A rotary opening and closing mechanism control data acquisition system

Abstract

The present application relates to precision electromechanical control and automation technical field, specifically to a kind of rotary opening and closing mechanism control data acquisition system, comprising: drive feature depth extraction unit, for receiving the current feedback and speed feedback of motor driver, generate drive fingerprint sequence;Heat-power coupling drift compensation unit, for receiving running time, ambient temperature and historical load intensity data, generate gap width drift correction coefficient;Three-state dynamics reconstruction unit, for feedforward correction to dynamic boundary threshold, divide system state and generate dynamics phase signal;Variable structure compliance control unit, for receiving the dynamics phase signal, output composite drive instruction, when the amplitude of oscillation exceeds safety threshold, generate the residual oscillation characteristic signal and feedback to the three-state dynamics reconstruction unit;The present application solves the inherent contradiction of fast response and flexible contact, eliminates the hard collision oscillation when crossing gap, reduces mechanical wear and improves positioning accuracy.

Description

Technical Field

[0001] This invention relates to the field of precision electromechanical control and automation technology, specifically to a control data acquisition system for a rotary opening and closing mechanism. Background Technology

[0002] With the continuous advancement of precision electromechanical control technology, the application of precision rotary opening and closing mechanisms is becoming increasingly widespread, and the requirements for the smoothness and accuracy of their motion control are also significantly increasing.

[0003] Currently, the control of such mechanisms mainly adopts traditional rigid control strategies or relies on external position sensors. Typically, the control system sets fixed gain parameters and drives the motor based on a preset ideal model to achieve a predetermined opening and closing position. However, this method ignores the nonlinear mechanical clearance dead zone and thermo-coupling effect that are common in mechanisms. In actual operation, changes in ambient temperature and frictional heat cause thermal expansion and contraction of metal parts, which in turn causes nonlinear drift in the mechanical clearance width. Traditional control strategies lack the ability to perceive and adapt to such dynamic clearance changes. At the moment when the motor rotor crosses the clearance and contacts the load, hard collision oscillations often occur because the control parameters cannot be adjusted in real time, leading to increased mechanical wear. Alternatively, to avoid oscillations, response speed is sacrificed, making it difficult to balance rapid crossing of the dead zone and flexible contact. Therefore, how to achieve accurate and compliant adaptive control without external sensors under complex working conditions with variable mechanical clearance and thermal drift interference has become an urgent problem to be solved in this field. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a control data acquisition system for a rotary opening and closing mechanism. Specifically, the technical solution of the present invention includes:

[0005] The drive feature deep extraction unit is used to receive current feedback and speed feedback from the motor driver, monitor the correlation between the rate of change of current signal and speed fluctuation in real time, identify the waveform combination that characterizes the motor idling and the waveform combination that characterizes the moment of contact, so as to generate a drive fingerprint sequence.

[0006] The thermo-mechanical coupling drift compensation unit is used to receive running time data, ambient temperature data and historical load intensity data, calculate the deformation trend based on the data and through the preset thermo-mechanical deformation mapping logic, and generate the gap width drift correction coefficient.

[0007] The three-state dynamics reconstruction unit is used to receive the driving fingerprint sequence, the gap width drift correction coefficient, and the feedback residual oscillation characteristic signal, perform feedforward correction on the dynamic boundary threshold according to the gap width drift correction coefficient, perform feedback correction on the dynamic boundary threshold according to the residual oscillation characteristic signal, and compare the driving fingerprint sequence with the corrected dynamic boundary threshold to divide the system state and generate a dynamic phase signal.

[0008] The variable structure compliant control unit is used to receive the dynamic phase signal, switch between different control parameter groups according to the dynamic phase signal to output composite drive commands, and monitor the oscillation amplitude after contact in real time. When the oscillation amplitude exceeds the safety threshold, the residual oscillation characteristic signal is generated and fed back to the three-state dynamic reconstruction unit.

