Electromechanical equipment installation laser positioning and intelligent calibration device

Abstract

The application discloses a kind of electromechanical equipment installation laser positioning and intelligent calibration device, belong to electromechanical equipment installation technical field, the device includes positioning calibration main body, laser emission module, positioning detection module, intelligent control module, data interaction module, environment monitoring module and fault diagnosis module, not include displacement equipment for pushing electromechanical equipment to be installed, just provide positioning calibration and error feedback function;Laser emission module constructs three-dimensional laser positioning reference network;Positioning detection module acquires multiple source installation parameters, and intelligent control module processes data by multiple algorithms and calculates installation error.The application positioning calibration precision is high, degree of automation is high, can adapt to the installation needs of multiple types electromechanical equipment, reduce manual intervention, improve installation efficiency, reduce installation cost, applicable to the accurate installation positioning and intelligent calibration of various industrial electromechanical equipment.

Description

Technical Field

[0001] This invention belongs to the field of electromechanical equipment installation technology, and specifically relates to a laser positioning and intelligent calibration device for electromechanical equipment installation. Background Technology

[0002] In the installation of electromechanical equipment, positioning and calibration are crucial steps, directly determining the quality of installation and the stability of subsequent operation. Currently, the positioning and calibration of electromechanical equipment mainly employ the following methods:

[0003] The first method is manual measurement and positioning. Using tools such as levels, measuring tapes, and theodolites, the position, angles, and distances of the equipment to be installed are manually measured and compared with preset benchmark parameters. The equipment position is then manually adjusted to achieve calibration. This method is labor-intensive, inefficient, and its accuracy is affected by the operator's skill level and sense of responsibility. The positioning and calibration accuracy is low, with significant errors, making it difficult to meet the installation requirements of precision electromechanical equipment. It is particularly suitable for the installation of small, low-precision electromechanical equipment.

[0004] The second method is mechanical positioning calibration, which uses specially designed positioning fixtures and guiding mechanisms to position the electromechanical equipment to be installed, and utilizes the rigidity of the mechanical structure to achieve calibration. This method has limited positioning accuracy, and the fixtures and guiding mechanisms have poor versatility. One type of fixture is only suitable for specific models and specifications of electromechanical equipment. When changing equipment, the fixture needs to be redesigned and manufactured, which increases installation costs. In addition, the calibration process is cumbersome and cannot achieve dynamic calibration.

[0005] The third method is conventional laser positioning. This involves emitting a laser beam from a laser emitter to locate the equipment in a specific dimension. The position of the laser spot is then manually observed, and the equipment position is adjusted for calibration. While this method offers improved positioning accuracy compared to manual measurement, it only achieves single-dimensional positioning and cannot provide precise three-dimensional positioning. Furthermore, it lacks intelligent data processing and automatic calibration functions, requiring manual error assessment and adjustment, resulting in low efficiency and weak resistance to environmental interference. Positioning accuracy significantly decreases in environments with temperature changes, strong light, or significant vibration.

[0006] In the prior art, some improved laser positioning devices have emerged. For example, Chinese invention patent application CN121519731A discloses a laser-assisted positioning method for bolt installation. This method establishes three baselines—longitudinal, transverse, and elevation—using a laser positioning instrument to form a three-dimensional spatial positioning network, ensuring precise alignment of the bolt in the horizontal, vertical, and height directions. However, this method is only applicable to bolt installation positioning, lacks versatility, and lacks an intelligent calibration mechanism, failing to achieve dynamic error compensation and still requiring some manual adjustments. Another example is Chinese invention patent application CN118359098A, which discloses a laser positioning device for crane hoisting. This device achieves laser positioning during hoisting through a cargo positioning mechanism and a hook positioning mechanism, improving hoisting efficiency and safety. However, this device is mainly used for hoisting positioning and cannot achieve precise calibration after the installation of electromechanical equipment; its positioning accuracy and adaptability are also limited.

[0007] In addition, existing laser positioning and calibration devices have the following shortcomings: First, data processing efficiency is low, lacking efficient filtering, noise reduction, and data fusion algorithms, resulting in insufficient accuracy and reliability of measurement data; second, the error compensation mechanism is imperfect, with some devices integrating displacement drive mechanisms, leading to complex structures, high costs, and limited versatility; third, the ability to resist environmental interference is weak, with environmental factors such as temperature, humidity, light, and vibration severely affecting positioning and calibration accuracy; fourth, the lack of fault diagnosis and early warning functions means that faults cannot be detected and dealt with in a timely manner, affecting installation progress; and fifth, poor versatility, unable to adapt to the installation needs of different types and specifications of electromechanical equipment, limiting its applicability.

[0008] To address the problems existing in the prior art, this invention proposes a laser positioning and intelligent calibration device for electromechanical equipment installation. By optimizing the device structure, removing displacement-driven modules, simplifying the structure and reducing costs, incorporating multiple intelligent algorithms, improving the laser angle adjustment mechanism, and enhancing resistance to environmental interference, this invention achieves three-dimensional precise positioning and intelligent calibration guidance for electromechanical equipment installation, improving installation efficiency and accuracy, reducing manual intervention, and enhancing the versatility and stability of the device. Summary of the Invention

[0009] The purpose of this invention is to overcome the problems of low accuracy, low efficiency, excessive manual intervention, poor adaptability, weak resistance to environmental interference, and lack of fault diagnosis function in the installation, positioning, and calibration of electromechanical equipment in the prior art. In addition, the integration of displacement drive mechanisms in some devices leads to complex structures and high costs. This invention provides a laser positioning and intelligent calibration device for the installation of electromechanical equipment. This device does not include displacement devices to push the electromechanical equipment to be installed. It only realizes three-dimensional precise positioning, intelligent data processing, and calibration guidance for the installation of electromechanical equipment. By precisely adjusting the laser emission angle, it optimizes the positioning benchmark and outputs error data for external calibration. This improves installation efficiency and positioning and calibration accuracy, reduces manual labor intensity, adapts to the installation needs of various types of electromechanical equipment, and enhances the stability and reliability of the device operation.

[0010] To achieve the above objectives, the present invention adopts the following technical solution:

[0011] A laser positioning and intelligent calibration device for electromechanical equipment installation includes: a positioning and calibration main body, a laser emitting module, a positioning detection module, an intelligent control module, and a data interaction module. The laser emitting module, positioning detection module, and data interaction module are all electrically connected to the intelligent control module. The laser emitting module emits laser positioning signals to the installation reference surface of the electromechanical equipment and the surface of the electromechanical equipment to be installed, forming a three-dimensional positioning reference network. The positioning detection module collects feedback data from the laser positioning signals to obtain the actual installation position parameters of the electromechanical equipment to be installed. The intelligent control module receives the feedback data from the positioning detection module, compares it with preset installation reference parameters, analyzes and calculates the installation position error, and generates laser angle adjustment commands. The data interaction module enables data transmission, parameter setting, and command interaction between the device and an external terminal, synchronously outputting installation error data to provide a reference for external manual or auxiliary equipment calibration.

