Wire feeding control method, main controller and wire feeder

Abstract

The application provides a wire feeding control method, a main controller and a wire feeder, and is applied to the technical field of precision automation control. The method comprises the following steps: acquiring multi-dimensional operation data of the wire feeder, wherein the multi-dimensional operation data comprises an actual wire feeding speed at a wire outlet, an actual torque of a servo motor and vibration data at the wire outlet; determining a feedback control torque amount according to a target wire feeding speed and the actual wire feeding speed; determining a vibration suppression torque compensation amount for the servo motor according to the vibration data; generating a control signal for the servo motor according to a weighted fusion result of the vibration suppression torque compensation amount and the feedback control torque amount; and sending the control signal to a servo driver, so that the servo driver controls the servo motor based on the control signal to drive a wire feeding wheel set to feed wire. The application improves the wire feeding control precision and stability, and better meets the strict requirements of high-end manufacturing fields on the high precision and high stability of processing.

Description

Technical Field

[0001] This application relates to the field of precision automation control technology, and in particular to a wire feeding control method, a main controller, and a wire feeder. Background Technology

[0002] In high-end manufacturing fields, such as semiconductor wire bonding, micro-beam plasma welding, high-precision 3D metal printing, and precision cladding, the performance of the wire feeder directly determines the stability of the process and the quality of the product. Taking 3D metal printing as an example, the wire feeder needs to maintain the continuity and stability of the filament during high-speed movement to ensure the density and geometric accuracy of the printed layer. Especially when printing small structures or complex curved surfaces, the real-time control capability of the wire feed becomes crucial. Therefore, precise and stable control of the wire feed is of paramount importance.

[0003] In related technologies, the current actual wire feeding speed is acquired in real time using a speed sensor; the actual wire feeding speed is compared with the set wire feeding speed to obtain the speed difference between the two speeds; the speed difference is calculated using a preset algorithm to obtain the actual energizing time of the wire feeding motor within the energizing time period that needs to be set, wherein the actual energizing time is the sum of the calibrated energizing time and the change in energizing time, and the actual energizing time is less than or equal to the energizing time period; within the energizing time period, the energizing time of the wire feeding motor is adjusted based on the actual energizing time so that the wire feeding motor adjusts the wire feeding speed to the target wire feeding speed.

[0004] However, the above methods suffer from poor control precision and stability, making it difficult to support the stringent requirements of high precision and high stability in high-end manufacturing. Summary of the Invention

[0005] This application provides a wire feeding control method, a main controller, and a wire feeder to improve the accuracy and stability of wire feeding control, and better meet the stringent requirements of high precision and high stability in high-end manufacturing.

[0006] In a first aspect, this application provides a wire feeding control method, which is applied to a main controller in a wire feeder. The main controller is connected to a servo driver in the wire feeder, and the servo driver is connected to a servo motor in the wire feeder. The servo motor drives the wire feeding wheel group to feed wire through a transmission mechanism.

[0007] The wire feeding control methods include:

[0008] Acquire multi-dimensional operating data of the wire feeder, which includes the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet.

[0009] The feedback control torque is determined based on the target wire feeding speed and the actual wire feeding speed.

[0010] Based on the vibration data, determine the damping torque compensation amount for the servo motor;

[0011] Based on the weighted fusion result of the vibration damping torque compensation and the feedback control torque, a control signal for the servo motor is generated.

[0012] A control signal is sent to the servo driver, which controls the servo motor based on the control signal to drive the wire feeding wheel assembly to feed the wire.

[0013] In one possible implementation, determining the feedback control torque amount based on the target wire feed speed and the actual wire feed speed includes:

[0014] Determine the speed error between the actual wire feeding speed and the target wire feeding speed;

[0015] Based on the target PID parameters, proportional, integral, and derivative operations are performed on the speed error, and the sum of the proportional, integral, and derivative operation results is determined as the feedback control torque.

[0016] In one possible implementation, based on the target PID parameters, proportional, integral, and derivative operations are performed on the speed error, including:

[0017] Obtain the property information of the filament during the filament feeding process;

[0018] Based on the index relationship between wire properties and PID parameters, the target PID parameters corresponding to the property information are determined.

[0019] Based on the target PID parameters, proportional, integral, and derivative operations are performed on the speed error.

[0020] In one possible implementation, determining the damping torque compensation amount for the servo motor based on vibration data includes:

[0021] Based on the Fast Fourier Transform algorithm, the vibration data is subjected to spectral analysis to obtain at least one dominant vibration frequency component, as well as the vibration amplitude and phase corresponding to the dominant vibration frequency component.

[0022] For each dominant vibration frequency component, a target vibration suppression velocity compensation amount with the same vibration amplitude and opposite phase as the dominant vibration frequency component is generated.

[0023] The target vibration suppression speed compensation amounts corresponding to each dominant vibration frequency component are added together to obtain the vibration suppression speed compensation amount for the servo motor.

[0024] The vibration damping speed compensation is converted into the vibration damping torque compensation for driving the servo motor.

[0025] In one possible implementation, a control signal for the servo motor is generated based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount, including:

[0026] Based on the preset dynamic model of the wire feeder, the feedforward control torque for the servo motor is determined according to the target wire feeding speed.

[0027] Based on the weighted fusion result of the vibration damping torque compensation, feedback control torque, and feedforward control torque, a control signal for the servo motor is generated.

[0028] In one possible implementation, the amount of feedforward control torque is specifically determined in the following way:

[0029]

[0030] in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; It is a nonlinear frictional torque.

[0031] In one possible implementation, a control signal for the servo motor is generated based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount, including:

[0032] When the wire feeder is in the wire feeding sliding state, the sliding torque compensation reduction used to reduce the output torque of the servo motor is determined based on the actual torque.

[0033] Based on the weighted fusion result of the vibration damping torque compensation, the feedback control torque, and the slip torque compensation reduction, a control signal for the servo motor is generated.

[0034] In one possible implementation, whether the wire feeder is in a wire feeding slippage state is determined by the following method:

[0035] Based on the fitting relationship between wire feeding speed and torque, the torque reference value is determined according to the actual wire feeding speed at the wire exit nozzle. The fitting relationship characterizes the dynamic correlation between wire feeding speed and torque under non-slip conditions.

[0036] If the actual torque continues to exceed a set multiple of the corresponding torque reference value within a set time period, it is determined that the wire feeder is in a wire feeding slippage state.

[0037] Secondly, this application provides a wire feeding control device, which is applied to the main controller in the wire feeder. The main controller is connected to the servo driver in the wire feeder, the servo driver is connected to the servo motor in the wire feeder, and the servo motor drives the wire feeding wheel group to feed wire through the transmission mechanism.

[0038] The wire feeding control device includes:

[0039] The acquisition module is used to acquire multi-dimensional operating data of the wire feeder, including the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet.

[0040] The determination module is used to determine the amount of feedback control torque based on the target wire feeding speed and the actual wire feeding speed;

[0041] The determination module is also used to determine the amount of vibration damping torque compensation for the servo motor based on the vibration data.

[0042] The generation module is used to generate control signals for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount;

[0043] The transmitting module is used to send control signals to the servo driver, which in turn controls the servo motor based on the control signals to drive the wire feeding wheel assembly to feed the wire.

