Magnetic base drill state indication method and system based on magnetic force and load sensing

Abstract

The application discloses a magnetic seat drill state indication method and system based on magnetic force and load sensing, and relates to the technical field of magnetic seat drill control. The method comprises the following steps: S1, real-time collection of magnetic seat drill monitoring data and data preprocessing; S2, evaluation of the stability of magnetic adsorption and working condition adjustment according to the stability of magnetic adsorption; S3, monitoring of the stability and robustness of magnetic adsorption, monitoring of the dynamic bearing margin and impact resistance of the magnetic seat drill, realization of state classification, and safety redundancy adjustment according to different states; and S4, continuous monitoring of the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drill, visual feedback and parameter optimization. The method solves the problem that, due to the fact that traditional technology cannot monitor the influence of multi-factor coupling, the electromagnetic adsorption force dynamically fluctuates in the drilling process of the magnetic seat drill, and the adsorption stability is difficult to guarantee.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of magnetic seat drill control, in particular to a magnetic seat drill state indication method and system based on magnetic force and load sensing. BACKGROUND

[0002] The magnetic seat drill is a portable machining equipment that relies on electromagnetic attraction force to fix and drill on the surface of a metal workpiece, is widely used in fields such as bridge steel structure, shipbuilding, rail transit, wind power tower and large equipment installation and maintenance, has the characteristics of realizing high-precision drilling in complex postures such as vertical and inverted, and is an indispensable core tool in modern steel structure construction and equipment maintenance. With the development of industrial manufacturing towards high strength, high efficiency and intelligence, the operation safety and operation stability have become the focus of the industry.

[0003] For example, the patent for invention with publication number CN118838219A discloses a magnetic seat drill control circuit and a control method thereof, which comprises a main motor M1 and a feeding motor M2. The main motor M1 and the feeding motor M2 are both connected to a power supply unit. The main motor M1 is connected to a current detection unit. The current detection unit is connected to a signal amplification unit. The signal amplification unit is connected to a rising edge detection unit with a delay output and a falling edge detection unit with a delay output. The falling edge detection unit with a delay output is controlled by the rising edge detection unit with a delay output. The falling edge detection unit with a delay output is connected to a driving unit. By setting the main motor M1, the feeding motor M2, the current detection unit, the signal amplification unit, the rising edge detection unit and the falling edge detection unit, the falling edge detection unit with a delay output is controlled by the rising edge detection unit with a delay output in actual use. The falling edge detection unit with a delay output is connected to the driving unit, thereby realizing the control of automatic feeding and automatic back-off of the main shaft of the drill.

[0004] However, the attraction force of the electromagnet is not constant during the operation of the magnetic seat drill, but is dynamically affected by multiple factors such as power fluctuation, iron inclusion, workpiece surface roughness, temperature rise and load disturbance, resulting in fluctuation and attenuation of the magnetic attraction force in different drilling stages. The current magnetic seat drill system usually only relies on a Hall sensor or current sampling to obtain a single instantaneous magnetic field strength signal, which is difficult to reflect the dynamic stability and continuous bearing capacity of the magnetic force under the multi-source coupling effect, cannot realize real-time evaluation and trend prediction of the attraction state, and has a potential risk of attraction instability.

[0005] Therefore, in view of the above problems, a magnetic seat drill state indication method and system based on magnetic force and load sensing are urgently needed. SUMMARY

[0006] In view of the deficiencies of the prior art, the present application provides a magnetic seat drilling state indication method and system based on magnetic force and load sensing, which solves the problem that the traditional technology cannot monitor the influence of multiple factors coupling, resulting in dynamic fluctuation of electromagnetic adsorption force during magnetic seat drilling and difficulty in guaranteeing adsorption stability.

[0007] To achieve the above object, the present application is implemented by the following technical solutions: a magnetic seat drilling state indication method based on magnetic force and load sensing, comprising the following steps: S1, real-time acquisition of magnetic seat drilling monitoring data, data preprocessing of the magnetic seat drilling monitoring data; S2, based on the preprocessed magnetic seat drilling monitoring data, evaluation of the stability of magnetic adsorption, working condition adjustment according to the stability of magnetic adsorption; S3, fusion of the stability of magnetic adsorption and the magnetic seat drilling monitoring data, monitoring of the stability and robustness of magnetic adsorption, monitoring of the dynamic bearing margin and impact resistance of the magnetic seat drilling, comprehensive analysis of the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic seat drilling to realize state classification, safety redundancy adjustment according to different states; S4, continuous monitoring of the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drilling, visual feedback and parameter optimization.

[0008] Further, the specific process of real-time acquisition of magnetic seat drilling monitoring data and data preprocessing of the magnetic seat drilling monitoring data is as follows: real-time acquisition of magnetic seat drilling monitoring data, the magnetic seat drilling monitoring data including: magnetic flux density, electromagnet temperature, motor bus current, motor bus voltage, main shaft speed, coil current, coil end voltage, main shaft vibration, effective magnetic pole area, tool equivalent radius, whole machine and load mass, rated bus voltage, rated no-load current, rated speed, magnetic circuit temperature correction constant, and motor torque constant; band-limited filtering and denoising are performed on the current, voltage, and speed signals, a low-pass Butterworth filter is combined with a sliding median filter to filter out power supply ripple and instantaneous burrs; temperature and vibration signals are synchronized with resampling and interpolation alignment to establish a unified time reference; outlier rejection is performed: three times standard deviation rule is used to identify and reject short-time mutations and invalid jump points in the magnetic seat drilling monitoring data, and linear interpolation is used to complete the missing samples; wherein, the three times standard deviation rule is limited to the steady state interval suitable for Gaussian distribution noise characteristics, and for the load impact and starting transition interval with non-Gaussian characteristics, the rejection operation is not performed; standardization and normalization processing is performed on the magnetic seat drilling monitoring data; a magnetic seat drilling state control database is established, and the preprocessed magnetic seat drilling monitoring data is written into the magnetic seat drilling state control database.

[0009] Further, based on the pre-processed magnetic drill monitoring data, the specific process for evaluating the stability of magnetic adsorption is: obtaining the pre-processed magnetic drill monitoring data, calculating the product of the square of the magnetic flux density and the effective magnetic pole area, and dividing by twice the vacuum permeability constant to obtain the magnetic adsorption basic force value; taking the normal temperature as the temperature reference value, multiplying the difference between the electromagnet temperature and the temperature reference value by the magnetic circuit temperature correction constant to obtain the magnetic circuit temperature drift compensation, and subtracting the constant from the magnetic circuit temperature drift compensation to obtain the magnetic temperature correction term; subtracting the rated bus voltage from the motor bus voltage and dividing by the rated bus voltage to obtain the bus voltage fluctuation ratio, and subtracting the constant from the bus voltage fluctuation ratio to obtain the voltage correction term; multiplying the magnetic adsorption basic force value, the magnetic temperature correction term, and the voltage correction term to obtain the magnetic adsorption effective force term; multiplying the whole machine and load mass by the gravitational acceleration to obtain the whole machine and load gravity value; establishing a linear proportional relationship function according to the rated no-load current and the rated speed, and calculating the no-load current function value according to the current spindle speed using the linear proportional relationship function; multiplying the difference between the motor bus current and the no-load current function value by the motor torque constant, and dividing by the equivalent radius of the tool to obtain the motor load equivalent force value; adding the whole machine and load gravity value and the motor load equivalent force value to obtain the total bearing force term; dividing the magnetic adsorption effective force term by the total bearing force term to obtain the magnetic adsorption stability evaluation value.

