Gantry platform synchronization error analysis method and system

Abstract

The invention discloses a gantry platform synchronization error analysis method and system, and the method comprises the steps: constructing a three-dimensional digital model of a gantry double-drive platform through employing a segmented modeling method, and decomposing the whole structure into five core modules: a pedestal, an X shaft, a crossbeam, a Y1 shaft, and a Y2 shaft; dynamic monitoring points are arranged at key motion nodes of the model, a system simulation test is completed through parameter optimization iteration, and multi-dimensional simulation data including displacement, speed and the like are obtained; and based on the parameterized model and a simulation data result, a kinematics equation expression facing the gantry platform is deduced and established. The system comprises a model building unit, a simulation unit and a control unit. Through refined modeling of a gantry platform mechanical system, it is ensured that simulation analysis is rapid and accurate. The method can be widely applied to the field of mechanical system error analysis.

Description

Technical Field

[0001] The present invention relates to the field of mechanical system error analysis, and in particular to a gantry platform synchronization error analysis method and system. Background Art

[0002] Across a wide range of mechanical equipment applications, gantry platforms, with their high rigidity, large travel range, and rapid response, have become key equipment for precision machining and automated production. In dual-motor-driven gantry platforms, the synchronization accuracy of the mechanical system directly impacts machining quality, making the determination and analysis of synchronization errors crucial.

[0003] Existing error analysis methods for gantry platforms focus on single-axis motion control (independent control of the X, Y, and Z axes), and do not specifically analyze the complex synchronization errors of dual motors. They ignore the coupling effects during dual-motor drive (such as torque imbalance caused by motor parameter differences and uneven loads). Their simplified mechanical models are somewhat different from actual instruments, and the algorithms implemented in simulations may not be suitable for practical applications. Summary of the Invention

[0004] In view of this, in order to solve the technical problem of low error analysis accuracy in existing gantry platform synchronization error analysis methods due to the limitations of the simplified model of traditional mechanical modeling, the present invention proposes a gantry platform synchronization error analysis method in the first aspect, which includes:

[0005] A segmented modeling method was used to construct a 3D digital model of the gantry dual-drive platform, breaking down the overall structure into five core modules: the basic support base, the X-axis motion module, the transverse connecting beam, and the Y1 / Y2 dual-drive shaft assembly.

[0006] Dynamic monitoring points are set at key motion nodes of the model, and system simulation tests are completed through parameter optimization iterations to obtain multi-dimensional simulation data including displacement and velocity;

[0007] Based on the parameterized model and simulation data results, the kinematic equation expression for the gantry platform is derived and established.

[0008] In some embodiments, the step of deriving and establishing a kinematic equation expression for the gantry platform based on the parameterized model and simulation data results specifically includes:

[0009] Define tracking error and synchronous review, and construct sliding surface;

[0010] Design continuous control signals for the imported co-simulation model.

[0011] In a second aspect, the present invention further provides a gantry platform synchronization error analysis system, comprising:

[0012] The model building unit uses a segmented modeling method to construct a 3D digital model of the gantry dual-drive platform, breaking down the overall structure into five core modules: the basic support base, the X-axis motion module, the transverse connecting beam, and the Y1 / Y2 dual-drive shaft assembly;

[0013] The simulation unit sets dynamic monitoring points at the key motion nodes of the model, completes system simulation testing through parameter optimization iteration, and obtains multi-dimensional simulation data including displacement, velocity, etc.

[0014] The control unit derives and establishes the kinematic equation expression for the gantry platform based on the parameterized model and simulation data results.

[0015] Based on the above scheme, the present invention constructs a refined model of the gantry platform mechanical system to comprehensively simulate the actual mechanical characteristics and provide a precise carrier for error analysis; in the refined mechanical model, a super-helical sliding mode control strategy that can be applied to the gantry dual-drive working condition is adopted, and through joint simulation and debugging, the synchronization error of the dual-motor drive mechanical system is analyzed and suppressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a flow chart of the steps of a gantry platform synchronization error analysis method of the present invention;

[0017] Figure 2 This is a data flow diagram of the control process of a specific embodiment of the present invention.

