Mechanical motion synchronous control device, digital factory and digital factory control method

Abstract

The invention discloses a mechanical motion synchronous control device, a digital factory and a digital factory control method. The mechanical motion synchronous control device comprises a first control system, a second control system and a synchronous controller, wherein the first control system comprises a first absolute value multi-turn encoder and a first motor actuator; the second control system comprises a second absolute value multi-turn encoder and a second motor actuator; the first absolute value multi-turn encoder and the second absolute value encoder are connected to the synchronous controller, the first control system transmits mechanical motion position data to the synchronous controller, and the synchronous controller transmits the position data to the second control system to control and adjust the second motor actuator so as to synchronously follow the motion rhythm of the first control system. The controller is connected with the first absolute value multi-turn encoder and the second absolute value multi-turn encoder, position signals can be obtained synchronously, action control over the motor actuator can be achieved by comparing the position signals, and action synchronization of the first absolute value multi-turn encoder and the second absolute value multi-turn encoder is achieved.

Description

Technical Field

[0001] The present invention relates to the field of digital equipment control, and in particular to a mechanical motion synchronization control device, a digital factory, and a digital factory control method. Background Art

[0002] If digital factory management can be used to plan and manage the energy consumption of factory machinery and equipment, significant energy savings can be achieved, reducing production power consumption and carbon emissions. This requires implementing digital sensing, synchronized collaborative automated control, and intelligent planning and management within the motor actuator power transmission components of factory production line machinery and equipment to reduce unnecessary motor motion energy consumption.

[0003] Motors account for the majority of factory energy consumption. Therefore, energy-efficient motor management, sensor-based perception of mechanical motion, digital planning, and the coordinated synchronization of motor production and mechanical motion across the factory have become crucial components of digital factory transformation.

[0004] The majority of motors in current factory equipment are variable-frequency motors, servo motors, stepper motors, and other types of motors. These are managed by programmable logic controllers (PLCs) and automated control systems, with mechanical transmissions driving various production and processing equipment. However, most of these motors lack digital closed-loop sensor sensing for mechanical motion, data upload, and even less systematic and coordinated mechanical motion scheduling. The mechanical motion of motors in various parts of factory production is largely decentralized and independent within small, independent control systems, lacking the synchronized and coordinated management of unified factory scheduling. This results in a high rate of inefficient and wasteful mechanical motion, resulting in motor idling and unnecessary mechanical wear that reduces the lifespan of mechanical equipment. In fact, factory motors rarely use "odometers" to record their mileage.

[0005] In factory automation, the control of factory motors is basically based on programmable logic controllers (PLCs), but also includes dedicated PC motion control and independent servo motion controllers. For example, a typical 6-axis robot is controlled by these controllers to control the inverter-variable frequency motor, servo amplifier-servo motor, or stepper motor, or directly start the motor with a switch.

[0006] We can collectively refer to combinations such as inverters and variable frequency motors, servo amplifiers and servo motors, and so on, as "motor actuators." Communication between controllers and motor actuators is accomplished via industrial fieldbuses or industrial Ethernet. Currently, industrial Ethernet is the most advanced technology. Numerous communication protocols exist for industrial fieldbuses and industrial Ethernet, and no unified protocol has yet been established.

[0007] At the same time, there are many industrial fieldbus protocols and many industrial Ethernet protocols in existing factories.

[0008] Industrial Ethernet is an Ethernet technology applied to the field of industrial control. Technologically, it is compatible with commercial Ethernet (IEEE802.3 standard) and can be applied to the production of digital factories and process automation. However, when Ethernet is used for industrial control, what needs to be reflected at the application layer are real-time communication, objects for system configuration, and application protocols for engineering models. Industrial Ethernet needs to meet the requirements of the industrial site in terms of interoperability, reliability, anti-interference, and intrinsic safety.

[0009] There are currently multiple protocols for industrial Ethernet, such as Profinet, EtherCat, CC-Link IE, ModbusTCP, Ethernet, and so on.

[0010] Each controller has its own programmable functions, and the versions of its programming software vary from manufacturer to manufacturer, are not compatible with each other, and have not been unified.

[0011] Therefore, the motor automation in the factory is managed and controlled separately. Unless the entire factory selects the same PLC and motion controller from the same manufacturer and selects the communication protocol of the same communication method. Due to different on-site process requirements in different factories and different user usage habits, it is difficult to choose to use only one PLC from one manufacturer and only one communication protocol, and it is impossible to achieve unified collaborative synchronous control, data recording, management, and scheduling of the factory motors.

