Distributed motion control method and system for multi-motor linear magnetic drive conveyor system

Abstract

This invention discloses a distributed motion control method and system for a multi-moving linear magnetic drive conveyor system. The method includes: a controller issuing a set of motion parameters for a single motion process to a target moving part; the moving part locally generating and tracking a motion trajectory within a first control cycle, and performing multi-loop closed-loop control of position, speed, and current according to the motion trajectory; the moving part reporting status data to the controller according to a second reporting cycle; when the moving part or the controller determines that the status data meets preset entry conditions, performing graded fault handling; after the fault is cleared, restoring the local trajectory tracking and the aligned reporting cycle according to preset exit conditions. This invention solves the technical problem of difficulty in stably reproducing control effects and safety boundaries in multi-moving concurrent scenarios.

Description

Technical Field

[0001] This invention relates to the field of mover control technology, and in particular to a distributed motion control method, system, computer equipment, and storage medium for a multi-motor linear magnetic drive conveyor system. Background Technology

[0002] Existing multi-motion subsystems mostly adopt a loosely coupled architecture with periodic command issuance from the master unit, follow-up adjustment on the mover side, asynchronous status reporting, and event-based interlocking. Affected by power supply contact fluctuations, short-term loss of position measurement connection, communication jitter, and concurrent scheduling, it is difficult for the master and master control cycles to form a strict correspondence. Trajectory reconstruction and safety handling often occur under inconsistent time references, making it difficult to stably reproduce the motion control effect and braking safety boundary. Summary of the Invention

[0003] The purpose of this application is to propose a distributed motion control method, system, computer equipment, and storage medium for a multi-motor linear magnetic drive conveyor system, in order to solve the technical problem of difficulty in stably reproducing control effects and safety boundaries in multi-motor concurrent scenarios.

[0004] To address the aforementioned technical problems, this application provides a distributed motion control method for a multi-motor linear magnetic drive conveyor system, employing the following technical solution:

[0005] The controller issues a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters.

[0006] The moving end locally generates and tracks the motion trajectory within the first control cycle, and performs multi-loop closed-loop control of position, speed and current according to the motion trajectory;

[0007] The moving end reports status data to the controller according to the second reporting cycle, and the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle;

[0008] When the mover end or controller determines that the preset entry conditions are met based on the state data, graded fault handling is performed. The graded fault handling includes at least: local emergency stop triggered by the mover end and full-line emergency stop triggered by the controller. The local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it. The full-line emergency stop is used to issue control commands to other movers that have motion association with the faulty mover to stop, decelerate, wait or switch to other transport paths.

[0009] After the fault is cleared, the local trajectory tracking and the alignment reporting cycle are restored according to the preset exit conditions, wherein the preset entry / exit conditions are determined at least for the power supply voltage and the position measurement chain status.

[0010] To address the aforementioned technical problems, this application also provides a distributed motion control system for a multi-motor linear magnetic drive conveyor system, employing the following technical solution:

[0011] The distribution module is configured so that the controller distributes a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters.

[0012] The generation module is configured to generate and track the motion trajectory locally at the mover end within the first control cycle, and perform multi-loop closed-loop control of position, speed and current according to the motion trajectory;

[0013] The reporting module is configured to report status data to the controller according to the second reporting cycle, wherein the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle;

[0014] The execution module is configured to perform graded fault handling when the mover end or the controller determines that the state data meets the preset entry conditions. The graded fault handling includes at least: a local emergency stop triggered by the mover end and a full-line emergency stop triggered by the controller. The local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it. The full-line emergency stop is used to issue control commands to other movers that have a motion association with the faulty mover to stop, decelerate, wait, or switch to other transport paths.

[0015] The recovery module is configured to restore the local trajectory tracking and the alignment reporting cycle according to preset exit conditions after the fault is cleared, wherein the preset entry / exit conditions are determined at least for the power supply voltage and the position measurement chain status.

[0016] To address the aforementioned technical problems, this application also provides a computer device that employs the following technical solution:

[0017] A computer device includes a memory and a processor, wherein the memory stores computer-readable instructions, and the processor executes the computer-readable instructions to implement the steps of the distributed motion control method for the multi-motor linear magnetic drive conveyor system as described above.

[0018] To address the aforementioned technical problems, this application also provides a computer-readable storage medium, employing the technical solution described below:

[0019] A computer-readable storage medium storing computer-readable instructions, which, when executed by a processor, implement the steps of the distributed motion control method for a multi-motor linear magnetic drive conveyor system as described above.

