Intelligent timing control method and control system of packaging production line

Abstract

The present application relates to the technical field of packaging machinery control, and discloses an intelligent timing control method and control system for a packaging production line, the method comprising the following steps: constructing a virtual main shaft current phase based on a rated reference clock frequency, and mapping the virtual main shaft current phase into target position instructions of a plurality of driven actuators; obtaining a continuous sequence of cross shaft torque currents of a main traction servo execution group, and extracting a slip characteristic energy value representing the cumulative degree of physical material slip; calculating second-order geometric gradients of each driven actuator at the current phase, and generating a modulation frequency width boundary based on the second-order geometric gradients; calculating a frequency adjustment amount based on the slip characteristic energy value, limiting the frequency adjustment amount by using the modulation frequency width boundary, and reconstructing a real-time dynamic clock frequency; updating the current phase according to the real-time dynamic clock frequency, and synchronizing the current phase to each driven actuator to calculate the target position instructions.

Description

Technical Field

[0001] This invention relates to the field of packaging machinery control technology, specifically to an intelligent timing control method and control system for a packaging production line. Background Technology

[0002] With the development of automation technology, modern continuous packaging production lines generally adopt a multi-axis electronic cam synchronous control architecture based on a virtual spindle to achieve macroscopic spatial coordination between the main traction mechanism and multiple processing stations (such as film feeding, filling, sealing, and cutting). During actual high-speed operation, flexible packaging materials inevitably experience microscopic stick-slip and physical position lag at the main traction roller due to uneven surface friction coefficients or transient tension fluctuations. Existing control systems typically rely on additional high-precision external tension sensors or visual displacement sensors at mechanical transmission nodes for slip detection. This approach not only increases hardware deployment costs and on-site wiring complexity, but also means that the mechanical response of the physical sensors often lags behind the transient changes in the underlying electromagnetic torque. To eliminate the cumulative slip error, traditional compensation strategies often involve directly sending additional position correction messages to each independent driven servo axis. However, this increases the bandwidth load of the industrial real-time communication bus, and independent correction of each axis easily disrupts the strict spatial relative topology between processing stations throughout the line. Some solutions attempt to achieve global unified timing delay compensation by directly and dynamically adjusting the operating pulse frequency of the virtual spindle. However, since the transient spatial kinematics of the entire driven mechanical mechanism is not taken into account, when the system is reconstructing the underlying time base, if a specific high-inertia actuator happens to be in the spatial curvature change zone of the electronic cam profile (i.e., the rapid acceleration and deceleration zone), the sudden change in the underlying time frequency will instantly introduce a huge additional spatial acceleration to the physical axis, which will cause the servo motor output torque to approach the limit, easily inducing severe high-frequency resonance of the mechanical transmission chain and loss of position tracking. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides an intelligent timing control method and control system for packaging production lines. This solves the problem that packaging production lines are prone to high-inertia mechanical resonance and multi-axis synchronization misalignment due to the lack of spatial kinematic constraints in adjusting the underlying clock frequency when sensing material slippage and performing global time base compensation.

[0004] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of the present invention provides an intelligent timing control method for a packaging production line, comprising the following steps: The current phase of the virtual spindle is constructed based on the rated reference clock frequency, and the current phase of the virtual spindle is mapped to the target position commands of multiple driven actuators. Obtain the continuous sequence of cross-axis torque current of the main traction servo actuator, and extract the slip characteristic energy value that characterizes the degree of material physical slip accumulation from it; Calculate the second-order geometric gradient of each driven actuator under the current phase of the virtual master axis, and generate the modulation bandwidth boundary accordingly; The original frequency adjustment is calculated based on the slip characteristic energy value. The original frequency adjustment is then limited by the modulation bandwidth boundary to output the final frequency adjustment, and the real-time dynamic clock frequency is reconstructed. The current phase of the virtual spindle is updated according to the real-time dynamic clock frequency and synchronized to each slave actuator to calculate the updated target position command.

[0005] In the aforementioned intelligent timing control method, the execution logic for obtaining the continuous sequence of quadrature-axis torque current of the main traction servo actuator and extracting the slip characteristic energy value is as follows: Within a set microsecond-level sampling period, the three-phase AC current signal of the stator winding of the main traction servo motor is continuously measured; the three-phase AC current signal is sequentially subjected to three-phase to two-phase orthogonal transformation processing in the stationary coordinate system and two-phase orthogonal transformation processing in the rotating coordinate system to decouple and output the continuous sequence of quadrature-axis torque current. The continuous sequence of quadrature-axis torque current is frequency domain filtered through a digital bandpass filter module to isolate the high-frequency harmonic current sequence; the instantaneous amplitude of the high-frequency harmonic current sequence within the set sliding time window length is subjected to square integral operation to generate the slip characteristic energy value.

[0006] The innovative principle of this invention lies in the fact that the above-mentioned feature extraction mechanism utilizes the magnetic field orientation control current observation data of the servo underlying layer, and isolates the low-frequency load fluctuations caused by the motor's operating fundamental frequency and macroscopic mechanical transmission through frequency domain truncation. It directly transforms the microscopic stick-slip friction and high-frequency tension release characteristics of the flexible packaging material surface into stable feedforward energy control variables, thereby realizing dynamic perception of material physical slip without external sensors.

[0007] In the aforementioned intelligent timing control method, the execution logic for calculating the second-order geometric gradient and generating the modulation bandwidth boundary is as follows: First, perform equally spaced second-order spatial difference calculations on each electronic cam function to generate a discrete second-order geometric gradient mapping table. Then, using the current phase of the virtual master axis as the reference index value, retrieve the discrete second-order geometric gradient from the mapping table and output the current second-order geometric gradient using a two-point linear interpolation formula. Next, compare the absolute values ​​of all second-order geometric gradients and extract the absolute value of the global maximum geometric gradient. Finally, use the absolute value of the global maximum geometric gradient to perform the calculation through inverse proportional mapping logic to generate the modulation bandwidth boundary.

[0008] The innovative principle of this invention lies in the fact that the second-order geometric gradient characterizes the instantaneous spatial acceleration requirement of the driven actuator in a specific phase. When any driven actuator enters the rapid acceleration or deceleration section of the electronic cam function, the absolute value of the extracted global maximum geometric gradient increases synchronously, and the modulation bandwidth boundary output by the inverse proportional mapping logic is forcibly compressed. This mechanism quantifies the spatial dynamic sensitivity of each processing station on the entire production line to the underlying time base fluctuations, and establishes the physical safety threshold for time and frequency adjustment.

[0009] In the aforementioned intelligent timing control method, the execution logic for reconstructing the real-time dynamic clock frequency is as follows: the slip characteristic energy value is input as a feedforward error to the proportional-integral (PI) controller to calculate the original frequency adjustment. When the absolute value of the original frequency adjustment is greater than the modulation bandwidth boundary, the final frequency adjustment is forced to be equal to the value of the modulation bandwidth boundary; when the absolute value of the original frequency adjustment is not greater than the modulation bandwidth boundary, the final frequency adjustment is equal to the original frequency adjustment. The final frequency adjustment is subtracted from the rated reference clock frequency to reconstruct the real-time dynamic clock frequency. Furthermore, when it is determined that the absolute value of the original frequency adjustment is greater than the modulation bandwidth boundary, the difference between the original frequency adjustment and the final frequency adjustment is calculated to generate a saturation deviation; the saturation deviation is multiplied by a preset anti-saturation feedback gain coefficient to generate a reverse compensation value; the reverse compensation value is accumulated in the integral status register inside the PI controller.

[0010] The innovative principle of this invention lies in the fact that, through the aforementioned nonlinear constraint mechanism, the single adjustment saturation amplitude of the reconstructed dynamic clock frequency is strictly limited, thereby cutting off the transmission path from the time-domain adjustment mutation to the high-frequency vibration in the physical space domain, and limiting the resonance of high-inertia mechanical actuators caused by the bottom time axis mutation; at the same time, by using the reverse compensation of saturation deviation, the blind accumulation of deep saturation that occurs during the amplitude limiting triggering period is suppressed, and the clock frequency response overshoot of the system is avoided when the material exits the slipping state.

