Flexible wire drive control method and system for precise measurement of camber

Abstract

The application provides a flexible line driving control method and system for precise measurement of a camber surface, relates to the technical field of data processing, and comprises the following steps: generating absolute position data by performing a magnetic flux-position conversion algorithm according to an MCU; encapsulating the absolute position data according to a synchronous serial communication protocol to obtain a data frame, and transmitting the data frame through a differential signal link to generate a data frame to be analyzed; receiving the data frame to be analyzed by a motion controller and performing analysis processing, generating a synchronous driving instruction of a multi-moving-block slider based on the analyzed position data when a state flag in the analysis indicates a valid position; and when the state flag in the analysis indicates an exception, interrupting the driving instruction and activating a magnetic grating scale damage diagnosis to finally generate a damage diagnosis report. The application improves the measurement efficiency and meets the demand of continuous and rapid measurement of a camber surface.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of data processing, in particular to a flexible line driving control method and system for precise measurement of curved surfaces. BACKGROUND

[0002] The precise measurement technology of curved surfaces has important application value in the field of high-end equipment manufacturing, such as the processing quality detection of complex curved surface components such as turbine blades and optical lenses. Traditional measurement methods such as contact probes and non-contact optical measurement have limitations: contact measurement is easily affected by probe radius correction error, and in small curvature radius surface measurement, it may introduce a few microns of deviation; optical measurement is sensitive to environmental vibration and light interference, and lacks real-time performance in dynamic scenarios.

[0003] Traditional technology has high measurement accuracy, but probe radius correction depends on linear fitting of adjacent measurement points. When measuring dense point clouds, signal noise caused by mechanical errors will amplify the deviation, and the error rate will increase in areas with sudden curvature changes. In addition, some traditional methods lack dynamic correction capability for measurement paths, making it difficult to meet the real-time measurement needs of complex curved surfaces. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a flexible line driving control method and system for precise measurement of curved surfaces, which improves the efficiency of measurement and meets the needs of continuous and rapid measurement of curved surfaces.

[0005] To solve the above technical problems, the technical solution of the present application is as follows:

[0006] In a first aspect, a flexible line driving control method for precise measurement of curved surfaces, the method comprising:

[0007] Step 1: Deploying a double-track magnetic scale on the surface of the curved track, the incremental code track adopts a periodic magnetization structure, and the absolute code track adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source;

[0008] Step 2: Based on the magnetic signal source, the magnetic communication signal is captured by the absolute value encoder integrated in the multi-mover slider, and the nonlinear space mapping algorithm is fused to correct the signal acquisition path in real time according to the spatial pose parameters of the encoder and the magnetic scale, to obtain the original magnetic communication signal;

[0009] Step 3: The original magnetic communication signal is parsed by the AMR sensor to generate a speed parameter; the original magnetic communication signal is parsed by the Hall sensor array to generate absolute position data according to the MCU executing the magnetic flux-position conversion algorithm after eliminating harmonic interference by the interpolation circuit.

[0010] Step 4, the absolute position data is encapsulated into a data frame according to a synchronous serial communication protocol, and transmitted through a differential signal link to generate a data frame to be parsed;

[0011] Step 5, the motion controller receives the data frame to be parsed and performs parsing processing, when the state flag parsed indicates a valid position, the motion controller generates a synchronous driving instruction of the multi-motor slider based on the parsed position data; when the state flag parsed indicates an exception, the driving instruction is interrupted and a magnetic scale damage diagnosis is activated, and finally a damage diagnosis report is generated.

[0012] Further, a double-track magnetic scale is deployed on the cambered track surface, the incremental code track adopts a periodic magnetization structure, and the absolute code track adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source, including:

[0013] Step 11, the minimum magnetization period length and the total number of magnetization units of the incremental code track are calculated based on the curvature radius of the cambered track and the preset measurement resolution; based on the period length and the total number of magnetization units, a continuous and equidistant N-pole and S-pole alternating magnetization operation is performed along the motion path direction on the cambered track surface, and finally a periodic incremental magnetization code track and a magnetization period length parameter are generated;

[0014] Step 12, based on the magnetization period length parameter, the physical length of a single code element of the absolute code track is calculated, and the maximum number of binary code elements that can be accommodated is determined according to the total length of the cambered track; taking the maximum number of code elements as the upper limit, a pseudo-random binary sequence is generated by a predetermined order linear feedback shift register algorithm;

[0015] Step 13, based on the pseudo-random binary sequence and the physical length of a single code element, a non-periodic magnetization encoding distribution is generated by performing absolute code track magnetization encoding mapping, and is spatially aligned and deployed in parallel with the periodic incremental magnetization code track to generate a magnetic signal source.

[0016] Further, the step 2 includes:

[0017] Step 21, based on the magnetic signal source, the spatial pose parameters of the multi-motor slider are obtained in real time, and the instantaneous spatial position offset vector, the attitude rotation matrix and the local normal vector between the sensor array and the magnetic scale are calculated by using the cambered track geometric model;

[0018] Step 22, based on the instantaneous attitude rotation matrix and the local normal vector, the actual pointing vector of the sensor detection axis is derived by a direction mapping function of nonlinear space mapping, and the direction deviation vector from the local normal vector is calculated to obtain the distortion direction; the normal distance between the sensor and the magnetic scale is calculated based on the instantaneous spatial position offset vector, and the effective deviation angle is derived according to the direction deviation vector to calculate the distortion level.

[0019] Step 23, generate dynamic compensation instructions based on the expected distortion direction and distortion level, and real-time fine-tune the physical pointing of the sensor array to establish a compensated acquisition pointing state; under the established compensated acquisition pointing state, the original space magnetic flux distribution signal of the double magnetic track magnetic scale is captured synchronously by the sensor array to obtain a magnetic communication signal;

[0020] Step 24, fuse the magnetic communication signal with the pose parameters to obtain the original magnetic communication signal.

[0021] Further, the step 3 comprises:

[0022] Step 31, extract the incremental code channel component in the original magnetic communication signal to input the AMR sensor to analyze the phase change and generate a speed parameter; and extract the absolute code channel component to input the Hall sensor array to analyze the original digital code sequence, and generate a purified sequence through an interpolation circuit harmonic filter;

[0023] Step 32, input the purified sequence and the pre-stored pseudo-random sequence into the MCU for matching to determine a unique position interval and obtain a coarse-grained absolute position estimate value;

[0024] Step 33, based on the speed parameter and the coarse-grained absolute position estimate value, according to the camber parameter, map the incremental code channel phase near the coarse position from the arc space to the linear expansion space; calculate the phase change of the incremental code channel in the linear expansion space to generate a fine displacement;

[0025] Step 34, the MCU fuses the coarse-grained position estimate value and the fine displacement to obtain a fused position value in the linear space, and applies a magnetic flux-position conversion algorithm to map the fused position to the actual camber space coordinates based on the pre-stored camber parameter, and finally generates absolute position data.

[0026] Further, the absolute position data is encapsulated according to a synchronous serial communication protocol to obtain a data frame, and is transmitted through a differential signal link to generate a data frame to be analyzed, comprising:

[0027] Step 41, the communication protocol processing unit receives the absolute position data result, and generates state flag bit information based on the real-time monitored signal integrity index; the communication protocol processing unit fuses the absolute position data result and the state flag bit information result to generate original encapsulation data packets;

[0028] Step 42, after the communication protocol processing unit receives the original encapsulation data packet, sequentially adds a protocol specified starting synchronization header, a generated check code and an end flag to generate a complete protocol data frame in the same synchronous serial communication protocol frame format;

[0029] Step 43, the differential signal driving circuit receives the complete protocol data frame, converts the contained serial data stream into a pair of differential voltage signals, and sends them to the motion controller side through the differential signal transmission link;

[0030] Step 44, the signal receiving and conditioning circuit receives the pair of differential voltage signals, recovers them into a single-ended digital signal stream through amplification and shaping, extracts the complete bit stream of the protocol frame structure through sampling, and finally generates the data frame to be parsed.

[0031] Further, the motion controller receives the data frame to be parsed and performs parsing processing. When the parsed state flag indicates a valid position, the motion controller generates a synchronous driving instruction for the multi-actuator slider based on the parsed position data. When the parsed state flag indicates an exception, the motion controller interrupts the driving instruction and activates the magnetic scale damage diagnosis, and finally generates a damage diagnosis report, including:

[0032] Step 51, the communication protocol stack processing unit of the motion controller decodes the data frame to be parsed, extracts the absolute position data, state flag bit information, and check code result, and passes the check code and the original data part to the data check and state determination unit for validity determination;

[0033] Step 52, if the data is determined to be valid, the multi-axis synchronous control unit generates a target instruction based on the absolute position data and calculates a synchronous driving instruction, which is finally output to the motor driver;

[0034] Step 53, if the data is determined to be abnormal, the safety control unit interrupts the driving instruction and sends an emergency stop instruction to the motor driver, activates the magnetic scale damage diagnosis task to generate a diagnosis start instruction. The diagnosis unit controls the slider to scan at a constant speed based on the diagnosis start instruction, collects position and magnetic signals in real time, and finally generates a damage diagnosis report.

