Intelligent control system for the entire production process of concrete poles

Abstract

This invention relates to the field of intelligent manufacturing and concrete product production equipment control technology, specifically an intelligent control system for the entire production process of concrete poles. The system includes: a reference parameter identification unit for performing a stepped acceleration test and calculating the empty mold impedance parameter characterizing the inherent mechanical resistance of the mold; a load torque observation unit for acquiring the electromagnetic drive torque in real time and extracting the net load torque acting only on the concrete material; a rheological and distribution state analysis unit for calculating the dimensionless eccentricity factor characterizing the uniformity of material distribution; and an adaptive closed-loop control unit for generating corresponding control commands: an emergency braking command is output when the eccentricity exceeds the safety limit, a constant-speed shearing command is output when the rheological state does not meet the standard, and an adaptive acceleration command is output when the rheological state meets the standard and the eccentricity is within the safe range. This invention solves the problem of the inability to directly observe the material state within a closed mold, achieving transparent monitoring of the physical properties of concrete.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing and concrete product production equipment control technology, specifically an intelligent control system for the entire production process of concrete poles. Background Technology

[0002] In the centrifugal molding production of concrete poles, the precise control of centrifugal process parameters directly determines the density and concentricity of the product. Existing production solutions generally rely on manual experience or preset fixed time-speed curves for open-loop control, which cannot perceive the actual rheological characteristics and distribution of concrete inside the mold in real time. Due to the differences in mechanical impedance between individual molds, and the dynamic changes in the physical properties of concrete in a closed environment during the centrifugation process, this control mode without feedback leads to a blind state in the production process, making it difficult to accurately control the timing of material liquefaction and the balance of distribution. This results in large fluctuations in product quality, low pass rates, and even equipment vibration failures due to severe eccentricity. Therefore, how to eliminate interference from equipment differences and achieve real-time quantitative perception and dynamic closed-loop adjustment of the physical state of materials inside the closed mold has become an urgent technical problem to be solved. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides an intelligent control system for the entire process of concrete pole production. Specifically, the technical solution of the present invention includes:

[0004] The intelligent control system for the entire production process of concrete poles includes: a reference parameter identification unit, a load torque observation unit, a rheological and distribution state analysis unit, and an adaptive closed-loop control unit.

[0005] The reference parameter identification unit is used to perform a step-by-step speed-up test under the no-load state of the centrifuge, collect the real-time operating data of the drive motor, calculate the empty mold impedance parameter that characterizes the inherent mechanical resistance of the mold through regression analysis, and send the empty mold impedance parameter to the load torque observation unit.

[0006] The load torque observation unit is used to acquire the electromagnetic drive torque in real time during the concrete feeding and centrifugation stages, and to calculate the mechanical consumption torque of the mold itself at the current speed using the empty mold impedance parameters. The electromagnetic drive torque is subtracted from the mechanical consumption torque to extract the net load torque that only acts on the concrete material.

[0007] The rheological and distribution state analysis unit is used to perform micro-disturbance response analysis on the net load torque, calculate the equivalent dynamic viscosity characterizing the flow state of concrete, and extract the frequency domain features of the net load torque to calculate the dimensionless eccentricity factor characterizing the uniformity of material distribution.

[0008] The adaptive closed-loop control unit is used to generate corresponding control commands based on the preset numerical range of the dimensionless eccentricity factor and the equivalent dynamic viscosity: when the eccentricity exceeds the safety limit, it outputs an emergency braking command; when the rheological state does not meet the standard, it outputs a constant-rate shear command; and when the rheological state meets the standard and the eccentricity is within the safe range, it outputs an adaptive acceleration command.

[0009] Preferably, the process by which the reference parameter identification unit calculates the empty-mode impedance parameters is as follows:

[0010] Collect data on the mechanical angular velocity, angular acceleration, and stator torque current components of the centrifuge during the no-load acceleration process;

[0011] A linear equation system based on rigid body dynamics is constructed, with the stator torque current component as the input variable and the mechanical angular velocity and angular acceleration as the state variables. The least squares algorithm is used to fit three constant terms, which are defined as the moment of inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque, respectively.

[0012] The rotational inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque are combined and set as the impedance parameters of the empty mold.