[0011] In the aforementioned intelligent timing control method, the logic for updating the current phase of the virtual spindle and executing synchronously is as follows: the phase increment is obtained by multiplying the underlying interpolation period by the real-time dynamic clock frequency, and the phase increment is accumulated to generate the updated current phase of the virtual spindle; the updated current phase of the virtual spindle is encapsulated in a process data object message, and under the trigger of a synchronization interrupt signal, it is broadcast concurrently to the servo drives of each slave actuator through the industrial real-time communication bus; each servo drive reads the received current phase of the virtual spindle and performs interpolation calculation in the locally stored two-dimensional data table to calculate the updated target position command.

[0012] The innovative principle of this invention lies in the fact that all physical execution nodes share the same reconstructed virtual spindle phase reference. During the period of dynamic clock frequency slowing down, the mechanical movements of each processing station synchronously generate a proportional, smooth, monotonic delay on the time axis. Without changing the set electronic cam spatial contour of each mechanical mechanism, the system completes adaptive synchronous position compensation and alignment for transient physical slip disturbances of the material.

[0013] A second aspect of the present invention provides an intelligent timing control system for a packaging production line, comprising: The reference construction unit is used to construct the current phase of the virtual spindle based on the rated reference clock frequency, and map the current phase of the virtual spindle to the target position commands of multiple driven actuators; The feature extraction unit is used to obtain the continuous sequence of cross-axis torque current of the main traction servo actuator and extract the slip characteristic energy value that characterizes the degree of material physical slip accumulation. The constraint calculation unit is used to calculate the second-order geometric gradient of each driven actuator under the current phase of the virtual master axis, and generate the modulation bandwidth boundary accordingly. The time base reconstruction unit is used to calculate the original frequency adjustment based on the slip characteristic energy value, limit the original frequency adjustment using the modulation bandwidth boundary, output the final frequency adjustment, and reconstruct the real-time dynamic clock frequency. The synchronous execution unit is used to update the current phase of the virtual spindle according to the real-time dynamic clock frequency and synchronize it to each slave actuator to solve the updated target position command.

[0014] This invention provides an intelligent timing control method and control system for a packaging production line. It has the following beneficial effects: 1. This invention obtains the continuous sequence of quadrature-axis torque current of the main traction servo motor, isolates high-frequency harmonic components through a digital bandpass filter, and generates slip characteristic energy values ​​by performing square integral operation on the high-frequency harmonic amplitude within the sliding time window. It uses the electromagnetic feedback data of the servo's underlying layer as feedforward control parameters, eliminating the need to configure external tension or displacement sensors at the mechanical transmission nodes. This allows for real-time quantification of the microscopic stick-slip friction and physical slip accumulation of flexible packaging materials, effectively reducing the hardware complexity and deployment cost of the control system.

[0015] 2. This invention extracts the absolute value of the global maximum geometric gradient by calculating the second-order geometric gradient of each driven actuator under the current phase of the virtual master axis, and generates the modulation bandwidth boundary according to the inverse proportional mapping logic. Then, it performs a limiting and truncation operation on the original frequency adjustment amount, and establishes a dynamic constraint mechanism between the underlying time frequency adjustment and the mechanical space acceleration state. When any actuator enters the rapid acceleration and deceleration section, the single adjustment amplitude of the clock frequency is forcibly compressed, cutting off the transmission path from the sudden change of the time axis to the high-frequency vibration in the spatial domain, and avoiding resonance and loss of synchronization of high-inertia mechanical components.

[0016] 3. This invention utilizes feedforward control and amplitude limiting judgment to reconstruct the real-time dynamic clock frequency. Based on the reconstructed clock frequency, the current phase of the globally unified virtual spindle is updated, and the data is concurrently broadcast to each driven actuator via a real-time communication bus to perform local two-dimensional data table calculations. Without changing the original electronic cam spatial contour of each mechanical station, the synchronous smooth delay of the multi-axis motion trajectory of the entire line is achieved by frequency conversion adjustment of a single time base. This eliminates the computational burden of sending complex position compensation messages to independent physical axes, ensuring the system's adaptive position alignment to material slippage disturbances. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the method flow of the present invention; Figure 2 This is a schematic diagram of the system architecture of the present invention; Figure 3 This is a schematic diagram of the slip characteristic energy and modulation bandwidth boundary state of the present invention. Detailed Implementation

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] This invention provides an intelligent timing control system for a packaging production line, applicable to packaging equipment that includes a continuous transmission mechanism and multiple physical processing stations. The system may include: a main control unit, an industrial real-time communication bus, a main traction servo execution group, and multiple driven servo execution groups.

[0020] The main control unit is configured as the core processing device of the packaging production line, specifically a programmable logic controller (PLC) or a motion controller. Internally, the main control unit includes a central processing unit (CPU), memory, and a bus communication interface. The CPU's memory stores executable control programs and electronic cam contour data. The CPU is configured to read and execute the aforementioned control programs according to a preset task cycle, generate a global time base, and parse the spatial position instructions of each driven actuator.

[0021] The industrial real-time communication bus connects the communication interface of the main control unit to all servo drive devices distributed on the production line. The industrial real-time communication bus is configured to perform bidirectional synchronous transmission of process data objects and service data objects between the main control unit and each servo drive device at defined communication cycles. The industrial real-time communication bus carries issued position commands and uploaded low-level electromagnetic feedback signals.

[0022] The main traction servo actuator group is located at the main drive node of the packaging equipment, and includes a main traction servo driver and a main traction servo motor. The rotor of the main traction servo motor is mechanically connected to the main traction roller mechanism of the packaging production line. The main traction servo driver contains a current sampling circuit. The current sampling circuit is configured to acquire the stator phase current of the main traction servo motor in real time within a set microsecond-level sampling period, and generate quadrature-axis torque current data through coordinate transformation. The main traction servo driver continuously uploads the above quadrature-axis torque current data to the main control unit through an industrial real-time communication bus.

[0023] Multiple slave servo actuator groups correspond to specific processing stations on the packaging production line, specifically including film feeding servo actuator groups, filling servo actuator groups, and sealing / cutting servo actuator groups. Each slave servo actuator group includes an independent slave-axis servo driver and a slave-axis servo motor. Each slave-axis servo motor is connected to the film feeding roller, filling fork, and sealing / cutting mechanism, respectively. Each slave-axis servo driver is configured to receive position commands from the main control unit and perform closed-loop position following control.

[0024] The flexible packaging material physically permeates all the aforementioned mechanical execution nodes. It sequentially passes through the main traction roller mechanism of the main traction servo execution group and the corresponding processing stations of multiple driven servo execution groups. A surface frictional contact exists between the flexible packaging material and the main traction roller mechanism. Under the combined traction and processing of multiple mechanical execution mechanisms, the flexible packaging material forms a continuous transmission coupling medium in physical space. The microscopic slip and tension deformation of the flexible packaging material act in the opposite direction on the rotor of the main traction servo motor through surface friction, causing electromagnetic torque fluctuations in the main traction servo motor.

[0025] The control architecture of the main control unit is logically divided into an application layer and a bottom layer. The application layer is configured to store a multi-axis electronic cam function array and manage the macroscopic trajectory mapping relationships of each machining station. The bottom layer is configured to generate the system's interrupt-level time base pulses and run a digital signal processing program. The digital signal processing program is configured to receive the quadrature-axis torque and current data uploaded by the main traction servo actuator, perform feature extraction, and reconstruct the firing frequency of the bottom-layer time base pulses using a time base phase-locked loop algorithm. Changes in the bottom-layer time base pulses directly drive the electronic cam parsing progress of the application layer.

