Single-sensor-based plc control single-axis automatic measurement system

Abstract

This invention discloses a single-sensor PLC-controlled single-axis automatic measurement system, relating to the field of industrial automation measurement. It includes: an interaction module for receiving system control commands input by the user and providing feedback on system operating status and measurement data; and a control module for acquiring control commands from the interaction module, collecting position signals from the detection module, outputting control commands to the drive module, and executing a preset origin positioning and measurement control program. This invention further simplifies the hardware configuration of single-axis measurement equipment, reduces hardware investment and on-site wiring complexity, and lowers equipment deployment and subsequent maintenance costs. Through an optimized origin positioning process, coupled with graded speed control and a retrace compensation mechanism, it effectively improves the origin positioning accuracy and repeatability consistency of single-axis motion, and avoids signal triggering errors caused by high-speed positioning.

Description

Technical Field

[0001] This invention relates to the field of industrial automation measurement technology, specifically to a single-sensor PLC-controlled single-axis automatic measurement system. Background Technology

[0002] In the field of industrial automation measurement, single-axis automatic measuring devices are widely used in various detection and positioning systems due to their simple structure and low cost. These devices typically consist of a PLC controller, a single-axis drive mechanism, a zeroing sensor, limit sensors, and measurement execution components. Their core workflow is as follows: the PLC controls the drive mechanism to move the measuring components, achieving coarse positioning of the device's origin using a single sensor or high-speed fine positioning of the origin using dual sensors, before proceeding with subsequent measurement operations.

[0003] However, existing single-axis automatic measuring devices suffer from insufficient origin positioning accuracy of a single sensor in practical applications, mainly due to the following reasons:

[0004] Origin positioning is slow and inefficient. Increasing the rotation speed introduces a delay between sensing the origin sensor and stopping, leading to overshoot and inaccurate origin positioning. The measuring component (moving component) generates inertia as it moves from operation to stop, causing it to continue moving forward and affecting zeroing accuracy. Traditional single-sensor PLC origin control programs only use the logic of "a single sensor trigger determines zeroing completion," lacking calibration and compensation mechanisms and failing to correct random errors.

[0005] The aforementioned defects result in a large origin positioning error for the measuring device, which in turn affects the accuracy of subsequent measurement results and fails to meet the requirements of high-precision industrial inspection. To solve this problem, existing technologies often employ increasing the number of sensors to achieve a three-stage origin return process of "high speed → deceleration and low-speed crawling" (e.g., the DSZR command of the FX3U), which provides higher positioning accuracy but increases the complexity and cost of the device structure.

[0006] To address this, we propose a single-sensor PLC-controlled single-axis automatic measurement system. Summary of the Invention

[0007] In view of the above-mentioned shortcomings of the existing technology, the present invention provides a single-sensor PLC-controlled single-axis automatic measurement system, which can effectively solve the problems of the existing technology.

[0008] To achieve the above objectives, the present invention is implemented through the following technical solutions;

[0009] This invention discloses a PLC-controlled single-axis automatic measurement system based on a single sensor, comprising:

[0010] The system comprises the following modules: an interaction module (receiving system control commands from the user and providing feedback on system operation status and measurement data), a control module (acquiring control commands from the interaction module, acquiring position signals from the detection module, outputting control commands to the drive module, and executing a preset origin positioning and measurement control program), a drive module (acquiring control commands from the control module, converting electrical signals into mechanical rotational motion, and driving the execution module to complete reciprocating motion along a preset single-axis path), an execution module (following the drive module to complete single-axis displacement, contacting the workpiece to perform measurement actions), a detection module (detecting the origin position and extreme positions on both sides of the single-axis path, and transmitting the real-time acquired position detection signals to the control module), and a power supply module (providing electrical power for the operation of the interaction module, control module, drive module, execution module, and detection module).

[0011] The interaction module is interconnected with the control module via Ethernet. The control module is interconnected with the drive module and the execution module via Ethernet. The execution module is interconnected with the detection module via Ethernet. The power module is connected to the interaction module, the control module, the drive module, the execution module, and the detection module via dielectric electrical connection.

[0012] Furthermore, the control module uses a programmable logic controller as the core control unit, and the programmable logic controller has a pre-stored origin positioning program, system setting program and measurement control program;

[0013] When the control module receives a zeroing command from the interaction module, it outputs a control command to the drive module based on the position signal collected by the detection module to complete the origin positioning operation. When the control module receives a measurement command from the interaction module, it outputs a control command to the drive module to drive the execution module to complete the preset movement and measurement operations.

