centralized loading servo controller of the present application highly integrates the main control module, signal input module, signal output module, communication module and conditioning and amplification module, so that when the centralized loading servo controller is applied in different scenarios, there is no need to combine the conditioning and amplification equipment of the application scenario for complex installation, and it is more convenient to use and more versatile. And the centralized loading servo controller provided by the present application highly integrates various modules, the volume of the whole device is very small, the occupied area is small, and it is more convenient to carry and use.

[0070] Reference Figure 2 , is a hardware topology diagram of a centralized loading servo controller provided in an embodiment of the present application, and is specifically described as follows:

[0071] Figure 1 The signal input module shown includes Figure 2 The analog quantity acquisition module, encoder acquisition module and digital quantity input module; Figure 1 The signal output module shown includes Figure 2 Digital output modules and analog output modules in; Figure 1 The communication modules shown include Figure 2Ethernet communication module, clock synchronization module and reflective memory module; Figure 1 The conditioning amplifier module shown includes Figure 2 The load amplification module, servo amplification module and switch module.

[0072] like Figure 2 As shown, the centralized loading servo controller further includes: a heat dissipation module, a switch button module, a display module, a buzzer and a DC power supply module; preferably, the heat dissipation module, the switch button module, the display module and the buzzer can form an auxiliary module. The DC power supply module is one of the power supply sources in the power supply module of the centralized loading servo controller.

[0073] The main control module of this application is the CPU main control module in the figure. Preferably, the CPU main control module uses a mature industrial computer motherboard, Intel high-performance i7 quad-core CPU, 16G memory, and 500G SSD to provide sufficient computing power for centralized loading servo controllers. The main control module provides relevant expansion slots for input and output modules. The expansion slot interface forms include but are not limited to PCI, PCIe, PXI, PXIe, CPCI, PMC, etc. Further, Figure 1 The signal input module and signal output module shown constitute an input-output module.

[0074] The analog quantity acquisition module in the present application is used to collect the position signal of the displacement sensor, and to collect the load signal amplified by the load amplification module in the conditioning and amplification module; the analog quantity acquisition module transmits the collected position signal and load signal to the CPU main control module.

[0075] The analog quantity acquisition module is also used to acquire analog quantity instructions. Further, the analog quantity acquisition module is also used to acquire BNC analog quantity instructions; wherein, the BNC may be a bayonet nut connector, and the analog quantity acquisition module is connected to the BNC, thereby acquiring the BNC analog quantity instructions of the device connected to the BNC.

[0076] Furthermore, the analog quantity acquisition module provides 32 channels of analog quantity acquisition, ±10VDC acquisition, and 16-bit resolution. The analog quantity acquisition module includes: 4 channels for acquiring load signals; 4 channels for acquiring analog displacement sensor signals; 4 channels for acquiring BNC analog quantity command input signals; and the remaining channels are for standby. The analog quantity acquisition module can be a separate board or module, or it can be an analog quantity acquisition module on a multi-function card.

[0077] The encoder acquisition module in the present application is used to acquire the encoder signal of the encoder; the encoder acquisition module also sends the acquired encoder signal to the CPU main control module.

[0078] Preferably, the encoder acquisition module provides 4-way orthogonal encoding signal acquisition, and the orthogonal encoding signal is an ABZ differential signal with a maximum of 48 VDC. The encoder acquisition module can be a separate board or module, or an encoder acquisition module on a multi-function card.

[0079] The digital input module of the present application is used to receive external control signals from external devices. The external devices here include but are not limited to external systems and external emergency stop buttons of the machine. Further, the external control signals include but are not limited to signals for controlling the emergency stop of the centralized loading servo controller and several digital quantity signals of the external system; further, the signals for controlling the emergency stop of the centralized loading servo controller can be obtained through the external system or through the external emergency stop button of the machine.

[0080] Furthermore, the digital input module provides 16 channels of digital signal acquisition; mainly including: 1 channel for external emergency stop acquisition; 1 channel for acquiring the local emergency stop button; several channels for acquiring switch button modules; several channels for acquiring digital signals from external systems; the remaining channels are reserved; the digital input module can be a separate board or module, or it can be a digital input module on a multi-function card.

