Audio equipment attitude resolving and emergency response control system oriented to unsteady state working condition

Abstract

The invention relates to the technical field of automatic control and precision detection, and discloses an audio equipment attitude resolving and emergency response control system for an unsteady working condition, which comprises an audio transduction unit, an audio acquisition unit, an attitude resolving processor and an emergency control module, the audio transduction unit emits an ultrasonic pulse of which the center frequency is not lower than 20kHz to a coupling gap between the controlled parts; the audio acquisition unit acquires a characteristic acoustic signal modulated by a physical interface; the attitude resolving processor compares the transmitting and receiving phases to determine a phase deviation vector, rejects interference components according to a fluid attenuation mapping relation, and generates attitude variables; the emergency control module converts attitude variables into driving pulses, the cavity pressure of an execution mechanism is changed and a dynamic rigidity buffer area is constructed by adjusting the current change rate of a driving coil, a response window is compressed to the microsecond magnitude through an acoustic phase locking mechanism, attitude correction is achieved before stress waves are conducted, and the dynamic rigidity buffer area is constructed. And the stability of the system in operation is effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of automatic control and precision detection technology, and in particular relates to an audio device attitude calculation and emergency response control system for non-steady-state working conditions. Background Technology

[0002] In current metal rolling production, maintaining the geometric stability between the actuator and the controlled component is a core element in ensuring the system's operational accuracy and the quality of automated operations. Position information of the controlled object is collected by displacement sensors, driving the servo actuator to adjust the target's posture. However, traditional control logic often struggles to balance the real-time requirements of signal sampling frequency and closed-loop feedback when facing unsteady conditions. This control method relies on the sampling accuracy of the sensors and the closed-loop response speed of the control system to maintain a constant roll gap. The propagation characteristics of sound waves in a quasi-enclosed space are modulated by spatial boundary conditions. When the geometric dimensions of the resonant cavity formed by the roll and bearing housing change by micrometers, the resonant frequency and the phase of the sound field shift by physical magnitude. Utilizing the physical coupling of acoustic characteristics and the mechanical structure's posture can provide a data foundation for non-contact posture sensing.

[0003] However, when the controlled system is in non-steady-state conditions such as start-stop, speed change, or sudden load impact, the operating environment is accompanied by strong mechanical vibration and environmental interference. Traditional laser sensors or magnetostrictive sensors will produce signal aliasing or sampling distortion under these conditions, resulting in reduced feedback signal accuracy. Due to data processing delays in the control loop and the inherent inertia of the hydraulic system, the compensation action usually lags behind the impact interference, creating a time delay gap between sensing and execution. This mismatch in the response window causes transient fluctuations in the strip in the thickness direction, and may even induce strip wrinkles. Increasing the sensor sampling frequency or increasing the physical rigidity of the frame are common approaches in the industry to alleviate these problems. Increasing the sampling frequency fails to eliminate the cumulative time delay of signal processing and actuator start-up, while increasing the frame weight increases the equipment construction cost and does not change the fundamental nature of poor dynamic response matching of large inertial systems. The rigidity of the frame is difficult to eliminate control delay, and software control methods also have shortcomings. For example, Chinese invention patent CN106825065B discloses a method for controlling the roll gap of a rolling mill. It calculates the rolling force by summing and averaging the pressure values ​​at the upper roll plunger end, the lower roll plunger end, and the frame end, and substitutes them into the bounce equation to calculate the real-time deformation of the frame. Although this feedback logic based on multiple corrections of pressure signals reduces the error of a single sensing point, it is a passive response after stress occurs. Under unsteady conditions, there is a physical time delay in the transmission of mechanical stress waves from the contact interface to the pressure sensor. It cannot overcome the inherent inertial lag of the hydraulic system and is difficult to achieve microsecond-level transient pre-control. This scheme relies on the stability of hydraulic medium pressure and lacks physical means to remove signal pseudo-deviations caused by oil mist fluctuations and fluid attenuation during rolling. This results in frequency redundancy or phase mismatch in compensation commands under harsh environments.

[0004] Therefore, the technical problem to be solved by this invention is how to design an audio device attitude calculation and emergency response control system for non-steady-state operating conditions, so as to eliminate the time delay gap between perception and execution and enhance the control stability of the system in complex environments. Summary of the Invention

[0005] This invention provides an audio device attitude calculation and emergency response control system for non-steady-state operating conditions. The system includes: an audio transducer unit, an audio acquisition unit, an attitude calculation processor, and an emergency control module.

[0006] The audio transducer unit is located on the side of the support base and is used to transmit an ultrasonic pulse sequence with a center frequency of not less than 20kHz to the controlled coupling gap between the controlled moving parts;

[0007] The audio acquisition unit is used to acquire the characteristic acoustic signal modulated by the physical interface within the controlled coupling gap;

[0008] The attitude calculation processor includes a phase difference resolution unit and a feature stripping unit. The phase difference resolution unit is used to compare the initial transmission phase of the ultrasonic pulse sequence with the real-time received phase of the characteristic acoustic signal to calculate the phase deviation vector characterizing the deflection of the controlled moving part. The feature stripping unit is used to monitor the amplitude envelope fluctuation of the characteristic acoustic signal, determine the interference component according to the preset fluid attenuation mapping relationship, and remove the interference component from the phase deviation vector to generate a high-fidelity attitude variable.