[0013] Preferably, the process by which the load torque observation unit obtains the net load torque is as follows:

[0014] Construct an observation model that includes a velocity feedback correction mechanism;

[0015] The stator current collected in real time is converted into electromagnetic drive torque;

[0016] Based on the current mechanical angular velocity and angular acceleration, and combined with the empty mold impedance parameters, the theoretical mechanical torque required for the mold to overcome inertia, viscous friction and static friction is calculated.

[0017] The difference between the electromagnetic drive torque and the theoretical mechanical torque is calculated, and this difference is superimposed with the compensation value generated based on the speed observation error. The final value after superposition is determined as the net load torque.

[0018] The preferred method for micro-perturbation response analysis and equivalent dynamic viscosity calculation is as follows:

[0019] A sinusoidal wave signal with a preset frequency and amplitude is superimposed on the basic speed command of the centrifuge.

[0020] The collected net load torque data and mechanical angular velocity data are subjected to high-pass filtering to remove the DC component and extract the torque fluctuation component and speed fluctuation component that are consistent with the frequency of the sinusoidal fluctuation signal.

[0021] Calculate the root mean square value of the torque fluctuation component and the root mean square value of the speed fluctuation component within the preset time window, respectively.

[0022] Calculate the ratio between the root mean square value of the torque ripple component and the root mean square value of the speed ripple component.

[0023] Obtain the inner radius and effective length of the mold, calculate the geometric constant related to the lateral area or volume of the cylinder determined by the two, divide the ratio by the geometric constant, and determine the result as the equivalent dynamic viscosity.

[0024] The preferred process for frequency domain feature extraction and the calculation of the dimensionless eccentricity factor is as follows:

[0025] Perform a fast Fourier transform on the net load torque data in the time domain to extract the spectral amplitude whose frequency is consistent with the fundamental frequency of the current centrifuge speed;

[0026] Obtain the total mass of the concrete, the gravitational acceleration constant, and the mold radius; calculate the product of these three values; and define the product as the theoretical maximum gravitational torque.

[0027] Calculate the ratio of the spectral amplitude to the theoretical maximum gravitational torque, and determine this dimensionless ratio as the dimensionless eccentricity factor.

[0028] Preferably, the instruction generation logic of the adaptive closed-loop control unit is as follows:

[0029] A critical eccentricity threshold characterizing the safety limit of the equipment and a rheological threshold characterizing the liquefaction state of concrete are preset.

[0030] Step 1: Determine if the dimensionless eccentricity factor is greater than the critical eccentricity threshold. If so, generate an emergency braking command directly.

[0031] The second step is to determine whether the equivalent dynamic viscosity is greater than the rheological threshold if the dimensionless eccentricity factor is less than or equal to the critical eccentricity threshold.

[0032] If so, it indicates that the concrete has not yet liquefied, and a constant-rate shear command is generated to maintain the current rotation speed;

[0033] If not, it indicates that the concrete has liquefied and is safely distributed, and an adaptive acceleration command is generated.

[0034] Preferably, the target acceleration included in the adaptive acceleration command is determined by the following logic:

[0035] Obtain the preset maximum allowable acceleration value and the preset eccentricity control limit;

[0036] Calculate the proportion of the current dimensionless eccentricity factor in the eccentricity control limit;

[0037] Calculate the difference between constant 1 and the numerical ratio, and use this difference as the dynamic weighting coefficient;

[0038] Calculate the product of the maximum permissible acceleration value and the dynamic weighting coefficient, and determine the resulting product value as the target acceleration;

[0039] When the dimensionless eccentricity factor exceeds the eccentricity control limit, the dynamic weighting coefficient becomes negative. The system then performs a linear deceleration operation based on the target acceleration of this negative value until the eccentricity condition is improved.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] 1. This invention accurately eliminates mechanical resistance interference caused by differences in size or wear of different molds by performing a stepped speed-up test under no-load conditions and analyzing the impedance parameters of the empty mold; in load observation, this parameter is used to strip away the wear of the mold itself in real time, retaining only the net load acting on the concrete, thereby eliminating the influence of individual equipment differences on the control system and ensuring the consistency of the production process of multiple machines and the accuracy of the observation data.

