High-precision driving and control integrated servo system

Abstract

The invention provides a high-precision driving and control integrated servo system, and belongs to the technical field of servo control. The high-precision drive and control integrated servo system comprises an intelligent modular drive and control integrated servo module, complete intelligent motion control is realized in a tiny volume, complex motion control, input and output port control and a current amplification drive circuit are all integrated in a control module with the minimum of 28 * 28 * 15mm, and a low-speed and high-precision control unit is used for controlling the intelligent modular drive and control integrated servo module. And a current-voltage hybrid multi-stage control algorithm is adopted. Through a current-voltage hybrid multi-section control algorithm, the problem of jitter of a traditional servo system during low-speed motion is effectively solved, high-precision stable control under low-speed motion smaller than 300 rpm is achieved, through an ARM + FPGA heterogeneous architecture and in combination with an intelligent control algorithm, the self-adaptive and self-learning servo control capability is achieved, and the stability of the system is improved. And the control performance of the system under various working conditions is improved.

Description

Technical Field

[0001] This application relates to the field of servo control, and more specifically, to a high-precision integrated drive and control servo system. Background Technology

[0002] In fields such as industrial automation, precision manufacturing, and robotics, servo systems serve as core driving components, and their control accuracy, response speed, and reliability directly determine the performance of the entire device. With technological advancements, market demands on servo systems are increasing. They not only require high-speed motion control but also stringent control accuracy requirements in low-speed operation scenarios, while also demanding good scalability, real-time performance, and collaborative control capabilities. Most existing servo systems employ a single-processor architecture or a simple multi-processor combination, making it difficult to balance the "slow but intelligent" decision-making needs with the "fast and deterministic" execution requirements. For example, pure ARM processor solutions, when handling high-speed real-time tasks such as current loop control and PWM signal generation, are limited by their serial processing characteristics and cannot achieve nanosecond-level control latency, resulting in insufficient control accuracy. Meanwhile, single FPGA solutions suffer from shortcomings in ecosystem and development efficiency in intelligent decision-making tasks such as complex trajectory planning and communication protocol processing. In low-speed control, existing technologies often employ fixed control algorithms covering the entire speed range, failing to address the unique challenges of frictional nonlinearity and vibration disturbances in different low-speed ranges. This leads to steady-state errors in the low-speed range, vibrations in the transition zone, and difficulty maintaining torque stability in the torque compensation zone. Furthermore, in multi-motor collaborative control scenarios, traditional servo systems often employ centralized or simple distributed bus architectures, resulting in large synchronization errors (typically greater than 1μs), long communication cycles, and high response delays, failing to meet the high-precision synchronization requirements of thousands of motors working collaboratively. Moreover, existing servo systems' event response mechanisms largely rely on periodic queries from the master control system, with response delays typically in the millisecond range. This inability to quickly process sudden signals such as emergency stops and limit switches reduces system safety and reliability. Therefore, developing an integrated drive-control servo system that combines high-precision control, high real-time response, high synchronization performance, and intelligent decision-making capabilities has become an urgent need in the current servo technology field. Summary of the Invention

[0003] To overcome the above shortcomings, this application provides a high-precision integrated drive and control servo system, which aims to improve the problems of large size, large low-speed jitter, long response cycle and low synchronization of traditional servo systems.

[0004] This application provides a high-precision integrated drive and control servo system, including... The intelligent modular drive and control integrated servo module achieves complete intelligent motion control in a small volume, integrating complex motion control, input and output port control and current amplification drive circuits into a control module as small as 28*28×15mm.

[0005] The low-speed, high-precision control unit adopts a current-voltage hybrid multi-segment control algorithm to achieve high-precision vibration-free servo control at low-speed motions of less than 300 rpm.

[0006] The event comparison and control unit establishes an event-action mapping by defining interrelated event tables and action tables, so that event units correspond to corresponding action units.

[0007] The hybrid bus control architecture divides the control system into two levels: the management layer and the execution layer, achieving a combination of centralized control and distributed control.

[0008] In one specific implementation, the intelligent modular drive and control integrated servo module includes an ARM processor unit and an FPGA execution unit.

[0009] In one specific implementation, the intelligent modular drive and control integrated servo module adopts an ARM+FPGA heterogeneous architecture, in which the ARM processor is responsible for trajectory planning, communication connection and system diagnosis, and the FPGA is responsible for current loop control, encoder interface processing, PWM generation and fault protection.

[0010] In one specific implementation, the FPGA implements current loop control with a switching frequency range of 100kHz to 1MHz, a closed-loop delay controlled within 1μs, and jitter not exceeding ±10ns. The FPGA also implements a high-resolution encoder interface, supporting 24-bit absolute encoders, including EnDat2.2 and BiSS-C protocols, with a synchronization error of less than 10ns in multi-axis synchronization scenarios.