[0009] Optionally, the driving feature depth extraction unit is specifically used for:

[0010] Monitor the correlation between the rate of change of the current signal and the speed fluctuation;

[0011] When a rapid increase in the current signal is detected and the speed feedback does not increase accordingly, it is identified as a motor idling characteristic;

[0012] When a sudden acceleration change is detected, it is identified as a feature of the instantaneous contact.

[0013] The driving fingerprint sequence containing high-frequency fluctuation information is generated based on the motor idling characteristics and the instantaneous contact characteristics.

[0014] Optionally, the thermo-mechanical deformation mapping logic is a qualitative relationship model fitted based on the thermal expansion coefficient of the material and experimental data; the thermo-mechanical coupling drift compensation unit is specifically used for:

[0015] The metal expansion amount is determined based on the running time data and the historical load intensity data;

[0016] The deformation trend is calculated based on the amount of metal expansion.

[0017] The dimensionless weighted factor is output as the gap width drift correction coefficient, and the dimensionless weighted factor is used to dynamically adjust the subsequent judgment criteria.

[0018] Optionally, the three-state dynamics reconstruction unit is specifically used for:

[0019] The feedforward correction is performed, and the dynamic boundary threshold is scaled or offset in real time using the gap width drift correction coefficient.

[0020] When the feedback correction is performed and the residual oscillation characteristic signal is received, an adaptive algorithm is triggered to progressively shrink the dynamic boundary threshold.

[0021] The driving fingerprint sequence is compared with the corrected dynamic boundary threshold.

[0022] Optionally, system states include:

[0023] Phase 0 indicates that the motor is in a decoupled state, idling within the gap;

[0024] Phase 1 indicates the contact state where the motor rotor is about to or has just contacted the load boundary;

[0025] Phase 2 indicates the coupled state in which the motor is driving the load.

[0026] Optionally, the variable structure compliance control unit is specifically used for:

[0027] In response to phase 0, a high response parameter set is loaded, fast forward mode is entered, and the maximum allowable acceleration is applied.

[0028] In response to phase 1, a forced switch to the high damping parameter group is initiated, entering a compliant transition mode, reducing the gain and injecting a virtual damping torque opposite to the velocity direction;

[0029] In response to phase 2, the system switches to a high-rigidity servo parameter group and enters a steady-state drive mode, employing PID position control or speed closed-loop control.

[0030] Optionally, it also includes a full lifecycle collaborative prediction unit, which is used for:

[0031] Receive the historical data stream of the gap width drift correction coefficient;

[0032] Track the evolution trend of the gap width drift correction coefficient;

[0033] When the gap width drift correction coefficient is detected to be unable to return to the reference range after the cooling cycle and shows an irreversible monotonic increasing trend, the mechanism is determined to have entered the late stage of wear.

[0034] Output preventative maintenance early warning signals.

[0035] Compared with the prior art, the present invention has the following beneficial effects:

[0036] 1. This invention uses a driving feature depth extraction unit to monitor the correlation between current and speed fluctuations in real time, constructs a driving fingerprint sequence, and achieves accurate capture of minute mechanical gaps without external position sensors. This method utilizes multi-physical quantity correlation analysis to effectively distinguish between electromagnetic noise and sudden changes in mechanical state, overcomes the limitations of single signal recognition, and significantly improves the sensitivity and accuracy of the system in identifying gap boundaries during dynamic operation.

[0037] 2. This invention introduces a thermo-coupling drift compensation mechanism, which comprehensively analyzes the running time, ambient temperature and load intensity, calculates the metal deformation trend and generates a drift correction coefficient. This mechanism can dynamically adjust the gap judgment benchmark, effectively offset the influence of nonlinear drift of mechanical gap caused by thermal expansion and contraction, solve the parameter mismatch problem of physical model in variable temperature environment, and ensure that the system can still maintain the robustness and consistency of control boundary under full temperature range and high frequency operation conditions.