[0035] Further, the MCU fuses the coarse-grained position estimate value and the fine displacement to calculate a fused position value in the linear space, and applies a magnetic flux-position conversion algorithm to map the fused position to the actual camber space coordinates based on the pre-stored camber curvature parameters, and finally generates absolute position data, including:

[0036] Step 61, the MCU performs vector superposition operation based on the coarse-grained absolute position estimate value and the fine displacement, algebraically adds the fine displacement and the coarse-grained absolute position estimate value in the linear expansion space, and calculates a linear space fused position value;

[0037] Step 62, divide the linear space fusion position value by the radius of curvature to obtain the corresponding central angle numerical value, calculate the tangent coordinate, radial coordinate and vertical coordinate according to the central angle, and generate the preliminary absolute position; separate the real-time magnetic field strength of the absolute code channel from the original magnetic communication signal, compare the deviation proportion of the real-time magnetic field strength and the pre-stored ideal value, and generate the compensated absolute position;

[0038] Step 63, based on the compensated absolute position, perform motion path cumulative arc length inverse calculation operation, bind and encapsulate the arc length value with space-time identifier, and finally generate absolute position data.

[0039] Secondly, a flexible line driving control system for precise measurement of curved surface, comprising:

[0040] A deployment module is configured to deploy a double-magnetic-track magnetic grating ruler on the curved surface track surface, the incremental code channel adopts a periodic magnetization structure, and the absolute code channel adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source.

[0041] A correction module is configured to capture the magnetic communication signal based on the magnetic signal source through the absolute value encoder integrated in the multi-mover slider, and fuse the nonlinear space mapping algorithm to correct the signal acquisition path in real time according to the space pose parameters of the encoder and the magnetic grating ruler, thereby obtaining the original magnetic communication signal.

[0042] A calculation module is configured to parse the incremental code channel generated by the AMR sensor to generate a speed parameter from the original magnetic communication signal, and parse the absolute code channel signal through the Hall sensor array, eliminate harmonic interference through an interpolation circuit, fuse the cylindrical surface projection development algorithm, and execute the magnetic flux-position conversion algorithm based on the MCU to generate absolute position data.

[0043] A transmission module is configured to encapsulate the absolute position data into a data frame according to a synchronous serial communication protocol, and transmit the data frame through a differential signal link to generate a data frame to be parsed.

[0044] A diagnosis module is configured to receive the data frame to be parsed by the motion controller and perform parsing processing, generate a synchronous driving instruction of the multi-mover slider based on the parsed position data when the parsed state flag indicates a valid position, and interrupt the driving instruction and activate the magnetic grating ruler damage diagnosis when the parsed state flag indicates an exception, thereby finally generating a damage diagnosis report.

[0045] Thirdly, a computing device, comprising:

[0046] One or more processors;

[0047] A storage device is configured to store one or more programs, when the one or more programs are executed by the one or more processors, so that the one or more processors implement the method.

[0048] In a fourth aspect, a computer readable storage medium is provided, and the computer readable storage medium stores a program, and the program is executed by a processor to implement the method.

[0049] The above scheme of the present application at least has the following beneficial effects:

[0050] By deploying a double magnetic track magnetic scale, the periodic magnetization structure of the incremental code track can quickly generate a speed parameter, the pseudo-random binary sequence magnetization encoding of the absolute code track can provide absolute position information, the nonlinear space mapping algorithm is fused to correct the signal acquisition path in real time, the signal deviation caused by the spatial pose change of the camber surface is effectively eliminated, the accuracy of the original magnetic communication signal is improved, and the accuracy of the final position measurement is improved.

[0051] By using a Hall sensor array to analyze the absolute code track signal and through an interpolation circuit to eliminate harmonic interference, the influence of external electromagnetic factors on the signal is reduced. In addition, by encapsulating data frames through a synchronous serial communication protocol and using a differential signal link for transmission, the anti-interference performance in the data transmission process is improved. BRIEF DESCRIPTION OF DRAWINGS

[0052] Figure 1 is a flexible line driving control method flow diagram for camber precision measurement provided by an embodiment of the present application.

[0053] Figure 2 is a flexible line driving control system diagram for camber precision measurement provided by an embodiment of the present application. DETAILED DESCRIPTION

[0054] Exemplary embodiments of the present disclosure will be described in greater detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. Rather, the embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be accurately conveyed to those skilled in the art.

[0055] As shown in Figure 1 An embodiment of the present application proposes a flexible line driving control method for camber precision measurement, which comprises the following steps:

[0056] Step 1, deploying a double magnetic track magnetic scale on the surface of the camber track, using a periodic magnetization structure for the incremental code track and a pseudo-random binary sequence magnetization encoding for the absolute code track to generate a magnetic signal source;

[0057] Step 2, based on the magnetic signal source, capturing the magnetic communication signal through an absolute value encoder integrated in a multi-mover slider, and fusing a nonlinear space mapping algorithm to correct the signal acquisition path in real time according to the spatial pose parameters of the encoder and the magnetic scale, to obtain an original magnetic communication signal;

[0058] Step 3, the original magnetic communication signal is parsed by the AMR sensor to generate a speed parameter of the incremental code channel; the original magnetic communication signal is parsed by the Hall sensor array to generate an absolute code channel signal, after harmonic interference is eliminated by an interpolation circuit, a cylindrical surface projection development algorithm is fused, a magnetic flux-position conversion algorithm is executed according to the MCU, and absolute position data is generated;

[0059] Step 4, the absolute position data is packaged into a data frame according to a synchronous serial communication protocol, and is transmitted through a differential signal link to generate a data frame to be parsed;

[0060] Step 5, the motion controller receives the data frame to be parsed and parses it, when the parsed state flag indicates a valid position, a synchronous driving instruction of the multi-moving slider is generated based on the parsed position data; when the parsed state flag indicates an exception, the driving instruction is interrupted and a magnetic grating ruler damage diagnosis is activated, and finally a damage diagnosis report is generated.

[0061] In the embodiment of the application, by deploying a double-track magnetic grating ruler, the periodic magnetization structure of the incremental code channel can quickly generate a speed parameter, the pseudo-random binary sequence magnetization encoding of the absolute code channel can provide absolute position information, the nonlinear space mapping algorithm is fused to correct the signal acquisition path in real time, the signal deviation caused by the spatial pose change of the arc surface is effectively eliminated, the accuracy of the original magnetic communication signal is improved, and the precision of the final position measurement is improved.

[0062] By parsing the absolute code channel signal by the Hall sensor array and eliminating the harmonic interference by the interpolation circuit, the influence of external electromagnetic factors on the signal is reduced. In addition, the data frame is packaged by the synchronous serial communication protocol and transmitted by the differential signal link, and the anti-interference performance in the data transmission process is improved.

[0063] In a preferred embodiment of the application, a double-track magnetic grating ruler is deployed on the surface of the arc track, the incremental code channel adopts a periodic magnetization structure, and the absolute code channel adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source, which includes:

[0064] Step 11, the minimum magnetization period length and the total number of magnetization units of the incremental code channel are calculated based on the curvature radius of the arc track and the preset measurement resolution; based on the period length and the total number of magnetization units, a continuous and equidistant N-pole and S-pole alternating magnetization operation is performed along the motion path direction on the surface of the arc track, and finally a periodic incremental magnetization code channel and a magnetization period length parameter are generated;

[0065] Step 12, based on the magnetization period length parameter, the physical length of the absolute code channel single code element is calculated, and the maximum number of binary code elements that can be accommodated is determined according to the total length of the arc track; the pseudo-random binary sequence is generated by the predetermined order linear feedback shift register algorithm with the maximum code element number as the upper limit.

[0066] Step 13, based on the pseudo-random binary sequence and the single code element physical length, absolute code channel magnetization encoding mapping is performed to generate aperiodic magnetization encoding distribution, and is spatially aligned and deployed in parallel with the periodic incremental magnetization code channel to generate a magnetic signal source.

[0067] In the embodiment of the application, the camber track curvature radius is set according to the flexible production line or the ring production line scene requirement, and the value range is 50mm-5000mm (adapted to small and medium-sized precision component camber measurement); the preset measurement resolution is 1μm (in line with the resolution standard of HCLA series encoder up to 1μm).

[0068] Based on the 1μm resolution and the actual magnetization process feasibility, the incremental code channel minimum magnetization period length adopts 5mm (that is, 5mm interval N-pole and S-pole alternate magnetization along the motion direction), and the period length can balance the signal recognition stability and the high resolution requirement, and is consistent with the magnetization design of HCLA series incremental code channel.

[0069] First, the total length L=R×θ (mm) after expansion is calculated by the camber track curvature radius R (mm) and the central angle θ (radian, usually 0.5π-2π); the total length is divided by the magnetization period length of 5mm to obtain the total number of magnetization units (integer, to ensure covering the entire camber track, and the last unit length is allowed to be not less than 2.5mm, that is, 1 / 2 of the period length).