[0044] In one possible implementation, the determining module is specifically used to: determine the speed error between the actual wire feeding speed and the target wire feeding speed; perform proportional, integral, and differential operations on the speed error based on the target PID parameters, and determine the sum of the proportional, integral, and differential operation results as the feedback control torque.

[0045] In one possible implementation, the determining module is further configured to: acquire attribute information of the filament during the filament feeding process; determine the target PID parameter corresponding to the attribute information based on the index relationship between the filament attribute and the PID parameter; and perform proportional, integral, and differential operations on the speed error based on the target PID parameter.

[0046] In one possible implementation, the determining module is further configured to: perform spectral analysis on the vibration data based on a fast Fourier transform algorithm to obtain at least one dominant vibration frequency component, as well as the vibration amplitude and phase corresponding to the dominant vibration frequency component; generate a target vibration suppression velocity compensation amount that is equal to and opposite in phase to the vibration amplitude of each dominant vibration frequency component for each dominant vibration frequency component; add the target vibration suppression velocity compensation amounts corresponding to each dominant vibration frequency component to obtain a vibration suppression velocity compensation amount for the servo motor; and convert the vibration suppression velocity compensation amount into a vibration suppression torque compensation amount for driving the servo motor.

[0047] In one possible implementation, the generation module is specifically used to: determine the feedforward control torque for the servo motor based on a preset wire feeder dynamics model and the target wire feeding speed; and generate a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation, the feedback control torque, and the feedforward control torque.

[0048] In one possible implementation, the amount of feedforward control torque is specifically determined in the following way:

[0049]

[0050] in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; It is a nonlinear frictional torque.

[0051] In one possible implementation, the generation module is further configured to: determine, based on the actual torque, a slip torque compensation reduction for reducing the output torque of the servo motor when the wire feeder is in a wire feeding slip state; and generate a control signal for the servo motor based on a weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the slip torque compensation reduction.

[0052] In one possible implementation, whether the wire feeder is in a wire feeding slippage state is determined by the following method: based on the fitting relationship between the wire feeding speed and the torque, a torque reference value is determined according to the actual wire feeding speed at the wire outlet. The fitting relationship characterizes the dynamic correlation between the wire feeding speed and the torque in the non-slippage state. If the actual torque is continuously greater than a set multiple of the corresponding torque reference value within a set time period, it is determined that the wire feeder is in a wire feeding slippage state.

[0053] Thirdly, this application provides a main controller, including: a memory and a processor;

[0054] The memory stores instructions that the computer executes;

[0055] The processor executes computer execution instructions stored in memory, causing the processor to perform the first aspect and / or various possible implementations of the first aspect as described above.

[0056] Fourthly, this application provides a wire feeder, including: a main controller, and a servo driver, a speed detection device, a vibration sensor and a current sensor, which are electrically connected to the main controller respectively. The servo driver is also electrically connected to a servo motor. The servo motor drives the wire feeding wheel set to feed wire through a transmission mechanism, and the wire is discharged through the wire outlet nozzle.

[0057] A speed detection device is installed at the wire exit nozzle to collect the actual wire feeding speed at the wire exit nozzle; a vibration sensor is installed at the wire exit nozzle to collect vibration data at the wire exit nozzle; and a current sensor is installed in the servo driver to collect the operating current of the servo motor.

[0058] The main controller is used to execute the wire feeding control method of the first aspect;

[0059] A servo driver is used to control a servo motor under the control of a main controller to drive the wire feeding wheel assembly to feed wire.

[0060] Fifthly, this application provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, are used to implement the first aspect and / or various possible embodiments of the first aspect.

[0061] In a sixth aspect, this application provides a computer program product, including a computer program that, when executed by a processor, implements the first aspect and / or various possible implementations of the first aspect.

[0062] The wire feeding control method, main controller, and wire feeder provided in this application are as follows: the main controller is connected to a servo driver in the wire feeder, the servo driver is connected to a servo motor in the wire feeder, and the servo motor drives the wire feeding wheel assembly to feed wire through a transmission mechanism; the wire feeding control method includes: acquiring multi-dimensional operating data of the wire feeder, including the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and vibration data at the wire outlet; determining the feedback control torque based on the target wire feeding speed and the actual wire feeding speed; determining the vibration suppression torque compensation amount for the servo motor based on the vibration data; generating a control signal for the servo motor based on the weighted fusion result of the vibration suppression torque compensation amount and the feedback control torque amount; and sending the control signal to the servo driver, which controls the servo motor based on the control signal to drive the wire feeding wheel assembly to feed wire. In this process, by introducing vibration sensing and implementing active vibration suppression control, high-frequency vibrations during wire feeding are significantly suppressed, making the wire feeding process smoother. By monitoring the real-time error between the target wire feeding speed and the actual wire feeding speed and actively correcting the speed error by controlling the motor torque, overshooting or oscillation of the wire feeding speed is avoided, ensuring the long-term accuracy of the wire feeding length. Furthermore, the vibration suppression torque compensation and feedback control torque are weighted and integrated to balance the high-precision speed control and stability of wire feeding, fundamentally resolving the conflict between these two control objectives, achieving precise and stable wire feeding, thereby improving the quality of process processing and production efficiency, and better meeting the stringent requirements of high precision and high stability in high-end manufacturing. Attached Figure Description

[0063] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0064] Figure 1 Flowchart of the wire feeding control method provided in the embodiments of this application Figure 1 ;

[0065] Figure 2 Flowchart of the wire feeding control method provided in the embodiments of this application Figure 2 ;

[0066] Figure 3 This is a schematic diagram of the wire feeder provided in an embodiment of this application;

[0067] Figure 4 This is a schematic diagram of the wire feeding control device provided in the embodiments of this application;

[0068] Figure 5 This is a schematic diagram of the main controller provided in an embodiment of this application.

[0069] Figure label:

[0070] 40: Wire feeding control device; 41: Acquisition module; 42: Determination module; 43: Generation module; 44: Sending module;

[0071] 50: Main controller; 501: Processor; 502: Memory; 503: Communication component; 504: Bus.

[0072] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0073] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0074] The terms “first,” “second,” etc., used in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, products, or apparatus.

[0075] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, data stored, data displayed, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties. Furthermore, the collection, use and processing of the relevant data must comply with relevant laws, regulations and standards, and corresponding operation entry points are provided for users to choose to authorize or refuse.

[0076] In related technologies, motor speed is mainly controlled indirectly by adjusting the energizing time within a fixed cycle, rather than directly controlling the motor's output torque. The actual output torque of the motor is not a simple linear relationship with the energizing time; the actual output torque is usually affected by power supply voltage fluctuations, motor temperature, and load changes (i.e., wire feeding resistance). Therefore, this speed correction based on energizing time is slow and inaccurate. Furthermore, this scheme heavily relies on a preset value for calibrated energizing time, which is usually measured under specific operating conditions (such as specific wire material, specific temperature, or new equipment). Once the operating conditions change (such as changing the wire material, insufficient lubrication, or equipment wear), the original calibration relationship becomes invalid, causing the system to always correct based on an incorrect foundation, resulting in decreased accuracy. In addition, this scheme suffers from significant wire vibration problems during wire feeding. For example, during high-speed wire feeding, the wire feeding system is inevitably subjected to various vibration sources, which may originate from the rotation of the servo motor itself, imbalance of the transmission mechanism, or interference from the external environment. These vibrations are transmitted to the filament nozzle, causing the filament to vibrate slightly at high frequencies. This can easily lead to longitudinal vibrations, resulting in discontinuous filament output and ultimately forming vibration marks on the surface of the molded part. This severely affects the appearance quality and dimensional accuracy of the product. The solution lacks effective online suppression methods, resulting in poor stability of filament output control.

