Dynamic decoupling and coupling processing method for six-dimensional force sensor

Abstract

The invention discloses a six-dimensional force sensor dynamic decoupling and coupling processing method, and relates to the technical field of mechanical measurement sensing detection, and the method comprises the steps: building a dynamic decoupling relation of six-dimensional mechanical component and elastomer strain response coupling mapping based on an original voltage signal and a static calibration parameter of a six-dimensional force sensor; dynamically modulating the mechanical compensation factor of the dynamic decoupling relation through the environmental influence factor; according to the modulated mechanical compensation factor, performing real-time suppression and compensation on coupling deviation caused by environmental disturbance, and outputting a six-dimensional mechanical component subjected to environmental compensation; performing high-precision decoupling processing on the six-dimensional mechanical component subjected to environment compensation to generate a corrected six-dimensional mechanical component; performing closed-loop online updating on the mechanical compensation factor of the dynamic decoupling relation by using the corrected six-dimensional mechanical component; according to the invention, the coupling deviation caused by environmental disturbance is suppressed and compensated in real time, and the defects of the six-dimensional force sensor in the aspects of decoupling precision and measurement stability are improved.

Description

Technical Field

[0001] This invention relates to the field of mechanical measurement and sensing technology, and in particular to a dynamic decoupling and coupling processing method for a six-dimensional force sensor. Background Technology

[0002] With the rapid development of robotics, intelligent manufacturing, and precision assembly, six-dimensional force sensors, as key measurement components, are widely used in scenarios such as grasping, grinding, surgical robots, and virtual interaction. These sensors are typically based on an elastic body structure with strain gauges, and achieve the correspondence between force and torque components and voltage output through a static calibration matrix, thereby obtaining six-dimensional measurement results of three-dimensional force and three-dimensional torque. In existing technologies, decoupling mainly relies on calibration models established under static conditions, and the separation of different components is achieved through matrix operations. This method can provide relatively accurate measurement results in laboratory or low-disturbance environments, and therefore has been widely adopted.

[0003] In complex real-world environments, the operating state of six-dimensional force sensors is often affected by a combination of dynamic factors, including temperature fluctuations, elastic body hysteresis, and external disturbances. These environmental disturbances are not deviations of a single variable, but rather complex disturbances that change and overlap over time, causing a significant deviation between the original static calibration parameters and the actual response. Existing methods rely solely on static decoupling models, lacking dynamic correction and online adjustment mechanisms. This often fails to suppress coupling deviations in dynamic environments, leading to a rapid decline in decoupling accuracy with changing operating conditions. Especially when temperature drift accumulates over a long period and sudden disturbances occur frequently, the sensor output not only experiences amplified deviations but may also exhibit response distortion, significantly reducing the stability and reliability of the decoupling results. It can be said that environmental interference has become the most challenging and critical problem for six-dimensional force sensors in engineering applications. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a dynamic decoupling and coupling processing method for a six-dimensional force sensor to solve the problems of decreased decoupling accuracy and insufficient measurement stability caused by the lack of an effective compensation and adjustment mechanism in dynamic environments.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] In a first aspect, the present invention provides a method for dynamic decoupling and coupling processing of a six-dimensional force sensor, comprising,

[0008] Obtain the original voltage signal and environmental influence factors of the six-dimensional force sensor; based on the original voltage signal and the static calibration parameters of the six-dimensional force sensor, establish the dynamic decoupling relationship between the coupling mapping of the six-dimensional mechanical components and the elastic strain response.

[0009] The mechanical compensation factor of the dynamic decoupling relationship is dynamically modulated by environmental impact factors; based on the modulated mechanical compensation factor, the coupling deviation caused by environmental disturbance is suppressed and compensated in real time, and the environmentally compensated six-dimensional mechanical components are output.

[0010] High-precision decoupling processing is performed on the environmentally compensated six-dimensional mechanical components to generate corrected six-dimensional mechanical components;

[0011] The mechanical compensation factor of the dynamic decoupling relationship is updated online in a closed loop using the modified six-dimensional mechanical components.

[0012] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the method for establishing the dynamic decoupling relationship between the six-dimensional mechanical components and the elastic body strain response coupling mapping includes:

[0013] Force and torque loads in each direction are applied sequentially to the six-dimensional force sensor, the original voltage signals of each elastic strain gauge are recorded, and a mapping relationship between the six-dimensional force and torque loads and the response of the elastic strain gauges is established to form a six-dimensional force-strain relationship.

[0014] A six-dimensional force-strain relationship is introduced into the static calibration parameters of the six-dimensional force sensor to analyze the coupling interference of the six-dimensional mechanical components to the responses of different elastic strain gauges. When the coupling interference of a certain six-dimensional mechanical component on an elastic strain gauge in a non-corresponding direction is greater than the preset interference tolerance, it is determined that there is a cross-coupling relationship between the six-dimensional mechanical component and the elastic strain gauge.

[0015] The cross-coupling relationship is corrected. When the amount of coupling interference in the non-corresponding direction is higher than the preset interference tolerance, the coupling coefficient of the non-corresponding direction in the six-dimensional force-strain mapping relationship is adjusted until the amount of coupling interference in the non-corresponding direction is lower than the preset interference tolerance, while maintaining the stability of the response in the corresponding direction. The modulated cross-coupling relationship is then recombined to form a dynamic decoupling relationship.

[0016] As a preferred embodiment of the six-dimensional force sensor dynamic decoupling and coupling processing method of the present invention, the method of dynamically modulating the mechanical compensation factor of the dynamic decoupling relationship through environmental influence factors includes:

[0017] When changes in environmental impact factors cause the coupling interference of the six-dimensional mechanical component in a non-corresponding direction to exceed the preset interference tolerance again, the mechanical compensation factor corresponding to the six-dimensional mechanical component is reduced until its coupling interference is lower than the preset interference tolerance, while maintaining the response in the corresponding direction within the preset allowable deviation range.

