Centering calibration method for coupler of motor twin trawling system
By collecting data in the motor-driven coupling system and using a computing device to automatically calculate the alignment deviation and adjustment amount, the problems of low accuracy, poor efficiency and high cost of traditional calibration methods are solved, and efficient and accurate coupling calibration is achieved.
Patent Information
- Application Number
- CN202511636826.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-10
- Publication Date
- 2026-01-27
AI Technical Summary
Traditional motor-driven coupling calibration methods suffer from low accuracy, poor efficiency, high cost, complex operation, and lack of automation, making it difficult to achieve accurate calibration in extreme environments.
By collecting data at multiple predetermined angular positions during the rotation of the coupling, a mathematical model is constructed using a computing device to automatically calculate the alignment deviation and adjustment amount, and generate visual guidance information to achieve fully automatic calibration.
Significantly improves calibration efficiency and accuracy, reduces calculation errors, shortens overall calibration time by more than 50%, adapts to extreme environments, and reduces equipment costs.
Smart Images
Figure CN121409083A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coupling alignment and calibration technology, and more specifically to a method for aligning and calibrating couplings in a motor-to-drive system. Background Technology
[0002] In motor-driven systems, the alignment and calibration of couplings is a crucial step in ensuring stable system operation. If the coupling has an axial deviation angle or a radial deviation displacement, it will lead to vibration, noise, decreased measurement accuracy, shortened coupling life, and even safety hazards. Traditional alignment and calibration methods include the ruler method, feeler gauge combined with dial indicator method, laser alignment instrument, optical alignment instrument, and inductive or capacitive systems. These methods generally have the following disadvantages: (1) Low accuracy and poor efficiency: Traditional methods rely on manual operation and experience, the calculation process is cumbersome, and it is easy to introduce human error. (2) High cost: Laser alignment instruments and other equipment are expensive and are easily affected by ambient light, vibration, and other factors. (3) Complex operation: Optical alignment instruments and other equipment require professional training, have limited applicable scenarios, and are difficult to achieve accurate calibration in extreme environments. (4) Lack of automation: The traditional process (measurement-recording-calculation-adjustment-re-inspection) is time-consuming and cannot provide real-time feedback on the adjustment amount. Summary of the Invention
[0003] To address the shortcomings of existing technologies, this invention provides a method for aligning and calibrating the coupling of a motor-to-trailer system. This method automatically collects data using a measuring instrument and constructs a mathematical model using a computing device. It automatically calculates the alignment deviation and adjustment amount and generates visual guidance information, significantly improving calibration efficiency and accuracy.
[0004] To achieve the above objectives, the present invention provides the following technical solution: A method for aligning and calibrating the coupling of a motor-to-trailer system includes: S1. Data acquisition steps: At multiple predetermined angular positions of the coupling rotation, acquire the readings of the axial and radial measuring instruments installed on it, and obtain the geometric parameters of the system. S2. Deviation calculation step: Input the readings and geometric parameters into the calculation device, which automatically calculates the alignment deviation value of the coupling based on a preset mathematical model. The alignment deviation value includes at least axial opening and radial offset deviation. S3. Adjustment calculation steps: The calculation device automatically calculates the adjustment amount of the motor support foot based on the centering deviation value and geometric parameters through the adjustment amount algorithm model; S4. Result Output Steps: Generate and output visual guidance information containing adjustment amounts; S5. Adjustment steps: Adjust the height of the front and rear feet of the motor and the left and right translation length according to the result indication; S6. Repeat the detection step: Repeat step S1. If the final result does not exceed the limit, the alignment accuracy meets the requirements. Tighten the bolts and install them completely. Remove the axial measuring instrument and the radial measuring instrument. If the final result exceeds the limit, repeat step S5.
[0005] In the further data acquisition step, the multiple predetermined angle positions include four positions: 0°, 90°, 180°, and 270°. The readings include the axial readings A0, A90, A180, and A270 at the four positions, and the radial readings R0, R90, R180, and R270 at the four positions. The geometric parameters include the coupling diameter D, the distance L1 from the front support of the motor to the plane of the meter rod, and the distance L2 between the front and rear supports of the motor.
[0006] In the further deviation calculation step, the centering deviation value is calculated as follows: Axial vertical opening = (A0 + A180) / 2 - (A90 + A270) / 2; Axial horizontal opening = (A90 + A270) / 2 - (A0 + A180) / 2; Radial vertical deviation = (R0 - R180) / 2; Radial horizontal deviation = (R90 - R270) / 2.