[0070] Based on the 5mm magnetization period length of the incremental code channel, the absolute code channel single code element physical length value range is 5mm-10mm (to avoid magnetic field crosstalk with the incremental code channel, and to guarantee the spatial compatibility of the double code channels). Combined with the HCLA series absolute track design, the length specification suitable for the 8-bit pseudo-random binary sequence is adopted.

[0071] According to the camber track total length (mm) divided by the single code element physical length (mm), the value needs to be combined with the actual specification of the magnetic grating ruler, for example, corresponding to the maximum measurement stroke 320mm specification in the MSA50 series magnetic grating ruler, the maximum code element number is about 64 (320mm÷5mm); corresponding to the 1280mm stroke specification, it is about 256 (1280mm÷5mm), and 5%-10% redundancy is reserved in actual calculation to cope with the camber processing error.

[0072] According to the maximum code element number, the order n is determined, which needs to meet 2 n -1≥maximum code element number; combined with the design of the HCLA series absolute track using the 8-bit pseudo-random binary sequence, the order n=8 (2 8 -1=255) is selected, which can cover the demand of the maximum 256 code elements, and ensure the absolute encoding uniqueness at any position of the camber.

[0073] A pseudo-random binary sequence is generated by an 8-stage linear feedback shift register algorithm, and "0" and "1" in the sequence correspond to N-pole and S-pole magnetization states of the absolute code channel respectively.

[0074] The periodic incremental code channel and the non-periodic absolute code channel are arranged in parallel along the width direction of the curved surface, and the interval is controlled to be 0.5mm-2mm (adapted to a 20mm wide magnetic ruler to avoid magnetic field interference); the position alignment error along the movement direction is ≤±0.1μm, so that the Hall sensor array of the encoder and the AMR sensor can synchronously collect the signals of the two code channels.

[0075] The magnetization parameters based on 1μm resolution design are highly matched with the precision performance of the HCLA series encoder, so that the high resolution requirement of the curved surface measurement can be guaranteed. The spatial deployment parameters of the double code channels adapt to the complex working conditions of the flexible production line or the ring production line, can support the high-speed operation of the multi-mover slider, and improve the stability of the system in the flexible scene. The parameters such as the 5mm period of the incremental code channel and the 8-bit sequence of the absolute code channel are compatible with the magnetization process of the existing magnetic grating ruler (such as the MSA50 series), so that the engineering implementation difficulty is reduced.

[0076] In a preferred embodiment of the present application, based on the magnetic signal source, the magnetic communication signal is captured by the absolute value encoder integrated in the multi-mover slider, and a nonlinear spatial mapping algorithm is fused to correct the signal acquisition path in real time according to the spatial pose parameters of the encoder and the magnetic grating ruler, so as to obtain the original magnetic communication signal, including:

[0077] Step 21, based on the magnetic signal source, the spatial pose parameters of the multi-mover slider are acquired in real time, the instantaneous spatial position offset vector, the attitude rotation matrix and the local normal vector between the sensor array and the magnetic grating ruler are calculated by using the curved surface track geometric model;

[0078] Step 22, based on the instantaneous attitude rotation matrix and the local normal vector, the actual pointing vector of the sensor detection axis is derived through the direction mapping function of the nonlinear spatial mapping, and the direction deviation vector between the local normal vector and the actual pointing vector is calculated to obtain the distortion direction; the normal distance between the sensor and the magnetic grating ruler is calculated based on the instantaneous spatial position offset vector, and the effective deviation angle is derived according to the direction deviation vector, so that the distortion level is calculated;

[0079] Step 23, based on the expected distortion direction and the distortion level, a dynamic compensation instruction is generated, and the physical pointing of the sensor array is adjusted in real time to establish a compensated acquisition pointing state; under the established compensated acquisition pointing state, the original spatial magnetic flux distribution signal of the double magnetic channel magnetic grating ruler is synchronously captured by the sensor array, so as to obtain the magnetic communication signal;

[0080] Step 24, the magnetic communication signal is fused with the pose parameters to obtain the original magnetic communication signal.

[0081] In the embodiment of the present application, the spatial pose parameters include axial angle, radial angle, radial offset, pitch angle and the gap between the sensor and the magnetic scale, and the values strictly follow the installation tolerance: axial angle ≤ 1°, radial angle ≤ +0.5°, radial offset ≤ +0.30mm, pitch angle ≤ 0.5°; the recommended gap is 1.2mm (the best value), the allowable range is 0.9mm-1.5mm (the maximum is not more than 1.6mm). The real-time collection is realized by the built-in attitude sensor (such as a micro inclinometer, a displacement sensor) integrated in the absolute value encoder of the multi-actuator slider, and the sampling frequency is consistent with the encoder data refresh rate (50KHz).

[0082] The cambered track geometric model takes the center of curvature as the origin, constructs a three-dimensional polar coordinate system (radius = track curvature radius, angle ∈ [start angle, end angle]), and maps to the Cartesian coordinate system (X, Y, Z), the Z axis is the cambered axis, the X-Y plane is the radial cross section, and the magnetic suspension ring line structure is adapted; based on the model, the real-time pose parameters are substituted into the calculation:

[0083] The coordinate deviation (ΔX, ΔY, ΔZ) of the sensor array center and the surface of the magnetic scale is ≤0.30mm (radial) and ≤1.6mm (normal); the rotation state of the sensor array relative to the magnetic scale is described, and the rotation angle range matches the installation tolerance (axial ≤1°, radial ≤0.5°); the normal direction vector of the surface of the magnetic scale at the current position is derived based on the cambered curvature parameters (the radius is adapted to the flexible production line scene).

[0084] The direction mapping function is constructed:

[0085] The direction mapping function of the nonlinear space mapping takes the "attitude rotation matrix + local normal vector" as the input and the "sensor detection axis actual pointing vector" as the output, and the function form is a polynomial fitting (including the first order term and the second order cross term, such as the square of the rotation angle and the angle product term), which captures the nonlinear pointing deviation under the non-ideal attitude.

[0086] After deriving the sensor detection axis actual pointing vector, the direction deviation vector is obtained by performing vector difference with the local normal vector, and the direction is decomposed along the X / Y / Z axis, and the angle deviation range is ≤1° (axial) and ≤0.5° (radial), which corresponds to the maximum offset of the installation tolerance.

[0087] The normal distance (i.e. the actual gap, 0.9mm-1.5mm) between the sensor and the magnetic scale is calculated based on the instantaneous spatial position offset vector; the effective deviation angle (converted from the angle deviation and the distance, the range is ≤50μm / m) is derived in combination with the direction deviation vector; and finally the distortion level is the product of the deviation angle and the normal distance, the range is ≤2μm (matching the encoder repeat accuracy <2μm).

[0088] Generate fine-tuning instructions based on distortion direction and magnitude: axial angle deviation → drive rotation mechanism compensation (range 0° ~ 1°), radial offset → drive translation mechanism compensation (0 ~ 0.30mm), normal distance deviation → fine-tuning sensor height (0.9mm ~ 1.5mm), ensure that the deviation of the sensor detection axis and the local normal vector after compensation is ≤0.1°, and the normal distance is stable at 1.2±0.3mm.

[0089] In the compensation state, the Hall sensor array (absolute code channel) and AMR sensor (incremental code channel) of the encoder synchronously capture the double magnetic channel magnetic communication signal, with a sampling frequency of 50KHz, ensuring time alignment of the signal; the captured magnetic communication signal range matches the magnetization intensity of the magnetic grating ruler (to avoid exceeding 50mT magnetic field density damage to the magnetic grating ruler).

[0090] Align the magnetic communication signal with the real-time pose parameters by timestamp, use a weighted fusion algorithm (the greater the pose deviation, the higher the corresponding parameter weight, weight range 0.1 ~ 0.5), correct the signal fluctuations caused by residual errors, and finally generate the original magnetic communication signal, with a signal error of ≤2μm (meeting the repeat accuracy requirement).

[0091] Construction, training and implementation process of nonlinear space mapping algorithm model:

[0092] Input layer: 4 key pose parameters (axial angle, radial angle, radial offset, normal distance); output layer: distortion direction vector (3 components) and distortion magnitude (1 scalar); model structure: use quadratic polynomial fitting model to capture nonlinear relationships through linear terms (such as axial angle), quadratic terms (such as axial angle 2 ), and cross terms (such as axial angle x radial angle), ensuring coverage of all poses within the installation tolerance range.