[0018] When changes in environmental impact factors cause response attenuation in the corresponding direction, the mechanical compensation factor in the corresponding direction is increased until the response recovers to the preset allowable deviation range, and the amount of coupling interference in the non-corresponding direction does not exceed the preset interference tolerance.

[0019] When the rate of change of environmental impact factors over time is lower than the long-term average rate of change, the mechanical compensation factor is continuously modulated according to a linear ratio; when the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the mechanical compensation factor is modulated according to a graded incremental modulation.

[0020] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the method for continuously modulating the mechanical compensation factor according to a linear ratio includes:

[0021] When environmental impact factors change gradually over time, the continuous correction ratio is determined by comparing the difference between their rate of change and the long-term average rate of change.

[0022] The continuous correction ratio is gradually applied to the mechanical compensation factor in the corresponding direction. During the continuous modulation process, it is adjusted in a small step according to a predetermined stepping method. The mechanical compensation factor is synchronously adjusted according to the changes in environmental impact factors.

[0023] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the method for hierarchical incremental modulation of the mechanical compensation factor includes:

[0024] When the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the degree of rate deviation is obtained by the difference between the real-time rate of change and the long-term average rate of change, and the degree of rate deviation is divided into several intervals.

[0025] Based on the range in which the real-time environmental change rate falls, the mechanical compensation factor in the corresponding direction is modulated by a predetermined increment step size until the response in the corresponding direction remains stable and the coupling interference in the non-corresponding direction does not exceed a preset interference tolerance.

[0026] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the method for real-time suppression and compensation of coupling deviations caused by environmental disturbances includes:

[0027] Based on the real-time measured six-dimensional mechanical components, the coupling interference in non-corresponding directions and the measured values ​​in corresponding directions are monitored.

[0028] If the amount of coupling interference in a non-corresponding direction exceeds the preset interference tolerance, the adjusted mechanical compensation factor in the corresponding direction is invoked to suppress the six-dimensional mechanical component until the amount of coupling interference in the non-corresponding direction drops below the preset interference tolerance.

[0029] If the measured value in the corresponding direction deviates from the preset allowable deviation range, the adjusted mechanical compensation factor in the corresponding direction is used to compensate for the six-dimensional mechanical component, so that it is restored to the preset allowable deviation range.

[0030] The suppressed and compensated six-dimensional mechanical components are recombined according to the direction of force and torque to output environmentally compensated six-dimensional mechanical components.

[0031] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the high-precision decoupling processing of the environmentally compensated six-dimensional mechanical components includes software decoupling control and hardware adaptive compensation.

[0032] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the software decoupling control method includes:

[0033] The environmentally compensated six-dimensional mechanical components are rebalanced according to the stiffness of each elastic body to obtain preliminary robust decoupled six-dimensional mechanical components.

[0034] Evaluate the non-corresponding directional coupling interference and corresponding directional error of the preliminary robust decoupling of the six-dimensional mechanical components;

[0035] When the amount of coupled interference is higher than the preset interference tolerance and the error exceeds the preset allowable deviation range, the decoupling gain coefficient in the corresponding direction is adjusted and the re-equalization process is iterated until the amount of coupled interference is lower than the preset interference tolerance and the error in the corresponding direction enters the preset allowable deviation range, thus forming a robust decoupling six-dimensional mechanical component.

[0036] As a preferred embodiment of the dynamic decoupling and coupling processing method for the six-dimensional force sensor described in this invention, the hardware adaptive compensation method includes:

[0037] The robustly decoupled six-dimensional mechanical components are converted into analog signals by a digital-to-analog converter and then input into the differential filtering circuit built into the six-dimensional force sensor.

[0038] The analog signal is compared with the ideal zero-point reference voltage for stress and torque directions by an adjustable differential amplifier in the differential filter circuit. When the difference voltage generated by the comparison exceeds the hardware compensation threshold, the feedback resistor of the corresponding differential amplifier is dynamically adjusted to change its common-mode rejection ratio.

[0039] The residual cross-sensitive components in the analog voltage signal representing the robustly decoupled six-dimensional mechanical components are suppressed using an adjusted differential amplifier until the absolute values ​​of all differential voltages are below the hardware compensation threshold; the corrected six-dimensional mechanical components are then generated.

[0040] As a preferred embodiment of the six-dimensional force sensor dynamic decoupling and coupling processing method of the present invention, the method for closed-loop online updating of the mechanical compensation factor of the dynamic decoupling relationship includes:

[0041] The corrected six-dimensional mechanical components are decomposed according to the directions of each force and moment to obtain the six-dimensional mechanical components corresponding to each direction; the actual response of each six-dimensional mechanical component is compared with the expected response calculated by the dynamic decoupling relationship to obtain the response deviation;

[0042] Based on the response deviation and changes in real-time environmental influence factors, the mechanical compensation factors in each direction of the dynamic decoupling relationship are increased or decreased to make the output of the dynamic decoupling relationship gradually approach the corrected six-dimensional mechanical components.

[0043] The mechanical compensation factors adjusted in each direction are recombined according to the order of the six-dimensional force and torque directions to complete the closed-loop online update of the dynamic decoupling relationship.

[0044] In a second aspect, the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, wherein when the computer program is executed by the processor, it implements any step of the six-dimensional force sensor dynamic decoupling and coupling processing method as described in the first aspect of the present invention.

[0045] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program is executed by a processor, it implements any step of the six-dimensional force sensor dynamic decoupling and coupling processing method as described in the first aspect of the present invention.

