Motion control system based on programmable automation controller

Abstract

This invention relates to the field of hydropower station equipment testing technology, and in particular provides a motion control system based on a programmable automation controller. The system includes a dual-motor drive module, a multi-axis transmission mechanism, and a closed-loop control core module. The dual-motor drive module consists of a rotary mechanism and a Z-axis lifting mechanism. The multi-axis transmission mechanism converts motor power into mechanical motion through a lead screw and nut pair and a gear and rack assembly, ensuring the rigidity and accuracy of power transmission. The closed-loop control core module uses a PAC ADVANCE controller as its core, integrating a Z-axis displacement sensor and a rotary axis angle encoder. It controls the dual motors through pulse direction signals and uses an electronic gear ratio configuration function to convert pulses into actual displacements. In the motion control of a hydropower turbine flow channel inspection robot, this system solves the problems of insufficient accuracy, low flow channel switching efficiency, and high safety risks.

Description

Technical Field

[0001] This invention relates to the field of hydropower station equipment testing technology, and in particular to a motion control system based on a programmable automatic controller. Background Technology

[0002] Traditional turbine runner inspection relies on manual operation, requiring point-by-point inspection of the runner after shutdown. This method suffers from problems such as extremely low efficiency (due to the huge size and complex curvature of the runner), high operational risks (the enclosed environment makes it easy to fall, electric shock, and other accidents), unstable inspection quality (affected by the experience and physical strength of personnel, making it easy to miss or misjudge), and lack of information traceability.

[0003] To address the shortcomings of manual inspection, existing solutions attempt to use a water turbine flow channel inspection robot platform to carry the inspection equipment, but there are still significant deficiencies: First, the robot base lacks integrated lifting and rotating functions, limiting its range of motion and making it unable to cover the complex curved surfaces of the flow channel, resulting in low inspection coverage; second, the mechanical structure has poor stability, making it difficult to ensure high-precision operation in uneven field environments, and it is also complex to disassemble and deploy.

[0004] At the control system level, existing technologies suffer from defects in coordination and adaptability: traditional single-axis control systems or dual-motor independent control schemes cannot achieve precise synchronization of lifting and rotational motions, resulting in broken flow channel switching trajectories and large positional deviations; fixed electronic gear ratios are difficult to adapt to variable load scenarios (such as torque fluctuations) in turbine detection, and modifications to trajectory parameters require rewriting the program, resulting in long deployment cycles; safety mechanisms are weak, with delayed emergency stop responses and the inability to record interruption positions, mechanical limits being disconnected from motion commands, and a high risk of collisions. Summary of the Invention

[0005] In view of this, the present invention provides a motion control system based on a programmable automation controller to solve the problems of insufficient accuracy, low efficiency of flow channel switching and high safety risks in the motion control of a water turbine flow channel inspection robot.

[0006] In a first aspect, the present invention provides a motion control system based on a programmable automation controller, the system comprising: a dual-motor drive module, a multi-axis transmission mechanism, and a closed-loop control core module;

[0007] The dual-motor drive module consists of a rotary mechanism and a Z-axis lifting mechanism: the rotary mechanism, driven by a rotary motor through a gear rack or rotary platform, is used for horizontal angle adjustment; the Z-axis lifting mechanism uses a lifting motor in conjunction with a lead screw and nut pair for vertical lifting of the robot base; the multi-axis transmission mechanism converts motor power into mechanical motion through the lead screw and nut pair and gear rack components, ensuring the rigidity and accuracy of power transmission; the closed-loop control core module uses the PACADVANCE controller as its core, integrating a Z-axis displacement sensor and a rotary axis angle encoder, controlling the dual motors through pulse direction signals, and using electronic gear ratio configuration to convert pulses into actual displacement; during rotation, it first descends, and then rises after reaching a safe position.

[0008] Optionally, the PAC ADVANCE controller utilizes trapezoidal acceleration / deceleration control and vector synthesis speed adjustment to achieve multi-axis interpolation linkage between the Z-axis lifting and rotating axes. During flow channel switching, after the Z-axis descent is initiated, the rotating axis begins to rotate synchronously at a low speed to ensure a smooth coordinated trajectory with the Z-axis descent. Simultaneously, the numerator, denominator, and backlash compensation values ​​of the electronic gear ratio can be directly set in the equipment parameter configuration interface, and the Z-axis descent speed and low-speed rotation parameters of the rotating axis can be adjusted in the control parameter interface to adapt to different loads and accuracy requirements. The motion parameters of the synchronous descent and rotation trajectory are encapsulated into an independent program module, which is activated by the module call command and set in conjunction with the number of loops.

[0009] Optionally, the electronic gear ratio parameter configuration is as follows: the physical meaning of the electronic gear is the number of pulses emitted corresponding to 0.001 mm; where, for the Z-axis: according to the PAC ADVANCE parameter calculation method, the number of pulses per revolution of the motor is set to... Lead screw mm, then the electronic gear ratio is This is used to achieve 0.001mm precision control; Rotary axis: Based on the PAC ADVANCE parameter calculation method, the number of pulses per revolution of the motor is set as follows. If the gear module is m and the number of teeth is n, the circumferential displacement corresponding to one revolution of the motor is... The electronic gear ratio is .

[0010] Optionally, the entire process can be controlled via instructions from the PAC ADVANCE controller: Before the first inspection, the base is calibrated and adjusted to the initial inspection position of the first flow channel, then the mechanical zero point return of the Z-axis and rotation axis is completed, and the initial coordinate system is set to ensure that the inspection starting point is unified; the dual-motor drive module is enabled or disabled synchronously by the control output to ensure that the lifting motor and the rotation motor start or stop simultaneously, so as to avoid trajectory deviation caused by start-stop timing deviation; after the current flow channel is inspected, the switching action is automatically executed according to the preset trajectory to reach the initial inspection position of the next flow channel; the actual position of the dual-motor drive module is compared with the target value in real time, and if the position deviation is greater than 0.01mm, fine-tuning compensation is immediately performed to avoid trajectory distortion.

