Translation transport mass comprehensive control system based on visual and mechanical strain signals

Abstract

The present application relates to the continuous transportation technical field, especially in translation transportation quality comprehensive control system based on vision and mechanical strain signal, including signal acquisition module, obtains the mechanical strain signal in the transportation plane and the vision information about the material form;Operation control module, receive the collected signal, establish the space coordinate system and carry out analysis in combination with the preset mathematical logic, output control instruction;Position adjustment module, according to control instruction adjusts the physical position of sensor to ensure continuous meet the measurement condition;Transmission execution module, according to control instruction drives the execution element to run and controls the speed of translation transportation;Feedback check module, monitor actual transportation state data and return to operation control module to form closed loop control.In the present application, by fusing the shape proportion signal of vision sensor and the linear strain signal of mechanical strain sensor, the accuracy of feed quality control is ensured.

Description

Technical Field

[0001] This invention relates to the field of continuous transportation technology, and in particular to a comprehensive quality control system for translational transportation based on visual and mechanical strain signals. Background Technology

[0002] Horizontal transport, as a core component of material transfer, is widely used in mining, agriculture, and environmental protection. Currently, quality control in horizontal transport mainly relies on methods such as pressure testing, visual inspection, or non-visual optical methods to monitor material flow during transport and control conveying quality by adjusting the speed of actuators to ensure production continuity.

[0003] Existing technologies mostly employ single detection or simple combination control, lacking deep mapping and fusion of visual information and mechanical strain signals. When faced with irregular materials with varied shapes or containing moisture, the system struggles to accurately capture the real-time dynamic quality of the material, easily leading to misjudgment of detection signals and fluctuations in transmission speed. This results in unstable feeding, slow control response, and low metering accuracy, failing to meet the requirements for high-precision conveying. Summary of the Invention

[0004] To overcome the above shortcomings, this invention provides a comprehensive translational transport quality control system based on visual and mechanical strain signals, which aims to improve the problems of unstable feeding, slow control response and low metering accuracy.

[0005] In a first aspect, the present invention provides the following technical solution: a comprehensive control system for translational transport quality based on visual and mechanical strain signals, comprising:

[0006] The signal acquisition module acquires mechanical strain signals within the transport plane, as well as visual information about the material's morphology. The computation and control module receives the collected signals, establishes a spatial coordinate system, analyzes the signals in conjunction with preset mathematical logic, and outputs control commands. The position adjustment module adjusts the physical position of the sensor according to control commands to ensure that the measurement conditions are continuously met. The transmission execution module drives the execution elements to operate and regulates the speed of translational transport according to control commands; The feedback verification module monitors the actual transportation status data and sends it back to the calculation and control module to form a closed-loop control.

[0007] Preferably, in the signal acquisition module, the step of arranging the mechanical strain sensor includes: Using the translational transport axis as the X-axis and the axis perpendicular to the positive transport direction and coinciding with the transport plane as the Y-axis, at least three measurement points are arranged within the transport plane; Ensure that the first measurement point is parallel to the X-axis, the second measurement point is parallel to the Y-axis, and the third measurement point is located on a straight line within the transport plane that forms a 45-degree angle with both the X-axis and the Y-axis. The spacing between adjacent measurement locations is controlled to be 20 millimeters, and the spacing between each measurement point exceeds the range of mutual interference.

[0008] Preferably, in the signal acquisition module, the step of arranging the vision sensor includes: Infrared imaging devices were selected as the visual sensors. The vision sensor is positioned in a plane perpendicular to the positive direction of transport and within the plane formed by the Z-axis and X-axis of the transport normal plane; Adjust the position of the field of view center of the vision sensor to capture the visual change process of transported materials from normal transport state to falling state.

[0009] Preferably, in the calculation control module, the steps for setting the material quality calculation logic include: Define the rated speed of motion, effective load length, and range of weight of the actuator; When there is no load, the reference signals output from the mechanical strain sensor in three directions and the no-load state signal output from the vision sensor are read. The arithmetic control module sends an idle state indication signal to maintain the system in a stable idle state.

