Die-cutting machine control system

Abstract

The invention discloses a die-cutting machine control system, which adopts an EtherCAT + CAN dual-bus closed-loop control architecture, and EtherCAT (high-speed real-time control instruction) and CAN bus (sensor real-time feedback) dual-protocol cooperative closed-loop communication, breaks through the limitation of the number of slave stations and the delay bottleneck of serial communication in the traditional PLC centralized control, and has the advantages of high-speed real-time control instruction, high-speed real-time control instruction, high-speed real-time control instruction and CAN bus real-time feedback. Sensor data (tension, angular displacement, temperature and pressure) are directly transmitted to the motion control module in a distributed mode through a CAN bus, millisecond-level response is ensured, die cutting errors caused by signal delay are avoided, and wiring is simplified. The three-layer algorithm of virtual axis-real axis mapping, dynamic decoupling and disturbance observation is taken as the core, the sleeve cutting precision, the tension stability and the system expansibility of the die cutting machine are improved to a new level, and intergenerational transition from PLC general control to a special intelligent control system for the die cutting process is realized.

Description

Technical Field

[0001] This invention relates to the field of equipment automation control technology, specifically to a die-cutting machine control system. Background Technology

[0002] Die-cutting machines, also known as cutting machines or CNC punching machines, are mainly used for die-cutting (full cut, half cut), creasing, hot stamping, lamination, and automatic waste removal of various non-metallic materials, self-adhesive labels, EVA, double-sided tape, electronic and mobile phone pads, etc. Die-cutting machines use steel knives, hardware molds, and steel wire (or templates carved from steel plates) to apply a certain pressure through the printing plate to cut printed materials or cardboard into a certain shape. They are important equipment for post-printing packaging processing.

[0003] Currently, most die-cutting machines on the market adopt a "traditional centralized control architecture," with a system architecture such as... Figure 1 As shown, a centralized control architecture is adopted, consisting of a PLC, multiple servo drivers, servo motors, mechanical reduction / transmission mechanisms, feeding and take-up mechanisms, and die-cutting mechanisms. The mainstream communication bus is an EtherCAT ring network. The PLC sends position / speed commands to all servos via EtherCAT. Sensor signals are sent back to the PLC from remote I / O via EtherCAT or hardwired. The die-cutting machine relies solely on motor encoder feedback and lacks real-time monitoring of key parameters such as bottom roller angular displacement, deformation (temperature / pressure), and material tension. Under high load, the number of slave stations on a single bus (such as EtherCAT) is limited, and data transmission delays lead to lagging control commands and insufficient real-time communication. In addition, the PLC performs simple position closed-loop or speed synchronization, lacking specialized compensation and decoupling algorithms for the die-cutting process (tension, roller temperature / pressure, phase synchronization). Summary of the Invention

[0004] In order to solve the technical problems existing in the background art, the present invention provides a die-cutting machine control system, which realizes real-time, high-precision, and dynamically stable control of the multi-axis coordinated motion of the die-cutting machine.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This invention provides a die-cutting machine control system, including a motion control module, multiple servo drive modules, multiple speed reduction transmission modules, multiple die-cutting operation modules, and a sensor module;

[0007] The motion control module sends control commands to multiple servo drive modules via EtherCAT.

[0008] The servo drive module receives the corresponding control commands from the motion control module, and then controls the operation of the servo motor.

[0009] The speed reduction transmission module converts the high speed of the servo motor in the servo drive module into a large torque output to the corresponding die-cutting module;

[0010] The die-cutting module is equipped with a sensor module for collecting data on the tension of the working material on the roller, the angular displacement of the roller, temperature, and pressure.

[0011] The sensor module transmits the data collected by the sensor module to the motion control module via CAN communication.

[0012] The above technical solution is adopted:

[0013] The system adopts an EtherCAT+CAN dual-bus closed-loop control architecture. EtherCAT (high-speed real-time control command) and CAN bus (real-time sensor feedback) are used for collaborative closed-loop communication, breaking through the limitations of the number of slave stations and the latency bottleneck of serial communication in traditional PLC centralized control. Sensor data (tension, angular displacement, temperature, pressure) are directly transmitted to the motion control module in a distributed manner through the CAN bus, ensuring millisecond-level response, avoiding die-cutting errors caused by signal delay, and simplifying wiring.