[0012] For this reason, it is difficult to achieve the digital unified scheduling and energy-saving goals of each motor in the factory. In addition to continuing to wait for the versions of various PLC programming software to be unified and waiting for various industrial field communication protocols to be unified, the transformation of digital factories also requires a technological breakthrough to solve the problem of digital unified scheduling and energy-saving of factory motors. Summary of the Invention

[0013] The technical problem to be solved by the present invention is to overcome the above-mentioned defect that it is difficult to achieve digital closed-loop sensor perception of the mechanical motion segment of the equipment motors in the factory in the prior art, and to provide a mechanical motion synchronous control device, a digital factory, and a digital factory control method.

[0014] The present invention solves the above technical problems through the following technical solutions:

[0015] A mechanical motion synchronization control device is used to control mechanical equipment in a factory. The mechanical motion synchronization control device includes: a first control system, a second control system, and a synchronization controller. The first control system includes a first absolute multi-turn encoder and a first motor actuator. The first absolute encoder is arranged at the mechanical motion end of the first motor actuator. The first absolute multi-turn encoder is used to sense the mechanical motion parameters of the first motor actuator. The second control system includes a second absolute multi-turn encoder and a second motor actuator. The second absolute encoder is arranged at the mechanical motion end of the second motor actuator. The second absolute multi-turn encoder is used to sense the mechanical motion parameters of the second motor actuator. The first absolute multi-turn encoder and the second absolute encoder are connected to the synchronization controller in a parallel serial port-to-point manner. The first control system transmits the mechanical motion position data of the first control system to the synchronization controller. The synchronization controller sends the mechanical motion position data of the first control system to the second control system. The second control system controls and adjusts the second motor actuator according to the mechanical motion position data of the first control system to synchronously follow the motion rhythm of the first control system. The second control system is also used to send a feedback signal to the synchronization controller. After comparing the feedback signal, the synchronization controller sends a control signal to the second control system.

[0016] In this solution, by adopting the above structure, the controller is used to connect the first absolute multi-turn encoder of the first control system and the second absolute multi-turn encoder of the second control system. Thus, the controller can synchronously obtain the position signals sent by the first absolute multi-turn encoder and the second absolute multi-turn encoder of the second control system. Furthermore, the action control of the first motor actuator or the second motor actuator can be realized by comparing the position signals, and the actions of the two can be synchronized. The mechanical motion synchronization control device can realize the digital closed-loop of sensor perception in the mechanical motion section and can achieve the high-efficiency energy saving of the digital factory.

[0017] Optionally, the synchronization controller includes a central processing unit and a corresponding control program. The central processing unit is used to calculate the input parameters. The control program can be used to set the parameters of the second control system.

[0018] Optionally, the synchronization controller is used to determine the starting points of the first absolute multi-turn encoder and the second absolute multi-turn encoder. The synchronization controller is also used to read and synchronously compare the absolute positions of the first absolute multi-turn encoder and the absolute positions of the second absolute multi-turn encoder in real time. According to the difference between the absolute positions of the first absolute multi-turn encoder and the absolute positions of the second absolute multi-turn encoder, the synchronization controller adjusts the deviation correction control of the second control system.

[0019] Optionally, when the difference between the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder is greater than a preset value, the synchronization controller is further configured to issue an alarm signal.

[0020] Optionally, the synchronization controller communicates with the second control system via an industrial Ethernet.

[0021] Optionally, the synchronization controller further includes two serial port inputs. The first control system and the second control system are respectively communicatively connected to the synchronization controller through the serial port inputs. The two serial port inputs are used to collect the signals of the first absolute multi-turn encoder and the second absolute multi-turn encoder in real time.

[0022] Optionally, the synchronization controller further includes a data memory for storing initialization parameters.

[0023] A digital factory, the digital work including the mechanical motion synchronization control device as described above.

[0024] A digital factory control method for controlling the digital factory as described in item 8 above.

[0025] On the basis of conforming to the common knowledge in the art, the above preferred conditions can be combined arbitrarily to obtain various preferred examples of the present invention.

[0026] The positive and progressive effects of the present invention are as follows:

[0027] In the gantry device of the present invention, by using a controller to connect the first absolute multi-turn encoder of the first control system and the second absolute multi-turn encoder of the second control system, the controller can synchronously obtain the position signals sent by the first absolute multi-turn encoder and the second absolute multi-turn encoder of the second control system. Furthermore, the action control of the first motor actuator or the second motor actuator can be realized by comparing the position signals, and the actions of the two can be synchronized. The mechanical motion synchronization control device can realize the digital closed-loop of the sensor in the mechanical motion section and can achieve the high-efficiency energy saving of the digital factory. Description of the Drawings

[0028] Figure 1 It is a schematic diagram of the mechanical motion synchronization control device of the present invention.