[0009] The emergency control module is connected to the attitude calculation processor to convert high-fidelity attitude variables into drive pulses for the position adjustment actuator. The emergency control module adjusts the rate of change of current in the servo valve drive coil to change the cavity pressure of the position adjustment actuator, thereby counteracting the deflection of the controlled moving parts and constructing a dynamic stiffness buffer.

[0010] Preferably, the emergency control module includes an energy flow gradient monitoring unit; in the context of characteristic acoustic signal input, the energy flow gradient monitoring unit is used to extract the energy gradient of the characteristic acoustic signal and determine the heterogeneous pulse at the controlled interface; when the energy gradient of the heterogeneous pulse at the controlled interface exceeds the preset locking threshold, the emergency control module enters the prestress locking mode before the output result of the phase difference analysis unit, and drives the position adjustment actuator to generate a preset pressure opposite to the deflection direction through the preset response gain.

[0011] Preferably, the audio acquisition unit includes a sound wave envelope discrimination module; the sound wave envelope discrimination module is used to analyze the energy spectrum envelope of the acoustic signal modulated by the physical interface, and to obtain the sound pressure distribution anomaly under the stress state of the controlled processed material; the sound wave envelope discrimination module calculates the asymmetry factor according to a preset discrimination criterion. The calculation formula is: ,in, The integral value of the acoustic field energy on the left side of the controlled coupling gap between the controlled moving parts, in J, is given by the emergency control module based on the asymmetry factor. The numerical adjustment position adjusts the left and right control gain of the actuator.

[0012] Preferably, based on the output of the phase difference resolution unit, the attitude calculation processor further includes an intrinsic frequency compensation unit; the intrinsic frequency compensation unit is used to extract the structural intrinsic frequency components in the characteristic acoustic signal and compare the deviation trend between the structural intrinsic frequency components and the main resonant frequency; the intrinsic frequency compensation unit determines the geometric drift of the controlled moving part according to the deviation trend and the preset thermal expansion image relationship, and feeds back the geometric drift as a background compensation reference to the phase difference resolution unit.

[0013] Preferably, the attitude calculation processor includes a reverberation analysis module; the reverberation analysis module is used to control the audio transducer unit to apply electroacoustic pulse excitation and obtain the reverberation attenuation slope of the characteristic acoustic signal in the controlled coupling gap between the controlled moving parts; the reverberation analysis module characterizes the micro-stiffness distribution of the contact interface of the controlled coupling gap between the controlled moving parts according to the reverberation attenuation slope, and transmits the micro-stiffness distribution to the emergency control module to adjust the servo response step size.

[0014] Preferably, the audio acquisition unit is provided with a high-frequency noise filtering layer; the high-frequency noise filtering layer is used to monitor the energy level distribution of characteristic acoustic signals outside the 100kHz frequency band, identify and eliminate periodic interference noise generated by the mechanical transmission system associated with the support base, and input the purified acoustic features to the phase difference resolution unit.

[0015] Preferably, a high-frequency pulse drive unit is connected between the emergency control module and the servo valve drive coil; the high-frequency pulse drive unit is used to convert the emergency control command into a pulse width modulation signal, and to achieve discrete control of the displacement of the position adjustment actuator limited by a preset control cycle of 50ms by controlling the on and off timing of the power switching device.

[0016] Preferably, the system includes a dual-redundancy verification unit; the dual-redundancy verification unit is used to compare the high-fidelity attitude variables output by the attitude calculation processor with the preset safe attitude envelope; when the high-fidelity attitude variables exceed the safe attitude envelope for three consecutive sampling periods, the dual-redundancy verification unit cuts off the main circuit of the emergency control module and outputs a fault shutdown command.

[0017] Preferably, the audio acquisition units are distributed on the upper and lower sides of the horizontal axis of the controlled moving part, forming a differential sensing array; the phase difference resolution unit performs differential operations on the multiple acoustic signals captured by the differential sensing array to eliminate the common mode interference caused by the overall vibration of the support base and extract the relative deflection angle of the controlled moving part relative to the reference position.

[0018] Preferably, the emergency control module includes a gain adaptive adjustment unit; the gain adaptive adjustment unit is used to determine the initial servo gain based on the moving speed and thickness of the controlled material and according to a preset linear response curve; when the attitude calculation processor detects that the load reaction force fluctuation rate exceeds a preset threshold, the gain adaptive adjustment unit increases the system transient response stiffness by increasing the current proportional control coefficient of the servo valve drive coil.

[0019] Compared with existing technologies, the audio device attitude calculation and emergency response control system of this invention for unsteady-state operating conditions has the following advantages:

[0020] 1. In the attitude calculation of audio equipment, a displacement-to-frequency mapping control mechanism based on the acoustic resonance principle is constructed. By utilizing the quasi-closed acoustic resonant cavity formed by the end face of the roll and the bearing seat, the extremely small mechanical attitude deviation is directly modulated into the intrinsic frequency drift and phase shift of the high-frequency sound wave, breaking the bottleneck of the limited sampling frequency of traditional contact or optical sensors in strong vibration and high-obscurity environments. The system adopts a phase-locked loop to directly convert the real-time acquired phase deviation into the command current change rate of the hydraulic servo mechanism, so that the generation and execution of the control response no longer lag behind the generation of the deviation. In the process of mechanical stress wave transmission to the equipment frame, attitude correction is completed synchronously, thereby improving the quasi-instantaneous self-stabilization capability of the adjustment system under non-steady-state conditions.

