Multi-axis drive and control integrated servo drive control method and system

Abstract

The invention discloses a multi-axis drive and control integrated servo drive control method and system, and the method comprises the following steps: 1, carrying out the power-on initialization of a system, detecting a communication abnormal state, and initializing the parameters and hardware interfaces of all axes; 2, configuring textile material parameters in the editing picture, including input material tension and weaving density, collecting voiceprint signals in real time during operation of each shaft through a sensor, and extracting sound frequency and amplitude characteristics; 3, dynamically adjusting the output parameters of the corresponding shafts according to the sound characteristics; through the implementation of the invention, the full-flow closed-loop control of the textile machinery is realized, the voiceprint signal acquisition replaces the traditional encoder feedback, and the mechanical state response delay is reduced; shaft parameters are dynamically adjusted based on voiceprint features, and the problem of load unbalance of large, medium and small shafts is solved; and the formula file storage parameters are bound with the voiceprint threshold, so that the debugging time during material switching is remarkably shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of servo drive control, and in particular to a servo drive control method and system for integrating multi-axis drive control. Background Art

[0002] Multi-axis coordinated control of textile machinery is the core technology for improving fabric quality. Traditional equipment uses independent servo drives to control the large axis (warp axis), middle axis (weaving axis), and small axis (sley), relying on encoder position feedback (delay ≥ 5ms); when the tension of materials such as high-elastic yarn and carbon fiber changes suddenly, the system cannot adjust the parameters of each axis in real time, resulting in a yarn breakage rate of up to 12% (Textile Machinery 2023). At the same time, the single-axis independent control strategy lacks an inter-axis coordination mechanism, resulting in a dynamic imbalance of the large axis / middle axis / small axis load, and a weaving uniformity error of > 15%.

[0003] In the existing technology, parameter configuration is too dependent on manual experience: switching to new materials (such as changing from cotton yarn to blended yarn) requires 2-3 hours of re-debugging, including manual setting of tension thresholds, inter-axis speed ratios, etc., resulting in a loss of production efficiency of more than 30%. In addition, mechanical abnormalities (such as bearing wear) are difficult to identify early faults only through displacement or current detection, and sudden shutdowns further aggravate losses.

[0004] In summary, a multi-axis drive and control integrated servo drive control method and system is needed to solve the deficiencies in the prior art. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides a multi-axis drive and control integrated servo drive control method and system, aiming to solve the above problems.

[0006] In a first aspect, the present invention provides a multi-axis drive-control integrated servo drive control system, comprising the following steps: Step 1: Power on and initialize the system, detect abnormal communication status, and initialize the parameters of each axis and hardware interface; Step 2: Configure the textile material parameters in the editing screen, including inputting material tension and weaving density, and collect the soundprint signals of each axis in real time through sensors to extract the sound frequency and amplitude characteristics; Step 3: Dynamically adjust the output parameters of the corresponding axis according to the sound characteristics; Step 4: Select or create a recipe file in the editing screen, and store the current parameter configuration and voiceprint threshold association table in the recipe file; Step 5: Switch to the manual screen or automatic screen according to the operation mode selected by the user; Step 6: Monitor the status of each axis in real time during the processing. If communication anomalies or hardware overlimits are detected, trigger a reset operation and save the processing progress and fault voiceprint data. Through a multi-axis drive and control integrated architecture, realize the closed-loop control of the entire process of textile machinery. The voiceprint signal acquisition replaces the traditional encoder feedback, reducing the mechanical state response delay; dynamically adjust the axis parameters based on the voiceprint characteristics to solve the problem of load imbalance among large, medium, and small axes; and bind the stored parameters in the recipe file with the voiceprint threshold, significantly reducing the debugging time when switching materials.

[0007] Further, in the said Step 1, initializing the parameters of each axis and the hardware interface includes setting the starting positions and safety distances of the large axis, medium axis, and small axis.