[0029] Figure 2 It is Figure 1 A schematic diagram of the structure of the absolute multi-turn encoder in the mechanical motion synchronization controller.

[0030] Figure 3 It is Figure 2Schematic diagram of the installation of an absolute encoder to the output shaft at the end of the motor reducer.

[0031] Figure 4 For Figure 2 Schematic diagram of the installation of an absolute encoder to the mechanical end of the servo motor - lead screw linear module.

[0032] Figure 5 For Figure 2 Schematic diagram of the installation of an absolute encoder to the robot chassis.

[0033] Figure 6 This is the first schematic diagram of the digital factory of the present invention.

[0034] Figure 7 This is the second schematic diagram of the digital factory of the present invention.

[0035] Figure 8 This is the first schematic diagram of the 6 - axis robot in the digital factory of the present invention.

[0036] Figure 9 This is the second schematic diagram of the 6 - axis robot in the digital factory of the present invention.

[0037] Figure 10 This is the first schematic diagram of the synchronization controller in the mechanical motion synchronization control device of the present invention.

[0038] Figure 11 This is the second schematic diagram of the synchronization controller in the mechanical motion synchronization control device of the present invention.

[0039] Figure 12 This is the schematic diagram of the parameter setting of the absolute multi - turn encoder in the mechanical motion synchronization control device of the present invention.

[0040] Figure 13 This is the schematic diagram of the working block flow of the synchronization controller in the mechanical motion synchronization control device of the present invention.

[0041] Figure 14 This is the schematic diagram of the logic program of the synchronization controller in the mechanical motion synchronization control device of the present invention.

[0042] Figure 15 This is the schematic diagram of the limit tolerance parameter setting in the mechanical motion synchronization control device of the present invention.

[0043] Figure 16 This is the schematic diagram of the on - site preset parameters in the mechanical motion synchronization control device of the present invention.

[0044] Figure 17 This is the schematic diagram of the address search parameter in the mechanical motion synchronization control device of the present invention.

[0045] Figure 18This is a schematic diagram of the output time domain of the synchronization controller in the mechanical motion synchronization control device of the present invention.

[0046] Figure 19 This is a schematic diagram of the motor actuator in the mechanical motion synchronization control device of the present invention.

[0047] Figure 20 This is a schematic diagram of the synchronization position in the mechanical motion synchronization control device of the present invention.

[0048] Figure 21 This is a schematic diagram of the remote management of the digital factory of the present invention.

[0049] Explanation of reference numerals:

[0050] Mechanical motion synchronization control device 100

[0051] First control system 11

[0052] Second control system 12 [[ID=2,6]]

[0053] Synchronization controller 13

[0054] Absolute encoder 20

[0055] Motor actuator 30

[0056] Digital factory 400 Specific implementation manners

[0057] The present invention will be more clearly and completely described below by way of examples in conjunction with the accompanying drawings, but the present invention is not limited to the scope of the examples.

[0058] As Figures 1 - 21 shown, this embodiment includes a mechanical motion synchronization control device 100, a digital factory 400 and a digital factory control method, wherein, the digital factory 400 and the digital factory control method make use of the mechanical motion synchronization control device 100.

[0059] The mechanical motion synchronization control device 100 is used to control the mechanical equipment in the factory. The mechanical motion synchronization control device 100 includes: a first control system 11, a second control system 12 and a synchronization controller 13. The first control system 11 includes a first absolute multi-turn encoder and a first motor actuator. The first absolute encoder 20 is arranged at the mechanical motion end of the first motor actuator. The first absolute multi-turn encoder is used to sense the mechanical motion parameters of the first motor actuator. The second control system 12 includes a second absolute multi-turn encoder and a second motor actuator. The second absolute encoder 20 is arranged at the mechanical motion end of the second motor actuator. The second absolute multi-turn encoder is used to sense the mechanical motion parameters of the second motor actuator. The first absolute multi-turn encoder and the second absolute encoder 20 are connected to the synchronization controller 13 in a parallel serial port point-to-point manner. The first control system 11 transmits the mechanical motion position data of the first control system 11 to the synchronization controller 13. The synchronization controller 13 sends the mechanical motion position data of the first control system 11 to the second control system 12. The second control system 12 controls and adjusts the second motor actuator according to the mechanical motion position data of the first control system 11 to synchronously follow the motion rhythm of the first control system 11. The second control system 12 is also used to send a feedback signal to the synchronization controller 13. After comparing the feedback signal, the synchronization controller 13 sends a control signal to the second control system 12. By connecting the first absolute multi-turn encoder of the first control system 11 and the second absolute multi-turn encoder of the second control system 12 with the controller, the controller can synchronously obtain the position signals sent by the first absolute multi-turn encoder and the second absolute multi-turn encoder of the second control system 12. Furthermore, the action control of the first motor actuator or the second motor actuator can be realized by comparing the position signals, and the action synchronization of the two can be achieved. The mechanical motion synchronization control device 100 can realize the digital closed-loop of sensor perception in the mechanical motion section and can achieve the high-efficiency energy saving of the digital factory.