[0042] 2. This invention constructs a non-intrusive sensing mechanism based on net load torque, which solves the problem that the material state inside a closed mold cannot be directly observed. Through micro-perturbation response analysis and frequency domain feature extraction, the equivalent dynamic viscosity characterizing the flow state and the dimensionless eccentricity factor characterizing the distribution uniformity are calculated in real time, realizing transparent monitoring of the physical properties of concrete and providing core data support for getting rid of dependence on manual experience and realizing digital production.

[0043] 3. This invention establishes an adaptive closed-loop control strategy that dynamically adjusts the process based on the real-time state of the material; the system can determine the degree of concrete liquefaction based on the viscosity index, and execute constant-rate shearing to promote rheology when the standard is not met, and automatically accelerate when the standard is met and balanced; this control method ensures that the concrete is centrifugally molded in the best physical state, effectively avoiding delamination or hollowing, and significantly improving the concrete density of the finished pole.

[0044] 4. This invention designs a multi-level safety protection and self-healing control mechanism; when the eccentricity factor is detected to exceed the safety limit, an emergency brake is immediately applied to protect the equipment; when the eccentricity is within a controllable range but exceeds the standard, linear deceleration is performed by dynamically adjusting the target acceleration, and the gravity collapse effect is used to promote the redistribution of the accumulated materials; this mechanism not only prevents equipment failure caused by severe vibration, but also gives the system the ability to automatically correct material distribution deviations, ensuring production continuity. Attached Figure Description

[0045] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0046] Figure 1 This is a structural diagram of the system of the present invention. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0048] Example 1:

[0049] Please see Figure 1 The intelligent control system for the entire production process of concrete poles includes a reference parameter identification unit, a load torque observation unit, a rheological and distribution state analysis unit, and an adaptive closed-loop control unit.

[0050] The reference parameter identification unit is used to perform a step-by-step speed-up test under the no-load state of the centrifuge, collect the real-time operating data of the drive motor, calculate the empty mold impedance parameter that characterizes the inherent mechanical resistance of the mold through regression analysis, and send the empty mold impedance parameter to the load torque observation unit.

[0051] The load torque observation unit is used to acquire the electromagnetic drive torque in real time during the concrete feeding and centrifugation stages, and to calculate the mechanical consumption torque of the mold itself at the current speed using the empty mold impedance parameters. The electromagnetic drive torque is subtracted from the mechanical consumption torque to extract the net load torque that only acts on the concrete material.

[0052] The rheological and distribution state analysis unit is used to perform micro-disturbance response analysis on the net load torque, calculate the equivalent dynamic viscosity characterizing the flow state of concrete, and extract the frequency domain features of the net load torque to calculate the dimensionless eccentricity factor characterizing the uniformity of material distribution.

[0053] The adaptive closed-loop control unit is used to generate corresponding control commands based on the preset numerical range of the dimensionless eccentricity factor and the equivalent dynamic viscosity: when the eccentricity exceeds the safety limit, it outputs an emergency braking command; when the rheological state does not meet the standard, it outputs a constant-rate shear command; and when the rheological state meets the standard and the eccentricity is within the safe range, it outputs an adaptive acceleration command.

[0054] This embodiment provides an intelligent control system for the entire process of concrete pole production, which aims to solve the problem of unstable product quality caused by reliance on manual experience and inability to perceive the material status in real time in traditional centrifugal processes. The system includes four core collaborative units: a reference parameter identification unit, a load torque observation unit, a rheological and distribution state analysis unit, and an adaptive closed-loop control unit.

[0055] The reference parameter identification unit, as the initialization calibration module of the system, is configured to operate in an unloaded state before the centrifuge is filled with concrete. It collects real-time operating data of the drive motor by performing a step-by-step speed-up test, and uses regression analysis to calculate the empty mold impedance parameter that characterizes the inherent mechanical resistance of the mold, and sends the empty mold impedance parameter to the load torque observation unit.

[0056] The load torque observation unit, as the sensing layer of the system, works during the concrete placement and centrifugation stages. It is configured to acquire the electromagnetic driving torque in real time and calculate the mechanical consumption torque of the mold itself at the current speed using the aforementioned empty mold impedance parameters. By subtracting the mechanical consumption torque from the electromagnetic driving torque, the unit can extract the net load torque that acts only on the concrete material, thereby achieving transparent monitoring of the stress on the material inside the mold.