[0014] Furthermore, the detection module includes an origin position sensor and a right-side limit sensor;

[0015] Both the origin position sensor and the right limit sensor are square metal proximity switches. The origin position sensor is fixed at the reference origin position of the single-axis motion path. It is used to collect the origin position signal of the execution module and transmit it to the control module. It also serves as the left limit protection unit of the single-axis motion path.

[0016] The right limit sensor is fixed at the right extreme position of the single-axis motion path. It is used to collect the extreme position signal of the execution module and transmit it to the control module, providing right limit protection for single-axis motion.

[0017] Furthermore, the drive module includes a stepper motor driver, a stepper motor, and a ball screw slide.

[0018] The signal input terminal of the stepper motor driver is connected to the control output terminal of the control module, the power input terminal of the stepper motor is connected to the output terminal of the stepper motor driver, the power output terminal of the stepper motor is connected to the ball screw slide, and the moving end of the ball screw slide is fixedly connected to the execution module, which is used to convert the rotational motion of the stepper motor into the linear reciprocating motion of the execution module along a single axis path.

[0019] Furthermore, the execution module includes a measuring probe and a slide table connection base;

[0020] The measuring probe is fixed to the motion output end of the drive module via a slide connecting seat, and moves synchronously along a single-axis path with the drive module to contact the workpiece being measured during the measurement process and complete the corresponding measurement action.

[0021] Furthermore, the interaction module is integrated with an industrial touch screen, which has three built-in user operation windows, including a startup window, a running window, and a settings window, for receiving system control commands input by the user and simultaneously displaying system operating status, positioning information, and measurement result data in real time.

[0022] Furthermore, when the control module executes the origin positioning program to complete the origin positioning operation, it includes the following steps:

[0023] Coarse zeroing step: The control module outputs control commands to the drive module, which drives the execution module to move towards the origin position at a first preset speed. When the origin position sensor of the detection module detects the execution module, the control module controls the drive module to stop moving.

[0024] Slow return compensation steps: The control module outputs control commands to the drive module, which drives the execution module to move back from the stop position to a direction away from the origin at a second preset speed. When the origin position sensor of the detection module detects that the execution module has left the sensing range, the control module controls the drive module to stop moving. The second preset speed is less than the first preset speed.

[0025] Origin verification steps: When the origin position sensor detects that the execution module has left the sensing range, the control module triggers the origin verification signal, clears the current position register to zero, and completes the origin positioning operation.

[0026] Furthermore, the control module acquires and latches the first rising edge trigger record of the origin position sensor during the coarse zeroing stage, and this trigger record corresponds to the stop action of the drive module during the coarse zeroing stage.

[0027] During the slow retrace compensation phase, the control module acquires the falling edge trigger signal of the origin position sensor in real time. Only when the latched rising edge trigger record and the real-time acquired falling edge trigger signal meet the preset timing matching requirements will the control module start the origin verification operation and clear the position register. Otherwise, the origin positioning is deemed invalid and the origin positioning process is restarted.

[0028] The timing matching requirements are as follows: the signal rising edge trigger and the signal falling edge trigger occur within the same origin positioning process, the time node of the signal rising edge trigger is earlier than the time node of the signal falling edge trigger, and there is only one back motion from the coarse zeroing stop position to the direction away from the origin between the two trigger nodes, without any triggering action from other origin position sensors.

[0029] Furthermore, after completing the origin verification phase, the control module synchronously performs origin compensation:

[0030] The control module outputs control commands to the drive module based on the preset origin compensation amount, which drives the execution module to run at the second preset speed for the preset compensation displacement and then stop moving. The current position register is then cleared again to complete the origin compensation operation.

[0031] Compared with the known prior art, the technical solution provided by this invention has the following beneficial effects:

[0032] In this invention, the system further simplifies the hardware configuration of the single-axis measuring device, reduces hardware investment and on-site wiring complexity, and lowers equipment deployment and subsequent operation and maintenance costs. Through an optimized origin positioning process, coupled with graded speed control and retrace compensation mechanism, it effectively improves the origin positioning accuracy and repeatability consistency of single-axis motion, and avoids signal triggering errors caused by high-speed positioning.