[0081] The digital output module in the present application is used to send a digital signal in the control signal for controlling the enable state of the servo drive device to the switch module in the conditioning and amplification module, so that the switch module sends an enable signal to the servo drive device according to the digital signal.

[0082] Preferably, the digital output module of the present application is connected to the switch module in the conditioning and amplification module, and is also connected to the buzzer and the display module; the digital output module also sends a digital signal to the buzzer to control the working state of the buzzer, and also sends a digital signal to the display module to control the working state of the display module.

[0083] The digital output module of the present application provides 16 digital signal outputs, mainly including 4 enable signal outputs; 1 buzzer control output; 4 indicator light control outputs in the indicator module; and the remaining outputs are standby. The digital output module can be a separate board or module, or a digital output module on a multi-function card.

[0084] The analog output module in the present application is used to send the voltage control signal in the control signal output by the main control module to the servo drive device, and to send the current control signal in the control signal to the servo amplifier module in the conditioning amplifier module, so that the servo amplifier module amplifies the current control signal and sends it to the servo drive device.

[0085] Preferably, the analog output module is also used for BNC analog load output. Preferably, the analog output module can also output analog load signals to a device connected to the BNC.

[0086] Furthermore, the analog output module provides 8 analog voltage output signals, ±10VDC, 16-bit resolution. The analog output module includes: 4 current control signal / voltage control signal output; 4 BNC analog load output; the remaining outputs are spare. The analog output module can be a separate board or module, or it can be an analog output module on a multi-function card.

[0087] The conditioning and amplification module in the present application includes a load amplification module, a servo amplification module and a switch module, wherein the load amplification module is used to amplify the load signal of the load sensor, and then send the amplified load signal to the CPU main control module; the switch module is used to receive the digital signal used to control the enable state of the servo drive device in the control signal output by the digital output module, and then send an enable signal to the servo drive device based on the received digital signal.

[0088] The load amplification module in the embodiment of the present application is a voltage amplification circuit, which provides filtering and amplification of 4 mV-level signals to V-level signals, and is used to amplify the input load signal. The input range is 0~±30mV, the output range is 0~±10VDC, the accuracy is 0.1%FS, and the bandwidth is 1kHz.

[0089] The servo amplifier module provided in the embodiment of the present application is a current amplifier circuit, which provides 4 current signals for controlling a servo control device (such as a servo valve), with an input range of 0~±10VDC voltage signal, an output range of 0~±60mA current signal, an accuracy of 0.1%FS, and a bandwidth of 1kHz.

[0090] The switch module provided in the embodiment of the present application is a relay module, which provides 4 24V enable outputs.

[0091] The Ethernet communication module provided in the embodiment of the present application is used to realize the data interaction between the CPU main control module and the loading host computer; further, the data cross-linking between the centralized loading servo controller and the loading host computer is also realized. The loading host computer here can be understood as Figure 1 Through the Ethernet communication module, the CPU control module receives the control configuration information sent by the loading host computer, including but not limited to sensor configuration, channel configuration, control parameter configuration, load configuration and other information, and uploads real-time data such as real-time load feedback and real-time position feedback to the loading host computer.

[0092] The reflective memory module provided in the embodiment of the present application is used to realize the real-time data cross-linking between the centralized loading servo controller and the external system (such as the simulation system). Through the reflective memory module, the CPU main control module receives the load instruction sent by the external system in real time, and uploads the real-time data such as real-time load feedback and real-time position feedback to the external system.

[0093] The clock synchronization module provided in the embodiment of the present application is used to realize the clock synchronization between the centralized loading servo controller and the external system (such as the simulation system), ensuring that the real-time data of the loading controller and the external system are under the same clock. Further, the centralized loading servo controller of the present application can also be referred to as a controller.