[0014] Furthermore, the motion control module can be a single controller unit or a combination of several controller units, including a controller CPU, digital input modules, digital output modules, remote I / O modules, analog input modules, and analog output modules.

[0015] The motion control module has two architecture modes: the first mode consists of a PLC and a signal converter, where the PLC acts as the main control unit and the signal converter is used for implementation. Signal relay introduces protocol conversion delays. The second mode consists of a dedicated motion controller that natively supports EtherCAT or CAN, allowing direct commands to the servo driver without conversion, reducing latency to the microsecond level.

[0016] The motion control module employs a three-level control algorithm, comprising a top-level trajectory planner, a middle-level multi-axis dynamic decoupling compensator, and a bottom-level axis-level robust controller. This forms a three-stage process: trajectory planning → dynamic decoupling → disturbance observation. Through multi-level collaborative optimization, the top level ensures "globally optimal trajectory," the middle level ensures "multi-axis collaboration and model matching," and the bottom level ensures "single-axis disturbance rejection, high speed, and high precision." This achieves high-speed, high-precision, and robust die-cutting control, and realizes a complete closed loop for the production line. The process flow is: process requirements → trajectory planner → decoupling compensator → axis-level robust controller → motor → machinery → sensor → back to trajectory planner, forming a real-time closed loop.

[0017] Top-level trajectory planner: Transforms discrete machining process requirements into multi-axis collaborative continuous motion control target commands. Through virtual axis collaborative formation and adaptive S-shaped speed planning, it reduces mechanical shock and improves high-speed operation stability (such as solving the material tensile deformation problem in the acceleration and deceleration phase of traditional systems). It also corrects the cutter roller phase online in real time based on the temperature of the cutter roller and the thermal expansion coefficient matrix of the material, using the thermal deformation compensation formula.

[0018] Mid-level dynamic decoupling compensator: Model-based inertial force / Coriolis force feedforward compensation + PD tracking + adaptive robust control, to counteract inter-axis coupling disturbances and maintain trajectory accuracy even with sudden load changes (such as uneven material thickness).

[0019] Low-level shaft-level robust controller: Real-time estimation of residual disturbances (such as torque fluctuations caused by wear of transmission gears) through disturbance observer, combined with time delay compensation, to suppress errors to a small level.

[0020] Furthermore, the top-level trajectory planner uses a virtual axis S-curve and a thermal deformation compensation formula to transform discrete machining process requirements into multi-axis collaborative continuous motion control target commands.

[0021] Specifically:

[0022] 1. Based on process requirements, the trajectory planner will first coordinate and group the spindles of the rotary cutter, that is, grouping spindles with the same motion mode into one group, and the motion position of each group is given by a discrete point sequence. In addition, the process parameters include maximum speed, maximum acceleration, and maximum jerk.

[0023] 2. Assign a virtual axis to each formation.

[0024] 3. When different imaginary axes work together, the timing needs to be optimized, and spatial spline interpolation is required to ensure smoothness.

[0025] 4. Perform velocity planning, such as adaptive S-curve, which is a motion trajectory planning for the imaginary axis.

[0026] 5. The motion trajectory planning of the virtual axis must be mapped to all real axes in the same formation. Based on the real-time feedback of the axis temperature, the deformation compensation amount of each axis is calculated in real time using the thermal expansion coefficient matrix. Based on the deformation compensation amount, the surface linear displacement and linear acceleration of each axis are converted into axis angular displacement and axis angular acceleration.

[0027] 6. The output of the trajectory planner is the motion control target command for each real axis.

[0028] Furthermore, the mid-level multi-axis dynamic decoupling compensator includes an inertial force feedforward compensation module, a Coriolis force compensation module, a PD tracking module, and an adaptive robust compensation module. Through model-based dynamic compensation, the system's stability is ensured by tracking the PD controller under ideal, disturbance-free conditions, and model errors are offset by the adaptive robust compensator.

[0029] Specifically:

[0030] 1. The multi-axis dynamic decoupling compensator includes an inertial force feedforward compensation module, a Coriolis force compensation module, a PD tracking module, and an adaptive robust compensation module.

[0031] 2. The inputs of the multi-axis dynamic decoupling compensator include the real axis motion position command and position change rate command output by the trajectory planner, and the real-time position of each real axis fed back.

[0032] 3. The inertial force feedforward compensation module and the Coriolis force compensation module constitute the model-based dynamic compensation, and their input is the motion position change rate command of the real axis.