[0033] In this invention, the system effectively filters invalid trigger signals through a strict timing matching and verification mechanism, avoiding origin positioning failure and ensuring the stability and reliability of equipment operation. At the same time, a single detection unit takes into account both origin positioning and single-sided limit protection functions, combined with limit protection on the other side, providing complete double-sided limit protection. This can effectively avoid the safety risks of equipment over-range operation. Furthermore, with intuitive human-computer interaction and automated measurement and control logic, the system minimizes the threshold for manual operation, reduces random errors caused by manual measurement, and improves the efficiency and accuracy of measurement operations. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0035] Figure 1 This is a schematic diagram of a single-sensor PLC-controlled single-axis automatic measurement system.

[0036] Figure 2 This is a block diagram of the system design in this invention;

[0037] Figure 3 This is a schematic diagram of the origin positioning method in this invention;

[0038] Figure 4 PLC control ladder diagram for origin positioning method;

[0039] Figure 5 This is a schematic diagram showing the physical appearance of the system in this invention;

[0040] The numbers in the diagram represent: 1. Touch screen; 2. PLC controller; 3. Single-axis drive module; 4. Measurement and execution module; 5. Origin position sensor; 6. Right limit sensor; 7. Power supply module. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0042] The present invention will be further described below with reference to embodiments.

[0043] Example 1:

[0044] This embodiment presents a single-sensor PLC-controlled single-axis automatic measurement system, such as... Figure 1 As shown, it includes:

[0045] The interaction module is used to receive system control commands input by the user and to provide feedback on the system's operating status and measurement data to the user.

[0046] The interaction module is integrated by an industrial touch screen, which has three built-in user operation windows, including a startup window, a running window, and a settings window, to receive system control commands input by the user and to display system operating status, positioning information, and measurement result data in real time.

[0047] The control module is used to acquire control commands from the interaction module, collect position signals from the detection module, output control commands to the drive module, and execute a preset origin positioning and measurement control program.

[0048] The control module uses a programmable logic controller (PLC) as the core control unit. The PLC has pre-stored the origin positioning program, system setting program, and measurement control program.

[0049] When the control module receives a zeroing command from the interaction module, it outputs a control command to the drive module based on the position signal collected by the detection module to complete the origin positioning operation. When the system control command received from the interaction module is a measurement command, it outputs a control command to the drive module to drive the execution module to complete the preset movement and measurement operation.

[0050] When the control module executes the origin positioning program to complete the origin positioning operation, it includes the following steps:

[0051] Coarse zeroing step: The control module outputs control commands to the drive module, which drives the execution module to move towards the origin position at a first preset speed. When the origin position sensor of the detection module detects the execution module, the control module controls the drive module to stop moving.

[0052] Slow return compensation steps: The control module outputs control commands to the drive module, which drives the execution module to move back from the stop position to a direction away from the origin at a second preset speed. When the origin position sensor of the detection module detects that the execution module has left the sensing range, the control module controls the drive module to stop moving. The second preset speed is less than the first preset speed.

[0053] Origin verification steps: When the origin position sensor detects that the execution module has left the sensing range, the control module triggers the origin verification signal, clears the current position register, and completes the origin positioning operation.

[0054] During the coarse zeroing stage, the control module collects and latches the first rising edge trigger record of the origin position sensor in this origin positioning process. This trigger record corresponds to the stop action of the drive module during this coarse zeroing stage.

[0055] During the slow retrace compensation phase, the control module acquires the falling edge trigger signal of the origin position sensor in real time. Only when the latched rising edge trigger record and the real-time acquired falling edge trigger signal meet the preset timing matching requirements will the control module start the origin verification operation and clear the position register. Otherwise, the origin positioning is deemed invalid and the origin positioning process is restarted.

[0056] The timing matching requirements are as follows: the signal rising edge trigger and the signal falling edge trigger occur within the same origin positioning process, the time node of the signal rising edge trigger is earlier than the time node of the signal falling edge trigger, and there is only one back motion from the coarse zeroing stop position to the direction away from the origin between the two trigger nodes, and there is no triggering action of other origin position sensors.

[0057] After the control module completes the origin verification phase, it synchronously performs origin compensation:

[0058] The control module outputs control commands to the drive module based on the preset origin compensation amount, which drives the execution module to run at the second preset speed for the preset compensation displacement and then stop moving. The current position register is then cleared again to complete the origin compensation operation.

[0059] The detection module includes an origin position sensor and a right-side limit sensor;

[0060] Both the origin position sensor and the right limit sensor use square metal proximity switches. The origin position sensor is fixed at the reference origin position of the single-axis motion path to collect the origin position signal of the execution module and transmit it to the control module. It also serves as the left limit protection unit of the single-axis motion path.