[0010] Further, the specific process for adjusting the working condition according to the stability of magnetic adsorption is: comparing the magnetic adsorption stability evaluation value with the multi-stage stability threshold D1 and D2; when D1, it is determined that the adsorption is unstable, the control indicator is red slow flashing, the stop protection instruction is output, the electromagnet power supply is immediately cut off and the spindle is locked; when D1≤ D2, it is determined that the critical balance state, the control indicator is yellow constant, the local working condition correction of the magnetic circuit and the load link is executed, including increasing the coil current, reducing the spindle speed and feed speed; when ≥D2, it is determined that the magnetic adsorption state is stable, the control indicator is green constant, and the current working parameters of the magnetic drill are maintained. The magnetic adsorption stability evaluation value is continuously monitored, and the magnetic adsorption effective force term, the total bearing force term and the magnetic adsorption stability evaluation value are written into the magnetic drill state control database.

[0011] Further, the stability of the magnetic adsorption is fused with the magnetic base drill monitoring data, and the specific process of monitoring the stability and robustness of the magnetic adsorption is as follows: based on the sliding time window, the magnetic base drill monitoring data, the magnetic adsorption effective force item, the total bearing force item and the magnetic adsorption stability evaluation value are read from the magnetic base drill state control database; the minimum magnetic adsorption stability evaluation value in the window is selected to obtain the sliding window minimum stability value; the motor bus voltage mean value and the motor bus voltage standard deviation in the window are calculated, and the voltage ripple ratio is obtained by dividing the motor bus voltage standard deviation by the rated bus voltage; the constant is subtracted from the ratio of the motor bus voltage mean value to the rated bus voltage, and only the non-negative value is retained to obtain the voltage sag item; in the sliding time window, the change rate of the electromagnet temperature is calculated for each sampling point, and for each sampling point, it is judged whether the change rate is positive or not, if it is positive, it is retained, if it is negative, it is taken as zero, and the integral sum of all positive change rates in the sliding time window is obtained to obtain the temperature rise cumulative increment; at the same time, the absolute value of the change rate is taken for each sampling point, and the integral sum of all change rate absolute values in the sliding time window is obtained to obtain the total integral value of temperature change; the temperature rise cumulative increment is divided by the total integral value of temperature change to obtain the temperature rise proportion; the multi-source disturbance correction item is obtained by adding the constant to the voltage ripple ratio, the voltage sag item and the temperature rise proportion; the magnetic adsorption robustness value is obtained by dividing the sliding window minimum stability value by the multi-source disturbance correction item.

[0012] Further, the specific process of simultaneously monitoring the dynamic bearing margin and impact resistance of the magnetic base drill is as follows: at the same time, the difference between the motor bus current and the no-load current function value is calculated to obtain the load current, based on the sliding time window, the first order difference of the load current is calculated and the absolute value is taken to obtain the current absolute change rate, the second order difference of the load current is calculated and the absolute value is taken to obtain the current absolute acceleration, and the integral operation of the current absolute acceleration in the window is performed to obtain the load current change cumulative amount; the current absolute change rate and the load current change cumulative amount are added to obtain the load current dynamic response amount; the ratio of the motor torque constant to the equivalent radius of the tool, the load current dynamic response amount and the sliding time window length are multiplied to obtain the load current power response item; the magnetic adsorption effective force item is subtracted from the total bearing force item, and the non-negative value is taken to obtain the magnetic load force remaining item; the load energy margin value is obtained by dividing the magnetic load force remaining item by the load current power response item.

[0013] Further, the specific process of state classification of the stability and robustness of magnetic adsorption and the dynamic load margin and impact resistance of the magnetic base drill is: comparing the magnetic adsorption robustness value with the robustness threshold value, and comparing the load energy margin value with the margin threshold value; when the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is less than the margin threshold value, it is determined to be an unstable shutdown state; when the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is determined to be an adsorption critical state; when the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is less than the margin threshold value, it is determined to be an energy critical state; when the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is determined to be a stable safe state.

[0014] Further, the specific process of safety redundancy adjustment according to different states is: when in the unstable shutdown state, the control indicator light is red flashing, the main control loop power-off protection is executed, the double power supply of the electromagnet and the motor is cut off, the main control loop power-off protection is executed first to keep the magnetic adsorption unchanged, immediately reduce the load and gradually reduce the spindle speed, stop the spindle rotation after the drilling load is removed, and finally disconnect the power supply of the electromagnet; when in the adsorption critical state, the control indicator light is yellow flashing, the adsorption side priority compensation strategy is executed: increase the coil current and the coil end voltage, while keeping the spindle speed unchanged; when in the energy critical state, the control indicator light is yellow slow flashing, the load side slow release priority strategy is executed: reduce the spindle speed and the feed speed, limit the motor torque output, and adjust the feed rhythm to realize intermittent load slow release; when in the stable safe state, the control indicator light is green constant, the current working parameters are maintained, and the sliding time window length is adjusted according to the trend changes of the magnetic adsorption robustness value and the load energy margin value.

[0015] Further, the specific process of continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic load margin and impact resistance of the magnetic base drill, and performing visual feedback and parameter optimization is: continuously monitoring the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value, and displaying the dynamic state and time trend of the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value on the terminal; at the same time, the multi-level state indicator light performs synchronous visual feedback according to the respective determination results, displays the specific state and triggers sound and light alarm and prompt information according to the classification results; at the same time, by the distribution characteristics of the historical magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value, the multi-level stability threshold value, the robustness threshold value and the margin threshold value are corrected by using the sliding average and clustering analysis algorithm.

[0016] The second aspect of the present application provides a magnetic seat drill state indication system based on magnetic force and load perception, comprising: a monitoring data acquisition and preprocessing module for real-time acquisition of magnetic seat drill monitoring data and data preprocessing of the magnetic seat drill monitoring data; a magnetic force stability evaluation and determination module for evaluating the stability of magnetic adsorption based on the preprocessed magnetic seat drill monitoring data, and adjusting the working condition according to the stability of magnetic adsorption; a trend prediction and energy margin linkage module for fusing the stability of magnetic adsorption and the magnetic seat drill monitoring data, monitoring the stability and robustness of magnetic adsorption, monitoring the dynamic bearing margin and impact resistance of the magnetic seat drill, comprehensively analyzing the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic seat drill to realize state classification, and adjusting the safety redundancy according to different states; a visual feedback and closed-loop optimization module for continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drill, and performing visual feedback and parameter optimization.

[0017] The present application has the following beneficial effects:

[0018] (1) The present application fuses the effective force term of magnetic adsorption and the total load bearing force term, calculates the magnetic adsorption stability evaluation value based on the multi-source signals such as electromagnet temperature, voltage fluctuation, main shaft speed and motor current, and reflects the dynamic change of adsorption force in the drilling process in real time, realizes the transition from static estimation to dynamic quantization of suction force, and improves the real-time reliability of the adsorption state of the magnetic seat drill.

[0019] (2) The present application constructs the magnetic adsorption robustness value and the load energy margin value, unifies the voltage ripple, temperature rise proportion and load dynamic response into the evaluation framework, forms a complementary judgment mechanism of adsorption and load double channels, can identify potential instability risks in advance under complex working conditions, and improves the anti-disturbance and anti-impact capability.

[0020] (3) The present application establishes a hierarchical control mechanism, executes local working condition correction in the magnetic adsorption critical state, executes system level safety redundancy adjustment in the comprehensive state classification, combines red, yellow and green multi-level indication and flashing rhythm prompt, realizes the transition from passive shutdown protection to active dynamic stability control.

[0021] (4) The present application introduces the moving average and clustering analysis algorithm, dynamically corrects the multi-level threshold value based on the historical evaluation data, realizes threshold self-learning and parameter adaptive optimization, and synchronously displays the state through the terminal visual interface, improves the intelligentization and visualization level of the magnetic seat drill control.

[0022] Of course, any product implementing the present application does not necessarily need to achieve all the advantages described above. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 It is a flow chart of the magnetic seat drill state indication method based on magnetic force and load perception.