[0033] 4. The PD tracker includes a proportional part and a differential part, and its input is the real-time error of the real axis motion position.

[0034] 5. The mathematical expression of the adaptive robust compensator is as follows: Its input is the real-time error of the real axis motion position.

[0035] 6. The core essence of the multi-axis dynamic decoupling compensator: through model-based dynamic compensation, the system e→0 in the ideal, disturbance-free state; through PD controller tracking to ensure system stability; and through an adaptive robust compensator to offset model errors.

[0036] Furthermore, the underlying shaft-level robust controller includes a disturbance estimation correction and compensation module and a nominal inertia compensation module; the nominal inertia compensation module calculates the ideal inertial torque caused by system acceleration; the disturbance estimation correction and compensation module includes a time delay compensation module and a disturbance observer, the time delay compensation module performs phase compensation for sensor data delay, and the disturbance observer corrects the motor torque based on the residual disturbance estimate.

[0037] Specifically:

[0038] 1. The shaft-level robust controller includes a disturbance estimation correction and compensation module and a nominal inertia compensation module.

[0039] 2. The disturbance estimation correction and compensation module includes a time delay compensation module and a disturbance observer.

[0040] 3. The nominal inertia compensator calculates the ideal inertial torque caused by the system acceleration to counteract most of the inertial force, so that the observer only needs to deal with the residual disturbance.

[0041] Furthermore, the die-cutting operation module includes a feeding module, a die-cutting module, and a take-up module; the feeding module is equipped with a feeding sensor module for collecting tension data of the working material on the unwinding roller; the die-cutting module is equipped with a die-cutting sensor module for collecting angular displacement, temperature, and pressure data of the die-cutting bottom roller; and the take-up module is equipped with a take-up sensor module for collecting tension data of the working material on the take-up roller.

[0042] Furthermore, the die-cutting sensor module includes a die-cutting bottom roller angle displacement sensor, a die-cutting bottom roller temperature sensor, a die-cutting bottom roller pressure sensor, and a first signal processing unit; the die-cutting bottom roller angle displacement sensor converts the angle displacement of the die-cutting bottom roller into an analog electrical signal; the die-cutting bottom roller temperature sensor converts the temperature of the die-cutting bottom roller into an analog electrical signal; the die-cutting bottom roller pressure sensor converts the pressure received by the die-cutting bottom roller into an analog electrical signal; the first signal processing unit converts the analog electrical signals from the die-cutting bottom roller angle displacement sensor, the die-cutting bottom roller temperature sensor, and the die-cutting bottom roller pressure sensor into digital signals conforming to standard transmission protocols.

[0043] Furthermore, both the unloading sensor module and the take-up sensor module include a tension sensor and a second signal processing unit; the tension sensor converts the tension of the working material on the unloading or take-up roller into an analog electrical signal, and the second signal processing unit converts the analog electrical signal from the tension sensor into a digital signal conforming to a standard transmission protocol.

[0044] Furthermore, the standard transmission protocol is either the CAN bus communication protocol or the RS-485 serial communication protocol. Preferably, the CAN bus communication protocol is used.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] (1) The system adopts an EtherCAT+CAN dual-bus closed-loop control architecture. EtherCAT (high-speed real-time control command) and CAN bus (real-time sensor feedback) are used for collaborative closed-loop communication, breaking through the limitations of the number of slave stations and the bottleneck of serial communication delay in traditional PLC centralized control. The servo drive still uses EtherCAT. Sensor data (tension, angular displacement, temperature, pressure) are directly transmitted to the motion control module through the distributed CAN bus. The closed-loop control of sensing → decision → servo drive ensures millisecond-level response, avoids die-cutting errors caused by signal delay, and simplifies wiring.

[0047] (2) The motion control module adopts a three-level control algorithm, which includes a top-level trajectory planner, a middle-level multi-axis dynamic decoupling compensator and a bottom-level axis-level robust controller, forming a three-stage process of trajectory planning → dynamic decoupling → disturbance observation. Through multi-level collaborative optimization, high-speed, high-precision, and robust modular control is achieved.

[0048] Top-level trajectory planner: Transforms discrete machining process requirements into multi-axis collaborative continuous motion control target commands. Through virtual axis collaborative formation and adaptive S-shaped speed planning, it reduces mechanical shock and improves high-speed operation stability (such as solving the material tensile deformation problem in the acceleration and deceleration phase of traditional systems). It also corrects the cutter roller phase online in real time based on the temperature of the cutter roller and the thermal expansion coefficient matrix of the material, using the thermal deformation compensation formula.