[0061] The right limit sensor is fixed at the right extreme position of the single-axis motion path. It is used to collect the extreme position signal of the execution module and transmit it to the control module to provide right limit protection for single-axis motion.

[0062] The drive module is used to acquire the control commands output by the control module, convert the electrical signals into mechanical rotational motion, and drive the execution module to complete the reciprocating motion along a preset single-axis path.

[0063] The drive module includes a stepper motor driver, a stepper motor, and a ball screw slide.

[0064] The signal input terminal of the stepper motor driver is connected to the control output terminal of the control module, the power input terminal of the stepper motor is connected to the output terminal of the stepper motor driver, the power output terminal of the stepper motor is connected to the ball screw slide transmission, and the moving end of the ball screw slide is fixedly connected to the execution module, which is used to convert the rotational motion of the stepper motor into the linear reciprocating motion of the execution module along a single axis path.

[0065] The execution module is used to complete single-axis displacement along with the drive module, and to contact the workpiece being measured to perform the measurement action.

[0066] The execution module includes a measuring probe and a slide table connector;

[0067] The measuring probe is fixed to the motion output end of the drive module via a slide connecting seat. It moves synchronously along a single-axis path with the drive module and is used to contact the workpiece being measured during the measurement process to complete the corresponding measurement action.

[0068] The detection module is used to detect the origin position and the extreme positions on both sides of the single-axis path, and transmits the real-time acquired position detection signals to the control module;

[0069] The power supply module provides electrical power to support the operation of the interaction module, control module, drive module, execution module, and detection module.

[0070] After the control module completes the origin verification phase, it synchronously performs origin compensation:

[0071] The control module outputs control commands to the drive module based on the preset origin compensation amount, which drives the execution module to run at the second preset speed for the preset compensation displacement and then stop moving. The current position register is then cleared again to complete the origin compensation operation.

[0072] In this embodiment, the interaction module receives system control commands input by the user, provides feedback on the system's operating status and measurement data to the user, and the control module synchronously acquires the control commands from the interaction module, collects the position signals from the detection module, outputs control commands to the drive module, and executes a preset origin positioning and measurement control program. The drive module then acquires the control commands output by the control module, converts the electrical signals into mechanical rotational motion, and drives the execution module to complete the reciprocating motion along a preset single-axis path. The execution module moves in real time along the single-axis direction with the drive module, contacts the workpiece being measured, and performs the measurement action. The detection module further detects the origin position and the extreme positions on both sides of the single-axis path and transmits the real-time acquired position detection signals to the control module.

[0073] During the overall operation of the system, the power supply module provides electrical power support for the operation of the interaction module, control module, drive module, execution module, and detection module.

[0074] In the above embodiments, the system achieves automated control based on a PLC. Dedicated sensors enable precise origin positioning and bidirectional limit protection. The positioning process includes coarse correction, slow-speed compensation, and verification stages, coupled with timing matching verification and origin compensation, significantly improving positioning accuracy. Smooth linear reciprocating motion is achieved through a motor and ball screw, and operation and data display are completed via a touchscreen. Measurement actions can be executed automatically, reducing human error, improving measurement efficiency, and mitigating the risk of equipment collisions through limit protection, thereby ensuring stable and safe system operation.

[0075] See Figure 2 As shown:

[0076] 1) Touch screen: The Kunlun Tongtai MCGS touch screen is used as the human-machine interface. It is designed with three user windows for startup, operation and settings, and provides command buttons and status result display.

[0077] 2) PLC controller: The Mitsubishi FX3U series PLC is used as the core control unit of the device. It pre-stores the origin positioning program, setting program and measurement control program, receives the zeroing command from the touch screen, and outputs control commands to the single-axis drive module to complete the origin positioning according to the signal from the origin position sensor; it also receives the measurement command from the touch screen and outputs control commands to the single-axis drive module to complete the movement and measurement functions of the measurement execution module.

[0078] 3) Single-axis drive module: including stepper motor, stepper motor driver and ball screw slide. The stepper motor driver is connected to the PLC controller, and the stepper motor is connected to the ball screw slide for transmission, which is used to drive the measurement execution module to move along a single axis.

[0079] 4) Measurement execution module: includes a measurement probe and a slide connecting seat. The measurement probe is fixed on the ball screw slide through the connecting seat and is used to contact the workpiece to be measured and realize the measurement function.