[0011] Optionally, the displacement deviation is a spatial error in three-dimensional space, and the coupling effect of the Z-axis linear deviation and the rotation axis angular deviation must be considered simultaneously. It is the error value between the target position and the actual position, the deviation of the rotation axis angle. This is the error value between the actual angle and the target angle; due to the large size of the turbine, the rotation shaft angle deviation... Significant arc length deviation will occur due to the rotation radius r; taking the rotation axis center as the origin, the rotation axis angle deviation is converted into the corresponding arc length deviation, and the linear displacement deviation of the Z axis is unified with the length unit to achieve the same dimension quantification of the deviation.

[0012] The principle of converting rotation axis angular deviation into arc length deviation:

[0013] Arc length formula: Rotation axis angle deviation The formula for converting to arc length deviation is: ;

[0014] Where s is the arc length deviation, representing the equivalent displacement deviation on the rotating shaft; r is the rotation radius, i.e., the distance from the rotation center to the measurement point, which needs to be determined according to the actual dimensions of the turbine. This is the deviation of the rotation axis angle. ; This is the coefficient for converting angles to radians;

[0015] The unified deviation compensation process is as follows: the actual linear position of the Z-axis is acquired by a grating ruler, and the actual angle of the rotary axis is acquired by an angle encoder. The deviations are calculated separately, and the linear deviation of the Z-axis is calculated directly. , rotate axis angle deviation According to the formula Converted to arc length deviation; the total deviation, the straight-line distance between two points in space, is calculated using the three-dimensional Pythagorean theorem, with the lateral arc length deviation and axial deviation as the legs of the right triangle, and its formula is: ,in, This is for positional deviation;

[0016] examine Is it greater than the threshold? If the value is greater than the threshold, the linear position of the Z-axis is finely adjusted, i.e., compensation is performed. The rotation axis is finely adjusted in angle and position, i.e., compensation. This is achieved by using a unified unit of length for compensation decisions, in order to avoid underestimating the rotation axis angle deviation due to a large radius.

[0017] Optionally, hardware safety protection includes: hardware limit switches at the extreme positions of the Z-axis lifting and rotating mechanisms. When the base movement approaches the mechanical limit, the switch is triggered and sends an interrupt signal to the PAC ADVANCE controller, forcibly stopping the motor to avoid collision or overtravel damage; the dual-motor drive module has a built-in overload protection module. When the load exceeds the rated value during lifting or rotation, it automatically cuts off the motor power and sends a fault signal to the PAC ADVANCE controller to prevent motor burnout or deformation of transmission components; a physical emergency stop button is also provided, connected to the emergency input port of the PAC ADVANCE controller. When an abnormality is detected, it can be manually triggered to instantly cut off all motor power for global emergency braking.

[0018] Optionally, the software anomaly handling logic is as follows: The PAC ADVANCE controller monitors limit switch trigger signals, overload and overcurrent fault signals from motor drivers, signal loss or abnormal jumps from position sensors and encoders, and abnormal signals indicating excessive synchronization deviation of the dual motors in real time. When any of these anomalies are detected, the system immediately jumps to the preset anomaly handling procedure. In terms of graded anomaly response, for minor deviations in position and speed within the compensation range, compensation is made through fine-tuning, and the deviation value is recorded for subsequent parameter optimization. For moderate anomalies where the deviation exceeds the limit but hardware protection is not triggered, both motors are stopped synchronously, and the operator is prompted to check via audible and visual alarms. Movement is restarted after manual confirmation. For severe faults that trigger limit switches, overload protection, or emergency stop signals, the system immediately terminates, disconnects motor enable, saves the current position data to the PAC ADVANCE controller's power-down memory area, and sends a fault code to the background system via the communication module for easy fault tracing. As for the post-interruption recovery mechanism, after the anomaly is cleared, the system does not need to be recalibrated. It automatically executes the rollback-retry process by calling the position data stored in the power-down memory area before the interruption.

[0019] Optionally, the Z-axis lifting mechanism's motor is connected to a lead screw via a coupling, and the nut is fixed to the base platform to achieve vertical movement. A 0.001mm grating ruler is added to the Z-axis guide rail, and the signal is connected to the high-speed counting port of the PAC ADVANCE controller to provide displacement feedback. The rotation mechanism is driven by a servo motor with an absolute encoder, which drives a gear rack through a reducer. The rack is fixed to the bottom of the rotation platform. Rotation; encoder signals are input to the position feedback port of the PAC ADVANCE controller to acquire angles; the multi-axis transmission mechanism relies on the guide rail positioning system to ensure rigidity; the PAC ADVANCE controller's pulse direction signal... Its pulse direction ports are connected to the Z-axis and rotary axis motor drivers respectively, and are driven by differential signals; in terms of sensors and safety components, the upper and lower limits of the Z-axis and the rotary axis... A normally closed limit switch is installed at the point, and the signal is connected to the digital input port of the PAC ADVANCE controller. The overload signal of the dual motor drive module is connected to the fault input port, and the physical emergency stop button is connected to the emergency stop port of the PAC ADVANCE controller and connected in series with the driver enable circuit.

[0020] Optionally, in the basic parameter configuration, the Z-axis calculates the electronic gear ratio based on the number of pulses per motor revolution and the lead screw to ensure preset millimeter-level pulse accuracy. The rotary axis calculates the electronic gear ratio based on the number of pulses per motor revolution and the circumferential displacement of the gear to meet the set angular-level accuracy. At the same time, the equipment parameter configuration includes backlash compensation, and the control parameters set the speed of each axis. In terms of motion control, after the initial run is calibrated, it first returns to zero and sets the reference to define the initial coordinate system. When switching flow channels, the function module is called to execute the corresponding instructions, and multi-flow channel batch detection is achieved through a loop program. In terms of deviation compensation and safety logic, deviation and position comparison are embedded for real-time fine-tuning of out-of-tolerance positions.