[0094] The centralized loading servo controller provided in the embodiment of the present application also includes a power supply module, which is used to provide power to relevant modules inside the centralized loading servo controller and external sensors. The power supply module is used to power the position sensor (24VDC); the load amplifier (24VDC); the encoder (5VDC); the servo amplifier module (24VDC); and the switch module (24VDC). Preferably, the power supply module includes a DC power supply module, which is connected to an external power supply to convert the AC power provided by the external power supply into DC power, thereby providing DC power for the centralized loading servo controller. Figure 2 As shown, the DC power supply module supplies power to the load amplification module, the servo amplification module and the switch module in the centralized loading servo controller; the DC power supply module also supplies power to the displacement sensor, the load sensor and the encoder connected to the centralized loading servo controller.

[0095] In the centralized loading servo controller provided in the embodiment of the present application, the heat dissipation module is a group of fans, which provide air supply for the centralized loading servo controller to provide air inlet and outlet, thereby realizing heat dissipation of the centralized loading servo controller.

[0096] In the centralized loading servo controller provided in the embodiment of the present application, the switch button module provides necessary control operations of the centralized loading servo controller, and the necessary control operations include but are not limited to: powering on the main control; restarting; powering on the power module; resetting the buzzer; and emergency stop.

[0097] The display module provided in the embodiment of the present application includes a plurality of status indicator lights for displaying the operating status of the centralized loading servo controller. Preferably, the plurality of status indicator lights include, but are not limited to, an indicator light for indicating that the centralized loading servo controller is powered on for the main control, an indicator light for indicating the hard disk read / write status of the centralized loading servo controller, an indicator light for indicating that the centralized loading servo controller is performing a self-check, and an indicator light for indicating that the centralized loading servo controller is in loading operation.

[0098] The buzzer provided in the embodiment of the present application is used to sound an alarm when the status of the centralized loading servo controller is abnormal, and the buzzer can be reset by a button.

[0099] The centralized loading servo controller provided in the embodiment of the present application also includes a box, in which the main control module, signal input module, signal output module, communication module, conditioning and amplification module, heat dissipation module, switch button module, display module, buzzer, and DC power supply module in the centralized loading servo controller are all integrated. Preferably, the box can also be understood as the shell of the centralized loading servo controller.

[0100] Reference Figure 3 , which is an example diagram of the appearance of a centralized loading servo controller including a box body provided in an embodiment of the present application.

[0101] Furthermore, the centralized loading servo controller provided in the embodiment of the present application has the following functional characteristics:

[0102] (1) Based on real-time system, the minimum control cycle is 0.5ms;

[0103] (2) The main control module uses Intel i7 quad-core high-performance CPU, 16GB memory, and 500GB SSD;

[0104] (3) Integration of real-time scheduling and servo control;

[0105] (4) Support multiple control modes such as open-loop control, position control, static load control, dynamic load control, speed control, etc.

[0106] (5) A single machine supports 4-channel collaborative control and coordinated loading;

[0107] (6) Support application scenarios such as electro-hydraulic servo control and electric servo control;

[0108] (7) Supports cross-linking of optical fiber reflective memory with external systems and has the capability of high-speed communication with external systems;

[0109] (8) Support clock synchronization with external systems;

[0110] (9) Support BNC analog input and output, support external instructions, and support external sweeper measurement.

[0111] Furthermore, the housing of the centralized loading servo controller provided in the embodiment of the present application includes a front panel and a rear panel. The housing of the centralized loading servo controller provided in the embodiment of the present application has a good human-computer interaction design, and the human-computer interaction panel has complete functions, and has relevant control buttons, indicator lights, buzzers, etc., which meet the use of loading control scenarios.

[0112] The front panel of the centralized loading servo controller box is equipped with a control module panel, a power module panel, a buzzer reset button, an emergency stop button, and a cooling fan. Figure 4 , which is an example diagram of the layout of the front panel of the box of the centralized loading servo controller provided in an embodiment of the present application.

[0113] The control module panel includes: main control power button: controls the switch of the CPU main control module; main control restart button: controls the restart of the CPU main control module; main control status indicator: indicates the power-on status of the main control module and the hard disk read and write status respectively; loading self-test indicator: after the controller self-test is successful, the red light is always on, and the controller is ready; loading operation indicator: lights up after the loading control is running; loading alarm indicator: lights up after the loading system protection occurs.

[0114] The power module panel includes: power module switch: a switch that supplies power to each internal module; status indicator: a power status indicator that lights up when the power module is turned on.