[0046] The beneficial effects of this invention are as follows: By implementing real-time suppression and compensation for coupling deviations caused by environmental disturbances, this invention improves the deficiencies of six-dimensional force sensors in terms of decoupling accuracy and measurement stability. It can effectively cope with the interference of uncertain factors such as temperature changes, hysteresis effects, and external disturbances on the decoupling process, and avoid mechanical component distortion or measurement drift caused by environmental fluctuations. This allows the sensor to maintain high robustness and consistency under various complex working conditions, and improves the data reliability and result credibility during long-term operation.

[0047] This mechanism not only reduces the impact of coupling interference on the overall measurement results, but also maintains good response characteristics under different load conditions, reducing measurement deviations caused by cross interference, thereby ensuring the stability and accuracy of real-time calculation of six-dimensional mechanical components. This technology shows significant advantages in high-precision measurement, complex operating environments, and long-term monitoring applications, and can provide more reliable data support and more stable mechanical information output for scenarios such as robot operation, precision assembly, and structural safety monitoring. Attached Figure Description

[0048] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. 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.

[0049] Figure 1 This invention presents a flowchart of a dynamic decoupling and coupling processing method for a six-dimensional force sensor;

[0050] Figure 2 This invention presents a flowchart for forming a dynamic decoupling relationship;

[0051] Figure 3 This invention provides a flowchart for updating the mechanical compensation factor;

[0052] Figure 4 The present invention provides a flowchart for completing the closed-loop online update. Detailed Implementation

[0053] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0054] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0055] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0056] Reference Figure 1 , Figure 2 , Figure 3 and Figure 4 As one embodiment of the present invention, this embodiment provides a method for dynamic decoupling and coupling processing of a six-dimensional force sensor, including the following steps:

[0057] Methods for establishing the dynamic decoupling relationship between the six-dimensional mechanical components and the strain response of an elastic body include:

[0058] Force and torque loads in each direction are applied sequentially to the six-dimensional force sensor, and the original voltage signals of each elastic strain gauge are recorded. A mapping relationship between the six-dimensional force and torque loads and the response of the elastic strain gauges is established, forming a six-dimensional force-strain relationship.

[0059] It should be noted that, according to the six independent directions of force (Fx, Fy, Fz) and torque (Mx, My, Mz), calibration loads of known magnitude and direction are sequentially applied to the six-dimensional force sensor; when loading in one direction, no additional loads are applied in other directions to ensure the singleness of the load and the accuracy of the measurement.

[0060] The magnitudes of force and torque in six independent directions are used as inputs. The voltage response values ​​output by each elastic strain gauge under various loads are recorded as outputs. The correspondence between inputs and outputs is established, and the response coefficients of each elastic strain gauge to different load components are calculated. The response coefficients are matrix-combined according to the six mechanical component directions to form an overall mapping that can simultaneously reflect the main response and cross response. The mapping is corrected for amplitude and direction consistency to obtain a complete six-dimensional force-strain relationship.

[0061] It should be noted that the expression for calculating the response coefficients of each elastic strain gauge to different load components is as follows:

[0062] ;

[0063] in, It is the first The elastic strain gauge for the first... The response coefficients of each load component It refers to the number of loads applied in the calibration experiment. It is an index variable for the number of load cycles. It is the index variable of the elastic strain gauge. It is the index variable of the load component. It is the first The strain gauge at the first The original voltage signal acquired during the second loading. It is the first The first load The known size of each load component.

[0064] A six-dimensional force-strain relationship is introduced into the static calibration parameters of the six-dimensional force sensor to analyze the coupling interference of the six-dimensional mechanical components to the responses of different elastic strain gauges. When the coupling interference of a certain six-dimensional mechanical component on an elastic strain gauge in a non-corresponding direction is greater than the preset interference tolerance, it is determined that there is a cross-coupling relationship between the six-dimensional mechanical component and the elastic strain gauge.

[0065] It should be noted that by comparing the voltage response of each six-dimensional mechanical component on each elastic strain gauge with the main response value in the corresponding direction, the ratio or difference between the response in the non-corresponding direction and the main response is calculated, and this ratio or difference is used as the coupling interference quantity.

[0066] The preset interference tolerance is set by statistically analyzing the mean and standard deviation of the voltage response of the elastic strain gauges in non-corresponding directions during the static calibration experiment of the six-dimensional force sensor, and the mean plus three times the standard deviation is used as the upper limit of the interference tolerance.

[0067] Cross-coupling refers to the significant voltage response generated on an elastic strain gauge in a non-corresponding direction by a certain six-dimensional mechanical component. That is, the output of the strain gauge not only reflects the main response in the corresponding direction, but is also disturbed by the force or torque in other directions.

[0068] The cross-coupling relationship is corrected. When the amount of coupling interference in the non-corresponding direction is higher than the preset interference tolerance, the coupling coefficient of the non-corresponding direction in the six-dimensional force-strain mapping relationship is adjusted until the amount of coupling interference in the non-corresponding direction is lower than the preset interference tolerance, while maintaining the stability of the response in the corresponding direction. The modulated cross-coupling relationship is then recombined to form a dynamic decoupling relationship.

[0069] Specifically, the correction method for the non-corresponding direction coupling coefficient is as follows: based on the amplitude of the non-corresponding direction elastic strain gauge exceeding the preset interference tolerance, determine the correction amount to be applied, and then adjust the corresponding off-diagonal elements in the six-dimensional force-strain mapping matrix by adding or subtracting them. For example, the amplitude can be taken as 20% to 50% of the excess value, so that the voltage response of the non-corresponding direction strain gauge drops to within the tolerance.

[0070] It should be noted that maintaining stable response in the corresponding direction means ensuring that the output of the elastic strain gauge in the corresponding direction still accurately reflects the actual magnitude of the six-dimensional mechanical components in that direction when adjusting the coupling coefficient in the non-corresponding direction, without introducing significant deviations.

