A multi-station intelligent production control system for conductive slip rings

Abstract

This invention relates to the field of conductive slip ring processing control technology, and discloses a multi-station intelligent production control system for conductive slip rings, including a servo pressing device, a multi-temperature zone curing device, an electrical performance testing device, a conveying mechanism, a material carrier, and a main control unit. The main control unit acquires temporal mechanical and displacement signals during the pressing stage and synthesizes a predicted deformation vector; it acquires temporal dielectric coupling impedance signals during the curing stage to determine the gel characteristic moment and compensation time window, calculates the target temperature for each temperature zone based on the predicted deformation vector, and outputs temperature distribution control commands; it acquires temporal dynamic contact resistance signals during the testing stage and extracts harmonic characteristics, performing thermal compensation response model identification and parameter correction. Through this invention, a feedforward compensation and closed-loop control mechanism is established between the pressing, curing, and testing processes, compensating for deformation caused by mechanical residual stress and reducing contact resistance fluctuations in the finished conductive slip ring.

Description

Technical Field

[0001] This invention relates to the field of conductive slip ring processing control technology, specifically to an intelligent production control system for multi-station processing of conductive slip rings. Background Technology

[0002] A conductive slip ring is an electromechanical component that enables power and signal transmission between two relatively rotating mechanisms and is widely used in various rotating equipment. The manufacturing process of a conductive slip ring typically involves multiple steps, including mechanical pressing of metal parts, heating and curing of insulating potting materials, and final electrical performance testing. To ensure the stability of signal transmission during rotating operation, the assembly precision and structural stability of its internal components are crucial. The coordinated control of multiple processes during manufacturing directly affects the final electrical performance indicators of the finished product.

[0003] In existing production control systems for multi-station machining processes, the pressing and curing processes are typically controlled as independent steps. During the mechanical pressing process, due to limitations in part tolerances and assembly deviations, unevenly distributed asymmetric mechanical residual stresses are generated within the conductive slip ring. When the product enters the curing process and is heated, the previously accumulated mechanical residual stresses are released and cause structural deformation as the rheological state of the polymer material changes. Current curing processes generally use a uniform reference temperature for global heating, lacking feedforward intervention methods to address the residual stress distribution in the preceding pressing process. This makes it difficult to generate reverse thermal stress through differentiated temperature field adjustments to compensate for the previous mechanical deformation.

[0004] The cumulative structural deformation from the aforementioned multiple processes ultimately affects the contact state inside the conductive slip ring, causing fluctuations in the dynamic contact resistance of the finished product during constant-speed rotation testing. Existing testing procedures primarily use dynamic contact resistance as the criterion for product qualification, without establishing a mapping relationship between electrical test results and process parameters from preceding manufacturing processes. Because it is impossible to reverse-engineer the electrical performance indicators of the finished product into feedback adjustment parameters for the thermosetting process, existing production lines lack a cross-process closed-loop control mechanism, making it difficult to control the fluctuation range of contact resistance during mass production. Therefore, this invention provides a multi-station intelligent production control system for conductive slip rings to address the shortcomings of existing technologies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a multi-station intelligent production control system for conductive slip rings. This system solves the problem that the asymmetric mechanical stress introduced during the pressing process in conductive slip ring processing causes structural deformation during the curing stage, resulting in fluctuations in the dynamic contact resistance of the finished product. Furthermore, existing production control processes lack cross-process feedforward compensation and closed-loop correction.

[0006] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of this invention provides a multi-station intelligent production control system for conductive slip rings, comprising: a servo pressing device, a multi-temperature zone curing device, an electrical performance testing device, a conveying mechanism, a material carrier, and a main control unit; the material carrier carries the conductive slip ring and moves it between the servo pressing device, the multi-temperature zone curing device, and the electrical performance testing device via the conveying mechanism; the main control unit is communicatively connected to the servo pressing device, the multi-temperature zone curing device, the electrical performance testing device, and the conveying mechanism; the main control unit includes a signal acquisition module, a vector mapping module, a thermal control module, and a feedback correction module.

[0007] The signal acquisition module acquires time-series mechanical and displacement signals during the pressing stage, time-series dielectric coupling impedance signals during the curing stage, and time-series dynamic contact resistance signals during the testing stage. The vector mapping module synthesizes a pressure-bonding asymmetric feature vector based on the time-series mechanical and displacement signals, inputs it to the structural mechanics transformation model, and outputs a predicted deformation vector. The thermodynamic control module determines the gel characteristic moment and compensation time window based on the time-series dielectric coupling impedance signal. Within the compensation time window, it calculates the target temperature for each temperature zone based on the predicted deformation vector and outputs temperature distribution control commands. The feedback correction module extracts the harmonic characteristics of the time-series dynamic contact resistance signal to construct a residual resistance harmonic feature vector. Based on the residual resistance harmonic feature vector, it identifies the thermal compensation response model and calculates the temperature zone control parameter correction amount.