[0077] To address the aforementioned technical issues, the wire feeding control scheme provided in this application significantly suppresses high-frequency vibrations during the wire feeding process by introducing vibration sensing and implementing active vibration suppression control, making the wire feeding process smoother. By monitoring the real-time error between the target wire feeding speed and the actual wire feeding speed and actively correcting the speed error by controlling the motor torque, it avoids wire feeding speed overshoot or oscillation, ensuring the long-term accuracy of the wire feeding length. Furthermore, by weighted and fused the vibration suppression torque compensation and feedback control torque, it balances high-precision speed control and stability of wire feeding, fundamentally resolving the conflict between these two control objectives, achieving precise and stable wire feeding, thereby improving the quality of the machining process and better meeting the stringent requirements of high precision and high stability in high-end manufacturing.

[0078] It should be noted that the application scenarios of this application are not limited to high-precision, stable, and intelligent wire feeding control in additive manufacturing (such as 3D printing) and automatic welding processes.

[0079] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0080] Figure 1 Flowchart of the wire feeding control method provided in the embodiments of this application Figure 1 This wire feeding control method is applied to the main controller in the wire feeder. The main controller is connected to the servo driver in the wire feeder, and the servo driver is connected to the servo motor in the wire feeder. The servo motor drives the wire feeding wheel assembly to feed the wire through a transmission mechanism. Figure 1 As shown, the wire feeding control method includes:

[0081] S101. Obtain multi-dimensional operating data of the wire feeder, which includes the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet.

[0082] The actual wire feeding speed is the wire feeding speed at the wire exit nozzle. Compared to other implementation methods that use the motor shaft speed as the actual wire feeding speed, the actual wire feeding speed at the wire exit nozzle more accurately reflects the true wire feeding speed, providing a reliable data foundation for subsequent end-loop control and is key to improving wire feeding accuracy control. Vibration data reflects the longitudinal vibration of the wire at the wire exit nozzle.

[0083] For example, during the wire feeding process, a high-resolution rotary encoder installed at the wire nozzle has a precision friction wheel mounted on its measuring shaft. The wire directly contacts the friction wheel, converting linear motion into rotational motion. The rotary encoder outputs pulse signals. Since each revolution of the rotary encoder corresponds to the feeding of a certain length of wire, the main controller acquires the pulse signals from the rotary encoder and calculates the real-time linear velocity, i.e., the actual wire feeding speed, by measuring the number of pulses per unit time. Simultaneously, the motor drive current is acquired through a current sensor inside the servo driver (or an external Hall current sensor). Since the output torque of the servo motor has a certain functional relationship with the current (e.g., positive correlation), the actual torque value of the servo motor can be accurately calculated after calibration. For vibration data, a vibration acceleration sensor attached to the wire outlet or a rigid structure nearby can be used to acquire the data. This vibration acceleration sensor outputs an electrical signal proportional to the vibration acceleration.

[0084] Furthermore, the acquired actual wire feeding speed, actual torque, and vibration data can be aligned in the time dimension to ensure data correlation and provide a real-time and reliable data foundation for subsequent dynamic compensation and control.

[0085] S102. Determine the feedback control torque based on the target wire feeding speed and the actual wire feeding speed.

[0086] The target wire feeding speed is the set wire feeding speed, such as the wire feeding speed sent by the user to the main controller through the host computer or the touch screen of the wire feeder.

[0087] This step constitutes a closed-loop feedback of the wire feeding speed. The speed correction amount is calculated through a preset algorithm and is achieved by correcting the torque, which is used to eliminate the wire feeding speed error during the wire feeding process.

[0088] For example, in one implementation, a pre-trained neural network model (e.g., an RNN) is used, taking the speed error between the target wire feed speed and the actual wire feed speed as input, and outputting a feedback control torque. This neural network model is trained using a large number of historical speed errors (historical speed errors being the difference between the target wire feed speed and the actual wire feed speed at historical moments) and historical feedback control torques.

[0089] In another implementation, the feedback control torque is calculated based on the speed error between the target wire feeding speed and the actual wire feeding speed using a standard PID algorithm, a fuzzy adaptive algorithm, or a nonlinear PID control algorithm.

[0090] S103. Based on the vibration data, determine the damping torque compensation amount for the servo motor.

[0091] Among them, the vibration damping torque compensation is an additional high-frequency motor torque command component used to actively counteract mechanical or wire vibrations during the wire feeding process, thereby eliminating the vibration effects during the wire feeding process.

[0092] This step involves real-time analysis of vibration data to identify at least one dominant disturbance feature. Based on this dominant disturbance feature, a vibration suppression torque compensation is generated using a compensator. Real-time analysis may include, for example, Fast Fourier Transform and adaptive frequency tracking. Dominant disturbance features may include, for example, frequency, amplitude, phase, or disturbance state. The compensator may include, for example, an inverting generator, an adaptive filter, or a state observer (specifically, a Kalman filter).

[0093] For example, in one implementation, based on a pre-designed Kalman filter, vibration data and actual yarn output speed are used as observations, and the disturbance, i.e., the vibration damping torque compensation amount, is estimated online in real time through the Kalman filter.

[0094] In another implementation, the vibration data is analyzed by fast Fourier transform to generate anti-phase compensation data with the same amplitude but opposite phase as the vibration data, which is the vibration suppression torque compensation amount.

[0095] S104. Based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount, generate a control signal for the servo motor.

[0096] It is understandable that the feedback control torque dominates speed tracking in the low and mid-frequency range, while the vibration suppression torque compensation acts on vibration suppression in the high-frequency range.

[0097] For example, the vibration suppression torque compensation and feedback control torque are superimposed according to preset weighting coefficients. In this embodiment, the weighting coefficients can be dynamically adjusted according to the system state to achieve a balance between different control objectives. For example, when a large vibration amplitude is detected (e.g., a first vibration amplitude threshold is set, and when the amplitude of the vibration signal exceeds this threshold), the weighting coefficient of the feedback control torque can be temporarily increased to prioritize the vibration suppression effect; when the amplitude of the vibration signal is less than a second vibration amplitude threshold, the weighting coefficient of the vibration suppression torque compensation is adjusted to 0 to avoid introducing unnecessary control noise during stable operation. During large dynamic processes such as system startup, the weight of the feedback control torque can be appropriately reduced to avoid the impact of vibration suppression interference on the main velocity loop. In one possible implementation, a mapping relationship between the weighting coefficients and the vibration suppression torque compensation and feedback control torque is pre-constructed, where the mapping relationship describes the weighting coefficients corresponding to different vibration suppression torque compensation and feedback control torque. That is, the weighting coefficients corresponding to different vibration suppression torque compensation and feedback control torque are not exactly the same.

