A method, apparatus, equipment and medium for controlling a mover without manual pushing

Abstract

This invention provides a manual-free mover control method, apparatus, device, and medium, relating to the field of automatic control technology. The method includes: when the magnetic drive conveyor system is powered on, acquiring magnetic field strength data through an electromagnetic component in a composite drive module; determining whether the mover is stationary on a suitable roller conveyor body based on the magnetic field strength data; if so, determining the stationary position of the mover based on the magnetic field strength data; and responding to a control signal sent by a controller, controlling the rotation of rollers on the roller conveyor body according to the stationary position to control the mover's activation. The control signal is a detection information sent by the composite drive module to the controller after detecting that the mover is stationary on the roller conveyor body, and a feedback signal from the controller to the controller based on the detection information. This invention can automatically identify the stationary position of the mover when the magnetic drive conveyor system is powered on, reducing the workload during system power-on and improving the system's ease of use.

Description

Technical Field

[0001] This invention relates to the field of automation technology, and in particular to a method, apparatus, device, and medium for controlling a mover without manual pushing. Background Technology

[0002] While traditional roller conveyors offer advantages such as simple structure and low cost, their low conveying efficiency and poor positioning accuracy severely restrict their widespread application in high-speed conveying. By combining the high-speed and high-precision characteristics of magnetic levitation conveyors with those of traditional roller conveyors, and embedding a magnetic drive control module within the high-speed roller conveyor body, the advantages of both technologies can be complemented. This simultaneously reduces product design complexity and manufacturing costs, creating favorable conditions for large-scale industrial applications.

[0003] Existing magnetic drive conveyor line position sensing devices are mostly incremental. After the equipment is powered on, if the movers are not manually pushed, the sensing device cannot confirm the actual position of each mover. This poses a serious problem for control: there is no feedback on the mover position, making it impossible to form a control closed loop. The movers must be manually pushed at least one station's distance (depending on the line specifications) to obtain the mover's position information. This is manageable for short lines, but if the line is long and there are many movers, manually pushing each mover will undoubtedly bring a lot of complicated and extra workload. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a method, device, equipment and medium for controlling a mover without manual pushing. By analyzing the magnetic field strength data, the stopping position of the mover is determined, thereby driving the mover to start. This solves the problem that the mover must be manually pushed at least one station distance to obtain the position information of the mover when the system is powered on, reducing the workload when the system is powered on and improving the ease of use of the system.

[0005] In a first aspect, embodiments of the present invention provide a manual-free mover control method applied to a composite drive module in a magnetic drive conveyor system. The system includes a controller, a mover, multiple composite drive modules, and a roller conveyor adapted to each composite drive module. The controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor. The mover is capable of moving on the roller conveyor. The method includes:

[0006] When the magnetic drive conveyor system is powered on, magnetic field strength data is collected by the electromagnetic components set in the composite drive module.

[0007] Based on the magnetic field strength data, determine whether the mover remains on the appropriate roller line.

[0008] If so, determine the position of the mover based on the magnetic field strength data;

[0009] In response to a control signal sent by the controller, the rollers on the roller line are rotated according to the stopping position to control the starter. The control signal is a detection information sent by the composite drive module to the controller after detecting that the mover is stopped on the roller line, and the controller feeds back the detection information to the controller.

[0010] In a preferred embodiment of the present invention, the composite drive module is provided with a plurality of electromagnetic components, each of which is evenly distributed on the left, middle and right sides of the composite drive module to form three acquisition areas. The electromagnetic components are used to acquire magnetic field strength data within the acquisition area.

[0011] When the magnetic drive conveyor system is powered on, magnetic field strength data is collected through the electromagnetic components installed in the composite drive module, including:

[0012] With the magnetic drive conveyor system powered on, magnetic field strength data for each of the acquisition areas are obtained.

[0013] In a preferred embodiment of the present invention, determining whether the mover remains on the adapted roller line body based on the magnetic field strength data includes:

[0014] The magnetic field strength data of each of the collected areas are compared with the intensity threshold in turn to obtain the comparison results;

[0015] If the comparison result is that the magnetic field strength data is greater than the strength threshold, it is determined that the mover is stationary on the adapted roller line.

[0016] If the comparison result shows that the magnetic field strength data is less than or equal to the strength threshold, it is determined that the mover is not stationary on the adapted roller line.

[0017] In a preferred embodiment of the present invention, determining the stationary position of the mover based on the magnetic field strength data includes:

[0018] The magnetic field strength data of each of the collected areas are compared to determine the maximum magnetic field strength data;

[0019] The area corresponding to the maximum magnetic field strength data is determined as the stationary position of the mover.

[0020] In a preferred embodiment of the present invention, the acquisition of magnetic field strength data through the electromagnetic components disposed in the composite drive module includes:

[0021] Acquire multiple initial magnetic field strength data within a preset time period;

[0022] The initial magnetic field strength data is calculated using a normal distribution to obtain the magnetic field strength data.