[0093] Based on the input pose parameters and output distortion parameters, the specific form of the quadratic polynomial fitting model is as follows (variable definition: α is the axial angle, β is the radial angle, d is the radial offset, h is the normal distance; Δx, Δy, Δz are the distortion direction vector components, s is the distortion magnitude; k is the polynomial coefficient):

[0094] X-direction distortion Δx:

[0095] Δx = k0 + k1α + k2β + k3d + k4h + k5α 2 + k6β 2 + k7d 2 + k8h 2 + k9αβ + k 10 αd + k 11 αh + k 12 βd + k 13 βh + k14 dh;

[0096] Y-direction distortion Ay:

[0097] Ay = m0 + m1a + m2b + m3d + m4h + m5a 2 + m6b 2 + m7d 2 + m8h 2 + m9ab + m 10 ad + m 11 ah + m 12 bd + m 13 bh + m 14 dh;

[0098] Z-direction distortion Az:

[0099] Az = n0 + n1a + n2b + n3d + n4h + n5a 2 + n6b 2 + n7d 2 + n8h 2 + n9ab + n 10 ad + n 11 ah + n 12 bd + n 13 bh + n 14 dh;

[0100] Distortion level s:

[0101] s = p0 + p1a + p2b + p3d + p4h + p5a 2 + p6b 2 + p7d 2 + p8h 2 + p9ab + p 10 ad + p 11 ah + p 12 bd + p 13 bh + p 14 dh;

[0102] Δx (X-direction distortion) represents the deviation of the magnetic communication signal collection path in the X-direction (tangent direction of the camber surface), unit: μm, value range ≤ 2 μm (matching the encoder repeat accuracy < 2 μm), mainly caused by the synergistic effect of axial angle a and radial offset d.

[0103] Δy (Y-direction distortion) represents the deviation of the magnetic communication signal collection path in the Y-direction (radial direction), unit: μm, value range ≤ 2 μm, significantly affected by the radial angle b and the radial offset d, and the distortion increases as the angle or offset increases.

[0104] Δz (Z-direction distortion) represents the deviation of the magnetic signal acquisition path in the Z-direction (normal direction), with a unit of μm, a value range of ≤2 μm, and is mainly caused by the fluctuation of the normal distance h and the inclination of the radial angle β. The more unstable the distance is, the more obvious the distortion is.

[0105] s (distortion level) represents the total deviation degree of the acquisition path, with a unit of μm, a value range of ≤2 μm, and is the synthesis result of Δx, Δy and Δz, and is used for quantifying the overall influence of the non-ideal pose on the magnetic signal and providing a level basis for dynamic compensation.

[0106] k0 represents a constant term, which is used for compensating the inherent zero-position distortion of the system (such as the mechanical deviation of sensor installation and the initial offset of the circuit), and Δx=k0 when all the pose parameters are zero (α=β=d=h=0). The value of k0 is usually ≤0.5 μm, which ensures that the initial distortion in the X-direction is the smallest when there is no pose deviation.

[0107] k1α represents the first-order term of the axial angle α (0°~1°), and k1 is a coefficient, which reflects the linear influence of α on the X-direction distortion. When α increases, Δx increases linearly with α if k1 is positive (for example, when α=1°, the contribution of this term to the distortion is k1×1°).

[0108] k2β represents the first-order term of the radial angle β (0°~+0.5°), and k2 is a coefficient, which quantifies the linear effect of β on the X-direction distortion. The greater the inclination angle β is, the more obvious the influence of this term on Δx is (because the range of β is small, the absolute value of k2 is usually smaller than k1).

[0109] k3d represents the first-order term of the radial offset d (0~+0.30 mm), and k3 is a coefficient, which reflects the linear influence of d on the X-direction distortion. The greater d is (the farther the radial offset is), the more Δx increases linearly with d if k3 is positive.

[0110] k4h represents the first-order term of the normal distance h (0.9 mm~1.5 mm), and k4 is a coefficient, which quantifies the indirect influence of h on the X-direction distortion (h mainly affects the Z-direction, so the absolute value of k4 is usually small).

[0111] k5α 2 represents the second-order term of the axial angle α, and k5 is a coefficient, which captures the nonlinear cumulative effect of α (for example, when α=1°, the distortion is twice as large as that when α=0.5°). The aggravating effect of α on Δx is more obvious when k5 is positive.

[0112] k6β 2 represents the second-order term of the radial angle β, and k6 is a coefficient, which reflects the nonlinear influence of the square of the inclination angle β on the X-direction distortion (because the range of β is small, the absolute value of k6 is usually smaller than k5).

[0113] k7d 2represents the quadratic term of the radial offset d, k7 is the coefficient, quantifying the cumulative effect of d2 on the X-direction distortion (this term has more significant impact than the linear term when d = 0.3 mm).

[0114] k8h 2 represents the quadratic term of the normal distance h, k8 is the coefficient, reflecting the indirect nonlinear effect of h2 on the X-direction distortion (h mainly affects the Z-direction, so k8 is small in absolute value).

[0115] k9αβ represents the cross term of the axial angle α and the radial angle β, k9 is the coefficient, capturing the coupled effect of the two on the X-direction distortion (e.g. when α = 0.5° and β = 0.3°, this term contributes k9 × 0.5° × 0.3° distortion, which is not equal to the sum of the effects of α or β alone).

[0116] k 10 αd represents the cross term of the axial angle α and the radial offset d, k 10 is the coefficient, quantifying the combined effect of α rotation and d offset on the X-direction distortion (the distortion may be more significant than the individual effects when the two are coupled).

[0117] k 11 αh represents the cross term of the axial angle α and the normal distance h, k 11 is the coefficient, reflecting the indirect effect of α rotation and h gap on the X-direction distortion (since h mainly affects the Z-direction, the coefficient of this term is small).

[0118] k 12 βd represents the cross term of the radial angle β and the radial offset d, k 12 is the coefficient, capturing the combined effect of β tilt and d offset on the X-direction distortion (both are radial parameters, so the coupling effect is more obvious).

[0119] k 13 βh represents the cross term of the radial angle β and the normal distance h, k 13 is the coefficient, quantifying the combined effect of β tilt and h gap on the X-direction distortion (since both have more significant effects on the Y / Z-direction, the coefficient of this term is small).

[0120] k 14 dh represents the cross term of the radial offset d and the normal distance h, k 14 is the coefficient, reflecting the indirect effect of d offset and h gap on the X-direction distortion (the coefficient is usually small).

[0121] m0 represents the constant term, compensating for the zero-position distortion in the Y-direction, the value is ≤ 0.5 μm, ensuring that the initial distortion is minimal when there is no pose deviation.

[0122] m1α represents the first order term of axial angle α, m1 is the coefficient, quantifying the linear effect of α on Y direction distortion (α rotation has direct effect on Y direction).

[0123] m2β represents the first order term of radial angle β, m2 is the coefficient, which is the key term affecting Y direction distortion (β is the radial tilt, which directly causes Y direction path offset, so m2 absolute value is usually large).

[0124] m3d represents the first order term of radial offset d, m3 is the coefficient, reflecting the linear effect of d on Y direction distortion (d is the radial offset, closely related to Y direction).

[0125] m4h represents the first order term of normal distance h, m4 is the coefficient, quantifying the indirect effect of h on Y direction distortion (the coefficient is small).

[0126] m5α 2 represents the second order term of axial angle α, m5 is the coefficient, capturing the nonlinear cumulative effect of α on Y direction.

[0127] m6β 2 represents the second order term of radial angle β, m6 is the coefficient, because β has obvious effect on Y direction, the absolute value of the coefficient is usually large.

[0128] m7d 2 represents the second order term of radial offset d, m7 is the coefficient, reflecting the cumulative effect of d square on Y direction distortion.

[0129] m8h 2 represents the second order term of normal distance h, m8 is the coefficient, the effect is small.

[0130] m9αβ represents the cross term of α and β, m9 is the coefficient, quantifying the coupled effect of the two on Y direction distortion.

[0131] m 10 αd represents the cross term of α and d, m 10 is the coefficient, reflecting the combined effect of α rotation and d offset on Y direction.

[0132] m 11 αh represents the cross term of α and h, m 11 is the coefficient, the effect is small.

[0133] m 12 βd represents the cross term of β and d, m 12 is the coefficient, because β and d are both radial parameters, the coupled effect is obvious.

[0134] m 13 βh represents the cross term of β and h, m 13 is the coefficient, capturing the combined effect of β tilt and h gap on Y direction.

[0135] m 14 dh represents the cross term of d and h, m 14 is the coefficient, which has a small impact.

[0136] n0 represents the constant term, which compensates for the zero position distortion in the Z direction, and the value is ≤0.5 μm.

[0137] n1α represents the first-order term of the axial angle α, and n1 is the coefficient, which quantifies the linear impact of α on the Z direction distortion (small impact).

[0138] n2β represents the first-order term of the radial angle β, and n2 is the coefficient, which reflects the linear effect of the β tilt on the Z direction distortion (β tilt will cause the normal distance to fluctuate, so the coefficient is relatively obvious).

[0139] n3d represents the first-order term of the radial offset d, and n3 is the coefficient, which has a small impact (d is a radial parameter and is weakly related to the Z direction).

[0140] n4h represents the first-order term of the normal distance h, and n4 is the coefficient, which is the key term affecting the Z direction distortion (h is the vertical gap, which directly determines the Z direction path deviation, and n4 has the largest absolute value).

