A multi-axis drive and control integrated servo drive control method and system

Abstract

The present invention discloses a servo drive control method and system with integrated multi-axis drive and control, which includes the following steps: Step 1: initializing the system upon power-on, detecting abnormal communication status, and initializing parameters of each axis and hardware interface; Step 2: configuring textile material parameters in an editing screen, including inputting material tension and weaving density, and collecting the soundprint signals of each axis during operation in real time through a sensor, and extracting sound frequency and amplitude characteristics; Step 3: dynamically adjusting the output parameters of the corresponding axis according to the sound characteristics; through the implementation of the present invention, full-process closed-loop control of textile machinery is realized, soundprint signal collection replaces traditional encoder feedback, and the mechanical state response delay is reduced; the axis parameters are dynamically adjusted based on the soundprint characteristics, which solves the problem of load imbalance among large, medium and small axes; and the recipe file storage parameters are bound to the soundprint threshold, which significantly reduces the debugging time when switching materials.

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 and control. Background Art

[0002] Multi-axis coordinated control of textile machinery is a core technology for improving fabric quality. Traditional equipment uses independent servo drives to control the main axis (warp beam), middle axis (weaving beam), and small axis (sley), relying on encoder position feedback (delay ≥ 5ms). When the tension of materials such as high-elastic yarn and carbon fiber suddenly changes, the system cannot adjust the parameters of each axis in real time, resulting in yarn breakage rates as high as 12% (Textile Machinery, 2023). Furthermore, the lack of inter-axis coordination in single-axis independent control strategies leads to dynamic load imbalance between the main axis, middle axis, and small axis, resulting in weaving uniformity errors exceeding 15%.

[0003] In existing technologies, parameter configuration relies too much on manual experience: switching to new materials (such as changing from cotton yarn to blended yarn) requires 2-3 hours of re-debugging, including manually setting the tension threshold, inter-axis speed ratio, 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 address 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 and control integrated servo drive control system, comprising the following steps:

[0007] Step 1: Power on the system and initialize it, detect abnormal communication status, and initialize the parameters of each axis and hardware interface;

[0008] Step 2: Configure the textile material parameters in the editing screen, including inputting material tension and weaving density. The sensor then collects the soundprint signals of each axis in real time during operation, extracting the sound frequency and amplitude characteristics.

[0009] Step 3: Dynamically adjust the output parameters of the corresponding axis according to the sound characteristics;

[0010] 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;

[0011] Step 5: Switch to the manual screen or automatic screen according to the operation mode selected by the user;

[0012] Step 6: During processing, the status of each axis is monitored in real time. If communication anomalies or hardware overruns are detected, a reset is triggered and the processing progress and fault soundprint data are saved. Through an integrated multi-axis drive and control architecture, closed-loop control of the entire textile machinery process is achieved. Soundprint signal acquisition replaces traditional encoder feedback, reducing mechanical state response delays. Dynamic adjustment of axis parameters based on soundprint characteristics resolves load imbalance issues for large, medium, and small axes. Furthermore, recipe file storage parameters are bound to soundprint thresholds, significantly reducing debugging time when switching materials.

[0013] Furthermore, in step 1, initializing the parameters of each axis and the hardware interface includes setting the starting position and safety distance of the large axis, the middle axis, and the small axis.

[0014] Furthermore, in step 2, the voiceprint signal processing includes:

[0015] Step 2.1: Collect the voiceprint signals of the large axis, middle axis, and small axis through a microphone array or vibration sensor, and extract the frequency domain features through filtering and Fourier transform. The frequency domain features include the fundamental frequency f0, the amplitude ratio of the 1st to 3rd harmonics, and the frequency band energy entropy, which constitute the voiceprint feature vector;

[0016] Step 2.2: Establish a normal voiceprint feature database for the large, medium, and small shafts, and calculate the deviation between the current voiceprint feature vector and the database in real time. The threshold setting is dynamically adjusted based on the material tension parameter. For every 5N increase in material tension, the frequency threshold increases by 2%.

[0017] Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, a corresponding axis parameter adjustment instruction is generated.