[0038] 3. This invention employs a three-state dynamics reconstruction and variable structure compliant control strategy, discretizing the motion process into different phases and matching them with dedicated control parameters; applying maximum acceleration during the idling phase to eliminate hysteresis, injecting virtual damping torque at the moment of contact to achieve soft landing, and restoring high rigidity control during the driving phase; this segmented strategy resolves the inherent contradiction between rapid response and flexible contact, eliminates hard collision oscillations when crossing gaps, reduces mechanical wear, and improves positioning accuracy;

[0039] 4. This invention utilizes a full lifecycle collaborative prediction unit to track the evolution trend of the gap width drift correction coefficient, achieving zero-cost equipment health management; by identifying the characteristic that the coefficient cannot return to the baseline after the cooling cycle and shows monotonous growth, it accurately determines the irreversible wear state of the mechanism and outputs an early warning; this enables the system to perform condition-based maintenance before a failure occurs, reducing the risk of unplanned downtime of critical equipment and improving the overall reliability of the system. Attached Figure Description

[0040] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0041] Figure 1 This is a structural diagram of the system of the present invention. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0043] Example 1:

[0044] Please see Figure 1 A rotary opening and closing mechanism control data acquisition system, comprising:

[0045] The drive feature deep extraction unit is used to receive current feedback and speed feedback from the motor driver, monitor the correlation between the rate of change of current signal and speed fluctuation in real time, identify the waveform combination that characterizes the motor idling and the waveform combination that characterizes the moment of contact, so as to generate a drive fingerprint sequence.

[0046] The thermo-mechanical coupling drift compensation unit is used to receive running time data, ambient temperature data and historical load intensity data, calculate the deformation trend based on the data and through the preset thermo-mechanical deformation mapping logic, and generate the gap width drift correction coefficient.

[0047] The three-state dynamic reconstruction unit is used to receive the driving fingerprint sequence, the gap width drift correction coefficient, and the feedback residual oscillation characteristic signal. It performs feedforward correction on the dynamic boundary threshold based on the gap width drift correction coefficient, and feedback correction on the dynamic boundary threshold based on the residual oscillation characteristic signal. It also compares the characteristic amplitude intensity extracted from the driving fingerprint sequence with the corrected dynamic boundary threshold to classify the system state and generate a dynamic phase signal.

[0048] The variable structure compliant control unit is used to receive dynamic phase signals, switch between different control parameter groups according to the dynamic phase signals to output composite drive commands, and monitor the oscillation amplitude after contact in real time. When the oscillation amplitude exceeds the safety threshold, it generates residual oscillation characteristic signals and feeds them back to the three-state dynamic reconstruction unit.

[0049] In the architecture design of this embodiment, a sensorless control system based on deep mining of electrical signals is constructed to address the problems of nonlinear mechanical backlash dead zone and thermal drift in precision rotary opening and closing mechanisms such as precision aperture adjustment mechanisms and industrial damper actuators. This system does not rely on external position sensors, but reconstructs the real-time dynamic state of the mechanical transmission chain by analyzing the deep characteristics of electromagnetic and mechanical coupling inside the motor.

[0050] The deep feature extraction unit, serving as the system's signal sensing front-end, directly connects to the underlying current and speed loops of the motor driver. This unit is not merely a data acquisition channel; its core logic lies in performing morphological correlation analysis of the signals. During motor operation, this unit continuously monitors the instantaneous rate of change of the current signal. The synchronization with the rotor's physical speed fluctuations aims to capture the abrupt mechanical state characteristics hidden in conventional electromagnetic noise; once a specific waveform combination is identified, the system encodes the signal characteristics at that moment into a drive fingerprint sequence, providing the original basis for subsequent state reconstruction.

[0051] The thermo-mechanical coupling drift compensation unit is an adaptive correction module designed to address environmental disturbances. Given that the thermal expansion and contraction of metallic materials can significantly alter minute mechanical gaps, this unit introduces a dimensionless parameter—the gap width drift correction coefficient. The generation of this coefficient relies on a pre-set thermo-mechanical deformation mapping logic. By comprehensively analyzing the system's cumulative operating time, real-time ambient temperature, and historical load intensity to reflect internal frictional heat generation, it quantitatively assesses the deformation trend of the metallic components under current operating conditions, thereby dynamically adjusting the system's prediction benchmark for gap width.