[0141] n5α 2 represents the second-order term of α, and n5 is the coefficient, which has a small impact.

[0142] n6β 2 represents the second-order term of β, and n6 is the coefficient, which captures the impact of the nonlinear accumulation of the β tilt on the Z direction (since β affects the normal distance, the coefficient of this term is relatively obvious).

[0143] n7d 2 represents the second-order term of d, and n7 is the coefficient, which has a small impact.

[0144] n8h 2 represents the second-order term of h, and n8 is the coefficient, which reflects the nonlinear accumulation effect of h squared on the Z direction distortion (h is the core parameter, and the coefficient of this term is relatively obvious).

[0145] n9αβ represents the cross term of α and β, and n9 is the coefficient, which has a small impact.

[0146] n 10 αd represents the cross term of α and d, and n 10 is the coefficient, which has a small impact.

[0147] n 11 αh represents the cross term of α and h, and n 11 is the coefficient, which quantifies the synergistic effect of α rotation and h gap on the Z direction.

[0148] n 12βd represents the cross term of β and d, n 12 is the coefficient, and the influence is small.

[0149] n 13 βh represents the cross term of β and h, n 13 is the coefficient, and the coupling influence is obvious because both β and h affect the normal.

[0150] n 14 dh represents the cross term of d and h, n 14 is the coefficient, and the influence is small.

[0151] p0 represents the constant term, compensates for the zero deviation of the total distortion, and the value is ≤0.5 μm.

[0152] p1α represents the first-order term of α, p1 is the coefficient, and quantifies the linear contribution of α to the total distortion.

[0153] p2β represents the first-order term of β, p2 is the coefficient, and reflects the linear influence of β on the total distortion.

[0154] p3d represents the first-order term of d, p3 is the coefficient, and quantifies the linear effect of d on the total distortion.

[0155] p4h represents the first-order term of h, p4 is the coefficient, and is the key contribution term of the total distortion (h directly affects the normal deviation).

[0156] p5α 2 represents the second-order term of α, p5 is the coefficient, and captures the influence of the nonlinear accumulation of α on the total distortion.

[0157] p6β 2 represents the second-order term of β, p6 is the coefficient, and reflects the effect of the nonlinear accumulation of β on the total distortion.

[0158] p7d 2 represents the second-order term of d, p7 is the coefficient, and quantifies the influence of the nonlinear accumulation of d on the total distortion.

[0159] p8h 2 represents the second-order term of h, p8 is the coefficient, and is an important nonlinear contribution term of the total distortion.

[0160] p9αβ represents the cross term of α and β, p9 is the coefficient, and captures the coupling influence of the two on the total distortion.

[0161] p 10 αd represents the cross term of α and d, p 10 is the coefficient, and quantifies the effect of the two on the total distortion.

[0162] p 11 αh represents the cross term of α and h, p 11is a coefficient, capturing the coupling of both on the total distortion.

[0163] p 12 is a coefficient, capturing the coupling of both on the total distortion. 12 is a coefficient, capturing the coupling of both on the total distortion.

[0164] p 13 is a coefficient, capturing the coupling of both on the total distortion. 13 is a coefficient, capturing the coupling of both on the total distortion.

[0165] p 14 is a coefficient, capturing the coupling of both on the total distortion. 14 is a coefficient, capturing the coupling of both on the total distortion.

[0166] Model training:

[0167] Simulate typical poses within the installation tolerance range (e.g. axial angle 0°→1°, interval 0.1°; normal distance 0.9mm→1.5mm, interval 0.1mm), record pose parameters and actual distortion (measured by laser interferometer, accuracy ≤1μm) simultaneously, generate 1000 groups of samples (80% training, 20% verification).

[0168] Training process: use least squares method to optimize polynomial coefficients, so that the error between the model predicted distortion and the actual distortion is ≤2μm; the error of the verification set must be ≤2μm to ensure generalization; physical consistency check (e.g. distortion increases when distance increases).

[0169] Training data collection:

[0170] Input parameter selection: axial angle: 0°-1° (interval 0.2°, total 6 points); radial angle: 0°-+0.5° (interval 0.1°, total 6 points); normal distance: 0.9mm-1.5mm (interval 0.2mm, total 4 points).

[0171] Output data measurement: for each sampling point, measure the actual magnetic flux distortion value (accuracy ≤1μm) with a laser interferometer, generate 6x6x4=144 groups of samples (80% for training, 20% for verification), to ensure coverage of all typical installation deviation scenarios.

[0172] Use a simplified polynomial ("linear term + key quadratic term") (only keep the terms that have the greatest impact on distortion, such as axial angle x radial angle, normal distance 2 ), reduce the number of coefficients, and avoid complex calculations.

[0173] The core target is that the deviation between the predicted distortion and the actual distortion is less than or equal to 2 μm (matching the repeatability of the encoder < 2 μm), and a complex error function is not defined separately, and the absolute value of the deviation is directly used as the optimization basis.

[0174] According to the physical law, the coefficient is preset (for example, when the normal distance increases, the coefficient of the corresponding distortion is positive), which ensures that the initial prediction direction is correct.

[0175] Iterative adjustment: only 3-5 coefficients with the greatest impact (such as the first term of the normal distance and the second term of the axial angle) are adjusted each time, and the adjustment amplitude is dynamically set according to the deviation (the larger the deviation, the larger the adjustment, and the smaller the deviation, the smaller the adjustment, the range is 0.01-0.1), avoiding the complexity of fixed step.

[0176] When the prediction deviation of all samples in the verification set is less than or equal to 2 μm, the iteration is stopped, and the error sum of squares is not calculated, and the actual deviation is directly used as the convergence mark.

[0177] The prediction effect of the optimized coefficient is checked by the verification set samples, and the requirements are: all sample deviations are less than or equal to 2 μm (repeatability of < 2 μm is met); the prediction deviation of the key parameter (such as the normal distance of 1.2 mm) is less than or equal to 1 μm (matching 1 μm resolution); only the coefficients meeting the above conditions are reserved, and are solidified to the encoder MCU to support real-time operation.

[0178] Model implementation:

[0179] The trained model is solidified to the internal MCU of the encoder, and after receiving the pose parameters in real time, the distortion result is output within 1 ms, supporting the real-time performance of dynamic compensation (matching the data refresh rate of 50KHz);

[0180] Through the nonlinear space mapping algorithm, the magnetic communication signal acquisition path error is improved, and the measurement deviation caused by the non-ideal pose is avoided. Compatible with the pose fluctuation within the installation tolerance range, it meets the complex working condition requirements of flexible production line or ring production line. The stability of the algorithm is not affected by temperature drift, which ensures the consistency of signal acquisition.

[0181] In a preferred embodiment of the present application, the step 3 comprises:

[0182] Step 31, extracting the incremental code channel component in the original magnetic communication signal to input the AMR sensor to analyze the phase change and generate the speed parameter; and extracting the absolute code channel component to be analyzed by the Hall sensor array to generate the original digital code sequence, and generating the purified sequence through the interpolation circuit harmonic filter;

[0183] Step 32, inputting the purified sequence and the pre-stored pseudo-random sequence into the MCU for matching to determine the unique position interval and obtain the coarse-grained absolute position estimate value;

[0184] Step 33, based on the speed parameter and the coarse-grained absolute position estimation value, the incremental code channel phase near the coarse position is mapped from the arc surface curvature parameter to the linear expansion space; the incremental code channel phase change is calculated in the linear expansion space to generate the fine displacement amount;

[0185] Step 34, the MCU fuses the coarse-grained position estimation value and the fine displacement amount to obtain the fusion position value in the linear space, and applies the magnetic flux-position conversion algorithm to reversely map the fusion position to the actual arc surface space coordinate based on the pre-stored arc surface curvature parameter, and finally generates the absolute position data.

[0186] In the embodiment of the application, the incremental code channel component (corresponding to the S / N alternating magnetization structure of 5mm long, that is, the incremental code channel period is 5mm) is separated from the original magnetic communication signal; the AMR sensor samples the component, and the sampling frequency is consistent with the encoder data refresh rate (50KHz), which ensures that the magnetic field change corresponding to every 1μm displacement can be captured at the maximum speed of 5m / s.

[0187] By detecting the phase change of the magnetic field generated by S / N alternation, the real-time speed is calculated in combination with the incremental code channel period (5mm); the speed parameter range covers 0-5m / s (including the maximum crossing speed), the calculation accuracy is adapted to 1μm resolution, and the speed error is ≤0.1% (based on the linearity of the sensor).

[0188] The absolute code channel component (corresponding to the 8-bit length pseudo-random binary sequence magnetization code) in the original magnetic communication signal is separated.

[0189] The Hall sensor array analysis: the Hall sensor array synchronously samples the absolute code channel component at multiple nodes (the sampling interval matches the physical length of the code element, and the code element length is 5-10mm, which is compatible with the 5mm incremental period), and converts the magnetic field signal into the original digital code element sequence (“0” / “1” corresponds to N / S pole).