[0021] 2. The system establishes a fixed-distance reference sound path independent of the main measurement path by setting a fixed-position reflective reference component inside the attitude sensing array. By monitoring the change in signal propagation delay within the reference sound path, the system calculates the fluctuation law of the medium sound velocity in the current environment in real time and generates a compensation operator. This not only eliminates the acoustic characteristic drift caused by temperature changes and oil mist spraying during the rolling process, but also uses multi-band differential impedance detection technology to utilize the sensitivity of specific frequency bands to the absorption characteristics of lubricating oil film, physically separating the amplitude interference caused by oil film thickness fluctuations from the geometric attitude variables. This ensures the decision-making accuracy of the control system under extreme working conditions and avoids malfunctions of the actuators caused by environmental spurious signals.

[0022] 3. The system introduces a collaborative pre-control mechanism that combines acoustic envelope asymmetric distortion discrimination with energy flow gradient monitoring. By analyzing the acoustic signal energy spectrum envelope modulated by the roll interface, it captures the microscopic acoustic pressure distribution anomalies caused by uneven strip stress and identifies fault precursors in the very early stage before the geometric attitude deflects beyond the limit. Combined with real-time extraction of acoustic signal energy gradient, when a sudden load pulse such as the passage of a metal joint is detected, the emergency control module can be triggered to enter the prestress locking mode before the attitude calculation results. By constructing a dynamic stiffness buffer through the pre-driven actuator, a leap from passive error compensation to causal-driven pre-control is achieved, reducing the fatigue loss of precision rolls under mechanical impact loads. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the attitude calculation and emergency response closed-loop control principle of the acoustic interface modulation of the present invention;

[0024] Figure 2 This is a flowchart of the dual-path parallel pre-control process of the present invention, which integrates energy flow gradient locking and phase calculation. Detailed Implementation

[0025] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0026] It should be noted that all directional and positional terms used in this invention, such as: up, down, left, right, front, back, vertical, horizontal, inner, outer, top, bottom, transverse, longitudinal, center, etc., are only used to explain the relative positional relationship and connection between components in a specific state (as shown in the accompanying drawings). They are only for the convenience of describing this invention and do not require that this invention be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention. In addition, the descriptions of "first," "second," etc., in this invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated.

[0027] In the description of this invention, unless otherwise explicitly specified and limited, the terms installation, connection, and linking should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0028] In the description of this specification, references to the terms "an embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example, and the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0029] This invention provides an audio device attitude calculation and emergency response control system for unsteady-state operating conditions, comprising a physical sensing layer, a signal processing layer, and an execution control layer coupled together. The physical sensing layer acquires real-time physical boundary information by constructing an acoustic monitoring field within the controlled coupling gap between controlled moving parts. The signal processing layer uses an attitude calculation processor to perform multi-dimensional analysis on the captured characteristic acoustic signals to extract high-fidelity attitude variables. The execution control layer, through an emergency control module, converts the high-fidelity attitude variables into drive pulses for the position adjustment actuator, thereby generating pose correction for the controlled moving parts under unsteady-state operating conditions. In conjunction with dynamic stiffness construction, the data flow of the entire system follows a logical closed loop from physical displacement modulation of the controlled coupling gap to acoustic feature analysis, and then to hydraulic servo execution. In the operation of precision industrial equipment such as metal rolling mills, the controlled coupling gap between the rolls and bearing housings often faces unsteady-state interference caused by mechanical vibration, oil mist spraying, and sudden load impacts. This condition leads to signal aliasing in conventional optical sensors, and the sampling bandwidth cannot cover the propagation velocity of mechanical stress waves. The system places the audio transducer unit on the side of the support base, transmitting a center frequency of not less than [a certain value] into the controlled coupling gap between the controlled moving parts. The ultrasonic pulse sequence, with the controlled coupling gap acting as a quasi-closed acoustic resonant cavity, allows the microscopic displacement of the roll end face to directly act on the acoustic boundary, thereby modulating the sound wave. The characteristic acoustic signal modulated by the physical interface within the controlled coupling gap is acquired by the audio acquisition unit. This sensing method converts micron-level mechanical deviations into high-frequency electroacoustic characteristics, solving the problem of limited sampling frequency of conventional displacement sensors under harsh working conditions.