[0018] Figure 3 It is a structural block diagram of a gantry platform synchronization error analysis system of the present invention. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0020] It should be noted that, for ease of description, only the parts related to the invention are shown in the drawings. In the absence of conflict, the embodiments and features in the embodiments of this application can be combined with each other.

[0021] It should be understood that the terms "system," "device," "unit," and / or "module" used in this application are a method for distinguishing different components, elements, parts, portions, or assemblies at different levels. However, if other terms can achieve the same purpose, the terms may be replaced by other expressions.

[0022] As used in this application and the claims, unless the context clearly indicates an exception, the terms "a," "an," "an," and / or "the" are not intended to refer to the singular and may include the plural, unless the context clearly indicates otherwise. Generally speaking, the terms "comprises" and "include" only indicate the inclusion of the steps and elements specifically identified, and these steps and elements do not constitute an exclusive list. A method or apparatus may also include other steps or elements. The phrase "comprises a..." does not preclude the presence of additional identical elements in the process, method, product, or apparatus that includes the elements.

[0023] In the description of the embodiments of this application, "plurality" refers to two or more than two. The terms "first" and "second" below are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include one or more of the features.

[0024] In addition, flow charts are used in this application to illustrate the operations performed by the system according to the embodiments of the present application. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, the steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0025] Reference Figure 1 , which is a flowchart of the steps of gantry platform synchronization error analysis proposed by the present invention, including:

[0026] Step S1, constructing a three-dimensional model of a gantry dual-drive platform and dividing the three-dimensional model of the gantry dual-drive platform into a base, an X-axis, a crossbeam, a Y1-axis, and a Y2-axis;

[0027] Step S2: Arrange monitoring points and adjust parameters, perform simulation based on the three-dimensional model of the gantry dual-drive platform, and obtain simulation results of tracking error and synchronization error;

[0028] The purpose of the simulation data is to obtain the feedback value of the gantry system, which serves as the source of the error e in the subsequent controller design.

[0029] Step S3: constructing a control signal expression based on the gantry dual-drive platform three-dimensional model and the simulation results.

[0030] In some feasible embodiments, step S1 is used as a refined modeling of the gantry platform mechanical system, which specifically includes:

[0031] In the 3D design software, based on the actual mechanical structure of the gantry platform, precise 3D models of components such as the crossbeam, slider, guide rail, linear motor, and motor mounting base were constructed. An adjustable experimental instrument module was integrated into the crossbeam, allowing for flexible adjustments based on experimental requirements. By simulating the workpiece load, the load mass and its distribution can be freely set, enabling accurate simulation of load changes under different working conditions, and further studying the impact of eccentric loads on the synchronization of the mechanical system. At the same time, geometric parameters such as the crossbeam length and slider size, as well as material properties such as density and elastic modulus, were precisely set. By calculating the mass and moment of inertia of the components, the simulation model's physical characteristics were made closer to real-world mechanical systems. Building on the 3D model simulation provided by Simscape, nonlinear influencing factors were carefully considered and the model was established. This precise modeling approach not only improves the reliability of the simulation results but also provides a solid foundation for subsequent rapid dynamic analysis and control strategy optimization.

[0032] To optimize the flexibility and maintainability of the simulation model and facilitate the adjustment of key parameters such as damping and spring stiffness, the present invention divides the originally complex assembly into five independent modular parts according to their respective motion characteristics and functions in the gantry platform: the base, X-axis, crossbeam, Y1-axis, and Y2-axis.

[0033] Each part is integrated through rigid connections to form independent rigid components, ensuring the stability and consistency of each component in the simulation.

[0034] This modular design not only simplifies model management but also facilitates independent adjustment of component parameters within the Simscape environment. Parameters such as damping coefficients and spring stiffness can be easily modified for each component without disrupting the overall structure, enabling rapid response to changing simulation requirements. This significantly enhances the adaptability of the simulation model and allows for faster and more convenient analysis.

[0035] In the new assembly, these five separate parts are reassembled into a single unit with the same structure as the original. This reassembly process not only preserves the functional integrity of the original assembly but also improves the scalability of the model through modular design. The parameters of each component can be flexibly adjusted to meet specific simulation requirements without requiring complex modifications to the entire model.