[0023] In a preferred embodiment of the present invention, the above-mentioned response to the control signal sent by the controller, controlling the rotation of the rollers on the roller conveyor according to the dwell position to control the start of the mover, includes:

[0024] In response to a control signal sent by the controller, the roller drive assembly is activated according to the dwell position to drive the rollers on the roller line and activate the mover.

[0025] In a preferred embodiment of the present invention, after determining the stopping position of the mover, the method further includes:

[0026] Based on the stationary position of the mover, detection information is generated and sent to the controller.

[0027] Secondly, embodiments of the present invention also provide a hand-operated mover control device, applied to a composite drive module in a magnetic drive conveyor system. The system includes a controller, a mover, multiple composite drive modules, and a roller conveyor adapted to each composite drive module. The controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor. The mover is movable on the roller conveyor. The device includes:

[0028] The data acquisition module is used to acquire magnetic field strength data through the electromagnetic components set in the composite drive module when the magnetic drive conveyor system is powered on.

[0029] The data analysis module is used to determine whether the mover is stationary on the adapted roller line body based on the magnetic field strength data.

[0030] The position determination module is used to determine the stationary position of the mover based on the magnetic field strength data if the condition is met.

[0031] The start-up module is used to respond to the control signal sent by the controller and control the rotation of the rollers on the roller line according to the dwell position, so as to control the start of the mover. The control signal is a signal sent by the composite drive module to the controller after detecting that the mover is dwelling on the roller line, and the controller feeds back the detection information to the controller.

[0032] Thirdly, embodiments of the present invention also provide an electronic device, including a processor and a memory, wherein the memory stores computer-executable instructions that can be executed by the processor, and the processor executes the computer-executable instructions to implement the manual-free actuator control method of the first aspect described above.

[0033] Fourthly, embodiments of the present invention also provide a computer-readable storage medium storing computer-executable instructions, which, when invoked and executed by a processor, cause the processor to implement the manual-free actuator control method of the first aspect described above.

[0034] The embodiments of the present invention bring the following beneficial effects:

[0035] This invention provides a manual-driven actuator control method. By analyzing magnetic field strength data, the stopping position of the actuator is determined, thereby driving the actuator to start. This solves the problem that the actuator must be manually pushed at least one station distance to obtain the actuator's position information when the system is powered on, reducing the workload when the system is powered on and improving the ease of use of the system.

[0036] Other features and advantages of the invention will be set forth in the following description, or some features and advantages may be inferred from the description or determined without doubt, or may be learned by practicing the techniques described above.

[0037] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0038] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0039] Figure 1 This is a schematic diagram of a hand-operated actuator control system provided in an embodiment of the present invention;

[0040] Figure 2 A flowchart illustrating a hand-operated actuator control method provided in an embodiment of the present invention;

[0041] Figure 3 A flowchart of another hand-push-free mover control method provided in an embodiment of the present invention;

[0042] Figure 4This is a schematic diagram of the structure of a hand-free actuator control device provided in an embodiment of the present invention;

[0043] Figure 5 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention.

[0044] icon:

[0045] 301-Data acquisition module; 302-Data analysis module; 303-Location determination module; 304-Startup module; 400-Memory; 401-Processor; 402-Bus; 403-Communication interface. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Traditional roller conveyor lines, while possessing advantages such as simple structure and low cost, suffer from disadvantages such as low conveying efficiency and poor positioning accuracy, which greatly limits the promotion and application of high-speed conveyor lines. Combining the high speed and high precision characteristics of magnetic levitation conveyor lines, a magnetic drive control module can be embedded in the high-speed roller conveyor line to form a magnetic drive conveyor line. This allows the line to possess the advantages of both, while reducing the design difficulty and cost of the product, which is conducive to the large-scale promotion of the product.

[0048] To minimize costs, the magnetic drive conveyor line is equipped with multiple stations, each fitted with a mover position sensor. Currently, most mover position sensors on magnetic drive conveyors are incremental. Once the equipment is powered on, if the movers are not manually pushed, the sensors cannot determine the actual position of each mover. This poses a serious problem for control: the lack of mover position feedback prevents the formation of a control loop, requiring manual pushing of the movers at least one station's distance (depending on the line specifications) to obtain position information. When the line is short (i.e., smaller in size) and the number of movers is small, the workload of manually pushing the movers is acceptable. However, if the line is long (i.e., larger in size) and the number of movers is large, requiring manual pushing of each mover undoubtedly leads to a cumbersome and excessive workload.

[0049] Since the actuator may be pushed to any position by staff during a power outage, the actuator's position before the power outage cannot accurately describe its position when the power is restored. This can easily cause safety issues when power is restored.