[0026] See attached document Figure 1 The intelligent timing control method for a packaging production line provided by this invention relies on the aforementioned main control unit and servo execution group to form a closed-loop execution cycle from underlying physical signal perception to global time base reconstruction. The main control unit has an independent task scheduling cycle, set to millisecond-level control ticks, to uniformly deploy the following processing steps.

[0027] During system startup, the main control unit internally constructs a virtual spindle phase reference based on clock frequency integration. The main control unit generates a low-level pulse signal according to the set rated reference clock frequency, and continuously accumulates and integrates this low-level pulse signal, outputting a continuously monotonically increasing current phase of the virtual spindle. The application layer program of the main control unit establishes a mapping relationship between the current phase of the virtual spindle and the target spatial position of each driven actuator according to a pre-configured electronic cam function relationship. In this initial state, all driven actuators parse their respective electronic cam trajectories according to the rated reference clock frequency.

[0028] During continuous operation of the production line, the system performs sensorless micro-disturbance signal acquisition. Within its internal current loop interrupt service routine, the main traction servo drive continuously reads the stator current of the main traction servo motor at microsecond sampling intervals and outputs a continuous sequence of quadrature-axis torque current using a coordinate transformation algorithm. The main control unit retrieves this continuous sequence of quadrature-axis torque current into its local buffer via the industrial real-time communication bus, according to an isochronous synchronization period.

[0029] The main control unit performs digital signal processing logic on the continuous sequence of quadrature-axis torque current in the buffer area. The main control unit calls a bandpass filter with preset passband parameters to process the received continuous sequence of quadrature-axis torque current, filtering out the fundamental frequency signal of the motor operation and low-frequency load fluctuation components caused by macroscopic mechanical transmission, and isolating the high-frequency harmonic current components caused by microscopic stick-slip friction on the surface of the flexible packaging material. The main control unit sets a sliding time window and calculates the square integral value of the high-frequency harmonic current components falling within this sliding time window, generating a slip characteristic energy value reflecting the current degree of physical slip accumulation of the flexible packaging material.

[0030] While acquiring the slip characteristic energy value, the main control unit performs parallel calculations of the safety constraints for the global kinematic state. The main control unit reads the current virtual master axis phase and, based on this phase, analyzes the second-order geometric gradients of all driven actuators on the packaging production line on their respective electronic cam functions. These second-order geometric gradients characterize the instantaneous spatial acceleration requirements of the driven actuators at a specific phase. The main control unit iterates through the absolute values ​​of the second-order geometric gradients of all driven actuators and extracts the global maximum geometric gradient. Subsequently, the main control unit uses a preset inverse mapping logic to transform this global maximum geometric gradient into a dynamic bandwidth boundary value that limits the adjustment amplitude of the underlying clock frequency.

[0031] The main control unit performs a restricted time base reconstruction using the aforementioned slip characteristic energy value and dynamic bandwidth boundary value. The main control unit inputs the slip characteristic energy value as a feedforward error into the internally configured proportional-integral regulator to calculate the original frequency adjustment command. The main control unit determines whether this original frequency adjustment command exceeds the range of the aforementioned dynamic bandwidth boundary value. If it does, the main control unit uses the dynamic bandwidth boundary value as the final adjustment amount; if it does not exceed the range, the main control unit uses the original frequency adjustment command as the final adjustment amount. The main control unit subtracts this final adjustment amount from the rated reference clock frequency to generate the reconstructed real-time clock frequency.

[0032] The master control unit re-executes the integration calculation using the reconstructed real-time clock frequency, outputting a corrected virtual spindle phase that includes adjustments for material physical characteristics. The master control unit synchronously broadcasts this corrected virtual spindle phase to all slave axis servo drives via the industrial real-time communication bus. Each slave axis servo drive receives and parses the corrected virtual spindle phase while maintaining its original electronic cam function setting profile, calculates the updated position command, and drives the corresponding slave axis servo motor. All of the above processing steps are executed cyclically within each task scheduling cycle of the master control unit.

[0033] The main control unit is equipped with a hardware timer, which provides a time scale reference for the underlying system operation.

[0034] The main control unit defines the rated reference clock frequency during the initialization phase. The rated reference clock frequency The pulse firing rate corresponds to the ideal processing speed of the packaging production line. The current system running time is set to... Historical running time is The main control unit internally maintains a dynamic clock frequency. During the system initialization phase, if no reconfiguration command is received, the control program will dynamically adjust the clock frequency. The value is equal to the rated reference clock frequency. .

[0035] The underlying logic operation unit of the main control unit is configured to operate on a dynamic clock frequency. Perform continuous time integration operations to generate the current phase of the virtual principal axis. Its core integral model formula is: ; In the formula, Indicating a historical moment The system's dynamic clock frequency value; Indicates the system at the current moment The current phase of the virtual principal axis is calculated and accumulated.

[0036] In the specific execution process of the digital signal processor architecture, this time integration operation is implemented through the discrete accumulator module. The main control unit sets a predetermined underlying interpolation period. In each underlying interpolation cycle Inside, the discrete accumulator module extracts the current dynamic clock frequency value and compares it with the underlying interpolation period. The phase increment of the current cycle is obtained by multiplication, and this phase increment is added to the phase value of the previous cycle stored in the main control unit register, thereby outputting the discretized virtual spindle current phase. .

[0037] The main control unit's memory is pre-configured and stores information for the packaging production line. An array of electronic cam functions for a physical driven actuator. Define the first... The electronic cam function corresponding to each driven actuator is: ,in The value is a positive integer and Each electronic cam function Specifically, this manifests as a two-dimensional data table stored in a register, containing a set of discrete mapping points generated based on a fifth-order polynomial interpolation algorithm. This two-dimensional data table establishes a deterministic mathematical mapping relationship between the virtual principal axis phase value, which serves as the input independent variable, and the target displacement value of the driven actuator, which serves as the output dependent variable.

[0038] The application layer program of the main control unit is configured to read the current phase of the virtual spindle in the register in real time within the millisecond-level task cycle set by the main control unit. The main control unit will read Numerical input synchronized to all Electronic cam function In the middle, the first is calculated by looking up a table and interpolation. At the current moment, each active implementing agency The target position command obtained from the solution Its core mapping model formula is: ; In the formula, Indicates the first At the current moment, each active implementing agency The target position command obtained from the calculation; Indicates the first Pre-configured spatial motion trajectory mapping rules corresponding to each driven actuator.

[0039] By applying the above model and hardware scheduling, the control system uniformly binds the macroscopic spatial motion trajectories of each physically dispersed driven servo actuator to the current phase of the virtual spindle. The main control unit targets dynamic clock frequencies. A single-dimensional numerical change can be synchronously converted into a coordinated change instruction in the multi-dimensional spatial position of the actuators throughout the packaging production line through concurrent mapping of multiple sets of electronic cam functions, avoiding the need to send independent correction messages to each physical axis of the packaging production line.

[0040] The main traction servo drive is configured to operate under a field-oriented control architecture. The power module of the main traction servo drive is equipped with current sensing hardware, specifically a current transformer or a Hall effect sensor. This current sensing hardware is configured to continuously measure the three-phase AC current signal of the stator winding of the main traction servo motor within a set microsecond-level sampling period. The digital signal processor inside the main traction servo drive receives the three-phase AC current signal after processing by the analog-to-digital converter module and executes a coordinate transformation algorithm according to a fixed current loop operation cycle. This coordinate transformation algorithm sequentially includes a three-phase to two-phase orthogonal transformation in a stationary coordinate system and a two-phase orthogonal transformation in a rotating coordinate system, thereby decoupling the stator current into direct-axis excitation current and quadrature-axis torque current. The main traction servo drive continuously outputs this continuous sequence of quadrature-axis torque current. Because the rotor of the main traction servo motor has direct mechanical frictional contact with the surface of the flexible packaging material through the main drive roller mechanism, the aforementioned continuous sequence of cross-axis torque current... The linear representation is a comprehensive electromagnetic torque signal that includes changes in the microscopic sliding friction torque of the material.