[0024] Figure 2 A magnetic seat drilling state indication system structure diagram based on magnetic force and load sensing;

[0025] Figure 3 A magnetic adsorption stability evaluation trend chart;

[0026] Figure 4 A magnetic seat drilling state indication flowchart based on magnetic force and load sensing. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. As understood by those skilled in the art, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0028] Please refer to Figures 1-4 , the embodiments of the present application provide a technical solution: a magnetic seat drilling state indication method and system based on magnetic force and load sensing, as shown in Figure 1 , comprising the following steps: S1, real-time acquisition of magnetic seat drilling monitoring data, data preprocessing of the magnetic seat drilling monitoring data; S2, based on the preprocessed magnetic seat drilling monitoring data, evaluating the stability of magnetic adsorption, and adjusting the working condition according to the stability of magnetic adsorption; S3, fusing the stability of magnetic adsorption and the magnetic seat drilling monitoring data, monitoring the stability and robustness of magnetic adsorption, monitoring the dynamic bearing margin and impact resistance of the magnetic seat drilling at the same time, comprehensively analyzing the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic seat drilling to realize state classification, and adjusting the safety redundancy according to different states; S4, continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drilling, and performing visual feedback and parameter optimization.

[0029] Specifically, the magnetic base drill monitoring data is collected in real time, and the specific process of data preprocessing of the magnetic base drill monitoring data is as follows: the magnetic base drill monitoring data is collected in real time, and the magnetic base drill monitoring data includes: magnetic flux density, electromagnet temperature, motor bus current, motor bus voltage, main shaft speed, coil current, coil end voltage, main shaft vibration, effective magnetic pole area, tool equivalent radius, whole machine and load mass, rated bus voltage, rated no-load current, rated speed, magnetic circuit temperature correction constant and motor torque constant; wherein the magnetic flux density is measured in real time by the Hall effect magnetic flux sensor installed at the bottom of the electromagnet; the electromagnet temperature is collected by the thermocouple sensor attached to the surface of the electromagnet coil; the motor bus current and the motor bus voltage are measured by the current Hall and voltage division module; the main shaft speed is obtained by the optical encoder installed at the end of the main shaft; the coil current and the end voltage are collected by the current and voltage sampling unit built in the coil drive controller; the main shaft vibration signal is monitored in real time by the MEMS three-axis acceleration sensor; the effective magnetic pole area is the measured value of the magnetic circuit geometry; the tool equivalent radius is obtained by calibrating the main shaft tool clamping structure parameters; the whole machine and load mass are determined by initial calibration; the rated bus voltage, rated no-load current, rated speed, magnetic circuit temperature correction constant and motor torque constant are obtained by equipment parameter calibration. The sampling frequency is preferably not less than 100Hz to ensure the timeliness and continuity of the data, different sensor signals are synchronously collected and time stamped through a unified collection interface module; the current, voltage and speed signals are band-limited filtered and denoised, a low-pass Butterworth filter and a sliding median filter are combined to filter out power supply ripple and transient burrs; wherein the low-pass filter cutoff frequency is automatically set according to the maximum frequency response characteristics of the motor system, preferably in the range of 50Hz to 200Hz; the window length of the sliding median filter is dynamically adjusted according to the sampling period, used to suppress high-frequency random noise and ensure signal smoothness. The temperature and vibration signals are synchronized and resampled and interpolated to establish a unified time reference; through the time stamp based synchronous resampling method, the signals with different sampling frequencies are unified to the same time axis, the linear interpolation method is used to realize the alignment, and all physical quantities have corresponding values at the same time point, to ensure the accuracy of the time sequence consistency analysis.Performing outlier rejection: identify and reject short-time mutations and invalid jump points in the magnetic seat drill monitoring data using the three-sigma rule, and use linear interpolation to complete the missing samples; wherein the three-sigma rule limits the steady-state interval suitable for Gaussian distribution noise characteristics, and is mainly used to identify statistical mutation points of current, voltage and speed signals in the stable running stage, to remove transient outliers caused by sampling errors, interference pulses and random noise, thereby improving signal smoothness and stability of feature extraction; while for the load impact and start-up transition interval with non-Gaussian characteristics, due to the obvious non-linear mutation and high skewness characteristics of the signal, if the three-sigma rejection is continued, it may lead to misjudgment and loss of actual impact response, acceleration transient and energy mutation characteristics, so the rejection operation is not performed to prevent the loss of real impact information; at the same time, for the case of continuous multiple point abnormalities, further sliding window statistical test is performed to prevent single mutation from leading to misjudgment of abnormal detection. The magnetic seat drill monitoring data is subjected to Z-score standardization and min-max normalization processing; a magnetic seat drill state control database is established, and the preprocessed magnetic seat drill monitoring data is written into the magnetic seat drill state control database to support time series indexing and batch retrieval.

[0030] In the embodiment, through multi-source sensor fusion acquisition and high-precision preprocessing, comprehensive, real-time and high-precision monitoring of the magnetic seat drill running state is realized. Through distributed synchronous acquisition of magnetic flux density, temperature, voltage, current, speed and vibration signals, and using band-limited filtering, outlier rejection and time resampling processing methods, noise interference and sampling errors are effectively eliminated, ensuring data continuity and authenticity. After standardization and normalization, the data is written into the state control database, providing unified and reliable data support for subsequent magnetic adsorption stability evaluation and energy margin analysis, thereby laying a foundation for intelligent control and dynamic stability regulation of the magnetic seat drill.

[0031] Specifically, based on the preprocessed magnetic seat drill monitoring data, the specific process of evaluating the stability of magnetic adsorption is as follows: obtaining the preprocessed magnetic seat drill monitoring data, calculating the product of the square of the magnetic flux density and the effective magnetic pole area, and dividing by twice the vacuum permeability constant to obtain the magnetic adsorption basic force value; wherein the vacuum permeability constant is The temperature reference value is normal temperature, i.e. 25°C. The magnetic circuit temperature drift compensation quantity is obtained by multiplying the difference between the electromagnet temperature and the temperature reference value by the magnetic circuit temperature correction constant. The magnetic circuit temperature correction constant is a device calibration parameter, reflecting the decay sensitivity of the magnetic performance with temperature change. The magnetic temperature correction term is obtained by subtracting the magnetic circuit temperature drift compensation quantity from the constant one. The bus voltage fluctuation ratio is obtained by subtracting the rated bus voltage from the motor bus voltage and dividing the result by the rated bus voltage. The voltage fluctuation ratio is used to quantify the influence of power supply stability on the magnetic field strength. The voltage correction term is obtained by subtracting the bus voltage fluctuation ratio from the constant one. The magnetic adsorption effective force term is obtained by multiplying the magnetic adsorption basic force value, the voltage correction term and the magnetic temperature correction term. The magnetic adsorption effective force term comprehensively reflects the effective adsorption output capability of the electromagnet under actual temperature rise and voltage disturbance, and is a direct representation of dynamic adsorption performance. The total machine and load gravity value is obtained by multiplying the total machine and load mass by the gravity acceleration, and is used to calculate the downward static load force. The linear proportional relationship function is established according to the rated no-load current and the rated speed as follows: wherein, I0 represents the no-load current function, ω represents the main shaft speed, I0 represents the rated no-load current, ω0 represents the rated speed. When the motor is running at no load, the total current mainly consists of two parts. One part is the fixed loss current independent of the speed, mainly derived from the core hysteresis loss, eddy current loss and mechanical friction resistance. The other part is the dynamic loss current linearly increasing with the speed, mainly reflecting the wind resistance loss and the additional loss caused by the armature rotating induced electromotive force. The former accounts for a high proportion at low speed, and the latter accounts for a rising proportion at high speed. The constants 0.3 and 0.7 are respectively used to represent the fixed loss part independent of the speed and the dynamic loss part linearly changing with the speed in the motor no-load current, so as to realize the linear correction of the no-load current at different speeds, thereby improving the accuracy and stability of the motor load force calculation. The no-load current function value is calculated according to the current main shaft speed by using the linear proportional relationship function. The motor load equivalent force value is obtained by multiplying the difference between the motor bus current and the no-load current function value by the motor torque constant and dividing the result by the tool equivalent radius, so as to realize the conversion of the motor load electrical signal into the corresponding mechanical action force. The motor torque constant is a device calibration parameter, used to represent the torque capability of the motor per unit current, and reflecting the electromagnetic energy conversion efficiency and electromagnetic torque response characteristics of the motor. The total bearing force term is obtained by adding the total machine and load gravity value and the motor load equivalent force value. The total bearing force term represents the total downward resultant force required for magnetic adsorption, and comprehensively considers the device self-weight and the drilling load. The magnetic adsorption stability evaluation value is obtained by dividing the magnetic adsorption effective force term by the total bearing force term. When the magnetic adsorption stability evaluation value is greater than 1, it indicates that the adsorption state is stable. When the magnetic adsorption stability evaluation value is close to or less than 1, it indicates that the magnetic adsorption may be unstable, so as to realize the quantitative dynamic evaluation of the magnetic adsorption stability.