[0098] For example, the control signal can be a torque control signal or a current control signal. If it is a torque control signal, the weighted fusion result directly generates the control signal, such as feedback control of the torque amount. =0.05Nm, vibration damping torque compensation amount =-0.02Nm, the control signal U generated after weighted fusion is 0.03Nm; if it is a current control signal, the current control signal can be obtained by linearly transforming the weighted fusion result based on the linear relationship between the current and torque of the servo motor.

[0099] Optionally, the fused control signal can be amplitude limited to ensure that the control signal is within the range of torque (or maximum allowable current) for safe operation of the servo motor.

[0100] S105. Send a control signal to the servo driver. The servo driver controls the servo motor based on the control signal to drive the wire feeding wheel assembly to feed the wire.

[0101] For example, control signals are sent to the servo driver in real time via a specific communication protocol, such as EtherCAT, CANopen, Modbus TCP, or analog voltage signals. The servo driver drives the motor to move precisely, thereby driving the wire feeding wheel assembly to perform wire feeding.

[0102] During the wire feeding process, steps S101 to S105 are executed cyclically. The entire process repeats within milliseconds, achieving continuous and precise wire feeding control.

[0103] This application embodiment significantly suppresses high-frequency vibrations during the wire feeding process by introducing vibration sensing and implementing active vibration suppression control, making the wire feeding process smoother. By monitoring the real-time error between the target wire feeding speed and the actual wire feeding speed, and actively correcting the speed error by controlling the motor torque, steady-state errors are continuously eliminated, avoiding wire feeding speed overshoot or oscillation, and ensuring the long-term accuracy of the wire feeding length. Furthermore, the vibration suppression torque compensation amount and the feedback control torque amount are weighted and fused to balance the high-precision speed control and stability of wire feeding, fundamentally solving the contradiction of sacrificing stability for improving response speed in traditional control. This allows the system to recover quickly and smoothly after being disturbed, achieving accurate and stable wire feeding, thereby improving the processing quality and production efficiency, and better meeting the stringent requirements of high precision and high stability in high-end manufacturing.

[0104] In some embodiments, the feedback control torque is determined based on the target wire feeding speed and the actual wire feeding speed, including: determining the speed error between the actual wire feeding speed and the target wire feeding speed; performing proportional, integral, and differential operations on the speed error based on the target PID parameters, and determining the sum of the proportional, integral, and differential operation results as the feedback control torque.

[0105] For example, the actual wire feed speed With target wire feed speed Speed ​​error between = The target PID parameters include proportional gain. Integral gain and differential gain The speed error is calculated through three steps: proportional, integral, and differential. Perform comprehensive correction and feedback control of torque. Among them, the result of the proportional calculation Provides a fast response proportional to the instantaneous value of the speed error; the larger the speed error, the greater the correction force, ensuring the system's response speed; integral calculation results. It can accumulate historical errors to eliminate steady-state errors; the result of differential operations It is used to predict error change trends, suppress overshoot, and improve the stability of wire feeding control.

[0106] In this embodiment, the synergistic effect of proportional, integral, and derivative components constructs a basic speed closed loop that is responsive, precise in adjustment, and stable in operation, ensuring that the actual wire feeding speed always converges to the target wire feeding speed, which is the fundamental guarantee for achieving precise wire feeding.

[0107] In 3D printing or welding processes, filaments of different materials (such as plastic, steel, aluminum, and copper) possess different physical properties, such as rigidity, coefficient of friction, and yield strength. Using the same set of fixed PID parameters to control the filament feeding process for all filaments can lead to a decline in control performance. For example, the target PID parameters for controlling flexible polylactic acid filaments, if used to control high-rigidity stainless steel filaments, may cause system oscillations or slow response, thus affecting print quality. Alternatively, manually setting the target PID parameters for each filament change is inefficient and prone to errors or inaccuracies due to human error, impacting processing quality. To address these issues, some embodiments perform proportional, integral, and differential calculations on the speed error based on the target PID parameters. This includes: acquiring filament attribute information during the feeding process; determining the target PID parameters corresponding to the attribute information based on the index relationship between filament attributes and PID parameters; and performing proportional, integral, and differential calculations on the speed error based on the target PID parameters.

[0108] The filament material properties include filament type (e.g., ABS resin, steel, aluminum, copper) and filament diameter (e.g., 0.4mm, 0.8mm, 1.0mm). The index relationship between filament material properties and PID parameters is preset in an expert database or table within the main controller. This database establishes different combinations of filament material properties (specifically, combinations of filament type and diameter) and optimal PID parameter sets (including...). and The mapping relationship between the attributes. For example, a set of PID parameters that can achieve the best control effect (such as small overshoot, fast response, and zero steady-state error) can be determined in advance for each attribute information through a large number of experiments and fine-tuning. These experiences are solidified and stored to form an expert database.

[0109] In this embodiment, the target PID parameters are a set of parameters most suitable for the current filament material, retrieved from the aforementioned index relationship based on the currently acquired filament material attribute information. and .

[0110] For example, before starting processing, the user selects the type of wire to be used from a preset wire library via a human-machine interface (such as a touchscreen) and inputs or selects the wire diameter. This selection information is then sent to the main controller via a communication protocol or interface. Another implementation involves using an RFID reader to read the electronic tag on the wire reel, automatically obtaining the wire's attribute information. The main controller then retrieves this attribute information from the RFID reader. Based on the attribute information, it searches an expert database for the optimal set of PID parameters to match, which is then used as the target PID parameters for the current operation. For example, if the attribute information changes from "ABS resin - 1.0mm" to "aluminum - 0.4mm", the main controller receives the new attribute information, immediately queries the expert database, and adjusts the PID parameters accordingly. =2.0, =0.15, =0.1) Automatically switch to ( =3.0, =0.2, =0.15).

[0111] Furthermore, based on the target PID parameters, proportional, integral, and derivative operations are performed on the speed error.

[0112] Optionally, after determining the corresponding target PID parameters through attribute information, the wire feeding control process can be further enhanced by incorporating an online learning mechanism to dynamically adjust the PID parameters through reinforcement learning or fuzzy logic algorithms. Specifically, the PID parameters are continuously fine-tuned based on real-time wire feeding quality (such as speed fluctuations) to maintain optimal matching between the PID parameters and the current operating conditions. For example, when the system experiences continuous small oscillations, the parameters can be appropriately reduced. or When the response is slow, increase the value appropriately. The online learning mechanism enables PID parameters to be dynamically optimized based on real-time operating conditions, rather than relying on a pre-set expert database. For example, when the wire diameter changes abruptly, the system can quickly adjust the PID parameters to the optimal state without manual intervention, significantly improving adaptability and achieving more precise and robust wire feeding control.

[0113] This application embodiment significantly improves the adaptability of the wire feeder to different wire materials by automatically determining PID parameters that match the wire material. This ensures that the system operates in near-optimal condition under any wire material, thereby improving wire feeding accuracy. Furthermore, during wire material switching, high-performance wire feeding can be achieved without manually adjusting any complex PID parameters, thus lowering the operational threshold, improving efficiency, and avoiding process quality fluctuations caused by inaccurate manual parameter adjustments. This, in turn, enhances the ease of use and user experience of the wire feeder.

[0114] In some embodiments, the vibration damping torque compensation amount for the servo motor is determined based on vibration data, including:

[0115] S1031. Based on the Fast Fourier Transform algorithm, perform spectral analysis on the vibration data to obtain at least one dominant vibration frequency component, as well as the vibration amplitude and phase corresponding to the dominant vibration frequency component.