[0020] Compared with the prior art, the embodiments of this application have the following main advantages:

[0021] The distributed motion control method for a multi-motor linear magnetic drive conveyor system disclosed in this application, through the one-time distribution of motion parameter sets, local trajectory control within the first control cycle of the mover end, and aligned reporting in a second reporting cycle that is an integer multiple of the parameter set, combined with hierarchical fault handling constrained by the remaining braking distance and exit determination based on power supply voltage and position measurement chain status, enables task assignment, trajectory control, status perception, and safety braking to operate collaboratively under a unified time reference. This significantly improves the timing determinism and consistency of motion and safety behavior of the multi-motor subsystem, reduces the communication and host computer load, and makes the braking distance and stopping position predictable. Attached Figure Description

[0022] To more clearly illustrate the solutions in this application, the accompanying drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a flowchart of an embodiment of the distributed motion control method for a multi-motor linear magnetic drive conveyor system according to this application;

[0024] Figure 2 This is a schematic diagram of a distributed motion control system of a multi-motor linear magnetic drive conveyor system according to an embodiment of the present application;

[0025] Figure 3 This is a schematic diagram of the structure of one embodiment of the computer device according to this application. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0027] refer to Figure 1 A flowchart illustrating an embodiment of a distributed motion control method for a multi-motor linear magnetic drive conveyor system according to this application is shown. The distributed motion control method for the multi-motor linear magnetic drive conveyor system includes the following steps:

[0028] Step S101: The controller sends a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters.

[0029] In this embodiment, the distributed motion control method of the multi-motor linear magnetic drive conveyor system allows the electronic devices running on it to send or receive data via wired or wireless connections. It should be noted that the aforementioned wireless connection methods may include, but are not limited to, 3G / 4G / 5G connections, WiFi connections, Bluetooth connections, WiMAX connections, Zigbee connections, UWB (ultra-wideband) connections, and other currently known or future-developed wireless connection methods.

[0030] In this embodiment, a host controller can act as the scheduling and task issuing unit. For each mover that needs to perform motion, the controller issues a set of motion parameters for that motion process all at once before the mover initiates a complete motion. The motion parameter set refers to the combination of parameters required for a single motion, such as target position coordinates, maximum running speed, maximum allowable acceleration, allowable speed and position error thresholds, whether a deceleration section is needed, and the upper limit of the expected motion time. After this initial issuance, the mover does not need to repeatedly receive new position commands during the motion process; instead, it performs motion planning and control locally based on this set of parameters. In practical applications, for example, if a mover on a production line needs to move from a material handling station to an assembly station, the target position can be set to an absolute coordinate of 3,000 millimeters on the track, the maximum speed to 1 meter per second, and the maximum acceleration to 2 meters per second squared. The motion parameter set can then include these constraint data.

[0031] In step S102, the moving end locally generates and tracks the motion trajectory within the first control cycle, and performs multi-loop closed-loop control of position, speed and current according to the motion trajectory.

[0032] In this embodiment, the mover typically integrates a control module and a power drive module. The control module performs closed-loop control in a first control cycle, which can be understood as the sampling and calculation cycle of the current loop or speed loop, for example, selected at the level of 125 microseconds to ensure rapid adjustment of torque current and speed. The mover includes a control module that integrates drive and control. Within the first control cycle, it executes position loop, speed loop, and current loop control sequentially or in parallel according to the locally generated motion trajectory, achieving precise servo control of the moving-coil linear motor.

[0033] In step S103, the moving end reports status data to the controller according to the second reporting cycle, and the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle.

[0034] In this embodiment, to balance real-time performance and communication load, the actuator does not send status data back to the controller in every first control cycle. Instead, it reports status data to the controller in alignment with the second reporting cycle. The second reporting cycle is an integer multiple of the first control cycle. For example, if the first control cycle is 125 microseconds, the second reporting cycle can be set to 4 milliseconds, meaning that status data is reported once every 32 first control cycles. This ensures the timing consistency of information on the control side while avoiding excessively high communication frequency. When each second reporting cycle arrives, the actuator sends the currently summarized status data, such as position, speed, operating mode, and fault flags, to the controller in a unified frame format.

[0035] Step S104: When the mover end or the controller determines that the preset entry conditions are met based on the status data, a graded fault handling is performed. The graded fault handling includes at least: a local emergency stop triggered by the mover end and a full-line emergency stop triggered by the controller. The local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it. The full-line emergency stop is used to issue control commands to other movers that have a motion association with the faulty mover to stop, decelerate, wait, or switch to other transport paths.