[0041] The main traction servo drive transmits the continuous sequence of quadrature shaft torque current through the synchronous data transmission mechanism of the industrial real-time communication bus. The data is reported in real time to the data buffer of the main control unit. The main control unit has an independent digital signal processing process, which includes a digital bandpass filter module. The main control unit processes the continuous sequence of quadrature-axis torque current in the data buffer. Import the digital bandpass filter module according to the timing sequence for frequency domain filtering.

[0042] The digital bandpass filter module is configured with clearly defined lower and upper cutoff frequency parameters. The main control unit acquires the current operating speed of the main traction servo motor and calculates the fundamental rotational frequency and the operating frequency components of the associated macroscopic mechanical transmission components accordingly. The main control unit sets the lower cutoff frequency parameter of the digital bandpass filter module to a value greater than the aforementioned fundamental rotational frequency and mechanical operating frequency components to completely block the low-frequency current fundamental wave generated during normal operation of the main traction motor, as well as low-frequency disturbance signals caused by mechanical eccentricity and periodic load changes. Simultaneously, the main control unit sets the upper cutoff frequency parameter to a value less than the system Nyquist sampling frequency and avoids the frequency band where the driver inverter switching frequency is located, in order to filter out high-frequency electromagnetic interference noise.

[0043] After the above-mentioned digital bandpass filter module's truncation and pass-through processing, the main control unit extracts the high-frequency harmonic current sequence characterizing the microscopic stick-slip friction and high-frequency tension release features of the packaging material surface. .

[0044] To convert the high-frequency harmonic current sequence, which contains alternating positive and negative characteristics, into a stable system control feedforward variable, the main control unit is equipped with an integral calculation module based on a sliding time window mechanism. The main control unit sets a predetermined sliding time window length parameter. The integration module performs square integration on the values ​​of all high-frequency harmonic current sampling points within the sliding time window. Its continuous domain calculation model formula is as follows: ; In the formula, This indicates the absolute time length of the sliding time window set by the system. Representing historical moments Instantaneous amplitude of the high-frequency harmonic current sequence output by the digital bandpass filter; Indicates the computing system at the current moment Output slip characteristic energy value.

[0045] During the discretized digital computation execution process of the main control unit, this integral calculation module is implemented through an internally configured first-in-first-out (FIFO) queue data structure. After receiving the latest instantaneous amplitude of the high-frequency harmonic current in each calculation cycle, the main control unit calculates its square and pushes it onto the top of the FIFO queue, while simultaneously removing the bottom end of the queue that exceeds the sliding time window length parameter. The stale data. The main control unit then performs an accumulation operation on all valid squared values ​​retained in the queue, and the accumulated result is used as the slip characteristic energy value for the current calculation cycle. It is output and stored, and used as the physical excitation basis for subsequent timing reconstruction.

[0046] This invention provides a bandwidth dynamic constraint method based on cam geometric gradient, which is executed by a constraint calculation unit configured inside the main control unit and configured to limit the rate of change of the underlying clock frequency in real time according to the spatial kinematic state of the entire driven shaft.

[0047] The constraint calculation unit of the main control unit extracts the current virtual spindle phase in each control cycle. Since the spatial position of each slave axis in a multi-axis electronic cam system is directly driven by the phase of the virtual master axis, the dynamic clock frequency of the underlying phase-locked loop is... When performing reconstruction adjustments, it is equivalent to changing the phase of the virtual principal axis on the time axis. The propulsion speed will then introduce additional spatial acceleration to the physical driven axis. If the electronic cam trajectory of a certain driven actuator is currently in a high acceleration range, the sudden change in the time base will cause the composite output torque of the driven axis servo motor to exceed its physical limit, resulting in increased following error or resonance in the transmission system.

[0048] To quantify the physical sensitivity of each processing station to time base fluctuations, the constraint computing unit calculates the first... Each driven actuator in the current virtual spindle phase The second-order geometric gradient below The second-order geometric gradient represents the second derivative of the target position relative to the principal axis phase, i.e., the space mechanical acceleration requirement per unit phase displacement. Its core calculation model formula is: ; In the formula, This represents the channel index number of the driven actuator, which is a positive integer. ; This represents the intermediate phase variable used for differentiation in spatial geometry; Indicates the first Pre-configured electronic cam function relationships corresponding to each driven actuator; Indicates the first At the current moment, each active implementing agency The second-order geometric gradient obtained through calculation.

[0049] During the execution of the digital program in the main control unit, the second-order geometric gradient... The acquisition is achieved using discrete data retrieval and linear interpolation algorithms. During the initialization phase before system startup, the main control unit pre-configures the electronic cam functions of each driven actuator. The spatial second-order difference calculation is performed at equal intervals along the complete virtual spindle main cycle, generating a corresponding discrete second-order geometric gradient mapping table and storing it in the cache of the main control unit. During production line operation, the constraint calculation unit uses the current virtual spindle phase... Using the baseline index value, the above discrete second-order geometric gradient mapping table is directly retrieved, and the current second-order geometric gradient is output using the two-point linear interpolation formula. .

[0050] Get all After obtaining the second-order geometric gradient values ​​for each driven actuator, the master control unit performs a global scan operation. The constraint calculation unit internally contains a traversal comparison logic unit that performs a comparison of the acquired second-order geometric gradient values ​​within each control cycle. The array is subjected to absolute value transformation sequentially, and the absolute value of the global maximum geometric gradient is extracted by the maximum value search operator. Its core mapping model formula is: ; In the formula, This represents the function for extracting the maximum value.

[0051] The main control unit is based on the extracted absolute value of the global maximum geometric gradient. The allowable modulation bandwidth boundary of the time-based phase-locked loop in the current control cycle is calculated using a dynamic constraint mapping function. Modulation bandwidth boundary The numerical value and the absolute value of the global maximum geometric gradient The relationship is inversely proportional, and its core mathematical model formula is: ; In the formula, This represents the system's preset bandwidth gain coefficient, used to adjust the overall sensitivity of the constraint mechanism to changes in spatial acceleration. This represents a preset positive bias constant, configured to prevent the denominator from being zero and to determine the upper limit of the maximum release bandwidth of the system in the completely uniform speed range.

[0052] When a high-inertia mechanical shaft on the packaging production line moves to a sudden acceleration or deceleration segment of the electronic cam curve, the absolute value of the second-order geometric gradient of that shaft... Increasing this value leads to the global maximum absolute value of the geometric gradient. The amplitude increases synchronously. At this point, based on the aforementioned inverse proportional mapping formula, the modulation bandwidth boundary of the output is calculated. Automatic tightening limits the single-adjustment saturation amplitude of the underlying time base reconstruction during the macroscopic high spatial acceleration segment. Conversely, when all stations along the entire line are in a stable, uniform speed segment, Approaching zero, modulation bandwidth boundary Automatic expansion and release of the modulation bandwidth of the time-locked loop allow the system to eliminate the accumulation of micro-slip in the material with a high response rate. The calculated modulation bandwidth boundary... It will be directly latched and output as the dynamic cutoff threshold of the time base reconstruction limiting module.

[0053] This invention provides a method for constrained time-base phase-locked loop (PLL) and full-line synchronization, which is jointly executed by the PLL module at the bottom layer of the main control unit and the bus communication unit.

[0054] The main control unit will use the aforementioned calculated slip characteristic energy values. This serves as the dynamic feedforward error input for the time-locked loop (TLL) module. The TLL module internally incorporates a proportional-integral (PI) controller with an anti-saturation mechanism. This PLI controller is configured to convert the microscopic slip physical characteristics of the flexible packaging material into a correction component for the underlying time elapsed velocity of the controller.