[0007] In the further step of calculating the adjustment amount, the adjustment amount is calculated as follows: Vertical adjustment amount of the front foot = (R0-R180) / 2 + ((A0 + A180) / 2-(A90+A270) / 2 / D)*L1; Vertical adjustment amount of the rear foot = (R0-R180) / 2 + ((A0+A180) / 2-(A90 +A270) / 2 / D)*(L1+L2); Horizontal adjustment amount of the front foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) * L1; Horizontal adjustment amount of the rear foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) *(L1+L2).
[0008] Furthermore, the computing device is a computer system running numerical computation and visualization software, including MATLAB or Python.
[0009] In the further data acquisition step, the axial and radial measuring instruments are digital dial indicators, and their measurement signals are transmitted to the computing device through a signal acquisition card. Furthermore, after the deviation calculation step and before the adjustment calculation step, the calculation device further includes: the calculation device performs a validity judgment on the alignment deviation value based on preset logic rules, and if the value is determined to be invalid, a prompt for remeasurement is issued.
[0010] An electronic device includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the steps of a method for aligning and calibrating a coupling in a motor-to-trailer system.
[0011] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of a method for aligning and calibrating a coupling in a motor-to-trailer system.
[0012] Compared with the prior art, the beneficial effects of the present invention are: 1. Fully automated calculation, executed by the MATLAB mathematical engine, is absolutely accurate and error-free. The mathematical model (adjustment amount = offset + (opening / diameter) × distance) is embedded in the program. The program automatically completes all complex calculations, determining the direction and displacement of the motor that need adjustment. The operator then adjusts the motor based on feedback until all values are within the allowable deviation range, eliminating manual calculation errors and ensuring absolute accuracy in every calculation.
[0013] 2. Compared to the traditional process of measuring, recording, calculating, adjusting, re-measuring, and re-calculating, which involves the most complex calculation step, this invention uses functions to display the adjustment amount and direction in real time, sets the data refresh frequency, and instantly displays the calculation results and adjustment suggestions. This allows maintenance personnel to focus their time and energy on the adjustment operation, thereby reducing the overall alignment time by more than 50%.
[0014] 3. Traditional methods rely heavily on the operator's "feeling" and "experience," such as judging whether the data is reliable and adjusting the order. This invention can have built-in logic checks to automatically determine whether the measurement is valid. For example, if the deviation value is within a certain range, it can meet the requirements. If the deviation does not meet the requirements, it can promptly remind the operator to remeasure.
[0015] The key to this invention lies in establishing a process for converting analog gauge readings into highly reliable digital data using mathematical algorithms and MATLAB software. The mathematical formula for similar triangles is applied to the MATLAB application, and the axial opening deviation and radial offset deviation are calculated using a predetermined deviation calculation model. These deviations, along with pre-stored parameters such as coupling diameter (D), front leg distance (L1), and front and rear leg distance (L2), are then substituted into an adjustment optimization algorithm model to solve for the vertical and horizontal adjustment amounts of the motor's front and rear legs. Finally, a visual image containing the adjustment amounts and deviation graphs is generated. Attached Figure Description
[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein: Figure 1 A schematic diagram of the process steps for aligning and calibrating the coupling in a motor-driven tow system; Figure 2 This is a schematic diagram showing the installation of the axial measuring instrument, radial measuring instrument, and coupling. Detailed Implementation
[0017] In the description of this invention, it should be noted that the directional terms such as "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this invention.
[0018] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to define a feature may explicitly or implicitly include one or more of that feature. In the description of this invention, "several" or "a number" means two or more, unless otherwise explicitly specified.
[0019] A method for aligning and calibrating the coupling of a motor-to-trailer system includes: S1. Data acquisition steps: At multiple predetermined angular positions of the coupling rotation, acquire the readings of the axial and radial measuring instruments installed on it, and obtain the geometric parameters of the system. S2. Deviation calculation step: Input the readings and geometric parameters into the calculation device, which automatically calculates the alignment deviation value of the coupling based on a preset mathematical model. The alignment deviation value includes at least axial opening and radial offset deviation. S3. Adjustment calculation steps: The calculation device automatically calculates the adjustment amount of the motor support foot based on the centering deviation value and geometric parameters through the adjustment amount algorithm model; S4. Result Output Steps: Generate and output visual guidance information containing adjustment amounts; S5. Adjustment steps: Adjust the height of the front and rear feet of the motor and the left and right translation length according to the result indication; S6. Repeat the detection step: Repeat step S1. If the final result does not exceed the limit, the alignment accuracy meets the requirements. Tighten the bolts and install them completely. Remove the axial measuring instrument and the radial measuring instrument. If the final result exceeds the limit, repeat step S5.