[0060] The first motor actuator and the second motor actuator correspond to the motor actuator 30 in the figure.

[0061] The synchronization controller 13 includes a central processing unit and corresponding control programs. The central processing unit is used to calculate the input parameters, and the control program can be used to set the parameters of the second control system 12.

[0062] The synchronization controller 13 is used to determine the starting points of the first absolute multi-turn encoder and the second absolute multi-turn encoder. The synchronization controller 13 is also used to read and synchronously compare the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder in real time. According to the difference between the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder, the synchronization controller 13 adjusts the deviation correction control of the second control system 12.

[0063] When the difference between the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder is greater than a preset value, the synchronization controller 13 is further configured to issue an alarm signal.

[0064] The synchronization controller 13 communicates with the second control system 12 via an industrial Ethernet.

[0065] The synchronization controller 13 further includes two serial port inputs. The first control system 11 and the second control system 12 are respectively communicatively connected to the synchronization controller 13 through the serial port inputs. The two serial port inputs are used to collect the signals of the first absolute multi-turn encoder and the second absolute multi-turn encoder in real time.

[0066] The synchronization controller 13 further includes a data memory for storing initialization parameters.

[0067] This embodiment further includes a digital factory 400, and the digital factory includes the mechanical motion synchronization control device 100 as described above.

[0068] This embodiment also includes a digital factory control method for controlling the digital factory 400 as described above.

[0069] There is no need to uniformly use the same type of PLC, nor the same communication protocol. By retaining the various process requirements and the original user usage habits of each factory, it is still possible to achieve the synchronous cooperation control of the motor actuators 30 in each hybrid automation control system within the factory through a set of mechanical motion sensing sensors (absolute multi-turn encoders) and an edge processor for synchronous calculation and processing. The number of a set of mechanical motion sensing sensors (absolute multi-turn encoders) can be 2 or other values.

[0070] Figure 4 The expressed main control system A, subsystem B1, subsystem B2, and subsystem B3 can all be automation control devices and motor actuators 30 with different PLC programming software versions and different industrial Ethernet communication protocol masters.

[0071] For two or more absolute multi-turn encoders, one absolute multi-turn encoder A is installed at the mechanical motion end of the first PLC-motor actuator 30 motion control system to sense the mechanical motion changes (position changes and speed changes) of the motor actuator 30 in this motion control system. Hereinafter, we refer to it as the main control system, or system A, and the absolute multi-turn encoder sensor is simply referred to as the A encoder.

[0072] Another one or more absolute multi-turn encoders B are installed at the mechanical motion end in another PLC-motor actuator 30 motion control system. The internal programming software of the PLC-motor actuator 30 motion control system is a PLC different from A, and it senses the mechanical motion changes of the motor actuator 30 in this system. The first control system 11 and the second control system 12 are hereinafter referred to as the sub-control system, the auxiliary control system, or the A system and the B system. And the sensors of this absolute multi-turn encoder that sense mechanical motion changes, namely the first absolute multi-turn encoder and the second absolute multi-turn encoder, can be simply referred to as the A encoder and the B encoder.

[0073] The A encoder and the B encoder are simultaneously input into a synchronous processing edge processor with a dual-core CPU in a serial port point-to-point parallel connection manner, which we hereinafter simply refer to as the "synchronous controller 13". The synchronous controller 13 outputs a set of optimized data information in the industrial Ethernet communication protocol already available in the PLC of the B system and enters the PLC of the B system. In the PLC program of the B system, a broadcast instruction of the current mechanical motion position information of the A system is thus obtained, and the motor actuator 30 under the B system is controlled and adjusted to synchronously follow the mechanical motion rhythm of the A system. Then, a typical motor actuator 30 in the B system is selected, and the B encoder is installed at its mechanical end as the mechanical motion sensing sensor of the B system. After the feedback signal is compared by the synchronous controller 13, it returns to the PLC of the B system to form a closed loop as the verification of the mechanical motion of the B system for the synchronous following result of the A system.