[0011] In one specific implementation, the low-speed, high-precision control unit includes: The current-voltage hybrid multi-segment control algorithm module achieves smooth low-speed control by employing different control strategies in different speed ranges.

[0012] The distributed motion curve lookup and completion module adopts hardware optimization to automatically parse complex motion tasks.

[0013] The encoder-based self-closed-loop motion control module integrates encoder feedback processing and dual closed-loop control functions for velocity and displacement.

[0014] In one specific implementation, the current-voltage hybrid multi-segment control algorithm subdivides the low-speed region into a micro-speed region, a transition region, and a torque compensation region: In the low-speed range, adaptive feedforward compensation based on model predictive control is adopted.

[0015] In the transition region, a fuzzy PID control strategy is adopted.

[0016] In the torque compensation region, dual sliding mode control based on adaptive neural networks is adopted.

[0017] In one specific implementation, the event comparison control unit includes: The event table stores event units and their corresponding expected parameters.

[0018] Action table, which stores action units and their corresponding control parameters.

[0019] When the sensor input control module detects a change in the sensor reading, it compares the result with the event table to generate a sensor change event.

[0020] The motion control module adjusts the motion mode and parameters according to the motion table.

[0021] In one specific implementation, the event comparison control unit can react to external changes within 100μs without intervention from the main control system. By designing a high-speed communication port and defining events of interest, the event unit can be quickly modified. The execution unit of the action list is quickly modified to execute actions when an event of interest occurs.

[0022] In one specific implementation, the hybrid bus control architecture includes: The management layer consists of a main control unit responsible for interacting with users' tasks / control processes.

[0023] The execution layer includes multiple intelligent actuators. The master controller issues commands to the intelligent actuators under each gateway device through the gateway device.

[0024] The management level employs a centralized control system, encapsulating the communication and control methods of various modules within the control system. The execution level employs a distributed control system, capable of independently handling local events and control processes.

[0025] In one specific implementation, the system supports the coordinated control of up to a thousand motors, achieving a synchronization error of less than 4 microseconds between motors through a high-precision time synchronization protocol. Employing the EtherCAT communication protocol, the communication cycle can be as short as 0.5ms.

[0026] The beneficial effects of this application are: 1. By integrating complete servo control functions within a tiny volume (as small as 28*28×15mm), it achieves extremely high power density and space utilization, making it suitable for space-constrained applications.

[0027] 2. By using a current-voltage hybrid multi-segment control algorithm, the jitter problem of traditional servo systems at low speeds is effectively solved, achieving high-precision and stable control at low micro-speed motions of less than 300 rpm.

[0028] 3. Through the event comparison control mechanism, a rapid response within 100μs is achieved, which greatly reduces the load on the main control system and improves the system's adaptability to changes in the external environment.

[0029] 4. Through a hybrid bus control architecture, precise synchronization control with a synchronization error of less than 4 microseconds is achieved for up to a thousand motors, meeting the high-precision synchronization requirements of large-scale automated equipment.

[0030] 5. By using a heterogeneous architecture of ARM+FPGA and combining it with intelligent control algorithms, adaptive and self-learning servo control capabilities are achieved, improving the system's control performance under various working conditions. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0032] Figure 1 This is an overall structural block diagram of the high-precision drive and control integrated servo system provided in the embodiments of this application; Figure 2 A flowchart of the high-precision drive and control integrated servo system provided for the embodiments of this application; Figure 3 A schematic diagram of the hybrid bus control architecture of the high-precision drive and control integrated servo system provided in the embodiments of this application. Detailed Implementation

[0033] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0034] Please see Figure 1-3 This application provides a high-precision integrated drive and control servo system, including... The intelligent modular drive and control integrated servo module achieves complete intelligent motion control in a small volume, integrating complex motion control, input and output port control and current amplification drive circuits into a control module as small as 28*28×15mm. The low-speed, high-precision control unit adopts a current-voltage hybrid multi-segment control algorithm to achieve high-precision vibration-free servo control at low-speed motions of less than 300 rpm.

[0035] The event comparison and control unit establishes an event-action mapping by defining interrelated event tables and action tables, so that event units correspond to corresponding action units.

[0036] The hybrid bus control architecture divides the control system into two levels: the management layer and the execution layer, achieving a combination of centralized control and distributed control.

[0037] The intelligent modular drive and control integrated servo module includes an ARM processor unit and an FPGA execution unit. The ARM processor unit uses a Cortex-M4 or Cortex-R series processor (operating frequency ≥170MHz) and is responsible for upper-level tasks such as trajectory planning, communication protocol processing, system diagnosis, parameter storage, and adaptive learning.

