High-speed real-time signal acquisition and control system for intelligent cutter displacement compensation

Abstract

The invention discloses a high-speed real-time signal acquisition and control system for intelligent cutter displacement compensation. The high-speed real-time signal acquisition and control system comprises a development board, an IO module, a signal conditioner and a driving amplifier, the development board is integrated with an ARM and a high-performance computing unit; the high-performance computing unit is integrated with a feedforward controller, a feedback controller and an equivalent disturbance observer; the advanced displacement compensation algorithm is embedded in the high-performance computing unit of the development board, and rapid data communication is performed by utilizing EtherCAT and IPC protocols, so that accurate and low-delay compensation is realized, and the performance and efficiency of the intelligent cutter in high-speed machining application are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent tool processing, and in particular to a high-speed real-time signal acquisition and control system for intelligent tool displacement compensation. Background Art

[0002] In the field of precision machining, smart tools play an increasingly critical role in improving manufacturing efficiency, accuracy and reliability. Smart tools integrate sensors, actuators and control algorithms to monitor and adjust the machining process in real time. These tools can automatically detect and compensate for deviations caused by tool wear, temperature changes, mechanical vibrations and other interferences, thereby improving machining quality and reducing downtime.

[0003] In intelligent tool systems, a major challenge is to accurately compensate tool displacement in real time during machining operations due to tool wear and other reasons. If the displacement error is not corrected in time, it may lead to defects in the final product, reduced tool life, and increased production costs. Traditional displacement compensation methods usually use fixed algorithms of feedforward feedback control, but they usually lack adaptability to dynamic changes in the machining environment, such as unexpected disturbances or changes in working conditions. Summary of the invention

[0004] The purpose of the present invention is to provide a high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, including a development board, an IO module, a signal conditioner, and a drive amplifier;

[0005] The signal conditioner collects real-time displacement signal data of the intelligent tool and transmits it to the development board through the IO module;

[0006] The development board is integrated with ARM and a high-performance computing unit;

[0007] The ARM side of the development board and the high-performance computing unit transmit data via the IPC protocol;

[0008] The ARM end of the development board receives the real-time displacement signal data of the IO module;

[0009] The high performance computing unit processes the real-time displacement signal data, generates a control signal, and transmits it back to the ARM end;

[0010] The ARM terminal transmits the control signal to the driving amplifier through the IO module;

[0011] The driving amplifier amplifies the control signal and transmits it to the piezoelectric compensation module on the intelligent tool to drive the intelligent tool to perform displacement compensation action;

[0012] The high performance computing unit integrates a feedforward controller, a feedback controller and an equivalent disturbance observer w(t)=w FF(t)+w FB (t)+w DC (t);

[0013] The feedforward controller analyzes the given reference trajectory displacement compensation input signal r(t) and calculates the feedforward control quantity w FF (t);

[0014] The feedback controller generates the feedback control quantity w based on the real-time error e(t) between the expected output and the actual output FB (t), correct the dynamic error;

[0015] The equivalent disturbance observer calculates the disturbance observation w DC (t), and dynamically compensate the control signal.

[0016] Furthermore, the feedforward control quantity w FF (t) is as follows:

[0017]

[0018] Where b1 and b2 are constants, and r(t) is the reference trajectory displacement compensation input signal.

[0019] Furthermore, the feedback control quantity w FB (t) is as follows:

[0020] w FB (t) = K I E1(t)+K P E2(t)+K D E3(t)(2)

[0021] In the formula, K I , K P , K D is the PID parameter; E1(t)=e(t), e(t) is the real-time error.

[0022] Furthermore, the equivalent disturbance observer is constructed based on the extended state space equations;

[0023] The expanded state space equations are shown below:

[0024]

[0025] In the formula, x1 and x2 are state variables, b1 and b2 are constants, q(t) is the overall equivalent disturbance, and y is the output of the system;

[0026] The equivalent disturbance observer is as follows:

[0027]

[0028] Where z1, z2, z3 are estimates of states x1, x2, x3, β1, β2, β3 are designed state observer gains, is the output of the state observer.

