Driving and control integrated multi-axis motion sliding table control system and control method thereof

Abstract

The invention discloses a driving and control integrated multi-axis motion sliding table control system and a control method thereof. The system comprises an upper computer, a controller, a driving plate and a mechanical module. The controller adopts a heterogeneous collaborative architecture of a digital signal processor and a field-programmable gate array, the digital signal processor is specially used for executing multi-axis position loop control, the field-programmable gate array is specially used for executing speed loop and current loop vector control of the servo motor, and the digital signal processor and the field-programmable gate array perform data synchronization through a shared memory. And the driving plate and the controller are directly and closely connected through a connector. The method is based on the system, high-precision closed-loop control over multi-axis motion is achieved, and the real-time performance and precision of multi-axis linkage control and the anti-interference capacity of the system are effectively improved through hardware division and integrated compact design.

Description

Technical Field

[0001] This invention relates to the field of industrial automation technology, and in particular to a multi-axis motion slide control system and control method that integrates drive and control. Background Technology

[0002] Multi-axis motion slides are core actuators in precision manufacturing, automated assembly, and semiconductor processing. The performance of their control systems directly determines the motion accuracy, response speed, and reliability of the equipment. Traditional multi-axis motion control systems typically employ a distributed architecture, where the host computer, motion controller, servo driver, and motor are connected via long-distance cables. In this architecture, the controller is responsible for trajectory planning and position loop control, while the driver independently handles the speed and current loop control. While this discrete design offers high modularity, it also has significant drawbacks: the various units within the system require numerous analog or pulse signal lines for connection, resulting in complex and costly wiring. Furthermore, long-distance transmission is susceptible to electromagnetic interference, affecting the stability and real-time performance of the control signals, ultimately hindering the improvement of the overall system accuracy and reliability.

[0003] To overcome the aforementioned problems, integrated drive and control technology has emerged. This technology aims to highly integrate motion controllers and servo drives at the physical and electrical levels to reduce external wiring, compress system size, and improve signal processing efficiency. Currently, some integrated drive and control solutions on the market primarily use a single high-performance processor (such as a multi-core ARM or high-end DSP) to perform multi-axis control algorithm calculations. However, this single-processor architecture often faces computational bottlenecks and task scheduling delays when handling real-time control tasks involving multiple axes and multiple closed loops (position, velocity, current), especially when the number of axes increases or the control cycle requirements are extremely stringent. Specifically, position loop, velocity loop, and current loop control tasks mutually consume computational resources, making it difficult to guarantee system real-time performance; complex vector control algorithms (such as field-oriented control) are inefficient under high dynamic response requirements. These problems mean that existing integrated drive and control solutions still have room for improvement in performance and reliability when achieving high-precision, high-synchronization multi-axis linkage control.

[0004] Therefore, how to design a solution that can inherit the advantages of integrated drive and control structure, such as compactness and strong anti-interference capability, while effectively meeting the requirements of multi-axis motion control systems for high real-time performance, high precision, and high reliability has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, embodiments of the present invention provide a multi-axis motion slide control system and control method that integrates drive and control.

[0006] To achieve the above objectives, the innovative aspects of this invention are as follows:

[0007] The host computer is used to provide the human-computer interaction interface, motion control algorithms, and Ethernet communication functions.

[0008] The controller communicates with the host computer and is used to receive position commands;

[0009] The driver board is electrically connected to the controller via connectors;

[0010] The controller includes a control board and a digital signal processor and a field-programmable gate array mounted on the control board;

[0011] The digital signal processor is configured to perform position loop control of the multi-axis motion slide;

[0012] The field-programmable gate array is configured to perform vector control of the velocity loop and current loop of a multi-axis motion slide;

[0013] The digital signal processor and the field-programmable gate array work together to generate multiple PWM control signals based on position commands, and transmit them to the driver board through connectors. The driver board then drives the servo motors of the multi-axis motion slide to achieve closed-loop vector control.