[0030] To address the attitude deviations generated by controlled moving parts during high-speed operation, the system utilizes a phase-locked mechanism for calculation. Specifically, the phase difference analysis unit within the attitude calculation processor employs zero-point detection logic, acquiring the echo voltage sequence output by the audio acquisition unit via a high-speed analog-to-digital converter, and identifying the time difference between two consecutive zero-crossing points in the echo voltage sequence. and compare it with the standard period provided by the synchronous clock source. The phase deviation vector is calculated by comparing the two values ​​using the formula. : ,in, The phase deviation vector characterizes the deflection of the controlled moving part, and its unit is radians; The zero-crossing delay of the echo is expressed in units of 1 / 2000. ; The preset period of the ultrasound pulse sequence, in units of The phase difference analysis unit calculates the spatial position deviation of the roll relative to the preset centerline by performing differential operations on the phase offset difference between the transmission side and the operation side of the rolling mill. It also captures early mechanical attitude deviations by utilizing the high-frequency phase characteristics of the acoustic signal. Considering that fluctuations in the lubricating oil film during rolling can cause nonlinear attenuation of the acoustic energy field, this interference component, if not eliminated, will induce malfunctions in the control system. Therefore, the system employs a feature stripping unit to monitor the amplitude envelope fluctuations of the characteristic acoustic signal and determines the interference component based on a preset fluid attenuation mapping relationship. This fluid attenuation mapping relationship is established through an offline calibration process, i.e., recording the absorption coefficients of lubricating media of different concentrations and thicknesses for specific frequency sound waves under a constant controlled coupling gap. The system will collect the characteristic acoustic signal amplitude Compared with standard amplitude The difference is substituted into the compensation operator to remove the interference component from the phase deviation vector, generating a high-fidelity attitude variable. When a sudden change in the lubricating oil mist concentration within the controlled coupling gap is detected, the feature stripping unit determines the function based on the absorption coefficient. The energy gain term in the phase deviation vector is corrected to ensure that the output attitude variable is driven only by changes in physical geometric position; the fluid attenuation mapping procedure is established as follows: [The text abruptly ends here, likely due to an incomplete translation or source material.] At the reference position, inject concentration steps into the gap. And the scope covers to Lubricating oil mist, record the characteristic acoustic signal voltage amplitude at each concentration point. The processor will measure the voltage amplitude. Compared with the standard amplitude of the initial no-load state Comparison calculation of absorption coefficient The calculation formula is: ,in Absorption coefficient, unit , Standard amplitude, unit , Real-time voltage amplitude, unit The absorption coefficient was established by first-order linear fitting. With oil mist concentration The mapping function subtracts the phase offset pseudo-variable introduced by the change in lubricating medium concentration in real time based on the fluctuation of the detected voltage amplitude.

[0031] When dealing with sudden load impacts such as those from strip joints, conventional hydraulic control circuits experience response delays due to sampling processing and mechanical inertia. To achieve pre-control before stress waves reach the frame, an emergency control module establishes a high-speed command channel. This module converts high-fidelity attitude variables into the rate of change of drive coil current. A high-frequency pulse drive unit, incorporating power switching devices, converts the commands from the position adjustment actuator into pulse width modulation signals. The emergency control module maintains a step mapping table, dividing the high-fidelity attitude variables into 100 levels with 0.01 rad steps. Each level corresponds to a 0.16 mA current increment in the servo valve drive coil. When an increase in attitude deflection angle is detected, the drive unit linearly adjusts the duty cycle from 20% to 80% within 1 ms, causing the emergency control module to output power to the torque motor coil of the hydraulic servo valve. to The simulated control current causes the valve core to deviate from the neutral position, thereby changing the flow rate of oil entering the hydraulic cylinder cavity, and thus... Internal generation not less than The system employs a pre-set thrust to counteract the roll deflection tendency. This servo mechanism controls the response window to the microsecond level, generating attitude correction before mechanical stress is applied to the strip. To address the risks caused by uneven strip stress, the system introduces an energy flow gradient monitoring unit to extract the time-domain energy gradient of the characteristic acoustic signal in real time. When the energy gradient exceeds the preset locking threshold At this time, the emergency control module enters the prestressed locking mode before the output of the phase difference analysis unit, and a preset locking threshold is set. It is calibrated by injecting pulse loads at different rolling speeds and calculating the root mean square value of the background change rate of the acoustic energy field. This procedure enables the system to identify heterogeneous pulses and drive the position adjustment actuator to generate a preset pressure opposite to the deflection direction to build a dynamic stiffness buffer.

[0032] To address the issue of thermal expansion of the rolls during long-term operation, the intrinsic frequency compensation unit extracts the structural intrinsic frequency components from the characteristic acoustic signal. Since the intrinsic frequencies of the roll material are insensitive to local positional shifts, the processor compares the deviation trend between the structural intrinsic frequency components and the main resonant frequency. Based on a preset thermal expansion mapping relationship, it calculates the geometric drift of the controlled moving parts. The system uses this geometric drift as a background compensation reference and feeds it back to the phase difference analysis unit for zero-point correction. When the structural intrinsic frequency is detected to be affected by thermal effects... When the offset occurs, the system automatically deducts the corresponding displacement offset in the solution model, maintaining the measurement accuracy of the system under varying temperature environments; and determines the preset locking threshold. The procedure includes: extracting the energy values ​​of characteristic acoustic signals from 1000 consecutive sampling periods during the non-impact operation phase of the equipment, and calculating the background mean of the energy values. With energy fluctuation standard deviation Set a preset locking threshold ,in To lock the threshold, unit , The mean background energy, in units , The standard deviation of energy fluctuation, in units To address the geometric drift caused by thermal expansion of controlled moving parts, the audio transducer unit applies... to Frequency sweep pulse excitation identifies the resonant peak frequency generated by the controlled coupling gap as the initial cold-state eigenfrequency. Record the support base in to Frequency shift during temperature rise Linear regression analysis was performed on the displacement data measured by the micrometer to determine the geometric drift compensation coefficient. ,in The compensation coefficient is expressed in units of... It is used to correct the zero-position reference of the phase difference analysis unit based on the real-time frequency shift.