[0010] Preferably, in the calculation control module, the step of performing the quality calculation during the feeding stage includes: When the material has not yet moved to the center of the field of view and the transmission device only performs the feeding function, the load signal output by the vision sensor is acquired. The percentage of pixels in the field-of-view image of the material detected by the vision sensor at different times is used as a variable. By combining the strain measurements in the X-axis, Y-axis, and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the product of the above variables and parameters is integrated to obtain the material mass.

[0011] Preferably, in the calculation control module, the step of performing quality calculation during the stable material feeding stage includes: Once the system enters a stable and continuous feeding and unloading state, the vision sensor is controlled to alternately output load signals and reference signals. Calculate the time difference between two alternating visual signal transformations; By using the difference between the load signal and the reference signal, combined with the strain measurements in the X-axis, Y-axis and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the parameters are multiplied to obtain the material mass.

[0012] Preferably, in the position adjustment module, the step of adjusting the sensor position includes: Receives the position deviation signal sent by the arithmetic control module; The installation location of the vision sensor or mechanical strain sensor that drives the mechanical structure to move; After confirming that the sensor position adjustment meets the preset requirements for measurement field of view and strain sensing area.

[0013] Preferably, in the transmission execution module, the step of regulating the transport speed includes: Receive material quality data calculated by the calculation and control module; Match the operating speed of the corresponding actuator at its maximum power based on the material quality data; The control actuator adjusts the current translational transport speed within the range of zero to maximum operating speed.

[0014] Preferably, in the feedback verification module, the step of performing signal feedback includes: Real-time acquisition of actual speed and direction data of material transportation; Calculate the offset between the actual data and the preset value; Send the offset to the calculation control module. The control command is corrected by the arithmetic control module through the PID controller.

[0015] Secondly, the present invention provides the following technical solution: a comprehensive control method for translational transport quality based on visual and mechanical strain signals, the method comprising: Step S1: Acquire mechanical strain signals within the transport plane and visual information about the material morphology through the signal acquisition module; Step S2: Receive the collected signals through the arithmetic control module, establish a spatial coordinate system, analyze the signals in conjunction with preset mathematical logic, and output control commands; Step S3: Adjust the physical position of the sensor according to the control command through the position adjustment module to ensure that the measurement conditions are continuously met; Step S4: The transmission execution module drives the execution element to run and adjusts the speed of translational transport according to the control command; Step S5: Monitor the actual transportation status data through the feedback verification module and send it back to the calculation control module to form a closed-loop control.

[0016] The present invention has the following beneficial effects: 1. In this invention, by fusing the shape proportion signal from the visual sensor and the linear strain signal from the mechanical strain sensor, the integral weight of the mechanical model is dynamically corrected using visual information. This effectively overcomes the signal drift and misjudgment problems of traditional single sensors when facing materials that are agglomerated, contain water, or have irregular shapes, thus ensuring the accuracy of feed quality control.

[0017] 2. In this invention, a three-dimensional strain sensor array layout parallel to the X-axis, Y-axis and 45-degree direction is adopted. Combined with XZ plane visual monitoring, a mathematical model based on principal stress calculation is constructed, which can accurately analyze and filter out non-target stress components caused by off-center loading and torsion during transportation, thereby maintaining the measurement signal-to-noise ratio under complex working conditions.

[0018] 3. In this invention, a segmented control strategy based on the feeding stage and the stable feeding stage is proposed. During stable transportation, the speed of the actuator is quickly adjusted by monitoring the difference between the visual and strain signals, avoiding the lag caused by complex integral calculations throughout the process, and realizing real-time and sensitive closed-loop control of the transportation speed. Attached Figure Description