[0190] The interpolation electronic element eliminates the harmonic interference of the original sequence, filters the electromagnetic noise (such as 50Hz power frequency interference) in the industrial environment through smoothing processing, generates the purified 8-bit pseudo-random code element sequence, and ensures that the code element recognition error rate is ≤0.1%.

[0191] Noise source and processing target: the noise of the original digital code element sequence mainly comes from the electromagnetic interference (such as 50Hz power frequency interference) in the industrial environment and the sensor sampling noise, which is manifested as the burr or jump (deviation range ±3-5μm) of the code element signal; the processing target is to attenuate the noise by more than 20dB, and ensure that the code element recognition error rate of the purified sequence is ≤0.1%.

[0192] Sliding window of 3-5 continuous symbols (window size matches the physical length of the symbol, 5-10 mm symbol corresponds to 15-50 mm window length), covering the local continuous area of the absolute code channel.

[0193] Take the mean of the original symbol sequence in the window, if the value of a symbol deviates from the mean of the window by more than ±3σ (σ is the standard deviation of the signal in the window, about 1-2 μm), it is determined as noise and replaced by the mean, eliminating isolated jumps.

[0194] For incomplete windows at the beginning and end of the sequence (length <3 symbols), use one-sided window mean (such as the first end using the last 3 symbol mean correction) to avoid edge distortion; the amplitude of the symbol jump of the processed sequence is ≤1 μm, which is compatible with the 1 μm resolution of the encoder, and the effectiveness of the filtering is verified by comparing the matching success rate of the processed sequence (improved to more than 99.9%).

[0195] MCU calls the pre-stored 8-bit pseudo-random binary sequence (completely consistent with the magnetization coding of the absolute code channel), and matches the purified sequence with the pre-stored sequence in a sliding window to locate the unique index of the current symbol in the sequence.

[0196] According to the physical length (5-10 mm) of the symbol corresponding to the index, determine the coarse-grained absolute position estimate value, whose error range is ≤10 mm (i.e. the length of a single symbol).

[0197] Model construction:

[0198] Coarse-grained absolute position estimate value, cambered surface curvature parameter (curvature radius R, adapted to the scenario of magnetic suspension ring-shaped line field), incremental code channel phase change; phase mapping value in linear expansion space; based on the geometric characteristics of cambered surface, construct the mapping relationship; project the incremental code channel phase of the cambered space (corresponding to arc length s=Rθ, θ is the central angle) to the linear space (length L=s), realize 1:1 mapping from cambered to linear, ensure that the projection deviation is ≤1 μm.

[0199] Model training:

[0200] Training data acquisition: on the cambered track with known curvature radius, measure the cambered coordinates (R, θ) of multiple feature points and their corresponding linear expansion length L by laser interferometer, generate 500 samples (cover the full journey of cambered surface); training process: use least squares method to optimize mapping parameters, so that the error between the projected linear length and the actual measured value is ≤1 μm (matching resolution); reserve 20% of the samples for verification to ensure the generalization of the cross-curvature range (adapt to different cambered surfaces of flexible production line); convergence criteria: the average error of the training set and the validation set is ≤1 μm.

[0201] Specific process of least squares method to optimize mapping parameters:

[0202] Model mapping parameter is the conversion coefficient k (dimensionless) from arc space to linear space, the goal is to make the error between the calculated linear expansion length and the actual measured value ≤1 pm (matching resolution); 50 feature points are uniformly selected in the full stroke of the arc track (such as 320 mm or 1280 mm, corresponding to the maximum measurement stroke in the document), covering different curvature positions (central angle θ from 0 to the maximum angle); for each feature point, the actual linear expansion length L corresponding to the arc coordinate is measured by a laser interferometer (accuracy ±0.5 pm), and the arc space parameters (curvature radius R, central angle θ) are recorded synchronously.

[0203] Initial parameter setting, based on geometric relationship (linear length ≈ R x θ), set the initial conversion coefficient w0 = 1.0 ± 0.1 (allow initial deviation); for each feature point, calculate the linear length calculated value L' = w x R x θ under the current parameter w, and the error eᵢ = L'-L of the actual value L, the total error square sum S = Σeᵢ 2 .

[0204] Minimize S by adjusting w, correct w each time (step 0.001), repeat 50-100 times, until S no longer decreases significantly (change <1 pm 2 ); the final optimized w needs to satisfy the error eᵢ of all feature points ≤1 pm, and the average error ≤0.5 pm; select another 10 feature points not involved in training (cover different curvatures) to verify that their errors are also ≤1 pm, ensuring that the parameters are effective in the full arc range.

[0205] Model implementation: the trained mapping relationship is solidified as a lookup table stored in the MCU, after receiving the coarse-grained position and curvature parameters in real time, the arc-to-linear projection calculation is completed within 1 ms, supporting the real-time generation of fine-tuning displacement.

[0206] In the linear expansion space, based on the speed parameter (reflecting the phase change per unit time) analyzed by the AMR sensor, the displacement corresponding to the incremental code channel phase change near the coarse-grained position is calculated, with an accuracy of ≤1 pm (based on 1 pm resolution).

[0207] The MCU fuses the coarse-grained position estimate (mm level) and the fine-tuning displacement (pm level) to obtain the fused position value in the linear space (error ≤2 pm, meeting the repeat accuracy requirement); then through the magnetic flux-position conversion algorithm, the linear position is inversely mapped to the actual arc coordinate (R, θ) based on the pre-stored arc curvature parameters, and the absolute position data is finally generated.

[0208] High-precision positioning: through the fusion of "coarse estimation + mu-level fine-tuning", the position requirements of precise motion control are met, and the dynamic control of multi-motor slider is adapted. The interpolation circuit filtering is matched with the pseudo-random sequence to reduce the influence of industrial noise on signal analysis and improve the stability under complex working conditions. The cylindrical surface projection development algorithm is constructed based on the geometric characteristics of the arc surface to accurately realize the mapping of the arc and linear space, and is suitable for the arc surface track scene of the magnetic suspension ring-shaped line.

[0209] In a preferred embodiment of the application, the absolute position data is encapsulated into a data frame according to a synchronous serial communication protocol, and is transmitted through a differential signal link to generate a data frame to be analyzed, which includes:

[0210] Step 41, the communication protocol processing unit receives the absolute position data result, and generates state flag bit information based on the real-time monitored signal integrity index; the communication protocol processing unit fuses the absolute position data result and the state flag bit information result to generate a raw encapsulation data packet;

[0211] Step 42, after the communication protocol processing unit receives the raw encapsulation data packet, the communication protocol processing unit adds the start synchronization header, the generated check code and the end flag in sequence according to the protocol to generate a complete protocol data frame with the same synchronous serial communication protocol frame format;

[0212] Step 43, the differential signal driving circuit receives the complete protocol data frame, converts the contained serial data stream into a differential voltage signal pair, and sends it to the motion controller side through the differential signal transmission link;

[0213] Step 44, the signal receiving and conditioning circuit receives the differential voltage signal pair, recovers it into a single-ended digital signal stream through amplification and shaping, extracts the complete bit stream of the protocol frame structure through sampling, and finally generates a data frame to be analyzed.

[0214] In the embodiment of the application, the absolute position data is 26 bits (corresponding to the encoder position information, right-aligned, MSB first, and the low bits are set to 0); the state flag bit is 2 bits (corresponding to the general condition: b1 and b0, wherein "L" indicates that the car is offline, "H" indicates that the car is online, and the associated indicator light state is also indicated, such as a blue light always on corresponding to a valid position, a purple light / red light corresponding to an invalid position, etc.); the signal integrity index includes data validity (based on position analysis result) and internal temperature (> 80℃ triggers state bit additional information); the communication protocol processing unit fuses the 26-bit position data and the 2-bit state flag bit to generate a 28-bit raw encapsulation data packet.

[0215] Start sync header: added according to the selected synchronous serial communication protocol (such as SSI, BiSS-C, MODBUS-RTU, etc.), length 1-2 bytes (for example, the SSI protocol sync header is a specific clock pulse sequence, and BiSS-C is a start symbol); check code: using parity check or CRC check (industry conventional way), length 1 byte, calculation range covers 28bit original data packet, ensuring data transmission integrity; end symbol: 1 byte (such as specific binary sequence “11111111”), indicating the end of frame transmission; total length of complete data frame: 28bit (original data) + 8-16bit (sync header) + 8bit (check code) + 8bit (end symbol) = 52-60bit, adapting to the frame format specified by the protocol.

[0216] The differential signal driving circuit receives the complete protocol data frame (serial data stream) and converts it into a pair of differential voltage signals (such as conforming to the RS485 standard, voltage range ±2V-±6V, transmitted through 485-A / 485-B pins); the transmission link uses a TPU high-flexible cable (double shielded, double twisted structure, shielding rate 90%, outer diameter 4.4±0.15mm), length range 0.5m (default) -10m (maximum allowed length).