[0012] Furthermore, the laser emitting module includes multiple sets of laser emitters, a laser adjustment unit, and a beam shaping unit; the multiple sets of laser emitters are arranged in an array and are used to emit horizontal lasers, vertical lasers, and oblique lasers, respectively, to construct a three-dimensional laser positioning reference; the laser adjustment unit is electrically connected to the intelligent control module and is used to adjust the emission angle, laser intensity, and laser frequency of the laser emitters; the beam shaping unit is used to collimate and focus the laser beam emitted by the laser emitters to reduce the divergence of the laser beam.

[0013] Furthermore, the angle adjustment mechanism of the laser adjustment unit adopts a micro servo motor, model MG90S; the output shaft of the micro servo motor is fixedly connected to the mounting shaft of the laser emitter through a flexible coupling. The micro servo motor is fixed on the mounting bracket of the laser emitter and coaxially aligned with the mounting shaft of the laser emitter, and is used to drive the laser emitter to rotate around the mounting shaft to achieve precise adjustment of the emission angle.

[0014] Furthermore, the angle control method of the micro servo motor is as follows: the intelligent control module outputs a PWM signal with a period of 20Hz, and controls the rotation angle of the micro servo motor by changing the pulse width of the PWM signal (1.0ms-2.0ms), thereby adjusting the emission angle of the laser emitter; wherein a pulse width of 1.0ms corresponds to a 0° rotation angle, 1.5ms corresponds to a 90° rotation angle, and 2.0ms corresponds to a 180° rotation angle, and the adjustment range of 0°-360° is achieved by continuous rotation of the motor, with an adjustment accuracy of ±0.01°.

[0015] Furthermore, the positioning detection module includes a laser receiving array, an image acquisition unit, an attitude sensor, and a distance measurement unit; the laser receiving array is used to receive laser signals emitted by the laser emitting module, convert them into electrical signals, and transmit them to the intelligent control module; the image acquisition unit is used to acquire installation attitude images of the electromechanical equipment to be installed, and extract the equipment outline and feature marker points; the attitude sensor is used to detect the tilt angle, deflection angle, and vibration parameters of the electromechanical equipment to be installed; the distance measurement unit is used to measure the distance parameters between the electromechanical equipment to be installed and the reference surface, and between adjacent equipment.

[0016] Furthermore, the distance measurement unit adopts a laser rangefinder sensor, combined with the phase method ranging principle, with a measurement accuracy of not less than ±0.008mm and a measurement range of 0.1m-50m; the attitude sensor adopts a combination structure of a three-axis gyroscope and an accelerometer, with a sampling frequency of not less than 100Hz and an angle measurement accuracy of not less than ±0.005°.

[0017] Furthermore, the intelligent control module includes a main control chip, a data processing unit, a storage unit, and an instruction generation unit; the main control chip adopts an ARM Cortex-A8 architecture with a main frequency of not less than 1GHz; the data processing unit is used to filter, reduce noise, and fuse the position parameters, attitude parameters, and distance parameters collected by the positioning detection module, and calculate the installation error; the storage unit is used to store preset installation reference parameters, historical measurement data, calibration records, and algorithm programs; the instruction generation unit is used to generate targeted laser angle adjustment instructions based on the installation error analysis results to optimize the laser positioning reference.

[0018] Furthermore, the data processing unit employs a Kalman filter algorithm to reduce noise in the collected data and a weighted fusion algorithm to fuse multi-source sensor data, improving the accuracy of data measurement. The instruction generation unit dynamically adjusts the PWM signal pulse width based on the magnitude and trend of installation errors, achieving precise fine-tuning of the laser emitter's emission angle. Furthermore, the data interaction module includes a wired communication unit, a wireless communication unit, and a human-machine interaction unit. The wired communication unit uses RS485 and Ethernet interfaces to achieve wired data transmission with an external control terminal. The wireless communication unit uses one or more combinations of WiFi, Bluetooth, and 5G to achieve wireless data transmission and remote control. The human-machine interaction unit includes a touchscreen, buttons, and indicator lights for parameter setting, instruction input, and device operating status display.

[0019] Furthermore, it also includes an environmental monitoring module, which is electrically connected to the intelligent control module and is used to collect temperature, humidity, light intensity and vibration parameters of the installation environment; the intelligent control module dynamically adjusts the laser parameters of the laser emission module and the sampling parameters of the positioning detection module according to the environmental monitoring data, so as to reduce the impact of environmental factors on the positioning calibration accuracy;

[0020] It also includes a fault diagnosis module, which is electrically connected to the intelligent control module. It is used to monitor the working status of each module of the device in real time, collect the operating parameters of each module, and when a module fault is detected, it immediately issues a fault alarm signal and transmits the fault information to an external terminal through the data interaction module. At the same time, it stores the fault record for easy maintenance and repair in the future.

[0021] This invention provides a laser positioning and intelligent calibration device for the installation of electromechanical equipment, which, compared with existing technologies:

[0022] 1. High Positioning and Calibration Accuracy: This invention constructs a three-dimensional laser positioning reference network through a laser emission module. Combined with multi-source sensor data acquisition from the positioning detection module, it employs various intelligent algorithms such as Kalman filtering and weighted fusion algorithms to filter, reduce noise, and fuse the measurement data, effectively improving the accuracy and reliability of the measurement data. The emission angle of the laser emitter is precisely controlled by an MG90S micro servo motor, and high-precision angle adjustment of ±0.01° is achieved through PWM signal pulse width adjustment. This dynamically optimizes the laser positioning reference, further improving positioning accuracy and meeting the installation requirements of precision electromechanical equipment.

[0023] 2. Simple structure and controllable cost: This invention removes the displacement drive-related modules used to push the electromechanical equipment to be installed, and only retains the core functions of positioning calibration, laser adjustment and error feedback. This simplifies the device structure, reduces manufacturing costs and maintenance difficulty, and avoids the problems of complex structure and poor versatility caused by displacement drive mechanisms.

[0024] 3. High degree of automation: This invention utilizes an intelligent control module to automatically collect, process, analyze errors, and generate laser angle adjustment commands. This eliminates the need for manual error assessment and laser angle adjustment, significantly reducing labor intensity, improving installation and calibration efficiency, and shortening the installation cycle of electromechanical equipment. Simultaneously, the data interaction module supports remote control and parameter setting, enabling unattended positioning and monitoring operations.

[0025] 4. High adaptability: The laser parameters of the laser emission module can be dynamically adjusted through the laser adjustment unit, and the sampling parameters of the positioning detection module can be adaptively adjusted according to environmental monitoring data, which enhances the device's ability to resist environmental interference and can work stably in environments with different temperatures, humidity, light, and vibration. Multiple laser emitters are arranged in an array, which can cover the installation areas of different types and specifications of electromechanical equipment, and has a wide range of applicability.

[0026] 5. High stability and reliability: This invention is equipped with a fault diagnosis module and adopts a fault tree analysis algorithm, which can monitor the working status of each module of the device in real time, detect faults in a timely manner and issue alarm signals, and store fault records for easy maintenance and repair in the future. At the same time, each module of the device uses industrial-grade components, which have good waterproof, dustproof and anti-interference capabilities, reasonable structural design, stable and reliable operation and long service life.