[0019] Figure 1 This is a block diagram of the integrated quality control system for translational transportation based on visual and mechanical strain signals proposed in this invention. Figure 2 This is a flowchart of the integrated quality control method for translational transportation based on visual and mechanical strain signals proposed in this invention. Figure 3 This is a structural diagram of the integrated translational transport quality control system based on visual and mechanical strain signals proposed in this invention. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Example 1 In a first embodiment of the present invention, the present invention provides a comprehensive translational transport quality control system based on visual and mechanical strain signals, such as... Figure 1 and Figure 3 As shown, it includes the following steps: The signal acquisition module acquires mechanical strain signals within the transport plane, as well as visual information about the material's morphology. The steps for deploying mechanical strain sensors in the signal acquisition module include: Using the translational transport axis as the X-axis and the axis perpendicular to the positive transport direction and coinciding with the transport plane as the Y-axis, at least three measurement points are arranged within the transport plane; Ensure that the first measurement point is parallel to the X-axis, the second measurement point is parallel to the Y-axis, and the third measurement point is located on a straight line within the transport plane that forms a 45-degree angle with both the X-axis and the Y-axis. The spacing between adjacent measurement positions is controlled to be 20 millimeters, and the spacing between each measurement point exceeds the range of mutual interference; The steps for deploying the vision sensor in the signal acquisition module include: Infrared imaging devices were selected as the visual sensors. The vision sensor is positioned in a plane perpendicular to the positive direction of transport and within the plane formed by the Z-axis and X-axis of the transport normal plane; Adjust the position of the field of view center of the vision sensor to capture the visual change process of transported materials from normal transport state to falling state; Specifically, to achieve an accurate description of the material's state during transportation, a spatial coordinate system suitable for the system is first established. The translational transportation axis is defined as the X-axis, with the direction of transportation forward as its positive direction; the axis perpendicular to the positive transportation direction and coinciding with the transportation plane is defined as the Y-axis, with the right side of the direction of transportation forward as its positive direction; the axis perpendicular to the positive transportation direction and within the normal transportation plane is defined as the Z-axis, with its positive direction aligned with the direction of gravitational acceleration. This coordinate system forms the basis for all subsequent sensor placement and mechanical model calculations.

[0022] The signal acquisition module, as the front-end sensing unit of the system, has the core function of acquiring mechanical strain signals within the transport plane and visual information about the material's morphology. This module mainly consists of mechanical strain sensors and vision sensors.

[0023] Regarding the arrangement of the mechanical strain sensors, this embodiment uses high-precision resistance strain gauges as sensing elements, whose response signal characteristics are linear strain. The plane in which the mechanical strain sensors are arranged is strictly located within the transport plane. In order to resolve the complex stress state within the transport plane, including normal stress and shear stress, at least three measurement points must be arranged.

[0024] The specific sensor layout is as follows: the strain-sensitive grid at the first measurement point is parallel to the X-axis, used to measure linear strain in the X-direction; the strain-sensitive grid at the second measurement point is parallel to the Y-axis, used to measure linear strain in the Y-direction; the third measurement point is located within the transport plane, and its strain-sensitive grid is aligned with a straight line forming a 45-degree angle with both the X-axis and Y-axis. This three-dimensional garland or independent combination layout at 0°, 90°, and 45° angles allows for the acquisition of all strain components required for calculating the principal stresses.

[0025] Regarding the positional relationship of the measurement points, this embodiment strictly limits the spacing between adjacent measurement positions, controlling the spacing to 20 millimeters. This spacing is based on the analysis of the stress transmission characteristics of the substrate material of common translational transport equipment. This ensures that the three measurement points reflect the stress state of the same micro-element region, while also ensuring that the spacing between each measurement point exceeds the range of electromagnetic interference or stress concentration interference between sensors, thus guaranteeing the independence and effectiveness of the signal. The mechanical strain sensor is connected to the signal conditioning unit via a Wheatstone bridge circuit, converting physical deformation into a voltage signal output.

[0026] For the arrangement of the vision sensor, this embodiment selects an infrared imaging device as the vision sensor. Infrared imaging devices have strong resistance to light interference and sensitivity to material temperature distribution, making them suitable for capturing material contours in complex industrial environments. The vision sensor is positioned perpendicular to the positive transport direction and lies within the plane formed by the Z-axis and X-axis of the transport normal plane, i.e., the XZ plane. The vision sensor is fixed by a rigid bracket, and its lens optical axis points towards the transport plane.

[0027] Regarding field-of-view adjustment, the center position of the vision sensor's field of view is adjusted to precisely cover the critical area at the end of the transport process, capturing the visual change in the material's appearance as it transitions from normal horizontal transport to a dropping state. This field-of-view area is the critical point between feeding and dropping, and also the basis for determining the state transition in the flow calculation model. The vision sensor transmits the acquired infrared image sequence to the computing and control module in real time via a data cable. The pixel distribution of the material in the image directly reflects the instantaneous accumulation pattern of the material.