[0008] In the technical solution provided by this invention, the signal acquisition module acquires physical quantity signals from different manufacturing stages. The vector mapping module converts the asymmetric work generated during the pressing stage into a predicted deformation vector, establishing the correspondence between mechanical stress distribution and thermal deformation tendency. The thermodynamic control module uses the gel characteristic moment as the reference node for the rheological state transformation of the polymer material, and combines the predicted deformation vector to establish an asymmetric local temperature field within the compensation time window. It utilizes the difference in thermal expansion to generate reverse thermal stress to compensate for the deformation caused by the residual stress of pressing. The feedback correction module extracts the harmonic components of the dynamic contact resistance at the electrical performance test end as a deformation characterization quantity, which is used to update the parameters of the thermal compensation response model, thereby establishing a feedforward and feedback control mechanism between multiple processes.

[0009] Preferably, the vector mapping module uses the time-series displacement signal as the integration variable, integrates the pressing work of the time-series mechanical signal to obtain the pressing work characteristic value of each independent assembly channel, and combines the physical arrangement angle of each independent assembly channel in the local polar coordinate system of the vehicle to perform vector synthesis of the pressing work characteristic value of each independent assembly channel to obtain the pressing asymmetric characteristic vector.

[0010] Furthermore, the intelligent production control system for multi-station machining of conductive slip rings also includes a positioning and identification sensor; the positioning and identification sensor is connected to the main control unit; the positioning and identification sensor detects the physical deflection angle of the material carrier relative to the global coordinate system when it arrives at the multi-temperature zone curing equipment; the thermal control module rotates the predicted deformation vector in the local polar coordinate system of the carrier according to the physical deflection angle, transforms the predicted deformation vector to the global coordinate system, and outputs the global deformation azimuth angle.

[0011] In a preferred embodiment of the present invention, the signal acquisition module applies a high-frequency detection micro-level to adjacent detection electrode pairs to acquire the time-series dielectric coupling impedance signal; the thermal control module smooths the time-series dielectric coupling impedance signal and then performs first-order and second-order difference operations. When the second-order difference operation result is reversed and the first-order difference operation result meets the preset change direction threshold and the preset number of sampling points is continuously maintained, the corresponding time is determined as the gel characteristic time.

[0012] Preferably, within the compensation time window, the thermal control module calculates the first-order rate of change of the timing dielectric coupling impedance signal, and generates a convergence condition satisfaction signal when the absolute value of the first-order rate of change is continuously lower than the steady-state rate of change threshold; after receiving the convergence condition satisfaction signal, the thermal control module reduces the target temperature increment of each temperature zone according to the preset descent slope, and controls each temperature zone to return to the basic curing temperature.

[0013] Furthermore, the thermal control module is equipped with a temperature difference response model, which maps the quantitative relationship between the temperature increment of the temperature zone, the duration of the compensation time window, the gel characteristic moment, and the equivalent deformation vector. The thermal control module calculates the target temperature corresponding to each temperature zone based on the predicted deformation vector and the temperature difference response model.

[0014] In a preferred embodiment of the present invention, the feedback correction module converts the time-series dynamic contact resistance signal into an angle-domain contact resistance sequence based on the angle pulse signal output by the incremental photoelectric encoder, and extracts the first phase-locked harmonic and the second phase-locked harmonic related to the mechanical rotation cycle; the feedback correction module constructs a residual resistance harmonic feature vector based on the amplitude and phase of each phase-locked harmonic that meet the validity conditions.

[0015] Preferably, the input state vector of the thermal compensation response model includes the predicted deformation lateral component, the predicted deformation longitudinal component, the lateral and longitudinal components of the actual temperature asymmetry feature vector, the duration of the compensation time window, the deviation of the gel characteristic moment from the reference gel time, and the current temperature zone control parameters; the feedback correction module uses the recursive least squares algorithm to identify the thermal compensation response model online, and combines constrained least squares operation to calculate the global target temperature difference gain correction, the compensation phase offset correction, and the temperature increment correction for each temperature zone.

[0016] Furthermore, the intelligent production control system for multi-station machining of conductive slip rings also includes a carrier label reading component. The material carrier is equipped with a fixed mechanical positioning zero point and a unique identification label. The main control unit establishes a local polar coordinate system of the carrier based on the fixed mechanical positioning zero point, and establishes a slip ring assembly state vector corresponding to the physical conductive slip ring based on the unique identification label. The main control unit calls the slip ring assembly state vector according to the reading result of the carrier label reading component.

[0017] In a preferred embodiment of the present invention, the multi-temperature zone curing device is provided with multiple temperature zones arranged in a ring array, and each temperature zone is equipped with a zone actuator and a temperature detection component; the main control unit adjusts the pulse width modulation duty cycle of the corresponding zone actuator through a temperature closed-loop controller according to the deviation between the target temperature and the actual control temperature collected by the temperature detection component.