[0055] The main control unit first uses a proportional-integral controller to calculate the original frequency adjustment amount without amplitude limiting constraints. Its continuous domain control model formula is: ; In the formula, Indicates the current time Input slip feature energy value; Representing historical moments The characteristic energy value of slip; This represents the preset proportional gain coefficient; This represents the preset integral gain coefficient; This represents the preset anti-saturation feedback gain coefficient; Representing historical moments The final frequency adjustment amount of the output; Representing historical moments The calculated original frequency adjustment amount; Indicates the current time The original frequency adjustment amount of the output.

[0056] In the specific discretization process of the digital signal processor, the above control model is converted into a discrete recursive algorithm. The main control unit sets the current control cycle number to be... The discrete sampled values ​​of the slip characteristic energy are expressed as follows: The main control unit performs each underlying interpolation cycle. Within, the saturation deviation of the previous cycle will be... Multiply by the anti-saturation feedback gain coefficient and the increment of the current integral term. The algebraic sum is then added, and the result is accumulated in the integral status register to update the discrete integral term, thereby preventing deep saturation of the integrator when the limit is triggered.

[0057] The main control unit then calls the amplitude limiting and saturation calculation unit, introducing the dynamic modulation bandwidth boundary obtained from the aforementioned steps. The calculated original frequency adjustment amount Perform nonlinear limiting and truncation processing to output the final frequency adjustment amount. The mathematical formula for its amplitude-limited saturation model is: ; In the formula, Indicates the current time The original frequency adjustment amount of the output; Indicates the current time The final frequency adjustment amount of the output. Indicates the current time The output is the original frequency adjustment amount. This limiting saturation model ensures that when the clock frequency is adjusted, the magnitude of a single adjustment will not exceed the dynamic safety boundary defined by the mechanical space acceleration limit.

[0058] The main control unit obtains the current time. Final frequency adjustment of the output Then, the parameters of the underlying system clock generator are directly modified to reconstruct the dynamic clock frequency of the virtual spindle. The reconstruction calculation formula is as follows: ; In the formula, This indicates the rated reference clock frequency. When the slip energy of the packaging material increases... It is a positive value. The value is lower than the rated reference clock frequency. This causes the clock tick of the virtual spindle to slow down monotonically.

[0059] The discrete accumulator module of the main control unit acquires the reconstructed dynamic clock frequency. Then, discrete integral propagation is performed to generate the updated virtual principal axis current phase. .

[0060] The entire synchronous actuator implements a phase broadcasting mechanism for isochronous synchronization via a bus communication unit. The bus communication unit updates the current phase of the virtual spindle. The process data object message is encapsulated within the industrial real-time communication bus. Triggered by a bus synchronization interrupt signal, the main control unit concurrently sends this process data object message to all distributed film delivery servo drives, filling servo drives, and sealing servo drives.

[0061] Each physical slave axis servo driver receives the unified virtual master axis current phase at the same communication clock node. Signals. The microprocessor inside each servo driver directly processes the received signals. The numerical values ​​are input into the respective pre-stored two-dimensional data tables of the electronic cam functions to perform local interpolation calculations, thereby determining the target position command that each physical slave axis should currently reach. .

[0062] The film feeding servo motor, filling servo motor, and sealing servo motor operate according to the aforementioned target position commands. It executes a three-loop closed-loop control system consisting of a current loop, a speed loop, and a position loop. Since all stations on the entire line share the same reconstructed virtual spindle phase reference, the dynamic clock frequency... During the adjustment period, the mechanical movements of each processing station generate a proportional, smooth, monotonic delay on the time axis, thereby achieving adaptive position alignment to the physical slip disturbance of the material without changing the constraints of the relative positional relationship in the mechanical space.

[0063] This invention provides a time-adaptive response method for a packaging production line operating at a constant speed and experiencing a sudden slippage. This method is executed during specific spatial phases when each processing station on the production line is in a state of low acceleration or constant speed transmission.

[0064] In the initial stage of stable operation of the packaging production line, the flexible packaging material is smoothly conveyed at a set speed under the drive of the main traction servo actuator. At this time, the film feeding servo actuator, filling servo actuator, and sealing and cutting servo actuator distributed throughout the line are all in the linear segment or smooth transition segment of their respective electronic cam functions. The constraint calculation unit extracts the second-order geometric gradient of each driven actuator in real time under the current virtual master axis phase. Since each driven axis is in the low spatial acceleration trajectory segment, the absolute value of the calculated second-order geometric gradient of each axis remains at a low baseline value.

[0065] The traversal comparison logic unit performs maximum filtering on the aforementioned array of second-order geometric gradient absolute values, and the output global maximum geometric gradient absolute value also remains at a low level close to zero. The main control unit inputs this low-order global maximum geometric gradient absolute value into the dynamic constraint mapping function. Due to the extremely small value of the independent variable, the modulation bandwidth boundary output by the inverse proportional mapping solution automatically expands to the maximum allowable safety threshold set by the system. This state indicates that the current mechanical spatial motion state of all driven axes has a very high tolerance for changes in the underlying time axis, allowing the time-based phase-locked loop module to release the maximum adjustment bandwidth.

[0066] Under this stable operating condition, if a sudden local slippage occurs between the flexible packaging material and the main traction roller mechanism due to a sudden change in the local surface friction coefficient or transient tension fluctuation, the actual displacement of the flexible packaging material will lag behind the rotor encoder position of the main traction motor in physical space. The microscopic stick-slip friction energy generated by the slippage is transmitted in reverse through the drive shaft to the output end of the main traction servo motor, causing high-frequency transient micro-disturbance fluctuations in the continuous sequence of stator quadrature shaft torque current.

[0067] The main control unit's data buffer receives and stores the aforementioned continuous sequence of quadrature-axis torque currents containing micro-perturbations in real time. The digital bandpass filter module immediately performs frequency domain interception on this sequence, filtering out conventional low-frequency load fluctuations and separating the high-frequency harmonic current sequence. Within the current task cycle, the integration calculation module squares and accumulates the high-frequency harmonic current sampling points falling within the sliding time window, causing the output slip characteristic energy value to increase abruptly from the near-zero physical baseline.

[0068] The time-base phase-locked loop (PLL) module directly inputs the sharply rising slip characteristic energy value as a feedforward error into the proportional-integral (PI) controller. The PLI controller performs discrete recursive calculations to determine the larger original frequency adjustment value. The amplitude limiting and saturation calculation unit then introduces the modulation bandwidth boundary, latched within the maximum permissible safety threshold during the current control cycle, to perform boundary condition determination on this original frequency adjustment value.

[0069] Since the entire workstation is currently in a low geometric gradient region, the modulation bandwidth boundary is open, and the amplitude limiting and saturation operation unit determines that the original frequency adjustment amount does not exceed the current modulation bandwidth boundary threshold. Therefore, the amplitude limiting and saturation operation unit outputs the full value of the original frequency adjustment amount as the final frequency adjustment amount, without performing a truncation or attenuation operation. This ensures that slippage disturbances in the physical layer can be propagated to the time reconstruction core without attenuation.

[0070] The clock generator module of the main control unit immediately performs a reconstruction calculation, subtracting the final frequency adjustment amount from the rated reference clock frequency in full, causing the real-time dynamic clock frequency to rapidly decrease within the current microsecond-level interrupt cycle. The discrete accumulator module performs phase integration based on the slowed real-time dynamic clock frequency, resulting in a monotonically shrinking advance step size of the current phase of the virtual spindle output within the current interpolation cycle, thus achieving a transient slowdown of the underlying time axis elapsed speed.

[0071] The bus communication unit encapsulates the lagging virtual spindle current phase into a synchronous communication message and broadcasts it concurrently to the film delivery servo driver, filling servo driver, and sealing servo driver via the industrial real-time communication bus. Each servo driver uses the received virtual spindle current phase, which includes the time lag, to re-retrieve its respective two-dimensional data table of spatial electronic cam functions.