[0014] Furthermore, the controller also includes a 24V DC power supply unit to power the control board.

[0015] Furthermore, the aforementioned control board is also equipped with peripheral circuitry connecting the digital signal processor and the field-programmable gate array (FPGA) to realize closed-loop control of the position loop, speed loop, and current loop.

[0016] Furthermore, the aforementioned field-programmable gate array implements a vector control algorithm for the current loop based on a system-on-a-chip platform.

[0017] Furthermore, the aforementioned digital signal processor runs control software based on the SYS / BIOS real-time operating system.

[0018] Furthermore, the aforementioned host computer was developed based on the RTX real-time operating system.

[0019] Furthermore, the aforementioned driver board is an independent board that can be plugged into and connected to the control board via connectors.

[0020] Furthermore, the system also includes a multi-axis motion slide mechanical module, with the output end of the drive board connected to the input end of each servo motor in the mechanical module.

[0021] This invention provides a control method for a multi-axis motion slide, comprising the following steps:

[0022] The host computer generates position commands and sends them to the controller;

[0023] The controller's digital signal processor receives instructions and performs position loop control calculations;

[0024] The controller's field-programmable gate array receives data from the digital signal processor and performs vector control calculations for the speed loop and current loop;

[0025] A digital signal processor and a field-programmable gate array work together to generate multiple PWM control signals;

[0026] The PWM control signal is transmitted to the driver board via a connector.

[0027] The driver board drives each servo motor according to the PWM control signal to realize closed-loop linkage control of the multi-axis motion slide.

[0028] Furthermore, the present invention also includes a system debugging step:

[0029] Connect the control system to the multi-axis motion slide mechanical module and perform joint debugging;

[0030] Optimize the control parameters until the position control accuracy of the multi-axis motion slide reaches ±0.01mm, the repeatability accuracy reaches ±0.005mm, and the multi-axis synchronization error is no greater than 0.002mm.

[0031] The beneficial effects of this invention are:

[0032] 1. High control precision and strong real-time performance. This invention employs a heterogeneous collaborative processing architecture of a digital signal processor (DSP) and a field-programmable gate array (FPGA), with a clear division of tasks: the DSP is dedicated to executing the computationally complex and relatively long-cycle position loop control algorithm (1ms cycle), while the FPGA executes the speed loop (100μs cycle) and current loop (50μs cycle) vector control algorithms in parallel and at high speed. This architecture fully leverages the respective advantages of the DSP in complex algorithm processing and the FPGA in high-speed parallel computing, achieving decoupling and precise timing scheduling of multi-closed-loop control tasks, effectively overcoming the computing power bottleneck and task interference problems of a single processor architecture. As a result, the system's control response to the servo motors of each axis is faster and more precise, providing a solid hardware and algorithmic foundation for achieving the high position control precision (±0.01mm) and high repeatability positioning precision (±0.005mm) described in the claims.

[0033] 2. High system reliability and strong anti-interference capability. This invention adopts a compact integrated drive and control hardware layout, directly connecting the controller and driver board adjacently via board-to-board connectors, forming an integrated unit. This design minimizes the lengthy power lines and signal cables required between the controller and driver in traditional distributed architectures. The short-distance connection significantly reduces signal attenuation, delay, and the risk of external electromagnetic interference during transmission, improving the transmission quality and reliability of PWM control signals and current feedback signals. Simultaneously, the simplified physical structure reduces potential connection failure points, making the entire control system more stable and reliable, especially suitable for industrial applications requiring high stability for long-term continuous operation. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the overall hardware architecture of the multi-axis motion slide control system of the present invention. Detailed Implementation

[0035] 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, and 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.

[0036] Example 1: Integrated Drive and Control Multi-Axis Motion Slide Control System

[0037] like Figure 1 As shown, the present invention provides a multi-axis motion slide control system that integrates drive and control. It adopts a modular integrated design, and its hardware architecture mainly includes four core modules: host computer 1, controller 2, drive board 3, and multi-axis motion slide mechanical module 4.

