Five-axis driving control integrated machine control method, system, device and medium

Abstract

The application relates to the technical field of all-in-one machine control, in particular to a five-axis drive control all-in-one machine control method, system, equipment and medium. The application detects a power supply state through a power management module and performs filtering, each separated inverter module is initialized in parallel to obtain an enable signal; target position instructions are generated based on user input and dynamic constraint parameters, real-time position and speed instructions are calculated; a five-axis servo system is driven to execute movement and feedback adjustment; current fluctuation characteristics and position deviation change rates are monitored in real time, when a source abnormality is detected, only the inverter module corresponding to the abnormal axis is turned off; after replacing the abnormal module, the parameters are automatically loaded and the inter-axis synchronization compensation is optimized through adaptive configuration. The application reduces electromagnetic interference through distributed filtering, reduces maintenance cost through modular fault isolation, and realizes system reliability through intelligent adaptive control.

Description

Technical Field

[0001] This application relates to the technical field of integrated machine control, and in particular to a five-axis drive and control integrated machine control method, system, equipment and medium. Background Technology

[0002] Servo drive and control integrated machines are core devices in the field of industrial automation, integrating servo drives and motion controllers into one unit. They are widely used in high-precision motion control scenarios such as CNC machine tools, industrial robots, and 3D printing. With the intelligent upgrading of manufacturing, higher requirements are being placed on the reliability, maintainability, and performance of servo drive and control integrated machines.

[0003] The existing servo drive and control integrated machine adopts a centralized filtering design, with the filter capacitors uniformly arranged near the rectifier bridge. The inverter module and bus drive circuit are integrated on the same PCB board, and power is supplied to each axis through a unified bus power supply system. The control circuits and power drive circuits of each axis are highly centralized in design.

[0004] In existing technology, the filter capacitors are far from the inverter modules, resulting in a large parasitic inductance. This causes high peak voltages on the bus during IGBT switching, which not only threatens the safety of the IGBT devices but also generates serious electromagnetic interference. Since the inverter modules of each axis are concentrated on the same PCB, if the circuit of one axis fails, it will affect the normal operation of other axes, requiring the replacement of the entire circuit board, resulting in high maintenance costs. This situation needs to be further improved. Summary of the Invention

[0005] To address the problems of severe electromagnetic interference and high maintenance costs associated with existing servo drive and control integrated machines, this application provides a control method, system, device, and medium for a five-axis drive and control integrated machine, employing the following technical solution: In a first aspect, this application provides a five-axis drive and control integrated machine control method, applied to an integrated machine control system. The integrated machine control system includes an integrated PCB control board, multiple electrically isolated and independently configured separate inverter modules, a power management module, a five-axis servo motor system, filter support capacitors, and a human-machine interface device. The integrated PCB control board executes the control method, including the following steps: The power management module detects the system power supply status, and the filter support capacitor filters the bus voltage to obtain a stable system power supply. The filter support capacitor is configured to provide independent local filter support for each inverter module by being directly installed at the bus end of each separate inverter module. Based on the stable system power supply, each discrete inverter module is initialized in parallel to obtain the enable signal for each axis inverter module; The human-computer interaction interface device receives motion parameters input by the user and combines them with the dynamic motion constraint parameters of each axis to obtain the target position command for each axis. Based on the target position command, the real-time position and speed commands of each axis are calculated; Based on the enable signals of each axis inverter module, the real-time position and speed commands, the five-axis servo motor system is driven by the separate inverter module to perform motion, thereby obtaining the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis; Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities. When a source-related anomaly is determined, based on the electrical isolation characteristics of the separate inverter module, a shutdown command is sent to the separate inverter module corresponding to the abnormal axis, causing the separate inverter module corresponding to the abnormal axis to be powered down independently, while the separate inverter modules of the other normal axes continue to operate; when a cascading anomaly is determined, the overall operating speed is reduced and a system status check is performed. After shutting down and replacing the faulty split inverter module, the module adaptive configuration program is executed. Based on the identification information of the newly replaced split inverter module, the corresponding parameters are automatically loaded. Based on the actual characteristics of the replaced split inverter module, the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis are re-optimized so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

[0006] Optionally, the current fluctuation characteristics, position deviation change rate, and motion state parameters of each axis are collected and analyzed in real time. Based on the preset fault diagnosis logic, the source abnormality and the related abnormality are distinguished. The specific steps include the following: Acquire real-time current fluctuation data, position deviation data, and speed tracking data for each axis, and calculate current fluctuation characteristics and position deviation change rate. The current fluctuation characteristics include current fluctuation amplitude and waveform distortion, and the position deviation change rate includes the instantaneous change rate and cumulative change trend of the position deviation. Analyze the motion state parameters of adjacent axes based on the current fluctuation characteristics and the rate of change of position deviation. The anomaly type is determined based on the preset fault diagnosis logic: When a sudden change in the amplitude of a single-axis current fluctuation or waveform distortion is detected, and the instantaneous rate of change exceeds a preset threshold, it is determined to be a source anomaly. When multiple axes are detected to simultaneously exhibit increasing speed following errors and a cumulative trend in position deviations, it is determined to be a cascading anomaly.

[0007] Optionally, the motion parameters input by the user are received through the human-computer interaction interface device, and combined with the dynamic motion constraint parameters of each axis, the target position command for each axis is obtained, specifically including the following steps: The target location parameters input by the user are received through the human-computer interaction interface device; The dynamic motion constraint parameters of each axis are obtained, including the starting speed, maximum speed, maximum acceleration, maximum deceleration, and jerk limit value. The dynamic motion constraint parameters are set according to preset values ​​determined by the load inertia and mechanical transmission characteristics of each axis, and are adjusted in real time according to the temperature change characteristics and vibration response characteristics. Generate acceleration / deceleration curves based on the dynamic motion constraint parameters; Priority is determined for the target positions of each axis to determine the startup sequence of each axis; Based on the startup timing and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated, and the speed parameters of each axis are compensated according to the synchronization coefficient. By combining the compensated speed parameters with the acceleration / deceleration curves, the target position commands for each axis are obtained.