[0052] The three-state dynamics reconstruction unit, as the logical decision-making center of the system, performs the critical state adjudication task. This unit adopts a bidirectional correction mechanism to maintain the accuracy of the dynamic boundary threshold. At the input end, feedforward correction is performed using the gap width drift correction coefficient to offset the interference of ambient temperature on gap judgment. At the feedback end, feedback self-learning is performed based on the residual oscillation characteristic signal to correct historical judgment deviations. On this basis, the unit performs high-frequency comparison between the real-time driving fingerprint sequence and the corrected threshold, discretizing the continuous physical motion process into a precise dynamic phase signal.

[0053] The variable structure compliant control unit, as the driving core of the actuator, is entirely controlled by the aforementioned phase signal. This unit abandons the single fixed gain control and instead presets multiple sets of control parameters optimized for different physical contact states. Based on the received phase signal, the unit switches between different parameter sets within milliseconds and outputs the final composite drive command. At the same time, this unit undertakes the real-time monitoring function. Once the physical oscillation amplitude is detected to exceed the preset safety threshold during the contact phase, a residual oscillation characteristic signal is generated and transmitted back, triggering the closed-loop self-evolution of the system.

[0054] This invention substantially solves the failure problem of traditional rigid control strategies when facing variable mechanical clearances by establishing a two-way deep coupling closed loop of perception and control. Through a thermo-mechanical coupling compensation mechanism, the system can still maintain the robustness of the judgment benchmark under the condition that the clearance drifts nonlinearly due to drastic changes in ambient temperature. Through the real-time linkage of three-state reconstruction and variable structure control, the control strategy is switched based on the physical contact state rather than a preset time, thereby achieving flexible and impact-free contact while ensuring rapid crossing of dead zones, significantly reducing mechanical wear and improving control accuracy.

[0055] Example 2:

[0056] The driving feature depth extraction unit is specifically used for:

[0057] Monitor the correlation between the rate of change of the current signal and the speed fluctuation;

[0058] When a rapid increase in current signal is detected without a corresponding increase in speed feedback, it is identified as a motor idling characteristic; when a sudden change in acceleration is detected, it is identified as a contact instant characteristic.

[0059] A drive fingerprint sequence containing high-frequency fluctuation information is generated based on the motor's idling characteristics and instantaneous contact characteristics.

[0060] Regarding the specific execution logic of the deep feature extraction unit, it adopts a feature fingerprint separation algorithm based on the difference between current-velocity decoupling; the core of this algorithm is to identify the time difference between the establishment of electromagnetic torque and the mechanical motion response.

[0061] In the specific monitoring process, this unit establishes a microsecond-level sliding time window; within this window, the unit calculates the derivative of the current signal in real time. When a steep upward trend is detected in the current signal, and the upward slope exceeds the preset current surge threshold (which is set to be more than 80% of the rated current rise rate of the motor), it indicates that the electromagnetic torque is being rapidly built up. At the same time, the unit synchronously monitors the speed feedback signal. If the change in the speed feedback value is lower than the preset dead zone threshold within the same time window of the current surge, it indicates that although the motor rotor is under force, it has not yet driven the load. Based on this, the system determines that the state is the motor idling characteristic, corresponding to the mechanical clearance crossing process.

[0062] When the unit detects a discontinuous positive or negative abrupt change in the second derivative acceleration of the velocity signal, and the abrupt change amplitude exceeds three times the standard deviation of the background noise, or when it detects a reverse oscillation waveform in the current signal caused by a sudden change in back electromotive force, the system marks this moment as the critical point for the establishment of the physical connection, i.e., the instantaneous contact feature. The unit packages the captured feature waveforms, their occurrence time, and their amplitude intensity to generate a driving fingerprint sequence containing rich high-frequency fluctuation information and outputs it.