[0050] Based on this, the present invention provides a manual-driven actuator control method that can determine the actuator's stopping position by analyzing magnetic field strength data, thereby driving the actuator to start. This solves the problem that the actuator must be manually pushed at least one station distance to obtain the actuator's position information when the system is powered on, reducing the workload when the system is powered on and improving the ease of use of the system.

[0051] To facilitate understanding of this embodiment, a manual-free actuator control system disclosed in this embodiment of the invention will first be described in detail.

[0052] Example 1

[0053] This invention provides a manual-driven actuator control system. Figure 1 This is a schematic diagram of a hand-operated actuator control system provided in an embodiment of the present invention. The system includes a controller, an actuator, multiple composite drive modules, and a roller conveyor adapted to each of the composite drive modules. Figure 1 Taking a composite drive module and a roller conveyor adapted to the composite drive module as an example, the controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor to work, and the mover can move on the roller conveyor.

[0054] Specifically, the magnetic drive conveyor system includes multiple roller conveyor bodies, which are connected sequentially according to actual needs to form the conveyor line required by the magnetic drive conveyor system. Each roller conveyor body corresponds to a composite drive module, which can be positioned centrally below the roller conveyor body. Multiple movers can be placed at different locations on the conveyor line, and the movers move along the conveyor line. The composite drive module is equipped with an electromagnetic coil, a magnetic drive assembly, and a roller drive assembly. When the magnetic drive conveyor system is powered on, the electromagnetic coil is energized, forming an electromagnet. During the movement of the movers, the movers cut magnetic field lines with the magnetic field generated by the electromagnet, causing an interaction between the magnetic field of the electromagnet and the magnetic field of the permanent magnet on the mover. The magnetic drive assembly changes the current flowing through the electromagnetic coil, thereby changing the magnetic field generated by the electromagnetic coil, and thus changing the interaction between the magnetic field of the electromagnet and the magnetic field generated by the permanent magnet on the mover, providing power for the movers in different directions of movement. It can be understood that the movement directions of the movers include forward, backward, and stop. The magnetic drive assembly controls the speed of the mover by changing the magnitude of the current flowing through the electromagnetic coil; for example, a larger current results in a faster speed. The direction of the mover's movement is controlled by changing the direction of the current flowing through the electromagnetic coil. The correspondence between the current direction and the movement direction is preset according to actual conditions. Multiple rollers, or rollers, are installed on the roller conveyor. When each roller rotates in the same direction, friction propels the mover in the same direction. Specifically, the direction of roller rotation is controlled by the roller drive assembly. When the system is powered on, the mover is stationary, so the magnetic drive assembly cannot move by cutting magnetic field lines, causing an interaction between the magnetic field of the electromagnet and the magnetic field of the permanent magnet on the mover, thus providing power to the mover. At this time, the roller drive assembly controls the rotation of the rollers, using friction to move the mover. After the mover begins to move, it will cut magnetic field lines, causing an interaction between the magnetic field of the electromagnet and the magnetic field of the permanent magnet on the mover. This then activates the magnetic drive assembly, providing power to the mover, and the roller drive assembly stops working.

[0055] The controller can be equipped with buttons, allowing operators to send control signals to the composite drive module by pressing these buttons. These control signals include forward signals, instructing the roller drive components within the composite drive module to control the rotation of the rollers on the roller conveyor, thereby initiating the mover. It is understood that the composite drive module is equipped with multiple electromagnetic components used to collect magnetic field strength data within its acquisition range. When the magnetic drive conveyor system is powered on, the electromagnetic components in the composite drive module collect magnetic field strength data and, based on this data, determine whether the mover is positioned on the appropriate roller conveyor. If so, the module determines the mover's stopping position. The composite drive module then sends this stopping position to the controller. The controller can display the received stopping position, and operators can, upon receiving this position, press a button to send a control signal to the composite drive module, instructing it to control the rotation of the rollers on the roller conveyor, thereby initiating the mover. Furthermore, the controller can also send control signals only to the composite drive module where the mover is positioned.

[0056] The controller can have multiple buttons, each used to send different control signals. These control signals can include forward, backward, and stop signals, used to indicate the direction of movement of the mover controlled by the composite drive module. The forward signal controls the mover to move forward, the backward signal controls the mover to move backward, and the stop signal controls the mover to stop. When the system is powered on, the forward signal is also used to start the mover.

[0057] The manual-driven mover control system of this invention can automatically detect the position of the mover after the system is powered on, and automatically start the mover according to the control command without manual intervention. This avoids the manual operation of pushing the mover, reduces reliance on on-site operators, lowers labor costs, greatly shortens the preparation time for mover start-up, reduces waiting time in the production process, and improves the operating efficiency of the entire magnetic drive conveyor system. It is especially suitable for large-scale, continuous production scenarios and can significantly improve the production cycle time.