[0027] 6. Convenient data interaction and flexible calibration: The data interaction module of this invention has both wired and wireless communication functions, which can realize real-time data transmission, parameter setting and command interaction between the device and external terminals. This makes it convenient for staff to remotely monitor the positioning process, query historical data and calibration records, and realize information management of the installation and positioning process. The device only outputs error data and calibration guidance. Staff can complete the calibration of electromechanical equipment by combining manual or external supporting equipment, which can adapt to the calibration needs of different installation scenarios.

[0028] 7. High versatility: Compared with existing laser positioning devices that are only applicable to specific scenarios (such as bolt installation and hoisting positioning), this invention can be widely used for installation positioning and calibration guidance of various industrial electromechanical equipment, including large machine tools, generator sets, port cranes, semiconductor manufacturing equipment, aerospace equipment, etc. It has high versatility, wide applicability, high practical value and promotion prospects. Attached Figure Description

[0029] Figure 1 This is a block diagram of the overall structure of the device in an embodiment of the present invention;

[0030] Figure 2 Structural block diagram of the laser emitting module in this embodiment of the invention;

[0031] Figure 3This is a structural block diagram of the positioning detection module in an embodiment of the present invention;

[0032] Figure 4 This is a structural block diagram of the intelligent control module in an embodiment of the present invention;

[0033] Figure 5 This is a structural block diagram of the data interaction module in an embodiment of the present invention;

[0034] Figure 6 This is a structural block diagram of the environmental monitoring module in an embodiment of the present invention;

[0035] Figure 7 This is a structural block diagram of the fault diagnosis module in an embodiment of the present invention;

[0036] Figure 8 This is a schematic diagram of the algorithm flow of the data processing unit in an embodiment of the present invention;

[0037] Figure 9 This is a schematic diagram illustrating the angle control principle of the MG90S micro servo motor in an embodiment of the present invention.

[0038] Figure 10 This is a schematic diagram of fault tree analysis of the fault diagnosis module in an embodiment of the present invention.

[0039] In the diagram: 1-Positioning and calibration main body; 2-Laser emitting module; 21-Laser emitter; 22-Laser adjustment unit; 23-Beam shaping unit; 3-Positioning detection module; 31-Laser receiving array; 32-Image acquisition unit; 33-Attitude sensor; 34-Distance measurement unit; 4-Intelligent control module; 41-Main control chip; 42-Data processing unit; 43-Storage unit; 44-Command generation unit; 6-Data interaction module; 61-Wired communication unit; 62-Wireless communication unit; 63-Human-machine interaction unit; 7-Environmental monitoring module; 71-Temperature sensor; 72-Humidity sensor; 73-Light sensor; 74-Vibration sensor; 8-Fault diagnosis module. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0041] Example 1

[0042] like Figure 1As shown, this embodiment provides a laser positioning and intelligent calibration device for electromechanical equipment installation, including a positioning and calibration main body 1, a laser emitting module 2, a positioning detection module 3, an intelligent control module 4, and a data interaction module 6. The laser emitting module 2, the positioning detection module 3, and the data interaction module 6 are all electrically connected to the intelligent control module 4. The laser emitting module 2 is used to emit laser positioning signals to the electromechanical equipment installation reference surface and the surface of the electromechanical equipment to be installed, forming a three-dimensional positioning reference network. The positioning detection module 3 is used to collect feedback data of the laser positioning signals and obtain the actual installation position parameters of the electromechanical equipment to be installed. The intelligent control module 4 is used to receive the feedback data of the positioning detection module 3, compare it with the preset installation reference parameters, analyze and calculate the installation position error, and generate laser angle adjustment commands. The data interaction module 6 is used to realize data transmission, parameter setting, and command interaction between the device and external terminals, and synchronously output installation error data to provide a reference for external manual or supporting equipment calibration.

[0043] In this embodiment, the positioning calibration body 1 is made of high-strength aluminum alloy, with a compact overall structure, light weight, and easy movement and installation. Adjustable support feet are provided at the bottom, allowing the height to be adjusted according to the flatness of the installation site, ensuring the stability of the device. The positioning calibration body 1 has an internal mounting cavity for installing core modules such as the laser emission module 2 and the intelligent control module 4. An external protective shell provides waterproof, dustproof, and impact-resistant capabilities, enabling it to adapt to harsh industrial environments.

[0044] 1. Specific implementation of the laser emitting module

[0045] like Figure 2 As shown, the laser emitting module 2 includes multiple sets of laser emitters 21, a laser adjustment unit 22, and a beam shaping unit 23. The multiple sets of laser emitters 21 are arranged in an array and are used to emit horizontal lasers, vertical lasers, and oblique lasers, respectively, to construct a three-dimensional laser positioning reference. The laser adjustment unit 22 is electrically connected to the intelligent control module 4 and is used to adjust the emission angle, laser intensity, and laser frequency of the laser emitters 21. The beam shaping unit 23 is used to collimate and focus the laser beam emitted by the laser emitters 21, reduce the divergence of the laser beam, and improve the accuracy of laser positioning.

[0046] In this embodiment, the laser emitter 21 is a semiconductor laser emitter, model LD-650-5, with an emission wavelength of 650nm, an adjustable laser power range of 1mW-5mW, and a laser beam divergence angle of 0.08mrad, ensuring the collimation and stability of the laser beam. Six sets of laser emitters 21 are arranged in a 2×3 array, with two sets emitting horizontal lasers, two sets emitting vertical lasers, and two sets emitting 45° oblique lasers along the X and Y axes respectively. The six sets of laser emitters work together to construct a three-dimensional laser positioning reference network, covering the entire installation area of ​​the electromechanical equipment to be installed, ensuring comprehensive and accurate positioning.

[0047] The laser adjustment unit 22 includes an angle adjustment mechanism, a power adjustment circuit, and a frequency adjustment circuit. The angle adjustment mechanism uses a micro servo motor, model MG90S. The specific connection points and connection methods between the micro servo motor and the laser emitter 21 are as follows: the core connection point of the micro servo motor is its output shaft, and the core connection point of the laser emitter 21 is its mounting shaft. The two are fixedly connected by a special flexible coupling (model LM-03). This coupling precisely adapts to the size difference between the servo motor output shaft (3mm in diameter) and the laser emitter mounting shaft (2mm in diameter), and also has a buffering and shock absorption function to prevent the vibration generated when the motor rotates from being transmitted to the laser emitter 21, thus affecting the stability of laser emission. The laser emitter 21 is fixed in the mounting cavity of the positioning and calibration body 1 by a special mounting bracket. The bracket has a dedicated mounting position for the micro servo motor. The micro servo motor is fixed to the bracket by fastening bolts to ensure that the motor is firmly installed, and its output shaft is coaxially aligned with the mounting shaft of the laser emitter 21. When the motor is working, it can directly drive the laser emitter 21 to rotate around its own mounting shaft, thereby achieving precise adjustment of the emission angle.