[0036] In this embodiment, both the controller and the mover can determine whether an anomaly has occurred based on these status data. When the power supply, position feedback, or motion state of a mover becomes abnormal and reaches a preset entry condition, it is considered that the preset entry condition has been met, triggering a graded fault handling process. Graded fault handling refers to fault handling being divided into different levels of response, including at least a local emergency stop triggered autonomously by the mover and a full-line emergency stop triggered uniformly by the controller. During a local emergency stop, the mover estimates the remaining braking distance at the maximum permissible deceleration based on the current speed and motion parameters; that is, the distance required to decelerate from the current position to a complete stop. Using this remaining braking distance as a constraint, a deceleration trajectory is regenerated, allowing the mover to smoothly decelerate to a stop within the shortest possible distance without position overshoot or excessive braking causing mechanical shock. For example, if the current mover speed is 0.8 meters per second and the maximum permissible deceleration is 2 meters per second squared, the remaining braking distance can be approximately calculated as 0.16 meters. Based on this, the mover plans a deceleration segment with a length of approximately 160 millimeters. In cases of severe malfunctions or interlocking relationships between multiple actuators, the controller can also broadcast an emergency stop command for the entire line, causing all actuators to stop.

[0037] Step S105: After the fault is cleared, the local trajectory tracking and the alignment reporting cycle are restored according to the preset exit conditions, wherein the preset entry / exit conditions are determined at least for the power supply voltage and the position measurement chain status.

[0038] In this embodiment, after the fault is cleared, to avoid jittery recovery, the system resumes its original local trajectory tracking and alignment reporting cycle according to preset exit conditions. These preset exit conditions require a comprehensive assessment of the power supply voltage and the position measurement chain status. For example, the DC bus voltage must return to its rated range and remain stable for a certain period; the position sensor or position measurement chain must return to normal and pass multiple self-checks; and the status data must indicate that the system is in a stable operating state for several consecutive second reporting cycles before the fault is cleared, and the mover is allowed to continue local trajectory tracking and second reporting cycle alignment reporting according to the motion parameter set. This process ensures that task assignment, local control, status reporting, and fault handling work collaboratively under a unified cycle relationship, maintaining predictability and consistency of motion control performance and safety boundaries even in complex operating conditions and scenarios with multiple movers operating concurrently.

[0039] This application enables task assignment, trajectory control, state perception, and safety braking to operate collaboratively under a unified time reference by issuing a set of motion parameters at once, implementing local trajectory control within the first control cycle of the moving part, and aligning the reporting in a second reporting cycle that is an integer multiple of the set. It also incorporates hierarchical fault handling constrained by the remaining braking distance and exit determination based on power supply voltage and position measurement chain status. This significantly improves the timing determinism and consistency of motion and safety behavior of the multi-movement subsystem, reduces the load on communication and host computer, and makes the braking distance and stopping position predictable.

[0040] In some optional implementations of this embodiment, the above-mentioned preset entry conditions include at least: the power supply DC bus voltage is lower than a first voltage threshold; the continuous disconnection time of the position measurement chain is not less than a first cycle counting threshold based on the first control cycle; and the trajectory tracking error exceeds the positioning threshold and remains not lower than a second cycle counting threshold.

[0041] The preset exit condition is that the power supply voltage and position measurement chain status return to normal, and the time for which the status self-test result is continuously stable is not less than the third cycle counting threshold.

[0042] In this embodiment, the preset entry conditions include a DC bus voltage below a first voltage threshold, which can be set, for example, below 40 or 42 volts in a 48-volt system, to identify persistent undervoltage or poor contact. The continuous disconnection time of the position measurement chain is based on the first control cycle, for example, 125 microseconds per cycle. When effective feedback cannot be obtained from the encoder or position sensor for several consecutive cycles, the position measurement chain is considered disconnected. If the number of consecutive disconnection cycles is not less than the first cycle counting threshold, for example, 250 consecutive cycles, a fault state is entered. The trajectory tracking error exceeding the positioning threshold and continuously not lower than the second cycle counting threshold is used to identify situations where the mover deviates from the target trajectory for a long time. For example, the positioning threshold is set to a position error of one millimeter. When the position error continuously exceeds one millimeter for several first control cycles, it is considered that the motion cannot be executed as planned, and fault handling needs to be triggered. The exit conditions require that the power supply voltage and position measurement chain status return to normal, and the status self-check result is continuously stable for a period of time not lower than the third cycle counting threshold. For example, if all key status flags are within the normal range for several consecutive second reporting cycles, the fault is considered to be resolved. By establishing the above entry and exit conditions, we can avoid frequent false triggers caused by momentary interference or short-term fluctuations, and also avoid premature resumption of operation before full recovery, thus giving the graded fault handling clear logical boundaries and repeatable judgment criteria.

[0043] This application refines the preset entry conditions into three types of measurements: DC bus voltage, continuous disconnection time of the position measurement chain, and duration of trajectory tracking error. It sets the entry and exit cycle counting thresholds with the first control cycle as a unified counting benchmark, making fault judgment insensitive to instantaneous disturbances and responding promptly to continuous anomalies. This reduces false alarms and false shutdowns and prevents faults from being ignored for a long time, thereby improving the reliability and stability of graded fault handling.