[0033] To enhance the ability to adjust for the thickness variations of thin strips, the system utilizes a reverberation analysis module to control the audio transducer unit to periodically apply electroacoustic pulse excitation and obtain the reverberation attenuation slope of the characteristic acoustic signal within the controlled coupling gap. Reverberation decay slope The reverberation analysis module is used to characterize the mechanical damping and micro-stiffness distribution of the roll contact interface. It extracts the sound pressure level from the echo energy spectrum when the level drops to a preset time threshold. The reverberation attenuation slope, characterizing the acoustic energy attenuation rate, is obtained by performing a logarithmic transformation and linear least squares regression fitting on the tail sequence. The attitude calculation processor is based on the formula The servo response step size output by the emergency control module to the position adjustment actuator is adjusted in real time. This is the servo response step size, and its unit is . , The attenuation matching factor, determined through a pre-set damping stiffness test, has the following dimensions: , This is the reverberation decay slope, and its unit is . The calibration method for the attenuation matching factor λ is as follows: During the static debugging phase, a standard step load of 10 kN is applied to the roll, and the reverberation attenuation slope is recorded from 500... Change to 1000 The process involves calculating the displacement response value under a unit acoustic energy attenuation rate, determining λ to be 0.12 mm / s. This procedure converts discrete acoustic signal dissipation characteristics into continuous control gain adjustment commands to characterize the damping distribution of the contact interface. The system utilizes a reference database to store the physical characteristic parameters of the support pose analysis. The reference database contains a multi-dimensional structured data table consisting of a resonant frequency field, a fluid attenuation image matrix field, and a thermal expansion compensation coefficient table field. The processor runs a data indexing procedure to convert the measured characteristic acoustic signal center frequency... The amplitude energy level obtained by the audio acquisition unit is mapped to the physical state address space of the reference database. The initial geometric zero-position bias of the controlled moving part is determined by comparing the resonant frequency field, and the energy compensation component for the phase deviation vector is calculated by calling the fluid attenuation mapping matrix field. This data management procedure solidifies the differences in physical properties of different batches of hardware into callable digital features to characterize the physical background reference of the controlled coupling gap under unsteady conditions.

[0034] Example 1: In the high-speed production scenario of an aluminum foil finishing mill, the system faces strip welding joints with speeds exceeding [a certain threshold]. The sudden impact load caused by the high speed entering the controlled coupling gap, at which point the controlled coupling gap is filled with saturated lubricating oil mist generated by high-speed rotation, causes conventional optical displacement monitoring devices to fail due to oil mist obscuring the surface. Furthermore, because the mechanical stress wave propagates between the frames in an extremely short time, the position adjustment actuator cannot complete pressure compensation before the strip wrinkles if it relies solely on conventional processing circuits. When the aforementioned impact load acts on the roll end face and causes a micrometer-level attitude deflection, the audio transducer unit located on the side of the support base emits a transmission center frequency of... The ultrasonic pulse sequence is modulated by the displacement of the physical interface within the acoustic resonant cavity of the controlled coupling gap. The audio acquisition unit instantly acquires the characteristic acoustic signal containing the phase variation and transmits it to the attitude resolution processor. The phase difference resolution unit identifies the zero-crossing time difference in the echo voltage sequence. According to the formula The phase deviation vector is calculated. ,in, The phase deviation vector characterizes the deflection of the controlled moving part, and its unit is radians. The zero-crossing delay of the echo is expressed in units of . , The preset period of the ultrasound pulse sequence, its unit is... Meanwhile, the feature stripping unit operates according to a preset absorption coefficient. By deducting the acoustic attenuation component caused by fluctuations in lubricating oil mist concentration in real time, a high-fidelity attitude variable unaffected by environmental media is generated.

[0035] The attitude calculation processor transmits high-fidelity attitude variables to the emergency control module via a high-speed command channel. This module drives the high-frequency pulse drive unit to output varying analog control current to the hydraulic servo valve torque motor, causing the position adjustment actuator to generate an attitude current of not less than [amount missing] before the stress wave fully acts on the frame. The preload reaction force constructs a dynamic stiffness buffer zone, ultimately controlling the lateral deflection of the rolls at the instant the joint passes through. Within this range, this method of adjusting the pressure of the actuator through acoustic phase modulation generates attitude correction and maintains the flatness of the strip within an extremely short response window.

[0036] Example 2: This experiment uses a non-steady-state dynamic load test environment built on a 1:1 precision rolling mill prototype platform to test the pose correction accuracy and interference suppression capability of the control system in the aforementioned specific implementation method when simulating an industrial site. The data collected in the experiment comes from a high-frequency data acquisition card integrated on the support base, with a resolution of 16 bits, and a sampling frequency of... The determination logic is as follows: Identify the sampling frequency affected by the transmission frequency of the audio transducer unit. Analyze the factors affecting the sampling frequency The technical factors in determining the value include the center frequency of the ultrasound pulse sequence. And the time resolution of the system emergency response, setting the sampling frequency. It is necessary to balance the phase difference resolution accuracy with the computational load of the attitude calculation processor. According to the sampling frequency setting rules, when the center frequency... When operating over a wider frequency band, to avoid signal aliasing, the sampling frequency... tending towards the center frequency More than 10 times that, under typical operating conditions, when the center frequency for At that time, sampling frequency Set as ,in, Sampling frequency, in units of , The center frequency of the ultrasound pulse sequence, in units of... .