[0036] Furthermore, through modular encapsulation, the present invention reduces the computational complexity of the model and improves simulation efficiency. The independence of each rigid body component enables more efficient dynamic analysis during the simulation process, reducing unnecessary calculations. This optimization method not only improves simulation efficiency but also provides a more flexible and efficient platform for subsequent control algorithm development and system performance evaluation.

[0037] In some embodiments, step S1 further includes: adding constraints. Specifically:

[0038] In the new assembly, the following steps are used to implement constraint design for the crossbeam and related components: A translation joint constraint is established between the crossbeam and the X-axis, implemented using a distance mate. This translation joint constraint allows the adjustable experimental instrument module to translate along the X-axis while restricting the other degrees of freedom to ensure the accuracy of the crossbeam's motion in the X-axis. A distance mate defines the relative position between the crossbeam and the X-axis, ensuring precise geometric alignment during assembly. The crossbeam is fixedly connected to the Y1Y2 motor using coincidence and distance mates. The coincidence mate ensures perfect geometric alignment between the connection points of the crossbeam and the motor, while the distance mate defines the relative position between them, ensuring a stable and precise connection. This constraint design effectively transmits the motor's driving force while ensuring the accuracy of the crossbeam's motion in the Y-axis. A three-degree-of-freedom constraint is established between the Y1Y2 linear motor and the guide rail, implemented using distance and parallel mates. Distance mates define the relative position between the motor and guide rail, ensuring precise alignment during assembly. Parallel mates constrain the relative rotational freedom between the motor and guide rail, allowing translational motion along the Y axis while also allowing the crossbar to rotate about the Z axis. This constraint design effectively enables independent control of the two motors and supports the calculation of asynchronous motion between them.

[0039] In some feasible embodiments, the following further comprises:

[0040] Use the Simscape Multibody Link plug-in to export the constructed 3D model as an XML format file.

[0041] This conversion process not only preserves the geometric structure of the model, but also accurately transfers key information such as material properties and assembly constraints, ensuring the integrity and accuracy of the model in Simulink.

[0042] In Simulink, by importing the generated XML file, you can quickly build a multi-body dynamics simulation model that is completely consistent with the model in the 3D modeling software.

[0043] In some feasible embodiments, step S2 specifically includes:

[0044] S2.1. In the Simscape Planner module, the spring stiffness and damping coefficients for the Y-axis dual motors and X-axis motors were precisely set to simulate the dynamic behavior of an actual mechanical system. The spring stiffness for the Y-axis dual motor in the X-axis direction was set to the following: Based on actual conditions, the upper limit of the safe range for the linear motor motion structure at high speeds was set, and optimization analysis was performed from the maximum value downward. This design was intended to simulate the actual effect of a linear motor being constrained by a guide rail.

[0045] Specifically, in the Planner module, spring stiffness and damping coefficient are key parameters that affect the dynamic response of the system. A larger spring stiffness can effectively limit the displacement of the Y-axis dual motor in the X-axis direction, simulate the physical constraints of the guide rail on the motor, and ensure that the movement of the motor in the X-axis direction is strictly restricted. This setting can perform high-speed performance analysis of the gantry dual-drive platform and quickly determine the dynamic response under suitable gantry dual-drive working conditions. In addition, the damping coefficient is set based on the parameters of the structural materials in the gantry three-dimensional platform model and the influence of the guide rail under the gantry dual-drive motion. Through the connection structure and motion position between the dual motors, the damping coefficient is accurately adjusted in the model to closely match the actual motion process of the Y-axis dual motor and X-axis motor.

[0046] S2.2. Carefully arrange monitoring points at the movement positions of the dual-motor drive shaft and slider to collect key operating data of the mechanical system in real time, including position and speed information.