[0021] Optionally, when a limit switch or overload signal is triggered, an abnormality handling process is initiated, the motor is stopped and an alarm is triggered. In case of emergency stop, the enable is cut off and the position is stored and a fault code is sent. After the abnormality is cleared, the power-down register data is called back a certain distance and the process is restarted without recalibration.

[0022] In a second aspect, embodiments of the present invention provide a computer-readable storage medium comprising a stored program, wherein, when the program is executed, it controls the device on which the computer-readable storage medium is located to execute a motion control system based on a programmable automation controller, as described in the first aspect or any possible implementation thereof.

[0023] Thirdly, embodiments of the present invention provide an electronic device, including: one or more processors; a memory; and one or more computer programs, wherein the one or more computer programs are stored in the memory, and the one or more computer programs include instructions that, when executed by the device, cause the device to perform a motion control system based on a programmable automation controller in the first aspect or any possible implementation of the first aspect.

[0024] The technical solution provided by this invention includes a dual-motor drive module, a multi-axis transmission mechanism, and a closed-loop control core module. The dual-motor drive module consists of a rotating mechanism and a Z-axis lifting mechanism: the rotating mechanism is driven by a rotary motor through a gear rack or rotating platform for horizontal angle adjustment; the Z-axis lifting mechanism uses a lifting motor in conjunction with a screw and nut pair for vertical lifting of the base; the multi-axis transmission mechanism converts motor power into mechanical motion through the screw and nut pair and gear rack components to ensure the rigidity and accuracy of power transmission; the closed-loop control core module uses a PACADVANCE controller as its core, integrating a Z-axis displacement sensor and a rotary axis angle encoder, controlling the dual motors through pulse direction signals, and using electronic gear ratio configuration to convert pulses into actual displacements; during rotation, the system first descends, and then rises after reaching a safe position. In the motion control of the water turbine flow channel inspection robot, this system solves the problems of insufficient accuracy, low flow channel switching efficiency, and high safety risks. Attached Figure Description

[0025] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 A schematic diagram of a motion control system based on a programmable automation controller provided in an embodiment of the present invention;

[0027] Figure 2 A schematic diagram of another motion control system based on a programmable automation controller provided in an embodiment of the present invention;

[0028] Figure 3 A flowchart of the entire process control provided in this embodiment of the invention;

[0029] Figure 4 A flowchart of the software exception handling logic provided in an embodiment of the present invention.

[0030] The numbers in the diagram are: 1-rotation mechanism, 2-Z-axis lifting mechanism, 3-multi-axis transmission mechanism, 4-target position, 5-Z-axis linear deviation, 6-actual position, 7-arc length deviation, 8-actual angle, 9-target angle, 10-rotation axis angle deviation. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] It should be understood that the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] The terminology used in the embodiments of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The singular forms “a,” “the,” and “the” used in the embodiments of this invention are also intended to include the plural forms unless the context clearly indicates otherwise.

[0034] It should be understood that the term "and / or" used in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0035] Depending on the context, the word "if" as used here can be interpreted as "when," "when," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determination" or "if detection (of the stated condition or event)" can be interpreted as "when determination," "in response to determination," "when detection (of the stated condition or event)," or "in response to detection (of the stated condition or event)."

[0036] This invention provides a motion control system based on a programmable automation controller, such as... Figures 1 to 4 As shown, the system includes: a dual-motor drive module, a multi-axis transmission mechanism 3, and a closed-loop control core module;

[0037] The dual-motor drive module consists of a rotary mechanism 1 and a Z-axis lifting mechanism 2. The rotary mechanism 1 is driven by a rotary motor through a gear rack or rotary platform for horizontal angle adjustment. The Z-axis lifting mechanism 2 uses a lifting motor in conjunction with a lead screw and nut pair for vertical lifting of the robot base. The lifting motor is fixed to the base of the lifting platform. The multi-axis transmission mechanism 3 converts motor power into mechanical motion through the lead screw and nut pair and gear rack components to ensure the rigidity and accuracy of power transmission. The closed-loop control core module is based on the PAC ADVANCE controller, integrating a Z-axis displacement sensor and a rotary axis angle encoder. It controls the dual motors through pulse direction signals and uses the electronic gear ratio configuration function to convert pulses into actual displacement, ensuring micron-level control accuracy. During rotation, to avoid interference, the robot first descends and then rises after reaching a safe position.

[0038] In this embodiment of the invention, the PAC ADVANCE controller is an integrated programmable automation controller that supports single-axis to four-axis control and possesses micron-level precision control capabilities. It achieves precise motor drive through pulse direction signals, supports multi-axis interpolation linkage, and can flexibly adapt to complex mechanical motion scenarios. It is feature-rich, including abundant input / output interfaces and an instruction system, supports modular programming, and can perform functions such as position comparison, deviation compensation, and synchronous start / stop. It is suitable for high-precision, high-stability automation control scenarios, such as machining and equipment inspection.

[0039] In this embodiment of the invention, the PAC ADVANCE controller utilizes trapezoidal acceleration / deceleration control and vector composite speed (F-value) adjustment functions to achieve multi-axis interpolation linkage between the Z-axis lifting and rotating axes. During flow channel switching, after the Z-axis descent action is initiated, the rotating axis begins to rotate synchronously at a low speed to ensure a smooth coordinated trajectory with the Z-axis descent action. This effectively avoids start-stop shocks and mechanism vibrations caused by excessively abrupt rotation or high speed, ensuring the stability of the motion process. Simultaneously, the numerator, denominator, and backlash compensation values ​​of the electronic gear ratio can be directly set in the equipment parameter configuration interface. The Z-axis descent speed and the low-speed rotation parameters of the rotating axis can be adjusted in the control parameter interface to adapt to different loads and accuracy requirements. The motion parameters of the synchronous descent and rotation trajectory are encapsulated into an independent program module. The program segment is activated by the module call instruction and set in conjunction with the number of loops to achieve batch detection of multiple flow channels, significantly improving programming efficiency.