[0008] Optionally, based on the startup timing and the parasitic parameter differences caused by the actual layout of the discrete inverter module, a synchronization coefficient between adjacent axes is calculated, and the speed parameters of each axis are compensated according to the synchronization coefficient. Specifically, this includes the following steps: Based on the start-up timing of each axis, the motion time ratio of adjacent axes is determined; Based on the motion time ratio and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated through a preset inter-axis compensation parameter table. The inter-axis compensation parameter table includes mechanical characteristic difference parameters of adjacent axes, which are used to compensate for dynamic synchronization errors during acceleration and deceleration. Obtain the current speed parameters of each axis, and compensate the speed parameters of each axis according to the synchronization coefficient so that the time for adjacent axes to reach the target position is consistent. Determine whether the compensated speed parameters meet the requirements of the dynamic motion constraint parameters. If they do not meet the requirements, recalculate the synchronization coefficient until they do.

[0009] Optionally, after detecting a single-axis abnormality and replacing the discrete inverter module corresponding to the abnormal axis, the control method further includes the following steps: The newly replaced split inverter module is configured with parameters through a preset module adaptive configuration program, wherein the module adaptive configuration program contains standard parameter configuration information corresponding to each model of inverter module; Based on the model information of the newly replaced split inverter module, the corresponding standard parameter configuration information is automatically loaded and the initialization settings are completed. At the same time, the preset values ​​of the dynamic motion constraint parameters of the abnormal axis and the inter-axis compensation parameters of the adjacent axis are re-acquired. The standard test procedure is executed in the preset mode to collect the inter-axis synchronization characteristic data. The inter-axis compensation parameters are automatically optimized based on the data until the system's preset synchronization accuracy requirements are met.

[0010] Optionally, after the inter-axis compensation parameters meet the system's preset synchronization accuracy requirements, the control method further includes the following steps: The five-axis system was tested using a pre-set multi-axis linkage test program. The multi-axis linkage test program included a pre-set standard motion trajectory and evaluation indicators, which were used to verify the overall performance of the system after replacing the split inverter module corresponding to the abnormal axis. During the test, position error, speed error, and current fluctuation parameters of each axis were collected. The overall machine operation characteristic evaluation index is calculated based on the position error, speed error and current fluctuation parameters. When the evaluation index meets the preset threshold, the system parameter configuration table is updated to complete the confirmation of the abnormal axis's recovery operation.

[0011] Optionally, the discrete inverter module is provided with a module identification circuit, which includes an identification chip and a module status detection circuit. The control method further includes the following steps: The module identification circuit receives identification information, which includes the module serial number, production batch number, and rated power parameters. The module status record is obtained by collecting the working time, switching frequency and temperature records of the discrete inverter module through the module status detection circuit. Based on the identity recognition information and the module status record, a separate inverter module operation file is established to record the usage status of the separate inverter module; Based on the operation file of the split inverter module, it is determined whether the split inverter module meets the preset usage conditions. If the usage conditions are not met, a replacement prompt message is sent to the human-machine interface device.

[0012] Secondly, this application provides a five-axis drive and control integrated machine control system, including: Integrated PCB control board; Multiple electrically isolated and independently configured discrete inverter modules; The power management module is used to detect the system's power supply status; Five-axis servo motor system; The filter support capacitor is configured to be directly installed at the bus end of each separate inverter module to provide independent local filter support for each inverter module. The human-computer interaction interface device is used to receive motion parameters input by the user, combine them with the dynamic motion constraint parameters of each axis, and obtain the target position command for each axis. The integrated PCB control board is used for: Based on the stable system power supply, each discrete inverter module is initialized in parallel to obtain the enable signal for each axis inverter module; Based on the target position command, the real-time position and speed commands of each axis are calculated; Based on the enable signals of each axis inverter module, the real-time position and speed commands, the five-axis servo motor system is driven by the separate inverter module to perform motion, thereby obtaining the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis; Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities. When a source-related anomaly is determined, based on the electrical isolation characteristics of the separate inverter module, a shutdown command is sent to the separate inverter module corresponding to the abnormal axis, causing the separate inverter module corresponding to the abnormal axis to be powered down independently, while the separate inverter modules of the other normal axes continue to operate; when a cascading anomaly is determined, the overall operating speed is reduced and a system status check is performed. After shutting down and replacing the faulty split inverter module, the module adaptive configuration program is executed. Based on the identification information of the newly replaced split inverter module, the corresponding parameters are automatically loaded. Based on the actual characteristics of the replaced split inverter module, the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis are re-optimized so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

[0013] Thirdly, this application provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the above-described five-axis drive and control integrated machine control method.

[0014] Fourthly, this application provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the above-described five-axis drive and control integrated machine control method.