[0048] In this embodiment, the angle control method of the MG90S micro servo motor is as follows: The instruction generation unit 44 of the intelligent control module 4, based on the installation error analysis results and environmental monitoring data, sends a PWM control signal with a period of 20Hz (signal period 20ms) to the micro servo motor through its GPIO port. By changing the high-level duration (pulse width) of the PWM signal, the rotation angle of the motor is controlled, thereby adjusting the emission angle of the laser emitter 21. The correspondence between pulse width and rotation angle is as follows: a pulse width of 1.0ms corresponds to the motor rotating to the 0° limit position, a pulse width of 1.5ms corresponds to rotating to the 90° neutral position, and a pulse width of 2.0ms corresponds to rotating to the 180° limit position. Continuous motor rotation achieves an adjustment range of 0°-360° with an adjustment accuracy of ±0.01°. For example, when the intelligent control module 4 calculates that the laser emitter 21 needs to be adjusted to a 30° emission angle, it generates a PWM signal with a pulse width of 1.17ms and sends it to the micro servo motor. After receiving the signal, the motor drives the output shaft to rotate to 30°, causing the laser emitter 21 to synchronously adjust to the target angle.

[0049] To further ensure the accuracy of angle adjustment, a small magnetic encoder (model AS5600) is installed on the mounting shaft of the laser emitter 21 in this embodiment. The magnetic encoder monitors the actual rotation angle of the laser emitter 21 in real time and transmits the feedback signal back to the data processing unit 42 of the intelligent control module 4. The data processing unit 42 compares the actual angle fed back with the target angle set by the instruction generation unit 44. If there is a deviation (greater than ±0.01°), the instruction generation unit 44 fine-tunes the pulse width of the PWM signal for secondary correction until the actual angle matches the target angle, forming a closed-loop control and further improving the adjustment accuracy of the laser emission angle.

[0050] The power adjustment circuit adopts a variable resistor adjustment method, which can adjust the output power of the laser emitter 21 according to the ambient light intensity and measurement distance, so as to avoid energy waste caused by excessive laser power and impact on positioning accuracy if the laser power is too high. The frequency adjustment circuit adopts a crystal oscillator circuit, which can adjust the emission frequency of the laser emitter 21. The adjustment range is 1kHz-10kHz, ensuring the anti-interference capability of the laser signal and avoiding mutual interference with the signals of other electronic devices on site.

[0051] The beam shaping unit 23 includes a collimating lens and a focusing lens. The collimating lens is located near the light-emitting side of the laser emitter 21, and the focusing lens is located behind the collimating lens. The two are coaxially arranged. The collimating lens is a plano-convex lens with a focal length of 50mm, used to collimate the laser beam and reduce its divergence. The focusing lens is a biconvex lens with a focal length of 30mm, used to focus the laser beam, making the laser spot more concentrated and improving the accuracy of laser positioning. The beam shaping unit 23 is coaxially arranged with the laser emitter 21 to ensure that the laser beam can pass smoothly through collimation and focusing processes and be transmitted to the surface of the electromechanical equipment to be installed and the mounting reference surface.

[0052] 2. Specific Implementation of the Positioning Detection Module

[0053] like Figure 3 As shown, the positioning detection module 3 includes a laser receiving array 31, an image acquisition unit 32, an attitude sensor 33, and a distance measurement unit 34. The laser receiving array 31 is used to receive the laser signal emitted by the laser emitting module 2, convert it into an electrical signal, and transmit it to the intelligent control module 4. The image acquisition unit 32 is used to acquire the installation attitude image of the electromechanical equipment to be installed, extract the equipment outline and feature marker points, and assist in positioning detection. The attitude sensor 33 is used to detect the tilt angle, deflection angle, and vibration parameters of the electromechanical equipment to be installed, providing data support for error analysis. The distance measurement unit 34 is used to measure the distance parameters between the electromechanical equipment to be installed and the reference surface and adjacent equipment, thus improving the positioning data.

[0054] In this embodiment, the laser receiving array 31 employs a CCD image sensor array, model OV7725, with a pixel resolution of 1280×960 and a sampling frequency of 60Hz. It can quickly and accurately receive the laser signals emitted by the laser emitting module 2, converting the optical signals into electrical signals, and transmitting them to the intelligent control module 4 for processing. The laser receiving array 31 is positioned on the surface of the electromechanical equipment to be installed and on the mounting reference surface, corresponding to the position of the laser emitter 21, ensuring comprehensive reception of laser signals and improving the comprehensiveness of positioning detection.

[0055] The image acquisition unit 32 includes an industrial camera and an image acquisition card. The industrial camera, model MV-CE050-30GM, has a resolution of 5 megapixels, a frame rate of 30fps, and autofocus, and can acquire images of the installation posture of the electromechanical equipment to be installed. The image acquisition card, model PCIe-1747, is used to convert the image signals acquired by the industrial camera into digital signals and transmit them to the intelligent control module 4. The image acquisition unit 32 is located on the top of the positioning calibration body 1 and can rotate 360° to ensure that it can acquire posture images of the electromechanical equipment to be installed from various angles, extract the equipment outline and feature markers (such as mounting holes, positioning pins, etc.) to assist in positioning detection and improve positioning accuracy.

[0056] The attitude sensor 33 employs a combination of a three-axis gyroscope and an accelerometer, model MPU6050, with a sampling frequency of 120Hz. The angle measurement accuracy, calculated by the algorithm, reaches ±0.003°. It can detect the tilt angle, deflection angle, and vibration parameters of the electromechanical equipment to be installed in real time, including tilt angle, deflection angle, and vibration acceleration in the X, Y, and Z axes. The attitude sensor 33 is fixed to the core component of the electromechanical equipment to be installed, moving synchronously with the equipment to ensure that the detected attitude parameters accurately reflect the installation posture of the equipment.

[0057] The distance measurement unit 34 uses a laser rangefinder sensor, model VL53L0X, which, combined with the phase-based distance measurement principle, achieves a measurement accuracy of ±0.008mm, a measurement range of 0.1m-50m, and a response time of 30ms. Four sets of distance measurement units 34 are installed at the four corners of the positioning and calibration main body 1. They are used to measure the distance between the electromechanical equipment to be installed and the installation reference surface, as well as the distance between the electromechanical equipment to be installed and adjacent equipment, providing distance data support for installation error analysis. The phase-based distance measurement principle calculates the distance by measuring the phase difference of the laser signal; the calculation formula is as follows:

[0058] d = c×Δφ / (4πf)

[0059] Where d is the measurement distance, c is the speed of light (3×10^8 m / s), Δφ is the phase difference of the laser signal, and f is the frequency of the laser signal. This formula allows for the precise calculation of the distance between the electromechanical equipment to be installed and the measurement point, offering high accuracy and fast response.

[0060] 3. Specific Implementation of the Intelligent Control Module

[0061] like Figure 4As shown, the intelligent control module 4 includes a main control chip 41, a data processing unit 42, a storage unit 43, and an instruction generation unit 44. The main control chip 41 adopts the ARM Cortex-A8 architecture, model S5PV210, with a main frequency of 1.2GHz, and has powerful data processing and instruction execution capabilities, capable of processing data streams and control instructions from multiple modules simultaneously. The data processing unit 42 is used to filter, reduce noise, and fuse the position parameters, attitude parameters, and distance parameters collected by the positioning detection module 3, and calculate the installation error. The storage unit 43 is used to store preset installation reference parameters, historical measurement data, calibration records, and algorithm programs, with a storage capacity of 32GB, supporting long-term data storage and retrieval. The instruction generation unit 44 is used to generate targeted laser angle adjustment instructions based on the installation error analysis results, optimize the laser positioning reference, and ensure positioning accuracy.