[0044] In some optional implementations of this embodiment, the step of the aforementioned mover end locally generating and tracking the motion trajectory within the first control cycle, and performing multi-loop closed-loop control of position, speed, and current according to the motion trajectory, includes:

[0045] Under the constraint of jerk limiting, a motion trajectory consisting of multiple smooth curves is generated, and the continuity of velocity and acceleration is ensured at the boundary of adjacent trajectory segments.

[0046] When the entry conditions for local emergency stop are met, the current trajectory is reconstructed into an emergency deceleration profile at the boundary of the most recent second reporting cycle, and deceleration to a stop is completed within the allowable range of the remaining braking distance.

[0047] In this embodiment, when the mover locally generates and tracks the motion trajectory within the first control cycle, it not only calculates the error between the current position and the target position, but also introduces an acceleration limiting constraint during the trajectory planning stage. Acceleration can be understood as the rate of change of acceleration over time, i.e., the amount of acceleration change per unit time. When the acceleration is too large, the combined inertial impact on the mover will increase significantly, easily causing mechanical vibration and structural fatigue. Therefore, when generating a motion trajectory composed of multiple smooth curves, the amplitude of acceleration change can be limited to an allowable range, for example, specifying that the acceleration change per millisecond does not exceed a certain set value, so that each trajectory segment maintains smooth acceleration changes over time. Simultaneously, at the boundaries of adjacent trajectory segments, velocity and acceleration continuity are forcibly guaranteed to avoid sudden jumps in velocity or acceleration when switching between segments. When the local emergency stop entry conditions are met, to ensure that the emergency stop process is aligned with the overall system's timing, it can be agreed to perform trajectory reconstruction at the boundary of the most recent second reporting cycle. That is, at the end of each second reporting cycle, it is determined whether the current trajectory needs to be switched to an emergency deceleration profile. If a switch is needed, the mover generates a controlled-length deceleration trajectory based on the current speed and the estimated remaining braking distance, allowing the mover to smoothly decelerate to a stop within that trajectory. For example, if the second reporting cycle is four milliseconds, this trajectory switch can be completed at the very end of a reporting cycle, thus ensuring that the control side has a clear understanding of the timing of the emergency stop action.

[0048] This application employs a multi-segment smooth curve with limited acceleration variation in the motion trajectory generated locally at the mover end, and reconstructs it into an emergency deceleration profile constrained by the remaining braking distance at the boundary of the most recent second reporting cycle when a local emergency stop is triggered. This achieves smooth motion and minimal mechanical impact during normal operation, and can quickly switch to a safe deceleration trajectory at the moment of alignment with the system cycle in abnormal situations, thus balancing operational efficiency with controllability and predictability during emergency stops.

[0049] In some optional implementations of this embodiment, when the aforementioned mover reports status data to the controller according to the second reporting cycle, the status data carries a timestamp and a beat number. The controller aggregates the status data of multiple movers within a preset alignment time window, updates the scheduling and interlocking decisions only at the boundary of adjacent second reporting cycles, and treats late status data that exceeds the alignment time window as degraded data and does not participate in the current aggregation.

[0050] In this embodiment, when the mover reports status data to the controller according to the second reporting cycle, the status data carries a timestamp and a beat number to enable the controller to accurately identify the acquisition time and position of each mover's status data on the entire time axis. The timestamp can be a time count value under a unified time base, and the beat number can be incremented according to the second reporting cycle. The controller aggregates the status data of multiple movers within a preset alignment time window. For example, an alignment window is set based on the time length of each second reporting cycle. Scheduling and interlocking decisions are only made when status data from multiple movers are received within this window. It is agreed that these decision results are updated only at the boundaries of adjacent second reporting cycles. This ensures that all system decisions are strictly aligned to a unified beat boundary, avoiding misalignment of decision times between different movers. Late status data that exceeds the alignment time window can be treated as degraded data, for example, only used for recording or alarming, and not involved in the current scheduling and interlocking decision, to avoid late data disrupting beat consistency. Through the above method, the time consistency and decision determinism of the entire system under multi-motor concurrency can be improved.

[0051] This application improves the time consistency and security of multi-sub-scheduling and interlocking control by including timestamps and beat numbers in the status data, aggregating multiple sub-states within the aligned time window, updating scheduling and interlocking decisions only at the boundary of the second reporting cycle, and downgrading late status data. This allows the host computer to perceive the status of the entire line on a unified time window, avoiding inconsistencies in decisions caused by communication jitter and individual late data.

[0052] In some optional implementations of this embodiment, before the aforementioned mover terminal locally generates and tracks the motion trajectory within the first control cycle, and performs multi-loop closed-loop control of position, speed, and current according to the motion trajectory, the method further includes:

[0053] Calculate the contact health value based on the DC bus voltage ripple amplitude and current change rate within the sliding window;

[0054] When the contact health value is lower than the second threshold, the actuator automatically reduces the maximum allowable speed limit to the derating speed limit and reports a pre-fault code to the controller.