[0115] Furthermore, the front panel of the box of the centralized loading servo controller is also provided with: a buzzer reset button: a buzzer sounds after the loading system is protected, and the buzzer reset button is used to reset the buzzer and turn off the alarm sound; an emergency stop button: used for emergency stop in emergency situations, after pressing the emergency stop button, the emergency stop button light lights up, the loading system stops and unloads, the load returns to zero, and the loading actuator is enabled; a cooling fan: the controller runs automatically after being powered by 220VAC, and draws air into the inside of the controller.

[0116] The rear panel of the box of the centralized loading servo controller provided in the embodiment of the present application is provided with the input and output signal interface of each channel of the centralized loading servo controller, the external control interface, the analog input and output interface (which can be a BNC analog input and output interface), the power supply interface (which can be a 220VAC power supply interface), the system interface, the buzzer, the external power supply interface and the fan outlet. The welcoming interface of the present application is complete, including optical fiber reflection memory, clock synchronization, Ethernet, and BNC analog quantity, which can meet the external control and synchronization requirements of various scenarios to the maximum extent.

[0117] Reference Figure 5 , which is an example diagram of the layout of the front panel of the box of the centralized loading servo controller provided in an embodiment of the present application.

[0118] Input and output signal interface of each channel: contains 4 channels, and the signal interface of each channel includes: load signal interface: connects to the load sensor (force sensor or torque sensor), provides power excitation, and collects the loading load feedback signal; position signal interface: connects to the position sensor (linear displacement sensor or rotary angle encoder), provides power excitation, and collects the loading position feedback signal; control output: connects to the control end of the servo drive device (such as: servo valve of electro-hydraulic servo transmission system, driver of electric servo drive system), and outputs voltage and current analog control signals; enable output: connects to the enable end of the servo drive device (such as: safety valve of electro-hydraulic servo transmission system, driver of electric servo drive system), and outputs digital 24VDC enable signal; driver IO: connects to the driver of the electric servo drive system, inputs and outputs digital 24VDC, controls and collects driver digital signals (such as fault alarm, fault clearing, etc.); test interface: load and position feedback signal test interface, used for external system to collect loading feedback signals; spare: spare hardware connection interface.

[0119] The external control interfaces include: EtherCAT interface: standard RJ45, used for communication with external control; fiber optic reflective memory interface: standard LC-LC, used for cross-linking with external systems through fiber optic reflective memory; external emergency stop: a mobile terminal used for handheld emergency stop. When encountering an emergency, press the emergency stop button to load the control to enable power disconnection (unloading); auxiliary interface: controller auxiliary function hardware interface.

[0120] BNC analog interface: The interface is a BNC socket, which is used to collect external loading command signals.

[0121] 220VAC power supply interface: The interface uses a standard T-shaped power cord; after the rocker switch is pressed, the red indicator light is always on; the controller has overcurrent protection, a fuse is installed in the rocker switch, and 1 spare fuse is equipped.

[0122] The system interfaces include: Network port: standard RJ45, used to connect to the loading host computer and send and receive data; USB: standard USB3.0, used to connect other device hardware; Backup interface: including backup network interface and debugging display interface.

[0123] Buzzer: When some specified faults are triggered, the buzzer will sound constantly. Press the buzzer reset button on the front panel to turn off the buzzer.

[0124] External power supply interface: used to power special servo drive systems, such as high-power servo valves used in hydraulic servo transmission systems.

[0125] Fan outlet: The cooling fan blows air outwards.

[0126] In the centralized loading servo controller provided by the present application, the traditional controller based on industrial computers and board forms is integrated and designed, and the main control module, signal input module, signal output module, communication module and conditioning and amplification module are highly integrated to form an integrated loading controller with a unified input and output interface; through hardware universal design, it is compatible with commonly used sensor types, including load (force / torque) sensors, analog displacement sensors, orthogonal encoding signal displacement sensors (such as magnetic scales, grating scales), angle encoders and other sensor types, and the hardware interfaces are complete, including optical fiber reflection memory, clock synchronization, Ethernet, and BNC analog quantities, which can maximize the external control and synchronization requirements of various scenarios; the machine interaction panel of the centralized loading servo controller of the present application is complete in function, with relevant control buttons, indicator lights and buzzers, which meet the use of loading control scenarios and have good human-computer interaction design.