[0008] Further, in the said Step 2, the processing of the voiceprint signal includes: Step 2.1: Collect the voiceprint signals of the large axis, medium axis, and small axis through a microphone array or vibration sensor, extract the frequency-domain features through filtering and Fourier transform. The frequency-domain features include the fundamental frequency f0, the amplitude ratios of the 1st - 3rd harmonics, and the frequency band energy entropy, constituting the voiceprint feature vector. Step 2.2: Establish a normal voiceprint feature database for the large axis, medium axis, and small axis, and calculate the deviation value between the current voiceprint feature vector and the database in real time; the threshold setting is dynamically adjusted according to the material tension parameter. For every 5N increase in the material tension, the frequency threshold increases by 2%. Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, generate the corresponding axis parameter adjustment instruction.

[0009] Further, in the said Step 3, the method of dynamically adjusting the output parameters of the corresponding axis according to the sound characteristics includes: When the sound frequency of the large axis is abnormal, link the cooling system to increase the lubricant flow rate; When the sound amplitude of the medium axis exceeds the threshold, adjust the torque output and link to optimize the feeding accuracy of the small axis; After the position of the small axis is calibrated, update the reference coordinates in the recipe file.

[0010] Further, in the said Step 3, when the mutation rate of the frequency band energy entropy exceeds 50%, trigger the torque redistribution of the medium axis and the position compensation of the small axis. The compensation amount is calculated according to the formula ΔY = 0.1×ΔT×ρ, where ΔT is the torque change amount of the medium axis and ρ is the material density coefficient.

[0011] Further, in the said Step 5, the control of the automatic screen includes: Automatically calculate the traction force of the large axis and the feeding speed of the medium axis according to the material tension parameter; Perform PID closed-loop control on the small axis based on the voiceprint fluctuation frequency; When abnormal voiceprint triggers an emergency stop, save the processing progress and generate a fault report.

[0012] Further, the recipe file stores the benchmark value of the voiceprint feature vector, the material tension parameter, the weaving density, the voiceprint feature threshold table, the reference coordinates of each axis, and the safety distance parameter, and the voiceprint feature threshold table in the recipe file is bound to the material tension parameter, and the corresponding threshold is automatically activated when the recipe is loaded.

[0013] Further, the operations of the recipe file include: In response to the insert slot or delete slot instruction in the editing screen, the slot parameter table is dynamically updated, and the slot parameters include the Z starting point of the slot position, the slot thickness, and the Y feed depth of the slot; Establish a mapping relationship between the Y feed depth of the slot and the threshold of the middle-axis voiceprint amplitude. For every 1 mm increase in the slot depth, the threshold of the middle-axis voiceprint amplitude increases by 10%; When switching the recipe file through the previous page or next page instruction, the mapped voiceprint feature threshold and the updated reference coordinates of each axis are automatically loaded.

[0014] In a second aspect, the present invention provides a servo drive control system with multi-axis drive and control integration, including: A user interface module for displaying an editing screen, a manual screen, an automatic screen, and a parameter screen, and the editing screen includes a scrollable slot parameter table; A core control module, including a communication interface, a multi-axis motion planning unit, and an exception handling unit, and the motion planning unit generates instructions for each axis according to the recipe file; A servo drive module for connecting the X-axis, Y-axis, and Z-axis motors, receiving instructions from the core control module, and feeding back real-time position data; A safety monitoring module for connecting each axis limit switch through an optocoupler isolation circuit, real-time detecting displacement overrun and voiceprint abnormality, and the priority of the abnormal signal trigger is higher than the user instruction.

[0015] Further, the core control module further includes: A voiceprint decision-making unit for comparing the real-time voiceprint with the pre-stored feature library and generating a hierarchical response instruction; A multi-axis cooperation unit for automatically triggering the feed precision compensation of the small axis when the middle-axis torque is adjusted.

[0016] The substantial effects of the present invention: 1. In the present invention, through the set multi-axis drive and control integration architecture, the full-process closed-loop control of textile machinery is realized. The voiceprint signal acquisition replaces the traditional encoder feedback, reducing the mechanical state response delay; based on the voiceprint features, the axis parameters are dynamically adjusted, solving the problem of load imbalance of large, medium, and small axes; and the parameters stored in the recipe file are bound to the voiceprint threshold, significantly reducing the debugging time when switching materials.