[0074] Combined Figure 2, as an implementation, both the first absolute multi-turn encoder and the second absolute multi-turn encoder are absolute multi-turn encoders. An absolute multi-turn encoder is a known mechanical motion sensing sensor. It has a mechanical rotating input shaft that drives a code disk inside the rotating absolute multi-turn encoder. During a 360-degree rotation, there is a unique encoding at each angular position on the code disk. These position encodings correspond one-to-one with the angular position of the rotating shaft of the absolute multi-turn encoder. These position encodings are sensed by an internal magnetoelectric principle sensor for this unique angular position encoding. The magnetoelectric principle sensor can also be an optoelectronic principle sensor. When the rotating shaft rotates more than 360 degrees, a set of gearboxes drives the multi-turn sensor code disk to continue sensing the multi-turn angular absolute position information with unique turn number encodings until the cycle zero crossing after the maximum number of turns is reached, and then continues to sense and work. For example, the turn number ranges are 16 turns, 32 turns, 4096 turns, etc. Within the turn number range, each position is unique, similar to the hours, minutes, and seconds in a 12-hour range of a clock. Because all position encodings are based on the encodings already existing on the single-turn 360-degree code disk and the certainty of the absolute position encoding of each unique position on the multi-turn gearbox code disk, the encoded value of the absolute multi-turn encoder is not affected by electrical interference, nor is it affected by the loss of the original zero position relationship due to accidental movement of the rotating shaft after a power outage.

[0075] Combined with Figure 3 , the absolute multi-turn encoder can be installed at the output shaft end of the variable frequency motor reducer, also known as the low-speed end of the reducer and the end of mechanical transmission, to sense the mechanical motion of the motor.

[0076] Combined with Figure 4 , the absolute multi-turn encoder can also be installed at the mechanical end of the lead screw of the servo motor - lead screw combination to sense the rotational motion of the servo motor.

[0077] The absolute multi-turn encoder can also be installed on the rotating shaft of the gear of the rack and pinion to sense the current position value of the relative mechanical motion of the rack and pinion; it can also be installed at the center of the rotating pulley of the rotating belt pulley, such as a factory conveyor belt, to sense the current position change of the mechanical motion of the pulley and the conveyor belt.

[0078] Combined with Figure 5 , the absolute multi-turn encoder can also be installed inside or outside the robot chassis. Through the transmission of large and small gears, the absolute multi-turn encoder is installed on the small gear shaft to sense the current absolute position value of the mechanical rotation of the robot chassis.

[0079] The synchronization controller 13 can be an electrical device that contains a dual-core CPU internally and is attached with a programming program and application parameters that can be pre-set according to the actual on-site conditions. The synchronization controller 13 can be connected to a laptop through serial communication. Through the software interface window of the laptop, the parameters of the two absolute multi-turn encoders connected to this synchronization controller 13 can be modified and set in the real on-site. When the two absolute multi-turn encoders, A and B, have been installed at their respective mechanical positions related to the A system and the mechanical positions related to the B system respectively, the synchronization controller 13 uses the laptop connected to these two absolute multi-turn encoders A and B through the serial port to unify the corresponding zero-point relationships for the mechanical motion perception of the A encoder and the B encoder, make the perceived rotation directions of the mechanical motion consistent, and make the resolution ratio relationship for the comparison between A and B consistent and deterministic, so as to determine that starting from this point, the two absolute multi-turn encoders A and B have a mutual relationship that can perform real-time absolute position reading and mutual synchronization comparison.

[0080] As an implementation method, the A encoder has been installed at the position for mechanical motion perception of the relevant motor drive in the A control system, and the B encoder has been installed at the position for mechanical motion perception of the relevant motor drive in the B control system. The two encoders A and B are input into the device synchronization controller 13 in a serial port point-to-point parallel connection manner. The two control systems A and B can be different types of PLCs and can be different industrial Ethernet communication protocols. The two PLC control systems A and B can be offline in electrical communication without a communication connection.

[0081] Combined Figure 7 、 Figure 8 and Figure 9 , as a special case of a dedicated servo motion controller, the B control system of the 6-axis robot follows the mechanical perception link synchronization of the main control system A as shown in Figure 7 . In Figure 8 , the 6-axis robot serves as the main control system A, and the conveying system for the upstream and downstream processes of robot processing serves as the B system. The B system of the 6-axis robot follows the mechanical perception link synchronization of the A main control system. In Figure 9 , the 6-axis robot is the A main control system, and the upstream and downstream processes of the conveyor belt serve as the B system and follow the synchronization.