[0029] Furthermore, the overall equivalent disturbance q(t) is observed by z3 in the state observer.

[0030] Furthermore, the disturbance observation w of the compensation controller for disturbance compensation control is DC (t) is as follows:

[0031]

[0032] Where b2 is a constant and z3 is an estimate of the state x3.

[0033] Furthermore, the development board communicates with multiple IO modules at high speed via the EtherCAT protocol, with a communication rate of 100Mbps-1Gbps.

[0034] Furthermore, the ARM side of the development board runs the Linux system, and the high-performance computing unit runs a real-time operating system.

[0035] Furthermore, the development board is developed in a Linux environment.

[0036] Furthermore, during development, the Linux system is modified using real-time patches so that the development board supports the EtherCAT protocol at the microsecond level; the real-time patches include but are not limited to RT-Preempt and Xenomai.

[0037] The technical effect of the present invention is undoubted, and the beneficial effects of the present invention are as follows:

[0038] 1) By embedding advanced displacement compensation algorithms in the high-performance computing unit of the development board and utilizing EtherCAT and IPC protocols for fast data communication, the system achieves precise, low-latency compensation, significantly improving the performance and efficiency of smart tools in high-speed machining applications.

[0039] 2) Significantly shortened response time: Traditional distributed control systems often have large delays in data transmission and processing, resulting in a long overall system response time. The present invention introduces the EtherCAT high-speed communication protocol to achieve microsecond-level data transmission and processing, greatly shortening the system response time. This improvement is particularly reflected in high-frequency data acquisition and real-time control tasks, ensuring that the system can quickly respond to external changes, greatly improving the real-time and efficiency of the control process.

[0040] 3) Improved synchronization: By adopting the EtherCAT protocol, data exchange between multiple IO modules and development boards can be ensured to be carried out with extremely high synchronization accuracy during the entire system operation. Through real-time scheduling and precise data transmission, each hardware device in the system can maintain microsecond synchronization, reducing signal delays and errors caused by asynchrony between hardware, thereby improving processing consistency and product quality.

[0041] 4) Real-time data processing and coordination: This system has excellent real-time performance in data processing and control decision-making. The entire system supports data processing directly in the device node during transmission, so that data transmission and calculation are completed almost simultaneously. In this way, when high-frequency data acquisition and complex calculations are required, the system can complete the acquisition, analysis, processing and feedback of input signals in a very short time, greatly improving the real-time control capability and system response speed.

[0042] 5) Significantly improved control accuracy: The present invention integrates a high-performance computing unit for implementing high-speed control algorithms, and combines the piezoelectric compensation micro-displacement control algorithm independently developed by the team to achieve precise control of tool wear under complex working conditions. Experiments show that the positioning error of the system in complex environments is significantly reduced. For example, in nano-scale motion control, this system improves positioning accuracy by more than 30% by real-time compensation for external disturbances and system nonlinear factors, which can better meet the needs of high-precision processing and precision assembly than traditional systems.

[0043] 6) Enhanced system stability: The present invention adopts a multi-level control architecture and redundant design, which effectively improves the stability of the system under complex working conditions. Through real-time compensation of external disturbances and internal errors, the system can maintain stable performance during long-term operation, significantly reducing the risk of downtime or failure caused by external factors, and improving the reliability of equipment operation.

[0044] The invention combines high-speed data communication with advanced three-degree-of-freedom control algorithms, significantly improving the stability and accuracy of intelligent tools under complex machining conditions, reducing machining errors, extending tool life, and reducing production costs, providing an innovative and efficient solution for high-precision machining in industrial applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 This is the principle block diagram of the displacement compensation control algorithm deployed on the high-performance computing unit;

[0046] Figure 2 The following is a flowchart of the construction process of the system of the present invention. DETAILED DESCRIPTION

[0047] The present invention is further described below in conjunction with the embodiments, but it should not be understood that the above subject matter of the present invention is limited to the following embodiments. Without departing from the above technical ideas of the present invention, various substitutions and changes are made according to the common technical knowledge and customary means in the art, which should all be included in the protection scope of the present invention.