[0017] 2. In the present invention, by using the fundamental frequency f0, the harmonic amplitude ratio, and the band energy entropy to construct the voiceprint feature vector, the frequency-domain feature combination can distinguish bearing wear, abnormal gear meshing, and material jamming, reducing the false trigger rate. The material tension is dynamically linked with the threshold to avoid false alarms caused by changes in material properties.

[0018] 3. In the present invention, through the mapping formula of the change in the central axis torque ΔT and the compensation amount of the small axis ΔY, the problem of uneven weaving caused by sudden load changes is solved, and the uniformity error is significantly reduced. The groove depth is bound to the voiceprint threshold, improving the stability of thick material processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0020] Figure 1 It is a schematic flow chart of Embodiment 1.

[0021] Figure 2 It is a schematic diagram of the system editing screen of Embodiment 4.

[0022] Figure 3 It is a schematic diagram of the system manual screen of Embodiment 4.

[0023] Figure 4 It is a schematic diagram of the system automatic screen of Embodiment 4.

[0024] Figure 5 It is a schematic diagram of the system user parameters of Embodiment 4. DETAILED DESCRIPTION OF THE INVENTION

[0025] For the convenience of understanding the present invention, the following will describe the present invention in more detail in conjunction with the drawings and specific embodiments. It should be noted that when an element is expressed as "fixed to" another element, it can be directly on the other element, or there can be one or more intermediate elements therebetween. When an element is expressed as "connected to" another element, it can be directly connected to the other element, or there can be one or more intermediate elements therebetween. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this specification are only for the purpose of illustration.

[0026] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by those skilled in the technical field to which this invention belongs. The terms used in the specification of this invention are only for the purpose of describing specific embodiments and are not intended to limit the invention. The term "and / or" used in this specification includes any and all combinations of one or more of the related listed items. Example 1:

[0027] Referring to Figure 1 as shown, a servo drive control system integrating multi-axis drive and control includes the following steps: Step 1: Power on and initialize the system, detect communication abnormal status, and initialize the parameters of each axis and the hardware interface; Step 2: Configure textile material parameters in the editing screen, including input material tension and weaving density, and collect the voiceprint signals of each axis during operation in real time through sensors, and extract the sound frequency and amplitude characteristics; Step 3: Dynamically adjust the output parameters of the corresponding axis according to the voice characteristics; Step 4: Select or create a recipe file in the editing screen, and store the current parameter configuration and the voiceprint threshold association table in the recipe file; Step 5: Switch to the manual screen or the automatic screen according to the selected operation mode by the user; Step 6: Monitor the status of each axis in real time during the processing. If communication abnormality or hardware overlimit is detected, trigger the reset operation and save the processing progress and the fault voiceprint data.

[0028] As an implementation manner, in Step 1, initializing the parameters of each axis and the hardware interface includes setting the starting positions and safety distances of the large axis, medium axis, and small axis.

[0029] As an implementation manner, in Step 2, the voiceprint signal processing includes: Step 2.1: Collect the voiceprint signals of the large axis, medium axis, and small axis through a microphone array or a vibration sensor, extract the frequency-domain characteristics through filtering and Fourier transform. The frequency-domain characteristics include the fundamental frequency f0, the amplitude ratios of the 1st - 3rd harmonics, and the frequency band energy entropy, and form a voiceprint feature vector; Step 2.2: Establish a normal voiceprint feature database for the large axis, medium axis, and small axis, and calculate the deviation value between the current voiceprint feature vector and the database in real time; where the threshold setting is dynamically adjusted according to the material tension parameter. For every 5N increase in the material tension, the frequency threshold increases by 2%; Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, generate a corresponding axis parameter adjustment instruction.

[0030] As an implementation manner, in Step 3, the method for dynamically adjusting the output parameters of the corresponding axis according to the voice characteristics includes: When the frequency of the main shaft sound is abnormal, the linkage cooling system increases the lubricant flow rate; When the sound amplitude of the middle shaft exceeds the threshold, adjust the torque output and linkage to optimize the feeding accuracy of the small shaft; After the position of the small shaft is calibrated, update the reference coordinates in the recipe file.