[0082] According to the above As shown, the programming software categories and communication interfaces of the two motion control systems can be different hybrid combinations, without the need for the same communication protocol and without the need for electrical communication in an electrical offline manner. Based on two absolute multi-turn encoders installed at the mechanical motion ends of the upper and lower channels A and B respectively, the mechanical motions of their respective typical motor actuators 30 are sensed respectively. The A encoder senses the mechanical motion of the A main control system and sends a signal through a synchronization controller 13 to the B sub-control system through the industrial Ethernet protocol interface already available in the B sub-control system, sending a broadcast command of the A mechanical motion position to the B sub-control system. The B encoder senses the typical motor actuator 30 of the mechanical motion of the B sub-control system and feeds it back to the synchronization controller 13, and is constantly synchronously aligned and compared with the A encoder signal collected in real time in parallel, adjusting the deviation correction control of the B system mechanical motion. When the synchronization deviation between the two exceeds the preset value, a logic switch alarm signal is output and sent to the B sub-control system through the industrial Ethernet protocol carried by the B system.

[0083] The synchronization controller 13 receives the sensor signals of the A encoder and the B encoder in parallel in real time, compares the position relationships between the internal CPUs, and communicates through the industrial Ethernet of the protocol loaded by the internal secondary CPU, and outputs to the B sub-control system. This communication protocol can be selected to be consistent with the communication protocol already available in the B system controller according to user needs, such as Profinet, Ethercat, CC-link IE, etc. The controller of the B system can process in place and in real time the control commands for adjusting the motor motion speed and position of the motor actuator 30 under its control according to the received broadcast command related to the synchronization information of the A mechanical motion.

[0084] The synchronization controller 13 uses the B encoder that senses the mechanical motion of a typical motor actuator 30 in the B system, and its feedback information enters the synchronization controller 13 again, and is in parallel input to the synchronization controller 13 in real time without time difference and low delay with the A encoder, verifying and confirming the synchronization control follow-up effect on the B system motor actuator 30. Such synchronization control is without time difference, without position error accumulation, real-time, with confirmability, and with safety.

[0085] As an implementation method, an A encoder, that is, an absolute multi-turn encoder A, can be installed at the mechanical motion end of the transmission mechanism associated with the motor actuator 30 of the A control system (main control PLC system). Secondly, a B encoder, that is, an absolute multi-turn encoder B, can be installed at the mechanical motion end of the transmission mechanism associated with the motor actuator 30 of the B control system. The installation method can refer to Figures 6 - 9 .

[0086] Reference Figures 1 - 4, the signals of the absolute multi-turn encoder A and the absolute multi-turn encoder B are in parallel input to the synchronization controller 13 through the fast communication signal of the point-to-point serial port. Inside the synchronization controller 13, the mechanical shaft sensor signals of the two encoders A and B are collected in parallel in real time with a refresh time better than 10 ms. The sensing information of the two absolute multi-turn encoders A and B is synchronous without time difference and delay, and there is no accumulation of position errors because it is absolute position encoding.

[0087] The synchronization controller 13 includes a dual-core CPU. The main computing CPU can perform data self-checking, optimization, parameter setting, and position initialization synchronization alignment on the collected encoders A and B, and compare the real-time position differences. The second slave CPU with an internal protocol converts the processing results of the first master CPU into an industrial Ethernet protocol stack consistent with the B system. The data of the two encoders is packaged and optimized into an industrial Ethernet signal for output at the same address. There are multiple standard industrial Ethernet communication protocols available for selection of the communication protocol loaded by the slave CPU inside the synchronization controller 13. For example: profinet, Ethercat, CC-link IE, Ethernet, etc.

[0088] Due to the optimized data of the two absolute multi-turn encoders, the data after synchronization comparison and edge processing, and the uploaded information such as logic switches, etc., only occupy one Ethernet address. The occupation of the Ethernet upload time domain once can greatly accelerate the total communication speed of the B system, save the Ethernet line resources of the B system, and control the B system motor actuator 30 in real time.

[0089] See Figure 10 , the synchronization controller 13 includes the following parts:

[0090] Two parallel inputs for point-to-point serial communication for real-time acquisition, with a refresh time better than 10 ms, such as 2 ms, or 8 ms suitable for longer signal transmission distances, for real-time acquisition of the signals of encoder A and encoder B.

[0091] It has a multi-segment isolated working power supply to provide the working power for each component of the synchronization controller 13.

[0092] The main computing CPU provides computing functions such as encoder data parameter optimization setting, initialization alignment, synchronization comparison calculation, and limit over-tolerance alarm switch, etc.

[0093] The data memory permanently stores the non-volatile initialization parameters of the encoder and other permanent initialization setting parameters.