[0015] In summary, this application includes at least one of the following beneficial technical effects: This application first detects and filters the power supply status through a power management module, and then obtains an enable signal after each discrete inverter module is initialized in parallel. Next, it generates target position commands based on user-input motion parameters and dynamic constraint parameters, and calculates real-time position and speed commands. Then, it drives the five-axis servo motor system to execute motion and performs feedback adjustment. Simultaneously, it monitors the current fluctuation characteristics and position deviation rate of change parameters of each axis in real time. When a source abnormality is detected, it only shuts down the inverter module corresponding to the abnormal axis, keeping other axes running normally. Finally, after replacing the abnormal module, it automatically loads parameters and optimizes inter-axis synchronization compensation through an adaptive configuration program, allowing the abnormal axis to reintegrate into the system. Distributed filtering design reduces electromagnetic interference, modular fault isolation mechanisms reduce maintenance costs, and intelligent adaptive control strategies enhance system reliability. This application first acquires real-time current fluctuation data, position deviation data, and velocity tracking data for each axis, calculates current fluctuation characteristics including current fluctuation amplitude and waveform distortion, and position deviation change rate including instantaneous change rate and cumulative change trend; then, it analyzes the motion state parameters of adjacent axes based on these characteristics; finally, it determines the anomaly type through preset diagnostic logic: when a sudden change in the amplitude of a single-axis current fluctuation or waveform distortion is detected, and the instantaneous change rate exceeds a preset threshold, it is determined to be a primary anomaly; when multiple axes simultaneously show an increase in velocity tracking error, and the position deviation shows a cumulative change trend, it is determined to be a related anomaly. Through multi-dimensional parameter analysis and logical judgment, the anomaly type is identified, providing a reliable basis for subsequent differentiated processing and improving the system's fault diagnosis accuracy and processing efficiency. This application constructs a multi-level motion parameter optimization and adaptive adjustment mechanism. In terms of motion planning, it controls based on complete dynamic constraint parameters and dynamically adjusts the system considering actual factors such as load inertia and temperature changes. In terms of inter-axis synchronization, it incorporates the parasitic parameter differences in the inverter module layout into the compensation range and achieves synchronization through motion time ratio and compensation parameter table. In terms of module maintenance, it supports automatic parameter configuration and optimization after replacement. This enables the system to maintain high-precision collaborative control during normal operation and abnormal handling, improving system performance and maintenance efficiency. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating a five-axis drive and control integrated machine control method according to an embodiment of this application; Figure 2 This is a flowchart illustrating step S130 in a five-axis drive and control integrated machine control method according to an embodiment of this application. Figure 3 This is a flowchart illustrating step S135 in a five-axis drive and control integrated machine control method according to an embodiment of this application. Figure 4This is a flowchart illustrating step S160 in a five-axis drive and control integrated machine control method according to an embodiment of this application. Figure 5 This is a schematic flowchart of the inter-axis compensation process in a five-axis drive and control integrated machine control method according to an embodiment of this application; Figure 6 This is a schematic diagram of the whole machine operation test in a control method for a five-axis drive and control integrated machine according to an embodiment of this application; Figure 7 This is a flowchart illustrating the module identification process in a five-axis drive and control integrated machine control method according to an embodiment of this application. Figure 8 This is a schematic diagram of a module of a five-axis drive and control integrated machine control system according to an embodiment of this application; Figure 9 This is an internal structural diagram of an electronic device according to an embodiment of this application. Detailed Implementation

[0017] The terminology used in the following embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. As used in the specification and appended claims of this application, the singular expressions “a,” “an,” “the,” “the,” “the,” and “this” are intended to include the plural expressions as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this application refers to any or all possible combinations including one or more of the listed items.

[0018] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0019] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0020] In a first aspect, this application provides a five-axis drive and control integrated machine control method, applied to an integrated machine control system. The integrated machine control system includes an integrated PCB control board, multiple electrically isolated and independently configured separate inverter modules, a power management module, a five-axis servo motor system, filter support capacitors, and a human-machine interface device. The integrated PCB control board executes the control method, referring to... Figure 1 The method includes the following steps: S110. The power management module detects the system power supply status and filters the bus voltage using the filter support capacitor to obtain a stable system power supply.

[0021] The filter support capacitor is configured to provide independent local filter support for each inverter module by being directly installed at the bus end of each separate inverter module.

[0022] In this embodiment, the power management module is a power management unit used to monitor and manage the power supply of the system; the filter support capacitor is a capacitor assembly used to suppress bus voltage fluctuations, where bus voltage refers to the DC bus voltage that supplies power to the inverter module; local filter support refers to the layout method of independently setting filter capacitors near each inverter module.

[0023] S120. Based on a stable system power supply, initialize each separate inverter module in parallel to obtain the enable signal for each axis inverter module.

[0024] In this embodiment, parallel initialization refers to the process of simultaneously configuring parameters and checking the status of multiple inverter modules; the enable signal is a logic control signal that controls the output status of the inverter module; the discrete inverter module is an independently packaged and individually configurable power conversion unit.

[0025] Specifically, after the system starts up, it first checks whether the power supply voltage is stable within the normal operating range, and then sends initialization commands to each inverter module.

[0026] S130. Receive motion parameters input by the user through the human-machine interface device, and combine them with the dynamic motion constraint parameters of each axis to obtain the target position command for each axis.

[0027] In this embodiment, the human-machine interface device includes a touch screen and a button input unit, which are used to realize information interaction between the user and the control system; the motion parameters include target position, motion speed and acceleration set values; the dynamic motion constraint parameters are system parameters that limit the motion characteristics of each axis, which are used to ensure the safe and stable operation of the mechanical system.

[0028] S140. Calculate the real-time position and speed commands for each axis based on the target position command.

[0029] In this embodiment, the real-time position command is a data sequence describing the position point that each axis should reach at any time; the speed command is the instantaneous speed change curve of each axis during the motion process.

[0030] S150: Based on the enable signals of each axis inverter module, real-time position and speed commands, the five-axis servo motor system is driven to perform motion through the separate inverter module to obtain the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis.

[0031] In this embodiment, the inverter module enable signal is used to control the power output switch; the actual motion state includes the position information and motor current information fed back by the encoder; the feedback adjustment is a closed-loop control process based on the deviation between the actual state and the command.