[0028] The signal acquisition module synchronously transmits the three mechanical strain signals acquired, corresponding to the X-axis, Y-axis, and 45-degree direction, along with a visual image signal, to the computing and control module, providing raw data support for subsequent mass inversion and speed control.

[0029] The computation and control module receives the collected signals, establishes a spatial coordinate system, analyzes the signals in conjunction with preset mathematical logic, and outputs control commands. In the calculation control module, the steps for setting the material quality calculation logic include: Define the rated speed of motion, effective load length, and range of weight of the actuator; When there is no load, the reference signals output from the mechanical strain sensor in three directions and the no-load state signal output from the vision sensor are read. The no-load status indication signal is issued by the operation and control module to maintain the system in a stable no-load state; In the calculation and control module, the steps for performing quality calculations during the feeding stage include: When the material has not yet moved to the center of the field of view and the transmission device only performs the feeding function, the load signal output by the vision sensor is acquired. The percentage of pixels in the field-of-view image of the material detected by the vision sensor at different times is used as a variable. By combining the strain measurements in the X-axis, Y-axis and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the product of the above variables and parameters is integrated to obtain the material mass. In the computational control module, the steps for performing quality calculations during the stable material feeding phase include: Once the system enters a stable and continuous feeding and unloading state, the vision sensor is controlled to alternately output load signals and reference signals. Calculate the time difference between two alternating visual signal transformations; By using the difference between the load signal and the reference signal, combined with the strain measurements in the X-axis, Y-axis and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the parameters are multiplied to obtain the material mass. Specifically, in the arithmetic control module, the system parameters are first initialized and the baseline is calibrated. The rated speed of the actuator is defined as follows: ,in , Define the operating speed of the actuator at maximum power; define the effective load-bearing length of the actuator as LL; set the allowable weight range of the system as... ,in , The maximum load capacity designed for the actuator.

[0030] In the initial state after system startup and with no load on the actuators, the computational control module executes the zero-point calibration procedure. The module reads the reference signals output by the mechanical strain sensor along the X-axis, Y-axis, and 45-degree direction, denoted as... Simultaneously, the no-load status signal output by the vision sensor is read and recorded as... At this time, the operation and control module sends an idle state indication signal, controlling the transmission execution module to maintain the system in a stable idle standby state, and... and This serves as a zero-point reference value for subsequent difference calculations.

[0031] When the actuator begins to carry material, the calculation and control module divides the control logic into "feeding stage" and "stable material dropping stage" based on the position of the material relative to the center of the field of view of the vision sensor, and uses different mathematical models to perform quality inversion.

[0032] During the feeding phase, before the material reaches the center of the field of view (before the critical material drop zone), when the conveyor only performs the feeding function, the computational control module executes integral calculation logic. At this time, the vision sensor outputs a load signal reflecting the current shape of the material in real time. The operation control module calls the following integral mathematical model to calculate the current cumulative material mass. : ; In this formula, Representing visual sensors at different times The percentage of pixels in the field-of-view image of the material detected within reflects the instantaneous coverage area of ​​the material on the transport plane; This is a preset conversion factor between the pixel ratio and the actual area occupied by the material. , , These represent the real-time strain values ​​measured by the mechanical strain sensor in the X-axis direction, Y-axis direction, and 45-degree direction, respectively. The elastic modulus of the substrate material of the conveying device; The model uses visual signals to correct the integral weights of the strain signals and calculates the total mass of the material during the feeding process by performing principal stress transformation calculations on the strain tensor. This is denoted by Poisson's ratio of the substrate material of the conveying device.

[0033] During the stable material feeding phase, i.e., after the material enters a stable and continuous feeding and feeding state, the system is in dynamic equilibrium. At this time, the computational control module controls the vision sensor to adjust the load signal. With reference signal Logical comparisons are performed between the components, and differential calculation logic is executed to quickly respond to load changes. The operation control module calls the following differential mathematical model to calculate the material mass within the infinitesimal time period. : ; In this formula, It is the time difference between two visual signal samplings or alternating transformations, representing the time step of the calculation; For dynamic flow conversion coefficient; This represents the change in the material's visual shape relative to the unloaded baseline at the current moment; the term within square brackets is consistent with the formula for the feeding stage, representing the instantaneous comprehensive stress state calculated based on triaxial strain data. Through this differential model, the computational control module can calculate the material's mass flow rate in real time, thus providing high-frequency, low-hysteresis feedback for speed regulation.