[0037] To simulate the complex noise under rolling conditions, the concentration range injected within the controlled coupling gap during the experiment was as follows: to The lubricating oil mist is superimposed in the acoustic monitoring field, and the signal-to-noise ratio is... Gaussian white noise and frequency of To mitigate power frequency electromagnetic interference, under the presence of interference, the time-domain energy gradient of characteristic acoustic signals is extracted in real time by an energy flow gradient monitoring unit. and with the preset locking threshold A comparison was conducted, in which, The energy gradient is expressed in units of 1000 kJ / m². , The preset locking threshold is in units of Table 1 below shows the performance test data of attitude control under unsteady conditions, displaying the phase analysis results and executed displacement deviation of the test group under different impact loads. The original input load simulates the transient characteristics when the metal joint enters the roll gap, and the intermediate data includes the phase deviation vector after processing by the feature stripping unit. The final output records the residual displacement of the roll after the position adjustment actuator corrects the deviation.

[0038] Table 1: Performance Test Data of Attitude Control under Unsteady Conditions

[0039]

[0040] Analysis of the measurement data in Table 1 shows that when the load impact strength increases within the working range of 5.0 kN to 25.0 kN, the phase deviation vector... The displacement correction residual is positively correlated with the impact strength, and remains at 1.5. The following demonstrates that the phase-locking mechanism produces a definite attitude characterization under the interference of lubricating oil mist and environmental noise, when the impact intensity is 30.0. At that time, the displacement correction residual was still within the process control parameters, confirming that the emergency control module shortened the command transmission delay by directly changing the pressure path of the actuator cavity through the high-frequency pulse drive unit, while the load impact intensity reached 35.0. After the boundary point, the displacement correction residuals show a nonlinear increase, and the emergency response time increases to 4.5 seconds. This indicates that the system has entered the servo valve flow saturation region, and further increasing the load cannot generate a matching reaction force. The above test data shows that when the system faces the coupling effect of lubricating medium decay and mechanical shock, it uses the feature stripping unit to eliminate interference components, so that the attitude calculation results are not affected by fluid fluctuations. Its high-fidelity attitude variable drives the position adjustment actuator to complete the prestress locking within microseconds, thereby maintaining the stability of the controlled moving parts under unsteady conditions. Through real-time monitoring and feedback of acoustic phase characteristics, it generates real-time posture correction under complex stress conditions.

[0041] Example 3: This example combines Figures 1 to 2 This document describes a control system for attitude calculation and emergency response of audio equipment under unsteady operating conditions. Figure 1The control system for attitude calculation and emergency response of audio equipment under unsteady conditions mainly consists of an audio transducer unit, an audio acquisition unit, an attitude calculation processor, and an emergency control module, forming a closed-loop operating architecture. The audio transducer unit transmits ultrasonic pulses with a center frequency of not less than 20kHz into the coupling gap between the controlled components. After being modulated by the physical interface in the coupling gap between the controlled components, the pulses form an acoustic signal. The audio acquisition unit acquires the characteristic acoustic signal modulated by the physical interface and transmits it to the attitude calculation processor. The processor performs calculations to determine the phase deviation vector by comparing the transmitted and received phases and to eliminate interference components based on the fluid attenuation image relationship to generate attitude variables. The emergency control module receives the attitude variables and converts them into drive pulses by adjusting the rate of change of the drive coil current. Finally, it changes the cavity pressure of the actuator and constructs a dynamic stiffness buffer to achieve drive control.

[0042] like Figure 2 As shown, the control process involves an audio acquisition unit, an energy flow gradient monitoring unit, a phase difference analysis unit, an emergency control module, a position adjustment actuator, and controlled moving parts. When the system detects a sudden load pulse, such as the passage of a metal joint, the input characteristic acoustic signal is analyzed quickly, and the energy flow gradient monitoring unit extracts the time-domain energy gradient and determines the heterogeneous pulse at the controlled interface. Once the energy gradient exceeds the locking threshold, the emergency control module triggers the prestress locking mode and responds before the phase analysis results by issuing a fast drive command through the activation of the preset response gain. This drives the position adjustment actuator to build a dynamic stiffness buffer and generate a reverse preset pressure to counteract the deflection direction until pre-control is completed and normal control takes over. During this period, the phase difference analysis unit performs phase deviation calculation in parallel and outputs precise attitude variables to generate fine adjustment commands. Under the condition that the energy gradient does not exceed the threshold, the system normally calculates the phase deviation and outputs high-fidelity attitude variables to generate regular control commands, thereby ensuring that pre-control is completed before stress wave propagation.

[0043] Example 4: Absorption coefficient required for the operation of the feature stripping unit when the system is under conditions of fluctuating lubricating medium and long-term heat accumulation. The following calibration procedure was used to determine that, when the controlled moving part is stationary and the controlled coupling gap is maintained at a certain value, the controlled moving part is in a stationary state. Under reference conditions, the audio transducer unit emits an ultrasonic pulse sequence, the audio acquisition unit captures the reference energy spectrum under no-load conditions, and a lubricating oil mist with a concentration gradient is injected into the controlled coupling gap through the lubrication spray system, with the concentration gradient at a ratio of 10. The step size is 0 Increase to 100 The processor records the amplitude attenuation value of the characteristic acoustic signal at each concentration gradient, establishes a mapping relationship between the amplitude attenuation and the oil mist concentration, and sets the absorption coefficient. Balancing the signal-to-noise ratio and the sensitivity of the compensation algorithm when the oil mist concentration is at 30 Up to 60 In the range, the absorption coefficient Select the first-order linear fit value when the concentration exceeds 80%. Subsequently, multiple scattering of the sound waves causes the attenuation rate to increase nonlinearly, at which point the system will reduce the absorption coefficient. The weights are shifted toward the nonlinear terms.