[0032] Specifically, after receiving the enable signal, the separate inverter module generates a corresponding PWM waveform based on real-time position and speed commands to drive the servo motor. The system achieves precise adjustment through a triple closed-loop control structure of position loop, speed loop, and current loop. The controller employs a PID algorithm based on a gain lookup table to automatically select appropriate control parameters according to different operating conditions, ensuring the system's response characteristics.

[0033] S160: Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities.

[0034] In this embodiment, the current fluctuation characteristics include the change in current amplitude and the degree of waveform distortion; the position deviation change rate represents the rate of change of the position following error; the motion state parameters of adjacent axes include the speed following error and the position synchronization error; the priming anomaly refers to the axis where the fault first occurs, and the cascading anomaly refers to the chain reaction caused by the faults of other axes.

[0035] Specifically, the system uses a sliding window method to acquire current signals in real time and analyzes the current waveform characteristics through Fourier transform. Simultaneously, a fault feature library based on threshold judgment is established, storing characteristic parameter combinations under typical fault conditions. The system performs pattern matching between the acquired features and the feature library, and combines this with motion correlation analysis of adjacent axes to determine the propagation path and impact range of the anomaly.

[0036] S170. When a source-related abnormality is determined, based on the electrical isolation characteristics of the split inverter module, a shutdown command is sent to the split inverter module corresponding to the abnormal axis, so that the split inverter module corresponding to the abnormal axis is powered down independently, while the split inverter modules of the other normal axes continue to operate; when a cascading abnormality is determined, the overall operating speed is reduced and a system status check is performed.

[0037] In this embodiment, when a source-related anomaly is detected, the control system sends a shutdown signal to the inverter module of the malfunctioning axis via an optocoupler isolation circuit, and simultaneously cuts off the power supply circuit of that module. The system maintains the normal operation of other axes and adjusts the motion parameters of the relevant axes according to a preset compensation strategy. When a cascading anomaly is detected, the system reduces the operating speed according to a preset deceleration curve, identifies the fault source by querying the fault diagnosis database, and executes the corresponding processing procedure.

[0038] S180. After shutting down and replacing the faulty split inverter module, execute the module adaptive configuration program. Automatically load the corresponding parameters according to the identification information of the newly replaced split inverter module, and re-optimize the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis based on the actual characteristics of the replaced split inverter module, so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

[0039] Specifically, after replacing the inverter module, the system reads the module's built-in identification code through the communication interface and queries the parameter configuration database to obtain the standard parameter set. The system executes standard test procedures, collects the response characteristics of the new module under different operating conditions, and establishes a real-time compensation model. Iterative optimization algorithms are used to adjust the inter-axis synchronization parameters until the synchronization error between adjacent axes meets the accuracy requirements. The system stores the optimized parameter combination in the configuration file, completing the reintegration of the abnormal axis.

[0040] In one embodiment, refer to Figure 2 In step S130, the motion parameters input by the user are received through the human-machine interface device, and the target position command for each axis is obtained by combining the dynamic motion constraint parameters of each axis. Specifically, the steps are as follows: S131. Receive the target location parameters input by the user through the human-computer interaction interface device.

[0041] S132. Obtain the dynamic motion constraint parameters for each axis.

[0042] The dynamic motion constraint parameters include the starting speed, maximum speed, maximum acceleration, maximum deceleration, and jerk limit values. The dynamic motion constraint parameters are set according to the preset values ​​determined by the load inertia and mechanical transmission characteristics of each axis, and are adjusted in real time according to the temperature change characteristics and vibration response characteristics.

[0043] In this embodiment, the human-machine interface device includes a touch screen and function buttons; the target position parameter refers to the target coordinate value of each axis; the dynamic motion constraint parameter is a set of system parameters that limit the motion characteristics; the load inertia refers to the rotational inertia of the mechanical load; the mechanical transmission characteristics include the transmission ratio and mechanical efficiency; the temperature change characteristics refer to the influence of the temperature of each component on the system performance; and the vibration response characteristics represent the vibration performance of the system at different frequencies.

[0044] Specifically, the system displays the current position and range of motion of each axis via a touchscreen, and verifies the validity of the target position after the user inputs it. The system reads the basic constraint parameters of each axis from the parameter configuration database and collects real-time operating data through temperature and vibration sensors. Based on the sensor data, a dynamic correction model is established to adjust the constraint parameters in real time, ensuring the safety and stability of the motion process.

[0045] S133. Generate acceleration / deceleration curves based on dynamic motion constraint parameters.

[0046] S134. Prioritize the target positions of each axis and determine the startup sequence of each axis.

[0047] In this embodiment, the system employs an S-shaped acceleration / deceleration algorithm to generate velocity curves, ensuring continuous acceleration variation. By analyzing the spatial distribution of the target position, an inter-axis positional relationship mapping table is established to identify motion regions where interference may occur. Based on the mapping table results, the system determines the start-up priority of each axis according to the principle of avoiding mechanical interference and generates timing control commands.

[0048] S135. Based on the startup timing and the parasitic parameter differences caused by the actual layout of the split inverter module, calculate the synchronization coefficient between adjacent axes, and compensate the speed parameters of each axis according to the synchronization coefficient.

[0049] S136. Combine the compensated speed parameters with the acceleration / deceleration curves to obtain the target position command for each axis.

[0050] In this embodiment, the synchronization coefficient is a correction factor used to adjust the motion parameters of adjacent axes; parasitic parameters include distributed inductance and stray capacitance.

[0051] Specifically, the system establishes a parasitic parameter distribution model based on the actual layout and calculates the inter-axis synchronization requirements in conjunction with the startup timing. It obtains baseline compensation values ​​by querying the compensation parameter data table and corrects the speed parameters. Finally, it combines the corrected speed parameters with acceleration / deceleration curves and generates the position command sequence for each axis through interpolation.