[0063] This extraction method based on the correlation analysis of multiple physical quantities overcomes the deficiency that a single signal is difficult to distinguish between electromagnetic interference and mechanical features; in particular, the logical judgment based on the specific combination of high-frequency current rise and speed lag greatly improves the sensitivity of micron-level identification of tiny mechanical gaps, ensuring that the system can still accurately capture gap boundaries during high-speed dynamic adjustment.

[0064] Example 3:

[0065] Thermo-mechanical deformation mapping logic is a multi-dimensional quantitative mapping model based on the thermal expansion coefficient of the material and experimental data; the thermo-mechanical coupling drift compensation unit is specifically used for:

[0066] The amount of metal expansion is determined based on running time data and historical load intensity data;

[0067] Calculate the deformation trend based on the amount of metal expansion;

[0068] The dimensionless weighted factor is output as the gap width drift correction coefficient. The dimensionless weighted factor is used to dynamically adjust the subsequent judgment criteria.

[0069] In the configuration of the thermo-mechanical coupling drift compensation unit, the thermo-mechanical deformation mapping logic running inside it is a multi-dimensional quantitative mapping model fitted based on the thermal expansion coefficient of specific mechanical materials such as martensitic stainless steel and a large amount of bench experimental data; this model aims to solve the parameter mismatch problem of physical models under variable temperature environments.

[0070] The specific calculation process of this unit is as follows: It receives the system's current real-time ambient temperature, accumulated operating time representing steady-state heat accumulation, and historical load intensity, such as the effective current value over the past 10 minutes, representing transient frictional heat generation; based on the mapping logic that integrates the ambient base temperature and temperature rise, the unit calculates the estimated metal expansion of the current metal transmission components; it should be noted that the expansion amount here is not an absolute length value, but a relative deformation after normalization of experimental data; based on this metal expansion amount, it calculates the specific impact on mechanical clearance, i.e., the deformation trend; for example, in an internal meshing structure, gear expansion may lead to a decrease in clearance; while in some linkage structures, thermal elongation may lead to an increase in stroke clearance;

[0071] This unit outputs a dimensionless weighted factor as a gap width drift correction coefficient; this coefficient is a floating-point value used to dynamically adjust the judgment benchmark; when the estimated thermal expansion causes the gap to increase significantly, the coefficient will be automatically adjusted to a value greater than 1.0, such as 1.2, indicating that subsequent units should relax the judgment threshold for idling stroke; conversely, if the gap decreases, the coefficient will be less than 1.0; this mechanism ensures that the judgment standard always maintains a dynamic match with the current physical gap size.

[0072] By introducing this data fitting-based compensation mechanism, the system successfully desensitized the thermo-mechanical coupling effect. Under complex working conditions such as ambient temperature changes or high-frequency operation leading to frictional heat generation, the correction coefficient acts as a soft sensor, automatically calibrating the control boundary of the system, effectively avoiding control overshoot or response lag caused by gap drift, and ensuring control consistency across the entire temperature range.

[0073] Example 4:

[0074] The three-state dynamics reconstruction unit is specifically used for:

[0075] Perform feedforward correction and use the gap width drift correction coefficient to perform real-time scaling or offset processing on the dynamic boundary threshold;

[0076] When a feedback correction is performed and a residual oscillation characteristic signal is received, an adaptive algorithm is triggered to gradually shrink the dynamic boundary threshold.

[0077] Feature amplitude intensity is extracted from the driving fingerprint sequence, and the feature amplitude intensity is compared with the corrected dynamic boundary threshold;

[0078] System status includes:

[0079] Phase 0 indicates that the motor is in a decoupled state, idling within the gap;

[0080] Phase 1 indicates the contact state where the motor rotor is about to or has just contacted the load boundary;

[0081] Phase 2 indicates the coupled state in which the motor is driving the load.