[0055] When the contact health value continuously falls below the second threshold and reaches the second cycle count threshold, the controller is requested to assign the nearest safe docking area and use that safe docking area as the new target location.

[0056] In this embodiment, the conveying system adopts a moving-coil linear magnetic drive structure. The mover integrates a coil and a drive control module, requiring continuous power supply from the DC bus via a sliding contact power supply structure (e.g., a conductive track with brush assembly or conductive slider) arranged along the conveying line. Since the sliding contact is susceptible to wear, contamination, or contact pressure fluctuations during long-term operation, changes in its contact state directly manifest as increased DC bus voltage ripple, short-term voltage drops, and abnormal current changes, thus posing a threat to the mover's motion stability and safe shutdown capability. Therefore, before the mover begins locally generating and tracking the motion trajectory, the power supply quality is first assessed. Based on the bus voltage and current data collected over a period of time, a contact health value is calculated, and a decision is made regarding whether derated operation or guiding the mover to a safe stopping area is necessary to reduce the risk of sudden power outages or loss of control due to poor sliding contact. Specifically, sampling values ​​of the DC bus voltage and corresponding current values ​​can be collected within a certain number of first control cycles to form a sliding window; the voltage fluctuation amplitude and current change rate within this window are calculated to reflect the stability of the sliding contact. For example, if the voltage ripple amplitude increases significantly and the current change rate is abnormal, it can be determined that the contact health value has decreased. The above calculation results are normalized to a contact health value. When this value is lower than the second threshold, the mover automatically reduces the maximum permissible speed limit to the derating speed limit, for example, reducing the original one meter per second limit to 0.6 meters per second, to reduce the instantaneous load on the power supply under operating conditions. Simultaneously, the mover can report a pre-fault code to the controller, indicating a trend of poor contact in the system. If the contact health value continuously falls below the second threshold to the second cycle counting threshold, for example, if the health value remains substandard for several consecutive second reporting cycles, the mover can request the controller to assign the nearest safe stopping area to the mover, such as a buffer area on the track, as a temporary stopping point. This safe stopping area is then used as the new target location. The mover then runs to the safe stopping area at a lower speed and stops, thus completing an orderly shutdown before the contact condition deteriorates further.

[0057] This application constructs a contact health value by utilizing the DC bus voltage ripple amplitude and current change rate. When the health value decreases, it first reduces the rated speed and reports a pre-fault code. When the condition continues to deteriorate, it requests the nearest safe stopping area as the new movement target. This transforms the degradation of sliding contact into a process of early warning, gradual rated reduction, and planned stopping, reducing the risk of sudden shutdowns caused by poor contact and the impact on production cycle. At the same time, it provides maintenance personnel with a clear basis for diagnosis and handling.

[0058] In some optional implementations of this embodiment, before the step of automatically reducing the maximum permissible speed limit to the derating speed limit and reporting a pre-fault code to the controller when the contact health value is lower than the second threshold, the method further includes:

[0059] The downward trend of the DC bus voltage sliding window sequence is predicted. When it is predicted that the voltage will be lower than the first voltage threshold in the first time window, the current motion trajectory is reconstructed into a safe deceleration trajectory in advance, so that the mover enters the local emergency stop preparation state and deceleration is performed at the boundary of the next second reporting cycle.

[0060] In this embodiment, based on the aforementioned contact health assessment, to further enhance the proactive handling capability for power supply risks, a downward trend prediction can be performed on the sliding window sequence of the DC bus voltage at the mover end. This involves not only checking if the current voltage value is below a certain threshold, but also analyzing the voltage value's changing trend over a period of time to determine whether it is likely to fall below the first voltage threshold in the near future. Specifically, linear fitting or other trend analysis can be performed on the voltage sequence within the sliding window to obtain the predicted voltage for a future period. When the prediction result shows that the voltage will be below the first voltage threshold within the first time window (e.g., the sum of several second reporting cycles), a safety procedure is triggered in advance: the current motion trajectory is reconstructed into a safe deceleration trajectory, causing the mover to enter a local emergency stop preparation state in advance. That is, while maintaining cycle alignment, the deceleration segment and stopping position are planned in advance, and deceleration begins at the boundary of the next second reporting cycle. In this way, even if the actual voltage has not yet fallen below the first voltage threshold, the risk of sudden undervoltage leading to loss of control can be reduced by decelerating and preparing to stop in advance.