[0052] In one embodiment, refer to Figure 3 In step S135, based on the startup timing and the parasitic parameter differences caused by the actual layout of the split inverter modules, the synchronization coefficient between adjacent axes is calculated, and the speed parameters of each axis are compensated according to the synchronization coefficient. Specifically, the steps include the following: S1351. Based on the startup timing of each axis, determine the motion time ratio of adjacent axes.

[0053] In this embodiment, the system records motion planning data for each axis according to a predetermined sampling period and calculates the theoretical motion time for each axis from start to reach the target position. By establishing a time relationship matrix, the system records the motion time difference and ratio between adjacent axes.

[0054] S1352. Based on the motion time ratio and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated through the preset inter-axis compensation parameter table.

[0055] The inter-axis compensation parameter table includes parameters showing the differences in mechanical characteristics between adjacent axes, which are used to compensate for dynamic synchronization errors during acceleration and deceleration.

[0056] In this embodiment, the parasitic parameter differences originate from the physical layout of the inverter module on the PCB board; the inter-axis compensation parameter table is a multi-dimensional data structure; the mechanical characteristic difference parameters include gear ratio, bearing friction coefficient, and load inertia ratio. The system obtains the reference values ​​of parasitic parameters for different layout positions by looking up tables, and establishes a compensation coefficient calculation model by combining the measured mechanical characteristic parameters. This model considers the impact of factors such as wiring length and component distribution on system performance, and obtains the real-time synchronization coefficient through interpolation.

[0057] S1353. Obtain the current speed parameters of each axis, and compensate the speed parameters of each axis according to the synchronization coefficient so that the time for adjacent axes to reach the target position is consistent.

[0058] Specifically, the system reads the original speed planning parameters of each axis and applies the calculated synchronization coefficient to the speed curve. By adjusting the time allocation of the acceleration and constant speed phases, the system achieves time synchronization of adjacent axes reaching the target position.

[0059] S1354. Determine whether the compensated speed parameters meet the requirements of the dynamic motion constraint parameters. If they do not meet the requirements, recalculate the synchronization coefficient until the requirements are met.

[0060] Specifically, the system compares the compensated speed parameters with preset constraints. When an over-limit situation occurs, the parameters are recalculated by adjusting the weight of the synchronization coefficient. The system uses a bisection method to gradually adjust the calculation parameters until a solution that satisfies all constraints is found, ultimately determining the parameter combination used for actual control.

[0061] In one embodiment, refer to Figure 4 In step S160, the current fluctuation characteristics, position deviation change rate, and motion state parameters of each axis are collected and analyzed in real time. Based on the preset fault diagnosis logic, the source abnormality and the related abnormality are distinguished. Specifically, the steps are as follows: S161. Obtain real-time current fluctuation data, position deviation data, and speed tracking data for each axis, and calculate the current fluctuation characteristics and position deviation change rate.

[0062] Among them, the current fluctuation characteristics include the current fluctuation amplitude and waveform distortion, and the position deviation change rate includes the instantaneous change rate and cumulative change trend of the position deviation.

[0063] In this embodiment, the system uses a high-speed AD converter to acquire the current signal at a sampling frequency of 10kHz. After eliminating high-frequency interference through a digital filter, the current characteristic value is calculated. Simultaneously, position data fed back from the encoder is read, and the position deviation change rate is calculated using a differential method. The system establishes a characteristic parameter data table to record the parameter variation range under normal operating conditions, serving as a benchmark for judging abnormal states.

[0064] S162. Analyze the motion state parameters of adjacent axes based on the current fluctuation characteristics and the rate of change of position deviation.

[0065] S163. Determine the anomaly type based on the preset fault diagnosis logic.

[0066] In this embodiment, the system first analyzes the degree of anomaly in the single-axis parameters and establishes a state vector containing current, position, and velocity characteristics. By querying a pre-established fault feature mapping table, the system identifies the type of abnormal state. For adjacent axes, the system calculates the correlation index of motion parameters to analyze the direction and intensity of anomaly propagation. Based on the temporal relationship and impact range of the anomaly, the system executes preset diagnostic logic to determine the anomaly type.

[0067] S164. When a sudden change in the amplitude of a single-axis current fluctuation or waveform distortion is detected, and the instantaneous rate of change exceeds a preset threshold, it is determined to be a source anomaly.

[0068] S165. When multiple axes are detected to have simultaneously increasing speed following errors and cumulative position deviations, it is determined to be a cascading anomaly.

[0069] In this embodiment, sudden change in current fluctuation amplitude refers to fluctuations where the peak-to-peak value of the current exceeds the normal range; the preset threshold is a judgment boundary set based on the dynamic characteristics of the system; the increase in speed following error refers to the continuous increase in the deviation between the actual speed and the commanded speed; the cumulative change trend of position deviation indicates the phenomenon that the position error continues to increase over time.

[0070] Specifically, when the system detects that the current fluctuation amplitude of a single axis exceeds a preset multiple of the rated value, or the harmonic distortion rate exceeds the reference value, and the change in position deviation within a single sampling period exceeds a threshold, the system classifies the anomaly as a primary anomaly. When the system detects that the speed following errors of multiple adjacent axes increase simultaneously, and the position deviation shows a cumulative increasing trend over multiple consecutive sampling periods, the system classifies the anomaly as a secondary anomaly.

[0071] In one embodiment, refer to Figure 5 When a single-axis anomaly is detected and the corresponding discrete inverter module of the anomaly axis is replaced, the control method also includes the following steps: S510: Configure the parameters of the newly replaced split inverter module through the preset module adaptive configuration program.

[0072] The module adaptive configuration program contains standard parameter configuration information corresponding to each model of inverter module.

[0073] In this embodiment, the system reads the built-in identification code of the newly replaced module through the communication interface and queries the module parameter database to obtain the standard configuration information of the corresponding model. The database establishes parameter groups according to different power levels and application scenarios, including basic operating parameters and protection parameters. The system selects the matching parameter group based on the read model information and prepares for configuration.