[0057] The rheology and distribution state analysis unit is responsible for converting physical signals into process state indicators. On the one hand, this unit performs micro-disturbance response analysis on the net load torque and calculates the equivalent dynamic viscosity that characterizes the flow state of concrete. On the other hand, it extracts frequency domain features from the net load torque and calculates the dimensionless eccentricity factor that characterizes the uniformity of material distribution.

[0058] The adaptive closed-loop control unit, acting as the decision-making layer, generates corresponding control commands based on the preset numerical range of the dimensionless eccentricity factor and the equivalent dynamic viscosity. Specifically, it outputs an emergency braking command when the eccentricity exceeds the safety limit; it outputs a constant-rate shearing command when the rheological state does not meet the standard; and it outputs an adaptive acceleration command when the rheological state meets the standard and the eccentricity is within the safe range. Through the coordination of the above units, this system can dynamically adjust the centrifugal process based on the real-time physical state of the material, significantly improving the compactness and concentricity of the pole.

[0059] Example 2:

[0060] The process of the reference parameter identification unit solving the empty mode impedance parameters is as follows:

[0061] Collect data on the mechanical angular velocity, angular acceleration, and stator torque current components of the centrifuge during the no-load acceleration process;

[0062] A linear equation system based on rigid body dynamics is constructed, with the stator torque current component as the input variable and the mechanical angular velocity and angular acceleration as the state variables. The least squares algorithm is used to fit three constant terms, which are defined as the moment of inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque, respectively.

[0063] The rotational inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque are combined and set as the impedance parameters of the empty mold.

[0064] This embodiment details the specific process of the reference parameter identification unit calculating the impedance parameters of the empty mold. In order to accurately eliminate the mechanical impedance interference caused by the differences in geometric dimensions, steel plate thickness and wear degree of different molds, this embodiment uses a physical model based on rigid body dynamics for parameter identification.

[0065] During data acquisition, the centrifuge is controlled to execute a stepped acceleration command under no-load conditions; during this process, the system collects the mechanical angular velocity in real time through a rotary encoder. The unit is radians per second. To suppress the interference of measurement noise on the differential calculation, the acquired mechanical angular velocity is first smoothed using a first-order low-pass filter or a linear tracking differentiator with a cutoff frequency of 50Hz to 100Hz. Then, the angular acceleration is obtained by differentiating the processed mechanical angular velocity. The unit is radians per second squared; the stator torque current components are acquired in real time through the frequency converter vector control unit. The unit is ampere;

[0066] In terms of model construction, this embodiment establishes the following system of linear equations based on rigid body dynamics:

[0067]

[0068] in, This is the motor torque constant, the value of which comes from the motor nameplate parameters or pre-calibrated values, and the unit is Newton-meter per ampere; Let be the moment of inertia of the empty mode to be identified, which characterizes the inertial drag during acceleration, and the unit is kilogram-meter square. The viscous friction coefficient of the mold to be identified is a bearing and wind resistance torque that is proportional to the rotational speed, expressed in Newton-meter-seconds per radian. Let be the Coulomb friction torque to be identified, which characterizes the inherent mechanical static friction torque independent of rotational speed, and is expressed in Newton-meters.

[0069] During parameter calculation, the system collects multiple sets of sampled data at different times. The least squares algorithm is used to perform regression fitting on the above linear equation, thereby solving for the three constant terms. , and These three parameters are combined and set as the aforementioned empty-mode impedance parameters, serving as a reference constant for load torque observation in subsequent production stages. This calibration method can eliminate individual equipment differences and ensure the accuracy of subsequent net load extraction.

[0070] Example 3:

[0071] The process by which the load torque observation unit obtains the net load torque is as follows:

[0072] Construct an observation model that includes a velocity feedback correction mechanism;

[0073] The stator current collected in real time is converted into electromagnetic drive torque;

[0074] Based on the current mechanical angular velocity and angular acceleration, and combined with the empty mold impedance parameters, the theoretical mechanical torque required for the mold to overcome inertia, viscous friction and static friction is calculated.

[0075] The difference between the electromagnetic drive torque and the theoretical mechanical torque is calculated, and this difference is superimposed with the compensation value generated based on the speed observation error. The final value after superposition is determined as the net load torque.