[0049] Mid-level dynamic decoupling compensator: Model-based inertial force / Coriolis force feedforward compensation + PD tracking + adaptive robust control, to counteract inter-axis coupling disturbances and maintain trajectory accuracy even with sudden load changes (such as uneven material thickness).

[0050] Low-level shaft-level robust controller: Real-time estimation of residual disturbances (such as torque fluctuations caused by wear of transmission gears) through disturbance observer, combined with time delay compensation, to suppress errors to a small level.

[0051] (3) This invention connects the data link between the sensor and the servo through the “EtherCAT+CAN dual bus closed-loop control architecture”, and takes the three-layer algorithm of “virtual axis-real axis mapping, dynamic decoupling, and disturbance observation” as the core to improve the cutting accuracy, tension stability and system scalability of the die-cutting machine to a new level, realizing the generational leap from “PLC general control” to “die-cutting process special intelligent control system”. Attached Figure Description

[0052] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0053] Figure 1 System architecture diagram of an existing die-cutting machine;

[0054] Figure 2 This is a system architecture diagram of the die-cutting machine in this invention;

[0055] Figure 3 This is an architecture diagram of the servo drive module in this invention;

[0056] Figure 4 This is a schematic diagram of the speed reduction transmission module in this invention;

[0057] Figure 5 This is a diagram illustrating the architecture of the die-cutting module in this invention.

[0058] Figure 6This is a schematic diagram of the die-cutting bottom roller sensor module in this invention;

[0059] Figure 7 This is an architectural diagram of the feeding sensor module and the receiving sensor module in this invention;

[0060] Figure 8 This is a diagram of the control algorithm architecture of the motion control module in this invention. Detailed Implementation

[0061] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] This invention discloses a die-cutting machine control system, such as Figure 2 As shown, it includes a motion control module, multiple servo drive modules, multiple speed reduction transmission modules, multiple die-cutting operation modules, and a sensor module.

[0063] The motion control module sends control commands to multiple servo drive modules via EtherCAT.

[0064] The servo drive module receives the corresponding control commands from the motion control module, and then controls the operation of the servo motor.

[0065] The speed reduction transmission module converts the high speed of the servo motor in the servo drive module into a large torque output to the corresponding die-cutting module;

[0066] The die-cutting module is equipped with a sensor module for collecting data on the tension of the working material on the roller, the angular displacement of the roller, temperature, and pressure.

[0067] The data collected by the sensor module is fed back to the motion control module via CAN bus communication.

[0068] In a specific embodiment, three servo drive modules and three speed reduction transmission modules are provided, with each servo drive module and speed reduction transmission module corresponding to and cooperating with the others.

[0069] The die-cutting module includes a feeding module, a die-cutting module, and a take-up module. The feeding module is equipped with a feeding sensor module for collecting tension data of the working material on the unwinding roller. The die-cutting module is equipped with a die-cutting bottom roller sensor module for collecting angular displacement, temperature, and pressure data of the die-cutting bottom roller. The take-up module is equipped with a take-up sensor module for collecting tension data of the working material on the take-up roller.

[0070] The above technical solution is adopted:

[0071] The system adopts an EtherCAT+CAN dual-bus closed-loop control architecture, using EtherCAT (high-speed real-time control command) and CAN (real-time sensor feedback) dual-protocol collaborative closed-loop communication. This breaks through the limitations of the number of slave stations in traditional PLC centralized control and the bottleneck of serial communication delay. Sensor data (tension, angular displacement, temperature, pressure) are directly transmitted to the motion control module in a distributed manner through the CAN bus, ensuring millisecond-level response, avoiding die-cutting errors caused by signal delay, and simplifying wiring.

[0072] The motion control module can be a single controller unit or a combination of several controller units. Its components include a controller CPU, digital input modules, digital output modules, remote I / O modules, analog input modules, and analog output modules. The motion control module architecture has two modes: the first mode consists of a PLC and a signal converter, where the PLC acts as the main control unit and requires a signal converter for operation. Signal relay introduces protocol conversion delays. The second mode consists of a dedicated motion controller that natively supports EtherCAT or CAN, allowing direct commands to the servo driver without conversion, reducing latency to the microsecond level.