[0018] A second aspect of this invention provides an intelligent production control method for multi-station machining of conductive slip rings, comprising the following steps: The system collects time-series mechanical and displacement signals during the pressing stage, time-series dielectric coupling impedance signals during the curing stage, and time-series dynamic contact resistance signals during the testing stage. The compression asymmetric feature vector is synthesized based on the time-series mechanical signal and the time-series displacement signal. The compression asymmetric feature vector is then input into the structural mechanics transformation model to obtain the predicted deformation vector. The characteristic time of the gel and the compensation time window are determined based on the time-series dielectric coupling impedance signal. Within the compensation time window, the target temperature of each temperature zone is calculated based on the predicted deformation vector and asymmetric temperature distribution control is performed. Harmonic features of the time-series dynamic contact resistance signal are extracted to construct a residual resistance harmonic feature vector. Based on the residual resistance harmonic feature vector, the parameters of the thermal compensation response model are identified, and the correction amount of the temperature control parameters is calculated.

[0019] This invention provides an intelligent production control system for multi-station machining of conductive slip rings. It has the following beneficial effects: 1. This invention synthesizes asymmetric feature vectors of the pressing process by collecting time-series mechanical signals and time-series displacement signals during the pressing stage, and outputs predicted deformation vectors using a structural mechanics transformation model. This transforms the unevenly distributed mechanical residual stress in the pressing process into quantified deformation parameters, enabling advance calculation of the subsequent thermal deformation trend of the conductive slip ring and providing basic data input for temperature feedforward compensation in the subsequent curing process.

[0020] 2. This invention determines the gel characteristic moment and compensation time window by analyzing the time-series dielectric coupling impedance signal during the curing stage, and controls the target temperature of each temperature zone of the multi-temperature zone curing equipment based on the predicted deformation vector. It uses dielectric properties to determine the rheological state transition node of the polymer material, and then generates directional thermal expansion stress by constructing an asymmetric local temperature field to compensate for the mechanical stress introduced in the pressing process, thereby controlling the deformation of the product after curing.

[0021] 3. This invention constructs a residual resistance harmonic feature vector by extracting the harmonic characteristics of the time-series dynamic contact resistance signal during the testing phase, and identifies the parameters of the thermal compensation response model based on this feature vector to calculate the temperature control parameter correction amount. The electrical performance test results of the finished product are transformed into feedback adjustment amount for the control parameters of the pre-heat curing process, forming a closed-loop control mechanism across processes, which reduces the fluctuation range of the conductive slip ring contact resistance during mass production. Attached Figure Description

[0022] Figure 1 This is a system framework diagram of the present invention; Figure 2 This is a flowchart of the method of the present invention; Figure 3 This is the logic diagram for the acquisition of crimping mechanical signals and the synthesis of asymmetric feature vectors in this invention; Figure 4 This is a schematic diagram of the temperature field distribution and closed-loop regulation principle of the multi-temperature zone curing equipment of the present invention; Figure 5 This is a schematic diagram of the assembly state vector and spatial coordinate system mapping of the conductive slip ring of the present invention; Figure 6 This is a schematic diagram of the dynamic contact resistance signal harmonic feature extraction and decomposition of the present invention; Figure 7 This is a flowchart illustrating the recursive correction and online update process of the thermal compensation response model parameters in this invention. Figure 8 This is a three-dimensional topology diagram of the multiphysics mapping and dielectric characteristic feedback of the present invention; Figure 9 This is a composite image of the model convergence trajectory and the high-dimensional mass distribution projection of the present invention.

[0023] Among them, 10 is the main control unit; 11 is the signal acquisition module; 12 is the vector mapping module; 13 is the thermal control module; 14 is the feedback correction module; 20 is the servo pressing equipment; 30 is the multi-temperature zone curing equipment; 40 is the electrical performance testing equipment; 50 is the material carrier; 60 is the positioning and identification sensor; 70 is the carrier label reading component; and 80 is the production line conveying mechanism. Detailed Implementation

[0024] 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.

[0025] See attached document Figure 1 The present invention provides a multi-station intelligent production control system for conductive slip rings, including a main control unit 10, and a servo pressing device 20, a multi-temperature zone curing device 30, an electrical performance testing device 40, a positioning and identification sensor 60, a carrier tag reading component 70, and a production line conveying mechanism 80, which are respectively connected to the main control unit 10.

[0026] The multi-zone curing equipment 30 has multiple independent temperature zones, each equipped with a zone actuator and a temperature detection component. The temperature detection component uses thermocouples, resistance temperature detectors (RTDs), or infrared temperature sensors, with the detection position set on the outer surface of the conductive slip ring corresponding to the temperature zone, or at a calibrated location capable of characterizing the temperature of the corresponding area. Before production, the correlation between the measured temperature of the furnace cavity, the surface temperature of the conductive slip ring, and the internal temperature of the insulating potting material is calibrated using an instrumented standard sample with internal temperature measuring points. The main control unit 10 converts the detected temperatures collected by the temperature detection component into the control temperature of the corresponding temperature zone based on the calibration results, and adjusts the output power of each zone actuator according to the control temperature.

[0027] The conductive slip ring is carried by the material carrier 50 and flows between processing stations via the production line conveyor 80. The material carrier 50 is equipped with a fixed mechanical positioning zero point and a unique identification tag. The main control unit 10 establishes a local polar coordinate system of the carrier based on the fixed mechanical positioning zero point, and establishes a slip ring assembly state vector corresponding to the physical conductive slip ring in the storage space according to the unique identification tag.