[0217] Match the maximum clock frequency of the protocol, such as 1MHz for SSI and 2.5MHz for BiSS-C, to ensure a data refresh rate of 50KHz.

[0218] The signal receiving and conditioning circuit receives the pair of differential voltage signals, amplifies and shapes them (gain adapts to cable loss, ensuring signal amplitude ≥0.5V) and then restores them to a single-ended digital signal stream (high and low levels correspond to logic “1” and “0” respectively, level range 0-5V); according to the sampling frequency specified by the protocol (matching the transmission rate, such as 1μs sampling interval for 1MHz clock), the bit stream is extracted, the start sync header, check code (verified) and end symbol are identified, and finally the 28bit original data packet is parsed to generate the data frame to be parsed.

[0219] The differential signal link, combined with the double-shielded double-twisted cable, improves the anti-electromagnetic interference capability and adapts to the complex industrial environment; the check code mechanism further ensures data integrity. Supports multiple synchronous serial communication protocols such as SSI, BiSS-C, MODBUS-RTU, etc., can adapt to different motion controller interfaces, and flexibly meets the equipment integration needs of flexible production lines or ring production lines. The transmission rate matches the 50KHz data refresh rate, taking into account high-speed transmission and long-distance deployment. The 2bit status flag is associated with the online status of the trolley and the validity of the data, combined with the indicator light information, to facilitate real-time monitoring of the transmission status and rapid positioning of abnormalities (such as offline, invalid position, etc.).

[0220] In a preferred embodiment of the present application, the motion controller receives the data frame to be parsed and performs parsing processing, when the parsed state flag indicates a valid position, the synchronous driving instruction of the multi-motion slider is generated based on the parsed position data; when the parsed state flag indicates an exception, the driving instruction is interrupted and the magnetic scale damage diagnosis is activated, and finally a damage diagnosis report is generated, including:

[0221] Step 51, the communication protocol stack processing unit of the motion controller decodes the data frame to be parsed, extracts the absolute position data, state flag bit information and check code result, and transmits the check code and the original data part to the data check and state determination unit for validity determination;

[0222] Step 52, if the data is determined to be valid, the multi-axis synchronous control unit generates target instructions based on the absolute position data and calculates synchronous driving instructions, and finally outputs to the motor driver;

[0223] Step 53, if the data is determined to be abnormal, the safety control unit interrupts the driving instruction and sends an emergency stop instruction to the motor driver, activates the magnetic scale damage diagnosis task to generate a diagnosis start instruction; the diagnosis unit controls the slider to scan at a constant speed based on the diagnosis start instruction, and finally generates a damage diagnosis report by real-time collecting position and magnetic communication signals and calculating.

[0224] In an embodiment of the present application, the communication protocol stack processing unit of the motion controller decodes the data frame to be parsed according to the selected synchronous serial communication protocol (such as SSI, BiSS-C, MODBUS-RTU, etc.), extracts 26-bit absolute position data (right-aligned, MSB first, and the low bits are 0), 2-bit state flag bits (b1 and b0, "H" indicates that the trolley is online, and "L" indicates that the trolley is offline), and 1 byte check code.

[0225] The data check and state determination unit compares the extracted check code with the recalculated check value of the original data (26-bit position data + 2-bit state flag bits), and if they are consistent, the check passes; the data validity is determined in combination with the state flag bit and the indicator light state (such as blue light always on corresponding valid position, purple light / red light corresponding invalid position); the determination time is ≤10us (SSI protocol) or 20us (BiSS-C protocol), which matches the protocol timeout requirement.

[0226] The multi-axis synchronous control unit executes trajectory planning based on the valid absolute position data in combination with the preset trajectory (such as an arc surface measurement path) to generate target position and speed instructions (speed range 0-5m / s, matching the maximum running speed).

[0227] The calculated synchronous driving instruction (including position deviation compensation, speed adjustment parameter) is output through the motor driver interface, ensuring that the synchronization error of the multi-mover slider is ≤2μm (matching the encoder repetition accuracy), and the response delay is ≤350ms (after power-on initialization).

[0228] The safety control unit immediately interrupts the original driving instruction, sends an emergency stop instruction to the motor driver, and ensures that the slider is decelerated to stop within ≤50ms, avoiding mechanical damage in abnormal states.

[0229] The diagnostic unit controls the slider to uniformly scan along the cambered track at a low speed (such as 1m / s, lower than the maximum speed) based on a diagnostic start instruction, and collects position data and magnetic signals in real time (sampling frequency 50KHz).

[0230] The real-time magnetic flux signal is compared with the pre-stored standard magnetic flux distribution (without damage), and the deviation value (deviation ≥5μm is determined as a potential damage point) is calculated; combined with the auxiliary detection of the magnetic display card, the damage position is located (accuracy ≤1mm, reference installation tolerance).

[0231] The report content includes damage point coordinates (cambered space position), damage type (such as magnetization abnormality, physical scratch), abnormal magnetic flux deviation value and recommended maintenance scheme, and the generation time is ≤10s (covering the maximum measurement travel of 1280mm).

[0232] Through double determination of check code and state flag bit, combined with the anti-interference ability of differential signal transmission, the reliability of data transmission and analysis is improved, which is suitable for industrial complex environment and meets the cooperation requirements of cambered precise measurement. Abnormal driving is quickly interrupted and emergency stop is started to avoid equipment damage; damage diagnosis can accurately locate the fault point to reduce maintenance time. Supports SSI, BiSS-C and other protocols, flexible adaptation to different motion controllers, and improves the integration convenience of equipment.

[0233] As shown in Figure 2 , the embodiment of the present application also provides a flexible line driving control system for cambered precise measurement, comprising:

[0234] A deployment module is used to deploy a double-magnetic-track magnetic grating ruler on the surface of the cambered track, the incremental code track adopts a periodic magnetization structure, and the absolute code track adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source;

[0235] A correction module is used to capture the magnetic signal based on the magnetic signal source through the absolute value encoder integrated in the multi-mover slider, and fuse a nonlinear space mapping algorithm to correct the signal acquisition path in real time according to the spatial pose parameters of the encoder and the magnetic grating ruler, and obtain the original magnetic signal.

[0236] The computing module is used for generating a speed parameter of an AMR sensor resolution incremental code channel from the original magnetic communication signal; the original magnetic communication signal is resolved into an absolute code channel signal through a Hall sensor array, after harmonic interference is eliminated by an interpolation circuit, and absolute position data is generated by a magnetic flux-position conversion algorithm executed by an MCU according to a cylindrical surface projection development algorithm;

[0237] The transmission module is used for encapsulating the absolute position data into a data frame according to a synchronous serial communication protocol, and transmitting the data frame through a differential signal link to generate a data frame to be resolved.

[0238] The diagnostic module is used for receiving the data frame to be resolved by the motion controller and performing resolution processing, generating a synchronous driving instruction of the multi-moving slider based on the resolved position data when a state flag resolved indicates a valid position, and interrupting the driving instruction and activating a magnetic grating ruler damage diagnosis when the state flag resolved indicates an exception, and finally generating a damage diagnosis report.

[0239] It should be noted that the system is a system corresponding to the above method, and all implementation manners in the above method embodiment are applicable to this embodiment and can achieve the same technical effects.

[0240] Embodiments of the application also provide a computing device, comprising a processor and a memory storing a computer program, wherein the computer program is executed by the processor to perform the method described above. All implementation manners in the above method embodiment are applicable to this embodiment and can achieve the same technical effects.

[0241] Embodiments of the application also provide a computer readable storage medium storing instructions, wherein the instructions are executed on a computer to make the computer perform the method described above. All implementation manners in the above method embodiment are applicable to this embodiment and can achieve the same technical effects.

[0242] The above is the preferred embodiment of the application, and it should be noted that for those skilled in the art, without departing from the principles of the application, a number of improvements and refinements can be made, and these improvements and refinements should also be considered as the protection scope of the application.