[0082] The three-state dynamic reconfiguration unit executes a dynamic threshold management strategy that integrates feedforward compensation and feedback learning, with the aim of accurately classifying the topological connection state between the motor and the load.

[0083] At the threshold maintenance level, this unit executes feedforward correction logic; it reads the gap width drift correction coefficient from the thermo-coupling drift compensation unit and uses the coefficient to scale or linearly offset the preset dynamic boundary threshold inside the system in real time; for example, when the correction coefficient indicates that the gap shrinks due to high temperature, the unit will automatically lower the current threshold for determining the end of idling, so that the system enters the contact preparation state earlier and prevents the contact moment from being missed due to the threshold being too high.

[0084] This unit executes feedback correction logic; this is a self-learning process based on historical errors; if the variable structure compliant control unit feedbacks residual oscillation characteristic signals in the previous action cycle, indicating that the control intervention at the last contact was too late, resulting in a hard collision, the unit will immediately trigger an adaptive algorithm to progressively shrink the dynamic boundary threshold; specifically, the threshold is adjusted by a preset step size in a more sensitive direction, such as reducing the judgment threshold by 5%, to ensure that the contact state can be identified earlier in the next cycle;

[0085] The specific execution logic of the dual correction follows the operation order of benchmark update-real-time scaling: the system subtracts the step value from the historical benchmark threshold based on the feedback correction logic to obtain the updated benchmark threshold; the updated benchmark threshold is multiplied by the gap width drift correction coefficient from the thermo-mechanical coupling drift compensation unit to calculate the dynamic boundary threshold finally used in the current control cycle.

[0086] After completing the above dual correction, the unit extracts characteristic amplitude intensity, such as the peak value of the current change rate or the oscillation energy value, from the real-time drive fingerprint sequence, and compares this characteristic value with this dynamically adjusted threshold to divide the physical state of the system into three discrete topological phases in real time: the system identifies phase 0 as the decoupling state, indicating that the motor rotor is still rotating freely within the mechanical dead zone and has not established a rigid connection with the load. At this time, the system is in a low impedance state; the system identifies phase 1 as the contact state, which is a very short-lived but most critical transitional state for control, indicating that the motor rotor has crossed the dead zone and is about to or has just made physical contact with the load boundary. At this time, the mechanical impedance of the system changes drastically; the system identifies phase 2 as the coupling state, indicating that the mechanical connection has been firmly established and the motor is effectively driving the load to move along a predetermined trajectory. At this time, the system is in a high impedance stable drive state.

[0087] This reconfiguration mechanism, which combines environmental adaptive feedforward with historical error correction feedback, endows the system with extremely strong adaptability to operating conditions. It can not only automatically offset the effects of thermal drift, but also automatically evolve its control logic as mechanical components wear out, ensuring the accuracy of capturing the key physical moment of contact state and providing precise timing for subsequent compliant control.

[0088] Implementation 5:

[0089] The variable structure compliance control unit is specifically used for:

[0090] In response to phase 0, load the high response parameter set, enter fast forward mode, and apply the maximum allowable acceleration;

[0091] In response to phase 1, a forced switch to the high-damping parameter group is initiated, entering a compliant transition mode, reducing the gain and injecting a virtual damping torque opposite to the velocity direction;

[0092] In response to phase 2, switch to the high-rigidity servo parameter group, enter steady-state drive mode, and adopt PID position control or speed closed-loop control.

[0093] The variable structure compliant control unit adapts to the nonlinear characteristics of the physical process by switching between three distinct control architectures in real time based on the received dynamic phase signal.

[0094] When the system is in phase 0, the unit enters fast forward mode; in this mode, the unit loads a preset high response parameter set and applies the maximum allowable acceleration set by the system to the motor; in the idle stroke phase where there is no known load resistance, the maximum torque is used to eliminate mechanical backlash in the shortest time and eliminate control lag.