[0116] The Fast Fourier Transform (FFT) algorithm is used to convert time-domain signals into frequency-domain signals, which can clearly show which frequency components are contained in the frequency-domain signal, as well as the intensity (amplitude) and phase of each frequency component.

[0117] For example, the main controller reads vibration data from the vibration accelerometer at a fixed sampling frequency (e.g., 2000Hz), and then processes the time-domain vibration data using a fast Fourier transform algorithm to obtain the vibration amplitude spectrum and phase spectrum. Peak values ​​exceeding a preset threshold are identified from the vibration amplitude spectrum; the frequencies corresponding to these peak values ​​are the dominant vibration frequency components (e.g., ...). =125 Hz, =250 Hz), and record the amplitude corresponding to each dominant vibration frequency component ( , ) and phase ( , The preset threshold is set based on historical data statistics or empirical formulas.

[0118] S1032. For each dominant vibration frequency component, generate a target vibration suppression velocity compensation amount that is equal to the vibration amplitude and opposite in phase to the dominant vibration frequency component.

[0119] Understandably, this step is based on active control theory. According to active control theory, to cancel a sinusoidal oscillation, it is necessary to generate a sinusoidal wave with the same frequency, equal amplitude, and opposite phase. The two waves, when superimposed, cancel each other out due to interference.

[0120] S1033. Add the target vibration suppression speed compensation amounts corresponding to each dominant vibration frequency component to obtain the vibration suppression speed compensation amount for the servo motor.

[0121] S1034. Convert the vibration damping speed compensation amount into the vibration damping torque compensation amount used to drive the servo motor.

[0122] The servo motor is ultimately driven by a torque control signal (or a current control signal). Therefore, it is necessary to convert the vibration damping speed compensation amount into an equivalent vibration damping torque compensation amount.

[0123] For example, through speed-torque conversion gain The vibration damping speed compensation amount Converted to vibration damping torque compensation amount ( The speed-torque conversion gain can be set based on an approximate model of the wire feeder system, such as the speed-torque conversion gain. ≈ ,in It is the total moment of inertia equivalent to the motor shaft. This is the motor torque constant. A more precise value for the speed-torque conversion gain can be obtained through experimental calibration.

[0124] This application embodiment, through spectral analysis of vibration data, accurately identifies and specifically suppresses vibrations of specific frequencies that have the greatest impact on processing quality, achieving precise vibration suppression. It can automatically adjust the vibration suppression torque compensation amount in response to changes in vibration frequency and amplitude, achieving dynamic vibration suppression. Precise and dynamic vibration suppression helps improve the quality of finished products and process stability.

[0125] Considering the limited response speed of ordinary motors and mechanical transmission systems, the wire feeding speed fluctuates significantly at low speeds or during start-stop phases, affecting processing quality. In some embodiments, a control signal for the servo motor is generated based on the weighted fusion result of the vibration damping torque compensation and the feedback control torque. This includes: determining the feedforward control torque for the servo motor based on a preset wire feeder dynamics model and the target wire feeding speed; and generating the control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation, the feedback control torque, and the feedforward control torque.

[0126] The wire feeder dynamics model is a mathematical model describing the physical laws of the wire feeding system, used to predict the force or torque required by the servo motor. The wire feeder dynamics model typically includes elements such as inertia, viscous friction, and Coulomb friction. The feedforward control torque does not depend on the current speed error, but is a predictive torque calculated directly from the target wire feeding speed using the wire feeder dynamics model. This can be understood as providing the main acceleration power to the servo motor, enabling it to start quickly and significantly reducing speed lag.

[0127] For example, in some embodiments, the amount of feedforward control torque is specifically determined in the following way:

[0128]

[0129] in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; It is a nonlinear frictional torque.

[0130] It should be noted that, , and These are the model parameters of the wire feeder's dynamic model, which can be obtained through multiple system identification experiments on the wire feeder.

[0131] Furthermore, different control objectives, including vibration damping torque compensation, feedback control torque, and feedforward control torque, are superimposed according to their corresponding weighting coefficients to generate a control signal for the servo motor.

[0132] In this embodiment, the weighting coefficients can be dynamically adjusted according to the system state to achieve a balance between different control objectives. For example, when the system strongly detects slippage, the weighting coefficient of the feedforward control torque can be temporarily reduced or even set to zero to avoid exacerbating slippage. At this time, the system prioritizes relying on the feedback control torque and the vibration damping torque compensation to maintain stability. During large acceleration processes such as system startup, the weighting coefficient of the feedforward control torque can be appropriately increased to ensure rapid response.

[0133] Optionally, the fused control signal can be amplitude limited to ensure that the control signal is within the range of torque (or maximum allowable current) for safe operation of the servo motor.

[0134] In this embodiment, feedforward control predicts the required feedforward control torque, fundamentally reducing response lag, improving dynamic response speed, and avoiding processing defects caused by speed fluctuations during low-speed or start-stop phases. Feedback control corrects speed errors, ensuring precise tracking of the target wire feeding speed. Active vibration suppression control effectively suppresses wire feeding speed fluctuations and wire vibration, eliminating vibration effects. The final control signal is generated by fusing the vibration suppression torque compensation, feedback control torque, and feedforward control torque, thereby achieving high-precision, high-stability, and high-response wire feeding control and ensuring the quality of the finished product.

[0135] In some embodiments, a control signal for the servo motor is generated based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount, including: when the wire feeder is in a wire feeding slip state, determining the slip torque compensation reduction amount for reducing the output torque of the servo motor based on the actual torque; and generating a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the slip torque compensation reduction amount.

[0136] The main characteristic of the wire feeding slippage state is a significant increase in the actual torque of the servo motor, while the actual wire feeding speed does not increase synchronously or even decreases. Under this condition, it indicates that the driving force of the servo motor has failed to be effectively converted into the forward propulsion of the wire. Wire feeding slippage usually occurs in scenarios such as slight blockage of the wire outlet or excessively small bending radius of the wire. In these situations, the wire feeding resistance suddenly increases, and the torque of the servo motor continues to rise in an attempt to maintain the wire feeding speed, but the wire is not effectively pushed, resulting in a decrease in the actual wire feeding speed.

[0137] When the wire feeder is detected to be in a wire feeding slippage state, it is necessary to actively reduce the output torque of the servo motor to release the excessively tight engagement between the wire feeding wheel and the wire, break the slippage state, and restore normal gripping. Therefore, the slippage torque compensation reduction should be calculated, rather than the slippage torque compensation increment.

[0138] For example, the actual torque of the servo motor is monitored in real time. If, within a preset short period of time, such as 10ms, the increase in actual torque exceeds a set threshold, and within the same period, the actual wire feeding speed does not increase accordingly, or even its rate of change is zero or negative, a wire feeding slippage state is determined. Once slippage is determined, a slippage torque compensation reduction is immediately generated. This slippage torque compensation reduction is proportional to the abnormal increase in actual torque. For example, the slippage torque compensation reduction... ,in, This represents an abnormal increase in the actual torque. The slip compensation coefficient is obtained through engineering tuning based on the physical characteristics of the wire feeder system and extensive experimental observations.