[0058] Example 2

[0059] This invention provides a method for controlling a mover without manual pushing. Figure 2 This is a flowchart illustrating a manual-driven actuator control method provided in an embodiment of the present invention. Figure 2 As shown, the manual-free actuator control method may include the following steps:

[0060] Step S101: When the magnetic drive conveyor system is powered on, magnetic field strength data is collected by the electromagnetic components set in the composite drive module.

[0061] After the magnetic drive conveyor system is powered on, the system enters the initialization state, at which point the electromagnetic components in the composite drive module begin to operate. In this invention, the number of electromagnetic components can be one or more, and these components can be high-precision magnetic field sensors, such as Hall effect sensors. The working principle of the magnetic field sensor is based on the Hall effect; when a magnetic field acts on the sensor, an electrical signal proportional to the magnetic field strength is generated at the sensor's output. The sensor collects the surrounding magnetic field strength in real time at a certain sampling frequency (e.g., 1000 times per second), converts the collected analog signals into digital signals, and stores them in the microcontroller of the composite drive module, forming a series of magnetic field strength data. During the acquisition process, to ensure the accuracy and stability of the data, the acquired data is also filtered to remove noise interference, for example, using moving average filtering or median filtering algorithms.

[0062] Furthermore, the composite drive module is provided with multiple electromagnetic components, which are evenly distributed on the left, middle and right sides of the composite drive module to form three acquisition areas. The electromagnetic components are used to acquire magnetic field strength data within the acquisition area. When the magnetic drive conveyor system is powered on, the acquisition of magnetic field strength data through the electromagnetic components in the composite drive module includes: acquiring magnetic field strength data of each acquisition area when the magnetic drive conveyor system is powered on.

[0063] The electromagnetic components on the composite drive module are evenly distributed in three regions: left, middle, and right. The number of electromagnetic components in each region is configured according to the module size and accuracy requirements. For example, on a module with a length of 400mm, five high-precision Hall sensors are arranged as electromagnetic components on the left, middle, and right sides.

[0064] Electromagnetic components typically consist of multiple high-precision magnetic field sensors (such as Hall sensors), which are distributed at different locations in the composite drive module to form a magnetic field sensing array.

[0065] After the magnetic drive conveyor system is powered on, the microcontroller sends synchronous acquisition commands to the electromagnetic components in the three acquisition areas. All electromagnetic components start operating simultaneously at a uniform sampling frequency (e.g., 1000Hz) to ensure the time consistency of the acquired data. These sensors convert the acquired analog signals into digital signals, which are then stored in the microcontroller to form magnetic field strength data for the left, middle, and right regions, respectively. During the acquisition process, to ensure the accuracy and stability of the data, the acquired data is filtered to remove noise interference, for example, using moving average filtering or median filtering algorithms.

[0066] By acquiring magnetic field strength data through electromagnetic components distributed in three regions, the location of the mover can be further determined based on the differences between the magnetic field strength data in different regions. This improves the positioning accuracy compared to data acquisition from a single sensor.

[0067] Step S102: Based on the magnetic field strength data, determine whether the mover is stationary on the appropriate roller line.

[0068] After acquiring the magnetic field strength data, the composite drive module analyzes and processes this data. Under normal circumstances, when the mover is not on the roller line, the magnetic field strength data collected by the electromagnetic component is within a relatively stable background value range; however, when the mover is on the roller line, the magnetic components (permanent magnets) on the mover itself change the surrounding magnetic field distribution, causing a significant change in the magnetic field strength data collected by the electromagnetic component.

[0069] Furthermore, determining whether the mover is stationary on the appropriate roller line based on the magnetic field strength data includes: sequentially comparing the magnetic field strength data of each of the collected areas with an intensity threshold to obtain a comparison result; if the comparison result is that the magnetic field strength data is greater than the intensity threshold, determining that the mover is stationary on the appropriate roller line; if the comparison result is that the magnetic field strength data is less than or equal to the intensity threshold, determining that the mover is not stationary on the appropriate roller line.

[0070] Specifically, a strength threshold can be preset. This threshold, determined through extensive experiments and data analysis, can accurately distinguish the difference in magnetic field strength between the presence and absence of a mover. The collected magnetic field strength data is compared with the preset strength threshold. If the data exceeds the strength threshold, it indicates that the mover is stationary on the roller conveyor; if the data does not exceed the strength threshold, it is considered that the mover is not on the roller conveyor.

[0071] Step S103: If yes, determine the stationary position of the mover based on the magnetic field strength data.

[0072] Once it is determined that the mover has stopped on the roller conveyor, its specific stopping position is further determined based on the magnetic field strength data. Specifically, the magnetic field strength data collected by multiple electromagnetic components on the composite drive module are compared, and the position of the electromagnetic component with the highest magnetic field strength data is determined as the stopping position of the mover.

[0073] Furthermore, determining the stationary position of the mover based on the magnetic field strength data includes: comparing the magnetic field strength data of each of the acquisition areas to determine the maximum magnetic field strength data; and determining the acquisition area corresponding to the maximum magnetic field strength data as the stationary position of the mover.