[0072] Because all slave axes share the same reconstructed virtual master axis current phase, the target position commands resolved by the servo motors at each station automatically and synchronously generate a smooth delay of the same proportion on the time axis. This delay precisely aligns with the actual position lag caused by slippage of the flexible packaging material at the physical level. Through this rapid reconstruction of the underlying time base, the entire line of driven actuators achieves adaptive synchronous absorption of sudden slippage disturbances without altering the macroscopic spatial trajectory morphology or triggering drastic acceleration corrections on independent axes. As slippage ends, the high-frequency current returns to normal, the slip characteristic energy value decays to zero, and the real-time dynamic clock frequency smoothly recovers to the rated reference clock frequency.

[0073] This embodiment describes a specific implementation of an anti-resonance protection mechanism, which is executed when a specific high-inertia driven actuator on the production line is in a high spatial acceleration trajectory segment and is simultaneously accompanied by physical layer micro-disturbances.

[0074] During specific periods of a continuous production cycle, high-inertia driven actuators configured within the packaging production line, such as the sealing and cutting servo actuator group, enter rapid acceleration or deceleration zones in the pre-configured electronic cam function. The constraint calculation unit within the main control unit reads the current phase of the virtual spindle within the current task scheduling cycle and performs synchronous calculations of the second-order geometric gradients for each driven actuator distributed throughout the line. The calculation results show that, due to being in the curvature abrupt change zone of the spatial trajectory, the absolute value of the second-order geometric gradient at the corresponding phase of the sealing and cutting servo actuator group exhibits a significant peak state.

[0075] The traversal comparison logic unit inside the main control unit compares and checks all the calculated absolute values ​​of the second-order geometric gradients, extracts the absolute value of the second-order geometric gradient of the cutting axis that exhibits a peak state, and uses it as the global maximum absolute value of the geometric gradient at the current moment. The main control unit inputs this global maximum absolute value of the geometric gradient, which is in a high-order position, into the dynamic constraint mapping function. According to the inverse proportional mapping rule, the modulation bandwidth boundary of the system's calculated output is forcibly compressed to a narrow numerical range. This narrow numerical range establishes a strict safety limit threshold for the adjustment of the system's underlying clock frequency within the current control cycle.

[0076] Under conditions of strictly limited timing adjustment bandwidth, if the flexible packaging material experiences transient micro-slippage or abnormal tension release at the main traction roller mechanism, the current sampling circuit and bandpass filter module of the main traction servo drive will extract the high-frequency harmonic sequence from the quadrature-axis torque current. The integral calculation module of the main control unit will then perform a square accumulation operation on the high-frequency harmonic sequence within the slip time window, outputting a continuously increasing slip characteristic energy value.

[0077] The proportional-integral regulator inside the main control unit receives the rising slip characteristic energy value as the feedforward error input and generates a relatively large original frequency adjustment value through a discrete recursive algorithm. Subsequently, the main control unit calls the amplitude limiting and saturation arithmetic unit to perform boundary condition determination on the original frequency adjustment value. Since the current modulation bandwidth boundary has been significantly compressed, the amplitude limiting and saturation arithmetic unit determines that the absolute value of the original frequency adjustment value exceeds the upper limit of the current modulation bandwidth boundary.

[0078] Upon triggering the over-limit judgment, the limiting saturation operation unit performs a nonlinear truncation operation, discarding the excess value in the original frequency adjustment and forcing the compressed modulation bandwidth boundary value to be output as the final frequency adjustment. Simultaneously, the anti-saturation feedback loop configured inside the proportional-integral controller is activated. The main control unit multiplies the saturation deviation generated before and after limiting by a preset feedback gain to generate a reverse compensation value, which is then injected into the accumulation register of the discrete integrator. This reverse compensation operation suppresses the continuous blind accumulation of the integral term during limiting, preventing excessive overshoot of the clock frequency response when the system exits the slippage state.

[0079] The main control unit reconstructs the clock generator parameters based on the truncated final frequency adjustment. At this point, the real-time dynamic clock frequency changes gradually with a limited down-adjustment rate. Consequently, the hysteresis advance slope of the current phase of the virtual spindle is strictly controlled to ensure that it does not exceed the mechanical dynamic response limit that the sealing servo actuator can withstand.

[0080] When the sealing and cutting servo drive receives the current phase of the smoothly delayed virtual spindle and uses it to generate the target position command by parsing the two-dimensional data table, the combined additional acceleration caused by the change in the underlying time base on the sealing and cutting servo motor rotor is effectively limited. While maintaining high spatial acceleration tracking in the macroscopic sense, the electromagnetic torque output of the sealing and cutting servo motor remains within the physical limit threshold. Through the above nonlinear constraints and execution process, the control system cuts off the transmission path from abrupt changes in the time domain to high-frequency vibrations in the spatial domain, limits the resonance and position loss of high-inertia mechanical actuators caused by drastic time base reconstruction, and gradually eliminates the microscopic slip accumulation error of the flexible packaging material within the extended adjustment period.

[0081] See attached document Figure 2 This invention provides an intelligent timing control system for a packaging production line, which is applied in a hardware architecture that includes a main control unit and multiple sets of servo actuators. The system may include: a benchmark construction unit, a feature extraction unit, a constraint calculation unit, a time base reconstruction unit, and a synchronous execution unit.

[0082] The reference construction unit is configured to establish a basic mapping relationship between time variables and the spatial coordinate system in the main control unit's memory. The reference construction unit includes a discrete accumulator submodule and a two-dimensional data table storage area. The discrete accumulator submodule is configured to continuously perform integral accumulation operations with a set rated reference clock frequency as the initial input parameter, according to the microsecond-level interpolation period allocated by the underlying hardware timer, continuously outputting a monotonically increasing current phase of the virtual master axis. The two-dimensional data table storage area is configured to store multiple sets of discrete coordinates of the electronic cam generated based on polynomial interpolation. The input parameters of this discrete coordinate set are linked to the current phase of the virtual master axis, and the output parameters are linked to the target displacement of each driven actuator, establishing a deterministic mathematical correspondence between time and space.

[0083] The feature extraction unit is configured to extract and isolate physical feature values ​​representing the microscopic sliding displacement of materials from the underlying operating electrical data of the main traction servo actuator. The feature extraction unit includes a data receiving interface, a digital bandpass filter, and a sliding integrator. The data receiving interface is configured to read the continuous sequence of stator quadrature-axis torque current of the main traction servo motor from the industrial real-time communication bus at a fixed communication cycle. The digital bandpass filter is configured to truncate the sequence in the frequency domain with a set cutoff frequency parameter, blocking low-frequency current fundamental waves below the mechanical operating fundamental frequency and filtering high-frequency noise above the Nyquist sampling frequency, outputting high-frequency harmonic current components. The sliding integrator is configured to perform continuous square accumulation operations on the high-frequency harmonic current components within a set sliding time window length to generate slip characteristic energy values.

[0084] The constraint calculation unit is configured to calculate the safety boundary values ​​for the underlying time axis adjustment based on the real-time spatial following state of all driven actuators on the packaging production line. The constraint calculation unit includes a differential calculator, a traversal logic unit, and a boundary mapper. The differential calculator is configured to read the current phase of the virtual master axis output by the baseline construction unit and perform second-order spatial differentiation calculations on the discrete coordinate set of the electronic cams corresponding to each driven actuator, outputting the absolute value of the second-order geometric gradient of each driven actuator in the current phase. The traversal logic unit is configured to compare all calculated absolute values ​​of the second-order geometric gradient within the current control cycle and extract the global maximum absolute value of the geometric gradient. The boundary mapper is configured to convert this global maximum absolute value of the geometric gradient into the modulation bandwidth boundary value of the time-based phase-locked loop module in the current cycle according to a set inverse proportional mapping function. When the spatial second-order geometric gradient increases, the boundary mapper reduces the modulation bandwidth boundary value in an inverse proportional relationship.