[0127] Preferably, the main control module of the centralized loading servo controller provided in the present application also includes a self-check module and a thread execution module; the self-check module and the thread execution module are modules obtained by generalizing the relevant software of the centralized loading servo controller.

[0128] The self-check module is used to perform a self-check on the centralized loading servo controller based on a preset self-check strategy when the centralized loading servo controller is started.

[0129] The thread execution module is used to execute various preset threads; each thread includes but is not limited to a configuration receiving thread, a control thread, a security protection thread, and a real-time data upload thread.

[0130] Preferably, after the software of the centralized loading servo controller is universally designed, it can realize self-check of the centralized loading server, and execute various threads such as configuration receiving thread, control thread, security protection thread and real-time data upload thread after initialization.

[0131] The self-check module is used to realize the self-check of each module in the centralized loading servo controller. Figure 6, which is an example diagram of the self-test process of the centralized loading servo controller provided in an embodiment of the present application. When the centralized loading servo controller performs self-test, the centralized loading servo controller is self-tested based on a preset self-test strategy. Preferably, the self-test strategy includes but is not limited to an abnormality inspection scheme for the main control module, an abnormality inspection scheme for the communication module, an abnormality inspection scheme for the signal input module, an abnormality inspection scheme for the signal output module, an abnormality inspection scheme for the conditioning and amplification module, and an abnormality inspection scheme for the interface; different components have different inspection schemes, and the centralized loading servo controller can be comprehensively inspected. An abnormality check can be performed before the centralized loading servo controller works, and abnormal centralized loading servo controllers can be discovered in time, effectively avoiding errors caused by the use of abnormal centralized loading servo controllers.

[0132] If the centralized loading servo controller provided in the embodiment of the present application succeeds in self-checking, the self-check success indicator light will be turned on to initialize the controller, and then the software will continue to run subsequent tasks, that is, execute the corresponding thread; if the self-check fails, the software will stop running, that is, it will end.

[0133] In the centralized loading servo controller provided in the embodiment of the present application, the execution of the configuration receiving thread is mainly to implement the parsing of configuration information and parameter localization, as well as to enable output. Figure 7 , which is an example diagram of the process of executing the configuration receiving thread provided by the embodiment of the present application; related instructions such as: configure communication initialization, then read communication, reading communication can be understood as communicating with the host computer, and then determine whether there is configuration information, if so, parse the configuration information, write the parameters obtained by parsing the configuration information into local variables, then enable output to the digital output module, and then determine whether it is finished, if not finished, return to the step of executing the reading communication; if finished, end. Further, in the step of determining whether there is data, if there is no data, return to the process of executing the reading communication.

[0134] Furthermore, the configuration information mainly includes:

[0135] (1) Channel control mode: The control modes include open loop, position control, static load control, dynamic load control, speed control, etc.

[0136] (2) Sensor parameters: including position sensors and load sensors. The main parameters include: 1) sensitivity coefficient; 2) working stroke, including voltage value and engineering quantity.

[0137] (3) Control strategy parameters: Control strategy parameters include: 1) PID control parameters; 2) redundant force control strategy parameters;

[0138] (4) Servo drive parameters: Parameters include: 1) maximum and minimum control signals; 2) zero bias; 3) polarity;

[0139] (5) Safety protection limits: 1) limit load parameters; 2) limit displacement parameters; 3) following error limit parameters, etc.

[0140] (6) Command configuration information: including command source (local machine / reflective memory / BNC analog quantity), command type (constant value, waveform, load spectrum, etc.), command content (amplitude, offset, frequency, phase, square wave duty cycle, load spectrum array, etc.).

[0141] By executing the configuration receiving thread, the configuration information sent by the host computer can be parsed, and then the parameters in the centralized loading servo controller can be configured so that the centralized loading servo controller can provide services in the deployed application environment.

[0142] Reference Figure 8 , is an example diagram of the process of executing the servo control thread provided in the embodiment of the present application, and the relevant description is as follows:

[0143] Step (1): Initialize the acquisition channel.