[0074] Because the electromagnetic components are evenly distributed across the various acquisition areas, when a mover approaches a particular acquisition area, the magnetic field strength data collected by the electromagnetic components in that area will be relatively large. By comparing the magnitudes of the data collected by the sensors in different sensing areas, the position of the mover can be determined.

[0075] Specifically, each acquisition area contains at least one electromagnetic component. For each acquisition area, the average magnetic field strength data collected by each electromagnetic component within that area is calculated and used as the magnetic field strength data for that area. The magnetic field data from the left, middle, and right acquisition areas are compared, and the highest magnetic field strength data is taken as the maximum magnetic field strength data. The acquisition area corresponding to the maximum magnetic field strength data is determined as the stationary position of the mover.

[0076] For example, the average magnetic field strength data in the left region is 18 mT, the average magnetic field strength data in the middle region is 32 mT, and the average magnetic field strength data in the right region is 15 mT. By comparison, it is found that the magnetic field strength data in the middle region is the largest, so the position of the mover is in the middle region.

[0077] Furthermore, when comparing the magnetic field strength data of each of the aforementioned collection areas to determine the maximum magnetic field strength data, the magnetic field strength data of each collection area can be compared with the strength threshold first. Magnetic field strength data that is less than the strength threshold can be removed, and the remaining magnetic field strength data can be compared to determine the maximum magnetic field strength data.

[0078] The location of the mover is determined by comparing the maximum magnetic field strength in three regions. This algorithm has low complexity and can quickly locate the mover, making it suitable for scenarios requiring real-time response. This method does not require complex sensor arrays or high-precision positioning components; its algorithm logic is simple, it has low requirements for the computing power of the microcontroller, and it can reduce system costs, making it suitable for large-scale industrial applications.

[0079] Step S104: In response to the control signal sent by the controller, the rollers on the roller line are controlled to rotate according to the dwell position, so as to control the starter to start.

[0080] The control signal is a signal sent by the composite drive module to the controller after detecting that the mover has stopped on the roller line, and then fed back to the controller based on the detection information. It is understood that the controller only sends control signals to roller lines where the mover is detected to be stopped.

[0081] After determining that the mover is stationary on the roller line and its stationary position, the composite drive module sends relevant detection information to the controller. Upon receiving the detection information, the controller generates corresponding control signals based on the preset control strategy and production task requirements. It can be understood that the detection information describes the mover's stationary position on the roller line adapted to the composite drive module. The composite drive module only sends detection information to the controller when a mover is stationary on the roller line adapted to it. If no mover is stationary on the roller line adapted to it, the composite drive module does not send detection information to the controller. When the composite drive module is connected to the controller, each composite drive module corresponds to one I / O interface of the controller. The controller determines the composite drive module where the mover is stationary and its stationary position based on the I / O interface that receives the detection information. After receiving the detection information, the controller feeds back a control signal to the I / O interface that received the detection information, instructing the composite drive module to control the rotation of the rollers on the roller line to control the mover's start.

[0082] The control signal includes control parameters for the rotation of the rollers on the roller conveyor, such as rotation direction and speed. After receiving the control signal from the controller, the composite drive module controls the motor on the roller conveyor to operate through the drive circuit, thereby driving the rollers to rotate. Due to the friction between the mover and the roller conveyor, the rotation of the rollers pushes the mover along the roller conveyor, thus starting the mover. During the starting process, different control strategies, such as accelerated start-up and smooth start-up, can be adopted according to the mover's dwell position and target position to ensure that the mover can accurately and efficiently reach the designated position. During the starting process, the rotation of all rollers on the roller conveyor can be controlled based on the mover's dwell position to start the mover; alternatively, the rotation of rollers located at the dwell position and in the mover's direction can be controlled based on the dwell position and the mover's direction of movement to start the mover.

[0083] Normally, the distance between two adjacent movers is greater than the length of the roller conveyor, so two adjacent roller conveyors cannot have movers stationed on them simultaneously. However, before the magnetic drive conveyor system is powered on, there may be instances where operator error causes a change in the mover position. In this case, the mover may be stationed between two adjacent roller conveyors. After the magnetic drive conveyor system is powered on, the composite drive module adapted to the two adjacent roller conveyors can collect magnetic field strength data and determine that a mover is stationary on one of the roller conveyors, which is not allowed by the magnetic drive conveyor system. In this situation, the magnetic drive conveyor system will report an error, and the relevant personnel need to manually push the mover to either of the two adjacent roller conveyors to ensure the normal operation of the magnetic drive conveyor system.