[0034] The calculation and control module will calculate the material mass. The speed is compared with the preset target value, and the corresponding speed control command is generated and sent to the transmission execution module to achieve closed-loop precise control of the translational transport speed.

[0035] The position adjustment module adjusts the physical position of the sensor according to control commands to ensure that the measurement conditions are continuously met. In the position adjustment module, the steps for adjusting the sensor position include: Receives the position deviation signal sent by the arithmetic control module; The installation location of the vision sensor or mechanical strain sensor that drives the mechanical structure to move; After confirming that the sensor position adjustment meets the preset requirements for measurement field of view and strain sensing area; Specifically, the position adjustment module consists of a mechanical drive device, a servo drive circuit, and a displacement feedback element. Its main function is to dynamically maintain the optimal geometric relationship between the sensor and the object being measured. Physically, this module is connected between the sensor's mounting bracket and the fixed frame of the translational transport equipment.

[0036] In the step of receiving the position deviation signal from the calculation and control module, this signal typically arises under two conditions: first, visual image analysis indicates that the material's drop point has deviated from the preset tolerance range of the field of view center; second, the distribution characteristics of the mechanical strain signal indicate a relative displacement between the force center of the transport plane and the sensor placement center. The position adjustment module receives digital commands containing target coordinates or adjustment step sizes via the industrial bus.

[0037] In the installation step of moving the vision sensor or mechanical strain sensor in the driving mechanical structure, for the vision sensor, the position adjustment module controls the multi-axis electric slide or electric pan-tilt head mounted on the XZ plane bracket. The drive circuit drives the stepper motor or servo motor to rotate, and through the ball screw or rack and pinion transmission mechanism, drives the infrared imaging device to translate along the X-axis or rotate around the Y-axis to adjust the pitch angle, thereby correcting the field of view coverage area. For the mechanical strain sensor, since it is arranged in the transport plane, the position adjustment module controls the linear module mounted at the bottom of the sensor support structure to drive the measuring unit carrying the strain sensor to make fine adjustments along the Y-axis (lateral correction) or X-axis (longitudinal alignment) to ensure that the three measuring points are always located on the effective strain transmission path of the material's gravity.

[0038] After confirming that the sensor position adjustment meets the preset requirements for the measurement field of view and strain sensing area, the position adjustment module reads the encoder value of the servo motor or the reading of the external grating ruler to determine that the physical displacement has reached the command requirements. Subsequently, the system waits for the next cycle of sampling verification from the calculation control module: that is, to confirm that the new image center has included the entire material falling process, and that the reference value of the three-dimensional strain signal has returned to the effective linear measurement range, thereby completing one closed-loop position adjustment.

[0039] The transmission execution module drives the execution elements to operate and regulates the speed of translational transport according to control commands; In the transmission execution module, the steps for adjusting the transport speed include: Receive material quality data calculated by the calculation and control module; Match the operating speed of the corresponding actuator at its maximum power based on the material quality data; The control actuator adjusts the current translational transport speed within the range of zero to maximum operating speed; Specifically, the transmission execution module mainly consists of a motor drive controller and a motor assembly. The motor, as the actuator, has its output shaft mechanically connected to the drive roller or sprocket of the translational transport equipment through a reduction mechanism or direct coupling, and is responsible for providing the power required for transportation.

[0040] In the step of receiving the material quality data calculated by the computing and control module, the transmission execution module reads the real-time material quality value output by the computing and control module at high frequency through the industrial fieldbus. This data is the result of a fusion calculation of visual and mechanical strain signals, reflecting the actual load situation on the current transport plane.