[0028] After the material carrier 50 arrives at each processing station, the carrier tag reading component 70 reads the unique identification tag. Based on this, the main control unit 10 calls the corresponding slip ring assembly state vector and writes and updates the data generated in the current process. When the unique identification tag reading fails, or the reading result is inconsistent with the current station record, the main control unit 10 pauses the current process and outputs an error message to avoid mismatch between the physical conductive slip ring and the slip ring assembly state vector.

[0029] The main control unit 10 includes a signal acquisition module 11, a vector mapping module 12, a thermal control module 13, and a feedback correction module 14.

[0030] The signal acquisition module 11 is used to: acquire the timing mechanical signals and timing displacement signals of each independent assembly channel during the pressing stage; apply high-frequency detection micro-level to adjacent detection electrode pairs during the curing stage and acquire the corresponding timing dielectric coupling impedance signals; and acquire the timing dynamic contact resistance signal during the constant speed rotation of the conductive slip ring during the testing stage.

[0031] The vector mapping module 12 calculates the crimping work characteristic value of each independent assembly channel based on the time-series mechanical signal and time-series displacement signal, and generates a crimping asymmetry characteristic vector by combining the physical arrangement angle of each independent assembly channel in the local polar coordinate system of the vehicle. The vector mapping module 12 inputs the crimping asymmetry characteristic vector, the crimping work characteristic value of each independent assembly channel, and the preset assembly process parameters into a pre-calibrated structural mechanics transformation model to obtain the predicted deformation vector. The predicted deformation vector includes the predicted deformation azimuth angle and the predicted deformation amplitude, which are used to characterize the trend of central axis offset or equivalent radial deformation trend of the ring channel after curing caused by the crimping process.

[0032] The thermal control module 13 reads the slip ring assembly state vector and performs coordinate transformation on the predicted deformation vector based on the physical deflection angle of the material carrier 50 relative to the multi-temperature zone curing device 30. The thermal control module 13 also determines the gel characteristic moment of the insulating potting material based on the timing dielectric coupling impedance signal and determines the compensation time window based on the gel characteristic moment.

[0033] Within the compensation time window, the thermal control module 13 calculates the target temperature for each temperature zone based on the predicted deformation azimuth angle, predicted deformation amplitude, and a pre-calibrated temperature difference-deformation response model. Then, based on the actual control temperature of each temperature zone, it performs closed-loop adjustment of the corresponding zone actuators to create a predetermined asymmetric temperature distribution along the circumference of the conductive slip ring. This asymmetric temperature distribution guides the insulating potting material to undergo directional curing shrinkage, thereby reducing the post-curing deformation corresponding to the predicted deformation vector.

[0034] When the rate of change of the time sequence dielectric coupling impedance signal meets the preset convergence condition, the thermal control module 13 gradually reduces the target temperature increment of each temperature zone according to the preset descent slope, so that each temperature zone can be smoothly restored to the basic curing temperature.

[0035] The feedback correction module 14 performs angle domain conversion and harmonic feature extraction on the time-series dynamic contact resistance signal to obtain the first-order phase-locked harmonics, second-order phase-locked harmonics, and preset higher-order phase-locked harmonics related to the mechanical rotation period of the conductive slip ring. The first-order phase-locked harmonics are used to extract periodic resistance features related to eccentric or unilateral asymmetric deformation, while the second-order phase-locked harmonics are used to extract periodic resistance features related to ring ellipticization. The quantitative correspondence between each order of resistance harmonics and mechanical deformation is determined by a pre-established resistance harmonic-mechanical deformation calibration model.

[0036] The feedback correction module 14 constructs a residual resistance harmonic characteristic vector based on the amplitude and phase of each effective phase-locked harmonic and transforms this characteristic vector to the local polar coordinate system of the vehicle. When a resistance harmonic-mechanical deformation calibration model is established, the feedback correction module 14 calculates an equivalent residual deformation vector based on the residual resistance harmonic characteristic vector, which can be used for mechanical deformation diagnosis and product quality evaluation. Without this calibration model, the residual resistance harmonic characteristic vector serves only as a feedback quantity for periodic resistance fluctuations.

[0037] During the cross-batch parameter update process, the feedback correction module 14 uniformly uses the residual resistance harmonic characteristic vector as the feedback output, uses a recursive algorithm to identify the thermal compensation response model, and calculates the temperature control parameter correction amount for the next production batch based on the identification results.

[0038] The main control unit 10 interacts with the servo pressing device 20, the multi-zone curing device 30, the electrical performance testing device 40, the positioning and identification sensor 60, the carrier tag reading component 70, and the production line conveyor mechanism 80 via an industrial bus or industrial Ethernet. The temperature detection component and zone actuator inside the multi-zone curing device 30 are connected to the main control unit 10 through the device controller.

[0039] See attached document Figure 2 This invention provides a multi-station intelligent production control method for the machining of conductive slip rings, comprising the following steps: S1. After the conductive slip ring reaches the servo crimping device 20, the signal acquisition module 11 synchronously acquires the timing mechanical signals and timing displacement signals of each independent assembly channel during the crimping process.