[0085] The time base reconstruction unit is configured to modify the parameters of the underlying clock generator of the main control unit based on the extracted slip characteristic energy value and the calculated modulation bandwidth boundary value. The time base reconstruction unit includes a proportional-integral (PI) regulator, a limiting saturator, and a clock modification register. The PI regulator receives the slip characteristic energy value as a feedforward error variable and outputs the unlimited original frequency adjustment amount after discrete recursive calculation. The limiting saturator is configured to determine whether the original frequency adjustment amount exceeds the modulation bandwidth boundary value. If it exceeds the limit, it performs a nonlinear truncation operation, outputs a final frequency adjustment amount equal to the boundary threshold, and feeds back the saturation difference generated by the truncation to the accumulator of the PI regulator to suppress integral accumulation. The clock modification register is configured to subtract the final frequency adjustment amount from the system-set rated reference clock frequency, output the reconstructed real-time dynamic clock frequency, and feed back this real-time dynamic clock frequency to the discrete accumulator submodule of the reference construction unit as the integral step size parameter for subsequent calculations.

[0086] The synchronous execution unit is configured to convert the reconstructed time base into spatial displacement distribution commands for each physical node and drive the mechanical mechanism. The synchronous execution unit relies on the bus communication interface of the underlying hardware and the microprocessors inside the servo drives distributed at each mechanical station. The bus communication interface is configured to encapsulate the current phase of the virtual spindle, obtained by the reference construction unit based on the integration of the real-time dynamic clock frequency, into a process data object and concurrently broadcast it to all slave axis servo drives in the entire line at each network synchronization interruption. The microprocessor within each slave axis servo drive is configured to directly extract this unified current phase of the virtual spindle and perform interpolation retrieval in its locally stored two-dimensional data table to calculate the target position command corresponding to the current moment. Each slave axis servo drive drives the corresponding physical motor to perform closed-loop position following according to the target position command, enabling all mechanical nodes in the line to synchronously generate adaptive position delay compensation introduced by changes in the real-time dynamic clock frequency in the time dimension, while maintaining the original macroscopic relative spatial position topology.

[0087] Specific application examples: This specific application example utilizes a continuous high-speed pillow packaging machine for deployment and verification. The machine's mechanical transmission system is configured with a hardware architecture comprising three physical execution nodes: a main traction servo execution group (corresponding to the film feeding roller), a film feeding servo execution group (corresponding to the center sealing mechanism), and a sealing and cutting servo execution group (corresponding to the end-sealing rotary cutter). The main control unit sets the system's rated reference clock frequency. The operating frequency is 10000Hz, and the basic operating speed of the packaging production line is set to 300 packages / minute. The sealing and cutting servo actuator has a large inertia, and its corresponding electronic cam function has a large spatial curvature change (i.e., a rapid acceleration and deceleration section) at the moment of end sealing and cutting.

[0088] In the experimental verification process, the production line was set to operate on a time scale. At that time, a sudden physical slippage disturbance occurred at the main traction roller due to uneven thickness of the flexible packaging material in certain areas. Simultaneously, to During this period, the mechanical operation phase of the sealing and cutting servo actuator group just entered the rapid acceleration zone of the electronic cam.

[0089] The main traction servo drive continuously acquires quadrature shaft torque current and outputs a high-frequency harmonic current sequence after passing through a digital bandpass filter. The integral calculation module of the main control unit extracts the slip characteristic energy value using the following formula: ; The experimental data acquisition system recorded that, back, The value of [something] increases dramatically. Simultaneously, the constraint calculation unit of the main control unit extracts the second-order geometric gradient of the sealing and cutting servo execution group in real time. Since the sealing and cutting blade is in a rapid acceleration zone at this time, the extracted absolute value of the global maximum geometric gradient [is...]. The peak value is displayed. The boundary mapper outputs the forced compression modulation bandwidth boundary according to the following formula: ; In the time base reconstruction stage, the original frequency adjustment amount calculated by the proportional-integral regulator. The absolute value increases rapidly. The amplitude limiting saturation arithmetic unit performs boundary condition determination and outputs the final frequency adjustment amount according to the following formula. : ; Because at this time The original frequency adjustment is severely compressed and non-linearly truncated. The main control unit reconstructs the clock generator parameters according to the following formula: ; Attached Figures and Comparative Analysis of Effects See attached document Figure 3 , Figure 3 The differences in dynamic response between traditional unconstrained compensation methods and the intelligent timing control method proposed in this invention when encountering the same material slippage disturbance are demonstrated.

[0090] Figure 3 It contains three sub-charts from top to bottom: The first subplot represents the disturbance input and boundary constraint state. The solid line represents the slip characteristic energy value. The time evolution trajectory shows a rapid increase at 1.5s, reflecting the cumulative process of material physical slippage. The dashed line represents the modulation bandwidth boundary calculated by the system of this invention. Because the servo execution group enters the rapid acceleration zone between 1.5s and 1.8s, the modulation bandwidth boundary... A concave contraction occurs, establishing a strict time-adjustment threshold.

[0091] The second sub-chart represents the reconstructed real-time dynamic clock frequency. Trajectory. Traditional methods (represented by dashed lines) lack spatial geometric gradient constraints, resulting in a steep, precipitous drop in clock frequency after sensing an increase in slip energy, in an attempt to quickly eliminate material slip deviation. The method of this invention (represented by solid lines), constrained by compressed modulation bandwidth boundaries, exhibits a smooth, limited, monotonically decreasing trend in its real-time dynamic clock frequency, with a limited amplitude for each adjustment.

[0092] The third sub-chart characterizes the electromagnetic torque output response of the sealing and cutting servo motor. The system sets the physical saturation limit of the electromagnetic torque to 300% of the rated torque (marked by a horizontal dotted line). Traditional methods (represented by dashed lines) introduce significant additional spatial acceleration during the rapid acceleration phase of the sealing and cutting blade due to a precipitous drop in clock frequency. This causes the servo motor's electromagnetic torque to momentarily exceed the 300% physical saturation limit, resulting in severe current cutoff, mechanical resonance, and positional loss. The method of this invention (represented by solid lines) effectively cuts off the transmission of abrupt changes in the time axis to the spatial domain. The peak torque output of the sealing and cutting servo motor is safely suppressed to approximately 220%, ensuring the smooth operation of high-inertia mechanical components. Simultaneously, it absorbs the physical slippage of the material within a slightly extended adjustment period (around 2.5s).