[0041] In the step of matching the operating speed of the corresponding actuator under its maximum power based on material quality data, the module has a pre-built load-speed characteristic mapping logic for the actuator. Following the constant power control principle of motor drives, the output power, driving force, and operating speed of the actuator satisfy the following physical constraints. The module calculates the theoretical maximum allowable operating speed under the current load conditions based on the following constant power constraint model. : ; in, The rated output power of the actuator (motor); Overall efficiency of mechanical transmission system; The real-time material quality calculated by the current calculation and control module; : Gravitational acceleration; The overall resistance coefficient of the translational transport mechanism (including rolling / sliding friction); The minimum acceleration requirement for system startup / acceleration.

[0042] This model ensures that: When load quality When the speed increases, the system automatically lowers the speed limit. To ensure the driving torque under constant power constraint It will not cause the motor to overload; When load quality When reduced, the speed limit is released to allow for higher operating efficiency.

[0043] The operation control module will This serves as the upper limit of the maximum permissible operating speed within the current control cycle.

[0044] In the step of adjusting the current translational transport speed within the range of zero to maximum operating speed, the motor drive controller sets the calculated upper speed limit as the saturation threshold of the current control cycle. Based on this threshold, the controller generates a corresponding pulse width modulation signal or frequency conversion drive signal, which is input to the motor stator winding. The motor responds to the drive signal, driving the translational transport mechanism to continuously adjust its speed within the range of zero to the currently allowed maximum operating speed. When the calculation and control module detects fluctuations in the feed rate, the transmission execution module responds immediately, dynamically adjusting the transport linear speed to ensure load matching and kinetic energy balance during continuous conveying.

[0045] The feedback verification module monitors the actual transportation status data and sends it back to the calculation and control module to form a closed-loop control. In the feedback verification module, the steps for performing signal feedback include: Real-time acquisition of actual speed and direction data of material transportation; Calculate the offset between the actual data and the preset value; Send the offset to the calculation control module. The control command is corrected by the computational control module through the PID controller; Specifically, in the process of sending the offset to the arithmetic control module, and the arithmetic control module correcting the control command using the PID controller, the speed deviation value is... (i.e., the current moment) The difference between the actual speed and the target speed is used as the input signal and fed into the digital PID control algorithm unit of the arithmetic control module. The arithmetic control module uses a position-based discrete PID control algorithm for calculation, and its control output is... Follow the mathematical model as follows: ; In this formula, For the current number Control output command value for each sampling period; The proportional coefficient is used to reflect the deviation signal of the system. ; The sampling period; This is the integration time constant, used to eliminate steady-state error; The differential time constant is used to reflect the changing trend of the deviation signal; This is the deviation value from the previous sampling time. The calculation and control module uses this value... The value generates a corresponding voltage regulation signal or frequency setting command for the inverter. This command directly updates the drive state of the transmission execution module, thereby quickly eliminating speed deviations, suppressing fluctuations caused by sudden load changes, ensuring that the translational transport speed strictly follows the set trajectory caused by changes in material quality, and maintaining the stable operation of the system.

[0046] Example 2: In industrial and agricultural horizontal transport scenarios, especially when conveying irregularly shaped and unevenly distributed materials such as wet coal, ore, or bulk crops, the lack of multi-dimensional sensing means means that single sensors are easily affected by belt tension fluctuations, material overloading, or changes in moisture content, resulting in signal drift. This leads to the system's inability to accurately measure the material mass flow rate in real time, causing technical problems such as unstable discharge and lag in transmission speed control. To solve these problems, this invention provides a comprehensive quality control method for horizontal transport based on visual and mechanical strain signals, the structure of which is as follows: Figure 2 As shown. The specific implementation process of this method is as follows: Step S1: Acquire mechanical strain signals within the transport plane and visual information about the material morphology through the signal acquisition module; Step S2: Receive the collected signals through the arithmetic control module, establish a spatial coordinate system, analyze the signals in conjunction with preset mathematical logic, and output control commands; Step S3: Adjust the physical position of the sensor according to the control command through the position adjustment module to ensure that the measurement conditions are continuously met; Step S4: The transmission execution module drives the execution element to run and adjusts the speed of translational transport according to the control command; Step S5: Monitor the actual transportation status data through the feedback verification module and send it back to the calculation control module to form a closed-loop control.