[0048] Embodiment 1:

[0049] See also Figure 1 to Figure 2 , high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, including development board, IO module, signal conditioner, and drive amplifier;

[0050] The signal conditioner collects real-time displacement signal data of the intelligent tool and transmits it to the development board through the IO module;

[0051] The development board is integrated with ARM and a high-performance computing unit;

[0052] The ARM side of the development board and the high-performance computing unit transmit data via the IPC protocol;

[0053] The ARM end of the development board receives the real-time displacement signal data of the IO module;

[0054] The high performance computing unit processes the real-time displacement signal data, generates a control signal, and transmits it back to the ARM end;

[0055] The ARM terminal transmits the control signal to the driving amplifier through the IO module;

[0056] The driving amplifier amplifies the control signal and transmits it to the piezoelectric compensation module on the intelligent tool to drive the intelligent tool to perform displacement compensation action;

[0057] The high performance computing unit integrates a feedforward controller, a feedback controller and an equivalent disturbance observer w(t)=w FF (t)+w FB (t)+w DC (t);

[0058] The feedforward controller analyzes the given reference trajectory displacement compensation input signal r(t) and calculates the feedforward control quantity w FF (t);

[0059] The feedback controller generates the feedback control quantity w based on the real-time error e(t) between the expected output and the actual output FB (t), correct the dynamic error;

[0060] The equivalent disturbance observer calculates the disturbance observation w DC (t), and dynamically compensate the control signal.

[0061] Feedforward control quantity w FF (t) is as follows:

[0062]

[0063] Where b1 and b2 are constants (their values ​​are obtained by calibrating historical data and used as control coefficients of the feedforward control quantity), and r(t) is the reference trajectory displacement compensation input signal.

[0064] Feedback control quantity w FB (t) is as follows:

[0065] w FB (t) = K I E1(t)+K P E2(t)+K D E3(t)(2)

[0066] In the formula, K I , K P , K D is the PID parameter; E1(t)=e(t), e(t) is the real-time error.

[0067] The equivalent disturbance observer is constructed based on the extended state space equation;

[0068] The expanded state space equations are shown below:

[0069]

[0070] In the formula, x1 and x2 are state variables, b1 and b2 are constants, q(t) is the overall equivalent disturbance, and y is the output of the system;

[0071] The equivalent disturbance observer is as follows:

[0072]

[0073] Where z1, z2, z3 are estimates of states x1, x2, x3, β1, β2, β3 are designed state observer gains, is the output of the state observer.

[0074] The overall equivalent disturbance q(t) is observed by z3 in the state observer.

[0075] The disturbance observation w used by the compensation controller to perform disturbance compensation control DC (t) is as follows:

[0076]

[0077] Where b2 is a constant and z3 is an estimate of the state x3.

[0078] The development board communicates with multiple IO modules at high speed via the EtherCAT protocol, with a communication rate of 100Mbps-1Gbps.

[0079] The ARM side of the development board runs the Linux system, and the high-performance computing unit runs a real-time operating system.

[0080] The development board with the ARM processor and the high performance computing unit is developed in a Linux environment, and a specific software development kit is installed to support a real-time operating system required by the high performance computing unit.

[0081] During development, the Linux system is modified using real-time patches so that the development board supports the EtherCAT protocol at the microsecond level; the real-time patches include but are not limited to RT-Preempt and Xenomai.