[0095] Upon receiving the phase 1 signal, the unit immediately executes a forced interrupt, switches to compliant transition mode, and loads a high-damping parameter set. In this mode, the unit not only significantly reduces the proportional gain of the position loop to reduce system stiffness and make it exhibit soft characteristics, but more importantly, based on the impedance control principle, it injects a virtual damping torque into the control loop that is opposite to the direction of the current rotor speed. This torque is achieved by applying a reverse current component in the motor windings, and its magnitude is proportional to the real-time speed. The virtual damping torque acts similarly to an electronic shock absorber, aiming to actively absorb the kinetic energy of the motor rotor at the moment of contact and achieve a soft landing.

[0096] Once the system smoothly transitions to phase 2, the unit switches to steady-state drive mode and loads a high-rigidity servo parameter set. At this point, standard PID position or speed closed-loop control is restored to ensure that the mechanism executes subsequent motion commands with high rigidity and accuracy, thus guaranteeing the final positioning accuracy.

[0097] This segmented variable structure control strategy cleverly resolves the inherent contradiction between rapid response and flexible contact; it approaches at high speed during the idle stroke, provides flexible buffering at the moment of contact, and rigidly drives during the load stroke. This mechanism completely eliminates the impact and oscillation caused by the accumulation of integral errors when traditional rigid control crosses the gap, thus protecting the precision mechanical structure and ensuring the high dynamic response performance of the control system.

[0098] Example 6:

[0099] This system also includes a full lifecycle collaborative prediction unit, which is used for:

[0100] Historical data stream receiving gap width drift correction coefficient;

[0101] The evolution trend of the gap width drift correction coefficient;

[0102] When the gap width drift correction coefficient is detected to be unable to return to the reference range after the cooling cycle and shows an irreversible monotonic increasing trend, the mechanism is determined to have entered the late stage of wear.

[0103] Output preventative maintenance early warning signals.

[0104] At the high-level functional layer of the system, the full lifecycle collaborative prediction unit uses data byproducts from the control process for equipment health management; this unit is configured to continuously monitor and record the historical data stream of the gap width drift correction coefficient.

[0105] The core logic of this unit lies in analyzing the long-term evolution trend of the coefficient. During the normal mechanical life cycle, the correction coefficient will exhibit reversible periodic fluctuations corresponding to thermal expansion and contraction as the equipment is heated and cooled. However, if the unit detects that the coefficient cannot return to the factory-set reference range after the equipment has undergone a complete cooling cycle, i.e., the temperature returns to room temperature, and shows an irreversible monotonous increasing trend on a weekly or monthly time scale, those skilled in the art should understand that this irreversible coefficient drift indicates that the physical dimensions of the mechanical clearance have been permanently changed, usually due to gear tooth wear or enlarged holes at the connecting rod connection. Based on this judgment, the unit confirms that the mechanism has entered the late stage of wear and immediately outputs a preventive maintenance warning signal to prompt the operator to inspect or replace the parts.

[0106] It achieves zero-cost predictive maintenance without the need for additional vibration or acoustic sensors; by deeply exploring the evolution of control parameters, the system can provide early warnings before mechanical failures occur, transforming reactive maintenance into condition-based maintenance and reducing the risk of unplanned downtime of critical equipment.

[0107] 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.

Claims

1. A control data acquisition system for a rotary opening and closing mechanism, characterized in that, include: The drive feature deep extraction unit is used to receive current feedback and speed feedback from the motor driver, monitor the correlation between the rate of change of current signal and speed fluctuation in real time, identify the waveform combination that characterizes the motor idling and the waveform combination that characterizes the moment of contact, so as to generate a drive fingerprint sequence. The thermo-mechanical coupling drift compensation unit is used to receive running time data, ambient temperature data and historical load intensity data, calculate the deformation trend based on the data and through the preset thermo-mechanical deformation mapping logic, and generate the gap width drift correction coefficient. The three-state dynamics reconstruction unit is used to receive the driving fingerprint sequence, the gap width drift correction coefficient, and the feedback residual oscillation characteristic signal, perform feedforward correction on the dynamic boundary threshold according to the gap width drift correction coefficient, perform feedback correction on the dynamic boundary threshold according to the residual oscillation characteristic signal, and compare the driving fingerprint sequence with the corrected dynamic boundary threshold to divide the system state and generate a dynamic phase signal. The variable structure compliant control unit is used to receive the dynamic phase signal, switch between different control parameter groups according to the dynamic phase signal to output composite drive commands, and monitor the oscillation amplitude after contact in real time. When the oscillation amplitude exceeds the safety threshold, the residual oscillation characteristic signal is generated and fed back to the three-state dynamic reconstruction unit.