[0084] The manual-free mover control method provided in this invention automatically detects the mover's position and starts it automatically according to control commands. This eliminates the need for manual intervention, significantly reducing preparation time and waiting time during production, and improving the overall efficiency of the magnetic drive conveyor system. It is particularly suitable for large-scale, continuous production, significantly increasing production cycle time. Furthermore, controlling the mover's start-up via commands avoids manual operation, reducing reliance on on-site personnel and lowering labor costs. Enterprises do not need to assign dedicated operators for mover start-up, reducing potential errors and safety hazards caused by manual operation, thus improving the safety and stability of the production process. This method achieves fully automated control of the mover from detection to start-up, significantly improving the automation level of the magnetic drive conveyor system.

[0085] Example 3

[0086] This invention also provides another method for controlling a mover without manual pushing; this method is implemented based on the method in the above embodiments; the method focuses on describing the specific implementation of collecting magnetic field strength data through the electromagnetic components set in the composite drive module.

[0087] Figure 3 A flowchart of another manual-free mover control method provided in an embodiment of the present invention is shown below. Figure 3 As shown, the manual-free actuator control method may include the following steps:

[0088] Step S201: When the magnetic drive conveyor system is powered on, acquire multiple initial magnetic field strength data within a preset time period.

[0089] The data collection period can be preset. After the magnetic drive conveyor system is powered on, the electromagnetic components continuously collect magnetic field strength data within the preset period and use it as the initial magnetic field strength data.

[0090] Step S202: Perform normal distribution calculation on the initial magnetic field strength data to obtain magnetic field strength data.

[0091] Based on the formulas for calculating the mean and standard deviation, the mean and standard deviation of the initial magnetic field strength data are calculated. Using the 3σ principle, data points deviating from the mean by more than three times the standard deviation are removed. A normal distribution curve is fitted using the remaining initial magnetic field strength data, and the mean is used as the final magnetic field strength data. Furthermore, when there are multiple electromagnetic components, a normal distribution is calculated for the initial magnetic field strength data collected from each electromagnetic component to obtain the final magnetic field strength data.

[0092] Step S203: Based on the magnetic field strength data, determine whether the mover is stationary on the appropriate roller line.

[0093] Step S204: If yes, determine the stationary position of the mover based on the magnetic field strength data.

[0094] Specifically, after determining the stopping position of the mover, the method further includes: generating detection information based on the stopping position of the mover and sending it to the controller.

[0095] Understandably, the microcontroller in the composite drive module includes an encoder. The encoder sets bits based on the stop position of the mover, and sends the resulting code as detection information to the controller. The encoder can generate a 12-bit binary code, where bits 1-4 correspond to the left region, bits 5-8 to the middle region, and bits 9-12 to the right region. When the stop position is in the left region, bits 1-4 are set to 1, and the other bits are 0. When the stop position is in the middle region, bits 5-8 are set to 1, and the other bits are 0. When the stop position is in the right region, bits 9-12 are set to 1, and the other bits are 0.

[0096] By generating detection information through encoder encoding, a direct mapping between physical space and digital encoding is achieved. The encoding combination of each region is unique, avoiding positional ambiguity and eliminating the need for complex calculations, thereby improving the efficiency and accuracy of detection information generation and transmission.

[0097] In step S205, in response to the control signal sent by the controller, the roller drive assembly is started according to the dwell position to drive the rollers on the roller line and start the mover.

[0098] After receiving the control signal from the controller, the composite drive module controls the motor on the roller line to operate through the drive circuit, which in turn starts the roller drive assembly, thereby driving the roller to rotate. Due to the friction between the mover and the roller line, the rotation of the roller pushes the mover to move along the roller line, thus starting the mover.

[0099] The handless mover control method provided in this embodiment of the invention uses the mean of the normal distribution as an unbiased estimate of the sample. As the number of samplings increases, the mean will be closer to the true magnetic field strength value. By calculating the magnetic field strength data using the normal distribution, the accuracy and stability of the data are ensured, and a reliable basis is provided for subsequent mover position judgment and control.

[0100] Example 4

[0101] Corresponding to the above method embodiments, this invention provides a handless actuator control device applied to a composite drive module in a magnetic drive conveyor system. The system includes a controller, an actuator, multiple composite drive modules, and roller conveyors adapted to each composite drive module. The controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor to work. The actuator can move on the roller conveyor. Figure 4 This is a schematic diagram of a hand-operated actuator control device provided in an embodiment of the present invention, as shown below. Figure 4 As shown, the hand-free actuator control device may include:

[0102] Data acquisition module 301 is used to acquire magnetic field strength data through the electromagnetic components set in the composite drive module when the magnetic drive conveyor system is powered on.

[0103] The data analysis module 302 is used to determine whether the mover is stationary on the adapted roller line body based on the magnetic field strength data.

[0104] The position determination module 303 is used to determine the stationary position of the mover based on the magnetic field strength data if the position is such.

[0105] The start module 304 is used to respond to the control signal sent by the controller and control the rollers on the roller line to rotate according to the dwell position, so as to control the start of the mover. The control signal is a signal sent by the composite drive module to the controller after detecting that the mover is dwelling on the roller line, and the controller feeds back the detection information to the controller.