[0076] This embodiment details the specific process by which the load torque observation unit obtains the net load torque; the unit uses logic based on the Luneburger observer structure to achieve real-time dynamic stripping of concrete load;

[0077] An observation model incorporating a speed feedback correction mechanism is constructed, which calculates the net load torque. The formula is as follows:

[0078]

[0079] in, The rotational speed estimate generated internally by the observer; The electromagnetic drive torque is derived from the stator current acquired in real time. With motor torque constant Multiply to get; the terms in parentheses The theoretical mechanical torque is based on the current mechanical angular velocity. and angular acceleration Combined with the empty-mode impedance parameters identified in the previous steps The calculated torque represents the torque required for the mold to overcome its own inertia, viscous friction, and static friction.

[0080] also, The observer's proportional gain is expressed in Newton-meter-seconds per radian. This parameter is used to adjust the observer's convergence speed. Its value is usually set according to the system bandwidth configuration principle, and the range is set to 3 to 5 times the system's mechanical pole frequency to ensure that the observer's convergence speed is faster than the system's mechanical response speed and to avoid excessive noise amplification. To measure the mechanical angular velocity; The rotational speed is estimated from the state inside the observer. This estimated rotational speed is obtained by real-time integration or discretized iterative solution of the following state differential equation:

[0081]

[0082] In digital control systems, the discrete-form update formula can be obtained using the Euler method:

[0083]

[0084] in, The system sampling period; This refers to the speed observation error; by superimposing the difference between the electromagnetic drive torque and the theoretical mechanical torque with a compensation value generated based on the speed observation error. The final value, after being superimposed, was determined to be the net load torque. This method uses a feedback correction mechanism to compensate for the slight drift of model parameters during operation, thereby accurately extracting the fluid load torque that acts only on the concrete.

[0085] Example 4:

[0086] The process of micro-perturbation response analysis and equivalent dynamic viscosity calculation is as follows:

[0087] A sinusoidal wave signal with a preset frequency and amplitude is superimposed on the basic speed command of the centrifuge.

[0088] The collected net load torque data and mechanical angular velocity data are subjected to high-pass filtering to remove the DC component and extract the torque fluctuation component and speed fluctuation component that are consistent with the frequency of the sinusoidal fluctuation signal.

[0089] Calculate the root mean square value of the torque fluctuation component and the root mean square value of the speed fluctuation component within the preset time window, respectively.

[0090] Calculate the ratio between the root mean square value of the torque ripple component and the root mean square value of the speed ripple component.

[0091] Obtain the inner radius and effective length of the mold, calculate the geometric constants related to the cylinder volume determined by the two, divide the ratio by the geometric constants, and determine the equivalent dynamic viscosity.

[0092] This embodiment details the micro-perturbation response analysis and equivalent dynamic viscosity calculation process in the rheological and distribution state analysis unit; the system uses virtual viscometer technology to detect whether concrete has reached the ideal flow state of shear thinning under non-invasive conditions.

[0093] Specifically, the system uses the centrifuge's base speed command. A sinusoidal wave signal with a preset frequency is superimposed on top. and preset amplitude This makes the reference speed become ,in For real-time variables;

[0094] The collected net load torque data and mechanical angular velocity data High-pass filtering is performed separately, and the cutoff frequency of the filter is... Set to preset frequency 0.1 to 0.2 times, that is To filter out the DC component and ensure that the frequency does not decay. The effective fluctuation signal is obtained, thereby extracting the torque fluctuation component with the same frequency as the sinusoidal fluctuation signal. and velocity fluctuation components ;

[0095] Calculate separately within the preset time window Root mean square value of internal torque ripple component and the root mean square value of the velocity fluctuation component Among them, time window The length is at least one fluctuation period;

[0096] Obtain the inner radius of the mold and effective length Based on the simplified assumption that the concrete material adheres tightly to the inner wall of the mold and that the change in material layer thickness with centrifugal force is ignored, the formula is used. Calculate the geometric constants of the mold This constant reflects the influence of the mold side area on viscosity measurement; the system calculates the ratio of the root mean square value of the torque fluctuation component to the root mean square value of the velocity fluctuation component, and divides this ratio by the geometric constant. The result obtained is the equivalent dynamic viscosity. The unit is Pascal-second; this index can sensitively reflect the critical point at which concrete transitions from a solid-liquid mixture to a liquid state.