[0071] Recombining the modified cross-coupling relationships means arranging the responses of all the adjusted six-dimensional mechanical components and each elastic strain gauge in sequence according to the order of the six-dimensional mechanical components Fx, Fy, Fz, Mx, My, Mz, and the order in which the elastic strain gauges are numbered in the sensor, so that the responses of all elastic strain gauges corresponding to each six-dimensional mechanical component are arranged sequentially.

[0072] Methods for using mechanical compensation factors that dynamically modulate and decouple the relationship between environmental impact factors include:

[0073] Traditional six-dimensional force sensors rely on static calibration parameters for measurement accuracy of six-dimensional mechanical components under changing environmental factors. They lack dynamic response adjustment methods to environmental influences such as temperature, humidity, or external disturbances. This leads to coupling interference in non-corresponding directions easily exceeding the allowable range, while the main response in the corresponding direction may decay or drift. As a result, they cannot maintain measurement stability and accuracy under different environmental conditions. During long-term use, the sensor output is prone to deviation, limiting the reliability and applicability of dynamic measurement of six-dimensional mechanical components.

[0074] When changes in environmental impact factors cause the coupling interference of the six-dimensional mechanical component in a non-corresponding direction to exceed the preset interference tolerance again, the mechanical compensation factor corresponding to the six-dimensional mechanical component is reduced until its coupling interference is lower than the preset interference tolerance, while maintaining the response in the corresponding direction within the preset allowable deviation range.

[0075] Specifically, the corresponding environmental influence factor change value is collected in real time for each six-dimensional mechanical component, and the output voltage of all elastic strain gauges is monitored at the same time. The coupling interference of elastic strain gauges in non-corresponding directions is compared with the preset interference tolerance to determine the amplitude that exceeds the limit.

[0076] The reduction amount of the mechanical compensation factor for the corresponding six-dimensional mechanical components is determined based on the amplitude exceeding the limit. For example, 20% to 50% of the amplitude exceeding the limit can be used as the initial adjustment range. After adjusting the mechanical compensation factor, the coupling interference of the strain gauge in the non-corresponding direction is collected again to confirm that its voltage response has dropped to within the preset interference tolerance. At the same time, it is checked whether the output of the elastic strain gauge in the corresponding direction is still within the preset allowable deviation range. If the response in the non-corresponding direction still exceeds the limit or the response in the corresponding direction deviates from the allowable range, the adjustment and measurement are repeated until the response in the non-corresponding direction is lower than the preset interference tolerance and the output in the corresponding direction is stable. The adjustment sequence can be performed in the order of the six-dimensional mechanical components Fx, Fy, Fz, Mx, My, Mz.

[0077] The specific implementation is as follows: Assuming the ambient temperature rises from 25℃ to 50℃, causing the six-dimensional force Fx to deviate from the tolerance of the output voltage of the Fz elastomer by 12 mV, the preset interference tolerance is ±5 mV, and the allowable deviation of the Fx elastomer output in the corresponding direction is ±0.1%;

[0078] Real-time acquisition of ambient temperature changes and output voltages of all elastomers; calculation of the non-corresponding direction coupling interference exceeding the amplitude ΔU = 12mV - 5mV = 7mV; determination of the reduction range of the mechanical compensation factor based on ΔU, taking 30% of ΔU as an example as the initial adjustment amount, adjusting the mechanical compensation factor corresponding to Fx from the original value of 1.0 to 0.97; immediately after adjustment, acquiring the output voltage of elastomer Fz to confirm that the coupling interference has decreased to below 5 mV, and simultaneously verifying that the output of Fx in the corresponding direction is still within the ±0.1% allowable deviation range; if the output of the non-corresponding direction still exceeds the limit or the output of the corresponding direction deviates from the allowable range, continue to fine-tune the mechanical compensation factor step by step according to the same proportion, repeating the measurement until the conditions are met;

[0079] Furthermore, environmental influencing factors include physical or external conditions that may affect the output of the six-dimensional force sensor, such as temperature, humidity, vibration, air pressure, and electromagnetic interference. These factors can cause the output of the elastomer strain gauge to shift or the cross-coupling of the six-dimensional mechanical components to change.

[0080] The mechanical compensation factor includes adjustable parameters for adjusting the output of the six-dimensional force sensor to reduce the amount of coupling interference in non-corresponding directions or to compensate for the response attenuation in corresponding directions. For example, it includes a scaling factor or correction factor for each six-dimensional mechanical component to keep the output voltage within a preset allowable range.

[0081] When changes in environmental impact factors cause response attenuation in the corresponding direction, the mechanical compensation factor in the corresponding direction is increased until the response recovers to the preset allowable deviation range, and the amount of coupling interference in the non-corresponding direction does not exceed the preset interference tolerance.

[0082] It should be noted that the preset allowable deviation range is the mean and fluctuation range obtained by statistically analyzing the multiple output voltage measurements of the elastic strain gauges in the corresponding direction during the static calibration experiment of the six-dimensional force sensor. For example, the mean plus or minus three times the standard deviation is taken as the upper and lower limits of the allowable deviation, which is used to judge the degree of deviation of the output in the corresponding direction under the influence of the environment.

[0083] A specific implementation example is as follows: Taking the six-dimensional mechanical component Fx as an example, in the static calibration experiment, the average value of the output voltage of the elastic strain gauge in the corresponding direction was 2.500 V, with a standard deviation of 0.005 V. The mean ± 3 times the standard deviation was taken as the allowable deviation range, i.e., 2.485 V ~ 2.515 V. An increase in ambient temperature caused the Fx output to drop to 2.480 V, exceeding the lower limit of the allowable deviation. At this point, the mechanical compensation factor corresponding to Fx was gradually increased, for example, from 1.00 to 1.03. After each small adjustment, the Fx elastic strain gauge output voltage was re-acquired, and the output of the elastic strain gauge in the non-corresponding direction was monitored simultaneously to ensure that its coupling interference remained within the preset interference tolerance. Through repeated adjustments and measurements, the Fx output recovered to 2.500 V, within the allowable deviation range, while the coupling interference in the non-corresponding direction remained stable, achieving real-time compensation under environmental influences.