[0106] The hand-operated mover control device provided in this invention automatically detects the mover's position and starts it automatically according to control commands. This is achieved by collecting and analyzing magnetic field strength data through electromagnetic components in the drive module after the system is powered on, determining whether the mover is positioned on the appropriate roller conveyor. No manual intervention is required, significantly shortening the mover start-up preparation time, reducing waiting time during production, and improving the overall operating efficiency of the magnetic drive conveyor system. It is particularly suitable for large-scale, continuous production scenarios, significantly increasing production cycle time. Simultaneously, controlling the mover start via control commands eliminates the need for manual pushing, reducing reliance on on-site operators and lowering labor costs. Enterprises do not need to assign dedicated operators for mover start-up, and this also reduces potential errors and safety hazards caused by manual operation, improving the safety and stability of the production process. This method achieves fully automated control of the mover from detection to start-up, significantly improving the automation level of the magnetic drive conveyor system.

[0107] In some embodiments, the composite drive module is provided with multiple electromagnetic components, which are evenly distributed on the left, middle, and right sides of the composite drive module to form three acquisition areas. The electromagnetic components are used to acquire magnetic field strength data within the acquisition area. The data acquisition module 301 is further used for:

[0108] With the magnetic drive conveyor system powered on, magnetic field strength data for each of the acquisition areas are obtained.

[0109] In some embodiments, the data analysis module 302 is further configured to:

[0110] The magnetic field strength data of each of the collected areas are compared with the intensity threshold in turn to obtain the comparison results;

[0111] If the comparison result is that the magnetic field strength data is greater than the strength threshold, it is determined that the mover is stationary on the adapted roller line.

[0112] If the comparison result shows that the magnetic field strength data is less than or equal to the strength threshold, it is determined that the mover is not stationary on the adapted roller line.

[0113] In some embodiments, the location determination module 303 is further configured to:

[0114] The magnetic field strength data of each of the collected areas are compared to determine the maximum magnetic field strength data;

[0115] The area corresponding to the maximum magnetic field strength data is determined as the stationary position of the mover.

[0116] In some embodiments, the data acquisition module 301 is further configured to:

[0117] Acquire multiple initial magnetic field strength data within a preset time period;

[0118] The initial magnetic field strength data is calculated using a normal distribution to obtain the magnetic field strength data.

[0119] In some embodiments, the startup module 304 is further configured to:

[0120] In response to a control signal sent by the controller, the roller drive assembly is activated according to the dwell position to drive the rollers on the roller line and activate the mover.

[0121] In some embodiments, the device further includes:

[0122] The information sending module is used to generate detection information based on the stationary position of the mover and send it to the controller.

[0123] The device provided in this embodiment of the invention has the same implementation principle and technical effect as the aforementioned method embodiment. For the sake of brevity, any parts not mentioned in the device embodiment can be referred to the corresponding content in the aforementioned method embodiment.

[0124] Example 5

[0125] This invention also provides an electronic device for running the above-described manual-driven actuator control method; see also Figure 5 The diagram shows the structure of an electronic device, which includes a memory 400 and a processor 401. The memory 400 stores one or more computer instructions, which are executed by the processor 401 to implement the aforementioned manual-free actuator control method.

[0126] Furthermore, Figure 5 The electronic device shown also includes a bus 402 and a communication interface 403. The processor 401, the communication interface 403 and the memory 400 are connected via the bus 402.

[0127] The memory 400 may include high-speed random access memory (RAM) and may also include non-volatile memory, such as at least one disk storage device. Communication between this system network element and at least one other network element is achieved through at least one communication interface 403 (which can be wired or wireless), such as the Internet, wide area network, local area network, metropolitan area network, etc. The bus 402 can be an ISA bus, PCI bus, or EISA bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 5 The symbol is represented by a single double-headed arrow, but this does not mean that there is only one bus or one type of bus.

[0128] Processor 401 may be an integrated circuit chip with signal processing capabilities. In implementation, each step of the above method can be completed by the integrated logic circuitry in the hardware of processor 401 or by instructions in software form. Processor 401 can be a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it can also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. It can implement or execute the methods, steps, and logic block diagrams disclosed in the embodiments of this invention. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the methods disclosed in the embodiments of this invention can be directly manifested as execution by a hardware decoding processor, or execution by a combination of hardware and software modules in the decoding processor. The software module can reside in a readily available storage medium in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, or registers. This storage medium is located in memory 400, and processor 401 reads information from memory 400 and, in conjunction with its hardware, completes the steps of the method described in the foregoing embodiments.

[0129] This invention also provides a computer-readable storage medium storing computer-executable instructions. When these computer-executable instructions are called and executed by a processor, they cause the processor to implement the aforementioned manual-driven actuator control method. For specific implementation details, please refer to the method embodiments, which will not be repeated here.