[0082] Embodiment 2:

[0083] High-speed real-time signal acquisition and control system for intelligent tool displacement compensation, including development board, IO module, signal conditioner, and drive amplifier;

[0084] The signal conditioner collects real-time displacement signal data of the intelligent tool and transmits it to the development board through the IO module;

[0085] The development board is integrated with ARM and a high-performance computing unit;

[0086] The ARM side of the development board and the high-performance computing unit transmit data via the IPC protocol;

[0087] The ARM end of the development board receives the real-time displacement signal data of the IO module;

[0088] The high performance computing unit processes the real-time displacement signal data, generates a control signal, and transmits it back to the ARM end;

[0089] The ARM terminal transmits the control signal to the driving amplifier through the IO module;

[0090] The driving amplifier amplifies the control signal and transmits it to the piezoelectric compensation module on the intelligent tool to drive the intelligent tool to perform displacement compensation action;

[0091] The high performance computing unit integrates a feedforward controller, a feedback controller and an equivalent disturbance observer w(t)=w FF (t)+w FB (t)+w DC (t);

[0092] The feedforward controller analyzes the given reference trajectory displacement compensation input signal r(t) and calculates the feedforward control quantity w FF (t);

[0093] The feedback controller generates the feedback control quantity w based on the real-time error e(t) between the expected output and the actual output FB (t), correct the dynamic error;

[0094] The equivalent disturbance observer calculates the disturbance observation w DC (t), and dynamically compensate the control signal.

[0095] Embodiment 3:

[0096] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content is the same as that of Example 2, further, the feedforward control quantity w FF (t) is as follows:

[0097]

[0098] Where b1 and b2 are constants, and r(t) is the reference trajectory displacement compensation input signal.

[0099] Embodiment 4:

[0100] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Embodiments 2-3, further, the feedback control quantity w FB (t) is as follows:

[0101] w FB (t) = K I E1(t)+K P E2(t)+K D E3(t)(2)

[0102] In the formula, K I , K P , K D is the PID parameter; E1(t)=e(t), e(t) is the real-time error.

[0103] Embodiment 5:

[0104] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Embodiments 2-4, and further, an equivalent disturbance observer is constructed according to an extended state space equation;

[0105] The expanded state space equations are shown below:

[0106]

[0107] In the formula, x1 and x2 are state variables, b1 and b2 are constants, q(t) is the overall equivalent disturbance, and y is the output of the system;

[0108] The equivalent disturbance observer is as follows:

[0109]

[0110] Where z1, z2, z3 are estimates of states x1, x2, x3, β1, β2, β3 are designed state observer gains, is the output of the state observer.

[0111] Embodiment 6:

[0112] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Examples 2-5, and further, the overall equivalent disturbance q(t) is obtained by observing z3 in the state observer.

[0113] Embodiment 7:

[0114] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of embodiments 2-6, and further, the disturbance observation quantity w of the compensation controller for disturbance compensation control DC (t) is as follows:

[0115]

[0116] Embodiment 8:

[0117] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Examples 2-7. Furthermore, the development board communicates with multiple IO modules at high speed via the EtherCAT protocol, with a communication rate of 100Mbps-1Gbps.

[0118] Embodiment 9:

[0119] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Examples 2-8. Furthermore, the ARM side of the development board runs a Linux system, and the high-performance computing unit runs a real-time operating system.

[0120] Embodiment 10:

[0121] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Examples 2-9, and further, the development board is developed in a Linux environment.

[0122] Embodiment 11:

[0123] A high-speed real-time signal acquisition and control system for intelligent tool displacement compensation, the technical content of which is the same as any one of Examples 2-10. Furthermore, during development, a real-time patch is used to transform the Linux system so that the development board supports the EtherCAT protocol at the microsecond level; the real-time patch includes but is not limited to RT-Preempt and Xenomai.

[0124] Embodiment 12:

[0125] High-speed real-time signal acquisition and control system for intelligent tool displacement compensation, such as Figure 1 and Figure 2 As shown in the figure, the system organically combines hardware communication with complex control algorithms to achieve precise control and displacement compensation of intelligent tools.