[0038] The intelligent modular drive and control integrated servo module adopts an ARM+FPGA heterogeneous architecture, in which the ARM processor is responsible for trajectory planning, communication connection and system diagnosis, and the FPGA is responsible for current loop control, encoder interface processing, PWM generation and fault protection.

[0039] The FPGA implements current loop control with a switching frequency range of 100kHz to 1MHz, closed-loop delay control within 1μs, and jitter not exceeding ±10ns. The FPGA also implements a high-resolution encoder interface, supporting 24-bit absolute encoders, including EnDat2.2 and BiSS-C protocols, with a synchronization error of less than 10ns in multi-axis synchronous scenarios.

[0040] The low-speed, high-precision control unit includes: The current-voltage hybrid multi-segment control algorithm module achieves smooth low-speed control by employing different control strategies in different speed ranges.

[0041] The distributed motion curve lookup and completion module adopts hardware optimization to automatically parse complex motion tasks.

[0042] The encoder-based self-closed-loop motion control module integrates encoder feedback processing and dual closed-loop control functions for velocity and displacement.

[0043] The current-voltage hybrid multi-segment control algorithm subdivides the low-speed region into a micro-speed region, a transition region, and a torque compensation region: In the low-speed range, adaptive feedforward compensation based on model predictive control is adopted.

[0044] In the transition region, a fuzzy PID control strategy is adopted.

[0045] In the torque compensation region, dual sliding mode control based on adaptive neural networks is adopted.

[0046] The event comparison control unit includes: The event table stores event units and their corresponding expected parameters.

[0047] Action table, which stores action units and their corresponding control parameters.

[0048] When the sensor input control module detects a change in the sensor reading, it compares the result with the event table to generate a sensor change event.

[0049] The motion control module adjusts the motion mode and parameters according to the motion table.

[0050] The event comparison control unit can react to external changes within 100μs without intervention from the main control system. By designing a high-speed communication port and defining events of interest, the event unit can be quickly modified. The execution unit of the action list can be quickly modified to execute actions when an event of interest occurs.

[0051] The hybrid bus control architecture includes: The management layer consists of a main control unit responsible for interacting with users' tasks / control processes.

[0052] The execution layer includes multiple intelligent actuators. The master controller issues commands to the intelligent actuators under each gateway device through the gateway device.

[0053] The management level adopts a centralized control system, which encapsulates the communication and control methods of various modules in the control system; the execution level adopts a distributed control system, which can independently handle local events and control processes.

[0054] The system supports the coordinated control of up to a thousand motors. Through a high-precision time synchronization protocol, the synchronization error between motors is less than 4 microseconds. The EtherCAT communication protocol is adopted, and the communication cycle can be as short as 0.5ms.

[0055] This high-precision integrated drive and control servo system operates as follows: When the system performs normal motion control tasks, the modules work together according to the following process: During the instruction receiving phase, the management layer leads the task initialization: The management layer of the hybrid bus control architecture acts as the command center. It first receives user motion commands, parses and performs feasibility checks on the commands, and decomposes the task into motion commands for each axis.

[0056] Command issuance phase: The management team uses the EtherCAT real-time Ethernet bus to send the decomposed single-axis motion commands in parallel to the corresponding intelligent modules, and at the same time sends synchronization commands to ensure that each axis starts moving at the same time, specifying the control mode and parameter settings.

[0057] Local execution phase: Each intelligent module receives motion commands and initiates the collaborative control mode of the ARM+FPGA heterogeneous architecture. The ARM processor completes local trajectory planning and interpolation calculations based on the issued commands, optimizes the motion curve by combining historical system operation data, and the FPGA responds immediately, initiating 100kHz~1MHz high-frequency closed-loop control to complete current loop adjustment, PWM signal generation, and encoder signal decoding.

[0058] Status monitoring phase: Once the system enters stable operation, a dual protection mechanism of "distributed monitoring + centralized monitoring" is activated. The event comparison and control unit monitors sensor signals (current, temperature, position), system status flags and external input signals in parallel within the FPGA to achieve early warning of anomalies. Each intelligent module reports core status data to the management layer at a 10ms cycle.

[0059] Task completion phase: Once each axis reaches its target position, it immediately sends a "task completed" confirmation signal to the management layer. Upon receiving completion signals from all participating axes, the management layer performs a global task verification. After confirming there are no motion deviations, it marks the task as complete and releases the bus communication resources occupied by the task. The system automatically switches to standby mode, awaiting the next round of motion commands.

[0060] Exception Handling Procedure: When the system detects an exception, it will be handled according to the following procedure: Anomaly detection phase: The system achieves comprehensive anomaly capture through a three-level monitoring network: the first level is the event comparison control unit, which compares the sensor value range, rate of change and external signals (such as emergency stop, limit switch) in real time to identify abnormal operating conditions; the second level is the intelligent module FPGA, which detects hardware anomalies such as overcurrent, overtemperature and encoder failure of power devices through hardware logic; the third level is the hybrid bus management layer, which monitors communication anomalies such as bus communication delay and data packet loss.