[0084] When the rate of change of environmental impact factors over time is lower than the long-term average rate of change, the mechanical compensation factor is continuously modulated according to a linear ratio; when the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the mechanical compensation factor is modulated according to a graded incremental modulation.

[0085] By modulating the mechanical compensation factor of the dynamic decoupling relationship in real time by using environmental impact factors, the compensation factor can be reduced when the amount of non-corresponding direction coupling interference exceeds the limit due to environmental changes, and increased when the corresponding direction response decays. At the same time, by combining the rate of environmental change and selecting linear or graded incremental modulation, the non-corresponding direction interference suppression and the corresponding direction response can be maintained within the preset allowable deviation range, thereby improving the measurement accuracy and robustness of the six-dimensional force sensor in dynamic environments.

[0086] Methods for continuously modulating the mechanical compensation factor according to a linear ratio include,

[0087] When environmental impact factors change gradually over time, the continuous correction ratio is determined by comparing the difference between their rate of change and the long-term average rate of change.

[0088] Specifically, the continuous correction ratio is calculated based on the deviation amplitude between the coupling interference of the non-corresponding direction elastic strain gauge and the preset interference tolerance, as well as the difference between the output of the corresponding direction elastic strain gauge and the preset allowable deviation range. For example, 20% to 50% of the deviation amplitude can be taken as the initial correction ratio to guide the increase or decrease of the mechanical compensation factor.

[0089] It should be noted that the expression for calculating the continuous correction ratio is:

[0090] ;

[0091] in, It is a continuous correction ratio. This is an empirical coefficient, typically ranging from 0.2 to 0.5. This is the real-time coupling interference voltage value of the strain gauge of the non-corresponding elastic body. The voltage value corresponding to the preset interference tolerance. This is the reference value for the output voltage of the elastic strain gauge in the corresponding direction.

[0092] The continuous correction ratio is gradually applied to the mechanical compensation factor in the corresponding direction. During the continuous modulation process, it is adjusted in a small step according to a predetermined stepping method. The mechanical compensation factor is synchronously adjusted according to the changes in environmental impact factors.

[0093] Specifically, by collecting real-time environmental impact factor values ​​and the outputs of all elastic strain gauges, the continuous correction ratio is applied to the mechanical compensation factor in the corresponding direction in step units. The step size is determined based on the deviation amplitude of the continuous correction ratio and the amount of coupling interference in the non-corresponding direction. For example, 5% to 10% of the total correction ratio is taken as the single-step adjustment range. After each application, the output voltage of the elastic body is immediately collected to confirm that the amount of coupling interference in the non-corresponding direction decreases and the output in the corresponding direction remains within the preset allowable deviation range. If necessary, the process is repeated multiple times until the adjustment is completed, so as to achieve synchronous and continuous response between the mechanical compensation factor and environmental changes.

[0094] The method of applying graded incremental modulation to the mechanical compensation factor includes,

[0095] When the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the degree of rate deviation is obtained by the difference between the real-time rate of change and the long-term average rate of change, and the degree of rate deviation is divided into several intervals.

[0096] It should be noted that the expression for the degree of deviation in the acquisition rate is:

[0097] ;

[0098] in, It refers to the degree of deviation in speed. It is the rate of change of real-time environmental influencing factors. It is the long-term average rate of change of environmental impact factors. Environmental impact factors The amount of change within a very small time interval The corresponding minimum time interval is exemplified as 0.1 seconds or 1 second.

[0099] Furthermore, the degree of deviation in rate can be divided into multiple levels in a linear or nonlinear manner. For example, it can be divided into: small deviation: the real-time environmental impact factor change rate is 0% to 10% higher than the long-term average change rate, and the corresponding mechanical compensation factor adjustment range is 10% to 20% of the total correction ratio; medium deviation: the real-time change rate is 10% to 30% higher than the long-term average change rate, and the corresponding mechanical compensation factor adjustment range is 20% to 35% of the total correction ratio; large deviation: the real-time change rate is 30% to 50% higher than the long-term average change rate, and the corresponding mechanical compensation factor adjustment range is 35% to 50% of the total correction ratio.

[0100] Based on the range in which the real-time environmental change rate falls, the mechanical compensation factor in the corresponding direction is modulated according to the corresponding predetermined incremental step size until the response in the corresponding direction remains stable and the amount of coupling interference in the non-corresponding direction does not exceed the preset interference tolerance.

[0101] Specifically, the system collects environmental impact factors and elastic strain gauge outputs in real time, determines the range of environmental change rate, applies incremental steps of the corresponding range to the mechanical compensation factor in the corresponding direction, and collects the output voltage after each application to confirm that the output in the corresponding direction has recovered to the preset allowable deviation range. At the same time, the amount of coupling interference in the non-corresponding direction is lower than the preset interference tolerance, thereby realizing closed-loop control of graded incremental modulation of the mechanical compensation factor.

[0102] Methods for real-time suppression and compensation of coupling deviations caused by environmental disturbances include,

[0103] Based on the real-time measured six-dimensional mechanical components, the coupling interference in non-corresponding directions and the measured values ​​in corresponding directions are monitored.

[0104] Specifically, the output voltage of the elastic strain gauge in each direction is collected by a six-dimensional force sensor, and the coupling interference of each six-dimensional mechanical component in the non-corresponding direction is calculated according to the pre-established six-dimensional force-strain mapping matrix. At the same time, the output voltage of the elastic body in the corresponding direction is recorded.