[0018] Furthermore, in step 3, the method of dynamically adjusting the output parameters of the corresponding axis according to the sound characteristics includes:

[0019] When the sound frequency of the main shaft is abnormal, the cooling system is linked to increase the lubricant flow;

[0020] When the sound amplitude of the middle axis exceeds the threshold, the torque output is adjusted and the small axis feed accuracy is optimized in conjunction;

[0021] Update the reference coordinates in the recipe file after the small axis position is calibrated.

[0022] Furthermore, in step 3, when the frequency band energy entropy mutation rate exceeds 50%, the central shaft torque redistribution and small shaft position compensation are triggered, and the compensation amount is calculated according to the formula ΔY=0.1×ΔT×ρ, where ΔT is the change in central shaft torque and ρ is the material density coefficient.

[0023] Furthermore, in step 5, the automatic screen control includes:

[0024] Automatically calculate the main shaft traction force and the middle shaft feeding speed according to the material tension parameters;

[0025] Perform PID closed-loop control on the small axis based on the sound pattern fluctuation frequency;

[0026] When an abnormal voiceprint triggers an emergency stop, the processing progress is saved and a fault report is generated.

[0027] Furthermore, the recipe file stores the voiceprint feature vector reference value, material tension parameters, weaving density, voiceprint feature threshold table, reference coordinates of each axis and safety distance parameters, and the voiceprint feature threshold table in the recipe file is bound to the material tension parameters, and the corresponding threshold is automatically activated when the recipe is loaded.

[0028] Furthermore, the operations of the recipe file include:

[0029] In response to the slot insert or slot delete command in the editing screen, the slot parameter table is dynamically updated, wherein the slot parameters include the slot position Z starting point, slot thickness and slot depth Y feed;

[0030] Establish a mapping relationship between the groove depth Y feed and the mid-axis soundprint amplitude threshold. For every 1mm increase in groove depth, the mid-axis soundprint amplitude threshold increases by 10%.

[0031] When switching recipe files through the previous page or next page command, the mapped voiceprint feature thresholds and the updated reference coordinates of each axis are automatically loaded.

[0032] In a second aspect, the present invention provides a multi-axis drive-control integrated servo drive control system, comprising:

[0033] A user interface module for displaying an editing screen, a manual screen, an automatic screen, and a parameter screen, wherein the editing screen includes a scrollable slot parameter table;

[0034] 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;

[0035] The servo drive module is 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;

[0036] 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.

[0037] Furthermore, the core control module further includes:

[0038] Voiceprint decision unit, used to compare real-time voiceprints with pre-stored feature libraries and generate hierarchical response instructions;

[0039] The multi-axis collaborative unit is used to automatically trigger the small axis feed accuracy compensation when the middle axis torque is adjusted.

[0040] Substantial effects of the present invention:

[0041] 1. In the present invention, a multi-axis drive and control integrated architecture is set up to achieve closed-loop control of the entire textile machinery process. Voiceprint signal acquisition replaces traditional encoder feedback, reducing the mechanical state response delay. The axis parameters are dynamically adjusted based on the voiceprint characteristics to solve the problem of load imbalance among large, medium and small axes. In addition, the recipe file storage parameters are bound to the voiceprint threshold, which significantly reduces the debugging time when switching materials.

[0042] 2. In the present invention, by using the fundamental frequency f0, harmonic amplitude ratio, and frequency band energy entropy to construct the voiceprint feature vector, the frequency domain feature combination can distinguish bearing wear, gear meshing abnormality, and material jamming, thereby reducing the false trigger rate. The material tension and threshold are dynamically linked to avoid false alarms caused by changes in material properties.

[0043] 3. In the present invention, the mapping formula of the central shaft torque change ΔT and the small shaft compensation ΔY is used to solve the uneven weaving problem caused by load mutation, the uniformity error is significantly reduced, the groove depth is bound to the soundprint threshold, and the stability of thick material processing is improved. 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 following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0045] Figure 1 Schematic diagram of the process of Example 1.

[0046] Figure 2 This is a schematic diagram of the system editing screen of Example 4.

[0047] Figure 3 This is a schematic diagram of the system manual screen of Example 4.

[0048] Figure 4 This is a schematic diagram of the system automatic screen of Example 4.