[0044] Table 2: Absorption Coefficient Calibration Process and Its Impact on Attitude Calculation Accuracy

[0045]

[0046] Locking threshold in energy flow gradient monitoring unit The determination was made using a statistical background noise modeling approach. During the non-impact period of equipment operation, the attitude calculation processor extracted the characteristic acoustic signal energy values ​​for 1000 consecutive sampling cycles and calculated the standard deviation of the energy values. Lock threshold It is set to be three times the standard deviation of the mean background energy, and the specific calculation formula is as follows: ,in, To lock the threshold, the unit is ; The mean background energy, in units of ; The standard deviation of energy fluctuation is expressed in units of 1000 kJ / m². The length of the sampling window is selected based on the system's real-time requirements. When the rolling speed exceeds... At that time, the sampling window is changed from Switch to This statistical basis enables the emergency control module to identify pulses that exceed normal background fluctuations, thereby triggering the prestressed locking mode.

[0047] To address the geometric drift caused by the thermal expansion of the rolls, the intrinsic frequency compensation unit applies broadband electroacoustic pulse excitation through an audio transducer unit. It then uses Fast Fourier Transform to extract the structural intrinsic frequency components of the controlled moving parts. The system monitors the shift of the intrinsic frequency relative to the initial cold-state frequency, establishing a correlation function between the geometric drift and the frequency shift. The proportional coefficient is calibrated by placing temperature sensors on the surface of the controlled moving parts and recording the changes from... Heat up to During the process, the processor stores the synchronous data of intrinsic frequency shift and geometric expansion in the reference database of the attitude calculation processor. Under continuous operation, the zero point of the phase difference resolution unit is corrected in real time according to the intrinsic frequency shift. This procedure eliminates temperature-induced static deviations and maintains the consistency of high-fidelity attitude variables at different temperatures.

[0048] Example 5: In a system calibration scenario involving cross-batch hardware deployment, the conversion gain between the high-fidelity attitude variables output by the attitude calculation processor and the rate of change of the hydraulic servo valve drive current. Calibrated through offline testing procedures, a gradient-arranged deflection displacement is applied to the roll end face using a high-precision micrometer in a controlled environment. The attitude calculation processor captures the phase variation of the characteristic acoustic signal caused by the deflection displacement in real time and calculates the corresponding phase deviation vector. The emergency control module is based on the conversion gain of different orders of magnitude. The drive position adjustment actuator outputs a preset thrust, and the processor synchronously monitors the displacement response characteristics of the position adjustment actuator under different hydraulic pressure conditions. By calculating the convergence index of the correction residual entering the steady-state error band within a preset time limit, it satisfies... Response time and residual less than The gain value is determined as the base parameter of the system mapping lookup table, where, This is the conversion gain, and its unit is . .

[0049] When the system is applied to a new production line containing controlled moving parts of different materials, a pre-calibration procedure is deployed on-site to initialize the geometric drift mapping relationship of the intrinsic frequency compensation unit. In the initial state where the frame is unloaded and the hydraulic servo valve maintains neutral pressure balance, the audio transducer unit emits signals covering... to The sweep pulse sequence was used to identify the resonant peak generated by the controlled coupling gap and define it as the initial cold-state eigenfrequency. On-site commissioning personnel changed the local thermal steady state of the support base through an external heating device and recorded the frequency shift of the structure's eigenfrequency components with temperature step changes. The processor will use frequency shift. Linear regression analysis was performed with the measured roll gap geometric displacement data, and the generated compensation coefficient table was injected into the interference correction operator of the feature stripping unit to eliminate the system zero-point drift caused by the difference in the thermal expansion coefficient of the material.

[0050] Example 6: In the deployment site of a multi-stand continuous rolling mill system, due to batch-to-batch variations in the physical stiffness of the support base, the system executes a pre-inspection procedure to reconstruct the acoustic characteristic benchmark. Under the condition that the stand maintains an initial constant preload, the audio transducer unit emits a sweep pulse sequence with a power gradient of 5W to 20W. The attitude calculation processor analyzes the power spectral density of the echo voltage sequence to extract the quality factor of the controlled coupling gap. Select quality factor The frequency at which the peak value is reached and the background noise energy level distribution is minimized is taken as the center frequency. The processor synchronously calculates the root mean square value of the background energy flux at this frequency and uses it as the adaptive locking threshold of the energy flux gradient monitoring unit. The background items, among which, The quality factor is dimensionless. The center frequency, in units of , To lock the threshold, the unit is .

[0051] When the system faces a rolling speed of 2 Switch to 15 During dynamic speed regulation, the energy flow gradient monitoring unit adjusts the sampling length of the sliding time window. To accommodate airflow pulsation interference caused by high-speed rotation, sampling length With rotational angular velocity The inverse proportional mapping relationship is satisfied, and the specific method for determining this is based on the formula. Calculate the number of discrete points in the current window, where, The sampling length is expressed in points. The preset step constant is in units of . , It is the rotational angular velocity, and its unit is ω. After detecting the energy gradient jump caused by the impact of the metal joint, the emergency control module utilizes the calibrated conversion gain. The hydraulic servo valve is driven to generate a preload reaction force, causing the phase shift of the controlled moving parts under load jumps to converge to 0.05. Within this range, the position adjustment actuator maintains a preset response gain when external constraints change.

[0052] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit of this application and the scope of protection of this invention, and all of these forms are within the protection scope of this application.