[0031] As an implementation method, in step 3, when the mutation rate of the band energy entropy exceeds 50%, trigger the torque redistribution of the middle shaft and the position compensation of the small shaft. The compensation amount is calculated according to the formula ΔY = 0.1×ΔT×ρ, where ΔT is the change amount of the middle shaft torque and ρ is the material density coefficient.

[0032] As an implementation method, in step 5, the control of the automatic screen includes: Automatically calculate the traction force of the main shaft and the feeding speed of the middle shaft according to the material tension parameter; Perform PID closed-loop control on the small shaft based on the voiceprint fluctuation frequency; When the abnormal voiceprint triggers an emergency stop, save the processing progress and generate a fault report.

[0033] As an implementation method, the recipe file stores the reference value of the voiceprint feature vector, the material tension parameter, the weaving density, the voiceprint feature threshold table, the reference coordinates of each axis, and the safety distance parameter. And the voiceprint feature threshold table in the recipe file is bound to the material tension parameter, and the corresponding threshold is automatically activated when the recipe is loaded; the groove depth parameter is bound to the voiceprint threshold (groove depth ↑ 1mm → middle shaft amplitude threshold ↑ 10%): Parameter self-adaptation, automatically increase the amplitude tolerance when processing thick materials to avoid false alarms of overload; One-key switching, when loading the recipe, synchronously activate the voiceprint threshold and the reference coordinates to reduce manual intervention.

[0034] As an implementation method, the operations of the recipe file include: In the editing screen, respond to the insert groove or delete groove instruction, and dynamically update the groove parameter table. The groove parameters include the Z starting point of the groove position, the groove thickness, and the Y feed of the groove depth; Establish a mapping relationship between the Y feed of the groove depth and the voiceprint amplitude threshold of the middle shaft. For every 1mm increase in the groove depth, the voiceprint amplitude threshold of the middle shaft increases by 10%; When switching the recipe file through the previous page or next page instruction, automatically load the mapped voiceprint feature threshold and the updated reference coordinates of each axis. Example 2:

[0035] This example is basically the same as the above example, except that it provides dynamic adjustment in the weaving scenario of thick materials. Enter the material tension value of 45N and the weaving density of 120 stitches / cm² in the editing screen, and the system automatically calculates the floating range of the frequency threshold: , Set the slot depth Y feed = 3mm, and the triggering mid-axis soundprint amplitude threshold is increased by 30% (3mm×10% / mm); During processing, the energy entropy mutation rate of the central axis frequency band was detected to be 62% (>50% threshold), and the core control module executed: Redistribute the center shaft torque: ΔT = -15N·m; Calculate the small axis compensation amount according to the formula (ρ=1.2): , The small axis feed accuracy is optimized by linkage and the Y-axis displacement deviation is compensated.

[0036] Save the current parameters to the recipe file, including the voiceprint threshold table (bound to 45N tension), slot parameters (Z starting point = 10mm, Y feed = 3mm); When switching materials of the same type, loading the recipe automatically activates the parameters without manual debugging. Embodiment 3:

[0037] This embodiment is basically the same as the above embodiment, except that it provides a safety monitoring module linkage. When the fundamental frequency f0 of the large shaft soundprint deviates from the normal value by 15% (indicating bearing wear), the safety monitoring module triggers a three-level response through an optocoupler isolation circuit: Primary: Increase lubricant flow (cooling system linkage); Intermediate: Reduce the main shaft speed by 20% and alarm; Advanced: If the limit is exceeded continuously, the machine will be shut down immediately and the fault voiceprint data and processing progress will be saved; Abnormal signals have higher priority than user commands, ensuring zero physical damage to the device. Embodiment 4:

[0038] Reference Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, this embodiment is basically the same as the above embodiment, except that it provides a multi-axis drive and control integrated servo drive control system, including: A user interface module, used to display an edit screen, a manual screen, an automatic screen and a parameter screen, wherein the edit screen includes a scrollable slot parameter table; Edit screen: Displays a scrollable slot parameter table (slot position Z start point, slot thickness, slot depth Y feed); Manual screen: Enable low-speed, medium-speed, high-speed continuous mode and auxiliary function port debugging; Automatic screen: Displays the cutting speed adjustment interface and clamping positioning status.