[0020] In the further data acquisition step, the multiple predetermined angle positions include four positions: 0°, 90°, 180°, and 270°. The readings include the axial readings A0, A90, A180, and A270 at the four positions, and the radial readings R0, R90, R180, and R270 at the four positions. The geometric parameters include the coupling diameter D, the distance L1 from the front support of the motor to the plane of the meter rod, and the distance L2 between the front and rear supports of the motor.
[0021] In the further deviation calculation step, the centering deviation value is calculated as follows: Axial vertical opening = (A0 + A180) / 2 - (A90 + A270) / 2; Axial horizontal opening = (A90 + A270) / 2 - (A0 + A180) / 2; Radial vertical deviation = (R0 - R180) / 2; Radial horizontal deviation = (R90 - R270) / 2.
[0022] In the further step of calculating the adjustment amount, the adjustment amount is calculated as follows: Vertical adjustment amount of the front foot = (R0-R180) / 2 + ((A0 + A180) / 2-(A90+A270) / 2 / D)*L1; Vertical adjustment amount of the rear foot = (R0-R180) / 2 + ((A0+A180) / 2-(A90 +A270) / 2 / D)*(L1+L2); Horizontal adjustment amount of the front foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) * L1; Horizontal adjustment amount of the rear foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) *(L1+L2).
[0023] Furthermore, the computing device is a computer system running numerical computation and visualization software, including MATLAB or Python.
[0024] In the further data acquisition step, the axial and radial measuring instruments are digital dial indicators, and their measurement signals are transmitted to the computing device through a signal acquisition card. Furthermore, after the deviation calculation step and before the adjustment calculation step, the calculation device further includes: the calculation device performs a validity judgment on the alignment deviation value based on preset logic rules, and if the value is determined to be invalid, a prompt for remeasurement is issued.
[0025] An electronic device includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the steps of a method for aligning and calibrating a coupling in a motor-to-trailer system.
[0026] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of a method for aligning and calibrating a coupling in a motor-to-trailer system.
[0027] Installation calculation process: A digital dial indicator is installed on the motor half-coupling to collect radial and axial deviations at the same angle. The signals are transmitted to the industrial control computer for decoding via a signal acquisition card. Measurement points: The coupling is rotated to four positions: 0° (initial position), 90°, 180°, and 270°. The axial dial indicator (measuring the opening) is responsible for recording the dial indicator reading at each position (A, A90, A180, A270). The pointer of the axial dial indicator should be as close as possible to the edge of the coupling end face. The radial dial indicator (measuring the offset) is responsible for recording the dial indicator reading at each position (R0, R90, R180, R270). Geometric dimensions: Accurately measure the coupling diameter D, the distance L1 from the front foot to the dial indicator rod, and the distance L2 between the front and rear feet.
[0028] Create a script file in MATLAB that can calculate the adjustment amount and direction. Based on the principle of similar triangles, establish the formula for calculating the adjustment amount. Front foot adjustment amount: directly affects the opening and offset. Rear foot adjustment amount: needs to be calculated based on the distance L2 between the front and rear feet and the coupling diameter D. Calculate the vertical and horizontal opening and offset values in real time based on data from four points.
[0029] Visualization is achieved by using MATLAB's plotting capabilities to visually display deviations and adjustments graphically.
[0030] Adjust the height of the front and rear feet of the motor and the left and right translation length according to the results.
[0031] advantage: Fully automated calculations are performed by the MATLAB mathematical engine, ensuring absolute accuracy and eliminating calculation errors. The mathematical model (adjustment amount = offset + (opening / diameter) × distance) is embedded in the program. The program automatically completes all complex calculations, determining the direction and displacement of the motor that need adjustment. The operator then adjusts the motor based on feedback until all values are within the allowable deviation range, eliminating manual calculation errors and ensuring absolute accuracy in every calculation.
[0032] Compared to the traditional process of measuring, recording, calculating, adjusting, re-measuring, and re-calculating, where the calculation step is the most complex, this invention uses functions to display the adjustment amount and direction in real time, sets the data refresh frequency, and instantly displays the calculation results and adjustment suggestions. This allows maintenance personnel to focus their main time and energy on the adjustment operation, thereby reducing the overall alignment time by more than 50%.