[0074] S520: Based on the model information of the newly replaced split inverter module, automatically load the corresponding standard parameter configuration information and complete the initialization settings. At the same time, re-acquire the preset values ​​of the dynamic motion constraint parameters of the abnormal axis and the inter-axis compensation parameters of the adjacent axis.

[0075] In this embodiment, the initialization settings include writing basic parameters and configuring functional modules; the preset values ​​of dynamic motion constraint parameters are motion limitation parameters determined based on load characteristics; and the inter-axis compensation parameters are used to optimize the cooperative performance between adjacent axes.

[0076] Specifically, the system first performs a parameter writing operation, configuring basic parameters such as PWM carrier frequency and dead time. Then, based on the mechanical load characteristics, it extracts the motion constraint parameters corresponding to the axis position from the system configuration database. Simultaneously, the system recalculates the positional relationship with adjacent axes and updates the baseline values ​​in the inter-axis compensation parameter table, preparing for subsequent optimization.

[0077] S530. Execute the standard test procedure in the preset mode, collect the inter-axis synchronization characteristic data, and automatically optimize the inter-axis compensation parameters based on the data until the system's preset synchronization accuracy requirements are met.

[0078] In this embodiment, the system executes a standard test procedure according to a preset test sequence, collecting position feedback signals and velocity feedback signals. By analyzing the variation patterns of inter-axle position and velocity deviations, a real-time compensation model is established. The system uses the gradient descent method to optimize the compensation parameters, adjusting them iteratively until the inter-axle synchronization error is reduced to below a preset threshold.

[0079] In one embodiment, refer to Figure 6 After the inter-axis compensation parameters meet the system's preset synchronization accuracy requirements, the control method also includes the following steps: S610. The five-axis system is tested for overall operation using a preset multi-axis linkage test program.

[0080] The multi-axis linkage test program includes preset standard motion trajectories and evaluation indicators, which are used to verify the overall performance of the system after replacing the split inverter module corresponding to the abnormal axis. Specifically, the system first loads preset standard trajectory data, which covers common motion combinations. The trajectory planning module generates motion command sequences for each axis, establishing a test dataset containing position, velocity, and acceleration commands. The system then executes different types of linked motion tests step-by-step according to a predetermined test sequence.

[0081] S620: During the test, collect the position error, speed error and current fluctuation parameters of each axis.

[0082] In this embodiment, position error refers to the deviation between the actual position and the commanded position; speed error represents the difference between the actual speed and the commanded speed; and current fluctuation parameter reflects the stability of the current signal.

[0083] S630: Calculate the overall machine operation characteristic evaluation index based on position error, speed error and current fluctuation parameters. When the evaluation index meets the preset threshold, update the system parameter configuration table and complete the confirmation of the abnormal axis's recovery operation.

[0084] In this embodiment, the overall machine operation characteristic evaluation index is a set of comprehensive performance parameters; the preset threshold defines the qualified standard of system performance; and the system parameter configuration table stores the various parameters required for normal operation.

[0085] Specifically, the system calculates contour accuracy, inter-axis synchronization, and dynamic following performance based on the collected test data. By establishing a scoring model, each indicator is weighted and calculated to obtain a comprehensive system performance score. When the score exceeds a preset threshold, the system writes the optimized parameters into the configuration table and generates a test report recording key data. This ensures that the system performance meets requirements after the abnormal axis resumes operation.

[0086] In one embodiment, refer to Figure 7 The discrete inverter module is equipped with a module identification circuit, which includes an identification chip and a module status detection circuit. The control method also includes the following steps: S710, receiving module identification circuit sends identity information.

[0087] The identification information includes the module serial number, production batch number, and rated power parameters.

[0088] Specifically, the system reads information stored in the identification chip via a serial communication interface. The identification process employs a hierarchical reading method, first verifying the validity of the module serial number, and then reading production information and technical parameters. The system compares the read data with the module management database to confirm the module's legitimacy and applicability.

[0089] S720: The module status record is obtained by collecting the working time, switching frequency and temperature records of the discrete inverter module through the module status detection circuit.

[0090] Specifically, the system records the module's operating time using an embedded counter, and stores the count value in non-volatile memory. The number of switching actions is obtained by monitoring the number of transitions in the enable signal. Temperature monitoring uses a multi-point sampling method to record temperature changes in the power devices and the heat dissipation system.

[0091] S730: Based on identity recognition information and module status records, establish a separate inverter module operation file to record the usage status of the separate inverter module.

[0092] Specifically, the system creates structured archive files based on the collected identity information and status data. The archive content includes a basic information area, an operation record area, and a performance evaluation area. The system processes the raw data through a data analysis module, generates usage status reports, and stores these reports in the archive management system, achieving full lifecycle tracking and management of the modules.

[0093] S740. Based on the operating file of the separate inverter module, determine whether the separate inverter module meets the preset usage conditions. If the usage conditions are not met, send a replacement prompt message to the human-machine interface device.

[0094] In this embodiment, the usage conditions include the maximum cumulative working time, the maximum number of switching operations, and the temperature stress limit; the replacement prompt information includes the warning level and recommended measures.

[0095] Specifically, the system periodically reads operational data and calculates the module's health index using a preset evaluation model. When the cumulative working time approaches the upper limit, the number of on / off cycles exceeds the set value, or the temperature record shows excessive stress, the system determines that the module does not meet the usage conditions. At this point, the system generates a prompt message containing specific reasons and suggested measures, issuing a warning to the operator through the human-machine interface to ensure timely replacement of aging modules.

[0096] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0097] Secondly, this application provides a five-axis drive and control integrated machine control system. The five-axis drive and control integrated machine control system of this application will be described below in conjunction with the above-mentioned five-axis drive and control integrated machine control method.