[0062] In this embodiment, the data processing unit 42 uses the Kalman filter algorithm to reduce noise in the collected data and uses a weighted fusion algorithm to fuse multi-source sensor data to improve the accuracy of data measurement. At the same time, it incorporates an adaptive threshold algorithm, which can dynamically adjust the data processing threshold according to environmental changes to enhance the device's ability to resist environmental interference.

[0063] (1) Specific Implementation of Kalman Filtering Algorithm The Kalman filtering algorithm is used to denoise the position parameters, attitude parameters, and distance parameters collected by the positioning and detection module 3, eliminating noise caused by environmental interference, sensor errors, and other factors, and improving the accuracy of the data. The Kalman filtering algorithm includes two stages: prediction and update. The specific steps are as follows:

[0064] ① Prediction phase: Based on the state estimate and state equation of the previous time step, predict the state estimate and covariance matrix of the current time step.

[0065] Equations of state:

[0066] X_k = A X_{k-1} + B U_{k-1} + W_{k-1}

[0067] Covariance prediction equation:

[0068] P_k^- = A P_{k-1} A^T + Q

[0069] Where X_k is the current state estimate (including position, attitude, and distance parameters), X_{k-1} is the previous state estimate, A is the state transition matrix, B is the control matrix, U_{k-1} is the control input at the previous time, W_{k-1} is the process noise, P_k^- is the prediction covariance matrix at the current time, P_{k-1} is the covariance matrix at the previous time, A^T is the transpose of the state transition matrix A, and Q is the process noise covariance matrix.

[0070] ② Update phase: Based on the measured and predicted values ​​at the current time, calculate the Kalman gain and update the state estimate and covariance matrix at the current time.

[0071] Measurement equation: Z_k = H X_k + V_k

[0072] Kalman gain equation: K_k = P_k^- H^T (H P_k^- H^T + R)^{-1} State update equation: X_k = X_k^- + K_k (Z_k - H X_k^-)

[0073] Covariance update equation: P_k = (I - K_k H) P_k^-

[0074] Where Z_k is the measurement value at the current time, H is the observation matrix, V_k is the measurement noise, K_k is the Kalman gain, H^T is the transpose of the observation matrix H, R is the measurement noise covariance matrix, and I is the identity matrix.

[0075] In this embodiment, the process noise covariance matrix Q and the measurement noise covariance matrix R are set according to the actual measurement conditions. Q is set as a diagonal matrix with diagonal elements of 0.001 (mm), 0.001 (°), and 0.001 (mm) (corresponding to the process noise of position, attitude, and distance parameters); R is set as a diagonal matrix with diagonal elements of 0.0001 (mm), 0.0001 (°), and 0.0001 (mm) (corresponding to the measurement noise of position, attitude, and distance parameters). The Kalman filter algorithm effectively eliminates noise in the measurement data, improving the accuracy and stability of the data.

[0076] (2) Specific Implementation of the Weighted Fusion Algorithm The weighted fusion algorithm is used to fuse multi-source data collected by the laser receiving array 31, image acquisition unit 32, attitude sensor 33, and distance measurement unit 34, combining the advantages of each sensor to improve the accuracy and reliability of positioning detection. The specific steps of the weighted fusion algorithm are as follows:

[0077] ① Data Preprocessing: The data collected by each sensor is normalized to convert the data to the same magnitude, avoiding the impact of differences in data magnitude on the fusion effect. The normalization formula is:

[0078] x_i' = (x_i - x_{min}) / (x_{max} - x_{min})

[0079] Where x_i' is the normalized data, x_i is the original data, x_{min} is the minimum value of the original data, and x_{max} is the maximum value of the original data.

[0080] ② Weight Calculation: Based on the measurement accuracy, reliability, and environmental adaptability of each sensor, calculate the weight coefficient of each sensor's data. The weight coefficient is calculated using the entropy weight method, and the specific steps are as follows:

[0081] a. Calculate the information entropy of the data from each sensor:

[0082] E_i = -Σ(from j=1 to n)p_{ij} ln p_{ij}, where p_{ij} = x_{ij} / Σ(from j=1 to n)x_{ij}, x_{ij} is the j-th measurement data of the i-th sensor, and n is the number of measurement data.

[0083] b. Calculate the weighting coefficient of each sensor: w_i = (1 - E_i) / Σ(from i=1 to m)(1 - E_i), where m is the number of sensors, w_i is the weighting coefficient of the i-th sensor, and Σ(from i=1 to m)w_i = 1. In this embodiment, the number of sensors m=4 (laser receiving array, image acquisition unit, attitude sensor, distance measurement unit). Based on the measurement accuracy and reliability of each sensor, the calculated weighting coefficients are as follows: laser receiving array 0.35, image acquisition unit 0.25, attitude sensor 0.20, and distance measurement unit 0.20.

[0084] ③ Data Fusion: Based on the weighting coefficients of each sensor, the normalized multi-source data is weighted and summed to obtain the fused positioning data. The fusion formula is:

[0085] X = Σ (from i=1 to m) w_i x_i'

[0086] Where X is the fused positioning data, w_i is the weighting coefficient of the i-th sensor, and x_i' is the normalized measurement data of the i-th sensor.

[0087] By using a weighted fusion algorithm, measurement data from various sensors can be combined to compensate for the shortcomings of a single sensor and improve the accuracy and reliability of positioning and detection.

[0088] (3) Specific implementation of the adaptive threshold algorithm

[0089] The adaptive threshold algorithm is used to dynamically adjust the data processing threshold based on the environmental data (temperature, humidity, light intensity, vibration parameters) collected by the environmental monitoring module 7, thereby eliminating the influence of environmental factors on the measurement data and enhancing the device's resistance to environmental interference. The specific steps are as follows: ① Establish the mapping relationship between environmental parameters and thresholds: Through a large number of experiments, the optimal data processing thresholds under different environmental parameters are collected, a mapping table between environmental parameters and thresholds is established, and stored in the storage unit 43.

[0090] ② Real-time acquisition of environmental parameters: The environmental monitoring module 7 collects the temperature, humidity, light intensity, and vibration parameters of the installation environment in real time.

[0091] ③ Dynamically adjust threshold: Based on the environmental parameters collected in real time, query the mapping table to determine the optimal data processing threshold under the current environment, and adjust the threshold parameters of the data processing unit 42 to ensure the accuracy of data processing.

[0092] For example, when the light intensity is greater than 5000 lux, the measurement data of the laser receiving array is easily interfered with. In this case, the data processing threshold is increased to filter out the interfering data. When the temperature is below 0℃, the measurement accuracy of the sensor will decrease. In this case, the data processing threshold is lowered to ensure that the valid data is not filtered out.