[0097] Example 5:

[0098] The process of frequency domain feature extraction and the calculation of the dimensionless eccentricity factor is as follows:

[0099] Perform a fast Fourier transform on the net load torque data in the time domain to extract the spectral amplitude whose frequency is consistent with the fundamental frequency of the current centrifuge speed;

[0100] Obtain the total mass of the concrete, the gravitational acceleration constant, and the mold radius; calculate the product of these three values; and define the product as the theoretical maximum gravitational torque.

[0101] Calculate the ratio of the spectral amplitude to the theoretical maximum gravitational torque, and determine this dimensionless ratio as the dimensionless eccentricity factor.

[0102] This embodiment details the process of frequency domain feature extraction and dimensionless eccentricity factor calculation in the rheological and distribution state analysis unit; this process aims to quantify the uniformity of concrete distribution and prevent equipment damage caused by eccentricity.

[0103] The system provides net load torque data in the time domain. The Fast Fourier Transform (FFT) is performed, and the specific extraction logic is as follows: based on the current centrifuge speed and fundamental frequency... The unit is rad / s, combined with the number of FFT sampling points. and sampling frequency Calculate the corresponding discrete spectrum index :

[0104]

[0105] Read the index directly from the FFT spectrum array. The corresponding modulus value, or the extracted index The energy centroid of the centrifuge and its neighboring points is used as the output frequency and the fundamental frequency of the current centrifuge speed. Consistent spectral amplitude This amplitude physically corresponds to the gravitational torque component generated by the eccentric mass.

[0106] At the same time, obtain the total mass of the concrete poured in. This value is provided by the feeding and weighing system; it is taken as the final static metering value before the start of the centrifugation process and is used as a fixed constant in the calculation throughout the entire centrifugation control cycle; the gravitational acceleration constant is obtained. and mold radius Calculate the product of these three values. The product is defined as the theoretical maximum gravitational torque, representing the extreme torque generated when all concrete is concentrated at a single point on the inner wall of the mold.

[0107] Calculate the spectral amplitude The ratio of this ratio to the theoretical maximum gravitational torque is defined as the dimensionless eccentricity factor. Since this factor eliminates the influence of mold size and equipment rigidity, it can serve as a universal safety assessment indicator, directly reflecting the relative uniformity of material distribution.

[0108] Example 6:

[0109] The instruction generation logic of the adaptive closed-loop control unit is as follows:

[0110] A critical eccentricity threshold characterizing the safety limit of the equipment and a rheological threshold characterizing the liquefaction state of concrete are preset.

[0111] Step 1: Determine if the dimensionless eccentricity factor is greater than the critical eccentricity threshold. If so, generate an emergency braking command directly.

[0112] The second step is to determine whether the equivalent dynamic viscosity is greater than the rheological threshold if the dimensionless eccentricity factor is less than or equal to the critical eccentricity threshold.

[0113] If so, it indicates that the concrete has not yet liquefied, and a constant-rate shear command is generated to maintain the current rotation speed;

[0114] If not, it indicates that the concrete has liquefied and is safely distributed, and an adaptive acceleration command is generated;

[0115] The target acceleration included in the adaptive acceleration command is determined by the following logic:

[0116] Obtain the preset maximum allowable acceleration value and the preset eccentricity control limit;

[0117] Calculate the proportion of the current dimensionless eccentricity factor in the eccentricity control limit;

[0118] Calculate the difference between constant 1 and the numerical ratio, and use this difference as the dynamic weighting coefficient;

[0119] Calculate the product of the maximum permissible acceleration value and the dynamic weighting coefficient, and determine the resulting product value as the target acceleration;

[0120] When the dimensionless eccentricity factor exceeds the eccentricity control limit, the dynamic weighting coefficient becomes negative. The system then performs a linear deceleration operation based on the target acceleration of this negative value until the eccentricity condition is improved.

[0121] It should be noted that when performing linear deceleration, the system will limit the maximum magnitude of the deceleration to no more than the preset safe deceleration threshold to prevent secondary impact caused by the instantaneous large-scale collapse of materials due to rapid deceleration.