[0098] Reference Figure 8 A five-axis drive and control integrated machine control system, comprising: Integrated PCB control board; Multiple electrically isolated and independently configured discrete inverter modules; The power management module is used to detect the system's power supply status; Five-axis servo motor system; The filter support capacitor is configured to be directly installed at the bus end of each separate inverter module to provide independent local filter support for each inverter module. The human-computer interaction interface device is used to receive motion parameters input by the user, combine them with the dynamic motion constraint parameters of each axis, and obtain the target position command for each axis. The integrated PCB control board is used for: Based on a stable system power supply, each discrete inverter module is initialized in parallel to obtain the enable signal for each axis inverter module; Based on the target position command, the real-time position and speed commands of each axis are calculated; Based on the enable signals of each axis inverter module, real-time position and speed commands, the five-axis servo motor system is driven by the separate inverter module to execute motion, thereby obtaining the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis; Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities. When a source-related anomaly is determined, based on the electrical isolation characteristics of the split inverter modules, a shutdown command is sent to the split inverter module corresponding to the abnormal axis, causing the split inverter module corresponding to the abnormal axis to be powered down independently, while the split inverter modules of the other normal axes continue to operate; when a cascading anomaly is determined, the overall operating speed is reduced and a system status check is performed. After shutting down and replacing the faulty split inverter module, the module adaptive configuration program is executed. Based on the identification information of the newly replaced split inverter module, the corresponding parameters are automatically loaded. Based on the actual characteristics of the replaced split inverter module, the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis are re-optimized so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

[0099] In one embodiment, this application provides an electronic device whose internal structure diagram can be as follows: Figure 9As shown, the electronic device includes a processor, memory, and network interface connected via a system bus. The processor provides computing and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores the operating system, computer programs, and a database. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The database stores data. The network interface communicates with external terminals via a network connection. When the computer program is executed by the processor, it implements a five-axis integrated drive and control machine control method.

[0100] Those skilled in the art will understand that Figure 9 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the electronic device to which the present application is applied. The specific electronic device may include more or fewer components than shown in the figure, or combine certain components, or have different component arrangements.

[0101] In one embodiment, an electronic device is also provided, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps in the above-described method embodiments.

[0102] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, or optical storage, etc. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM can be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM), etc.

[0103] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A control method for a five-axis integrated drive and control machine, characterized in that, The control method is applied to an all-in-one machine control system, which includes an integrated PCB control board, multiple electrically isolated and independently configured separate inverter modules, a power management module, a five-axis servo motor system, filter support capacitors, and a human-machine interface device. The integrated PCB control board executes the control method, which includes the following steps: The power management module detects the system power supply status, and the filter support capacitor filters the bus voltage to obtain a stable system power supply. The filter support capacitor is configured to provide independent local filter support for each inverter module by being directly installed at the bus end of each separate inverter module. Based on the stable system power supply, each discrete inverter module is initialized in parallel to obtain the enable signal for each axis inverter module; The human-computer interaction interface device receives motion parameters input by the user and combines them with the dynamic motion constraint parameters of each axis to obtain the target position command for each axis. Based on the target position command, the real-time position and speed commands of each axis are calculated; Based on the enable signals of each axis inverter module, the real-time position and speed commands, the five-axis servo motor system is driven by the separate inverter module to perform motion, thereby obtaining the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis; Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities. When a source-related anomaly is determined, based on the electrical isolation characteristics of the separate inverter module, a shutdown command is sent to the separate inverter module corresponding to the abnormal axis, causing the separate inverter module corresponding to the abnormal axis to be powered down independently, while the separate inverter modules of the other normal axes continue to operate; when a cascading anomaly is determined, the overall operating speed is reduced and a system status check is performed. After shutting down and replacing the faulty split inverter module, the module adaptive configuration program is executed. Based on the identification information of the newly replaced split inverter module, the corresponding parameters are automatically loaded. Based on the actual characteristics of the replaced split inverter module, the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis are re-optimized so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

2. The five-axis drive and control integrated machine control method according to claim 1, characterized in that, The system collects and analyzes the current fluctuation characteristics, position deviation change rate, and motion state parameters of each axis in real time. Based on the preset fault diagnosis logic, it distinguishes between primary abnormalities and related abnormalities. The specific steps include the following: Acquire real-time current fluctuation data, position deviation data, and speed tracking data for each axis, and calculate current fluctuation characteristics and position deviation change rate. The current fluctuation characteristics include current fluctuation amplitude and waveform distortion, and the position deviation change rate includes the instantaneous change rate and cumulative change trend of the position deviation. Analyze the motion state parameters of adjacent axes based on the current fluctuation characteristics and the rate of change of position deviation. The anomaly type is determined based on the preset fault diagnosis logic: When a sudden change in the amplitude of a single-axis current fluctuation or waveform distortion is detected, and the instantaneous rate of change exceeds a preset threshold, it is determined to be a source anomaly. When multiple axes are detected to simultaneously exhibit increasing speed following errors and a cumulative trend in position deviations, it is determined to be a cascading anomaly.

3. The five-axis drive and control integrated machine control method according to claim 1, characterized in that, The human-computer interaction interface device receives motion parameters input by the user and combines them with the dynamic motion constraint parameters of each axis to obtain the target position command for each axis. Specifically, the steps include the following: The target location parameters input by the user are received through the human-computer interaction interface device; The dynamic motion constraint parameters of each axis are obtained, including the starting speed, maximum speed, maximum acceleration, maximum deceleration, and jerk limit value. The dynamic motion constraint parameters are set according to preset values ​​determined by the load inertia and mechanical transmission characteristics of each axis, and are adjusted in real time according to the temperature change characteristics and vibration response characteristics. Generate acceleration / deceleration curves based on the dynamic motion constraint parameters; Priority is determined for the target positions of each axis to determine the startup sequence of each axis; Based on the startup timing and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated, and the speed parameters of each axis are compensated according to the synchronization coefficient. By combining the compensated speed parameters with the acceleration / deceleration curves, the target position commands for each axis are obtained.