[0047] By accurately calculating the position and velocity differences in the corresponding feedback under dual-motor drive, we can gain a deeper understanding of the system's synchronization performance. Position synchronization error reflects the relative spatial deviation of the two sliders, while velocity synchronization error reveals the difference in their motion rhythm. These error metrics provide a quantitative basis for evaluating the system's coordination. Simultaneously, output force data is collected to conduct in-depth analysis of the load torque differences between the drive shafts caused by mechanical coupling. Mechanical coupling effects can lead to uneven load torques on different drive shafts, which can further affect system synchronization. By monitoring and analyzing load torque differences, potential system issues can be identified, providing key information for optimizing design and control strategies.

[0048] In some feasible embodiments, step S3 specifically includes:

[0049] In this patent, the super-helical sliding mode controller serves as a control method for improving and ensuring the synchronous performance of the gantry platform's dual-motor drive, and is also the final control execution link of the simulation process. Based on the high-precision dynamic model (including dual motors, mechanical coupling constraints and interference characteristics) output by the previous modeling and simulation links, it realizes dynamic compensation of the synchronization error of the gantry platform's dual motors, analyzes the control impact, and determines the synchronous motion performance.

[0050] First, build a system dynamics model:

[0051]

[0052] in, is the acceleration of motor 1, K f1 is the thrust constant of motor 1, M1 is the system mass of motor 1, is the q-axis current of motor 1, B1 is the damping coefficient of motor 1, is the speed of motor 1, d1 is the model uncertainty and disturbance of motor 1; is the acceleration of motor 2, K f2 is the thrust constant of motor 2, M2 is the system mass of motor 2, is the q-axis current of motor 2, B2 is the damping coefficient of motor 2, is the speed of motor 2, and d2 is the model uncertainty and disturbance of motor 2.

[0053] Define tracking error:

[0054] e1=x1-x d

[0055] e2=x2-x d

[0056] e s =x1-x2

[0057] Among them, e1 is the error of motor 1, x1 is the actual position of motor 1, and x d is the target position, e2 is the error of motor 2, x2 is the actual position of motor 2, e s is the synchronization error.

[0058] Sliding surface design:

[0059]

[0060] Among them, s i is the sliding surface, is the first-order derivative of the sliding surface, e i is the tracking error, represents the derivative of the tracking error, c i is the sliding surface parameter, k i is the weight coefficient, e s is the synchronization error, K fi is the motor thrust constant, M i is the system quality, is the q-axis current of the motor, φ i is the intermediate variable, d i is model uncertainty and disturbance.

[0061] By adjusting the weight coefficient ki Dynamically balance synchronization performance and single motor tracking accuracy, solving the problem of the two being difficult to coordinate in traditional methods

[0062] Decoupling control input:

[0063]

[0064] Among them, u i For control input.

[0065] Substituting the superhelical control law, we can get the expression of the final control signal:

[0066] u i =-k i1 |s i | 1 / 2 sign(s i )+v i

[0067]

[0068] Among them, k i1 、k i2 is an adjustable parameter, sign(s i ) is the symbolic function, v i is an intermediate variable.

[0069] Arranged:

[0070]

[0071] Compared with the switching function of traditional sliding mode control, the super-helical algorithm generates a continuous control signal through the second-order sliding mode characteristics. It is suitable for gantry dual-motor control and avoids the impact of high-frequency vibration on the mechanical system.

[0072] This controller acquires the status of the dual motors in real time through the Simscape interface and dynamically generates control signals based on the sliding surface. These signals are fed back to the simulation model to drive the motors, forming a closed-loop verification chain of "modeling-coupling analysis-control." Ultimately, it outputs key data such as synchronization error curves and control torque, providing high-confidence pre-verification for optimizing synchronization control parameters on an actual gantry platform.

[0073] This paper accurately constructs a simulation model of the gantry platform's mechanical components within the Simscape environment, fully accounting for nonlinear characteristics such as guideway friction and thrust fluctuations. By incorporating realistic material properties and motion constraints, the simulation model more accurately reproduces the dynamic characteristics of the mechanical system, significantly improving the reliability of synchronization error simulation.

[0074] In terms of error analysis, this paper not only focuses on single-axis position tracking errors, but also delves into issues such as synchronization errors. By collecting multi-dimensional data, the complex mechanisms of synchronization errors are fully explored, providing a more comprehensive and in-depth theoretical basis for error suppression.