[0144] Step (2): Read the collected data and write it into local variables.

[0145] Specifically, the load feedback, position feedback, analog and digital input signals of each channel are read from the acquisition module and assigned to local variables.

[0146] Step (3): Calculate the load, position and velocity, and perform filtering.

[0147] Step (4): Determine whether to run the loading. If not, return to step (2). If yes, go to step (5).

[0148] Preferably, while determining whether to load and run, determine whether to feedback and output. If so, set the load and position feedback value to the analog output module or reflective memory for output according to the feedback output mode. If not, no output is performed.

[0149] Step (5): Determine whether it is enabled. If it is enabled, perform instruction calculation; if not, return to step (2) to continue execution.

[0150] When performing instruction calculation, the current instruction value of each channel is obtained based on the instruction source, instruction type and instruction content set in the instruction.

[0151] Step (6): Determine whether the control mode is open loop. If it is open loop, directly jump to the step of determining whether over-limit protection is in effect; if not, execute step (7).

[0152] Step (7): Instruction optimization compensation.

[0153] Optimize and compensate the instructions according to actual usage.

[0154] Step (8): Normalization of command feedback.

[0155] By normalizing the command feedback, the command and feedback dimensions are unified.

[0156] Step (9): Run the closed-loop control algorithm.

[0157] The control output value is obtained by running the closed-loop control algorithm. The control algorithm is the core of real-time control. It runs once in each control cycle. According to the collected force feedback and position feedback, it compares the control instructions calculated by the signal generator, calculates the control output, and drives the servo drive. The control algorithm runs in a real-time environment. The control algorithm preferably uses anti-integral saturation composite PID control. If large nonlinear factors or time-varying characteristics are found during on-site debugging, consider using algorithms such as fuzzy PID, LQG, adaptive inverse or MPC for precise control.

[0158] Step (10): Execute the redundant force elimination algorithm.

[0159] The control output value in step (9) is further calculated by the redundant force elimination algorithm such as feedforward to obtain the control output value. The loading control system suppresses the redundant force through the redundant force elimination algorithm, including active compensation algorithm based on control strategy, speed synchronization control algorithm, feedforward compensation strategy based on speed feedback signal, enhanced compensation strategy and follow-up force loop control strategy, etc. It is necessary to select the most appropriate control algorithm / strategy according to the actual situation of the system to achieve the maximum elimination of redundant force (torque).

[0160] Step (11): Determine whether the load, position, error, etc. are over-limit protection. If over-limit protection is required, disable and control the output to zero to close the loading operation process, then enable the output to the digital output module and execute step (2); if not over-limit protection, execute step (12).

[0161] Step (12): Perform zero bias processing.

[0162] The control output value is subjected to zero bias processing. After the zero bias processing, step (13) is executed and the control output value and real-time data such as load and position feedback are packaged to obtain a real-time data package, and then the real-time data package is put into a queue.

[0163] Step (13): Perform polarity treatment.

[0164] Step (14): Send the final control signal to the analog output module for output.

[0165] Step (15): Determine whether there is an emergency stop. If not, execute step (16); if so, disable and control the output to zero to close the loading and running process, then enable the output to the digital output module and execute step (2).

[0166] Step (16): Determine whether the process is finished. If not, jump to step (2) and continue running. If so, the process is finished.

[0167] Figure 8 The process shown is the process of program execution of the servo control thread. The centralized loading servo controller provided in the embodiment of the present application realizes closed-loop control of the load and data queuing by executing the servo control thread.

[0168] Reference Fig. 9 , which is a flowchart of the centralized loading servo controller provided in the embodiment of the present application executing the real-time data upload thread, and the relevant instructions are as follows: initialize the real-time data queue and the communication; then obtain the queue status of the real-time data queue; determine whether the dequeue length is reached according to the queue status, if the dequeue length is reached, obtain the real-time data package from the real-time data queue, and send the obtained real-time data package to the host computer, and then determine whether it is ended, if so, it is ended; if not, return to the step of obtaining the queue status of the real-time data queue. It should be noted that the data stored in the real-time data queue is the real-time data package, and the queue status includes the length of the data stored in the queue. The queue status is used to determine whether the data in the real-time data queue reaches the dequeue length, specifically: when the real-time data queue is full of data, it is determined that the dequeue length is reached, otherwise, it is determined that the dequeue length is not reached; or, when the data length in the real-time data queue reaches the preset length, it is determined that the dequeue length is reached, otherwise, it is determined that the dequeue length is not reached.