[0040] S2, the vector mapping module 12 uses the time-series displacement signal as the integration variable to integrate the time-series mechanical signal to obtain the pressure-bonding work characteristic value of each independent assembly channel; then, according to the physical arrangement angle of each independent assembly channel in the local polar coordinate system of the vehicle, the pressure-bonding work characteristic value is vector synthesized to obtain the pressure-bonding asymmetric characteristic vector.

[0041] The vector mapping module 12 inputs the asymmetric characteristic vector of the pressing, the characteristic value of the pressing work of each independent assembly channel, and the preset assembly process parameters into the pre-calibrated structural mechanics transformation model to calculate the predicted lateral and longitudinal components of the deformation, and obtain the predicted deformation azimuth and amplitude accordingly. Subsequently, the characteristic value of the pressing work, the asymmetric characteristic vector of the pressing, the predicted lateral component of the deformation, the predicted longitudinal component of the deformation, the predicted deformation azimuth, and the predicted deformation amplitude are written into the slip ring assembly state vector.

[0042] S3, after the material carrier 50 arrives at the entrance of the multi-temperature zone curing equipment 30, the carrier label reading component 70 reads the unique identification label, and the main control unit 10 calls the slip ring assembly state vector corresponding to the current conductive slip ring according to the reading result.

[0043] The positioning and identification sensor 60 detects the physical deflection angle of the material carrier 50 relative to the global coordinate system of the multi-temperature zone curing equipment 30. The thermal control module 13 rotates the predicted deformation vector in the local polar coordinate system of the carrier according to the physical deflection angle, transforms the predicted deformation vector to the global coordinate system, and obtains the global deformation azimuth angle through a two-variable arctangent operation.

[0044] S4, after the material carrier 50 enters the multi-temperature zone curing equipment 30, the signal acquisition module 11 continuously acquires the timing dielectric coupling impedance signal between adjacent detection electrode pairs.

[0045] The adjacent detection electrode pair consists of adjacent metal loops disconnected from the external business circuit during the curing stage, or dedicated detection electrodes disposed on both sides of the insulating potting area and capacitively coupled with the insulating potting material. When the dedicated detection electrode is disposed on the material carrier 50, its detection end extends to the vicinity of the potting area of ​​the conductive slip ring and remains electrically isolated from the business conductive circuit of the conductive slip ring.

[0046] The thermal control module 13 performs first-order and second-order differential operations on the smoothed time-series dielectric coupling impedance signal. When the second-order differential undergoes a sign change in a preset direction, the first-order differential satisfies the change direction threshold corresponding to the current insulating material, and this state is maintained at a preset number of sampling points, the thermal control module 13 determines the gel characteristic moment.

[0047] The thermal control module 13 determines the compensation time window based on the gel characteristic moment and calculates the target temperature for each temperature zone according to the global deformation azimuth angle, predicted deformation amplitude, and pre-calibrated temperature difference-deformation response model. The temperature detection components of each temperature zone collect the actual temperature, and the thermal control module 13 adjusts the corresponding zone actuators according to the deviation between the target temperature and the actual temperature, so that the conductive slip ring forms a predetermined asymmetric temperature distribution in the circumference.

[0048] The predicted thermal micro-warping vector generated by this asymmetric temperature distribution is opposite in direction to the predicted deformation vector, or it can reduce the predicted deformation amplitude. When the absolute value of the rate of change of the dielectric coupling impedance signal is continuously lower than the steady-state rate of change threshold, the thermal control module 13 gradually reduces the target temperature increment of each temperature zone according to the preset descent slope, so that each temperature zone smoothly recovers to the basic curing temperature.

[0049] S5, after the conductive slip ring arrives at the electrical performance testing equipment 40, the signal acquisition module 11 acquires the time-series dynamic contact resistance signal during the constant-speed rotation of the conductive slip ring. The feedback correction module 14 converts the time-series dynamic contact resistance signal into an angle-domain contact resistance sequence based on the angle information output by the incremental photoelectric encoder, and synchronously averages the angle-domain contact resistance sequence over multiple consecutive rotation cycles.

[0050] The feedback correction module 14 extracts the amplitude and phase of the first phase-locked harmonic, the second phase-locked harmonic, and the preset higher-order phase-locked harmonics, and constructs the residual resistance harmonic characteristic vector based on each order of harmonics that meet the validity conditions. Subsequently, based on the calibration relationship between the mechanical zero position of the electrical performance testing equipment 40 and the mechanical positioning zero position of the material carrier 50, the residual resistance harmonic characteristic vector is converted to the local polar coordinate system of the carrier.

[0051] The feedback correction module 14 uses the predicted deformation vector, actual temperature asymmetry characteristic vector, compensation time window parameters, and temperature zone control parameters of the current production batch as inputs to the thermal compensation response model, and the residual resistance harmonic characteristic vector as the model output. It then updates the thermal compensation response model using a recursive least squares algorithm. After completing the model update, the feedback correction module 14 calculates the temperature zone control parameter correction amount for the next production batch based on the thermal compensation response model and sends the corrected temperature zone control parameters to the thermal control module 13.