[0032] wherein, the specific formula of the magnetic adsorption stability evaluation value is:

[0033] ;

[0034] In the formula, represents the magnetic adsorption stability evaluation value, which is used for dynamic evaluation of the magnetic adsorption stability of the magnetic base drill under different working conditions; represents the magnetic flux density, reflecting the surface magnetic field strength of the electromagnet, which is the core variable of the adsorption force, and is proportional to the adsorption force after being squared; represents the effective magnetic pole area, which is a fixed parameter of the device, and is the effective contact area of the magnetic field. The larger the effective contact area, the stronger the adsorption force; represents the vacuum permeability constant, which is a physical constant, and the value is ; represents the magnetic circuit temperature correction constant, which is a material parameter calibration value, describes the sensitivity of the temperature rise to the decay of the magnetic energy, and reflects the temperature correction effect; represents the electromagnet temperature. The temperature rise will cause the magnetic permeability to decrease, and then correct the adsorption force; represents the temperature reference value, which is the normal temperature of 25℃; represents the motor bus voltage, reflecting the power supply stability; represents the rated bus voltage, which is used for voltage fluctuation correction; represents the whole machine and load mass, which is a fixed parameter of the device, representing the static gravity generated by the device and the load; represents the gravitational acceleration, which is a fixed constant, and the value is 9.81 m / s²; represents the motor torque constant, which is a material parameter calibration value, and converts the current into torque; represents the motor bus current, representing the current motor load state; represents the no-load current function value, which deducts the no-load loss and extracts the pure load component, wherein, represents the spindle speed; represents the equivalent radius of the tool, which is a fixed parameter of the device, and is the length of the force arm when converting torque into axial force; represents the magnetic adsorption effective force term, representing the effective adsorption force of the electromagnet under the current temperature and voltage fluctuation conditions, considering the correction of the weakening of the magnetic energy caused by the temperature rise and the decay of the magnetic field caused by the power supply fluctuation; represents the total bearing force term, representing the comprehensive downward force of the magnetic base drill under the current working condition, including the device gravity and the motor drilling load force, which is the resistance term that the adsorption force needs to balance.

[0035] In this embodiment, Table 1 is a data table of magnetic adsorption stability evaluation values. The effective magnetic pole area is 0.0025, the magnetic circuit temperature correction constant is 0.004, the rated bus voltage is 24, the total mass and load mass is 25, the motor torque constant is 0.35, and the equivalent radius of the cutting tool is 0.05. The table details the magnetic flux density, electromagnet temperature, motor bus voltage, motor bus current, no-load current function value, and magnetic adsorption stability evaluation value at five different times. Specifically, time 1 corresponds to a magnetic flux density of 0.82, an electromagnet temperature of 30, a motor bus voltage of 23.8, a motor bus current of 5.1, a no-load current function value of 2.1, and a magnetic adsorption stability evaluation value of 2.441; time 2 corresponds to a magnetic flux density of 0.85, an electromagnet temperature of 35, a motor bus voltage of 23.4, a motor bus current of 5.3, a no-load current function value of 2.4, and a magnetic adsorption stability evaluation value of 2.533; time 3 ...4 corresponds to a magnetic flux density of 0.85, an electromagnet temperature of 35, a motor bus voltage of 23.4, a motor bus current of 5.3, a no-load current function value of 2.4, and a magnetic adsorption stability evaluation value of At time four, the magnetic flux density is 0.78, the electromagnet temperature is 40°C, the motor bus voltage is 22.8 ohms, the motor bus current is 5.7 ohms, the no-load current function value is 2.7, and the magnetic adsorption stability evaluation value is 2.030. At time five, the magnetic flux density is 0.83, the electromagnet temperature is 38°C, the motor bus voltage is 23.0 ohms, the motor bus current is 5.9 ohms, the no-load current function value is 2.6, and the magnetic adsorption stability evaluation value is 2.320. At time five, the magnetic flux density is 0.87, the electromagnet temperature is 28°C, the motor bus voltage is 23.9 ohms, the motor bus current is 5.0 ohms, the no-load current function value is 2.2, and the magnetic adsorption stability evaluation value is 2.797.

[0036] Table 1. Magnetic Adsorption Stability Assessment Data:

[0037]

[0038] like Figure 3 The figure shows the trend of magnetic adsorption stability assessment values. The broken line in the figure represents the changing trend of magnetic adsorption stability assessment values ​​at each time point; the two dashed lines represent the multi-level stability thresholds D1 and D2, which are 2.2 and 2.6, respectively. According to Table 1 and... Figure 3 It can be seen that the magnetic adsorption stability assessment value at time 3 is significantly lower than 2.2, indicating that the magnetic adsorption force decreases significantly at this time, and there is a risk of adsorption instability. The adsorption stability assessment values ​​at times 1, 2, and 4 are between D1 and D2, which is a critical equilibrium state. The magnetic adsorption performance fluctuates slightly but can still be maintained. At time 5, the magnetic adsorption stability assessment value exceeds D2, indicating that the magnetic adsorption state has recovered to stability and entered a safe steady state range. The overall magnetic adsorption stability assessment value shows a trend of "first decreasing and then increasing" over time, indicating that the magnetic adsorption force is temporarily weakened by various factors during the drilling process, but gradually recovers after compensation.

[0039] In this embodiment, by coupling and calculating the multi-source monitoring data of magnetic flux density, temperature, voltage, current and rotating speed, a magnetic adsorption stability evaluation model is constructed, which includes temperature drift correction, voltage disturbance correction and motor load conversion. The dynamic comparison of the actual adsorption force of electromagnet and the total load capacity of the machine is realized, the magnetic adsorption stability can be quantified in real time during drilling, and the comprehensive influence of adsorption strength with temperature, power fluctuation and load change can be accurately reflected, so as to improve the adsorption reliability and safety of magnetic base drill under complex working conditions.

[0040] Specifically, the specific process of adjusting the working condition according to the stability of magnetic adsorption is as follows: comparing the magnetic adsorption stability evaluation value with the multi-stage stability threshold D1 and D2; when D1, it is determined that the adsorption is unstable, the control indicator light is red slow flashing, the stop protection instruction is output, the electromagnet power supply circuit and the motor driving module are closed to immediately cut off the electromagnet power supply and lock the main shaft, and the state signal is uploaded to the magnetic base drill state control database to trigger the safety locking logic to ensure complete power-off stop in a short time; when D1≤ D2, it is determined that the critical equilibrium state, the control indicator light is yellow constant, the local working condition correction of magnetic circuit and load link is executed, including increasing the coil current by PWM modulation, dynamically adjusting the excitation voltage to enhance the magnetic flux density, and reducing the main shaft rotating speed and the feed speed to reduce the instantaneous load impact; when D2, it is determined that the magnetic adsorption state is stable, the control indicator light is green constant, the current working parameters of the magnetic base drill are maintained, and the magnetic adsorption characteristic parameters in the magnetic adsorption stable interval are recorded regularly for subsequent threshold correction and working condition optimization. The magnetic adsorption stability evaluation value is continuously monitored, and the magnetic adsorption effective force item, the total load capacity item and the magnetic adsorption stability evaluation value are written into the magnetic base drill state control database to form a traceable state evolution sequence, realizing real-time sensing and adaptive regulation of adsorption state.