[0061] This application predicts the downward trend of the DC bus voltage sliding window sequence, reconstructs the safe deceleration trajectory in advance when the first voltage threshold is about to be reached, and puts the mover into a local emergency stop preparation state. The deceleration execution time is aligned with the boundary of the subsequent second reporting cycle, so that the system can move the passive undervoltage emergency stop that originally relied on threshold triggering forward into an active and smooth pre-deceleration process, reducing the occurrence of undervoltage impact and unplanned shutdown, and further enhancing the safety redundancy in power supply abnormality scenarios.

[0062] In some optional implementations of this embodiment, in the steps of generating and tracking the motion trajectory locally within the first control cycle and performing multi-loop closed-loop control of position, speed and current according to the motion trajectory, when the continuous disconnection time of the position measurement chain is not less than the second cycle counting threshold, the system switches to a degraded operation mode based solely on motion model calculation and limits the maximum allowable speed.

[0063] In this embodiment, during the local generation and tracking of the motion trajectory at the mover end in the first control cycle, if the continuous disconnection time of the position measurement chain is not less than the second cycle counting threshold, it does not immediately stop. Instead, it switches to a degraded operation mode based solely on motion model estimation and limits the maximum allowable speed. The position measurement chain includes position sensors, encoders, and related acquisition lines. If the system immediately stops when a short-term interference causes feedback interruption, it may cause unnecessary impact on the production cycle. Therefore, within a set time, such as several first control cycles, if the position measurement chain is only temporarily disconnected, it can continue to wait for recovery. When the number of consecutive disconnection cycles reaches the second cycle counting threshold, it is considered that the position measurement chain is indeed in an abnormal state. At this time, it switches to a mode that relies solely on the motion model for position estimation. The so-called motion model estimation can be obtained by integrating the speed commands and acceleration estimates of the recent period to obtain an estimate of the current position. At the same time, the maximum operating speed limit is further reduced to reduce the risk caused by the accumulation of position estimation errors. In this degraded mode, the mover can maintain operation at a lower speed for a period of time, such as until it reaches a predetermined buffer zone or safe stopping area. Once the position measurement chain returns to normal, it can then be restored to normal closed-loop control through subsequent position correction methods. This tiered approach, compared to immediately stopping when position feedback is lost, is more conducive to ensuring both safety and production continuity.

[0064] This application switches to a degraded operation mode based solely on motion model calculations after the position measurement chain continuously loses connection and reaches the second cycle counting threshold, while limiting the maximum allowable speed. This allows the system to continue performing necessary actions under controlled speed and limited accuracy without immediate shutdown when position measurement is short-term or locally abnormal, while keeping the risk within an acceptable range. It also provides a buffer for subsequent measurement recovery and position correction, improving the overall line's fault tolerance to sensor link failures.

[0065] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by instructing related hardware through computer-readable instructions. These computer-readable instructions can be stored in a computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above methods. The aforementioned storage medium can be a non-volatile storage medium such as a magnetic disk, optical disk, or read-only memory (ROM), or random access memory (RAM).

[0066] It should be understood that although the steps in the flowcharts of the accompanying figures are shown sequentially as indicated by the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the accompanying figures may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same time, but can be executed at different times, and their execution order is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the sub-steps or stages of other steps.

[0067] Further reference Figure 2 As a response to the above Figure 1 The implementation of the method shown in this application provides an embodiment of a distributed motion control system for a multi-actuator linear magnetic drive conveyor system. This system embodiment is similar to... Figure 1 Corresponding to the method embodiments shown, the system can be specifically applied to various electronic devices.

[0068] like Figure 2 As shown, the distributed motion control system 200 of the multi-moving linear magnetic drive conveyor system described in this embodiment includes: a distribution module 201, a generation module 202, a reporting module 203, an execution module 204, and a recovery module 205. Wherein:

[0069] The sending module 201 is configured to allow the controller to send a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters.

[0070] The generation module 202 is configured to generate and track the motion trajectory locally at the mover end during the first control cycle, and perform multi-loop closed-loop control of position, speed and current according to the motion trajectory;

[0071] The reporting module 203 is configured to report status data to the controller according to the second reporting cycle, wherein the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle;

[0072] The execution module 204 is configured to perform graded fault processing when the mover end or the controller determines that the state data meets the preset entry conditions. The graded fault processing includes at least: local emergency stop triggered by the mover end and full-line emergency stop triggered by the controller, wherein the local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it.

[0073] The recovery module 205 is configured to restore the local trajectory tracking and the alignment reporting cycle according to preset exit conditions after the fault is cleared, wherein the preset entry / exit conditions are determined at least for the power supply voltage and the position measurement chain status.

[0074] The distributed motion control system of the multi-motor linear magnetic drive conveyor system provided in this embodiment of the invention can realize all the processes of the distributed motion control method of the multi-motor linear magnetic drive conveyor system in the above embodiment. The functions and technical effects of each module in the device are the same as the functions and technical effects of the distributed motion control method of the multi-motor linear magnetic drive conveyor system in the above embodiment, and will not be repeated here.