[0047] Specifically, in step S1: The system first activates the mechanical strain sensor array located within the transport plane. This array operates strictly according to a preset layout: the first measurement point collects linear strain signals parallel to the X-axis, the second measurement point collects linear strain signals parallel to the Y-axis, and the third measurement point collects linear strain signals located within the transport plane at a 45-degree angle to both the X and Y axes. The system simultaneously ensures that the spacing between adjacent measurement positions is strictly maintained at 20 millimeters to guarantee the spatial correlation and independence of the strain data. Meanwhile, an infrared imaging device is selected as the visual sensor. This sensor operates perpendicular to the positive transport direction and within the plane formed by the Z-axis and X-axis of the transport normal plane, capturing real-time infrared image sequences of the transported material. The visual sensor focuses on the central region of the field of view, recording the visual morphological changes of the material as it moves from a normal translational transport state to a dropping state, and converts this visual information into digital signals for transmission to the next-level module.

[0048] Step S2: The calculation and control module first defines a spatial coordinate system including the translational transport axis, the vertical transport positive direction axis, and the normal axis. Then, the module executes the material mass calculation logic. When the system is in the feeding stage, i.e., before the material has moved to the center of the field of view and the conveying device only performs the feeding function, the module acquires the load signal from the vision sensor. Using the percentage of pixels containing the material in the field of view image as a variable, and combining the strain measurements in the three directions with the elastic modulus and Poisson's ratio of the conveying device's base material, the module integrates the product of the above variables and parameters to obtain the cumulative material mass. When the system enters a stable continuous feeding and dropping state, the module controls the vision sensor to alternately output the load signal and the reference signal, calculates the time difference between the two visual signal alternations, and uses the difference between the load signal and the reference signal, combined with the strain measurements in the three directions and material property parameters, to perform a product calculation to obtain the instantaneous material mass. Finally, the calculation and control module generates the corresponding speed control command based on the calculated mass data.

[0049] Step S3: The position adjustment module receives the position deviation signal from the calculation and control module in real time. This deviation signal reflects the offset of the material drop center relative to the visual field center, or the offset of the stress transmission center relative to the strain sensor group. Once the deviation signal is received, the position adjustment module immediately drives the mechanical drive structure connected to the sensor bracket. For visual sensors, the module drives them to translate along the X-axis or Y-axis; for mechanical strain sensors, the module drives them to make fine adjustments below the transport plane. This adjustment process continues until it is confirmed that the sensor position adjustment once again meets the preset measurement field coverage requirements and strain sensing area alignment requirements, thereby ensuring the accuracy of signal acquisition.

[0050] Step S4: The transmission execution module receives the material mass data calculated by the calculation and control module. Internally, based on the physical characteristics of the actuator, the module executes constant power matching logic, that is, it calculates the maximum speed allowed for the actuator under maximum power limitations based on the current material mass data. Subsequently, the module sends a drive signal to the actuator, controlling it to adjust the current translational transport speed within the range from zero speed to the calculated maximum operating speed. When the material mass increases, the module automatically reduces the operating speed to provide sufficient drive torque; when the material mass decreases, the module increases the operating speed to improve conveying efficiency, thereby achieving dynamic adaptive matching between load and speed.

[0051] Step S5: The feedback verification module uses speed detection elements to collect real-time data on the actual linear velocity and direction of motion of the material transport. The module compares the collected actual data with the target value set by the system and calculates the offset between the two. This offset is sent back to the calculation control module, which calls the proportional-integral-derivative (PID) control algorithm to correct the control commands. Based on the magnitude of the offset, the cumulative error, and the trend of change, the calculation control module calculates the corrected drive commands and updates them to the transmission execution module, thereby eliminating speed errors and ensuring that the actual transport state strictly follows the preset control strategy.

[0052] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A comprehensive quality control system for translational transport based on visual and mechanical strain signals, characterized in that, include: The signal acquisition module acquires mechanical strain signals within the transport plane, as well as visual information about the material's morphology. The arithmetic control module receives the collected signals, establishes a spatial coordinate system, analyzes the signals in conjunction with preset mathematical logic, and outputs control commands. The position adjustment module adjusts the physical position of the sensor according to control commands to ensure that the measurement conditions are continuously met. The transmission execution module drives the execution elements to operate and regulates the speed of translational transport according to control commands; The feedback verification module monitors the actual transportation status data and sends it back to the calculation and control module to form a closed-loop control.