[0169] The centralized loading servo controller provided in the embodiment of the present application executes the real-time data upload thread to package and send the real-time data of the loading system (load feedback, position feedback, speed, control output, etc.) to the loading host computer. Preferably, the real-time data includes: time scale, instructions of all channels, position, load, control output, speed, acceleration, protection, emergency stop and other data.

[0170] Reference Fig.10 , which is a flowchart of the centralized loading servo controller executing the safety protection thread provided in the embodiment of the present application, and related instructions such as: monitoring various states such as position, speed, load and forward load; judging whether there is an over-limit state in each state according to the monitored states, if so, unloading the loading system, if not, returning to the step of monitoring various states such as position, speed, load and forward load.

[0171] The centralized loading servo controller provided in the embodiment of the present application executes a safety protection thread and monitors various states such as position, speed, load, error, and forward load in real time. Once the limit is exceeded, the loading system is unloaded, thereby ensuring the safe operation of the centralized loading servo controller.

[0172] The embodiment of the present application provides a centralized loading servo controller, the software and hardware of the centralized loading servo controller are universally designed, with strong versatility, reliability and stability, and improved development and debugging efficiency. In terms of hardware, the centralized loading servo controller highly integrates the main control module, signal input module, signal output module, conditioning and amplification module, etc., is compatible with the loading control requirements of different scenarios, significantly reduces the volume of the loading controller, and saves on-site space; in terms of software, the relevant software is universally designed, based on configuration operation, without the need to modify the code, only need to modify several configurations, call different projects to achieve switching and adaptation in different projects and working conditions, improve the versatility of the controller, and do not need to perform complex installation in different application scenarios.

[0173] The centralized loading servo controller provided in the embodiment of the present application can constitute a loading control system, referring to Fig.11 , is a structural example diagram of a loading control system provided by an embodiment of the present application. As shown in the figure, the loading control system includes a loading host computer, a centralized loading servo controller, a servo drive device, a loading actuator, a load sensor, a position sensor, a test piece, and a bench fixture. The loading host computer and the centralized loading servo controller communicate via Ethernet, the position sensor feeds back a position signal to the centralized loading servo controller, the load sensor feeds back a load signal to the centralized loading servo controller, and the centralized loading servo controller sends a control signal to the servo drive state.

[0174] In the loading control system provided in the embodiment of the present application, the centralized loading servo controller receives relevant sensor, load, control and other configuration information from the loading host computer, collects load sensor and position sensor signals in real time, obtains load feedback and position feedback (i.e., obtains load signals and position signals), runs the control algorithm, outputs control information to control the servo drive device, realizes closed-loop servo control of each channel, and finally makes the loading actuator output the specified load to realize load simulation.

[0175] The centralized loading servo controller provided in the embodiment of the present application is aimed at high-frequency and high-precision electro-hydraulic / electric servo control scenarios. It adopts an original force-position hybrid control algorithm to achieve hybrid decoupling control of force / torque and position, meeting the needs of high-frequency loading testing and robot motion control for precise control of force and position, and has the characteristics of hard real-time, high dynamics, versatility, stability and reliability.

[0176] Although the present application depicts operations in a particular order, this should not be understood as requiring that the operations be performed in the particular order shown or in a sequential order.Multitasking and parallel processing may be advantageous under certain circumstances.

[0177] It should be understood that the various steps described in the method embodiments of the present disclosure may be performed in different orders and / or in parallel. In addition, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present disclosure is not limited in this respect.

[0178] It should be noted that the information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, stored data, displayed data, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant laws, regulations and standards in the relevant regions.

[0179] The specific implementation processes and derivative methods of the above-mentioned embodiments are all within the protection scope of the present invention.