[0139] Furthermore, different control objectives, including vibration damping torque compensation, feedback control torque, and slip torque compensation reduction, are superimposed according to their corresponding weighting coefficients to generate a control signal for the servo motor.

[0140] In this embodiment, the weighting coefficients can be dynamically adjusted according to the system state to achieve a balance between different control objectives. In this wire feeding slippage state, resolving the slippage and restoring normal wire feeding becomes the highest priority task, and the corresponding weighting coefficient is higher than the vibration damping torque compensation amount and the feedback control torque amount.

[0141] It should be noted that slip torque compensation is usually a transient process. The abnormal increase in actual torque may only exist for tens to hundreds of milliseconds. Once the main controller detects that the wire feeding slip state has been resolved, that is, the actual torque begins to decrease and the actual wire feeding speed begins to recover, the main controller controls the servo motor based on the vibration damping torque compensation amount and the feedback control torque amount to stabilize the actual wire feeding speed at the target wire feeding speed, thereby restoring normal wire feeding speed tracking control.

[0142] In this embodiment, by actively controlling and reducing the output torque of the servo motor during wire feeding slippage, the worsening of slippage faults is effectively prevented, and wire feeding errors caused by accumulated slippage are eliminated, ensuring the safe and stable operation of the wire feeder. By integrating vibration damping torque compensation, feedback control torque, and slippage torque compensation reduction for wire feeding control, the control accuracy is improved while enhancing the continuity and stability of the wire feeding process, thus ensuring the quality of the finished product.

[0143] Compared to related technologies, the lack of a detection mechanism for wire feeding slippage leads to misinterpretation as insufficient wire feeding speed when the wire feeder experiences slippage. This results in increased output torque of the servo motor, exacerbating the slippage and creating a vicious cycle that can ultimately lead to wire wear, stacking, or even breakage. In contrast, this application's embodiment introduces detection and proactive handling of wire feeding slippage, enabling self-healing of slippage faults and effectively improving the accuracy, continuity, and stability of wire feeding control.

[0144] In some embodiments, whether the wire feeder is in a wire feeding slippage state is determined by the following method: based on the fitting relationship between the wire feeding speed and the torque, a torque reference value is determined according to the actual wire feeding speed at the wire outlet. The fitting relationship characterizes the dynamic correlation between the wire feeding speed and the torque in the non-slippage state. If the actual torque is continuously greater than a set multiple of the corresponding torque reference value within a set time period, it is determined that the wire feeder is in a wire feeding slippage state.

[0145] It should be understood that, under ideal no-slip conditions, the torque of the wire feeding system is mainly used to overcome inertia, friction, and wire feeding resistance, and has a certain functional relationship with the wire feeding speed. Therefore, a mathematical model describing the correspondence between the actual wire feeding speed and the actual torque of the servo motor (i.e., the fitting relationship in this embodiment) can be constructed by fitting a large amount of torque and wire feeding speed data under normal conditions. This mathematical model may be linear or nonlinear, and it also characterizes the inherent dynamic characteristics of the wire feeding system.

[0146] For example, during the wire feeding process, the real-time actual wire feeding speed is substituted into a preset fitting relationship to calculate the corresponding torque reference value. The main controller continuously monitors this; if the actual torque is greater than a set multiple of the corresponding torque reference value, a timer is started. If this state of the actual torque being greater than a set multiple of the corresponding torque reference value continues for a preset duration, it is ultimately determined that the wire feeder is in a wire feeding slippage state. For example, the actual torque... Corresponding torque reference value Set the multiplier Set dynamic threshold = Set the multiplier This is an empirical value, for example, set between [1.2, 1.5], to calculate the threshold at the current actual wire feeding speed in real time. Compare actual torque Is it greater than ,like If the setting is maintained for 30 milliseconds, it is determined that the wire feeding is in a slip state, and the slip torque compensation logic is triggered.

[0147] This application embodiment avoids the problems of insensitivity at high-speed wire feeding and easy false alarms at low-speed wire feeding when using the fixed threshold method for slip detection in related technologies by setting different normal torque benchmarks for different wire feeding speeds, thereby improving the detection accuracy of wire feeding slippage. Introducing a set duration into the judgment condition effectively filters out instantaneous interference, reduces the false alarm rate, and ensures the accuracy of wire feeding slippage judgment.

[0148] Based on the above embodiments, further, combined with Figure 2 The wire feeding control method provided in the embodiments of this application will be described in detail. Figure 2 Flowchart of the wire feeding control method provided in the embodiments of this application Figure 2 ,like Figure 2 As shown, the wire feeding control method includes:

[0149] S201. Obtain multi-dimensional operating data of the wire feeder, which includes the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet.

[0150] See S101 for details.

[0151] S202. Determine the feedback control torque based on the target wire feeding speed and the actual wire feeding speed.

[0152] In one implementation, the speed error between the actual wire feeding speed and the target wire feeding speed is determined; the attribute information of the wire during the wire feeding process is obtained; based on the index relationship between the wire attributes and PID parameters, the target PID parameters corresponding to the attribute information are determined; after determining the corresponding target PID parameters through the attribute information, during the wire feeding control process, an online learning mechanism is further combined to dynamically adjust the PID parameters through reinforcement learning or fuzzy logic algorithms; based on the adjusted target PID parameters, proportional, integral, and derivative operations are performed on the speed error, and the sum of the proportional, integral, and derivative operation results is determined as the feedback control torque.

[0153] S203. Based on the vibration data, determine the vibration damping torque compensation amount for the servo motor.

[0154] For details, please refer to S1031~S1034 in the aforementioned embodiments.

[0155] S204. Based on the preset wire feeder dynamics model, determine the feedforward control torque for the servo motor according to the target wire feeding speed.

[0156] For example, the dynamic model of the wire feeder can be represented as: ,in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; The torque is a nonlinear frictional torque. By substituting the target wire feeding speed into the above-mentioned wire feeder dynamics model, the feedforward control torque is calculated.

[0157] S205. Based on the actual wire feeding speed and actual torque, determine whether the wire feeder is in a wire feeding slippage state.

[0158] For example, the real-time actual wire feeding speed is substituted into a preset fitting relationship to calculate the corresponding torque reference value. The main controller continuously monitors the torque; if the actual torque is greater than a set multiple of the corresponding torque reference value, a timer is started. If this state of the actual torque being greater than a set multiple of the corresponding torque reference value continues for a preset duration, it is finally determined that the wire feeder is in a wire feeding slippage state.

[0159] If the wire feeding is in a sliding state, then execute S206;

[0160] If the wire feeding is not in the wire feeding slippage state, then execute S208.

[0161] S206. Based on the actual torque, determine the slip torque compensation reduction used to reduce the output torque of the servo motor.

[0162] For example, the actual torque of the servo motor is monitored in real time. If, within a preset short period of time, such as 10ms, the increase in actual torque exceeds a set threshold, and within the same period, the actual wire feeding speed does not increase accordingly, or even its rate of change is zero or negative, a wire feeding slippage state is determined. Once slippage is determined, a slippage torque compensation reduction is immediately generated. This slippage torque compensation reduction is proportional to the abnormal increase in actual torque. For example, the slippage torque compensation reduction... ,in, This represents an abnormal increase in the actual torque. The slip compensation coefficient is obtained through engineering tuning based on the physical characteristics of the wire feeder system and extensive experimental observations.