[0040] In this embodiment of the invention, the electronic gear ratio parameter is configured as follows: the physical meaning of the electronic gear is the number of pulses emitted corresponding to 0.001 mm; wherein, Z-axis: according to the PAC ADVANCE parameter calculation method, the number of pulses for one revolution of the motor is set to... Lead screw mm, then the electronic gear ratio is This is used to achieve 0.001mm precision control; Rotary axis: Based on the PACADVANCE parameter calculation method, the number of pulses per revolution of the motor is set as follows. If the gear module is m and the number of teeth is n, the circumferential displacement corresponding to one revolution of the motor is... The electronic gear ratio is .

[0041] In this embodiment of the invention, the entire process is controlled by instructions from the PAC ADVANCE controller: Before the first test, the base is calibrated and adjusted to the initial test position of the first flow channel, then the mechanical zero point return of the Z-axis and the rotation axis is completed, and the initial coordinate system is set to ensure that the test starting point is unified; the dual-motor drive module is enabled or disabled synchronously by the control output to ensure that the lifting motor and the rotation motor start or stop simultaneously, so as to avoid trajectory deviation caused by start-stop timing deviation; after the current flow channel is tested, the switching action is automatically executed according to the preset trajectory to reach the initial test position of the next flow channel; the actual position 6 of the dual-motor drive module is compared with the target value in real time, and if the position deviation is greater than 0.01mm, fine-tuning compensation is immediately performed to avoid trajectory distortion.

[0042] In the motion control of the robot base for inspecting the turbine flow channel, positional deviation directly affects the accuracy and stability of the flow channel switching trajectory.

[0043] Displacement deviations mainly originate from accumulated errors in mechanical transmission, such as lead screw and nut pair clearance, gear meshing errors, and motor step loss, or from position detection deviations caused by sensor feedback delays. This manifests as a deviation between the actual Z-axis lifting distance and the target value, or a discrepancy between the actual rotation axis angle and the target value, directly affecting the accuracy of the initial position of the next flow channel. These deviations directly impact the accuracy of the initial position of the turbine flow channel. Existing closed-loop control uses position comparison and relative position commands for fine-tuning, but the threshold values ​​(0.01° and 0.01mm) for the rotation axis angle deviation (10 degrees) and position deviation (mm) need to be unified into a length-based deviation value for overall deviation compensation.

[0044] In this embodiment of the invention, the displacement deviation is a spatial error in three-dimensional space, and the coupling effect of the Z-axis linear deviation 5 and the rotation axis angle deviation 10 must be considered simultaneously. This is the error value between the target position 4 and the actual position 6, representing the deviation of the rotation axis angle. 10 represents the error between the actual angle 8 and the target angle 9; due to the large size of the turbine, the rotation shaft angle deviation... 10 will produce a significant arc length deviation of 7 due to the rotation radius r; taking the rotation axis center as the origin, the rotation axis angle deviation 10 is converted into the corresponding arc length deviation 7, and the linear displacement deviation of the Z axis is unified with the length unit to achieve the same dimension quantification of the deviation.

[0045] The principle of converting a rotation axis angle deviation of 10° into an arc length deviation of 7°:

[0046] Arc length formula: Rotation axis angle deviation The formula for converting 10 degrees to an arc length deviation of 7 millimeters is: ;

[0047] Where s is the arc length deviation, which represents the equivalent displacement deviation on the rotating shaft; r is the rotation radius (mm), which is the distance from the rotation center to the measuring point, and needs to be determined according to the actual dimensions of the turbine. The rotation axis angle deviation is 10 (degrees). ; This is the coefficient for converting angles to radians;

[0048] The unified deviation compensation process is as follows: the actual linear position (in millimeters) of the Z-axis is acquired by a grating ruler, and the actual angle (in degrees) of the rotary axis is acquired by an angle encoder (rotary encoder). The deviations are calculated separately, and the linear deviation of the Z-axis is directly calculated. , rotate axis angle deviation 10. According to the formula Converted to arc length deviation 7; the total deviation, the straight-line distance between two points in space, is calculated using the three-dimensional Pythagorean theorem, with the lateral arc length deviation 7 and the axial deviation as the legs of the right triangle, as follows: ,in, This is for positional deviation;

[0049] examine Is it greater than the threshold (e.g., 0.01 mm)? Greater than the threshold ( If the error is greater than 0.01mm, then the linear position of the Z-axis is finely adjusted, i.e., compensation is applied. The rotation axis is finely adjusted in angle and position, i.e., compensation. This is achieved by using a unified unit of length for compensation decisions, in order to avoid underestimating the 10° deviation of the rotation axis angle due to the large radius.

[0050] In this embodiment of the invention, hardware safety protection is provided as follows: hardware limit switches are set at the extreme positions of the Z-axis lifting mechanism 2 and the rotating mechanism 1. When the base movement approaches the mechanical limit, the switch is triggered and an interrupt signal is sent to the PAC ADVANCE controller to forcibly stop the motor operation, so as to avoid collision or overtravel damage to the mechanism; the dual motor drive module has a built-in overload protection module. When the load exceeds the rated value during lifting or rotation, the motor power is automatically cut off and a fault signal is fed back to the PAC ADVANCE controller to prevent the motor from burning out or the transmission components from deforming; at the same time, a physical emergency stop button is provided, which is connected to the emergency input port of the PAC ADVANCE controller. When an abnormality is detected (such as trajectory deviation or abnormal noise of the equipment), it is manually triggered to instantly cut off the power of all motors to achieve global emergency braking.

[0051] In embodiments of the present invention, such as Figure 3 As shown, after initializing the position, it checks whether the current flow channel detection is complete. If not, it waits for the detection to complete. If yes, it checks whether it is the last flow channel and switches the flow channel. If not, it continues to check whether the current flow channel detection is complete. If yes, it ends. After switching the flow channel, it monitors the position in real time. When the deviation exceeds the limit, it performs instruction compensation and continues to monitor the position in real time. When the hardware limit is triggered, it stops urgently.