[0180] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between the embodiments can refer to each other, and each embodiment focuses on the differences from other embodiments. In particular, for the system or system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can refer to the partial description of the method embodiment. The system and system embodiments described above are merely schematic, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the scheme of this embodiment. Ordinary technicians in this field can understand and implement it without creative work.

[0181] Professionals may further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in the above description according to function. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians may use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0182] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A centralized loading servo controller, characterized in that: include: Main control module, signal input module, signal output module, communication module and conditioning and amplification module; The signal input module is used to collect the position signal, the encoder signal, the external control signal and the load signal amplified by the conditioning and amplification module, and send the position signal, the load signal, the encoder signal and the external control signal as input signals to the main control module; The main control module is used to obtain the control configuration information of the host computer through the communication module and receive the input signal collected by the signal input module, and process the input signal based on the control configuration information to output a control signal for controlling the servo drive device; The signal output module is used to receive the control signal output by the main control module and send the control signal to the servo drive device.

2. The centralized loading servo controller according to claim 1, characterized in that: The signal input module comprises: Analog quantity acquisition module, encoder acquisition module and digital quantity input module; The analog quantity acquisition module is used to acquire the position signal of the displacement sensor and the load signal amplified by the load amplification module in the conditioning and amplification module; The encoder acquisition module is used to acquire the encoder signal of the encoder; The digital quantity input module is used to receive an external control signal of an external device.

3. The centralized loading servo controller according to claim 2, characterized in that: The analog quantity acquisition module is also used to receive analog quantity instructions.

4. The centralized loading servo controller according to claim 1, characterized in that: The signal output module comprises: Digital output module and analog output module; The digital quantity output module is used to send a digital quantity signal in the control signal for controlling the enabling state of the servo drive device to the switch module in the conditioning and amplification module, so that the switch module sends an enabling signal to the servo drive device according to the digital quantity signal; The analog output module is used to send the voltage control signal in the control signal output by the main control module to the servo drive device, and to send the current control signal in the control signal to the servo amplifier module in the conditioning and amplifier module, so that the servo amplifier module amplifies the current control signal and sends it to the servo drive device.

5. The centralized loading servo controller according to claim 4, characterized in that: The analog output module is also used to output analog load signals to the outside.

6. The centralized loading servo controller according to claim 1, characterized in that: The communication module comprises: Ethernet communication module; The Ethernet communication module is used to support the main control module in receiving the control configuration data of the host computer.

7. The centralized loading servo controller according to claim 6, characterized in that: The communication module also includes: a clock synchronization module and a reflective memory module; The reflective memory module is used to realize data cross-linking between the centralized loading servo controller and an external system; The clock synchronization module is used to achieve clock synchronization between the centralized loading servo controller and an external system.

8. The centralized loading servo controller according to claim 1, characterized in that: Also includes: Heat dissipation module, switch button module, display module, buzzer and DC power supply module; The heat dissipation module is used to dissipate heat for the centralized loading servo controller; The switch button module is used to provide control operations for the centralized loading servo controller; The display module includes a plurality of status indicator lights for displaying the operating status of the centralized loading servo controller; The buzzer is used to issue an alarm when the state of the centralized loading servo controller is abnormal; The DC power supply module is used to provide DC power to the centralized loading servo controller.

9. The centralized loading servo controller according to claim 8, characterized in that: Also includes: Box; The main control module, signal input module, signal output module, communication module, conditioning and amplification module, heat dissipation module, switch button module, display module, buzzer, and DC power supply module in the centralized loading servo controller are all integrated in the box; The front panel of the box is provided with a control module panel, a power module panel, a buzzer reset button, an emergency stop button and a cooling fan; The rear panel of the box is provided with the input and output signal interfaces of each channel of the centralized loading servo controller, an external control interface, an analog input and output interface, a power supply interface, a system interface, a buzzer, an external power supply interface and a fan outlet.

10. The centralized loading servo controller according to claim 1, characterized in that: The main control module also includes: Self-check module and thread execution module; The self-check module is used to perform a self-check on the centralized loading servo controller based on a preset self-check strategy when the centralized loading servo controller is started; The thread execution module is used to execute each preset thread.

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