[0122] This embodiment details the instruction generation logic and target acceleration determination method of the adaptive closed-loop control unit; this unit implements variable structure control based on real-time calculated state variables;

[0123] The system presets two key thresholds: critical eccentricity threshold. and rheological threshold Among them, the critical eccentricity threshold The safety boundary is determined based on the mechanical resonance limit of the centrifuge rotor system; rheological threshold. It is a liquefaction criterion calibrated based on concrete slump test data;

[0124] Determine the dimensionless eccentricity factor Is it greater than the critical eccentricity threshold? If so, it indicates that the centrifuge is facing a risk of severe vibration. The system immediately generates an emergency braking command to stop the machine at maximum braking deceleration. The specific operation of the emergency braking command is as follows: immediately block the PWM pulse output and control the mechanical brake to close, or apply a preset maximum reverse braking current to the motor stator. Perform energy-efficient braking;

[0125] If the dimensionless eccentricity factor Less than or equal to the critical eccentricity threshold Then, further determine the equivalent dynamic viscosity. Is it greater than the rheological threshold? ;

[0126] like This indicates that the concrete has not yet fully liquefied. At this point, a constant-rate shear command is generated to maintain the current rotation speed and reduce the viscosity of the material by using continuous shearing action.

[0127] like This indicates that the concrete has liquefied and its distribution is within a safe range, and the system generates an adaptive acceleration command.

[0128] Target acceleration in adaptive acceleration command It is not a fixed value, but is determined through the following logic:

[0129] Get the preset maximum allowable acceleration value and preset eccentricity control limits ,in Less than , serving as a reference line for process optimization;

[0130] Calculate the current dimensionless eccentricity factor Eccentricity control limits The proportion of the value in ;

[0131] calculate The difference between the ratio of this value and the actual value is... This difference is used as a dynamic weighting coefficient;

[0132] Calculate the maximum permissible acceleration value The target acceleration is obtained by multiplying it by the dynamic weighting coefficient:

[0133]

[0134] Obtain target acceleration Then, the adaptive closed-loop control unit uses this value to update the speed reference command for the next control cycle. The updated formula is:

[0135]

[0136] in To update the control system, the updated speed reference command will be sent to the motor servo driver for execution.

[0137] In particular, when the dimensionless eccentricity factor Exceeding the eccentricity control limit When the dynamic weighting coefficient becomes negative, the system performs linear deceleration based on the target acceleration of the negative value. This mechanism uses the gravity collapse effect during the deceleration process to redistribute the accumulated concrete until the eccentricity is improved and then automatically resumes acceleration, thereby realizing self-healing control of the production process.

[0138] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. An intelligent control system for the entire production process of concrete utility poles, characterized in that: It includes a reference parameter identification unit, a load torque observation unit, a rheological and distributed state analysis unit, and an adaptive closed-loop control unit; The reference parameter identification unit is used to perform a step-by-step speed-up test under the no-load state of the centrifuge, collect the real-time operating data of the drive motor, calculate the empty mold impedance parameter that characterizes the inherent mechanical resistance of the mold through regression analysis, and send the empty mold impedance parameter to the load torque observation unit. The load torque observation unit is used to acquire the electromagnetic drive torque in real time during the concrete feeding and centrifugation stages, and to calculate the mechanical consumption torque of the mold itself at the current speed using the empty mold impedance parameters. The electromagnetic drive torque is subtracted from the mechanical consumption torque to extract the net load torque that only acts on the concrete material. The rheological and distribution state analysis unit is used to perform micro-disturbance response analysis on the net load torque, calculate the equivalent dynamic viscosity characterizing the flow state of concrete, and extract the frequency domain features of the net load torque to calculate the dimensionless eccentricity factor characterizing the uniformity of material distribution. The adaptive closed-loop control unit is used to generate corresponding control commands based on the preset value range of the dimensionless eccentricity factor and the equivalent dynamic viscosity: when the eccentricity exceeds the safety limit, it outputs an emergency braking command; when the rheological state does not meet the standard, it outputs a constant-speed shear command; and when the rheological state meets the standard and the eccentricity is within the safe range, it outputs an adaptive acceleration command. The micro-perturbation response analysis and equivalent dynamic viscosity calculation process are as follows: A sinusoidal wave signal with a preset frequency and amplitude is superimposed on the basic speed command of the centrifuge. The collected net load torque data and mechanical angular velocity data are subjected to high-pass filtering to remove the DC component and extract the torque fluctuation component and speed fluctuation component that are consistent with the frequency of the sinusoidal fluctuation signal. Calculate the root mean square value of the torque fluctuation component and the root mean square value of the speed fluctuation component within the preset time window, respectively. Calculate the ratio between the root mean square value of the torque ripple component and the root mean square value of the speed ripple component. Obtain the inner radius and effective length of the mold, calculate the geometric constant related to the cylindrical lateral area or volume determined by the two, divide the ratio by the geometric constant, and determine the equivalent dynamic viscosity; the geometric constant reflects the influence of the mold lateral area on viscosity measurement; The process of frequency domain feature extraction and the calculation of the dimensionless eccentricity factor is as follows: Perform a fast Fourier transform on the net load torque data in the time domain to extract the spectral amplitude whose frequency is consistent with the fundamental frequency of the current centrifuge speed; Obtain the total mass of the concrete, the gravitational acceleration constant, and the mold radius; calculate the product of these three values; and define the product as the theoretical maximum gravitational torque. Calculate the ratio of the spectral amplitude to the theoretical maximum gravitational torque, and determine this dimensionless ratio as the dimensionless eccentricity factor.