[0075] In terms of control optimization, this application is based on the above-mentioned refined mechanical simulation model, and systematically debugs the super-helical sliding mode parameters in the simulation environment, achieving a deep integration of the control strategy and the characteristics of the gantry platform mechanical system. Compared with the control strategy design of the existing simplified model, this application can more efficiently optimize the gantry platform synchronization error suppression effect. Through multiple simulation iterations, the optimal super-helical sliding mode parameters under different working conditions are quickly determined, which significantly reduces the cost and cycle of actual mechanical system debugging and greatly improves development efficiency.

[0076] The present invention forms a complete technology chain from three-dimensional modeling, multi-body dynamics simplification, constraint application to control embedding, providing a complete solution for gantry platform synchronization control from theoretical design to rapid feasibility verification. It is particularly suitable for the synchronization control scenario of the gantry dual-motor collaborative drive, focusing on the consistency of the two-axis motion to meet the high-precision synchronization requirements.

[0077] like Figure 3 As shown, a gantry platform synchronization error analysis method includes the following steps:

[0078] A model building unit, configured to execute step S1;

[0079] A simulation unit, configured to execute step S2;

[0080] A control unit is configured to execute step S3.

[0081] The contents of the above method embodiments are all applicable to the present system embodiments. The functions specifically implemented by the present system embodiments are the same as those of the above method embodiments, and the beneficial effects achieved are also the same as those achieved by the above structural embodiments.

[0082] The above is a specific description of the preferred implementation of the present invention, but the invention is not limited to the embodiments. Those skilled in the art can make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A gantry platform synchronization error analysis method, characterized in that: include: Constructing a three-dimensional model of a gantry dual-drive platform and dividing the three-dimensional model of the gantry dual-drive platform into a base, an X-axis, a crossbeam, a Y1-axis, and a Y2-axis; Arrange monitoring points and adjust parameters, perform simulation based on the three-dimensional model of the gantry dual-drive platform, and obtain simulation results such as tracking error and synchronization error; A control signal expression is constructed based on the three-dimensional model of the gantry dual-drive platform and the simulation results.

2. A gantry platform synchronization error analysis method according to claim 1, characterized in that: Also includes: Create a moving joint constraint between the beam and the X axis; Securely connect the crossbeam to the Y1-axis and Y2-axis motors.

3. A gantry platform synchronization error analysis method according to claim 1, characterized in that: The parameters include spring parameters and damping coefficients.

4. A gantry platform synchronization error analysis method according to claim 1, characterized in that: The step of constructing a control signal expression based on the gantry dual-drive platform three-dimensional model and the simulation results specifically includes: Defining tracking error and synchronization error based on the three-dimensional model of the gantry dual-drive platform; Constructing a sliding surface by combining the tracking error, the synchronization error and the simulation result; Based on the three-dimensional model of the gantry dual-drive platform and the sliding surface, a continuity control signal expression is constructed.

5. A gantry platform synchronization error analysis method according to claim 3, characterized in that: The expression of the sliding surface is as follows: e i =x i -x d And s =x1-x2 in, represents the derivative of the tracking error, c i represents the sliding surface parameter, e i represents the tracking error; k i represents the weight coefficient; e s represents synchronization error; x i Indicates the feedback position of the i-th motor, x d represents the target position, x1 represents the actual position of motor 1, and x2 represents the actual position of motor 2.

6. A gantry platform synchronization error analysis method according to claim 1, characterized in that: The expression of the control signal is as follows: Among them, M i represents the system mass, represents the motor thrust constant, φ i represents the intermediate variable, k i1 、k i2 It is an adjustable parameter.

7. A gantry platform synchronization error analysis system, characterized in that: include: A model building unit is used to build a three-dimensional model of the gantry dual-drive platform and divide the three-dimensional model of the gantry dual-drive platform into a base, an X-axis, a crossbeam, a Y1-axis, and a Y2-axis; A simulation unit is used to arrange monitoring points and adjust parameters, and to perform simulation based on the three-dimensional model of the gantry dual-drive platform to obtain simulation results; A control unit constructs a control signal expression based on the three-dimensional model of the gantry dual-drive platform and the simulation results.

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