[0126] like Figure 2 As shown in Figure 1, the system mainly consists of a development board (including ARM and high-performance computing unit), IO module, signal conditioner, drive amplifier and intelligent tool. The development board communicates with multiple IO modules at high speed through the EtherCAT protocol. The IO module is responsible for collecting real-time signal data of the intelligent tool and transmitting the data to the high-performance computing unit for processing. As the core computing unit of the system, the high-performance computing unit deploys a three-degree-of-freedom control algorithm (see Figure 1 ), the algorithm consists of a feedforward controller, a feedback controller and an equivalent disturbance observer, and uses the Hammerstein model to achieve real-time compensation control of the intelligent tool.

[0127] 1. For heterogeneous multi-core processor development boards that include ARM and high-performance computing units, usually the ARM side runs the Linux system, while the high-performance computing unit and other processor cores (such as Cortex-M4) run real-time operating systems, such as SYS / BIOS. When the ARM side runs the Linux system, and the high-performance computing unit or other processor cores run a real-time operating system, and joint development is achieved through IPC components, development must be carried out in a Linux environment, and a specific software development kit must be installed to support the real-time operating system required by the high-performance computing unit. This configuration is suitable for a variety of development boards with heterogeneous multi-core processors. By reasonably configuring the development environment and software tools, efficient collaboration and real-time data processing between different processor cores can be achieved. Only after completing the above configuration as required can the IPC protocol be configured.

[0128] 2. In the traditional Linux system, due to the lack of real-time characteristics, the EtherCAT protocol cannot be directly supported, and the real-time performance of the system needs to be enhanced through real-time patches (such as RT-Preempt or Xenomai). The present invention uses a real-time Linux system (Linux-RT) modified by the RT patch, so that the development board can achieve accurate and low-latency support for the EtherCAT protocol. In this way, the system can achieve microsecond-level data communication and processing, greatly improving the real-time response capability of the intelligent tool.

[0129] Algorithm principle (combined with Figure 1 )

[0130] Estimator and feedback linearization: During the control process of the intelligent tool, the system identifies the nonlinear characteristics of the tool through the estimator and uses feedback linearization technology to simplify the system dynamics, thereby improving the efficiency and accuracy of the control algorithm.

[0131] Feedforward controller: The feedforward controller calculates the feedforward control quantity w by analyzing the expected input signal r(t) FF (t), predict and adjust system operation in advance. Feedforward control signals are directly input into the control system to provide fast response capability and reduce errors caused by delays.

[0132] Feedback controller: The feedback controller generates the feedback control quantity w based on the real-time error e(t) (the difference between the expected output and the actual output) FB (t) Correct the dynamic error of the system to ensure control accuracy. This closed-loop feedback mechanism effectively suppresses various uncertainties in the machining process.

[0133] Equivalent disturbance observer: This module monitors the disturbance factors in the system in real time and calculates the disturbance observation w DC (t), and dynamically compensate the control signal. The equivalent disturbance observer enables the system to adapt to changes in the external environment in a timely manner, thereby improving the stability of the intelligent tool.

[0134] System operation process (combined with Figure 2 )

[0135] 1. Data acquisition and transmission: The IO module collects digital and analog signals of the intelligent tool through the EtherCAT protocol, and transmits the data to the high-performance computing unit of the development board for real-time processing.

[0136] 2. Real-time calculation and compensation: The three-degree-of-freedom control algorithm deployed by the high-performance computing unit analyzes and calculates the collected signals to generate accurate control signals. After the calculation is completed, the control signal is transmitted to the ARM through the IPC and then returned to the IO module through the Ethernet interface.

[0137] 3. Control execution: After the displacement control signal is amplified by the signal drive amplifier, it finally drives the piezoelectric ceramic to produce a piezoelectric effect, thereby controlling the intelligent tool to perform precise compensation actions. The entire process achieves high-speed, low-latency closed-loop control.