2. The intelligent control system for the entire process of concrete pole production according to claim 1, characterized in that, The process by which the reference parameter identification unit calculates the empty-mode impedance parameters is as follows: Collect data on the mechanical angular velocity, angular acceleration, and stator torque current components of the centrifuge during the no-load acceleration process; A linear equation system based on rigid body dynamics is constructed, with the stator torque current component as the input variable and the mechanical angular velocity and angular acceleration as the state variables. The least squares algorithm is used to fit three constant terms, which are defined as the moment of inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque, respectively. The rotational inertia of the empty mold, the viscous friction coefficient of the mold, and the Coulomb friction torque are combined and set as the impedance parameters of the empty mold.

3. The intelligent control system for the entire process of concrete pole production according to claim 1, characterized in that, The process by which the load torque observation unit obtains the net load torque is as follows: Construct an observation model that includes a velocity feedback correction mechanism; The stator current collected in real time is converted into electromagnetic drive torque; Based on the current mechanical angular velocity and angular acceleration, and combined with the empty mold impedance parameters, the theoretical mechanical torque required for the mold to overcome inertia, viscous friction and static friction is calculated. The difference between the electromagnetic drive torque and the theoretical mechanical torque is calculated, and this difference is superimposed with the compensation value generated based on the speed observation error. The final value after superposition is determined as the net load torque.

4. The intelligent control system for the entire process of concrete pole production according to claim 1, characterized in that, The instruction generation logic of the adaptive closed-loop control unit is as follows: A critical eccentricity threshold characterizing the safety limit of the equipment and a rheological threshold characterizing the liquefaction state of concrete are preset. Step 1: Determine if the dimensionless eccentricity factor is greater than the critical eccentricity threshold. If so, generate an emergency braking command directly. The second step is to determine whether the equivalent dynamic viscosity is greater than the rheological threshold if the dimensionless eccentricity factor is less than or equal to the critical eccentricity threshold. If so, it indicates that the concrete has not yet liquefied, and a constant-rate shear command is generated to maintain the current rotation speed; If not, it indicates that the concrete has liquefied and is safely distributed, and an adaptive acceleration command is generated.

5. The intelligent control system for the entire process of concrete pole production according to claim 4, characterized in that, The target acceleration included in the adaptive acceleration command is determined by the following logic: Obtain the preset maximum allowable acceleration value and the preset eccentricity control limit; Calculate the proportion of the current dimensionless eccentricity factor in the eccentricity control limit; Calculate the difference between constant 1 and the numerical ratio, and use this difference as the dynamic weighting coefficient; Calculate the product of the maximum permissible acceleration value and the dynamic weighting coefficient, and determine the resulting product value as the target acceleration; When the dimensionless eccentricity factor exceeds the eccentricity control limit, the dynamic weighting coefficient becomes negative. The system then performs a linear deceleration operation based on the target acceleration of this negative value until the eccentricity condition is improved.

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