[0130] The computer program product for the manual-driven actuator control method provided in this embodiment of the invention includes a computer-readable storage medium storing non-volatile program code executable by a processor. The instructions included in the program code can be used to execute the methods described in the preceding method embodiments. For specific implementation details, please refer to the method embodiments, which will not be repeated here.

[0131] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0132] In the several embodiments provided by this invention, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the coupling or direct coupling or communication connection shown or discussed may be through some communication interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0133] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0134] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0135] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this invention, essentially, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0136] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for controlling a mover without manual pushing, characterized in that, A composite drive module is applied in a magnetic drive conveyor system. The system includes a controller, a mover, multiple composite drive modules, and a roller conveyor adapted to each composite drive module. The controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor. The mover can move on the roller conveyor. The method includes: When the magnetic drive conveyor system is powered on, magnetic field strength data is collected by the electromagnetic components set in the composite drive module. Based on the magnetic field strength data, determine whether the mover remains on the appropriate roller line. If so, determine the position of the mover based on the magnetic field strength data; In response to a control signal sent by the controller, the rollers on the roller line located at the stop position and the moving direction are controlled to rotate according to the stop position and the moving direction, so as to control the start of the mover. The control signal is a detection information sent by the composite drive module to the controller after detecting that the mover is stopped on the roller line, and the controller feeds back the detection information to the composite drive module.

2. The method according to claim 1, characterized in that, The composite drive module is equipped with multiple electromagnetic components, which are evenly distributed on the left, middle and right sides of the composite drive module to form three acquisition areas. The electromagnetic components are used to acquire magnetic field strength data within the acquisition area. When the magnetic drive conveyor system is powered on, magnetic field strength data is collected through the electromagnetic components installed in the composite drive module, including: With the magnetic drive conveyor system powered on, magnetic field strength data for each of the acquisition areas are obtained.

3. The method according to claim 2, characterized in that, Determining whether the mover remains on the appropriate roller conveyor based on the magnetic field strength data includes: The magnetic field strength data of each collection area are compared with the intensity threshold in turn to obtain the comparison results; If the comparison result is that the magnetic field strength data is greater than the strength threshold, it is determined that the mover is stationary on the adapted roller line. If the comparison result shows that the magnetic field strength data is less than or equal to the strength threshold, it is determined that the mover is not stationary on the adapted roller line.

4. The method according to claim 3, characterized in that, Determining the stationary position of the mover based on the magnetic field strength data includes: The magnetic field strength data of each collection area are compared to determine the maximum magnetic field strength data; The area corresponding to the maximum magnetic field strength data is determined as the stationary position of the mover.

5. The method according to claim 1, characterized in that, The acquisition of magnetic field strength data through the electromagnetic components installed in the composite drive module includes: Acquire multiple initial magnetic field strength data within a preset time period; The initial magnetic field strength data is calculated using a normal distribution to obtain the magnetic field strength data.

6. The method according to claim 1, characterized in that, In response to a control signal sent by the controller, and based on the dwell position and the moving direction of the mover, the rollers on the roller conveyor located at the dwell position and the moving direction are controlled to rotate, thereby controlling the mover to start, including: In response to a control signal sent by the controller, the roller drive assembly on the composite drive module is activated according to the dwell position and the moving direction of the mover, so as to drive the rollers on the roller line located at the dwell position and the moving direction, and activate the mover.

7. The method according to claim 1, characterized in that, After determining the stationary position of the mover, the method further includes: Based on the stationary position of the mover, detection information is generated and sent to the controller.

8. A hand-operated actuator control device, characterized in that, A composite drive module is applied in a magnetic drive conveyor system. The system includes a controller, a mover, multiple composite drive modules, and a roller conveyor adapted to each composite drive module. The controller is connected to the composite drive module and can control the composite drive module to drive the adapted roller conveyor. The mover can move on the roller conveyor. The device includes: The data acquisition module is used to acquire magnetic field strength data through the electromagnetic components set in the composite drive module when the magnetic drive conveyor system is powered on. The data analysis module is used to determine whether the mover is stationary on the adapted roller line body based on the magnetic field strength data. The position determination module is used to determine the stationary position of the mover based on the magnetic field strength data if the condition is met. The start-up module is used to respond to the control signal sent by the controller, and control the rollers on the roller line located at the stop position and the moving direction to rotate according to the stop position and the moving direction of the mover, so as to control the mover to start. The control signal is a detection information sent by the composite drive module to the controller after detecting that the mover is stopped on the roller line, and the controller feeds back the detection information to the composite drive module.

9. An electronic device, characterized in that, It includes a processor and a memory, the memory storing computer-executable instructions that can be executed by the processor, the processor executing the computer-executable instructions to implement the hand-pushing-free actuator control method according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions, which, when invoked and executed by a processor, cause the processor to implement the manual-free actuator control method according to any one of claims 1 to 7.

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