[0163] S207. Based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, the feedforward control torque amount, and the slip torque compensation reduction amount, a control signal for the servo motor is generated.

[0164] Different control objectives, including vibration damping torque compensation, feedback control torque, feedforward control torque, and slip torque compensation reduction, are superimposed according to their corresponding weighting coefficients to generate a control signal for the servo motor. In this embodiment, the weighting coefficients can be dynamically adjusted according to the system state to achieve a balance between different control objectives.

[0165] By reducing response lag through feedforward control (specifically, feedforward control torque), compensating for slip and speed errors through adaptive PID feedback (specifically, slip torque compensation reduction and feedback control torque), and eliminating vibration through active vibration suppression (specifically, vibration suppression torque compensation), high-precision and high-stability wire feeding control is ultimately achieved.

[0166] Then, execute S209.

[0167] S208. Based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the feedforward control torque amount, a control signal for the servo motor is generated.

[0168] Different control objectives, including vibration damping torque compensation, feedback control torque, and feedforward control torque, are superimposed according to their corresponding weighting coefficients to generate a control signal for the servo motor. In this embodiment, the weighting coefficients can be dynamically adjusted according to the system state to achieve a balance between different control objectives.

[0169] S209. Send a control signal to the servo driver. The servo driver controls the servo motor based on the control signal to drive the wire feeding wheel assembly to feed the wire.

[0170] For example, control signals are sent to the servo driver in real time via a specific communication protocol, such as EtherCAT, CANopen, Modbus TCP, or analog voltage signals. The servo driver drives the motor to move precisely, thereby driving the wire feeding wheel assembly to perform wire feeding.

[0171] It should be noted that there is no specific execution order among S202, S203, S204, and S205; they are executed in parallel.

[0172] This application embodiment achieves comprehensive dynamic perception of the wire feeding process through multimodal sensor information fusion and intelligent decision-making algorithms, enabling precise fault diagnosis (such as wire blockage and wire feeding slippage), improving equipment reliability, and significantly enhancing the performance of the wire feeder. First, by directly detecting the wire feeding speed at the end of the wire outlet and employing a micro-slippage compensation mechanism, the insufficient accuracy problem caused by open-loop control in traditional wire feeders is solved, ensuring the continuity and stability of the wire feeding process. Second, the feedforward-feedback composite control combined with an active vibration suppression strategy effectively suppresses fluctuations in wire feeding speed and wire vibration, improving dynamic response capabilities and avoiding process defects caused by speed fluctuations during low-speed or start-stop phases. Furthermore, the introduction of an expert database and online learning mechanism allows the wire feeder to automatically call the optimal PID parameters based on the wire material and diameter, and achieve adaptive optimization through real-time fine-tuning, significantly reducing the need for manual intervention. Finally, the system continuously optimizes the wire feeding process through closed-loop control, achieving high-precision, high-stability, and highly intelligent wire feeding control, meeting the stringent requirements of high-end manufacturing fields for processing accuracy and stability.

[0173] Figure 3 This is a schematic diagram of the wire feeder provided in an embodiment of this application. It should be noted that... Figure 3 This is merely an example and does not specifically limit the structural configuration of the wire feeder provided in the embodiments of this application.

[0174] like Figure 3 As shown, the wire feeder includes: a main controller, and a servo driver, a speed detection device, a vibration sensor, and a current sensor, all electrically connected to the main controller. The servo driver is also electrically connected to a servo motor, which drives the wire feeding wheel assembly to feed wire via a transmission mechanism (the wire feeding wheel assembly includes...). Figure 3 The active wire feeding wheel and the driven wire pressing wheel in the middle), the wire is discharged through the wire exit nozzle.

[0175] For example, the speed detection device can be a high-resolution rotary encoder, with a precision friction wheel on its measuring shaft. The precision friction wheel is in contact with the surface of the wire to convert the linear motion of the wire into rotational motion. The vibration sensor includes a piezoelectric vibration accelerometer with a frequency response range covering 0.5Hz to 10kHz. The current sensor includes a Hall effect current sensor.

[0176] A speed detection device is installed at the wire exit nozzle to collect the actual wire feeding speed at the wire exit nozzle; a vibration sensor is installed at the wire exit nozzle to collect vibration data at the wire exit nozzle; and a current sensor is installed in the servo driver to collect the operating current of the servo motor.

[0177] The main controller is used to execute the methods described in the above-described wire feeding control method embodiments;

[0178] A servo driver is used to control a servo motor under the control of a main controller to drive the wire feeding wheel assembly to feed wire.

[0179] Figure 4 This is a schematic diagram of the wire feeding control device provided in an embodiment of this application. The wire feeding control device is applied to the main controller in the wire feeder. The main controller is connected to the servo driver in the wire feeder. The servo driver is connected to the servo motor in the wire feeder. The servo motor drives the wire feeding wheel assembly to feed wire through a transmission mechanism. Figure 4 As shown, the wire feeding control device 40 provided in this embodiment includes:

[0180] The acquisition module 41 is used to acquire multi-dimensional operating data of the wire feeder, including the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet.

[0181] The determination module 42 is used to determine the amount of feedback control torque based on the target wire feeding speed and the actual wire feeding speed;

[0182] The determination module 42 is also used to determine the amount of vibration damping torque compensation for the servo motor based on the vibration data.

[0183] The generation module 43 is used to generate a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount;

[0184] The sending module 44 is used to send control signals to the servo driver, which controls the servo motor based on the control signals to drive the wire feeding wheel assembly to feed the wire.

[0185] In one possible implementation, the determining module 42 is specifically used to: determine the speed error between the actual wire feeding speed and the target wire feeding speed; perform proportional, integral, and differential operations on the speed error based on the target PID parameters, and determine the sum of the proportional, integral, and differential operation results as the feedback control torque.

[0186] In one possible implementation, the determining module 42 is further configured to: acquire the attribute information of the filament during the filament feeding process; determine the target PID parameter corresponding to the attribute information based on the index relationship between the filament attribute and the PID parameter; and perform proportional, integral and differential operations on the speed error based on the target PID parameter.

[0187] In one possible implementation, the determining module 42 is further configured to: perform spectral analysis on the vibration data based on the Fast Fourier Transform algorithm to obtain at least one dominant vibration frequency component, as well as the vibration amplitude and phase corresponding to the dominant vibration frequency component; generate a target vibration suppression speed compensation amount that is equal to and opposite in phase to the vibration amplitude of each dominant vibration frequency component for each dominant vibration frequency component; add the target vibration suppression speed compensation amounts corresponding to each dominant vibration frequency component to obtain the vibration suppression speed compensation amount for the servo motor; and convert the vibration suppression speed compensation amount into a vibration suppression torque compensation amount for driving the servo motor.

[0188] In one possible implementation, the generation module 43 is specifically used to: determine the feedforward control torque for the servo motor based on a preset wire feeder dynamics model and the target wire feeding speed; and generate a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation, the feedback control torque, and the feedforward control torque.

[0189] In one possible implementation, the amount of feedforward control torque is specifically determined in the following way:

[0190]

[0191] in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; It is a nonlinear frictional torque.

[0192] In one possible implementation, the generation module 43 is further configured to: determine, based on the actual torque, a slip torque compensation reduction for reducing the output torque of the servo motor when the wire feeder is in a wire feeding slip state; and generate a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the slip torque compensation reduction.