Claims

1. A non-steady-state operating condition oriented audio device posture solving and emergency response control system, characterized in that, The system comprises: An audio transduction unit is arranged laterally on the support base, and is configured to emit a sequence of ultrasonic pulses with a central frequency not less than 20 kHz to a controlled coupling gap between the controlled motion component; An audio acquisition unit is configured to acquire a characteristic acoustic signal modulated by the physical interface in the controlled coupling gap; The attitude calculation processor comprises a phase difference analysis unit and a characteristic stripping unit; the phase difference analysis unit is configured to compare an initial emission phase of the sequence of ultrasonic pulses with a real-time receiving phase of the characteristic acoustic signal, and calculate a phase deviation vector representing the deflection of the controlled motion component; the characteristic stripping unit is configured to monitor the amplitude envelope fluctuation of the characteristic acoustic signal, determine an interference component according to a preset fluid attenuation mapping relationship, and remove the interference component from the phase deviation vector to generate a high-fidelity attitude variable; An emergency control module is connected with the attitude calculation processor, and is configured to convert the high-fidelity attitude variable into a driving pulse of a position adjusting actuator; the emergency control module changes the cavity pressure of the position adjusting actuator by adjusting the current change rate of a servo valve driving coil, offsets the deflection of the controlled motion component, and constructs a dynamic stiffness buffer zone.

2. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The emergency control module comprises an energy flow gradient monitoring unit; in the context of the input of the characteristic acoustic signal, the energy flow gradient monitoring unit is configured to extract the energy gradient of the characteristic acoustic signal, and determine a controlled interface heterogeneous pulse; when the energy gradient of the controlled interface heterogeneous pulse exceeds a preset locking threshold, the emergency control module enters a pre-stress locking mode prior to the output result of the phase difference analysis unit, and generates a preset pressure opposite to the deflection direction by driving the position adjusting actuator through a preset response gain.

3. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The audio acquisition unit comprises a sound wave envelope discrimination module; The sound wave envelope discrimination module is configured to analyze the energy spectrum envelope of the acoustic signal modulated by the physical interface, and acquire the sound pressure distribution anomaly of the controlled processing material under the stress state; The acoustic envelope discrimination module calculates the asymmetry factor according to a preset discrimination criterion. The calculation formula is: ,in, The integral value of the acoustic field energy on the left side of the controlled coupling gap between the controlled moving parts, in J, is given by the emergency control module based on the asymmetry factor. The numerical adjustment position adjusts the left and right control gain of the actuator.

4. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, On the basis of the output result of the phase difference analysis unit, the attitude calculation processor further comprises an intrinsic frequency compensation unit; the intrinsic frequency compensation unit is configured to extract a structural intrinsic frequency component in the characteristic acoustic signal, and compare the deviation trend of the structural intrinsic frequency component and a main resonance frequency; the intrinsic frequency compensation unit determines a geometric drift of the controlled motion component according to the deviation trend and a preset thermal expansion mapping relationship, and feeds back the geometric drift as a background compensation reference to the phase difference analysis unit.

5. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The attitude calculation processor comprises a reverberation analysis module; the reverberation analysis module is configured to control the audio transduction unit to apply an electroacoustic pulse excitation, and acquire a reverberation attenuation slope of the characteristic acoustic signal in the controlled coupling gap between the controlled motion components; the reverberation analysis module represents the micro-rigidity distribution of the contact interface of the controlled coupling gap between the controlled motion components according to the reverberation attenuation slope, and transmits the micro-rigidity distribution to the emergency control module to adjust the servo response step.

6. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The audio acquisition unit is provided with a high-frequency noise filtering layer; the high-frequency noise filtering layer is configured to monitor the energy level distribution of the characteristic acoustic signal outside the 100 kHz frequency band, identify and remove periodic interference noise generated by a mechanical transmission system associated with the support base, and input the purified acoustic characteristics to the phase difference analysis unit.

7. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The emergency control module is connected with a high-frequency pulse driving unit between the servo valve driving coil; the high-frequency pulse driving unit is used for converting the emergency control instruction into a pulse width modulation signal.

8. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The system comprises a dual-channel redundancy checking unit; the dual-channel redundancy checking unit is used for comparing the high-fidelity attitude variable output by the attitude resolving processor with a preset safety attitude envelope; when the high-fidelity attitude variable exceeds the safety attitude envelope for three consecutive sampling periods, the dual-channel redundancy checking unit cuts off the main loop of the emergency control module and outputs a fault shutdown instruction.

9. The audio device posture resolving and emergency response control system for unsteady state conditions of claim 1, wherein, The audio acquisition unit is distributed on the upper and lower sides of the horizontal axis of the controlled motion component, and constitutes a differential sensing array; the phase difference analysis unit eliminates the common-mode interference term generated by the overall vibration of the support base by performing differential operation on the multi-channel acoustic signals captured by the differential sensing array, and extracts the relative deflection angle of the controlled motion component relative to the reference position.

10. The audio device posture solving and emergency response control system for unsteady working conditions of claim 1, wherein, The emergency control module comprises a gain adaptive adjustment unit; the gain adaptive adjustment unit is used for determining the initial servo gain according to the preset linear response curve according to the moving speed and thickness of the controlled processing material; when the attitude resolving processor monitors that the load reaction fluctuation rate exceeds the preset threshold, the gain adaptive adjustment unit improves the system transient response stiffness by increasing the current proportional control coefficient of the servo valve driving coil.

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