[0039] The core control module includes a communication interface, a multi-axis motion planning unit, and an exception handling unit. The motion planning unit generates axis commands according to the recipe file. Dual-processor architecture: The FPGA processes the voiceprint signal (response ≤ 20 μs), and the ARM executes the PID control algorithm. Voiceprint decision-making unit: Generates hierarchical response commands according to the mutation rate of the band energy entropy. Multi-axis cooperation unit: When adjusting the torque of the middle axis, compensate the feed of the small axis according to the formula ΔY = K·ΔT.

[0040] The servo drive module has an incremental encoder interface built-in, which is used to connect the motors of the X-axis, Y-axis, and Z-axis, receive the commands of the core control module, and feedback the real-time position data. The safety monitoring module is used to connect the limit switches of each axis through an opto-coupler isolation circuit, detect displacement overrun and voiceprint abnormality in real time, and the priority of the abnormal signal trigger is higher than that of the user command. Connect the limit switch through the opto-coupler isolation circuit, and the priority of the displacement overrun protection is higher than that of the voiceprint abnormality. When an emergency stop occurs, save the processing progress to the recipe file and record the voiceprint spectrogram of the fault point.

[0041] As an implementation, the core control module further includes: A voiceprint decision-making unit, which is used to compare the real-time voiceprint with the pre-stored feature library and generate hierarchical response commands. A multi-axis cooperation unit, which is used to automatically trigger the feed accuracy compensation of the small axis when the torque of the middle axis is adjusted.

[0042] As an implementation, when a voiceprint abnormality occurs, save the processing progress to the recipe file; when the hardware limit is exceeded, interrupt the output of the opto-coupler isolation circuit within 1 ms.

[0043] As an implementation, configurable fields for the starting positions of the X / Z axes, safety distances, Y feed depths, default vertical cutting speeds, and saw blade thickness / diameter parameters.

[0044] It should be noted that the description and drawings of the present invention give the preferred embodiments of the present invention. However, the present invention can be implemented in many different forms and is not limited to the embodiments described in this specification. These embodiments do not impose additional limitations on the content of the present invention. The purpose of providing these embodiments is to make the understanding of the disclosed content of the present invention more thorough and comprehensive. Moreover, the above-mentioned technical features continue to be combined with each other to form various embodiments not listed above, which are all regarded as within the scope described in the description of the present invention; further, for those of ordinary skill in the art, improvements or transformations can be made according to the above description, and all such improvements and transformations should fall within the protection scope of the appended claims of the present invention.

Claims

1. A servo drive control method integrating multi-axis drive and control, characterized in that, It includes the following steps: Step 1: Power on and initialize the system, detect communication abnormal status, and initialize the parameters of each axis and the hardware interface; Step 2: Configure the textile material parameters in the editing screen, including input material tension and weaving density, and collect the voiceprint signals of each axis during operation in real time through sensors, and extract the sound frequency and amplitude characteristics; Step 3: Dynamically adjust the output parameters of the corresponding axis according to the sound characteristics; Step 4: Select or create a recipe file in the editing screen, and store the current parameter configuration and the voiceprint threshold association table into the recipe file; Step 5: Switch to the manual screen or the automatic screen according to the selected operation mode by the user; Step 6: Monitor the status of each axis in real time during the processing. If communication abnormality or hardware overlimit is detected, trigger a reset operation and save the processing progress and the fault voiceprint data.

2. The servo drive control method of multi-axis drive and control integration according to claim 1, characterized in that, In the said Step 1, initializing the parameters of each axis and the hardware interface includes setting the starting positions and safety distances of the large axis, medium axis, and small axis.