[0041] In this embodiment, by setting the magnetic adsorption stability threshold and combining with real-time evaluation value for dynamic comparison, adaptive grading and automatic control of the adsorption state of the magnetic base drill are realized. When unstable, it can quickly stop protection, in the critical stage, automatically execute magnetic circuit compensation and load adjustment, in the stable stage, maintain the optimal working condition, so as to form a temperature, voltage and adsorption force closed-loop control mechanism, significantly improve the safety and operation reliability of the system under complex working conditions.

[0042] In particular, the stability of magnetic adsorption is combined with the magnetic base drill monitoring data to monitor the stability of magnetic adsorption. The specific process is as follows: based on a sliding time window, the sliding time window length can be adaptively set according to the sampling frequency and the response characteristics, which is used to smooth the instantaneous fluctuations and extract short-term trend information; the magnetic base drill monitoring data, the magnetic adsorption effective force item, the total bearing force item and the magnetic adsorption stability evaluation value are read from the magnetic base drill state control database; the minimum magnetic adsorption stability evaluation value in the window is selected to obtain the sliding window minimum stability value, which is used to reflect the weakest link of the magnetic adsorption state in the specified time period, and is the reference quantity for subsequent stability calculation; the motor bus voltage mean and the motor bus voltage standard deviation in the window are calculated, and the voltage ripple ratio is obtained by dividing the motor bus voltage standard deviation by the rated bus voltage, which is used to quantify the influence of short-term power disturbance on power supply stability; the constant is subtracted from the ratio of the motor bus voltage mean to the rated bus voltage, and only the non-negative value is retained, that is, compared with 0, if the calculation result is greater than 0, the actual calculation result is taken, otherwise 0 is taken, to obtain the voltage sag item; when the motor bus voltage appears short-term drop, the voltage sag item is automatically amplified to reflect the risk of magnetic field attenuation caused by power supply shortage. In the sliding time window, the change rate of the electromagnet temperature is calculated for each sampling point, and for each sampling point, it is judged whether the change rate is positive or not, if it is positive, it is retained, if it is negative, it is taken as zero, and the integral sum of all positive change rates in the sliding time window is obtained to obtain the temperature rise cumulative increment, which is used to identify the continuous heating trend of the coil in a short time, so as to reflect the risk of magnetic circuit thermal saturation; at the same time, the absolute value of the change rate is taken for each sampling point, and the integral sum of all change rate absolute values in the sliding time window is obtained to obtain the total integral value of temperature change; the temperature rise proportion is obtained by dividing the temperature rise cumulative increment by the total integral value of temperature change, which is used to quantify the proportion of the continuously rising part in the coil temperature change, and is a key indicator for representing thermal stability; the multi-source disturbance correction item is obtained by adding the voltage ripple ratio, the voltage sag item and the temperature rise proportion to the constant, which comprehensively reflects the coupling effect of power supply fluctuation and thermal disturbance, and is used to correct the stability deviation of the magnetic adsorption state under the influence of multi-physical disturbance; the magnetic adsorption stability degree value is obtained by dividing the sliding window minimum stability value by the multi-source disturbance correction item; the magnetic adsorption stability degree value quantitatively represents the adsorption stability margin under short-term disturbance conditions, and when it is lower than the threshold value, it indicates that the stability decreases and there is a risk of instability, and the trend analysis in the window realizes early warning and protection triggering. Under the same working condition, the AUC of the magnetic adsorption stability degree value in distinguishing the magnetic adsorption stability and instability state is increased by about 12% to 17%, which indicates that it is significantly better than the traditional technology in the accuracy of instability prediction and state identification; at the same time, the false alarm rate under the steady state condition is decreased by about 25%, which can effectively avoid false alarms caused by transient voltage disturbance and thermal fluctuation.

[0043] wherein the specific formula of the magnetic adsorption stability degree value is:

[0044] ;

[0045] In the formula, represents the magnetic adsorption robustness value, which is used to comprehensively evaluate the robustness of the magnetic seat drill in the dynamic working condition in the window; represents the minimum stability value of the sliding window, that is, the minimum value of the magnetic adsorption stability evaluation value in the window, extracts the weakest point of the magnetic adsorption stability in the time window, and ensures the safety redundancy of the evaluation result; represents the standard deviation of the bus voltage of the motor, indicating the intensity of the bus voltage fluctuation; represents the rated bus voltage; represents the voltage ripple ratio, which measures the disturbance degree of voltage fluctuation on magnetic adsorption. The greater the ripple, the worse the adsorption stability; represents the average value of the bus voltage of the motor; represents the voltage sag term, which describes the compensation effect of the adsorption force attenuation when the supply voltage is lower than the rated value. The superscript is a non-negative operation, that is, if the calculation result is greater than 0, it is the actual calculation result, otherwise it is 0; represents the cumulative increment of temperature rise, indicating the continuous temperature rise trend; represents the total integral value of temperature change, which is used to normalize the temperature change amplitude; represents the temperature rise proportion, which represents the proportion of the temperature rise trend relative to the total temperature fluctuation, and reflects the thermal instability; represents the multi-source disturbance correction term, which comprehensively reflects the joint influence of voltage and temperature multi-source disturbance on system stability, and is a weakening term of adsorption stability.

[0046] In the embodiment, by introducing the sliding time window mechanism, short-time sequence analysis and multi-source disturbance correction of the magnetic adsorption state are carried out, and dynamic quantitative evaluation of the magnetic adsorption robustness is realized. Considering three types of disturbance factors of voltage ripple, supply sag and temperature rise proportion, the integral and ratio calculation are used to realize the adaptive correction of the multi-physical field coupling influence, which can identify the magnetic adsorption performance degradation trend in advance, and early warning the potential instability risk, thereby significantly improving the anti-disturbance performance and operation safety of the magnetic seat drill in complex working conditions.

[0047] Specifically, the specific process of simultaneously monitoring the dynamic bearing margin and impact resistance of the magnetic seat drill is as follows: simultaneously, the difference between the motor bus current and the no-load current function value is calculated to obtain the load current, which represents the additional electromagnetic load intensity of the motor under the current working condition, wherein the no-load current function value is calculated according to the rated parameters and the current main shaft speed, so as to reflect the incremental characteristics of the load relative to the no-load; based on the sliding time window, the first order difference of the load current is calculated and the absolute value is taken to obtain the current absolute change rate, which is used to characterize the instantaneous change speed of the motor load and reflect the sensitivity of the load change; the second order difference of the load current is calculated and the absolute value is taken to obtain the current absolute acceleration, which is used to depict the aggravation degree and mutation intensity of the load change, and is an important index for identifying the impact load. The integral operation is performed on the current absolute acceleration in the window to obtain the load current change cumulative amount, which comprehensively reflects the persistence and cumulative influence of the load change in the window time period; the load current dynamic response amount is obtained by adding the current absolute change rate and the load current change cumulative amount; the load current dynamic response amount is used to depict the response activity and impact degree of the load current as a whole, and can reflect the dynamic response intensity; the load current power response term is obtained by multiplying the ratio of the motor torque constant and the equivalent radius of the tool, the load current dynamic response amount and the sliding time window length, which corresponds to the dynamic power consumption level of the motor caused by load disturbance in the window period, and is a core parameter for measuring the sensitivity of load energy change; the magnetic load force remaining term is obtained by subtracting the total bearing force term from the magnetic adsorption effective force term and taking the non-negative value, and the magnetic load force remaining term is used to represent the margin of the magnetic adsorption force against the load force, and when the result is zero, it indicates that the magnetic adsorption force has reached the limit balance state; the load energy margin value is obtained by dividing the magnetic load force remaining term by the load current power response term, which quantitatively reflects the safety redundancy degree under the conditions of dynamic impact and energy consumption, and when the margin value drops below the threshold value, it can be determined that there is a risk of overload, thereby triggering the adaptive adjustment and protection mechanism.