[0080] 5) Origin position sensor: A square metal proximity switch is used and fixed at the reference position of the single-axis motion. It is used to detect and measure the zero (origin) position of the execution module and output a signal to the PLC controller. It also serves as a left limit switch for safety protection.

[0081] 6) Right limit sensor: A square metal proximity switch is used, which is fixed at the farthest position on the right side of the single-axis movement. When the measurement and execution module malfunctions, the signal is sent to the PLC controller to stop the single-axis drive module and continue to move to the right, which serves as a safety protection function.

[0082] 7) Power module: Used to provide a stable power supply for the entire device.

[0083] See Figure 3As shown, it intuitively presents the complete execution flow and motion control logic of the four-stage origin positioning under a single sensor of the present invention. It clearly shows the motion direction, speed parameter switching, signal state changes of the origin position sensor, and triggering nodes of PLC-related auxiliary relays and special registers in each stage of the measurement execution module. The figure clearly marks the motion paths of the coarse zeroing stage (10kHz high-speed movement towards the origin), the slow return compensation stage (300Hz turning back to the right), the origin verification stage (sensor falling edge triggering), and the origin compensation stage (300Hz optional leftward compensation). It also shows the on / off changes of the origin sensor X0 from OFF to ON and back to OFF, the on / off triggering logic of the M8443 contact, and the key operation of clearing the M8340 special register, completely restoring the entire motion process from coarse positioning overshoot to precise origin positioning.

[0084] See Figure 4 As shown, this ladder diagram is the core program implementation carrier developed based on the Mitsubishi FX3U series PLC, adapted for high-precision origin positioning with a single sensor. It is the hardware programming mapping of the four-stage origin positioning control logic of this invention. Based on the control flow of coarse zeroing, slow retrace compensation, origin verification, and optional origin compensation, the ladder diagram rationally configures the logical connections of PLC core components such as input ports (origin position sensor X0), output ports (Y0 corresponding to the single-axis drive module), auxiliary relays (M8443), and special position registers (M8340). Through typical PLC ladder diagram programming actions such as contact on / off, falling edge triggering, DDRVI motion instruction calls, and register clearing, it realizes automatic switching of each positioning stage, precise speed control of the drive module, real-time response of sensor signals, and flexible execution of compensation. It also takes into account the safety protection logic of the origin position sensor as well as the left limit switch. The program logic is clear and can be adapted and ported to other brands of PLCs according to their instruction sets and port configurations.

[0085] See Figure 5 As shown in the figure, this figure further illustrates the appearance of the system in this embodiment.

[0086] In summary, the system in the above embodiments simplifies the hardware configuration of single-axis measuring equipment, reduces hardware investment and on-site wiring complexity, and lowers equipment deployment and subsequent operation and maintenance costs. Through an optimized origin positioning process, coupled with graded speed control and retrace compensation mechanisms, it effectively improves the origin positioning accuracy and repeatability consistency of single-axis motion, avoids signal triggering errors caused by high-speed positioning, and effectively filters invalid triggering signals through a strict timing matching and verification mechanism to prevent origin positioning failure and ensure the stability and reliability of equipment operation. Furthermore, a single detection unit combines origin positioning and single-sided limit protection functions, along with limit protection on the other side, providing complete double-sided limit protection, which can effectively avoid the safety risks of equipment over-range operation. Moreover, with intuitive human-machine interaction and automated measurement control logic, it minimizes the threshold for manual operation, reduces random errors caused by manual measurement, and improves the efficiency and data accuracy of measurement operations.

[0087] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A single-sensor PLC-controlled single-axis automatic measurement system, characterized in that, include: The interaction module is used to receive system control commands input by the user and to provide feedback on the system's operating status and measurement data to the user. The control module is used to acquire control commands from the interaction module, collect position signals from the detection module, output control commands to the drive module, and execute a preset origin positioning and measurement control program. The drive module is used to acquire the control commands output by the control module, convert the electrical signals into mechanical rotational motion, and drive the execution module to complete the reciprocating motion along a preset single-axis path. The execution module is used to complete single-axis displacement along with the drive module, and to contact the workpiece being measured to perform the measurement action. The detection module is used to detect the origin position and the extreme positions on both sides of the single-axis path, and transmits the real-time acquired position detection signals to the control module; The power supply module provides electrical power to support the operation of the interaction module, control module, drive module, execution module, and detection module.

2. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 1, characterized in that, The control module uses a programmable logic controller as the core control unit. The programmable logic controller has pre-stored the origin positioning program, the system setting program and the measurement control program. When the control module receives a zeroing command from the interaction module, it outputs a control command to the drive module based on the position signal collected by the detection module to complete the origin positioning operation. When the control module receives a measurement command from the interaction module, it outputs a control command to the drive module to drive the execution module to complete the preset movement and measurement operations.

3. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 2, characterized in that, The detection module includes an origin position sensor and a right-side limit sensor; Both the origin position sensor and the right limit sensor are square metal proximity switches. The origin position sensor is fixed at the reference origin position of the single-axis motion path. It is used to collect the origin position signal of the execution module and transmit it to the control module. It also serves as the left limit protection unit of the single-axis motion path. The right limit sensor is fixed at the right extreme position of the single-axis motion path. It is used to collect the extreme position signal of the execution module and transmit it to the control module, providing right limit protection for single-axis motion.

4. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 1, characterized in that, The drive module includes a stepper motor driver, a stepper motor, and a ball screw slide. The signal input terminal of the stepper motor driver is connected to the control output terminal of the control module, the power input terminal of the stepper motor is connected to the output terminal of the stepper motor driver, the power output terminal of the stepper motor is connected to the ball screw slide, and the moving end of the ball screw slide is fixedly connected to the execution module, which is used to convert the rotational motion of the stepper motor into the linear reciprocating motion of the execution module along a single axis path.

5. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 1, characterized in that, The execution module includes a measurement probe and a slide table connection base; The measuring probe is fixed to the motion output end of the drive module via a slide connecting seat, and moves synchronously along a single-axis path with the drive module to contact the workpiece being measured during the measurement process and complete the corresponding measurement action.

6. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 1, characterized in that, The interactive module is integrated with an industrial touch screen, which has three built-in user operation windows, including a startup window, a running window, and a settings window, for receiving system control commands input by the user and simultaneously displaying system operating status, positioning information, and measurement result data in real time.

7. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 2, characterized in that, When the control module executes the origin positioning program to complete the origin positioning operation, it includes the following steps: Coarse zeroing step: The control module outputs control commands to the drive module, which drives the execution module to move towards the origin position at a first preset speed. When the origin position sensor of the detection module detects the execution module, the control module controls the drive module to stop moving. Slow return compensation steps: The control module outputs control commands to the drive module, which drives the execution module to move back from the stop position to a direction away from the origin at a second preset speed. When the origin position sensor of the detection module detects that the execution module has left the sensing range, the control module controls the drive module to stop moving. The second preset speed is less than the first preset speed. Origin verification steps: When the origin position sensor detects that the execution module has left the sensing range, the control module triggers the origin verification signal, clears the current position register to zero, and completes the origin positioning operation.

8. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 7, characterized in that, The control module acquires and latches the first rising edge trigger record of the origin position sensor in the current origin positioning process during the coarse zeroing stage. This trigger record corresponds to the stop action of the drive module in the current coarse zeroing stage. During the slow retrace compensation phase, the control module acquires the falling edge trigger signal of the origin position sensor in real time. Only when the latched rising edge trigger record and the real-time acquired falling edge trigger signal meet the preset timing matching requirements will the control module start the origin verification operation and clear the position register. Otherwise, the origin positioning is deemed invalid and the origin positioning process is restarted. The timing matching requirements are as follows: the signal rising edge trigger and the signal falling edge trigger occur within the same origin positioning process, the time node of the signal rising edge trigger is earlier than the time node of the signal falling edge trigger, and there is only one back motion from the coarse zeroing stop position to the direction away from the origin between the two trigger nodes, without any triggering action from other origin position sensors.

9. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 7, characterized in that, After completing the origin verification phase, the control module synchronously performs origin compensation: The control module outputs control commands to the drive module based on the preset origin compensation amount, which drives the execution module to run at the second preset speed for the preset compensation displacement and then stop moving. The current position register is then cleared again to complete the origin compensation operation.

10. The single-sensor-based PLC-controlled single-axis automatic measurement system according to claim 1, characterized in that, The interaction module is interconnected with the control module via Ethernet. The control module is interconnected with the drive module and the execution module via Ethernet. The execution module is interconnected with the detection module via Ethernet. The power module is connected to the interaction module, the control module, the drive module, the execution module, and the detection module via dielectric electrical connection.

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