[0061] Rapid response phase: In the event of a local anomaly, the event comparison control unit immediately triggers a protection action, the FPGA performs fault protection within microseconds, and the intelligent module sends an anomaly alarm to the management layer.

[0062] System decision-making stage: Management receives abnormal alarms, conducts assessments and makes decisions on whether to continue operation, degrade operation, or conduct an emergency shutdown, and sends control commands to the relevant modules.

[0063] Recovery processing phase: After ruling out the cause of the anomaly, the system restores its status. The management layer resends the motion command or starts the recovery process, and the system gradually returns to normal operation.

[0064] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

Claims

1. A high-precision integrated drive and control servo system, characterized in that, include The intelligent modular drive and control integrated servo module achieves complete intelligent motion control in a small volume, integrating complex motion control, input and output port control and current amplification drive circuits into a control module as small as 28*28×15mm. The low-speed, high-precision control unit adopts a current-voltage hybrid multi-segment control algorithm to achieve high-precision vibration-free servo control at low-speed motion of less than 300 rpm. The event comparison and control unit establishes an event-action mapping by defining interrelated event tables and action tables, so that event units correspond to corresponding action units; The hybrid bus control architecture divides the control system into two levels: the management layer and the execution layer, achieving a combination of centralized control and distributed control.

2. The high-precision integrated drive and control servo system according to claim 1, characterized in that, The intelligent modular integrated drive and control servo module includes an ARM processor unit and an FPGA execution unit.

3. The high-precision integrated drive and control servo system according to claim 2, characterized in that, The intelligent modular drive and control integrated servo module adopts an ARM+FPGA heterogeneous architecture, in which the ARM processor is responsible for trajectory planning, communication connection and system diagnosis, and the FPGA is responsible for current loop control, encoder interface processing, PWM generation and fault protection.

4. The high-precision integrated drive and control servo system according to claim 3, characterized in that, The FPGA implements current loop control with a switching frequency range of 100kHz to 1MHz, closed-loop delay control within 1μs, and jitter not exceeding ±10ns. The FPGA also implements a high-resolution encoder interface, supporting 24-bit absolute encoders, including EnDat2.2 and BiSS-C protocols, with a synchronization error of less than 10ns in multi-axis synchronization scenarios.

5. A high-precision integrated drive and control servo system according to claim 1, characterized in that, The low-speed, high-precision control unit includes: The current-voltage hybrid multi-segment control algorithm module achieves smooth low-speed control by employing different control strategies in different speed ranges. The distributed motion curve lookup and completion module uses hardware optimization to automatically parse complex motion tasks. The encoder-based self-closed-loop motion control module integrates encoder feedback processing and dual closed-loop control functions for velocity and displacement.

6. A high-precision integrated drive and control servo system according to claim 5, characterized in that, The current-voltage hybrid multi-segment control algorithm subdivides the low-speed region into a micro-speed region, a transition region, and a torque compensation region: In the low-speed range, adaptive feedforward compensation based on model predictive control is adopted; In the transition zone, a fuzzy PID control strategy is adopted; In the torque compensation region, dual sliding mode control based on adaptive neural networks is adopted.

7. A high-precision integrated drive and control servo system according to claim 5, characterized in that, The event comparison and control unit includes: The event table stores event units and their corresponding expected parameters; Action table, which stores action units and their corresponding control parameters; The sensor input control module, when it detects a change in sensor readings, compares the readings with the event table and generates a sensor change event. The motion control module adjusts the motion mode and parameters according to the motion table.

8. A high-precision integrated drive and control servo system according to claim 7, characterized in that, The event comparison control unit can react to external changes within 100μs without the need for intervention from the main control system; by designing a high-speed communication port and defining events of interest, the event unit can be quickly modified; by quickly modifying the execution unit of the action list, the action execution when the event of interest occurs can be realized.

9. A high-precision integrated drive and control servo system according to claim 8, characterized in that, The hybrid bus control architecture includes: The management layer consists of a main control unit responsible for interacting with users' tasks / control processes; The execution layer includes multiple intelligent actuators. The master controller issues commands to the intelligent actuators under each gateway device through the gateway device. The management level adopts a centralized control system, which encapsulates the communication and control methods of various modules in the control system; the execution level adopts a distributed control system, which can independently handle local events and control processes.

10. A high-precision integrated drive and control servo system according to claim 8, characterized in that, The system supports the coordinated control of up to a thousand motors. Through a high-precision time synchronization protocol, the synchronization error between motors is less than 4 microseconds. The EtherCAT communication protocol is used, and the communication cycle can be as short as 0.5ms.

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