[0048] wherein the specific formula of the load energy margin value is:

[0049] ;

[0050] in the formula, represents the load energy margin value, which is used to represent the dynamic stability margin of the magnetic seat drill under the current working condition; represents the magnetic adsorption effective force term, which is equal to ; represents the total bearing force term, which is equal to ; represents the magnetic load force remaining term, which measures the "force margin" of adsorption against external load, and represents the instantaneous energy storage capacity for resisting impact, and the superscript represents the non-negative operation, that is, if the calculation result is greater than 0, it is the actual calculation result, otherwise it is 0; represents the current absolute change rate, wherein represents the load current, ; represents the absolute acceleration of current; represents the length of the sliding time window, determines the time scale and energy accumulation range of dynamic response in response to the monitoring period, balances sensitivity and stability in load power response, and serves as a regulatory benchmark for subsequent adaptive prediction and parameter optimization; represents the motor torque constant; represents the equivalent radius of the tool; represents the load current power response term, used to characterize the load dynamic response strength and power consumption level of the motor system within the prediction period, and comprehensively reflects the amplitude, persistence and energy consumption trend of the load disturbance, which is a quantitative description of "dynamic load sensitivity".

[0051] In this embodiment, by performing first-order and second-order difference analysis on the motor current signal and combining sliding time window integral calculation, quantitative evaluation of the load dynamic response and impact energy change of the magnetic seat drill is realized. It can identify the load mutation and energy consumption trend in real time, and the calculated load energy margin value reflects the safety margin of the system under complex drilling conditions, effectively improving the adaptive adjustment ability and overall operation stability of the magnetic seat drill under impact conditions.

[0052] Specifically, the specific process of comprehensively analyzing the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance ability of the magnetic seat drill to realize state classification is: comparing the magnetic adsorption robustness value with the robustness threshold value, comparing the load energy margin value with the margin threshold value, the magnetic adsorption robustness value is used to quantify the comprehensive stability of magnetic adsorption under multi-source disturbance, the load energy margin value is used to reflect the residual resistance ability under dynamic load and impact conditions, and the combination of the two can realize the joint evaluation of the adsorption and load state on both sides; the magnetic adsorption robustness value and the load energy margin value form a two-dimensional state space, forming a four-quadrant distribution with the robustness threshold value and the margin threshold value as the coordinate axes, realizing the coupling judgment and state positioning of the adsorption and load double channels. Each quadrant corresponds to a running state, and triggers differentiated safety redundancy adjustment strategies; when the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is less than the margin threshold value, it is judged as an unstable shutdown state, indicating that the performance of magnetic adsorption and load decreases at the same time, which cannot maintain safe operation, and emergency power-off protection and shutdown measures need to be immediately executed; when the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is judged as an adsorption critical state, at this time, the magnetic adsorption link has a tendency to lose stability, but the load is still in a safe range, and rapid recovery can be achieved by enhancing the magnetic field and compensating current; when the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is less than the margin threshold value, it is judged as an energy critical state, indicating that the load side energy consumption is too high or the impact is too strong, although the magnetic adsorption is stable, but needs to be slowed down and reduced to prevent energy depletion from leading to secondary instability; when the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is judged as a stable safe state, which is in an ideal adsorption and load balance state, and can maintain normal drilling operation and continue to monitor the trend change.

[0053] In the embodiment, by jointly judging the magnetic adsorption robustness value and the load energy margin value, the dual-parameter dynamic classification judgment of the magnetic adsorption side and the load side is realized, which can accurately distinguish between adsorption instability, energy overload and stable safety and other operating states. The magnetic seat drill has the ability of adaptive identification and classification control, thereby significantly improving the safety, responsiveness and stability under complex drilling conditions.

[0054] Specifically, the specific process of safety redundancy adjustment according to different states is as follows: when in the unstable shutdown state, the control indicator light is red flashing, the double protection logic is triggered immediately, the main control loop power-off protection is executed, the double power supply of the electromagnet and the motor is cut off, the main control loop power-off protection is executed first to keep the magnetic adsorption unchanged, the load is immediately reduced and the main shaft speed is gradually reduced, the main shaft rotation is stopped after the drilling load is removed, and finally the electromagnet power supply is disconnected to realize the controlled release of magnetic adsorption. The whole process is controlled by the interlocking logic of the main control loop to ensure controllable shutdown sequence and stable adsorption force decay, preventing mechanical slip and equipment falling caused by residual magnetic field and rotational inertia; when in the adsorption critical state, the control indicator light is yellow flashing, the adsorption side priority compensation strategy is executed: the coil current and coil end voltage are automatically increased by the controller to enhance the magnetic field strength and restore the adsorption force, while the main shaft speed is kept unchanged to avoid further interference of load dynamic change on the stability of the magnetic circuit, realizing rapid adsorption recovery; when in the energy critical state, the control indicator light is yellow slow flashing, the load side slow release priority strategy is executed: the main shaft speed and feed speed are gradually reduced, the motor torque output is limited, and the intermittent load slow release is realized by adjusting the feed rhythm to realize energy consumption slow release, preventing motor overheating and magnetic adsorption loosening caused by overload impact; when in the stable safety state, the control indicator light is green constant, the current working parameters are maintained, and the sliding time window length is adjusted according to the trend change of the magnetic adsorption robustness value and the load energy margin value. The trend monitoring is continuously executed in the safety state, and when the magnetic adsorption robustness value or the load energy margin value is detected to have a downward trend, the time window is automatically shortened to improve the response sensitivity, and vice versa to prolong it to smooth fluctuations, realizing the self-balance of stability and real-time performance.

[0055] In the embodiment, by executing hierarchical safety redundancy adjustment in different states, a coordinated dynamic protection mechanism of the adsorption side and the load side is realized. When the magnetic adsorption or energy state appears critical fluctuation, differentiated adjustment measures such as improving the magnetic field strength, reducing the main shaft speed or executing intermittent load slow release can be automatically triggered to effectively prevent instability diffusion and quickly restore the safe working condition, thereby significantly improving the anti-interference performance, operation continuity and overall operation safety of the magnetic seat drill.

[0056] Specifically, the specific process of continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drill, visualizing feedback and optimizing parameters is as follows: continuously monitoring the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value, the monitoring period can be dynamically adjusted according to the sampling frequency and the response period to ensure real-time capture of short-term fluctuations and smooth reflection of long-term trends, and the dynamic state and time trend of the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value are displayed on the terminal, the synchronous display of the three types of indexes is realized through the method of superimposing multiple curves, the horizontal axis is time, the vertical axis is the normalized value of the corresponding index, and the interface is provided with a state color identification area and a numerical dynamic label for facilitating operators to observe the adsorption state evolution and critical interval approach in real time; At the same time, the multi-stage state indicator light synchronously visualizes the feedback according to the respective determination results, the color and flashing rhythm of the indicator light correspond to different state grades respectively, and the specific state is displayed and the sound and light alarm and prompt information are triggered according to the grading results, the indicator light module and the control logic board directly communicate through the GPIO interface to realize low-delay state indication and sound and light alarm linkage; At the same time, the multi-stage stability threshold, the robustness threshold and the margin threshold are corrected by using the sliding average and clustering analysis algorithm based on the distribution characteristics of the historical magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value; The specific implementation method is as follows: continuously store the time series data of each index during operation, periodically extract the past set time, and preferably select a historical data window of 5 to 10 minutes, perform a sliding average operation on each index in the window to smooth transient fluctuations and obtain a steady-state central trend; Then, based on the data set after smoothing, K-means clustering analysis is performed, and for multi-stage threshold, the index value is divided into three clusters of high, medium and low according to statistical characteristics, and the center point and variance range of each cluster are calculated; The dividing point between the low cluster and the medium cluster is determined as the first threshold, and the dividing point between the high cluster and the medium cluster is determined as the second threshold; For a single threshold, the clustering is divided into a low cluster and a high cluster, and the midpoint of the centers of the two clusters is used as the candidate value of the threshold to form an updated threshold set; The threshold updating process is automatically iterated at each time period, and the maximum update step is set to 5% of the last threshold to prevent excessive fluctuations; Finally, the updated multi-stage stability threshold, the robustness threshold and the margin threshold are stored and real-time synchronized to the determination module, realizing self-learning and adaptive correction of the threshold, so that the optimal determination sensitivity and stability can be automatically maintained with the change of working conditions, equipment aging and environmental disturbance.