[0052] In this embodiment of the invention, the software anomaly handling logic is as follows: The PAC ADVANCE controller monitors in real time the limit switch trigger signal, the overload and overcurrent fault signals fed back by the motor driver, the signal loss or abnormal jump of the position sensor and encoder, and the abnormal signal of excessive synchronous deviation of the dual motors. When the above anomalies are detected, it immediately jumps to the preset anomaly handling program. In terms of graded anomaly response, for slight deviations in position and speed within the compensation range, compensation is made by fine-tuning, and the deviation value is recorded for subsequent parameter optimization. For moderate anomalies where the deviation exceeds the limit but does not trigger hardware protection, the dual motors are stopped synchronously, and the operator is prompted to check through audible and visual alarms. The movement is restarted after manual confirmation. For serious faults that trigger limit switches, overload protection, or emergency stop signals, the process ends immediately, the motor enable is cut off, the current position data is saved to the power-down memory area of ​​the PAC ADVANCE controller, and the fault code is sent to the background system through the communication module for easy fault tracing. In terms of the post-interruption recovery mechanism, after the anomaly is cleared, the system does not need to be recalibrated. By calling the position data before the interruption stored in the power-down memory area, the rollback-retry process is automatically executed to ensure that the flow channel switching task continues and reduce the detection interruption time.

[0053] In embodiments of the present invention, such as Figure 4As shown, after an anomaly occurs, the anomaly type is determined. If the deviation is minor, the instruction is used for compensation, the deviation is recorded, and operation continues. If the anomaly is moderate, the operation is paused and an alarm is triggered. The manual confirmation is then checked. If the confirmation is successful, operation continues. If the confirmation fails, the system is stopped immediately, the location is stored, the fault code is saved, and the system waits for a reset. Upon receiving a reset signal, the system is instructed to roll back and restart. If the anomaly is severe, the system is stopped immediately, the location is stored, the fault code is saved, and the system waits for a reset. Upon receiving a reset signal, the system is instructed to roll back and restart.

[0054] In this embodiment of the invention, a modular collaborative control architecture is used to integrate the mechanical structure with the pulse direction signal of the PAC ADVANCE controller. This system achieves synchronous drive of dual motors, solving the problem of insufficient coordination in traditional independent dual-motor control. It ensures precise linkage between lifting and rotating motions to meet the continuity requirements of flow channel switching trajectories. Relying on a dynamic deviation compensation mechanism and based on the PAC ADVANCE controller function, it achieves precise conversion between pulses and displacements through electronic gear ratio configuration, corrects position deviations in real time, adapts to variable load scenarios in turbine testing, and ensures micron-level control accuracy. It adopts parameterized trajectory and efficient deployment methods, encapsulating the flow channel switching trajectory into a function module containing height and angle parameters. Batch testing is achieved through the parameters within the module, adapting to different turbine models without rewriting the program, significantly shortening the deployment cycle. A three-level safety protection system is constructed, integrating hardware limit switches, motor overload protection, and physical emergency stop buttons, with a graded abnormal response and power-off memory recovery mechanism to solve the problems of weak safety mechanisms and the need for recalibration after interruption in traditional systems. At the same time, motion logic adapted to the flow channel structure is designed. To address the blade interference problem between turbine flow channels, a spiral obstacle avoidance is planned, combined with the multi-axis interpolation function of the PAC ADVANCE controller to achieve smooth motion transition, avoid mechanism collisions, and improve testing safety.

[0055] In this embodiment of the invention, the motor of the Z-axis lifting mechanism 2 is connected to a lead screw via a coupling, and the nut is fixed to the base platform to achieve vertical movement. A 0.001mm grating ruler is installed on the Z-axis guide rail, and the signal is connected to the high-speed counting port of the PAC ADVANCE controller to provide displacement feedback. The rotation mechanism 1 is driven by a servo motor with an absolute encoder through a reducer, which drives a gear rack. The rack is fixed to the bottom of the rotation platform to achieve vertical movement. Rotation; encoder signals are input to the position feedback port of the PAC ADVANCE controller to acquire angles; the multi-axis transmission mechanism 3 relies on the guide rail positioning system to ensure rigidity; the pulse direction signal of the PAC ADVANCE controller... Its pulse direction ports are connected to the Z-axis and rotary axis motor drivers respectively, and are driven by differential signals; in terms of sensors and safety components, the upper and lower limits of the Z-axis and the rotary axis... A normally closed limit switch is installed at the point, and the signal is connected to the digital input port of the PAC ADVANCE controller. The overload signal of the dual motor drive module is connected to the fault input port, and the physical emergency stop button is connected to the emergency stop port of the PAC ADVANCE controller and connected in series with the driver enable circuit.

[0056] In this embodiment of the invention, in the basic parameter configuration, the Z-axis calculates the electronic gear ratio based on the number of pulses per revolution of the motor and the lead screw to ensure a preset millimeter-level pulse accuracy. The rotary axis calculates the electronic gear ratio based on the number of pulses per revolution of the motor and the circumferential displacement of the gear to meet the set angular-level accuracy. Simultaneously, the equipment parameter configuration includes backlash compensation, and the control parameters set the speed of each axis. In the motion control process, after initial calibration, the system first returns to zero and sets the initial coordinate system. When switching flow channels, the function module is called to execute the corresponding instructions, and multi-flow channel batch detection is achieved through a loop program. Regarding deviation compensation and safety logic, deviation and position comparison are embedded for real-time fine-tuning of out-of-tolerance positions. The specific program is as follows:

[0057] N001 Mechanical Zeroing A:00 Control Axis: Z Zeroing Direction: Negative (Z-axis returns to mechanical zero point);

[0058] N002 Mechanical Zeroing A:00 Control Axis: Y Zeroing Direction: Negative (Rotational Axis (Y-axis substitute)); Return to Mechanical Zero Point;

[0059] N003 sets the datum A:00, X:0.000, Y:0.000 (setting the initial coordinate system);

[0060] N004 Program loop A:00 Loop number: 00012 Jump address: 005 (Loop 12 times (corresponding to 12 flow channels));