Claims

1. A flexible wire drive control method for precise measurement of a camber, characterized by, The method comprises: Step 1, deploying a double-track magnetic scale on the cambered track surface, the incremental code track adopts a periodic magnetization structure, and the absolute code track adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source; Step 2, based on the magnetic signal source, capturing the magnetic communication signal through the absolute value encoder integrated in the multi-mover slider, and fusing the nonlinear space mapping algorithm to correct the signal acquisition path in real time according to the space pose parameters of the encoder and the magnetic scale, to obtain the original magnetic communication signal; Step 3, the original magnetic communication signal is parsed by the AMR sensor to generate a speed parameter; the original magnetic communication signal is parsed by the Hall sensor array to generate an absolute position data, including: extracting the incremental code track component in the original magnetic communication signal to input the AMR sensor to generate a speed parameter by analyzing the phase change; and extracting the absolute code track component to generate a purified sequence through the interpolation circuit harmonic filter; inputting the purified sequence and the pre-stored pseudo-random sequence into the MCU to match the unique position interval and obtain a coarse-grained absolute position estimate value; based on the speed parameter and the coarse-grained absolute position estimate value, the incremental code track phase near the coarse position is mapped from the arc space to the linear expansion space according to the camber curvature parameters; the phase change of the incremental code track in the linear expansion space is calculated to generate a fine displacement; the MCU fuses and calculates the coarse-grained position estimate value and the fine displacement to obtain a fused position value in the linear space, and applies the flux-position conversion algorithm to inversely map the fused position to the actual camber space coordinates based on the pre-stored camber curvature parameters, to finally generate the absolute position data; Step 4, the absolute position data is packaged into a data frame according to a synchronous serial communication protocol, and is transmitted through a differential signal link to generate a data frame to be parsed; Step 5, the motion controller receives the data frame to be parsed and performs parsing processing, generates a synchronous driving instruction of the multi-mover slider based on the parsed position data when the parsed state flag indicates a valid position; when the parsed state flag indicates an exception, the driving instruction is interrupted and a magnetic scale damage diagnosis is activated, and finally a damage diagnosis report is generated.

2. The flexible wire drive control method for precise measurement of a camber surface according to claim 1, wherein, Deploying a double-track magnetic scale on the cambered track surface, the incremental code track adopts a periodic magnetization structure, and the absolute code track adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source, including: Step 11, calculating the minimum magnetization period length and the total number of magnetization units of the incremental code track through the curvature radius of the cambered track and the preset measurement resolution; based on the period length and the total number of magnetization units, performing continuous and equally spaced N-pole and S-pole alternating magnetization operations on the cambered track surface along the motion path direction, to finally generate a periodic incremental magnetization code track and a magnetization period length parameter; Step 12, based on the magnetization cycle length parameter, calculate the absolute code channel single code element physical length, and determine the maximum number of binary code elements that can be accommodated according to the total length of the cambered track; With the maximum number of code elements as the upper limit, a pseudo-random binary sequence is generated by a predetermined order linear feedback shift register algorithm; Step 13, based on the pseudo-random binary sequence and the single code element physical length, perform absolute code channel magnetization encoding mapping to generate aperiodic magnetization encoding distribution, and perform spatial alignment and parallel deployment with the periodic incremental magnetization code channel to generate a magnetic signal source.

3. The flexible wire drive control method for precise measurement of a camber surface according to claim 2, wherein, The step 2 comprises: Step 21, based on the magnetic signal source, real-time acquisition of the spatial pose parameters of the multi-actuator slider, using the cambered track geometric model to calculate the instantaneous spatial position offset vector, attitude rotation matrix and local normal vector between the sensor array and the magnetic grating ruler; Step 22, based on the instantaneous attitude rotation matrix and the local normal vector, the actual pointing vector of the sensor detection axis is derived through the direction mapping function of the nonlinear space mapping, and the direction deviation vector between the actual pointing vector and the local normal vector is calculated to obtain the distortion direction; Based on the instantaneous spatial position offset vector, the normal distance between the sensor and the magnetic grating ruler is calculated, and the effective deviation angle is derived according to the direction deviation vector, and the distortion level is calculated; Step 23, based on the expected distortion direction and the distortion level, generate dynamic compensation instructions, and real-time fine-tune the physical pointing of the sensor array to establish the compensation after acquisition pointing state; Under the established compensation after acquisition pointing state, the original space magnetic flux distribution signal of the double magnetic channel magnetic grating ruler is captured synchronously through the sensor array to obtain the magnetic communication signal; Step 24, fuse the magnetic communication signal and the pose parameters to obtain the original magnetic communication signal.

4. The flexible wire drive control method for precise measurement of a camber surface according to claim 3, wherein, The absolute position data is encapsulated into a data frame according to a synchronous serial communication protocol, and is transmitted through a differential signal link to generate a data frame to be analyzed, comprising: Step 41, the communication protocol processing unit receives the absolute position data result, and generates state flag bit information based on the real-time monitored signal integrity index; The communication protocol processing unit fuses the absolute position data result and the state flag bit information result to generate an original encapsulation data packet; Step 42, after the communication protocol processing unit receives the original encapsulation data packet, the start synchronization header, the generated check code and the end flag specified by the protocol are sequentially added to generate a complete protocol data frame conforming to the frame format of the synchronous serial communication protocol; Step 43, the differential signal driving circuit receives the complete protocol data frame, converts the contained serial data stream into a differential voltage signal pair, and sends it to the motion controller side through the differential signal transmission link; Step 44, the signal receiving and conditioning circuit receives the differential voltage signal pair, recovers it into a single-ended digital signal stream through amplification and shaping, extracts the complete bit stream of the protocol frame structure, and finally generates the data frame to be analyzed.

5. The flexible wire drive control method for precise measurement of a camber surface according to claim 4, wherein, The motion controller receives the data frame to be analyzed and performs analysis processing, when the analyzed state flag indicates a valid position, the motion controller generates a synchronous driving instruction for the multi-actuator slider based on the analyzed position data; When the analyzed state flag indicates an exception, the driving instruction is interrupted and the magnetic grating ruler damage diagnosis is activated, and finally a damage diagnosis report is generated, comprising: Step 51, the communication protocol stack processing unit of the motion controller decodes the data frame to be parsed, extracts the absolute position data, state flag information and check code result, and transmits the check code and the original data part to the data check and state determination unit for validity determination; Step 52, if the data is determined to be valid, the multi-axis synchronous control unit generates target instructions based on the absolute position data, calculates synchronous driving instructions, and finally outputs to the motor driver; Step 53, if the data is determined to be abnormal, the safety control unit interrupts the driving instructions and sends an emergency stop instruction to the motor driver, activates the magnetic scale damage diagnosis task to generate a diagnosis start instruction; the diagnosis unit controls the slider to scan at a constant speed based on the diagnosis start instruction, collects position and magnetic signals in real time and calculates, and finally generates a damage diagnosis report.

6. The flexible wire drive control method for precise measurement of a camber surface according to claim 5, wherein, The MCU fuses the coarse-grained position estimation value and the fine displacement to obtain a fused position value in a linear space, and applies a magnetic flux-position conversion algorithm to reversely map the fused position to an actual cambered surface space coordinate based on pre-stored cambered surface curvature parameters, and finally generates absolute position data, including: Step 61, the MCU performs vector superposition operation based on the coarse-grained absolute position estimation value and the fine displacement, and performs algebraic addition of the fine displacement and the coarse-grained absolute position estimation value in a linear expansion space to calculate and generate a linear space fused position value; Step 62, divide the linear space fused position value by the curvature radius to obtain a corresponding central angle value, calculate the cambered surface tangential coordinate, radial coordinate and vertical coordinate based on the central angle, and generate a preliminary absolute position; separate the real-time magnetic field intensity of the absolute code channel from the original magnetic communication signal, compare the deviation proportion of the real-time magnetic field intensity and the pre-stored ideal value, and generate a compensated absolute position; Step 63, based on the compensated absolute position, perform motion path cumulative arc length reverse calculation operation, bind and package the arc length value and space-time identifier, and finally generate absolute position data.

7. A flexible wire drive control system for precise measurement of a cambered surface, the system implementing the method of any one of claims 1 to 6, characterized in that, It includes: A deployment module is used to deploy a double-track magnetic scale on the surface of a cambered track, the incremental code channel adopts a periodic magnetization structure, and the absolute code channel adopts a pseudo-random binary sequence magnetization encoding to generate a magnetic signal source; A correction module is used to capture the magnetic communication signal based on the magnetic signal source through the absolute value encoder integrated in the multi-mover slider, and fuse the nonlinear space mapping algorithm to correct the signal acquisition path in real time according to the space pose parameters of the encoder and the magnetic scale, to obtain the original magnetic communication signal; A calculation module is used to parse the incremental code channel of the original magnetic communication signal to generate a speed parameter through an AMR sensor; The absolute code channel signal is parsed through a Hall sensor array, after harmonic interference is eliminated by an interpolation circuit, a cylindrical surface projection expansion algorithm is fused, and absolute position data is generated based on the MCU executing a magnetic flux-position conversion algorithm; A transmission module is used to package the absolute position data into a data frame according to a synchronous serial communication protocol, and transmit the data frame through a differential signal link to generate a data frame to be parsed. The diagnostic module is used for the motion controller to receive and parse the data frame to be parsed, and when the parsed state flag indicates a valid position, a synchronous driving instruction of the multi-mover slider is generated based on the parsed position data; when the parsed state flag indicates an exception, the driving instruction is interrupted and a magnetic scale damage diagnosis is activated, and finally a damage diagnosis report is generated.

8. A computing device, comprising: comprising: one or more processors; a memory device for storing one or more programs, when the one or more programs are executed by the one or more processors, so that the one or more processors implement the method as claimed in any one of claims 1 to 6.

9. A computer-readable storage medium, characterized in that, The computer readable storage medium stores a program, which is executed by the processor to implement the method as claimed in any one of claims 1 to 6.

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