[0105] If the amount of coupling interference in a non-corresponding direction exceeds the preset interference tolerance, the adjusted mechanical compensation factor in the corresponding direction is invoked to suppress the six-dimensional mechanical component until the amount of coupling interference in the non-corresponding direction drops below the preset interference tolerance.

[0106] If the measured value in the corresponding direction deviates from the preset allowable deviation range, the adjusted mechanical compensation factor in the corresponding direction is used to compensate for the six-dimensional mechanical component, so that it is restored to the preset allowable deviation range.

[0107] The suppressed and compensated six-dimensional mechanical components are recombined according to the direction of force and torque to output environmentally compensated six-dimensional mechanical components.

[0108] It should be noted that the adjusted six-dimensional mechanical components are arranged into a 6×1 column vector in the order of Fx, Fy, Fz, Mx, My, Mz, and output to the host computer or control system through the data interface for display and further control; the output signal update frequency is, for example, once every 10 ms to ensure real-time performance and synchronization of closed-loop continuous adjustment.

[0109] High-precision decoupling processing is performed on the environmentally compensated six-dimensional mechanical components, including software decoupling control and hardware adaptive compensation.

[0110] Software decoupling control methods include,

[0111] The environmentally compensated six-dimensional mechanical components are rebalanced based on the stiffness of each elastic body to obtain preliminary robust decoupled six-dimensional mechanical components.

[0112] Specifically, for each of the six-dimensional force and moment directions, the reequilibrium value is calculated according to the following formula:

[0113] ;

[0114] in, The six-dimensional mechanical components after environmental compensation are in the 1st... Measurements in direction, It is the first The direction corresponds to the stiffness parameter of the elastic body. The six-dimensional mechanical components after rebalancing are in the th... The result value in the direction, These are the three force directions along a three-dimensional Cartesian coordinate system. These are the three torque directions around a three-dimensional rectangular coordinate system;

[0115] Will By recombining the six-dimensional mechanical components according to their directional order, a six-dimensional vector is formed, resulting in a preliminary robust decoupling of the six-dimensional mechanical components.

[0116] The non-corresponding directional coupling interference and corresponding directional error of the six-dimensional mechanical components were evaluated for preliminary robust decoupling.

[0117] When the amount of coupled interference is higher than the preset interference tolerance and the error exceeds the preset allowable deviation range, the decoupling gain coefficient in the corresponding direction is adjusted and the re-equalization process is iterated until the amount of coupled interference is lower than the preset interference tolerance and the error in the corresponding direction enters the preset allowable deviation range, thus forming a robust decoupling six-dimensional mechanical component.

[0118] Specifically, the process of adjusting the decoupling gain coefficient in the corresponding direction and iteratively rebalancing is as follows:

[0119] ;

[0120] in, It is the first The direction will be in the next iteration (the first iteration). (Updated decoupling gain coefficients) It is the first Direction in Decoupling gain coefficient of the next iteration It is the step adjustment coefficient. This is the measurement error in the corresponding direction. The amplitude of non-corresponding directional coupling interference exceeds the limit. This is the measurement error in the corresponding direction. The weighting coefficients, Is the non-corresponding direction coupling interference exceeding the limit value? Weighting coefficients;

[0121] After each update, the new gain coefficient is applied to the six-dimensional mechanical components for rebalancing. This process is repeated iteratively until the convergence condition is met: the amount of coupling interference in the non-corresponding direction is ≤ the preset interference tolerance and the error in the corresponding direction is ≤ the preset allowable deviation range.

[0122] Hardware adaptive compensation methods include,

[0123] The robustly decoupled six-dimensional force components are converted into analog signals by a digital-to-analog converter and then input into the differential filter circuit built into the six-dimensional force sensor.

[0124] It should be noted that the function of the digital-to-analog converter is to convert the robustly decoupled six-dimensional mechanical component signal obtained by the software into an analog signal in voltage form, so as to perform analog processing in the differential filter circuit. Each mechanical component in each direction corresponds to an analog voltage channel, ensuring that it can be differentially compared with the reference voltage in that direction.

[0125] The analog signal is compared with the ideal zero-point reference voltage for stress and torque directions by an adjustable differential amplifier in the differential filter circuit. When the difference voltage generated by the comparison exceeds the hardware compensation threshold, the feedback resistor of the corresponding differential amplifier is dynamically adjusted to change its common-mode rejection ratio.

[0126] It should be noted that the six-dimensional force sensor continuously collects the output voltage of each elastic strain gauge several times (e.g., 100 times) under no force or torque, and calculates the average value in each direction as the ideal zero-point reference voltage in that direction.

[0127] Specifically, the analog voltage signals representing the robust decoupling of the six-dimensional mechanical components are sequentially input into the adjustable differential amplifier in the differential filter circuit built into the six-dimensional force sensor. The signal in each direction is compared with the ideal zero-point reference voltage in that direction to obtain the difference voltage.

[0128] When the voltage difference in a certain direction exceeds the hardware compensation threshold (e.g., 5 mV), the feedback resistor adjustment of the differential amplifier is triggered. The feedback resistor of the differential amplifier can be adjusted in the range of 1 kΩ to 50 kΩ in 1 kΩ increments. By increasing or decreasing the feedback resistor, the common-mode rejection ratio of the amplifier is changed, thereby reducing the residual cross-sensitivity component.

[0129] The residual cross-sensitive components in the analog voltage signal representing the robustly decoupled six-dimensional mechanical components are suppressed using an adjusted differential amplifier until the absolute values ​​of all differential voltages are below the hardware compensation threshold; the corrected six-dimensional mechanical components are then generated.