[0073] Among them, such as Figure 3 As shown, the servo drive module includes a servo driver and a servo motor. The servo driver receives control commands from the motion controller module (host computer) and outputs control current to control the servo motor; the servo motor converts the current from the servo driver into torque output; the servo motor integrates a rotary encoder, which converts the position and angle of the motor shaft into a signal and feeds it back to the servo driver.

[0074] Among them, such as Figure 4 As shown, the speed reduction transmission module includes a speed reducer, a coupling, a drive roller, and a drive roller gear. The speed reducer converts the low-torque, high-speed output of the servo motor into a high-torque, low-speed output; the coupling connects the output of the speed reducer to the drive roller; the drive roller is coaxially coupled with the drive roller gear; the drive roller gear outputs low speed and high torque.

[0075] Among them, such as Figure 5As shown, the die-cutting module is the die-cutting operation part of an existing die-cutting machine. In a specific embodiment, the die-cutting module includes a die-cutting bottom roller gear, a die-cutting bottom roller, a die-cutting gear, and a die. The die-cutting gear and the die can be replaced with a rubber roller gear and a rubber roller. During operation, the die-cutting bottom roller receives input torque from the transmission bottom roller gear. The die-cutting bottom roller gear and the die-cutting bottom roller are coaxially coupled and drive the die-cutting bottom roller to rotate. The die-cutting bottom roller gear and the die-cutting gear directly mesh and drive the die-cutting gear to rotate. The die-cutting gear and the die are coaxially coupled and drive the die to rotate. The specific structure of the die-cutting module is not limited to the above structure; other die-cutting operation structures can be used, but a die-cutting bottom roller will be provided in all die-cutting modules.

[0076] like Figure 6 As shown, the die-cutting bottom roller sensor module includes a die-cutting bottom roller angle displacement sensor, a die-cutting bottom roller temperature sensor, a die-cutting bottom roller pressure sensor, and a first signal processing unit. The die-cutting bottom roller angle displacement sensor converts the angle displacement of the die-cutting bottom roller into an analog electrical signal. The die-cutting bottom roller temperature sensor converts the temperature of the die-cutting bottom roller into an analog electrical signal. The die-cutting bottom roller pressure sensor converts the pressure received by the die-cutting bottom roller into an analog electrical signal. The first signal processing unit converts the analog electrical signals from the die-cutting bottom roller angle displacement sensor, the die-cutting bottom roller temperature sensor, and the die-cutting bottom roller pressure sensor into digital signals conforming to standard transmission protocols.

[0077] Among them, such as Figure 7 As shown, the feeding module includes a feeding reel that carries working material and supplies it to the die-cutting module by rotation. The receiving module includes a receiving reel that rotates to wind up the working material processed by the die-cutting module.

[0078] Both the unloading sensor module and the take-up sensor module include a tension sensor and a second signal processing unit. The tension sensor converts the tension of the working material on the unloading or take-up roller into an analog electrical signal, and the second signal processing unit converts the analog electrical signal from the tension sensor into a digital signal that conforms to a standard transmission protocol.

[0079] The standard transmission protocol is either the CAN bus communication protocol or the RS-485 serial communication protocol. The CAN bus communication protocol is preferred. The signal processing unit includes a microprocessor CPU, digital input modules, digital output modules, remote I / O modules, analog input modules, analog output modules, and a protocol converter, etc.

[0080] Among them, such as Figure 8As shown, the motion control module adopts a three-level control algorithm, including a top-level trajectory planner, a middle-level multi-axis dynamic decoupling compensator, and a bottom-level axis-level robust controller, forming a three-stage process of trajectory planning → dynamic decoupling → disturbance observation. Through multi-level collaborative optimization, the top level ensures "globally optimal trajectory", the middle level ensures "multi-axis collaboration and model matching", and the bottom level ensures "single-axis disturbance resistance, high speed and high precision", realizing high-speed, high-precision, and robust die-cutting control, and realizing a complete closed loop of the pipeline. Process requirements → trajectory planner → decoupling compensator → axis-level robust controller → motor → machinery → sensor → back to trajectory planner, forming a real-time closed loop.