[0049] Figure 5 This is a schematic diagram of system user parameters in Example 4. DETAILED DESCRIPTION

[0050] For ease of understanding of the present invention, the present invention will be described in more detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that when an element is described as "fixed to" another element, it can be directly on the other element, or there can be one or more centered elements therebetween. When an element is described as "connected to" another element, it can be directly connected to the other element, or there can be one or more centered elements therebetween. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this specification are for illustrative purposes only.

[0051] Unless otherwise defined, all technical and scientific terms used in this specification have the same meanings as those commonly understood by those skilled in the art to which this invention pertains. The terms used in this specification are intended solely for the purpose of describing specific embodiments and are not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items. Example 1:

[0052] Reference Figure 1 As shown, a multi-axis drive and control integrated servo drive control system includes the following steps:

[0053] Step 1: Power on the system and initialize it, detect abnormal communication status, and initialize the parameters of each axis and hardware interface;

[0054] Step 2: Configure the textile material parameters in the editing screen, including inputting material tension and weaving density. The sensor then collects the soundprint signals of each axis in real time during operation, extracting the sound frequency and amplitude characteristics.

[0055] Step 3: Dynamically adjust the output parameters of the corresponding axis according to the sound characteristics;

[0056] 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;

[0057] Step 5: Switch to the manual screen or automatic screen according to the operation mode selected by the user;

[0058] Step 6: Monitor the status of each axis in real time during the processing. If a communication anomaly or hardware overrun is detected, trigger a reset operation and save the processing progress and fault voiceprint data.

[0059] As an implementation method, in step 1, initializing the parameters of each axis and the hardware interface includes setting the starting position and safety distance of the large axis, the middle axis, and the small axis.

[0060] As an implementation method, in step 2, the voiceprint signal processing includes:

[0061] Step 2.1: Collect the voiceprint signals of the large axis, middle 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 ratio of the 1st to 3rd harmonics, and the frequency band energy entropy, which constitute the voiceprint feature vector.

[0062] Step 2.2: Establish a normal voiceprint feature database for the large, medium, and small shafts, and calculate the deviation between the current voiceprint feature vector and the database in real time. The threshold setting is dynamically adjusted based on the material tension parameter. For every 5N increase in material tension, the frequency threshold increases by 2%.

[0063] Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, a corresponding axis parameter adjustment instruction is generated.

[0064] As an embodiment, in step 3, the method of dynamically adjusting the output parameters of the corresponding axis according to the sound characteristics includes:

[0065] When the sound frequency of the main shaft is abnormal, the cooling system is linked to increase the lubricant flow;

[0066] When the sound amplitude of the middle axis exceeds the threshold, the torque output is adjusted and the small axis feed accuracy is optimized in conjunction;

[0067] Update the reference coordinates in the recipe file after the small axis position is calibrated.

[0068] As an implementation method, in step 3, when the frequency band energy entropy mutation rate exceeds 50%, the central shaft torque redistribution and small shaft position compensation are triggered, and the compensation amount is calculated according to the formula ΔY=0.1×ΔT×ρ, where ΔT is the change in central shaft torque and ρ is the material density coefficient.

[0069] As an implementation method, in step 5, the automatic screen control includes:

[0070] Automatically calculate the main shaft traction force and the middle shaft feeding speed according to the material tension parameters;

[0071] Perform PID closed-loop control on the small axis based on the sound pattern fluctuation frequency;

[0072] When an abnormal voiceprint triggers an emergency stop, the processing progress is saved and a fault report is generated.

[0073] As an implementation method, the recipe file stores the voiceprint feature vector baseline value, material tension parameters, weaving density, voiceprint feature threshold table, axis reference coordinates, and safety distance parameters. The voiceprint feature threshold table in the recipe file is bound to the material tension parameters, 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 → mid-axis amplitude threshold ↑10%):

[0074] Parameters are self-adaptive, automatically increasing the amplitude tolerance when processing thick materials to avoid false overload alarms;

[0075] One-touch switching enables simultaneous activation of voiceprint thresholds and reference coordinates when loading recipes, reducing manual intervention.

[0076] As an implementation method, the operations of the recipe file include:

[0077] In the editing screen, in response to the slot insert or slot delete command, the slot parameter table is dynamically updated. The slot parameters include the slot position Z starting point, slot thickness and slot depth Y feed;

[0078] Establish a mapping relationship between the groove depth Y feed and the mid-axis soundprint amplitude threshold. For every 1mm increase in groove depth, the mid-axis soundprint amplitude threshold increases by 10%.