[0094] The secondary CPU of the selectable industrial Ethernet protocol packet, and the open communication protocols include Profinet, CC-link IE, Ethercat, Ethernet, Modbus TCP, etc. ○5 and ○3 are dual-core CPUs integrated in one package with internal high-speed signal connections.

[0095] Status display indicator lights for various indications of working status and fault status.

[0096] RJ45 standard Ethernet interface.

[0097] The human-machine setting software interface for the connection between the synchronization controller 13 and an external laptop computer, which can perform parameter setting and initialization alignment setting for encoders A and B.

[0098] After encoders A and B are connected to the synchronization controller 13, the two encoders can be initialized for synchronization processing. At the connection port of encoder A at the input port, an external laptop computer can also be connected during the debugging stage for the human-machine interface software for setting process requirements on-site. The current position parameters of each encoder sensor, the logical switch planning of each encoder sensor, and the logical switch planning between multiple encoder sensors can be preset. This external human-machine interface connection can be a RS485 to USB device, connected to the laptop computer, and a software for human-machine interface setting on the PC computer is provided. There is a setting window on this software interface, and the numerical parameters required by the on-site process can be preset. Combined Figure 11 , the basic parameter preset interface of each encoder is shown in the figure.

[0099] After the parameters of the two encoders are set and adjusted, their rotation directions are the same, and their rotation resolutions are the same. The resolution is also called the electronic gear ratio. Then, the initial positions of the two encoders are set to be aligned. This is used as the starting position for subsequent synchronization.

[0100] In Figure 12 , the working block flow of the synchronization controller 13 is shown in the figure. The main CPU always compares the positions of the two encoders with each other, and stores the vector value of B - A in the temporary data memory and then sends it to the subsequent secondary CPU. When the position difference between the two encoders exceeds the preset logical switch comparison value, the corresponding digital logic switch 0 / 1 is output. In Figure 13 , the logic program diagram of the synchronization controller 13 is shown in the figure.

[0101] Combined Figure 14 , for the edge processing of the calculation data of B - A, the setting of the limit over-tolerance logic switch can refer to Figure 15 . The setting interface preset according to the on-site process requirements for the output switch type can refer to Figure 15For the setting of the address of the switch output on the data link for the B sub-control system to find, reference can be made to Figure 16 。

[0102] When the absolute deviation value of (B - A) compared by the synchronization controller 13 in real time is greater than a preset value, it is output to the B system in the form of a digital switch alarm of 0 / 1 codes in the output data of the synchronization controller 13. The B system then promptly sends the switch information of its synchronization loss and alarm stop to the main control A system, and the A system and the B system can promptly handle the fault of mechanical motion synchronization loss. This is the safety function of the synchronization controller 13. This fault digital information can also be uploaded and recorded in the system record of the daily equipment digital management of the factory.

[0103] After the synchronization controller 13 undergoes synchronization edge processing, the time domain of the output signal in the industrial Ethernet protocol that can be received by the B system is shown in Figure 17 。

[0104] Combined with Figure 18 、 20 The industrial Ethernet signal output by the synchronization controller 13 enters the PLC of the B sub-control system. The B system controls and adjusts the motor speed and position of the motor actuator 30 below it, so that the mechanical motion of the motor in the B system is synchronized with the motion control of the mechanical system of the motor in the A system. In Figure 19 PID adjustment can be performed on the position and speed of the motor actuator 30 according to the partition of the deviation magnitude until the position difference reaches 0.

[0105] Select a typical motor actuator 30 in the B system, and install an absolute multi-turn encoder B encoder at the mechanical end of its mechanical transmission. The rotating shaft of the B encoder rotates with the mechanical motion and real-time senses the current absolute position value. The signal of this absolute multi-turn encoder is then fed back to the synchronization controller 13 to verify whether the mechanical motion of the B system and the A system is synchronized. When the deviation of the synchronization control exceeds the preset limit value, a safety limit out-of-tolerance alarm switch signal is output to the B control system, and the B control system broadcasts an alarm with the switch signal to the A control system. The main control A system and the sub-control B system of the entire factory stop to check the cause of the synchronization loss fault and eliminate the fault causing mechanical motion asynchrony.