[0052] The following section further explains the acquisition of physical quantities, feature extraction, coordinate mapping, thermal compensation control, and feedback correction processes during the machining of conductive slip rings, combining each logic execution module and each control step.

[0053] See attached document Figure 3 The present invention provides an embodiment of the crimping signal acquisition and crimping asymmetric feature mapping principle.

[0054] In step S1, after the conductive slip ring reaches the servo crimping device 20, the signal acquisition module 11 synchronously acquires the timing mechanical signals and timing displacement signals of each independent assembly channel during the crimping process.

[0055] When the crimping actuator of the servo crimping device 20 is started, the signal acquisition module 11 acquires the spindle motion start signal through hardware triggering and sets the time corresponding to the signal as the acquisition start time. The signal acquisition module 11 generates a timestamp based on the internal crystal oscillator clock, which is used to correlate the mechanical signal, displacement signal and spindle motion state.

[0056] Due to the transmission delay difference between the sampling links of the mechanical sensor and the displacement grating ruler, the signal acquisition module 11 reads the real-time data of each sensor through the industrial communication bus, and performs time alignment of the data of different sampling links according to the timestamp to obtain the time-series mechanical signal and time-series displacement signal under the same time reference.

[0057] The signal acquisition module 11 performs low-pass filtering on the acquired raw signal to attenuate high-frequency vibration interference caused by the action of the crimping actuator. The low-pass filter can be a first-order inertial filter or a Butterworth low-pass filter. The filter order and cutoff frequency are determined according to the operating conditions of the servo crimping device 20 and the sensor sampling frequency.

[0058] After filtering, the signal acquisition module 11 converts the sampled values ​​into force and displacement values ​​with actual dimensions according to the calibration coefficients of the mechanical sensor and the displacement sensor, and performs zero-point drift correction, press body elastic deformation compensation and no-load friction compensation in sequence.

[0059] No-load friction compensation is achieved by pre-collecting the no-load force-displacement curve when the pressing actuator is not in contact with the component to be pressed. Elastic deformation compensation of the press body is achieved by performing pressing tests on rigid calibration parts to obtain the elastic displacement of the press body under different loads, and then subtracting the corresponding elastic displacement from the measured displacement. After completing the pressing work integration, the pressing work characteristic values ​​of each channel can be normalized according to the pressing work calibration range of the same type of conductive slip ring for subsequent model calculations.

[0060] The vector mapping module 12 reads the force and displacement values ​​after calibration and compensation, and selects the loading stroke from the effective contact between the pressing actuator and the component to be pressed until the pressing action terminates. Within this loading stroke, the vector mapping module 12 integrates the pressing work of the force value with displacement as the integral variable to obtain the pressing work characteristic value of each independent assembly channel.

[0061] The integral area formed by the force-displacement curve within the loading stroke represents the mechanical work of the pressing actuator input to the corresponding assembly channel. This mechanical work includes elastic deformation work, plastic deformation work, and frictional losses, and is therefore not directly equivalent to recoverable mechanical strain energy.

[0062] For the first conductive slip ring Each independent assembly channel, crimping characteristic value The calculation formula is as follows: ; In the formula, Indicates the first The characteristic value of the crimping work absorbed by each independent assembly channel during the crimping process; This represents the first time variable after eliminating the time variable. Force-displacement envelope function for each independent assembly channel; This indicates the initial displacement that occurred during the crimping action of the corresponding channel; This indicates the displacement when the crimping action of the corresponding channel terminates.

[0063] The main control unit 10 establishes a local polar coordinate system for the material carrier 50 based on the fixed mechanical positioning zero position. Each independent assembly channel has a predetermined physical arrangement angle in the local polar coordinate system. This physical arrangement angle is calibrated according to the structural design parameters of the conductive slip ring and stored in the main control unit 10.

[0064] When the crimping state of each independent assembly channel is consistent, the crimping work characteristics of each channel tend to be balanced in the circumferential direction; when assembly tolerance, material difference or crimping execution deviation causes the crimping state of each channel to be inconsistent, the crimping work characteristic value of each channel will show an asymmetrical distribution in the circumferential direction.

[0065] The vector mapping module 12 uses the crimping work characteristic value of each independent assembly channel as the characteristic amplitude in the corresponding physical arrangement angle direction, and performs vector synthesis in the local polar coordinate system of the vehicle to obtain the crimping asymmetric characteristic vector. Asymmetric characteristic vector of press-fit It is used to characterize the degree of asymmetry and dominant direction of the crimping work distribution in each independent assembly channel, and does not directly represent the actual mechanical force.

[0066] Crimping asymmetric characteristic vector The formulas for calculating the horizontal and vertical components are as follows: ; ; In the formula, The horizontal component of the asymmetric characteristic vector of the indentation in the local polar coordinate system of the vehicle is represented. The vertical component represents the indentation asymmetric characteristic vector of the vehicle in its local polar coordinate system. Indicates the total number of independent assembly channels; Indicates the first The physical arrangement angle of each independent assembly channel in the local polar coordinate system of the vehicle.

[0067] Based on the horizontal axis component and vertical axis components The asymmetric characteristic vector of the crimping can be further calculated. The modulus and azimuth.