[0038] 1. Module composition and functions

[0039] The host computer 1, an industrial control computer, runs control software based on the RTX real-time operating system and is responsible for human-computer interaction, motion trajectory planning, and Ethernet communication. Host computer 1 generates multi-axis coordinated position commands and sends them to controller 2 in real time via Ethernet.

[0040] Controller 2, the core processing unit of the system, adopts an integrated drive and control design and integrates the following internal components:

[0041] The digital signal processor 21, based on the SYS / BIOS real-time operating system, is specifically responsible for multi-axis position loop control, including interpolation calculation and position PID adjustment;

[0042] The Field Programmable Gate Array 22, based on a system-on-a-chip platform, is specifically responsible for the vector control of the speed loop and current loop of servo motors;

[0043] Peripheral circuits 23, including clock circuits, signal conditioning circuits, isolation circuits, etc., support the collaborative operation of digital signal processor 21 and field programmable gate array 22;

[0044] Connector 24 is a standard board-to-board connector used to output PWM control signals.

[0045] The controller 2 receives position commands from the host computer 1 and generates multiple PWM control signals through the coordinated processing of the digital signal processor 21 and the field programmable gate array 22. The controller 2 also includes a 24V DC power supply unit 25 to power the control board.

[0046] Driver board 3 is a power drive unit, which is directly and pluggably connected to controller 2 via connector 24, and internally includes:

[0047] The three-phase inverter bridge 31 converts the PWM control signal into three-phase AC power to drive the servo motor.

[0048] The current sampling circuit 32 monitors the motor phase current in real time and is used for current loop closed-loop control.

[0049] The fault protection circuit 33 provides overcurrent, overtemperature, and short-circuit protection functions.

[0050] The multi-axis motion slide mechanical module 4 is an actuator, which includes multiple servo motor modules 41. Each module includes a servo motor and a position encoder to achieve precise multi-axis linkage motion.

[0051] 2. Signal flow and control loop

[0052] The signal flow of the system forms a complete closed-loop control.

[0053] Forward control pathway:

[0054] Host computer 1 → Controller 2 → Drive board 3 → Multi-axis motion slide mechanical module 4.

[0055] The specific process is as follows:

[0056] 1. The host computer 1 sends the position command to the digital signal processor 21 of the controller 2 via Ethernet;

[0057] 2. The digital signal processor 21 performs position loop calculation and transmits the target speed command to the field programmable gate array 22;

[0058] 3. The field-programmable gate array 22 performs speed loop and current loop calculations to generate multiple PWM signals;

[0059] 4. The PWM signal is transmitted to the three-phase inverter bridge 31 of the driver board 3 through connector 24;

[0060] 5. The inverter bridge converts the PWM signal into a power drive signal to drive the servo motors of each axis.

[0061] Feedback control path:

[0062] Multi-axis motion slide mechanical module 4 → Controller 2 → Control parameter adjustment.

[0063] The specific process is as follows:

[0064] 1. The encoders of each axis servo motor provide real-time feedback of position and speed signals;

[0065] 2. The current sampling circuit 32 of the driver board 3 monitors the motor phase current in real time;

[0066] 3. The encoder signal and current sampling signal are fed back to the field programmable gate array 22 of the controller 2;

[0067] 4. The field-programmable gate array 22 uses feedback signals for closed-loop control of the speed loop and current loop;

[0068] 5. Adjust the PWM output in real time to control deviation, forming a complete closed-loop control circuit.

[0069] 3. Spatial Layout Characteristics

[0070] like Figure 1 As shown, the system adopts a compact integrated drive and control layout:

[0071] The host computer 1 is located on the left side of the system and is connected to the controller 2 via Ethernet;

[0072] Controller 2 is located to the right of host computer 1, and is closely adjacent to driver board 3;

[0073] The driver board 3 is located to the right of the controller 2 and is directly connected via connector 24;

[0074] The multi-axis motion slide mechanical module 4 is located at the bottom of the system and receives power from the drive board 3.