[0057] As Figure 4As shown in the figure, the magnetic seat drill state indication flowchart based on magnetic force and load perception is shown. The dynamic state control of the magnetic seat drill in complex drilling working conditions is shown, and the complete closed-loop logic from monitoring, evaluation to feedback optimization is embodied. First, the multi-source monitoring data of the magnetic seat drill is collected in real time and filtered, synchronized and abnormality removed to ensure signal quality; then the magnetic adsorption stability evaluation value is calculated and compared with the multi-level threshold to judge the magnetic adsorption state, realizing the dynamic judgment from adsorption instability to critical balance to stable adsorption. Then, the magnetic adsorption stability evaluation value sequence is extracted through the sliding time window, and the magnetic adsorption robustness value and the load energy margin value are calculated combining with the voltage ripple ratio, the temperature rise ratio and the load current dynamic change rate, etc. The stability of the magnetic adsorption side and the load side is jointly analyzed, and the unstable shutdown, adsorption critical, energy critical and stable safety of the magnetic adsorption side and the load side are distinguished through threshold comparison. Finally, the trend curves of the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value are displayed in real time, the sliding average and clustering analysis are used to dynamically correct the thresholds, the parameter self-learning and control strategy self-optimization are realized, and the magnetic seat drill has the ability of intelligent perception, self-adaptive adjustment and stable maintenance in the drilling process.

[0058] In the embodiment, by dynamically correcting the multi-level and single-level thresholds based on historical data, sliding average and clustering analysis algorithm, the self-learning and adaptive updating of the thresholds can be realized, so as to automatically adapt to the working condition changes, equipment aging and environmental disturbances; wherein the sliding average effectively smooths the short-term fluctuations and extracts the steady-state characteristics, and the clustering analysis automatically identifies the high and low intervals according to the index distribution law, realizes the intelligent segmentation and updating of the threshold boundary; without manual calibration, the optimal determination sensitivity and stability can be maintained for a long time, and the intelligentization and self-evolution ability of the magnetic seat drill state control is improved.

[0059] Referring to Figure 2 As shown in the figure, the second aspect of the present application provides a magnetic seat drill state indication system based on magnetic force and load perception, which is applied to the magnetic seat drill state indication method based on magnetic force and load perception, comprising: a monitoring data acquisition and preprocessing module for acquiring magnetic seat drill monitoring data in real time and preprocessing the magnetic seat drill monitoring data; a magnetic force stability evaluation and judgment module for evaluating the stability of magnetic adsorption based on the preprocessed magnetic seat drill monitoring data, and adjusting the working condition according to the stability of magnetic adsorption; a trend prediction and energy margin linkage module for fusing the stability of magnetic adsorption and the magnetic seat drill monitoring data, monitoring the stability and robustness of magnetic adsorption, monitoring the dynamic bearing margin and impact resistance of the magnetic seat drill, comprehensively analyzing the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic seat drill to realize state classification, and adjusting the safety redundancy according to different states; a visual feedback and closed-loop optimization module for continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drill, and performing visual feedback and parameter optimization.

[0060] In the embodiment, by constructing a magnetic seat drilling state control system integrating data acquisition, magnetic force stability evaluation, energy margin linkage and visual closed-loop optimization, multi-source fusion monitoring and intelligent decision of magnetic adsorption force, load energy and system robustness are realized; adsorption instability and energy abnormality can be identified in real time under complex drilling conditions, adaptive adjustment and safety redundancy control are executed, and state and trend are dynamically fed back through a visual interface to realize intelligent transformation of magnetic seat drilling from passive protection to active steady-state control.

[0061] It should be noted that, in this document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0062] The preferred embodiments of the application disclosed above are only used to help explain the application. The preferred embodiments do not describe all the details of the application, and the application is not limited to the specific embodiments described. As those skilled in the art understand, many modifications and variations can be made according to the content of the specification. The specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the application, so that those skilled in the art can well understand and utilize the application. The application is limited only by the claims and their full scope and equivalents.

Claims

1. A magnetic seat drill status indication method based on magnetic force and load sensing, characterized in that, The method comprises the following steps: S1, real-time collection of magnetic base drilling monitoring data, the magnetic base drilling monitoring data comprising: magnetic flux density, electromagnet temperature, motor bus current, motor bus voltage, main shaft speed, coil current, coil end voltage, main shaft vibration, effective magnetic pole area, tool equivalent radius, whole machine and load mass, rated bus voltage, rated no-load current, rated speed, magnetic circuit temperature correction constant and motor torque constant; data preprocessing of the magnetic base drilling monitoring data; S2, based on the preprocessed magnetic base drilling monitoring data, evaluating the stability of magnetic adsorption, and adjusting the working condition according to the stability of magnetic adsorption; The specific process of evaluating the stability of magnetic adsorption based on the preprocessed magnetic base drilling monitoring data is as follows: The preprocessed magnetic base drilling monitoring data is obtained, the product of the square of the magnetic flux density and the effective magnetic pole area is calculated, and the magnetic adsorption basic force value is obtained by dividing by twice the vacuum permeability constant; the difference between the electromagnet temperature and the temperature reference value is multiplied by the magnetic circuit temperature correction constant to obtain the magnetic circuit temperature drift compensation amount, and the magnetic temperature correction term is obtained by subtracting the constant one from the magnetic circuit temperature drift compensation amount; the motor bus voltage is subtracted from the rated bus voltage and divided by the rated bus voltage to obtain the bus voltage fluctuation ratio, and the voltage correction term is obtained by subtracting the constant one from the bus voltage fluctuation ratio; the magnetic adsorption basic force value, the magnetic temperature correction term and the voltage correction term are multiplied to obtain the magnetic adsorption effective force term; The whole machine and load mass is multiplied by the gravitational acceleration to obtain the whole machine and load gravity value; According to the rated no-load current and the rated speed, a linear proportional relationship function is established, and the no-load current function value is calculated according to the current main shaft speed by using the linear proportional relationship function; the difference between the motor bus current and the no-load current function value is multiplied by the motor torque constant, and the motor load equivalent force value is obtained by dividing by the tool equivalent radius; the whole machine and load gravity value and the motor load equivalent force value are added to obtain the total bearing force term; the magnetic adsorption stability evaluation value is obtained by dividing the magnetic adsorption effective force term by the total bearing force term; S3, fusion of the stability of magnetic adsorption and the magnetic base drilling monitoring data, monitoring of the stability and robustness of magnetic adsorption, monitoring of the dynamic bearing margin and impact resistance of the magnetic base drilling, comprehensive analysis of the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic base drilling to realize state classification, and safety redundancy adjustment according to different states; The specific process of monitoring the stability and robustness of magnetic adsorption by fusing the stability of magnetic adsorption and the magnetic base drilling monitoring data is as follows: Based on a sliding time window, the magnetic base drilling monitoring data, the magnetic adsorption effective force term, the total bearing force term and the magnetic adsorption stability evaluation value are read from the magnetic base drilling state control database; the minimum magnetic adsorption stability evaluation value in the window is selected to obtain the sliding window minimum stability value; The motor bus voltage mean value and the motor bus voltage standard deviation in the window are calculated, and the voltage ripple ratio is obtained by dividing the motor bus voltage standard deviation by the rated bus voltage; The constant one is subtracted from the ratio of the motor bus voltage mean value to the rated bus voltage, and only the non-negative value is retained to obtain the voltage sag term; In the sliding time window, the rate of change of electromagnet temperature is calculated sample by sample, and for each sample, it is judged whether the rate of change is positive or not, if it is positive, it is reserved, if it is negative, it is taken as zero, and the temperature rise cumulative increment is obtained by integrating and summing all positive rate of change in the sliding time window; At the same time, the absolute value of the rate of change is taken for each sample, and the total integral value of temperature change is obtained by integrating and summing all the absolute values of the rate of change in the sliding time window; The temperature rise proportion is obtained by dividing the temperature rise cumulative increment by the total integral value of temperature change; The multi-source disturbance correction term is obtained by adding the voltage ripple ratio, the voltage sag term and the temperature rise proportion to the constant; The magnetic adsorption stability value is obtained by dividing the sliding window minimum stable value by the multi-source disturbance correction term; S4, continuously monitor the stability of magnetic adsorption, the stability of magnetic adsorption, and the dynamic bearing margin and impact resistance of magnetic drill, and perform visual feedback and parameter optimization.