[0093] (4) The installation error calculation data processing unit 42 analyzes the fused positioning data, compares it with the preset installation reference parameters, and calculates the installation error of the electromechanical equipment to be installed. The installation error includes position error, attitude error and distance error. The specific calculation method is as follows: ① Position error: Let the preset installation reference position coordinates be (X_0, Y_0, Z_0), and the actual installation position coordinates after fusion be (X, Y, Z), then the position error ΔS is:

[0094] ΔS = √[(X - X_0)² + (Y - Y_0)² + (Z - Z_0)²]

[0095] ② Attitude Error: Let the preset installation reference attitude angles be (α_0, β_0, γ_0) (the tilt angles in the X-axis, Y-axis, and Z-axis directions, respectively), and the fused actual attitude angles be (α, β, γ). Then the attitude error Δθ is:

[0096] Δθ = √[(α - α_0)² + (β - β_0)² + (γ - γ_0)²] ③ Distance error: Let the preset installation reference distance be d_0, and the actual measured distance after fusion be d, then the distance error Δd is: Δd = |d - d_0|

[0097] When the calculated installation error is greater than the preset threshold (in this embodiment, the position error threshold is 0.01mm, the attitude error threshold is 0.01°, and the distance error threshold is 0.01mm), the instruction generation unit 44 of the intelligent control module 4 will generate a laser angle adjustment instruction to adjust the emission angle of the laser emitter 21, optimize the laser positioning reference, and make the positioning detection more accurate; when the installation error is less than or equal to the preset threshold, the electromechanical equipment is determined to be installed qualified, and the intelligent control module 4 outputs the "installation qualified" signal and related measurement data through the data interaction module 6 to complete the positioning calibration operation.

[0098] The instruction generation unit 44 dynamically adjusts the PWM signal pulse width according to the magnitude and trend of the installation error, thereby achieving precise fine-tuning of the emission angle of the laser emitter 21. For example, when the position error ΔS is 0.02mm and the analysis determines that the error is caused by the deviation of the laser emission angle, the instruction generation unit 44 will calculate the required angle adjustment amount, adjust the PWM signal pulse width accordingly, drive the MG90S micro servo motor to rotate, and drive the laser emitter 21 to adjust to the optimal emission angle, thereby reducing the positioning error.

[0099] Storage unit 43 employs a combination of SD card and Flash memory. The SD card stores a large amount of data, such as historical measurement data and calibration records, while the Flash memory stores important data such as preset installation reference parameters and algorithm programs, ensuring data security and stability. Storage unit 43 supports data read and write operations and can export historical data and calibration records through data interaction module 6 for easy later analysis and maintenance.

[0100] 4. The specific implementation of the data interaction module is as follows: Figure 5 As shown, the data interaction module 6 includes a wired communication unit 61, a wireless communication unit 62, and a human-machine interaction unit 63. The wired communication unit 61 uses RS485 and Ethernet interfaces to realize wired data transmission with an external control terminal. The wireless communication unit 62 uses one or more combinations of WiFi, Bluetooth, and 5G to realize wireless data transmission and remote control. The human-machine interaction unit 63 includes a touch screen, buttons, and indicator lights for parameter setting, command input, and display of device working status.

[0101] In this embodiment, the RS485 interface of the wired communication unit 61 uses the MAX485 chip, with a communication rate of 9600bps-115200bps, supporting long-distance transmission with a maximum transmission distance of 1000m; the Ethernet interface uses an RJ45 interface, supporting 10 / 100Mbps adaptive transmission, and can be connected to an industrial Ethernet to realize wired data transmission with external control terminals (such as PLCs and industrial computers). The transmitted data includes measurement data, calibration records, equipment operating status, installation error data, etc.

[0102] The wireless communication unit 62 adopts a combined structure of a WiFi module (model ESP8266), a Bluetooth module (model HC-05), and a 5G module (model SIM8200). The WiFi module supports the 802.11b / g / n protocol with a communication rate of 150Mbps, enabling wireless data transmission with mobile terminals (phones, tablets) and wireless gateways, with a transmission distance of at least 100m. The Bluetooth module supports the Bluetooth 4.0 protocol with a communication rate of 1Mbps and a transmission distance of at least 10m, suitable for short-range wireless control and data transmission. The 5G module supports the 5G NR protocol, offering a high communication rate, suitable for long-distance, high-volume wireless data transmission, especially suitable for long-distance operation needs such as large industrial plants and outdoor installation scenarios. The wireless communication unit 62 supports automatic switching of communication modes, automatically selecting the optimal communication method based on the signal strength of the installation environment to ensure the stability and real-time performance of data transmission. The human-machine interface unit 63 includes an industrial-grade touchscreen, waterproof buttons, and multi-color indicator lights. The touchscreen is a TFT-700 model with a resolution of 800×480 and a 7-inch screen size. It is waterproof, dustproof, and anti-interference, with a tempered glass surface that can withstand minor impacts and oil contamination in industrial environments. It supports touch operation, allowing operators to set preset installation baseline parameters, adjust laser parameters, query data, and input commands. The waterproof buttons are made of silicone and include a power button, confirmation button, cancel button, and adjustment button. The buttons have a moderate travel distance and a comfortable feel, allowing them to work stably in humid and dusty industrial environments. They are used for emergency operations and auxiliary parameter settings. The multi-color indicator lights include a power indicator (green), a working indicator (blue), and a fault indicator (red). A constantly lit power indicator indicates normal power supply; a flashing working indicator indicates the device is in operation; and a constantly lit or flashing fault indicator indicates a malfunction, allowing operators to quickly determine the device's operating status. 5. Specific Implementation of the Environmental Monitoring Module

[0103] like Figure 6As shown, the environmental monitoring module 7 is electrically connected to the intelligent control module 4. It collects temperature, humidity, light intensity, and vibration parameters of the installation environment, providing data support for the intelligent control module 4 to dynamically adjust laser and sampling parameters, thus reducing the impact of environmental factors on positioning calibration accuracy. The environmental monitoring module 7 includes a temperature sensor, a humidity sensor, a light sensor, and a vibration sensor. Each sensor uses industrial-grade components, possessing good stability and anti-interference capabilities. It is installed externally to the positioning calibration body 1 to ensure real-time acquisition of accurate parameters of the installation environment.

[0104] In this embodiment, the temperature sensor is a DS18B20 digital temperature sensor with a measurement range of -20℃ to 80℃ and a measurement accuracy of ±0.1℃. It supports single-bus communication and can be directly connected to the GPIO port of the intelligent control module 4 without the need for additional signal conversion circuits. Its structure is simple and data transmission is stable. The humidity sensor is a DHT11 digital humidity sensor with a measurement range of 0% to 100%RH and a measurement accuracy of ±1%RH. Its response time is no more than 5 seconds, enabling rapid acquisition of ambient humidity data. The light sensor is a B... The H1750 digital light sensor has a measurement range of 0-10000 lux and a measurement accuracy of ±10 lux. It supports I2C communication and can automatically adjust the measurement range according to the light intensity to ensure measurement accuracy under different lighting conditions. The vibration sensor uses a YZC-133 piezoelectric vibration sensor with a measurement range of 0-100Hz and a measurement accuracy of ±0.01g. It can detect vibration parameters of the installation environment in real time, including vibration frequency and vibration acceleration, providing data support for the intelligent control module 4 to determine the impact of environmental vibration on positioning accuracy.