[0193] In one possible implementation, whether the wire feeder is in a wire feeding slippage state is determined by the following method: based on the fitting relationship between the wire feeding speed and the torque, a torque reference value is determined according to the actual wire feeding speed at the wire outlet. The fitting relationship characterizes the dynamic correlation between the wire feeding speed and the torque in the non-slippage state. If the actual torque is continuously greater than a set multiple of the corresponding torque reference value within a set time period, it is determined that the wire feeder is in a wire feeding slippage state.

[0194] The wire feeding control device provided in this embodiment can execute the method provided in the above method embodiment. Its implementation principle and technical effect are similar, and will not be described in detail here.

[0195] Figure 5 This is a schematic diagram of the main controller provided in an embodiment of this application. Figure 5 As shown, the main controller 50 provided in this embodiment includes at least one processor 501 and a memory 502. Optionally, the main controller 50 further includes a communication component 503. The processor 501, memory 502, and communication component 503 are connected via a bus 504.

[0196] In a specific implementation, at least one processor 501 executes computer execution instructions stored in memory 502, causing at least one processor 501 to perform the above-described method.

[0197] The specific implementation process of processor 501 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0198] In the above embodiments, it should be understood that the processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this invention can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor.

[0199] The memory may include random access memory (RAM) and may also include non-volatile memory (NVM), such as at least one disk storage device.

[0200] The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of illustration, the buses shown in the accompanying drawings are not limited to a single bus or a single type of bus.

[0201] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the above-described method.

[0202] This application also provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, implement the above-described method.

[0203] The aforementioned readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. The readable storage medium can be any available medium accessible to a general-purpose or special-purpose computer.

[0204] An exemplary readable storage medium is coupled to a processor, enabling the processor to read information from and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can reside in an Application Specific Integrated Circuit (ASIC). Alternatively, the processor and the readable storage medium can exist as discrete components in the device.

[0205] The division of units is merely a logical functional division; in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0206] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0207] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0208] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0209] Those skilled in the art will understand that all or part of the steps of the above-described method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When executed, the program performs the steps of the above-described method embodiments; and the aforementioned storage medium includes various media capable of storing program code, such as ROM, RAM, magnetic disks, or optical disks.

[0210] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A wire feeding control method, characterized in that, A main controller is used in a wire feeder. The main controller is connected to a servo driver in the wire feeder. The servo driver is connected to a servo motor in the wire feeder. The servo motor drives the wire feeding wheel assembly to feed wire through a transmission mechanism. The wire feeding control method includes: The multi-dimensional operating data of the wire feeder is obtained, including the actual wire feeding speed at the wire outlet, the actual torque of the servo motor, and the vibration data at the wire outlet. The feedback control torque is determined based on the target wire feeding speed and the actual wire feeding speed. Based on the vibration data, determine the damping torque compensation amount for the servo motor; Based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount, a control signal for the servo motor is generated. The control signal is sent to the servo driver, and the servo driver controls the servo motor based on the control signal to drive the wire feeding wheel assembly to feed the wire.

2. The wire feeding control method according to claim 1, characterized in that, Determining the feedback control torque based on the target wire feeding speed and the actual wire feeding speed includes: Determine the speed error between the actual wire feeding speed and the target wire feeding speed; Based on the target PID parameters, proportional, integral, and derivative operations are performed on the speed error, and the sum of the proportional, integral, and derivative operation results is determined as the feedback control torque.

3. The wire feeding control method according to claim 2, characterized in that, The step of performing proportional, integral, and derivative operations on the speed error based on the target PID parameters includes: Obtain the property information of the filament during the filament feeding process; Based on the index relationship between wire properties and PID parameters, the target PID parameters corresponding to the property information are determined; Based on the target PID parameters, the speed error is subjected to proportional, integral, and derivative operations.

4. The wire feeding control method according to any one of claims 1 to 3, characterized in that, The step of determining the vibration damping torque compensation amount for the servo motor based on the vibration data includes: Based on the Fast Fourier Transform algorithm, the vibration data is subjected to spectral analysis to obtain at least one dominant vibration frequency component, as well as the vibration amplitude and phase corresponding to the dominant vibration frequency component. For each dominant vibration frequency component, a target vibration suppression velocity compensation amount is generated that is equal in amplitude and opposite in phase to the dominant vibration frequency component. The target vibration suppression speed compensation amounts corresponding to each of the dominant vibration frequency components are added together to obtain the vibration suppression speed compensation amount for the servo motor. The vibration damping speed compensation amount is converted into a vibration damping torque compensation amount used to drive the servo motor.

5. The wire feeding control method according to any one of claims 1 to 3, characterized in that, The step of generating a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount includes: Based on the preset wire feeder dynamics model, the feedforward control torque for the servo motor is determined according to the target wire feeding speed. Based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the feedforward control torque amount, a control signal for the servo motor is generated.

6. The wire feeding control method according to claim 5, characterized in that, The feedforward control torque is determined in the following way: in, This refers to the feedforward control torque. Target wire feeding speed; This is the total moment of inertia equivalent to the motor shaft; The coefficient of viscous friction of the wire feeder; It is a nonlinear frictional torque.

7. The wire feeding control method according to any one of claims 1 to 3, characterized in that, The step of generating a control signal for the servo motor based on the weighted fusion result of the vibration damping torque compensation amount and the feedback control torque amount includes: When the wire feeder is in the wire feeding sliding state, the sliding torque compensation reduction for reducing the output torque of the servo motor is determined based on the actual torque. Based on the weighted fusion result of the vibration damping torque compensation amount, the feedback control torque amount, and the slip torque compensation reduction, a control signal for the servo motor is generated.

8. The wire feeding control method according to claim 7, characterized in that, Whether the wire feeder is in a wire feeding slippage state is determined by the following method: Based on the fitting relationship between the wire feeding speed and the torque, the torque reference value is determined according to the actual wire feeding speed at the wire exit nozzle. The fitting relationship characterizes the dynamic correlation between the wire feeding speed and the torque under non-slip conditions. If the actual torque continues to be greater than a set multiple of the corresponding torque reference value within a set time period, then the wire feeder is determined to be in a wire feeding sliding state.

9. A main controller, characterized in that, include: Memory, processor; The memory stores computer-executed instructions; The processor executes computer execution instructions stored in the memory, causing the processor to perform the method as described in any one of claims 1 to 8.

10. A wire feeder, characterized in that, include: The main controller, and a servo driver, a speed detection device, a vibration sensor and a current sensor, which are electrically connected to the main controller respectively. The servo driver is also electrically connected to a servo motor. The servo motor drives the wire feeding wheel group to feed the wire through a transmission mechanism. The wire is discharged through the wire outlet. The speed detection device is installed at the wire exit nozzle and is used to collect the actual wire feeding speed at the wire exit nozzle; the vibration sensor is installed at the wire exit nozzle and is used to collect vibration data at the wire exit nozzle. The current sensor is installed in the servo driver and is used to collect the operating current of the servo motor; The main controller is used to execute the wire feeding control method as described in any one of claims 1 to 8; The servo driver is used to control the servo motor under the control of the main controller to drive the wire feeding wheel assembly to feed wire.

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