2. The rotary opening and closing mechanism control data acquisition system according to claim 1, characterized in that, The driving feature depth extraction unit is specifically used for: Monitor the correlation between the rate of change of the current signal and the speed fluctuation; When the current signal is detected to show a steep upward trend and the upward slope exceeds the preset current surge threshold, if the change in speed feedback value is lower than the preset dead zone threshold within the same time window of the current surge, the system determines that the state is a motor idling characteristic. When the unit detects a discontinuous positive or negative abrupt change in the second derivative acceleration of the velocity signal, and the abrupt change amplitude exceeds three times the standard deviation of the background noise, or when it detects a reverse oscillation waveform in the current signal caused by a sudden change in back electromotive force, the system marks this moment as the critical point for the establishment of physical connection, i.e. the instantaneous contact characteristic. The driving fingerprint sequence containing high-frequency fluctuation information is generated based on the motor idling characteristics and the instantaneous contact characteristics.

3. The rotary opening and closing mechanism control data acquisition system according to claim 1, characterized in that, The thermo-mechanical deformation mapping logic is a multi-dimensional quantitative mapping model based on the thermal expansion coefficient of the material and experimental data; the thermo-mechanical coupling drift compensation unit is specifically used for: The metal expansion amount is determined based on the running time data, ambient temperature data, and historical load intensity data; The deformation trend is calculated based on the amount of metal expansion. The dimensionless weighted factor is output as the gap width drift correction coefficient, and the dimensionless weighted factor is used to dynamically adjust the subsequent judgment criteria.

4. The rotary opening and closing mechanism control data acquisition system according to claim 1, characterized in that, The three-state dynamics reconstruction unit is specifically used for: The feedforward correction is performed, and the dynamic boundary threshold is scaled or offset in real time using the gap width drift correction coefficient. When the feedback correction is performed and the residual oscillation characteristic signal is received, an adaptive algorithm is triggered to progressively shrink the dynamic boundary threshold. The driving fingerprint sequence is compared with the corrected dynamic boundary threshold.

5. The rotary opening and closing mechanism control data acquisition system according to claim 1, characterized in that, The system state includes: Phase 0 indicates that the motor is in a decoupled state, idling within the gap; Phase 1 indicates the contact state where the motor rotor is about to or has just contacted the load boundary; Phase 2 indicates the coupled state in which the motor is driving the load.

6. The rotary opening and closing mechanism control data acquisition system according to claim 5, characterized in that, The variable structure compliant control unit is specifically used for: In response to phase 0, a high response parameter set is loaded, fast forward mode is entered, and the maximum allowable acceleration is applied. In response to phase 1, a forced switch to the high damping parameter group is initiated, entering a compliant transition mode, reducing the proportional gain of the position loop and injecting a virtual damping torque opposite to the velocity direction; In response to phase 2, the system switches to a high-rigidity servo parameter group and enters a steady-state drive mode, employing PID position control or speed closed-loop control.

7. The rotary opening and closing mechanism control data acquisition system according to claim 1, characterized in that, It also includes a full lifecycle collaborative prediction unit, which is used for: Receive the historical data stream of the gap width drift correction coefficient; Track the evolution trend of the gap width drift correction coefficient; When the gap width drift correction coefficient is detected to be unable to return to the reference range after the cooling cycle and shows an irreversible monotonic increasing trend, the mechanism is determined to have entered the late stage of wear. Output preventative maintenance early warning signals.

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