[0068] Obtain the asymmetric characteristic vector of the press-fit Then, the vector mapping module 12 calls the pre-established structural mechanics conversion model to convert the asymmetric features generated by the pressing process into predicted deformation vectors.

[0069] The structural mechanics conversion model was established through finite element analysis and standard sample calibration. During the calibration process, asymmetric pressing conditions with different circumferential orientations and degrees were applied to the standard samples, and the pressing work characteristic values ​​of each independent assembly channel were recorded. After pressing, each standard sample was uniformly cured using the same basic curing temperature program without applying asymmetric thermal compensation to eliminate the influence of thermal compensation on the calibration results of residual deformation after pressing.

[0070] After the standard sample has been cured, the offset of the central axis and the radial deformation of the ring are measured using roundness measuring equipment, radial displacement measuring equipment or coordinate measuring equipment. The measurement results are decomposed into the measured lateral component and the measured longitudinal component of the deformation in the local polar coordinate system of the vehicle.

[0071] The structural mechanics transformation model uses the horizontal component of the compression asymmetric characteristic vector. , Vertical axis component The crimping work characteristic value of each independent assembly channel and the preset assembly process parameters are used as inputs to predict the lateral component of deformation. and predicting longitudinal components of deformation As output.

[0072] The calibration samples include model-fitted samples and independent verification samples. Model-fitted samples are used to determine the parameters of the structural mechanics conversion model, while independent verification samples are used to verify the model's prediction error. When the prediction error of the independent verification sample is lower than the preset allowable error, the main control unit 10 uses the corresponding structural mechanics conversion model for the production control of the same type of conductive slip ring; when the prediction error exceeds the preset allowable error, the number of calibration samples is increased or the model calibration is re-executed.

[0073] In one embodiment, the structural mechanics transformation model employs a linear transformation matrix established using the least squares method. When there is a significant nonlinear relationship between the compression work characteristics and the measured deformation, a piecewise linear lookup table or a nonlinear regression model can be used for transformation.

[0074] Vector mapping module 12 predicts the lateral component of deformation. and predicting longitudinal components of deformation Calculate the predicted deformation amplitude The bivariate arctangent function was used to calculate the predicted deformation azimuth angle. Predicting deformation amplitude The equivalent radial displacement is used to characterize the expected degree of central axis offset or equivalent radial deformation of the annulus after curing; the deformation azimuth angle is predicted. Used to characterize the circumferential orientation of the expected deformation in the local polar coordinate system of the vehicle.

[0075] During subsequent thermal compensation, the thermal control module 13 calculates the deformation azimuth angle based on the predicted deformation azimuth angle. Determine the spatial reference for temperature compensation and based on the predicted deformation amplitude. Determine the compensation intensity for the target temperature distribution.

[0076] After completing the above calculations, the vector mapping module 12 writes the crimping work characteristic value, crimping asymmetry characteristic vector, predicted deformation lateral component, predicted deformation longitudinal component, predicted deformation amplitude, and predicted deformation azimuth angle of each independent assembly channel into the slip ring assembly state vector.

[0077] The main control unit 10 establishes a data index between the physical conductive slip ring and the slip ring assembly state vector based on the unique identification tag of the material carrier 50, so that the feature data generated by the pressing station can be called in the subsequent multi-temperature zone curing station as the material carrier 50 flows.

[0078] See attached document Figure 4 The present invention provides an embodiment of the coordinate system spatial alignment and thermal micro-warping adaptive compensation principle.

[0079] After the data writing at the crimping station is completed, the main control unit 10 sends a transfer instruction to the production line conveying mechanism 80, which then transports the material carrier 50 carrying the conductive slip ring to the multi-temperature zone curing equipment 30.

[0080] After the material carrier 50 arrives at the entrance of the multi-temperature zone curing equipment 30, the positioning and identification sensor 60 collects a feature image of the material carrier 50. In this embodiment, the positioning and identification sensor 60 is an industrial vision camera. Due to the mechanical clearance of the conveyor track and the positioning repetition error, the material carrier 50 may undergo circumferential deflection relative to the global coordinate system of the multi-temperature zone curing equipment 30 when it arrives at the curing station.

[0081] The positioning and recognition sensor 60 sends the acquired images to the main control unit 10. The main control unit 10 performs contour matching or feature point registration on the images according to the preset reference template to determine the actual pixel position of the fixed mechanical positioning zero position of the material carrier 50; then, combined with the camera's intrinsic and extrinsic parameters and the calibration relationship between the pixel position and the actual spatial position, it calculates the physical deflection angle of the material carrier 50 relative to the global coordinate system.

[0082] When the image matching confidence is lower than the preset threshold, the fixed mechanical positioning zero position is blocked, or the calculated physical deflection angle exceeds the allowable range, the main control unit 10 suspends the material carrier 50 from entering the multi-temperature zone curing equipment 30 and outputs a prompt for repositioning or manual verification.