[0079] When switching recipe files through the previous page or next page command, the mapped voiceprint feature thresholds and the updated reference coordinates of each axis are automatically loaded. Example 2:

[0080] This embodiment is basically the same as the above embodiment, except that it provides dynamic adjustment for thick material weaving scenarios. In the editing screen, enter the material tension value of 45N and the weaving density of 120 needles / cm², and the system automatically calculates the frequency threshold floating range:

[0081] ,

[0082] Set the groove depth Y feed = 3mm, and the triggering axis soundprint amplitude threshold is increased by 30% (3mm×10% / mm);

[0083] During processing, the central axis frequency band energy entropy mutation rate was detected to be 62% (>50% threshold). The core control module executed:

[0084] Redistribute the center axle torque: ΔT = -15N·m;

[0085] Calculate the small axis compensation amount (ρ=1.2) according to the formula:

[0086] ,

[0087] The small axis feed accuracy is optimized in linkage mode to compensate for the Y-axis displacement deviation.

[0088] Save the current parameters to the recipe file, including the voiceprint threshold table (bound to 45N tension) and slot parameters (Z starting point = 10mm, Y feed = 3mm);

[0089] When switching materials of the same type, the loaded recipe automatically activates the parameters without manual debugging. Example 3:

[0090] This embodiment is basically the same as the above embodiment, except that it provides linkage with a safety monitoring module. 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:

[0091] Primary: Increase lubricant flow (cooling system linkage);

[0092] Intermediate: Reduce the main shaft speed by 20% and alarm;

[0093] 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;

[0094] Abnormal signals take priority over user commands, ensuring zero physical damage to the device. Example 4:

[0095] 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:

[0096] User interface module, used to display the editing screen, manual screen, automatic screen and parameter screen, the editing screen includes a scrollable slot parameter table;

[0097] Editing screen: displays a scrollable groove parameter table (groove position Z starting point, groove thickness, groove depth Y feed);

[0098] Manual screen: Enable low-speed, medium-speed, high-speed continuous mode and auxiliary function port debugging;

[0099] Automatic screen: Displays the cutting speed adjustment interface and clamping positioning status.

[0100] 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 based on the recipe file.

[0101] Dual-processor architecture: FPGA processes voiceprint signals (response ≤ 20μs), and ARM executes PID control algorithm;

[0102] Voiceprint decision unit: Generates graded response instructions based on the frequency band energy entropy mutation rate;

[0103] Multi-axis collaborative unit: When adjusting the torque of the middle axis, the feed amount of the small axis is compensated according to the formula ΔY=K·ΔT.

[0104] The servo drive module has a built-in incremental encoder interface for connecting to the X-axis, Y-axis, and Z-axis motors, receiving instructions from the core control module and feeding back real-time position data.

[0105] 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;

[0106] The limit switch is connected through an optocoupler isolation circuit, and the displacement over-limit protection takes priority over the voiceprint abnormality;

[0107] In case of emergency shutdown, the processing progress is saved to the recipe file and the voiceprint spectrum of the fault point is recorded.

[0108] As an implementation method, the core control module further includes:

[0109] Voiceprint decision unit, used to compare real-time voiceprints with pre-stored feature libraries and generate hierarchical response instructions;

[0110] The multi-axis collaborative unit is used to automatically trigger the small axis feed accuracy compensation when the middle axis torque is adjusted.

[0111] As an implementation method, when the voiceprint is abnormal, the processing progress is saved to the recipe file; when the hardware exceeds the limit, the optocoupler isolation circuit is triggered to interrupt the output within 1ms.

[0112] As an implementation method, configurable fields for X / Z axis starting position, safety distance, Y feed depth, default vertical cutting speed and saw blade thickness / diameter parameters.

[0113] It should be noted that the preferred embodiments of the present invention are given in the specification and drawings 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 serve as additional limitations on the content of the present invention. The purpose of providing these embodiments is to make the understanding of the disclosure of the present invention more thorough and comprehensive. In addition, the above-mentioned technical features continue to be combined with each other to form various embodiments not listed above, which are all considered to be within the scope of the description of the present invention; further, it is obvious to those skilled in the art that improvements or changes can be made based on the above description, and all such improvements and changes should fall within the scope of protection of the claims attached to the present invention.