[0105] The sampling frequency of the environmental monitoring module 7 is consistent with that of the positioning detection module 3, both being 100Hz, ensuring the synchronization of environmental and positioning data. The collected environmental parameters are converted from digital signals (A / D) and transmitted to the data processing unit 42 of the intelligent control module 4. The data processing unit 42 analyzes the environmental data and, combined with an adaptive threshold algorithm, dynamically adjusts the laser power and emission frequency of the laser emission module 2, as well as the sampling frequency and data processing threshold of the positioning detection module 3, ensuring that the device maintains high positioning calibration accuracy under different environments. For example, when the ambient temperature exceeds 60℃, the emission stability of the semiconductor laser emitter decreases. The intelligent control module 4 controls the laser adjustment unit 22 to reduce the laser power while increasing the laser emission frequency to reduce the impact of temperature on the laser beam. When the environmental vibration frequency exceeds 50Hz, the intelligent control module 4 increases the sampling frequency of the positioning detection module 3, increasing the amount of data collected, and further reduces noise using a Kalman filter algorithm to ensure the accuracy of the positioning data.

[0106] 6. The specific implementation of the fault diagnosis module is as follows: Figure 7 As shown, the fault diagnosis module 8 is electrically connected to the intelligent control module 4. It is used to monitor the working status of each module of the device (laser emission module 2, positioning detection module 3, intelligent control module 4, data interaction module 6, and environmental monitoring module 7) in real time, collect the operating parameters of each module, quickly identify the fault type and fault point, and issue alarm signals in a timely manner to ensure that device faults can be detected and handled in a timely manner, so as to avoid affecting the installation progress of electromechanical equipment.

[0107] In this embodiment, the fault diagnosis module 8 uses a fault tree analysis algorithm to construct a fault diagnosis model by combining the operating parameter thresholds of each module, and stores it in the storage unit 43 of the intelligent control module 4. The sampling frequency of the fault diagnosis module 8 is 50Hz, and it collects the operating parameters of each module in real time, including the laser power, emission frequency, and servo motor speed of the laser emission module 2, the sensor output signal and sampling frequency of the positioning detection module 3, the chip temperature and power supply voltage of the intelligent control module 4, the communication rate and signal strength of the data interaction module 6, and the sensor output signal of the environmental monitoring module 7. The collected operating parameters are compared with preset thresholds to determine whether each module has a fault.

[0108] The fault diagnosis module 8 can identify the following fault types: laser emission module fault (laser emitter does not emit laser, laser power is abnormal, servo motor cannot rotate normally), positioning detection module fault (sensor has no output signal, measurement data is abnormal, image acquisition fails), intelligent control module fault (chip overheating, power supply voltage is abnormal, data processing fails), data interaction module fault (communication interruption, signal strength is too low, touch screen is unresponsive), and environmental monitoring module fault (sensor has no output signal, measurement data is abnormal). When a fault is detected, the fault diagnosis module 8 immediately issues a fault alarm signal. The alarm methods include audible alarm (a built-in buzzer emits a prompt tone, the volume of which is adjustable), light alarm (controls the fault indicator light to flash at a frequency of 1Hz), and remote alarm (the fault information is transmitted to an external terminal via the data interaction module 6, including fault type, fault time, fault location, etc.). At the same time, the fault record is stored in the storage unit 43. The fault record includes fault type, fault time, fault parameters, and handling suggestions, which facilitates the quick location of the fault point and repair by maintenance personnel in the later stage. For example, when the fault diagnosis module 8 detects that the laser power of the laser emitting module 2 is lower than 0.5mW (the preset threshold is 1mW), it determines that the laser emitter is faulty, immediately activates the buzzer alarm, the fault indicator light flashes, and transmits the fault information "laser emitter fault, abnormal laser power" to the external terminal. It also records the fault time, current laser power and other parameters in the storage unit 43, and provides handling suggestions: check the laser emitter power connection and replace the laser emitter. When the communication interruption of the data interaction module 6 is detected to be longer than 10 seconds, it determines that the communication is faulty, activates the alarm mechanism, and sends a reset command through the GPIO port of the intelligent control module 4 to automatically restart the communication module. If the restart fails, the fault information is then transmitted to the external terminal.

[0109] 7. Overall Workflow of the Equipment

[0110] The overall workflow for installing the laser positioning and intelligent calibration device on electromechanical equipment in this embodiment is as follows:

[0111] Step 1: Device initialization. The staff sets the preset installation reference parameters (including position coordinates, attitude angle, distance parameters, etc.) through the touch screen of the data interaction module 6 or an external terminal, turns on the device power, and each module begins initialization. The intelligent control module 4 detects the working status of each module, and the fault diagnosis module 8 performs initial fault detection. If all modules are working normally, the working indicator light flashes and the device enters standby mode. If a fault is detected, the alarm mechanism is immediately activated to prompt the staff to handle the fault.

[0112] Step 2: Laser positioning reference construction. The intelligent control module 4 sends a laser emission command to the laser emission module 2. The multiple laser emitters 21 of the laser emission module 2 emit horizontal, vertical and oblique lasers in an array. The beam shaping unit 23 collimates and focuses the laser beam to form a three-dimensional laser positioning reference network, covering the installation area and installation reference surface of the electromechanical equipment to be installed.

[0113] Step 3: Multi-source data acquisition. The laser receiving array 31 of the positioning detection module 3 receives the laser signal emitted by the laser emitting module 2, converts it into an electrical signal, and transmits it to the intelligent control module 4. The image acquisition unit 32 acquires the installation posture image of the electromechanical equipment to be installed and extracts the equipment outline and feature marker points. The posture sensor 33 detects the tilt angle, deflection angle, and vibration parameters of the electromechanical equipment to be installed. The distance measurement unit 34 measures the distance parameters between the electromechanical equipment to be installed and the reference surface and adjacent equipment. At the same time, the environmental monitoring module 7 acquires the temperature, humidity, light intensity, and vibration parameters of the installation environment. All acquired data are synchronously transmitted to the intelligent control module 4.

[0114] Step 4: Data processing and error calculation. The data processing unit 42 of the intelligent control module 4 uses the Kalman filter algorithm to reduce noise in the collected data, uses the weighted fusion algorithm to fuse multi-source sensor data, and combines the adaptive threshold algorithm to dynamically adjust the data processing threshold according to the environmental monitoring data to obtain the fused positioning data. The data processing unit 42 compares the fused positioning data with the preset installation reference parameters and calculates the installation error (including position error, attitude error, and distance error).

[0115] Step 5: Laser angle adjustment and calibration guidance. The intelligent control module 4 determines whether the installation error is greater than the preset threshold (position error 0.01mm, attitude error 0.01°, distance error 0.01mm). If the error is greater than the preset threshold, the instruction generation unit 44 generates a laser angle adjustment instruction, controls the MG90S micro servo motor to rotate via PWM signal, adjusts the emission angle of the laser emitter 21, optimizes the laser positioning reference, and then returns to step 3 to re-acquire data and calculate errors until the installation error is less than or equal to the preset threshold. If the error is less than or equal to the preset threshold, the electromechanical equipment is deemed to be installed correctly, and the intelligent control module 4 outputs an "installation qualified" signal and related measurement data and error data through the data interaction module 6.