[0130] It should be noted that the voltage difference in each direction is collected again to confirm that it has dropped below the hardware compensation threshold (e.g., 2 mV) before adjusting the next direction. After adjusting all six-dimensional mechanical component directions in sequence, the corrected six-dimensional mechanical components are generated.

[0131] Methods for closed-loop online updating of the mechanical compensation factor for dynamic decoupling relationships include:

[0132] The corrected six-dimensional mechanical components are decomposed according to the directions of each force and moment to obtain the six-dimensional mechanical components corresponding to each direction; the actual response of each six-dimensional mechanical component is compared with the expected response calculated by the dynamic decoupling relationship to obtain the response deviation.

[0133] Specifically, for the corrected six-dimensional mechanical components, the measured values ​​in the six directions of Fx, Fy, Fz, Mx, My, and Mz are extracted sequentially and compared with the expected values ​​calculated in the corresponding directions in the dynamic decoupling relationship. The magnitude of the deviation in each direction is recorded to obtain the response deviation. Directions with deviations exceeding the preset allowable range are marked as needing adjustment. At the same time, it is checked whether the output of the elastic strain gauge in the non-corresponding direction is within the preset interference tolerance to ensure that the adjustment will not introduce new coupling interference.

[0134] Based on the response deviation and changes in real-time environmental influence factors, the mechanical compensation factors in each direction of the dynamic decoupling relationship are adjusted by increasing or decreasing, so that the output of the dynamic decoupling relationship gradually approaches the corrected six-dimensional mechanical components.

[0135] Specifically, the mechanical compensation factors are adjusted sequentially in the directions Fx, Fy, Fz, Mx, My, and Mz. For each direction, the step size is calculated based on the current response deviation amplitude and changes in environmental influence factors; for example, the step size can be 20%–50% of the deviation. After each adjustment, the actual output is remeasured, and the measured six-dimensional mechanical components are compared with the corrected target six-dimensional mechanical components, recording the new response deviation. Then, the compensation factors are adjusted again based on the new deviation. This process is iterated multiple times, with each adjustment bringing the output closer to the corrected six-dimensional mechanical components, until the actual output in all directions falls within the preset allowable deviation range, and the coupling interference in non-corresponding directions remains within the tolerance limit.

[0136] The mechanical compensation factors adjusted in each direction are recombined according to the order of the six-dimensional force and torque directions to complete the closed-loop online update of the dynamic decoupling relationship.

[0137] This embodiment also provides a computer device applicable to the dynamic decoupling and coupling processing method of a six-dimensional force sensor, including: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to implement the dynamic decoupling and coupling processing method of the six-dimensional force sensor proposed in the above embodiment.

[0138] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0139] This embodiment also provides a storage medium storing a computer program. When executed by a processor, the program implements the dynamic decoupling and coupling processing method for a six-dimensional force sensor as proposed in the above embodiments. The 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 Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0140] In summary, this invention improves the shortcomings of six-dimensional force sensors in decoupling accuracy and measurement stability by implementing real-time suppression and compensation for coupling deviations caused by environmental disturbances. It can effectively cope with the interference of uncertain factors such as temperature changes, hysteresis effects, and external disturbances on the decoupling process, and avoid mechanical component distortion or measurement drift caused by environmental fluctuations. This allows the sensor to maintain high robustness and consistency under various complex working conditions, and improves the data reliability and result credibility during long-term operation.

[0141] This mechanism not only reduces the impact of coupling interference on the overall measurement results, but also maintains good response characteristics under different load conditions, reducing measurement deviations caused by cross interference, thereby ensuring the stability and accuracy of real-time calculation of six-dimensional mechanical components. This technology shows significant advantages in high-precision measurement, complex operating environments, and long-term monitoring applications, and can provide more reliable data support and more stable mechanical information output for scenarios such as robot operation, precision assembly, and structural safety monitoring.

[0142] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for dynamic decoupling and coupling processing of a six-dimensional force sensor, characterized in that: include, S1. Obtain the original voltage signal and environmental influence factors of the six-dimensional force sensor; based on the original voltage signal and the static calibration parameters of the six-dimensional force sensor, establish the dynamic decoupling relationship between the coupling mapping of the six-dimensional mechanical components and the elastic strain response. S2. The mechanical compensation factor of the dynamic decoupling relationship is dynamically modulated by environmental impact factors; based on the modulated mechanical compensation factor, the coupling deviation caused by environmental disturbance is suppressed and compensated in real time, and the six-dimensional mechanical components after environmental compensation are output. S3. Perform high-precision decoupling processing on the environmentally compensated six-dimensional mechanical components to generate the corrected six-dimensional mechanical components; S4. The mechanical compensation factor of the dynamic decoupling relationship is updated online in a closed loop using the modified six-dimensional mechanical components.

2. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 1, characterized in that: The method for establishing the dynamic decoupling relationship between the six-dimensional mechanical components and the elastic body strain response coupling mapping includes, Force and torque loads in each direction are applied sequentially to the six-dimensional force sensor, the original voltage signals of each elastic strain gauge are recorded, and a mapping relationship between the six-dimensional force and torque loads and the response of the elastic strain gauges is established to form a six-dimensional force-strain relationship. A six-dimensional force-strain relationship is introduced into the static calibration parameters of the six-dimensional force sensor to analyze the coupling interference of the six-dimensional mechanical components to the responses of different elastic strain gauges. When the coupling interference of a certain six-dimensional mechanical component on an elastic strain gauge in a non-corresponding direction is greater than the preset interference tolerance, it is determined that there is a cross-coupling relationship between the six-dimensional mechanical component and the elastic strain gauge. The cross-coupling relationship is corrected. When the amount of coupling interference in the non-corresponding direction is higher than the preset interference tolerance, the coupling coefficient of the non-corresponding direction in the six-dimensional force-strain mapping relationship is adjusted until the amount of coupling interference in the non-corresponding direction is lower than the preset interference tolerance, while maintaining the stability of the response in the corresponding direction. The modulated cross-coupling relationship is then recombined to form a dynamic decoupling relationship.

3. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 2, characterized in that: The method for dynamically modulating the mechanical compensation factor based on the dynamic decoupling relationship of environmental impact factors includes: When changes in environmental impact factors cause the coupling interference of the six-dimensional mechanical component in a non-corresponding direction to exceed the preset interference tolerance again, the mechanical compensation factor corresponding to the six-dimensional mechanical component is reduced until its coupling interference is lower than the preset interference tolerance, while maintaining the response in the corresponding direction within the preset allowable deviation range. When changes in environmental impact factors cause response attenuation in the corresponding direction, the mechanical compensation factor in the corresponding direction is increased until the response recovers to the preset allowable deviation range, and the amount of coupling interference in the non-corresponding direction does not exceed the preset interference tolerance. When the rate of change of environmental impact factors over time is lower than the long-term average rate of change, the mechanical compensation factor is continuously modulated according to a linear ratio; when the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the mechanical compensation factor is modulated according to a graded incremental modulation.

4. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 3, characterized in that: The method for continuously modulating the mechanical compensation factor according to a linear ratio includes: When environmental impact factors change gradually over time, the continuous correction ratio is determined by comparing the difference between their rate of change and the long-term average rate of change. The continuous correction ratio is gradually applied to the mechanical compensation factor in the corresponding direction, and micro-adjustments are made according to a predetermined stepping method during continuous modulation. The mechanical compensation factor is synchronously adjusted according to changes in environmental impact factors.

5. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 3, characterized in that: The method for applying graded incremental modulation to the mechanical compensation factor includes: When the rate of change of environmental impact factors over time is higher than the long-term average rate of change, the degree of rate deviation is obtained by the difference between the real-time rate of change and the long-term average rate of change, and the degree of rate deviation is divided into several intervals. Based on the range in which the real-time environmental change rate falls, the mechanical compensation factor in the corresponding direction is modulated according to the corresponding predetermined incremental step size until the response in the corresponding direction remains stable and the amount of coupling interference in the non-corresponding direction does not exceed the preset interference tolerance.

6. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 1, characterized in that: The method for real-time suppression and compensation of coupling deviations caused by environmental disturbances includes: Based on the real-time measured six-dimensional mechanical components, the coupling interference in non-corresponding directions and the measured values ​​in corresponding directions are monitored. If the amount of coupling interference in a non-corresponding direction exceeds the preset interference tolerance, the adjusted mechanical compensation factor in the corresponding direction is invoked to suppress the six-dimensional mechanical component until the amount of coupling interference in the non-corresponding direction drops below the preset interference tolerance. If the measured value in the corresponding direction deviates from the preset allowable deviation range, the adjusted mechanical compensation factor in the corresponding direction is used to compensate for the six-dimensional mechanical component, so that it is restored to the preset allowable deviation range. The suppressed and compensated six-dimensional mechanical components are recombined according to the direction of force and torque to output environmentally compensated six-dimensional mechanical components.

7. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 1, characterized in that: The high-precision decoupling process for the environmentally compensated six-dimensional mechanical components includes software decoupling control and hardware adaptive compensation.

8. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 7, characterized in that: The software decoupling control method includes: The environmentally compensated six-dimensional mechanical components are rebalanced according to the stiffness of each elastic body to obtain preliminary robust decoupled six-dimensional mechanical components. Evaluate the non-corresponding directional coupling interference and corresponding directional error of the preliminary robust decoupling of the six-dimensional mechanical components; When the amount of coupled interference is higher than the preset interference tolerance and the error exceeds the preset allowable deviation range, the decoupling gain coefficient in the corresponding direction is adjusted and the re-equalization process is iterated until the amount of coupled interference is lower than the preset interference tolerance and the error in the corresponding direction enters the preset allowable deviation range, thus forming a robust decoupling six-dimensional mechanical component.

9. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 7, characterized in that: The hardware adaptive compensation method includes, The robustly decoupled six-dimensional mechanical components are converted into analog signals by a digital-to-analog converter and then input into the differential filtering circuit built into the six-dimensional force sensor. The analog signal is compared with the ideal zero-point reference voltage for stress and torque directions by an adjustable differential amplifier in the differential filter circuit. When the difference voltage generated by the comparison exceeds the hardware compensation threshold, the feedback resistor of the corresponding differential amplifier is dynamically adjusted to change its common-mode rejection ratio. The residual cross-sensitive components in the analog voltage signal representing the robustly decoupled six-dimensional mechanical components are suppressed using an adjusted differential amplifier until the absolute values ​​of all differential voltages are below the hardware compensation threshold; the corrected six-dimensional mechanical components are then generated.

10. The dynamic decoupling and coupling processing method for a six-dimensional force sensor as described in claim 9, characterized in that: The method for closed-loop online updating of the mechanical compensation factor for dynamic decoupling relationships includes: The corrected six-dimensional mechanical components are decomposed according to the directions of each force and moment to obtain the six-dimensional mechanical components corresponding to each direction. The actual response of each six-dimensional mechanical component is compared with the expected response calculated by the dynamic decoupling relationship to obtain the response deviation; Based on the response deviation and changes in real-time environmental influence factors, the mechanical compensation factors in each direction of the dynamic decoupling relationship are increased or decreased to make the output of the dynamic decoupling relationship gradually approach the corrected six-dimensional mechanical components. The mechanical compensation factors adjusted in each direction are recombined according to the order of the six-dimensional force and torque directions to complete the closed-loop online update of the dynamic decoupling relationship.

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