4. The five-axis drive and control integrated machine control method according to claim 3, characterized in that, Based on the startup timing and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated, and the speed parameters of each axis are compensated according to the synchronization coefficient. Specifically, the following steps are included: Based on the start-up timing of each axis, the motion time ratio of adjacent axes is determined; Based on the motion time ratio and the parasitic parameter differences caused by the actual layout of the split inverter module, the synchronization coefficient between adjacent axes is calculated through a preset inter-axis compensation parameter table. The inter-axis compensation parameter table includes mechanical characteristic difference parameters of adjacent axes, which are used to compensate for dynamic synchronization errors during acceleration and deceleration. Obtain the current speed parameters of each axis, and compensate the speed parameters of each axis according to the synchronization coefficient so that the time for adjacent axes to reach the target position is consistent; Determine whether the compensated speed parameters meet the requirements of the dynamic motion constraint parameters. If they do not meet the requirements, recalculate the synchronization coefficient until they do.

5. The control method for a five-axis integrated drive and control machine according to claim 4, characterized in that, After a single-axis malfunction is detected and the discrete inverter module corresponding to the malfunctioning axis is replaced, the control method further includes the following steps: The newly replaced split inverter module is configured with parameters through a preset module adaptive configuration program, wherein the module adaptive configuration program contains standard parameter configuration information corresponding to each model of inverter module; Based on the model information of the newly replaced split inverter module, the corresponding standard parameter configuration information is automatically loaded and the initialization settings are completed. At the same time, the preset values ​​of the dynamic motion constraint parameters of the abnormal axis and the inter-axis compensation parameters of the adjacent axis are re-acquired. The standard test procedure is executed in the preset mode to collect the inter-axis synchronization characteristic data. The inter-axis compensation parameters are automatically optimized based on the data until the system's preset synchronization accuracy requirements are met.

6. The control method for a five-axis integrated drive and control machine according to claim 5, characterized in that, After the inter-axis compensation parameters meet the system's preset synchronization accuracy requirements, the control method further includes the following steps: The five-axis system was tested using a pre-set multi-axis linkage test program. The multi-axis linkage test program included a pre-set standard motion trajectory and evaluation indicators, which were used to verify the overall performance of the system after replacing the split inverter module corresponding to the abnormal axis. During the test, position error, speed error, and current fluctuation parameters of each axis were collected. The overall machine operation characteristic evaluation index is calculated based on the position error, speed error and current fluctuation parameters. When the evaluation index meets the preset threshold, the system parameter configuration table is updated to complete the confirmation of the abnormal axis's recovery operation.

7. The control method for a five-axis integrated drive and control machine according to claim 1, characterized in that, The discrete inverter module is equipped with a module identification circuit, which includes an identification chip and a module status detection circuit. The control method further includes the following steps: The module identification circuit receives identification information, which includes the module serial number, production batch number, and rated power parameters. The module status record is obtained by collecting the working time, switching frequency and temperature records of the discrete inverter module through the module status detection circuit. Based on the identity recognition information and the module status record, a separate inverter module operation file is established to record the usage status of the separate inverter module; Based on the operation file of the split inverter module, it is determined whether the split inverter module meets the preset usage conditions. If the usage conditions are not met, a replacement prompt message is sent to the human-machine interface device.

8. A five-axis drive and control integrated machine control system, characterized in that, include: Integrated PCB control board; Multiple electrically isolated and independently configured discrete inverter modules; The power management module is used to detect the system's power supply status; Five-axis servo motor system; The filter support capacitor is configured to be directly installed at the bus end of each separate inverter module to provide independent local filter support for each inverter module. The human-computer interaction interface device is used to receive motion parameters input by the user, combine them with the dynamic motion constraint parameters of each axis, and obtain the target position command for each axis. The integrated PCB control board is used for: Based on the stable system power supply, each discrete inverter module is initialized in parallel to obtain the enable signal for each axis inverter module; Based on the target position command, the real-time position and speed commands of each axis are calculated; Based on the enable signals of each axis inverter module, the real-time position and speed commands, the five-axis servo motor system is driven by the separate inverter module to perform motion, thereby obtaining the actual motion state of each axis, and feedback adjustment is performed according to the operating state of each axis; Real-time acquisition and analysis of current fluctuation characteristics, position deviation change rate, and motion state parameters of adjacent axes; based on preset fault diagnosis logic, distinguish between primary abnormalities and related abnormalities. When a source-related anomaly is determined, based on the electrical isolation characteristics of the separate inverter module, a shutdown command is sent to the separate inverter module corresponding to the abnormal axis, causing the separate inverter module corresponding to the abnormal axis to be powered down independently, while the separate inverter modules of the other normal axes continue to operate; when a cascading anomaly is determined, the overall operating speed is reduced and a system status check is performed. After shutting down and replacing the faulty split inverter module, the module adaptive configuration program is executed. Based on the identification information of the newly replaced split inverter module, the corresponding parameters are automatically loaded. Based on the actual characteristics of the replaced split inverter module, the inter-axis synchronization compensation parameters between the faulty axis and the adjacent axis are re-optimized so that the faulty axis can be reintegrated into the five-axis system and the synchronization accuracy can be restored.

9. An electronic device, characterized in that, The system includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the five-axis drive and control integrated machine control method according to any one of claims 1-7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the steps of the five-axis drive and control integrated machine control method according to any one of claims 1-7.

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