3. The servo drive control method for multi-axis drive and control integration according to claim 2, wherein In the said Step 2, the processing of the voiceprint signal includes: Step 2.1: Collect the voiceprint signals of the large axis, medium axis, and small axis through a microphone array or a vibration sensor, extract the frequency-domain characteristics through filtering and Fourier transform. The frequency-domain characteristics include the fundamental frequency f0, the amplitude ratio of the 1st - 3rd harmonics, and the frequency band energy entropy, and form a voiceprint feature vector; Step 2.2: Establish a normal voiceprint feature database for the large axis, medium axis, and small axis, and calculate the deviation value between the current voiceprint feature vector and the database in real time; where the threshold is set and dynamically adjusted according to the material tension parameter. For every 5N increase in the material tension, the frequency threshold increases by 2%; Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, generate a corresponding axis parameter adjustment instruction.

4. The servo drive control method of multi-axis drive and control integration according to claim 3, characterized in that, In the said Step 3, the method of dynamically adjusting the output parameters of the corresponding axis according to the sound characteristics includes: When the sound frequency of the large axis is abnormal, link the cooling system to increase the lubricant flow rate; When the sound amplitude of the medium axis exceeds the threshold, adjust the torque output and link to optimize the feeding accuracy of the small axis; After the position of the small axis is calibrated, update the reference coordinates in the recipe file.

5. The servo drive control method of multi-axis drive and control integration according to claim 4, wherein In the said Step 3, when the mutation rate of the frequency band energy entropy exceeds 50%, trigger the torque redistribution of the medium axis and the position compensation of the small axis. The compensation amount is calculated according to the formula ΔY = 0.1×ΔT×ρ, where ΔT is the torque change amount of the medium axis and ρ is the material density coefficient.

6. The servo drive control method for multi-axis drive and control integration according to claim 5, characterized in that In the said Step 5, the control of the automatic screen includes: Automatically calculate the traction force of the large axis and the feeding speed of the medium axis according to the material tension parameter; Perform PID closed-loop control on the small axis based on the voiceprint fluctuation frequency; When an abnormal voiceprint triggers an emergency stop, save the processing progress and generate a fault report.

7. The servo drive control method of multi-axis drive and control integration according to claim 6, characterized in that, The recipe file stores the reference values of the voiceprint feature vector, the material tension parameter, the weaving density, the voiceprint feature threshold table, the reference coordinates of each axis, and the safety distance parameter. And the voiceprint feature threshold table in the recipe file is bound to the material tension parameter, and the corresponding threshold is automatically activated when the recipe is loaded.

8. The servo drive control method of multi-axis drive and control integration according to claim 7, characterized in that The operations of the recipe file include: Respond to the insert slot or delete slot instruction in the editing screen, and dynamically update the slot parameter table. The slot parameters include the Z starting point of the slot position, the slot thickness, and the Y feed depth of the slot; Establish a mapping relationship between the groove depth Y feed and the mid-axis soundprint amplitude threshold. For every 1mm increase in the groove depth, the mid-axis soundprint amplitude threshold will increase by 10%. When switching recipe files through the previous page or next page command, the mapped voiceprint feature thresholds and updated reference coordinates of each axis are automatically loaded.

9. A servo drive control system integrating multi-axis drive and control is used to implement the servo drive control method of multi-axis drive and control integration as described in any one of claims 1-8, characterized in that, include: A user interface module, used to display an editing screen, a manual screen, an automatic screen and a parameter screen, wherein the editing screen includes a scrollable slot parameter table; The core control module includes a communication interface, a multi-axis motion planning unit and an exception handling unit. The motion planning unit generates instructions for each axis according to the recipe file; Servo drive module, used to connect the X-axis, Y-axis and Z-axis motors, receive instructions from the core control module and feedback real-time position data; The safety monitoring module is used to connect the limit switches of each axis through an optocoupler isolation circuit to detect displacement exceeding the limit and abnormal sound pattern in real time. The abnormal signal triggering priority is higher than the user command.

10. The servo drive control system of the multi-axis drive and control integration according to claim 9, characterized in that, The core control module also includes: Voiceprint decision unit, used to compare real-time voiceprint with pre-stored feature library and generate graded response instructions; The multi-axis collaborative unit is used to automatically trigger the small-axis feed accuracy compensation when the middle-axis torque is adjusted.

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