[0081] Top-level trajectory planner: Transforms discrete machining process requirements into multi-axis collaborative continuous motion control target commands. Through virtual axis collaborative formation and adaptive S-shaped speed planning, it reduces mechanical shock and improves high-speed operation stability (such as solving the material tensile deformation problem in the acceleration and deceleration phase of traditional systems). It also corrects the cutter roller phase online in real time based on the temperature of the cutter roller and the thermal expansion coefficient matrix of the material, using the thermal deformation compensation formula.

[0082] Mid-level dynamic decoupling compensator: Model-based inertial force / Coriolis force feedforward compensation + PD tracking + adaptive robust control, to counteract inter-axis coupling disturbances and maintain trajectory accuracy even with sudden load changes (such as uneven material thickness).

[0083] Low-level shaft-level robust controller: Real-time estimation of residual disturbances (such as torque fluctuations caused by wear of transmission gears) through disturbance observer, combined with time delay compensation, to suppress errors to a small level.

[0084] In practical applications, the top-level trajectory planner uses a virtual axis S-curve and a thermal deformation compensation formula to transform discrete machining process requirements into multi-axis collaborative continuous motion control target commands.

[0085] Specifically: 1. Based on process requirements, the trajectory planner will first coordinate and group the spindles of the rotary cutter, that is, grouping spindles with the same motion mode into one group, and the motion position of each group is given by a discrete point sequence. In addition, the process parameters include maximum speed, maximum acceleration, and maximum jerk.

[0086] 2. Assign a virtual axis to each formation.

[0087] 3. When different imaginary axes work together, the timing needs to be optimized, and spatial spline interpolation is required to ensure smoothness.

[0088] 4. Perform velocity planning, such as adaptive S-curve, which is a motion trajectory planning for the imaginary axis.

[0089] 5. The motion trajectory planning of the virtual axis must be mapped to all real axes in the same formation. Based on the real-time feedback of the axis temperature, the deformation compensation amount of each axis is calculated in real time using the thermal expansion coefficient matrix. Based on the deformation compensation amount, the surface linear displacement and linear acceleration of each axis are converted into axis angular displacement and axis angular acceleration.

[0090] 6. The output of the trajectory planner is the motion control target command for each real axis.

[0091] The mid-level multi-axis dynamic decoupling compensator includes an inertial force feedforward compensation module, a Coriolis force compensation module, a PD tracking module, and an adaptive robust compensation module. Through model-based dynamic compensation, the system's stability is ensured by tracking the PD controller under ideal, disturbance-free conditions, and model errors are offset by the adaptive robust compensator.

[0092] Specifically:

[0093] 1. The multi-axis dynamic decoupling compensator includes an inertial force feedforward compensation module, a Coriolis force compensation module, a PD tracking module, and an adaptive robust compensation module.

[0094] 2. The inputs of the multi-axis dynamic decoupling compensator include the real axis motion position command and position change rate command output by the trajectory planner, and the real-time position of each real axis fed back.

[0095] 3. The inertial force feedforward compensation module and the Coriolis force compensation module constitute the model-based dynamic compensation, and their input is the motion position change rate command of the real axis.

[0096] 4. The PD tracker includes a proportional part and a differential part, and its input is the real-time error of the real axis motion position.

[0097] 5. The mathematical expression of the adaptive robust compensator is as follows: Its input is the real-time error of the real axis motion position.

[0098] 6. The core essence of the multi-axis dynamic decoupling compensator: through model-based dynamic compensation, the system e→0 in the ideal, disturbance-free state; through PD controller tracking to ensure system stability; and through an adaptive robust compensator to offset model errors.

[0099] The underlying shaft-level robust controller includes a disturbance estimation correction and compensation module and a nominal inertia compensation module; the nominal inertia compensation module calculates the ideal inertial torque caused by system acceleration; the disturbance estimation correction and compensation module includes a time delay compensation module and a disturbance observer, the time delay compensation module performs phase compensation for sensor data delay, and the disturbance observer corrects the motor torque based on the residual disturbance estimate.

[0100] Specifically:

[0101] 1. The shaft-level robust controller includes a disturbance estimation correction and compensation module and a nominal inertia compensation module.

[0102] 2. The disturbance estimation correction and compensation module includes a time delay compensation module and a disturbance observer.

[0103] 3. The nominal inertia compensator calculates the ideal inertial torque caused by the system acceleration to counteract most of the inertial force, so that the observer only needs to deal with the residual disturbance.