[0075] This layout significantly reduces long-distance cabling in traditional distributed architectures, improving the reliability and interference resistance of signal transmission.

[0076] 4. Collaborative work and task division between DSP and FPGA

[0077] The control system adopts a heterogeneous collaborative architecture of digital signal processor 21 and field programmable gate array 22, which achieve efficient data exchange through shared memory.

[0078] Digital signal processor 21 processing domain: primarily responsible for the position loop control of the multi-axis motion slide, specifically including:

[0079] Receive position commands sent by the host computer;

[0080] Perform forward-looking processing of motion trajectories;

[0081] Perform multi-axis linear / circular interpolation calculations;

[0082] Complete the PID control of the position loop;

[0083] Output the target speed command to shared memory.

[0084] The 22-bit field-programmable gate array (FPGA) processing domain is primarily responsible for the vector control of the servo motor's speed and current loops, specifically including:

[0085] Read the target speed instruction calculated by the digital signal processor 21 from shared memory;

[0086] Execute the PI control algorithm for the speed loop;

[0087] Perform Clarke / Park transformation to achieve magnetic field orientation control;

[0088] PI regulation of the current loop is implemented;

[0089] The PWM drive signal is generated by inverse Park transform and SVPWM modulation.

[0090] Collaborative work sequence:

[0091] The position loop control cycle is 1ms, which is completed by the digital signal processor 21 in each cycle;

[0092] The speed loop control cycle is 100μs and is executed at high speed by a 22-field programmable gate array.

[0093] The current loop control cycle is 50μs and is processed in parallel by a 22-field programmable gate array.

[0094] The digital signal processor 21 and the field programmable gate array 22 achieve data synchronization through shared memory, ensuring the consistency of control timing.

[0095] During multi-axis data synchronization, if the data update of a certain axis is abnormal, the system uses the valid data from the previous cycle for interpolation compensation and triggers an abnormal alarm to ensure that the system can still operate safely under partial failure.

[0096] Data exchange mechanism:

[0097] A shared memory area is provided on the control board. The digital signal processor 21 writes the calculated target speed command into this area, and the field-programmable gate array 22 reads the command in each control cycle. Simultaneously, the field-programmable gate array 22 writes the real-time status data of the motor into the shared memory for system monitoring and fault handling by the digital signal processor 21. The shared memory adopts a dual-port RAM structure and is equipped with a read-write mutual exclusion mechanism to ensure the integrity and consistency of multi-axis data during concurrent access.

[0098] Example 2: Control method for multi-axis motion slide

[0099] Using the system described in Embodiment 1, the control method includes the following steps:

[0100] 1. Initialization and parameter settings

[0101] The system is powered on and initializes the digital signal processor 21, the field programmable gate array 22, and the peripheral circuits 23.

[0102] Set servo motor parameters;

[0103] Configure control parameters.

[0104] 2. Main Control Flow

[0105] 1. Host computer trajectory planning: Host computer 1 generates a multi-axis coordinated position command sequence based on the machining task and sends it to controller 2 in real time via Ethernet;

[0106] 2. Position loop processing of digital signal processor 21: Digital signal processor 21 receives position commands, performs interpolation calculations and position loop PID adjustment, and calculates the target speed of each axis;

[0107] 3. Data writing to the shared area: The digital signal processor 21 writes the target speed command to the memory area shared with the field programmable gate array 22;

[0108] 4. Speed ​​loop processing of the field-programmable gate array 22: The field-programmable gate array 22 reads the target speed from the shared memory, combines it with the actual speed fed back by the encoder, and performs speed loop PI adjustment;

[0109] 5. Current loop processing of the field-programmable gate array 22: The field-programmable gate array 22 performs Clarke / Park conversion, executes current loop PI regulation, and generates PWM signal through SVPWM modulation;

[0110] 6. Signal transmission and driving: The PWM signal is transmitted to the driver board 3 through connector 24, and after being amplified by the three-phase inverter bridge 31, it drives each servo motor;

[0111] 7. Feedback Acquisition and Processing: The motor encoder signal is fed back to the field programmable gate array 22 in real time for closed-loop control;

[0112] 8. Cyclic execution: The above steps are executed cyclically in each control cycle to achieve continuous motion control.