2. The integrated control system for translational transport quality based on visual and mechanical strain signals according to claim 1, characterized in that, The steps for deploying mechanical strain sensors in the signal acquisition module include: Using the translational transport axis as the X-axis and the axis perpendicular to the positive transport direction and coinciding with the transport plane as the Y-axis, at least three measurement points are arranged within the transport plane; Ensure that the first measurement point is parallel to the X-axis, the second measurement point is parallel to the Y-axis, and the third measurement point is located on a straight line within the transport plane that forms a 45-degree angle with both the X-axis and the Y-axis. The spacing between adjacent measurement locations is controlled to be 20 millimeters, and the spacing between each measurement point exceeds the range of mutual interference.

3. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, The steps for deploying the vision sensor in the signal acquisition module include: Infrared imaging devices were selected as the visual sensors. The vision sensor is positioned in a plane perpendicular to the positive direction of transport and within the plane formed by the Z-axis and X-axis of the transport normal plane; Adjust the position of the field of view center of the vision sensor to capture the visual change process of transported materials from normal transport state to falling state.

4. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the calculation control module, the steps for setting the material quality calculation logic include: Define the rated speed of motion, effective load length, and range of weight of the actuator; When there is no load, the reference signals output from the mechanical strain sensor in three directions and the no-load state signal output from the vision sensor are read. The arithmetic control module sends an idle state indication signal to maintain the system in a stable idle state.

5. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the calculation and control module, the step of performing quality calculation during the feeding stage includes: When the material has not yet moved to the center of the field of view and the transmission device only performs the feeding function, the load signal output by the vision sensor is acquired. The percentage of pixels in the field-of-view image of the material detected by the vision sensor at different times is used as a variable. By combining the strain measurements in the X-axis, Y-axis, and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the product of the above variables and parameters is integrated to obtain the material mass.

6. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the operation control module, the step of performing quality calculation during the stable material feeding stage includes: Once the system enters a stable and continuous feeding and unloading state, the vision sensor is controlled to alternately output load signals and reference signals. Calculate the time difference between two alternating visual signal transformations; By using the difference between the load signal and the reference signal, combined with the strain measurements in the X-axis, Y-axis and 45-degree directions, as well as the elastic modulus and Poisson's ratio of the base material of the conveying device, the parameters are multiplied to obtain the material mass.

7. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the position adjustment module, the step of adjusting the sensor position includes: Receives the position deviation signal sent by the arithmetic control module; The installation location of the vision sensor or mechanical strain sensor that drives the mechanical structure to move; After confirming that the sensor position adjustment meets the preset requirements for measurement field of view and strain sensing area.

8. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the transmission execution module, the step of regulating the transport speed includes: Receive material quality data calculated by the calculation and control module; Match the operating speed of the corresponding actuator at its maximum power based on the material quality data; The control actuator adjusts the current translational transport speed within the range of zero to maximum operating speed.

9. The integrated translational transport quality control system based on visual and mechanical strain signals according to claim 1, characterized in that, In the feedback verification module, the step of performing signal feedback includes: Real-time acquisition of actual speed and direction data of material transportation; Calculate the offset between the actual data and the preset value; Send the offset to the calculation control module. The control command is corrected by the arithmetic control module through the PID controller.

10. A comprehensive quality control method for translational transportation based on visual and mechanical strain signals, characterized in that, The method for the integrated translational transport quality control system based on visual and mechanical strain signals as described in any one of claims 1-9 includes: Step S1: Acquire mechanical strain signals within the transport plane and visual information about the material morphology through the signal acquisition module; Step S2: Receive the collected signals through the arithmetic control module, establish a spatial coordinate system, analyze the signals in conjunction with preset mathematical logic, and output control commands; Step S3: Adjust the physical position of the sensor according to the control command through the position adjustment module to ensure that the measurement conditions are continuously met; Step S4: The transmission execution module drives the execution element to run and adjusts the speed of translational transport according to the control command; Step S5: Monitor the actual transportation status data through the feedback verification module and send it back to the calculation control module to form a closed-loop control.

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