2. The magnetic force and load-aware magnetic standoff drill status indication method of claim 1, wherein, The specific process of data preprocessing of the magnetic drill monitoring data is: For current, voltage and speed signals, band-limited filtering and denoising are performed, low-pass Butterworth filter and sliding median filter are combined to filter out power supply ripple and instantaneous burr; For temperature and vibration signals, synchronous resampling and interpolation alignment are used to establish a unified time reference; Execute outlier rejection: identify and remove short-term mutations and invalid jump points in the magnetic drill monitoring data using the three-sigma rule, and linearly interpolate the missing samples; The three-sigma rule is limited to the steady-state interval suitable for Gaussian distribution noise characteristics, and for load impact and start-up transition interval with non-Gaussian characteristics, the rejection operation is not performed; For magnetic drill monitoring data, standardization and normalization processing is performed; Establish a magnetic drill state control database, and write the preprocessed magnetic drill monitoring data into the magnetic drill state control database.

3. The magnetic force and load-aware magnetic standoff drill status indication method of claim 1, wherein, The specific process of adjusting the working condition according to the stability of magnetic adsorption is: magnetic adsorption stability evaluation value comparison with multi-stage stability threshold values D1 and D2; When When D1, it is determined that the adsorption is unstable, the control indicator is red slow flashing, the output stop protection instruction is output, the power supply of the electromagnet is immediately cut off and the main shaft is locked. When D1≤ When D2, the critical balance state is determined, the control indicator is yellow constant, the local working condition correction of magnetic circuit and load link is executed, including increasing the coil current, reducing the spindle speed and feed speed. When When D2 is greater than or equal to D1, it is determined that the magnetic attraction state is stable, the control indicator is green constant, and the current magnetic base drill working parameters are maintained. Continuously monitor the magnetic adsorption stability evaluation value, and write the magnetic adsorption effective force term, the total bearing force term and the magnetic adsorption stability evaluation value into the magnetic drill state control database.

4. The magnetic force and load-aware magnetic standoff drill status indication method of claim 1, wherein, The specific process of simultaneously monitoring the dynamic bearing margin and impact resistance of the magnetic drill is: At the same time, the difference between the motor bus current and the no-load current function value is calculated to obtain the load current, based on the sliding time window, the first order difference of the load current is calculated and the absolute value is taken to obtain the current absolute change rate, the second order difference of the load current is calculated and the absolute value is taken to obtain the current absolute acceleration, and the integral operation is performed on the current absolute acceleration in the window to obtain the load current change cumulative amount; The load current absolute change rate and the load current change cumulative amount are added to obtain the load current dynamic response amount; The ratio of the motor torque constant and the equivalent radius of the tool, the load current dynamic response amount and the sliding time window length are multiplied to obtain the load current power response term; The magnetic load force residual term is obtained by subtracting the total bearing force term from the magnetic adsorption effective force term and taking the non-negative value; The load energy margin value is obtained by dividing the magnetic load force residual term by the load current power response term.

5. The magnetic force and load-aware magnetic standoff drill status indication method of claim 4, wherein, The specific process of comprehensive analysis of the stability and robustness of magnetic adsorption, the dynamic bearing margin and impact resistance of the magnetic drill to realize state classification is: The magnetic adsorption robustness value is compared with a robustness threshold value, and the load energy margin value is compared with a margin threshold value; When the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is less than the margin threshold value, it is determined to be an unstable shutdown state; When the magnetic adsorption robustness value is less than the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is determined to be an adsorption critical state; When the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is less than the margin threshold value, it is determined to be an energy critical state; When the magnetic adsorption robustness value is greater than or equal to the robustness threshold value and the load energy margin value is greater than or equal to the margin threshold value, it is determined to be a steady-state safe state.

6. The magnetic force and load-aware magnetic standoff drill status indication method of claim 1, wherein, The specific process of safety redundancy adjustment according to different states is: When in the unstable shutdown state, the control indicator light is red flashing, the main control loop power-off protection is executed, the double power supply of the electromagnet and the motor is cut off, the main control loop power-off protection is executed first to keep the magnetic adsorption unchanged, immediately reduce the load and gradually reduce the main shaft speed, and then stop the main shaft rotation after the drilling load is removed, and finally disconnect the power supply of the electromagnet; When in the adsorption critical state, the control indicator light is yellow flashing, the adsorption side priority compensation strategy is executed: the coil current and the coil end voltage are increased, and the main shaft speed is kept unchanged; When in the energy critical state, the control indicator light is yellow slow flashing, the load side slow release priority strategy is executed: the main shaft speed and the feed speed are reduced, the motor torque output is limited, and the intermittent load slow release is realized by adjusting the feed rhythm; When in the steady-state safe state, the control indicator light is green constant, the current working parameters are maintained, and the sliding time window length is adjusted according to the trend changes of the magnetic adsorption robustness value and the load energy margin value.

7. The magnetic force and load-aware magnetic standoff drill status indication method of claim 4, wherein, The specific process of continuously monitoring the stability of magnetic adsorption, the stable robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic seat drill, and visualizing the feedback and parameter optimization is: The magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value are continuously monitored, and the dynamic state and time trend of the magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value are displayed on the terminal. At the same time, the multi-level state indicator synchronously visualizes the feedback according to the respective determination results, displays the specific state, and triggers the audible and light alarms and prompt information according to the classification results. At the same time, the multi-level stability threshold value, the robustness threshold value and the margin threshold value are corrected by using the sliding average and clustering analysis algorithm based on the distribution characteristics of the historical magnetic adsorption stability evaluation value, the magnetic adsorption robustness value and the load energy margin value.

8. A magnetic seat drill status indication system based on magnetic force and load awareness, applying the magnetic seat drill status indication method based on magnetic force and load awareness as claimed in any one of claims 1-7, characterized by, It includes: A monitoring data acquisition and preprocessing module for real-time acquisition of magnetic seat drill monitoring data and data preprocessing of the magnetic seat drill monitoring data; A magnetic force stability evaluation and determination module for evaluating the stability of magnetic adsorption based on the preprocessed magnetic seat drill monitoring data, and adjusting the working condition according to the stability of magnetic adsorption; The trend prediction and energy margin linkage module is used for fusing the stability of magnetic adsorption and the magnetic base drill monitoring data, monitoring the stability and robustness of magnetic adsorption, monitoring the dynamic bearing margin and impact resistance of the magnetic base drill, comprehensively analyzing the stability and robustness of magnetic adsorption and the dynamic bearing margin and impact resistance of the magnetic base drill to realize state classification, and performing safety redundancy adjustment according to different states. The visual feedback and closed-loop optimization module is used for continuously monitoring the stability of magnetic adsorption, the stability and robustness of magnetic adsorption, and the dynamic bearing margin and impact resistance of the magnetic base drill, and performing visual feedback and parameter optimization.

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