[0138] The present invention combines high-speed data communication and advanced three-degree-of-freedom control algorithms to achieve real-time displacement compensation for intelligent tools. Compared with traditional compensation methods, the present invention can dynamically detect and adjust various disturbances that occur during the processing process, improving the compensation accuracy and response speed of the system. Utilizing the powerful computing power of the high-performance computing complex and the high-speed communication of EtherCAT, the system can complete data acquisition, calculation and feedback in a very short time, ensuring that the intelligent tool maintains high-precision control in a high-speed processing environment.

[0139] The present invention significantly improves the stability and accuracy of intelligent tools under complex processing conditions, reduces processing errors, extends the service life of tools, and reduces production costs, providing an innovative and efficient solution for high-precision processing in industrial applications.

Claims

1. High-speed real-time signal acquisition and control system for intelligent tool displacement compensation, characterized by: Including development board, IO module, signal conditioner, and driver amplifier. The signal conditioner collects real-time displacement signal data of the intelligent tool and transmits it to the development board through the IO module; The development board is integrated with ARM and a high-performance computing unit; The ARM side of the development board and the high-performance computing unit transmit data via the IPC protocol; The ARM end of the development board receives the real-time displacement signal data of the IO module; The high performance computing unit processes the real-time displacement signal data, generates a control signal, and transmits it back to the ARM end; The ARM terminal transmits the control signal to the driving amplifier through the IO module; The driving amplifier amplifies the control signal and transmits it to the piezoelectric compensation module on the intelligent tool to drive the intelligent tool to perform displacement compensation action; The high performance computing unit integrates a feedforward controller, a feedback controller and an equivalent disturbance observer w(t)=w FF (t)+w FB (t)+w DC (t); The feedforward controller analyzes the given reference trajectory displacement compensation input signal r(t) and calculates the feedforward control quantity w FF (t); The feedback controller generates the feedback control quantity w based on the real-time error e(t) between the expected output and the actual output FB (t), correct the dynamic error; The equivalent disturbance observer calculates the disturbance observation w DC (t), and dynamically compensate the control signal.

2. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: Feedforward control quantity w FF (t) That is, the inverse of the calculation model is as follows: Where b1 and b2 are constants, and r(t) is the reference trajectory displacement compensation input signal.

3. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: Feedback control quantity w FB (t) is as follows: w FB (t)=K I E1(t)+K P E2(t)+K D E3(t)(2) In the formula, K I , K P , K D is the PID parameter; E1(t)=e(t), e(t) is the real-time error.

4. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: The equivalent disturbance observer is constructed based on the extended state space equation; The expanded state space equations are shown below: In the formula, x1 and x2 are state variables, b1 and b2 are constants, q(t) is the overall equivalent disturbance, and y is the output of the system; The equivalent disturbance observer is as follows: Where z1, z2, z3 are estimates of states x1, x2, x3, β1, β2, β3 are designed state observer gains, is the output of the state observer.

5. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: The overall equivalent disturbance q(t) is observed by z3 in the state observer.

6. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 5, characterized in that: The disturbance observation w used by the compensation controller to perform disturbance compensation control DC (t) is as follows: Where b2 is a constant and z3 is an estimate of the state x3.

7. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: The development board communicates with multiple IO modules at high speed via the EtherCAT protocol, with a communication rate of 100Mbps-1Gbps.

8. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: The ARM side of the development board runs the Linux system, and the high-performance computing unit runs a real-time operating system.

9. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 1, characterized in that: The development board is developed in the Linux environment.

10. The high-speed real-time signal acquisition and control system for intelligent tool displacement compensation according to claim 9, characterized in that: During development, the Linux system is modified using real-time patches so that the development board supports the EtherCAT protocol at the microsecond level; the real-time patches include but are not limited to RT-Preempt and Xenomai.

Images