[0106] The mechanical motion synchronization control device 100 can realize the real-time sensing monitoring and synchronous cooperation control of the underlying machinery in the digital factory 400 under the condition that it is still impossible to unify the PLC software programming and the industrial Ethernet communication protocol, and intelligently realize the sensing, position zero alignment, and acquisition data clock alignment of the power machinery on the entire production line, and the mechanical motion networking synchronous linkage cooperation control based on the industrial Ethernet. The benefits brought by this technology to the digital factory 400 are as follows:

[0107] The factory production line using the mechanical motion synchronization control device 100 is highly efficient and energy-saving. Due to the planning and synchronous linkage of the mechanical motion of the motor actuator 30 on the production line, the rhythm of the previous and subsequent production processes is coordinated, which reduces unnecessary mechanical movements, motor idling waiting, and the waste of adjusting the motor mechanical movement due to failure. It improves production efficiency and saves energy consumption of each motor on the production line. It takes the first step towards the energy-saving goal in the management of mechanical energy consumption at the factory level.

[0108] The mechanical motion synchronization control device 100 can improve the safe production of the digital factory 400. Due to the planning and synchronous linkage of the movement of the motor on the production line, the logical calculation provides a position limit protection switch and a front and rear asynchronous tolerance limit switch, which can greatly reduce the unsafe factors of the equipment exceeding the limit position and the unsafe factors of the uncoordinated processing rhythm of the front and rear process equipment.

[0109] Combine Figure 20 Figure 21 The digital factory 400 can realize remote digital management. Each motor automation control system, including the main control system or the sub-control system, has a typical motor actuator 30 whose mechanical motion information is measured and sensed in real time by an absolute multi-turn encoder. These perception signals have realized industrial Ethernet communication and can be converted into commercial Ethernet through a dedicated data switch to realize digital cloud. In the cloud, the data accumulation of the mechanical motion of the motors in the factory and the process AI modeling of the production site can be completed, thereby realizing remote visualization of the production site and intelligent smart manufacturing.

[0110] Although specific embodiments of the present invention have been described above, those skilled in the art will appreciate that these are merely illustrative and that the scope of the present invention is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, and such changes and modifications are intended to fall within the scope of the present invention.

Claims

1. A mechanical motion synchronization control device for controlling mechanical equipment in a factory, characterized in that, The mechanical motion synchronization control device includes: A first control system, the first control system includes a first absolute multi-turn encoder and a first motor actuator, the first absolute encoder is arranged at the mechanical motion end of the first motor actuator, and the first absolute multi-turn encoder is used to sense the mechanical motion parameters of the first motor actuator; A second control system, the second control system includes a second absolute multi-turn encoder and a second motor actuator, the second absolute encoder is arranged at the mechanical motion end of the second motor actuator, and the second absolute multi-turn encoder is used to sense the mechanical motion parameters of the second motor actuator; A synchronization controller, the first absolute multi-turn encoder and the second absolute encoder are connected to the synchronization controller in a parallel manner of serial port point-to-point. The first control system transmits the mechanical motion position data of the first control system to the synchronization controller, and the synchronization controller sends the mechanical motion position data of the first control system to the second control system. The second control system controls and adjusts the second motor actuator according to the mechanical motion position data of the first control system to synchronously follow the motion rhythm of the first control system; The second control system is also used to send a feedback signal to the synchronization controller. After comparing the feedback signal, the synchronization controller sends a control signal to the second control system.

2. The mechanical motion synchronization control device according to claim 1, characterized in that, The synchronization controller includes a central processing unit and a corresponding control program. The central processing unit is used to calculate the input parameters, and the control program can be used to set the parameters of the second control system.

3. The mechanical motion synchronization control device according to claim 1, wherein The synchronization controller is used to determine the starting points of the first absolute multi-turn encoder and the second absolute multi-turn encoder. The synchronization controller is also used to read and synchronously compare the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder in real time; according to the difference between the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder, the synchronization controller adjusts the deviation correction control of the second control system.

4. The mechanical motion synchronization control device according to claim 2, characterized in that, When the difference between the absolute positions of the first absolute multi-turn encoder and the second absolute multi-turn encoder is greater than a preset value, the synchronization controller is also used to send an alarm signal.

5. The mechanical motion synchronization control device according to claim 1, characterized in that, Industrial Ethernet is used for communication between the synchronization controller and the second control system.

6. The mechanical motion synchronization control device according to claim 1, wherein, The synchronization controller also includes two serial port inputs. The first control system and the second control system are respectively connected to the synchronization controller through the serial port inputs for communication. The two serial port inputs are used to collect the signals of the first absolute multi-turn encoder and the second absolute multi-turn encoder in real time.

7. The mechanical motion synchronization control device according to claim 1, characterized in that The synchronization controller also includes a data memory, and the data memory is used to store initialization parameters.

8. A digital factory, characterized in that, The digitalized work includes the mechanical motion synchronization control device as described in any one of claims 1-7.

9. A digital factory control method, characterized in that, The digitalized factory control method is used to control the digitalized factory as described in claim 8.

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