[0104] This invention establishes a data link between sensors and servos through an "EtherCAT+CAN dual-bus closed-loop control architecture," and uses a three-layer algorithm of "virtual axis-real axis mapping, dynamic decoupling, and disturbance observation" as its core to improve the die-cutting machine's cutting accuracy, tension stability, and system scalability to a new level, achieving a generational leap from "PLC general control" to "die-cutting process-specific intelligent control system."

[0105] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A die-cutting machine control system, characterized in that, It includes a motion control module, multiple servo drive modules, multiple speed reduction transmission modules, multiple die-cutting operation modules, and sensor modules; The motion control module sends control commands to multiple servo drive modules via EtherCAT. The servo drive module receives the corresponding control commands from the motion control module, and then controls the operation of the servo motor. The speed reduction transmission module converts the high speed of the servo motor in the servo drive module into a large torque output to the corresponding die-cutting module; The die-cutting module is equipped with a sensor module for collecting data on the tension of the working material on the roller, the angular displacement of the roller, temperature, and pressure. The sensor module transmits the data collected by the sensor module to the motion control module via CAN communication.

2. The die-cutting machine control system according to claim 1, characterized in that, The motion control module is a single controller unit or a combination of several controller units. The motion control module adopts a three-level control algorithm, which includes a top-level trajectory planner, a middle-level multi-axis dynamic decoupling compensator, and a bottom-level axis-level robust controller, forming a three-stage process of trajectory planning → dynamic decoupling → disturbance observation.

3. The die-cutting machine control system according to claim 2, characterized in that, The top-level trajectory planner uses a virtual axis S-curve and thermal deformation compensation formula to transform discrete machining process requirements into multi-axis collaborative continuous motion control target commands.

4. The die-cutting machine control system according to claim 2, characterized in that, The mid-level multi-axis dynamic decoupling compensator includes an inertial force feedforward compensation module, a Coriolis force compensation module, a PD tracking module, and an adaptive robust compensation module. Through model-based dynamic compensation, the system's stability is ensured by tracking the PD controller under ideal, disturbance-free conditions, and model errors are offset by the adaptive robust compensator.

5. The die-cutting machine control system according to claim 2, characterized in that, The underlying shaft-level robust controller includes a disturbance estimation correction and compensation module and a nominal inertia compensation module; the nominal inertia compensation module calculates the ideal inertial torque caused by system acceleration; the disturbance estimation correction and compensation module includes a time delay compensation module and a disturbance observer, the time delay compensation module performs phase compensation for sensor data delay, and the disturbance observer corrects the motor torque based on the residual disturbance estimate.

6. The die-cutting machine control system according to claim 1, characterized in that, The die-cutting module includes a feeding module, a die-cutting module, and a receiving module; the feeding module is equipped with a feeding sensor module for collecting tension data of the working material on the unwinding roller. The die-cutting module is equipped with a die-cutting sensor module for collecting angular displacement, temperature, and pressure data of the die-cutting bottom roller; The take-up module is equipped with a take-up sensor module for collecting tension data of the working material on the take-up roller.

7. The die-cutting machine control system according to claim 6, characterized in that, The die-cutting sensor module includes a die-cutting bottom roller angle displacement sensor, a die-cutting bottom roller temperature sensor, a die-cutting bottom roller pressure sensor, and a first signal processing unit. The die-cutting bottom roller angle displacement sensor converts the angle displacement of the die-cutting bottom roller into an analog electrical signal. The die-cutting bottom roller temperature sensor converts the temperature of the die-cutting bottom roller into an analog electrical signal. The die-cutting bottom roller pressure sensor converts the pressure received by the die-cutting bottom roller into an analog electrical signal. The first signal processing unit converts the analog electrical signals from the die-cutting bottom roller angle displacement sensor, the die-cutting bottom roller temperature sensor, and the die-cutting bottom roller pressure sensor into digital signals conforming to standard transmission protocols.

8. The die-cutting machine control system according to claim 7, characterized in that, Both the unloading sensor module and the take-up sensor module include a tension sensor and a second signal processing unit. The tension sensor converts the tension of the working material on the unloading or take-up roller into an analog electrical signal, and the second signal processing unit converts the analog electrical signal from the tension sensor into a digital signal that conforms to a standard transmission protocol.

9. The die-cutting machine control system according to claim 8, characterized in that, The standard transmission protocol is either the CAN bus communication protocol or the RS-485 serial communication protocol.

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