Claims

1. A multi-axis drive and control integrated servo drive control method, characterized in that: The following steps are involved: Step 1: Power on the system and initialize it, 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. The sensor then collects the soundprint signals of each axis in real time during operation, extracting the sound frequency and amplitude characteristics. Calculate the deviation between the current voiceprint feature vector and the database in real time; the threshold setting is dynamically adjusted based on the material tension parameter. For every 5N increase in material tension, the frequency threshold increases by 2%. Step 3: Dynamically adjust the output parameters of the corresponding axis according to the sound characteristics; In 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 main shaft is abnormal, the cooling system is linked to increase the lubricant flow; When the sound amplitude of the middle axis exceeds the threshold, the torque output is adjusted and the small axis feed accuracy is optimized in conjunction; Update the reference coordinates in the recipe file after the small axis position is calibrated; 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 a communication anomaly or hardware overrun is detected, trigger a reset operation and save the processing progress and fault voiceprint data.

2. The servo drive control method for multi-axis drive and control integration according to claim 1, characterized in that: In step 1, initializing the parameters of each axis and the hardware interface includes setting the starting position and safety distance of the large axis, the middle axis, and the small axis.

3. The servo drive control method for multi-axis drive and control integration according to claim 2, characterized in that: In step 2, the voiceprint signal processing includes: Step 2.1: Collect the voiceprint signals of the large axis, middle axis, and small axis through a microphone array or vibration sensor, and extract the frequency domain features through filtering and Fourier transform. The frequency domain features include the fundamental frequency f0, the amplitude ratio of the 1st to 3rd harmonics, and the frequency band energy entropy, which constitute the voiceprint feature vector; Step 2.2: Establish a normal voiceprint feature database for the large axis, middle axis, and small axis; Step 2.3: When the deviation value exceeds the dynamically adjusted threshold, a corresponding axis parameter adjustment instruction is generated.

4. The multi-axis drive and control integrated servo drive control method according to claim 3, characterized in that: In step 3, when the frequency band energy entropy mutation rate exceeds 50%, the central shaft torque redistribution and small shaft position compensation are triggered, and the compensation amount is calculated according to the formula ΔY=0.1×ΔT×ρ, where ΔT is the change in central shaft torque and ρ is the material density coefficient.

5. The servo drive control method for integrated multi-axis drive and control according to claim 4, characterized in that: In step 5, the automatic screen control includes: Automatically calculate the main shaft traction force and the middle shaft feeding speed according to the material tension parameters; Perform PID closed-loop control on the small axis based on the sound pattern fluctuation frequency; When an abnormal voiceprint triggers an emergency stop, the processing progress is saved and a fault report is generated.

6. The multi-axis drive and control integrated servo drive control method according to claim 5, characterized in that: The recipe file stores the voiceprint feature vector reference value, material tension parameters, weaving density, voiceprint feature threshold table, reference coordinates of each axis and safety distance parameters, and the voiceprint feature threshold table in the recipe file is bound to the material tension parameters, and the corresponding threshold is automatically activated when the recipe is loaded.

7. The multi-axis drive and control integrated servo drive control method according to claim 6, characterized in that: The operations of the recipe file include: In response to the slot insert or slot delete command in the editing screen, the slot parameter table is dynamically updated, wherein the slot parameters include the slot position Z starting point, slot thickness and slot depth Y feed; Establish a mapping relationship between the groove depth Y feed and the mid-axis soundprint amplitude threshold. For every 1mm increase in groove depth, the mid-axis soundprint amplitude threshold increases by 10%. When switching recipe files through the previous page or next page command, the mapped voiceprint feature thresholds and the updated reference coordinates of each axis are automatically loaded.

8. A multi-axis drive-control integrated servo drive control system, used to implement the multi-axis drive-control integrated servo drive control method according to any one of claims 1 to 7, characterized in that: include: A user interface module for displaying 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; The servo drive module is 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.

9. The multi-axis drive and control integrated servo drive control system according to claim 8, characterized in that: The core control module also includes: Voiceprint decision unit, used to compare real-time voiceprints with pre-stored feature libraries and generate hierarchical 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.

Images