[0061] N005 Function call A:00 Function name: 009 (Calling synchronous spin function);

[0062] N006 Relative position A:00 X:0.000 Y:24.000 F:200 (rotation axis increment 24° (single channel spacing angle));

[0063] N00 position comparison A:00 Comparison condition: greater than comparison axis: Y Comparison value: 0.010 Jump address: 80 (monitoring equivalent deviation of rotation axis);

[0064] N008 Program End A:00 (All flow channel detection completed);

[0065] Synchronous derotation function module (function name: 009):

[0066] N009 Function Start A:00 (Function Start Marker);

[0067] N010 Relative position A:00 X: -240.000 Y: 0.000 F: 500 (Z-axis descends 240mm to safe rotation height);

[0068] N011 Position Comparison A:00 Comparison Condition: Greater than Comparison Axis: X Comparison Value: 0.010 Jump Address: 80 (Monitoring Z-axis descent deviation);

[0069] N012 Relative position A:00 X:0.000 Y:5.000 F:100 (Synchronous rotation of the rotating shaft (low speed 100mm / min));

[0070] N013 Position Comparison A:00 Comparison Condition: Greater than Comparison Axis: Y Comparison Value: 0.010 Jump Address: 82 (Monitoring Rotational Deviation);

[0071] N014 Delay Time A:00 Delay Time: 3 (Waiting for rotation to complete (delay 3 seconds));

[0072] N015 Relative position A:00 X:240.000 Y:0.000 F:500 (Z-axis rises to detection height);

[0073] N016 Control Output A:00 Output Port: 1 Status: ON (Trigger detection device starts working);

[0074] N017 Delay Time A:00 Delay Time: 5 (Detection lasts for 5 seconds);

[0075] N018 Control Output A:00 Output Port: 1 Status: Off (Detection End);

[0076] N019 Function End A:00 (Function End Marker);

[0077] Compensation subroutine:

[0078] N080 Relative position A: 00 X: 0.000 Y: -0.005 F: 50 (rotation axis fine-tuning compensation);

[0079] N081 jumps back to N012;

[0080] N082 Relative position A:00 X:0.003 Y:0.000 F:50 (Z-axis fine-tuning compensation);

[0081] Jump from N083 back to N014.

[0082] In this embodiment of the invention, when a limit switch or overload signal is triggered, an abnormality handling process is initiated, the motor is stopped and an alarm is triggered. During an emergency stop, the enable is cut off, the position is stored, and a fault code is sent. After the abnormality is resolved, the power-down register data is called back a certain distance before the process restarts, without the need for recalibration. The specific procedure is as follows:

[0083] The main program now includes security monitoring:

[0084] N030 Conditional Jump A:00 Input Port: 1 Condition: Pass Jump Address: 50 (Input Port 1 corresponds to the Z-axis limit switch);

[0085] N031 Conditional Jump A:00 Input Port: 2 Condition: Pass Jump Address: 50 (Input Port 2 corresponds to motor overload signal);

[0086] N001 Mechanical Zeroing A:00 Control Axis: Z Zeroing Direction: Negative;

[0087] Exception handler (address 50):

[0088] N50 control output A:00 Output port: 3 Status: ON (Output port 3 corresponds to audible and visual alarm);

[0089] N51 control output A:00 Output port: 1 Status: Off (Output port 1 corresponds to dual motor enable (disconnect and stop));

[0090] N52 program ended A:00 (Enabled off, current position automatically stored in power-down memory area);

[0091] Manually trigger recovery after the anomaly is resolved:

[0092] N53 Absolute Position A:00 X:XXX.XXX Y:XXX.XXX F:100 (Recalls the position before the interrupt from the power-down memory area);

[0093] N54 relative position A:00 X: -2.000 Y: -2.000 F: 50 (retreat 2mm to avoid obstacles);

[0094] N55 absolute jump A:00 Jump address: 005 (retry flow channel switching process).

[0095] In this embodiment of the invention, the system is based on dual-motor synchronous drive, and through modular hardware design and precise control logic, it achieves efficient switching and stable operation of the flow channel detection position. It integrates the Z-axis lifting mechanism 2 (lifting motor + lead screw and nut pair) and the rotation mechanism 1 (rotation motor + gear rack / rotation platform), and uses the pulse direction signal from the PAC ADVANCE controller (… This achieves coordinated control of two motors, forming a modular coordinated control architecture. It controls the operating sequence of the lifting and rotating motors through pulse signals output within the same control cycle, solving the problem of insufficient coordination in traditional independent dual-motor control. Based on the PAC ADVANCE controller, a dynamic synchronization strategy for the coordinated control model of the two motors is constructed. This strategy adjusts the electronic gear ratio parameters by real-time acquisition of load feedback data (such as torque signals). To eliminate the impact of load disturbances on motion accuracy, incremental position adjustment and absolute coordinate positioning are achieved based on preset trajectory parameters. Deviation is calculated by real-time comparison of the actual position and the target value, triggering micron-level fine-tuning compensation for dynamic adaptation and high-precision control. The synchronous drive signal output by the PAC ADVANCE controller controls the enable state (simultaneously on or off) of the dual-motor drivers, enabling synchronous start and stop of the dual motors. A three-level safety protection system is constructed in conjunction with the guide rail limit structure: hardware limit switches trigger mechanical braking, preset abnormal judgment logic (real-time monitoring of limit signals, overload signals, etc.) initiates emergency stop response, and a real-time deviation compensation mechanism corrects out-of-tolerance positions, optimizing emergency stop response time and using a power-down memory module to record the interruption position, thus building an integrated safety and start / stop mechanism. The flow channel switching trajectory parameters (height, angle, speed, etc.) are encapsulated into callable parameter modules. By modifying the parameters within the modules, different flow channel switching requirements can be adapted without rewriting the control program, achieving parameterized trajectory and efficient deployment. An innovative unified compensation algorithm for angle deviation and arc length deviation is adopted, which compensates for the rotation axis angle deviation (…). )10. Through the arc length formula ( Converted to length unit deviation, and linear deviation of Z-axis 5 ( The total deviation is synthesized using the three-dimensional Pythagorean theorem. This system compares the deviation with 0.01mm to achieve closed-loop compensation with 0.01mm-level accuracy. Simultaneously, leveraging the trapezoidal acceleration / deceleration, dynamic electronic gear ratio configuration, and function encapsulation capabilities of the PAC ADVANCE controller, the trajectory is encapsulated into a cyclically callable function module, adaptable to batch inspection of multiple flow channels. Through dual-motor collaborative control and a unified deviation compensation algorithm, this system achieves 0.01mm-level position control accuracy, superior to the traditional 0.1mm requirement. Combined with hardware limits, software graded anomaly handling, and power-off memory functions, it significantly reduces collision risks and ensures a stable and reliable inspection process. This invention effectively solves the problems of insufficient motion accuracy and poor coordination in the inspection of large turbine flow channels through the integrated control and innovative deviation compensation strategy of the PAC ADVANCE controller. It is suitable for high-precision, high-efficiency multi-flow channel automated inspection scenarios of large turbine runner flow channels. By precisely controlling the lifting and rotating motion of the robot base, it achieves efficient switching of multi-flow channel inspection positions, meeting the requirements for motion accuracy and stability in turbine flow channel defect detection and status monitoring.