[0033] 3. Traditional methods rely heavily on the operator's "feeling" and "experience," such as judging whether the data is reliable and adjusting the order. This invention can have built-in logic checks to automatically determine whether the measurement is valid. For example, if the deviation value is within a certain range, it can meet the requirements. If the deviation does not meet the requirements, it can promptly remind the operator to remeasure.
[0034] The key to this invention lies in establishing a process for converting analog gauge readings into highly reliable digital data using mathematical algorithms and MATLAB software. The mathematical formula for similar triangles is applied to the MATLAB application, and the axial opening deviation and radial offset deviation are calculated using a predetermined deviation calculation model. These deviations, along with pre-stored parameters such as coupling diameter (D), front leg distance (L1), and front and rear leg distance (L2), are then substituted into an adjustment optimization algorithm model to solve for the vertical and horizontal adjustment amounts of the motor's front and rear legs. Finally, a visual image containing the adjustment amounts and deviation graphs is generated.
[0035] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.
Claims
1. A method for aligning and calibrating the coupling of a motor-driven tow system, characterized in that, include: S1. Data acquisition steps: At multiple predetermined angular positions of the coupling rotation, acquire the readings of the axial and radial measuring instruments installed on it, and obtain the geometric parameters of the system. S2. Deviation calculation step: Input the readings and geometric parameters into the calculation device, which automatically calculates the alignment deviation value of the coupling based on a preset mathematical model. The alignment deviation value includes at least axial opening and radial offset deviation. S3. Adjustment calculation steps: The calculation device automatically calculates the adjustment amount of the motor support foot based on the centering deviation value and geometric parameters through the adjustment amount algorithm model; S4. Result Output Steps: Generate and output visual guidance information containing adjustment amounts; S5. Adjustment steps: Adjust the height of the front and rear feet of the motor and the left and right translation length according to the result indication; S6. Repeat the detection step: Repeat step S1. If the final result does not exceed the limit, the alignment accuracy meets the requirements. Tighten the bolts and install them completely. Remove the axial measuring instrument and the radial measuring instrument. If the final result exceeds the limit, repeat step S5.
2. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 1, characterized in that: In the data acquisition step, multiple predetermined angle positions include four positions: 0°, 90°, 180°, and 270°. The readings include the axial readings A0, A90, A180, and A270 at the four positions, and the radial readings R0, R90, R180, and R270 at the four positions. The geometric parameters include the coupling diameter D, the distance L1 from the front support of the motor to the plane of the meter rod, and the distance L2 between the front and rear supports of the motor.
3. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 2, characterized in that: In the deviation calculation step, the centering deviation value is calculated as follows: Axial vertical opening = (A0 + A180) / 2 - (A90 + A270) / 2; Axial horizontal opening = (A90 + A270) / 2 - (A0 + A180) / 2; Radial vertical deviation = (R0 - R180) / 2; Radial horizontal deviation = (R90 - R270) / 2.
4. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 3, characterized in that: In the adjustment calculation step, the adjustment amount is calculated as follows: Vertical adjustment amount of the front foot = (R0-R180) / 2 + ((A0 +A180) / 2-(A90+A270) / 2 / D)*L1; Vertical adjustment amount of the rear foot = (R0-R180) / 2 + ((A0+A180) / 2-(A90+A270) / 2 / D)*(L1+L2); Horizontal adjustment amount of the front foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) * L1; Horizontal adjustment amount of the rear foot = (R90 - R270) / 2 + ((A90 + A270) / 2 - (A0 + A180) / 2 / D) *(L1+L2).
5. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 1, characterized in that: The computing device is a computer system running numerical calculation and visualization software, including MATLAB or Python.
6. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 1, characterized in that: In the data acquisition step, the axial and radial measuring instruments are digital dial indicators, and their measurement signals are transmitted to the computing device through a signal acquisition card.
7. The method for aligning and calibrating the coupling of a motor-to-trailer system according to claim 1, characterized in that: After the deviation calculation step and before the adjustment calculation step, the method further includes: the calculation device performs a validity judgment on the alignment deviation value based on preset logic rules, and if the value is determined to be invalid, it issues a prompt to remeasure.
8. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the steps of the method for centering and calibrating the coupling of a motor-driven towing system as described in any one of claims 1-7.
9. A computer-readable storage medium having a computer program stored thereon, characterized in that, When executed by a processor, the program implements the steps of a method for aligning and calibrating a motor-driven coupling system as described in any one of claims 1 to 7.