[0075] To address the aforementioned technical problems, embodiments of this application also provide a computer device. Please refer to [link / reference needed] for details. Figure 3 , Figure 3 This is a basic structural block diagram of the computer device in this embodiment.

[0076] The computer device 3 includes a memory 31, a processor 32, and a network interface 33 that are interconnected via a system bus. It should be noted that only the computer device 3 with components 31-33 is shown in the figure; however, it should be understood that it is not required to implement all the shown components, and more or fewer components can be implemented alternatively. Those skilled in the art will understand that the computer device described here is a device capable of automatically performing numerical calculations and / or information processing according to pre-set or stored instructions, and its hardware includes, but is not limited to, microprocessors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), embedded devices, etc.

[0077] The computer device can be a desktop computer, laptop, handheld computer, or cloud server, etc. The computer device can interact with the user via a keyboard, mouse, remote control, touchpad, or voice control.

[0078] The memory 31 includes at least one type of readable storage medium, including flash memory, hard disk, multimedia card, card-type memory (e.g., SD or DX memory), random access memory (RAM), static random access memory (SRAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), programmable read-only memory (PROM), magnetic memory, disk, optical disk, etc. In some embodiments, the memory 31 may be an internal storage unit of the computer device 3, such as the hard disk or memory of the computer device 3. In other embodiments, the memory 31 may also be an external storage device of the computer device 3, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the computer device 3. Of course, the memory 31 may also include both the internal storage unit and its external storage device of the computer device 3. In this embodiment, the memory 31 is typically used to store the operating system and various application software installed on the computer device 3, such as computer-readable instructions for a distributed motion control method of a multi-motor linear magnetic drive conveyor system. In addition, the memory 31 can also be used to temporarily store various types of data that have been output or will be output.

[0079] In some embodiments, the processor 32 may be a central processing unit (CPU), controller, microcontroller, microprocessor, or other data processing chip. The processor 32 is typically used to control the overall operation of the computer device 3. In this embodiment, the processor 32 is used to execute computer-readable instructions stored in the memory 31 or to process data, such as computer-readable instructions for executing the distributed motion control method of the multi-actuator linear magnetic drive conveyor system.

[0080] The network interface 33 may include a wireless network interface or a wired network interface, which is typically used to establish communication connections between the computer device 3 and other electronic devices.

[0081] This application also provides another embodiment, namely, providing a computer-readable storage medium storing computer-readable instructions that can be executed by at least one processor to cause the at least one processor to perform the steps of the distributed motion control method for the multi-motor linear magnetic drive conveyor system described above.

[0082] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal device (which may be a mobile phone, computer, server, air conditioner, or network device, etc.) to execute the methods described in the various embodiments of this application.

[0083] The above are merely preferred embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A distributed motion control method for a multi-motor linear magnetic drive conveyor system, characterized in that, Includes the following steps: The controller issues a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters. The moving end locally generates and tracks the motion trajectory within the first control cycle, and performs multi-loop closed-loop control of position, speed and current according to the motion trajectory; The moving part reports status data to the controller according to the second reporting cycle, and the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle. When the moving part reports status data to the controller according to the second reporting cycle, the status data carries a timestamp and a beat number. The controller aggregates the status data of multiple moving parts within a preset alignment time window, updates the scheduling and interlocking decisions only at the boundary of adjacent second reporting cycles, and treats late status data that exceeds the alignment time window as degraded data and does not participate in the current aggregation. The timestamp adopts a time count value under a unified time base, and the beat number is incremented according to the second reporting cycle. When the mover end or controller determines that the preset entry conditions are met based on the state data, graded fault handling is performed. The graded fault handling includes at least: local emergency stop triggered by the mover end and full-line emergency stop triggered by the controller. The local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it. The full-line emergency stop is used to issue control commands to other movers that have motion association with the faulty mover to stop, decelerate, wait or switch to other transport paths. After the fault is cleared, the system recovers to the following state based on the preset exit conditions: the moving end generates and tracks the motion trajectory locally within the first control cycle, and performs multi-loop closed-loop control of position, speed and current according to the motion trajectory; and the moving end reports status data to the controller according to the second reporting cycle, and the controller only updates the scheduling and interlocking decisions at the boundary of adjacent second reporting cycles, wherein the preset entry / exit conditions are determined at least for the power supply voltage and position measurement chain status.

2. The method according to claim 1, characterized in that, The preset entry conditions include at least the following: the DC bus voltage is lower than the first voltage threshold; the continuous disconnection time of the position measurement chain is not less than the first cycle counting threshold based on the first control cycle; and the trajectory tracking error exceeds the positioning threshold and remains not lower than the second cycle counting threshold. The preset exit condition is that the power supply voltage and position measurement chain status return to normal, and the time for which the status self-test result is continuously stable is not less than the third cycle counting threshold.