[0096] The technical solution provided by this invention includes a dual-motor drive module, a multi-axis transmission mechanism, and a closed-loop control core module. The dual-motor drive module consists of a rotating mechanism and a Z-axis lifting mechanism: the rotating mechanism is driven by a rotary motor through a gear rack or rotating platform for horizontal angle adjustment; the Z-axis lifting mechanism uses a lifting motor in conjunction with a screw and nut pair for vertical lifting of the base; the multi-axis transmission mechanism converts motor power into mechanical motion through the screw and nut pair and gear rack components to ensure the rigidity and accuracy of power transmission; the closed-loop control core module uses a PACADVANCE controller as its core, integrating a Z-axis displacement sensor and a rotary axis angle encoder, controlling the dual motors through pulse direction signals, and using electronic gear ratio configuration to convert pulses into actual displacements; during rotation, the system first descends, and then rises after reaching a safe position. In the motion control of the water turbine flow channel inspection robot, this system solves the problems of insufficient accuracy, low flow channel switching efficiency, and high safety risks.

[0097] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0098] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A motion control system based on a programmable automation controller, characterized in that, The system includes: a dual-motor drive module, a multi-axis transmission mechanism, and a closed-loop control core module; The dual-motor drive module consists of a rotating mechanism (1) and a Z-axis lifting mechanism (2): the rotating mechanism (1) is driven by a rotary motor through a gear rack or rotating platform for horizontal angle adjustment; the Z-axis lifting mechanism (2) uses a lifting motor in conjunction with a screw and nut pair for vertical lifting of the robot base; the multi-axis transmission mechanism (3) converts motor power into mechanical motion through the screw and nut pair and gear rack components to ensure the rigidity and accuracy of power transmission; the closed-loop control core module is based on the PAC ADVANCE controller, integrating a Z-axis displacement sensor and a rotary axis angle encoder, controlling the dual motors through pulse direction signals, and using the electronic gear ratio configuration function to complete the conversion between pulses and actual displacement; during rotation, it first descends, and then rises after rotating to a safe position; The displacement deviation is a spatial error in three-dimensional space. The coupling effect of the Z-axis linear deviation (5) and the rotation axis angle deviation (10) must be considered simultaneously. It is the error value between the target position (4) and the actual position (6), and the deviation of the rotation axis angle. (10) is the error value between the actual angle (8) and the target angle (9); due to the large size of the turbine, the rotation shaft angle deviation (10) will produce a significant arc length deviation (7) due to the rotation radius r; taking the rotation axis center as the origin, the rotation axis angle deviation (10) is converted into the corresponding arc length deviation (7), and the linear displacement deviation of the Z axis is unified with the length unit to realize the same dimension quantification of the deviation; The principle of converting rotation axis angle deviation (10) into arc length deviation (7): Arc length formula: Rotation axis angle deviation (10) The formula for converting to arc length deviation (7) is: ; Where s is the arc length deviation (7), which represents the equivalent displacement deviation on the rotating shaft; r is the rotation radius, which is the distance from the rotation center to the measurement point, and needs to be determined according to the actual size of the turbine. The rotation axis angle deviation is (10). ; This is the coefficient for converting angles to radians; The unified deviation compensation process is as follows: the actual linear position of the Z-axis is acquired by a grating ruler, and the actual angle of the rotary axis is acquired by an angle encoder. The deviations are calculated separately, and the linear deviation of the Z-axis is calculated directly. , rotate axis angle deviation (10) According to the formula Converted to arc length deviation (7); the total deviation, which is the straight-line distance between two points in space, is calculated using the three-dimensional Pythagorean theorem, with the transverse arc length deviation (7) and axial deviation as the legs of the right triangle, and its formula is: ,in, This is for positional deviation; examine Is it greater than the threshold? If the value is greater than the threshold, the linear position of the Z-axis is finely adjusted, i.e., compensation is performed. The rotation axis is finely adjusted in angle position, i.e., compensation. This allows for compensation decisions based on a unified unit of length.

2. The system according to claim 1, characterized in that, The PAC ADVANCE controller utilizes trapezoidal acceleration / deceleration control and vector synthesis speed adjustment to achieve multi-axis interpolation linkage between the Z-axis lifting and the rotary axis. During flow channel switching, after the Z-axis descent is initiated, the rotary axis begins to rotate synchronously at a low speed to ensure a smooth coordinated trajectory with the Z-axis descent. Simultaneously, the electronic gear ratio numerator, denominator, and backlash compensation value can be directly set in the equipment parameter configuration interface. The Z-axis descent speed and the low-speed rotation parameters of the rotary axis can be adjusted in the control parameter interface to adapt to different loads and accuracy requirements. The motion parameters of the synchronous descent and rotation trajectory are encapsulated as an independent program module, which is activated by module call instructions and set in conjunction with the number of loops.