[0113] 3. Feedback control loop

[0114] The encoder signals of each axis motor are fed back to the encoder decoding module of the field programmable gate array 22 in real time;

[0115] The field-programmable gate array 22 simultaneously acquires three-phase current signals and performs current loop closed-loop control.

[0116] Position and speed deviations are adjusted in real time to ensure motion accuracy.

[0117] 4. System debugging and optimization

[0118] Servo parameter tuning should be performed upon first use;

[0119] Measure the motion accuracy of each axis using a laser interferometer;

[0120] Repeatedly adjust the control parameters until the preset performance indicators are achieved:

[0121] Position control accuracy: ±0.01mm;

[0122] Repeatability: ±0.005mm;

[0123] Multi-axis synchronization error: ≤0.002mm.

[0124] 5. Fault Handling and Protection

[0125] Real-time monitoring of motor current, temperature and other parameters;

[0126] It automatically enters protection mode in case of overcurrent, overtemperature, or overload.

[0127] Fault information is uploaded to the host computer 1 for display and recording.

[0128] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0129] Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

[0130] In conclusion, 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 protection scope of the present invention.

Claims

1. A multi-axis motion slide control system integrating drive and control, characterized in that, include: The host computer is used to provide the human-computer interaction interface, motion control algorithms, and Ethernet communication functions. The controller is communicatively connected to the host computer and is used to receive position commands; The driver board is electrically connected to the controller via connectors; The controller includes a control board and a digital signal processor and a field-programmable gate array (FPGA) mounted on the control board. The digital signal processor is configured to perform position loop control of the multi-axis motion slide; The field-programmable gate array is configured to perform vector control of the velocity loop and current loop of the multi-axis motion slide; The digital signal processor works in conjunction with the field-programmable gate array to generate multiple PWM control signals based on the position command, and transmits them to the driver board through the connector. The driver board then drives the servo motors of the multi-axis motion slide to achieve closed-loop vector control.

2. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The controller also includes a 24V DC power supply unit for powering the control board.

3. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The control board is also equipped with peripheral circuits that connect the digital signal processor and the field programmable gate array, for realizing closed-loop control of the position loop, speed loop and current loop.

4. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The field-programmable gate array implements the vector control algorithm of the current loop based on a system-on-a-chip platform.

5. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The digital signal processor runs control software based on the SYS / BIOS real-time operating system.

6. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The host computer is developed based on the RTX real-time operating system.

7. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The driver board is an independent board that can be plugged into and connected to the control board via the connector.

8. The integrated drive and control multi-axis motion slide control system according to claim 1, characterized in that, The system also includes a multi-axis motion slide mechanical module, and the output end of the drive board is connected to the input end of each servo motor in the mechanical module.

9. A control method for a multi-axis motion slide, employing the system as described in any one of claims 1 to 8, characterized in that, Includes the following steps: The host computer generates position commands and sends them to the controller; The controller's digital signal processor receives the instructions and performs position loop control calculations; The controller's field-programmable gate array receives data from the digital signal processor and performs vector control calculations for the speed loop and current loop; A digital signal processor and a field-programmable gate array work together to generate multiple PWM control signals; The PWM control signal is transmitted to the driver board via a connector; The drive board drives each servo motor according to the PWM control signal to realize closed-loop linkage control of the multi-axis motion slide.

10. The control method according to claim 9, characterized in that, It also includes system debugging steps: Connect the control system to the multi-axis motion slide mechanical module and perform joint debugging; Optimize the control parameters until the position control accuracy of the multi-axis motion slide reaches ±0.01mm, the repeatability accuracy reaches ±0.005mm, and the multi-axis synchronization error is no greater than 0.002mm.

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