3. The method according to claim 2, characterized in that, The step of the mover terminal locally generating and tracking the motion trajectory within the first control cycle, and performing multi-loop closed-loop control of position, speed, and current according to the motion trajectory, includes: Under the constraint of jerk limiting, a motion trajectory consisting of multiple smooth curves is generated, and the continuity of velocity and acceleration is ensured at the boundary of adjacent trajectory segments. When the entry conditions for local emergency stop are met, the current trajectory is reconstructed into an emergency deceleration profile at the boundary of the most recent second reporting cycle, and deceleration to a stop is completed within the allowable range of the remaining braking distance.

4. The method according to claim 3, characterized in that, Before the step of the mover terminal locally generating and tracking the motion trajectory within the first control cycle, and performing multi-loop closed-loop control of position, speed, and current according to the motion trajectory, the method further includes: Calculate the contact health value based on the DC bus voltage ripple amplitude and current change rate within the sliding window; When the contact health value is lower than the second threshold, the actuator automatically reduces the maximum allowable speed limit to the derating speed limit and reports a pre-fault code to the controller. When the contact health value continuously falls below the second threshold and reaches the second cycle count threshold, the controller is requested to assign the nearest safe docking area and use that safe docking area as the new target location.

5. The method according to claim 4, characterized in that, Before the step of automatically reducing the maximum permissible speed limit to the derating speed limit and reporting a pre-fault code to the controller when the contact health value is lower than the second threshold, the method further includes: The downward trend of the DC bus voltage sliding window sequence is predicted. When it is predicted that the voltage will be lower than the first voltage threshold in the first time window, the current motion trajectory is reconstructed into a safe deceleration trajectory in advance, so that the mover enters the local emergency stop preparation state and deceleration is performed at the boundary of the next second reporting cycle.

6. The method according to claim 2, characterized in that, In the process of generating and tracking the motion trajectory locally within the first control cycle and performing multi-loop closed-loop control of position, speed and current according to the motion trajectory, when the continuous disconnection time of the position measurement chain is not less than the second cycle counting threshold, it switches to a degraded operation mode based solely on motion model calculation and limits the maximum allowable speed.

7. A distributed motion control system for a multi-motor linear magnetic drive conveyor system, characterized in that, include: The distribution module is configured so that the controller distributes a set of motion parameters for a single motion process to the target mover at one time. The set of motion parameters includes at least the target position and motion constraint parameters. The generation module is configured to generate and track the motion trajectory locally at the mover end within the first control cycle, and perform multi-loop closed-loop control of position, speed and current according to the motion trajectory; The reporting module is configured to have the moving part report status data to the controller according to a second reporting cycle, wherein the first control cycle is less than the second reporting cycle, and the second reporting cycle is an integer multiple of the first control cycle. When the moving part reports status data to the controller according to the second reporting cycle, the status data carries a timestamp and a beat number. The controller aggregates the status data of multiple moving parts within a preset alignment time window, updates the scheduling and interlocking decisions only at the boundary of adjacent second reporting cycles, and treats late status data that exceeds the alignment time window as degraded data and does not participate in the current aggregation. The timestamp adopts a time count value under a unified time base, and the beat number is incremented according to the second reporting cycle. The execution module is configured to perform graded fault handling when the mover end or the controller determines that the state data meets the preset entry conditions. The graded fault handling includes at least: a local emergency stop triggered by the mover end and a full-line emergency stop triggered by the controller. The local emergency stop generates a deceleration profile based on the remaining braking distance of the mover and executes it. The full-line emergency stop is used to issue control commands to other movers that have a motion association with the faulty mover to stop, decelerate, wait, or switch to other transport paths. The recovery module is configured to restore the system to the following state after the fault is cleared, based on preset exit conditions: the moving end locally generates and tracks the motion trajectory within the first control cycle, and performs multi-loop closed-loop control of position, speed and current according to the motion trajectory; and the moving end reports status data to the controller according to the second reporting cycle, and the controller only updates the scheduling and interlocking decisions at the boundary of adjacent second reporting cycles, wherein the preset entry / exit conditions are determined at least for the power supply voltage and the position measurement chain status.

8. A computer device, characterized in that, The system includes a memory and a processor, wherein the memory stores computer-readable instructions, and the processor executes the computer-readable instructions to implement the steps of the distributed motion control method for the multi-motor linear magnetic drive conveyor system as described in any one of claims 1 to 6.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-readable instructions, which, when executed by a processor, implement the steps of the distributed motion control method for the multi-motor linear magnetic drive conveyor system as described in any one of claims 1 to 6.

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