3. The system according to claim 2, characterized in that, Electronic gear ratio parameter configuration: The physical meaning of the electronic gear is the number of pulses emitted corresponding to 0.001 mm; where, Z-axis: according to the PAC ADVANCE parameter calculation method, let the number of pulses for one motor revolution be... Lead screw mm, then the electronic gear ratio is This is used to achieve 0.001mm precision control; Rotary axis: Based on the PAC ADVANCE parameter calculation method, the number of pulses per revolution of the motor is set as follows. If the gear module is m and the number of teeth is n, the circumferential displacement corresponding to one revolution of the motor is... The electronic gear ratio is .

4. The system according to claim 1, characterized in that, The entire process is controlled by the PAC ADVANCE controller: before the first test, the base is calibrated and adjusted to the initial test position of the first flow channel, then the mechanical zero point return of the Z-axis and the rotary axis is completed, and the reference definition initial coordinate system is set to ensure that the test starting point is consistent. By controlling the output to synchronously enable or disconnect the dual motor drive module, the lifting motor and the rotary motor can be started or stopped simultaneously to avoid trajectory deviation caused by start-stop timing deviation. After the current flow channel is inspected, the switching action is automatically executed according to the preset trajectory to reach the initial position of the next flow channel inspection; The actual position (6) of the dual-motor drive module is compared with the target value in real time. If the position deviation is greater than 0.01mm, fine-tuning compensation is immediately performed to avoid trajectory distortion.

5. The system according to claim 1, characterized in that, Hardware safety protection: Hardware limit switches are set at the extreme positions of the Z-axis lifting mechanism (2) and the rotating mechanism (1). When the base moves close to the mechanical limit, the switch is triggered and an interrupt signal is sent to the PAC ADVANCE controller to force the motor to stop running in order to avoid collision or overtravel damage to the mechanism; The dual motor drive module has a built-in overload protection module. When the load is greater than the rated value during lifting or rotating, the motor power is automatically cut off and a fault signal is fed back to the PAC ADVANCE controller to prevent the motor from burning out or the transmission components from deforming; At the same time, a physical emergency stop button is equipped and connected to the emergency input port of the PAC ADVANCE controller. When an abnormality is detected, it is manually triggered to instantly cut off the power of all motors to achieve global emergency braking.

6. The system according to claim 5, characterized in that, Software anomaly handling logic: The PAC ADVANCE controller monitors limit switch trigger signals, overload and overcurrent fault signals from motor drivers, signal loss or abnormal jumps from position sensors and encoders, and abnormal signals indicating excessive synchronization deviation of the dual motors in real time. When any of these anomalies are detected, the system immediately jumps to the preset anomaly handling procedure. Regarding graded anomaly responses, for minor deviations in position and speed within the compensation range, compensation is achieved through fine-tuning, and the deviation value is recorded for subsequent parameter optimization. For moderate anomalies where deviation exceeds limits but hardware protection is not triggered, both motors are stopped synchronously, and an audible and visual alarm prompts the operator to check. Movement is restarted after manual confirmation. For severe faults that trigger limit switches, overload protection, or emergency stop signals, the system immediately terminates, disconnects motor enable, saves the current position data to the PAC ADVANCE controller's power-down memory area, and sends a fault code to the backend system via the communication module for easy fault tracing. Regarding the post-interruption recovery mechanism, after the anomaly is resolved, the system does not need to recalibrate; it automatically executes a rollback-retry process by calling the position data stored in the power-down memory area before the interruption.

7. The system according to claim 1, characterized in that, The motor of the Z-axis lifting mechanism (2) is connected to the lead screw via a coupling, and the nut is fixed to the base platform to achieve vertical movement. A 0.001mm grating ruler is installed on the Z-axis guide rail, and the signal is connected to the high-speed counting port of the PACADVANCE controller to provide displacement feedback. The rotation mechanism (1) is driven by a servo motor with an absolute encoder through a reducer to drive a gear rack. The rack is fixed to the bottom of the rotating platform to achieve vertical movement. Rotation, encoder signal input to PACADVANCE controller position feedback port to acquire angle; multi-axis transmission mechanism (3) relies on guide rail positioning system to ensure rigidity; PACADVANCE controller pulse direction signal Its pulse direction ports are connected to the Z-axis and rotary axis motor drivers respectively, and are driven by differential signals; in terms of sensors and safety components, the upper and lower limits of the Z-axis and the rotary axis... A normally closed limit switch is installed at the point, and the signal is connected to the digital input port of the PAC ADVANCE controller. The overload signal of the dual motor drive module is connected to the fault input port, and the physical emergency stop button is connected to the emergency stop port of the PAC ADVANCE controller and connected in series with the driver enable circuit.

8. The system according to claim 1, characterized in that, In the basic parameter configuration, the Z-axis calculates the electronic gear ratio based on the number of pulses per motor revolution and the lead screw to ensure preset millimeter-level pulse accuracy. The rotary axis calculates the electronic gear ratio based on the number of pulses per motor revolution and the circumferential displacement of the gear to meet the set angular-level accuracy. At the same time, the equipment parameter configuration includes backlash compensation, and the control parameters set the speed of each axis. In terms of motion control, after the initial run is calibrated, it first returns to the zero point and sets the reference to define the initial coordinate system. When switching flow channels, the function module is called to execute the corresponding instructions, and multi-flow channel batch detection is achieved through a loop program. In terms of deviation compensation and safety logic, deviation and position comparison are embedded for real-time fine-tuning of out-of-tolerance positions.

9. The system according to claim 5, characterized in that, When a limit switch or overload signal is triggered, abnormal handling is initiated, the motor is stopped and an alarm is triggered. During emergency stop, the enable is cut off and the position is stored and a fault code is sent. After the abnormality is cleared, the power-down register data is called back a certain distance and the process is restarted without recalibration.

Images