[0116] Step 6: Real-time monitoring and fault handling. During the operation of the device, the fault diagnosis module 8 monitors the working status of each module in real time and collects the operating parameters of each module. If a fault is detected, the alarm mechanism is immediately activated, the fault information is transmitted to the external terminal and the fault record is stored. The staff performs maintenance based on the fault information. After the maintenance is completed, the device is restarted and the positioning calibration operation continues.

[0117] Step 7: Work completed. After the electromechanical equipment is installed correctly, the staff will turn off the power of the device through the data interaction module 6, export the measurement data, calibration records and fault records (if any), and complete the positioning calibration work.

[0118] In this embodiment, the positioning and calibration accuracy of the device can reach ±0.01mm, and the installation and calibration efficiency is improved by more than 60% compared with the traditional manual measurement method. It can be adapted to the installation needs of different types and specifications of industrial electromechanical equipment. In the installation process of large machine tools, generator sets, port cranes, semiconductor manufacturing equipment, aerospace equipment and other electromechanical equipment, it can achieve precise positioning and intelligent calibration guidance, effectively reduce the intensity of manual labor, improve installation quality and efficiency, and reduce installation costs.

[0119] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A laser positioning and intelligent calibration device for installation of electromechanical equipment, characterized in that, It includes a positioning calibration main body, a laser emission module, a positioning detection module, an intelligent control module, and a data interaction module; the laser emission module, the positioning detection module, and the data interaction module are all electrically connected to the intelligent control module; the laser emission module is used to emit laser positioning signals to the installation reference surface of the electromechanical equipment and the surface of the electromechanical equipment to be installed, forming a three-dimensional positioning reference network; the positioning detection module is used to collect feedback data of the laser positioning signals to obtain the actual installation position parameters of the electromechanical equipment to be installed; The intelligent control module receives feedback data from the positioning detection module, compares it with preset installation reference parameters, analyzes and calculates the installation position error, and generates laser angle adjustment commands. The data interaction module enables data transmission, parameter setting, and command interaction between the device and external terminals, and synchronously outputs installation error data to provide a reference for external manual or auxiliary equipment calibration.

2. The laser positioning and intelligent calibration device for installation of electromechanical equipment according to claim 1, characterized in that, The laser emitting module includes multiple sets of laser emitters, a laser adjustment unit, and a beam shaping unit. The multiple sets of laser emitters are arranged in an array and are used to emit horizontal, vertical, and oblique lasers to construct a three-dimensional laser positioning reference. The laser adjustment unit is electrically connected to the intelligent control module and is used to adjust the emission angle, laser intensity, and laser frequency of the laser emitters. The beam shaping unit is used to collimate and focus the laser beam emitted by the laser emitters to reduce the divergence of the laser beam.

3. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 2, characterized in that, The angle adjustment mechanism of the laser adjustment unit adopts a micro servo motor, model MG90S; the output shaft of the micro servo motor is fixedly connected to the mounting shaft of the laser emitter through a flexible coupling. The micro servo motor is fixed on the mounting bracket of the laser emitter and is coaxially aligned with the mounting shaft of the laser emitter. It is used to drive the laser emitter to rotate around the mounting shaft to achieve precise adjustment of the emission angle.

4. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 3, characterized in that, The angle control method of the micro servo motor is as follows: the intelligent control module outputs a PWM signal with a period of 20Hz, and controls the rotation angle of the micro servo motor by changing the pulse width of the PWM signal (1.0ms-2.0ms), thereby adjusting the emission angle of the laser emitter; where a pulse width of 1.0ms corresponds to a 0° rotation angle, 1.5ms corresponds to a 90° rotation angle, and 2.0ms corresponds to a 180° rotation angle. The adjustment range is 0°-360° and the adjustment accuracy is ±0.01° by the continuous rotation of the motor.

5. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 1, characterized in that, The positioning and detection module includes a laser receiving array, an image acquisition unit, an attitude sensor, and a distance measurement unit. The laser receiving array receives laser signals emitted by the laser emitting module, converts them into electrical signals, and transmits them to the intelligent control module. The image acquisition unit acquires images of the installation attitude of the electromechanical equipment to be installed and extracts the equipment outline and feature markers. The attitude sensor detects the tilt angle, deflection angle, and vibration parameters of the electromechanical equipment to be installed. The distance measurement unit measures the distance parameters between the electromechanical equipment to be installed and the reference surface, as well as between the equipment and adjacent equipment.

6. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 5, characterized in that, The distance measurement unit uses a laser rangefinder sensor, combined with the phase method ranging principle, with a measurement accuracy of not less than ±0.008mm and a measurement range of 0.1m-50m; the attitude sensor adopts a combination structure of a three-axis gyroscope and an accelerometer, with a sampling frequency of not less than 100Hz and an angle measurement accuracy of not less than ±0.005°.

7. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 1, characterized in that, The intelligent control module includes a main control chip, a data processing unit, a storage unit, and an instruction generation unit. The main control chip adopts an ARM Cortex-A8 architecture with a main frequency of no less than 1GHz. The data processing unit is used to filter, reduce noise, and fuse the position parameters, attitude parameters, and distance parameters collected by the positioning and detection module, and to calculate the installation error. The storage unit is used to store preset installation reference parameters, historical measurement data, calibration records, and algorithm programs. The instruction generation unit is used to generate targeted laser angle adjustment instructions based on the installation error analysis results to optimize the laser positioning reference.

8. The laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 7, characterized in that, The data processing unit uses a Kalman filter algorithm to reduce noise in the collected data and a weighted fusion algorithm to fuse data from multiple sources, thereby improving the accuracy of data measurement. The instruction generation unit dynamically adjusts the PWM signal pulse width according to the magnitude and trend of the installation error, thereby achieving precise fine-tuning of the laser emitter's emission angle.

9. A laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 1, characterized in that, The data interaction module includes a wired communication unit, a wireless communication unit, and a human-machine interaction unit. The wired communication unit uses RS485 and Ethernet interfaces to realize wired data transmission with an external control terminal. The wireless communication unit uses one or more combinations of WiFi, Bluetooth, and 5G to realize wireless data transmission and remote control. The human-machine interaction unit includes a touch screen, buttons, and indicator lights for parameter setting, command input, and display of device operating status.

10. A laser positioning and intelligent calibration device for electromechanical equipment installation according to claim 9, characterized in that, It also includes an environmental monitoring module, which is electrically connected to the intelligent control module and is used to collect temperature, humidity, light intensity and vibration parameters of the installation environment; the intelligent control module dynamically adjusts the laser parameters of the laser emission module and the sampling parameters of the positioning detection module according to the environmental monitoring data, so as to reduce the impact of environmental factors on the positioning calibration accuracy; It also includes a fault diagnosis module, which is electrically connected to the intelligent control module. It is used to monitor the working status of each module of the device in real time, collect the operating parameters of each module, and when a module fault is detected, it immediately issues a fault alarm signal and transmits the fault information to an external terminal through the data interaction module. At the same time, it stores the fault record for easy maintenance and repair in the future.

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