Claims

1. An intelligent timing control method for a packaging production line, characterized in that, Includes the following steps: The current phase of the virtual spindle is constructed based on the rated reference clock frequency, and the current phase of the virtual spindle is mapped to the target position commands of multiple driven actuators. Obtain the continuous sequence of cross-axis torque current of the main traction servo actuator, and extract the slip characteristic energy value that characterizes the degree of material physical slip accumulation from it; The step of calculating the second-order geometric gradient of each of the driven actuators under the current phase of the virtual master axis, and generating the modulation bandwidth boundary accordingly, includes: The second-order geometric gradient represents the second derivative of the target position on the axis with respect to the phase of the principal axis; The second-order geometric gradient of each of the driven actuators under the current phase of the virtual spindle is calculated using a pre-configured electronic cam function; Compare the absolute values ​​of all the second-order geometric gradients and extract the absolute value of the global maximum geometric gradient. The absolute value of the global maximum geometric gradient is calculated using an inverse proportional mapping relationship to generate the modulation bandwidth boundary. The core mathematical model formula for the inverse proportional mapping relationship is: ； In the formula, For the modulation bandwidth boundary, It is the absolute value of the global maximum geometric gradient. This represents the system's preset bandwidth gain coefficient, used to adjust the overall sensitivity of the constraint mechanism to changes in spatial acceleration. This represents a preset positive bias constant, configured to prevent the denominator from being zero and to determine the upper limit of the maximum release bandwidth of the system in the completely uniform speed segment; The step of calculating the second-order geometric gradient of each of the driven actuators under the current phase of the virtual master axis using a preset electronic cam function includes: Beforehand, equal-interval spatial second-order difference calculations are performed on each of the aforementioned electronic cam functions to generate a discrete second-order geometric gradient mapping table; Using the current phase of the virtual principal axis as the reference index value, the discrete second-order geometric gradient mapping table is retrieved, and the current second-order geometric gradient is output using a two-point linear interpolation formula. The step of obtaining the continuous sequence of cross-axis torque current of the main traction servo actuator and extracting the slip characteristic energy value characterizing the degree of material physical slip accumulation includes: Obtain the continuous sequence of quadrature-axis torque current of the main traction servo motor in the main traction servo execution group; The frequency domain filtering process of the continuous sequence of quadrature axis torque current is performed by a digital bandpass filter module to isolate the high-frequency harmonic current sequence. Perform a square integral operation on the instantaneous amplitude of the high-frequency harmonic current sequence within the set sliding time window length to generate the slip characteristic energy value; The steps of calculating the original frequency adjustment based on the slip characteristic energy value, limiting the original frequency adjustment using the modulation bandwidth boundary to output the final frequency adjustment, and reconstructing the real-time dynamic clock frequency include: The slip characteristic energy value is used as a feedforward error input to the proportional-integral controller to calculate the original frequency adjustment amount; When the absolute value of the original frequency adjustment is greater than the modulation bandwidth boundary, the final frequency adjustment is forced to be equal to the value of the modulation bandwidth boundary. When the absolute value of the original frequency adjustment is not greater than the modulation bandwidth boundary, the final frequency adjustment is equal to the original frequency adjustment. The real-time dynamic clock frequency is reconstructed by subtracting the final frequency adjustment from the rated reference clock frequency. The current phase of the virtual spindle is updated according to the real-time dynamic clock frequency, and synchronized to each of the driven actuators to calculate the updated target position command.

2. The intelligent timing control method for a packaging production line according to claim 1, characterized in that, When determining that the absolute value of the original frequency adjustment amount is greater than the modulation bandwidth boundary, the method further includes: Calculate the difference between the original frequency adjustment and the final frequency adjustment to generate the saturation deviation. The saturation deviation is multiplied by a preset anti-saturation feedback gain coefficient to generate a reverse compensation value. The reverse compensation value is accumulated into the integral state register inside the proportional-integral regulator to suppress deep saturation when the limit is triggered.

3. The intelligent timing control method for a packaging production line according to claim 1, characterized in that, The steps of updating the current phase of the virtual spindle according to the real-time dynamic clock frequency and synchronizing it to each of the driven actuators to calculate the updated target position command include: The phase increment is obtained by multiplying the underlying interpolation period by the real-time dynamic clock frequency, and the phase increment is accumulated to generate the updated current phase of the virtual spindle; The updated current phase of the virtual spindle is encapsulated in a process data object message and, triggered by a synchronous interrupt signal, is concurrently broadcast to the servo drivers of each of the driven actuators via the industrial real-time communication bus. Each of the servo drives reads the current phase of the received virtual spindle and performs interpolation calculations in a locally stored two-dimensional data table to calculate the updated target position command.

4. The intelligent timing control method for a packaging production line according to claim 1, characterized in that, When any of the driven actuators enters the rapid acceleration or deceleration section of the electronic cam function, the extracted absolute value of the global maximum geometric gradient increases synchronously, and the modulation bandwidth boundary calculated and output by the core mathematical model formula of the inverse mapping relationship is forcibly compressed. After the modulation bandwidth boundary is compressed, the single adjustment saturation amplitude of the reconstructed real-time dynamic clock frequency is limited, which is used to limit the abrupt change in the underlying time axis that could cause resonance in high-inertia mechanical actuators.

5. The intelligent timing control method for a packaging production line according to claim 1, characterized in that, The step of obtaining the continuous sequence of quadrature-axis torque current of the main traction servo motor in the main traction servo execution group includes: Within the set microsecond-level sampling period, the three-phase AC current signal of the stator winding of the main traction servo motor is continuously measured. The three-phase AC current signal is subjected to a three-phase to two-phase orthogonal transformation in a stationary coordinate system and a two-phase orthogonal transformation in a rotating coordinate system in sequence, and the continuous sequence of quadrature-axis torque current is decoupled and output.

6. An intelligent timing control system for a packaging production line, characterized in that, The intelligent timing control method applied to a packaging production line as described in any one of claims 1-5 includes: A reference construction unit is used to construct the current phase of a virtual spindle based on a rated reference clock frequency, and to map the current phase of the virtual spindle into target position commands for multiple driven actuators. The feature extraction unit is used to obtain the continuous sequence of cross-axis torque current of the main traction servo actuator and extract the slip characteristic energy value that characterizes the degree of material physical slip accumulation. Specifically, the feature extraction unit is used to perform the following operations: Obtain the continuous sequence of quadrature-axis torque current of the main traction servo motor in the main traction servo execution group; The frequency domain filtering process of the continuous sequence of quadrature axis torque current is performed by a digital bandpass filter module to isolate the high-frequency harmonic current sequence. Perform a square integral operation on the instantaneous amplitude of the high-frequency harmonic current sequence within the set sliding time window length to generate the slip characteristic energy value; The constraint calculation unit is used to calculate the second-order geometric gradient of each of the driven actuators under the current phase of the virtual master axis, and generate the modulation bandwidth boundary accordingly. The second-order geometric gradient represents the second derivative of the target position on the axis with respect to the phase of the principal axis; The constraint calculation unit is specifically used to perform the following operations: The second-order geometric gradient of each of the driven actuators under the current phase of the virtual master axis is calculated using a pre-configured electronic cam function, specifically including: Beforehand, equal-interval spatial second-order difference calculations are performed on each of the aforementioned electronic cam functions to generate a discrete second-order geometric gradient mapping table; Using the current phase of the virtual principal axis as the reference index value, the discrete second-order geometric gradient mapping table is retrieved, and the current second-order geometric gradient is output using a two-point linear interpolation formula. Compare the absolute values ​​of all the second-order geometric gradients and extract the absolute value of the global maximum geometric gradient. The absolute value of the global maximum geometric gradient is calculated using an inverse proportional mapping relationship to generate the modulation bandwidth boundary. The core mathematical model formula for the inverse proportional mapping relationship is: ； In the formula, For the modulation bandwidth boundary, It is the absolute value of the global maximum geometric gradient. This represents the system's preset bandwidth gain coefficient, used to adjust the overall sensitivity of the constraint mechanism to changes in spatial acceleration. This represents a preset positive bias constant, configured to prevent the denominator from being zero and to determine the upper limit of the maximum release bandwidth of the system in the completely uniform speed segment; The time base reconstruction unit is used to calculate the original frequency adjustment amount based on the slip characteristic energy value, limit the original frequency adjustment amount using the modulation bandwidth boundary to output the final frequency adjustment amount, and reconstruct the real-time dynamic clock frequency. Specifically, the time base reconstruction unit is used to perform the following operations: The slip characteristic energy value is used as a feedforward error input to the proportional-integral controller to calculate the original frequency adjustment amount; When the absolute value of the original frequency adjustment is greater than the modulation bandwidth boundary, the final frequency adjustment is forced to be equal to the value of the modulation bandwidth boundary. When the absolute value of the original frequency adjustment is not greater than the modulation bandwidth boundary, the final frequency adjustment is equal to the original frequency adjustment. The real-time dynamic clock frequency is reconstructed by subtracting the final frequency adjustment from the rated reference clock frequency. The synchronous execution unit is used to update the current phase of the virtual spindle according to the real-time dynamic clock frequency, and synchronize it to each of the slave actuators to solve the updated target position command.

Images