[0083] The thermal control module 13 reads the predicted deformation vector from the slip ring assembly state vector and performs coordinate rotation based on the physical deflection angle, transforming the predicted deformation vector in the local polar coordinate system of the carrier to the global coordinate system of the multi-temperature zone curing device 30. The coordinate rotation transformation formula is as follows: ; In the formula, and These represent the horizontal and vertical components in the global coordinate system, respectively. and These represent the horizontal and vertical components in the local polar coordinate system of the vehicle, respectively. This represents the physical deflection angle of the material carrier 50 relative to the global coordinate system.

[0084] Physical deflection angle The counterclockwise rotation angle of the vehicle's local polar coordinate system's horizontal axis relative to the global coordinate system's horizontal axis is taken as positive. After completing the coordinate rotation, the thermal control module 13 uses a bivariate arctangent function to calculate the global deformation azimuth angle. This is to avoid quadrant judgment errors caused by ordinary arctangent calculation. Through the above coordinate transformation, a correspondence is established between the predicted spatial orientation of deformation and the installation orientation of each zone actuator in the multi-temperature zone curing equipment 30.

[0085] After the material carrier 50 enters the heating chamber of the multi-temperature zone curing equipment 30, the signal acquisition module 11 applies a high-frequency detection micro-level to the adjacent detection electrode pair through the spring probe interface set on the material carrier 50, and acquires the timing dielectric coupling impedance signal between the adjacent detection electrode pairs.

[0086] Adjacent detection electrode pairs can be formed by adjacent metal loops disconnected from external business circuits during the curing stage, or by dedicated detection electrodes mounted on the conductive slip ring or material carrier 50. The detection ends of the dedicated detection electrodes are located on either side of the insulating potting area or extend near the insulating potting area, and are electrically isolated from the business conductive loop of the conductive slip ring. For conductive slip rings where no available free metal loops exist, dedicated detection electrodes are used for dielectric coupling impedance detection.

[0087] The frequency of the high-frequency detection micro-level is set in the range of 10kHz to 1MHz, with an amplitude on the order of millivolts, to reduce the influence of the detection electric field on the curing process of the insulating potting material and to avoid dielectric breakdown. Adjacent metal rings or dedicated detection electrodes and the insulating potting material located between them form a capacitive detection structure, the equivalent impedance of which is affected by the complex permittivity, dielectric loss, conductivity, temperature, and electrode geometry of the insulating potting material.

[0088] The signal acquisition module 11 includes a high-frequency excitation source, a known sampling impedance, a differential voltage acquisition circuit, and a phase detection circuit. The signal acquisition module 11 calculates the dielectric coupling impedance based on the voltage amplitude across the detection electrode pair, the current amplitude flowing through the sampling impedance, and the phase difference between the voltage and current.

[0089] Before processing the current batch of materials, the signal acquisition module 11 calibrates the detection circuit using an unloaded material carrier and a known standard impedance component to obtain the parasitic impedance and measurement deviations introduced by the spring probe, connecting cables, furnace environment, and acquisition circuit. A fully cured reference sample is used to determine the steady-state impedance reference and steady-state noise level corresponding to the current product structure. During the actual curing process, the signal acquisition module 11 compensates for the dielectric coupling impedance measurement results based on the detection circuit calibration results.

[0090] The operating frequency of the high-frequency excitation is determined by frequency scanning of the current insulating potting material. The main control unit 10 selects the frequency with a large ratio of impedance characteristic change to background noise during the gelation process as the operating frequency and writes this operating frequency into the process parameters of the corresponding material batch. The time-series dielectric coupling impedance signal is used to characterize the comprehensive electrical state changes during the curing process of the insulating potting material, and does not attribute the impedance change solely to the change in dielectric constant.

[0091] When a set of adjacent detection electrode pairs is set, the thermodynamic control module 13 determines the gel characteristic moment based on the dielectric coupling impedance signal of that set. When multiple sets of adjacent detection electrode pairs are set along the circumference of the conductive slip ring, the signal acquisition module 11 acquires the dielectric coupling impedance signal of each set, and the thermodynamic control module 13 determines the gel characteristic moment based on the median value of the gel characteristic moment obtained from each set of signals, or based on the detection results that meet the preset consistency conditions.

[0092] The main control unit 10 pre-calibrates the correspondence between dielectric coupling impedance characteristics and rheological gelation time through rheological and impedance tests of the same batch of insulating potting materials. For materials whose impedance amplitude increases near the gelation stage, the thermal control module 13 determines the gelation characteristic moment based on the following logical conditions: and ; In the formula, This represents a smoothed timing dielectric coupling impedance signal; Indicates the curing time.

[0093] For materials whose impedance amplitude decreases near the gelation stage, the first-order change direction condition is adjusted to a negative change condition; for materials with more pronounced impedance phase change characteristics, the impedance phase sequence is used instead of the impedance amplitude sequence for inflection point detection. The specific change direction, judgment threshold, and allowable gelation time range are pre-calibrated based on the rheological and impedance test results of the corresponding materials.

[0094] The signal acquisition module 11 first performs low-pass filtering or local polynomial smoothing on the time-series dielectric coupling impedance signal, and then calculates the first-order and second-order differences. When the second-order difference between adjacent sampling points undergoes a sign change in a preset direction, and the first-order difference satisfies the change direction threshold corresponding to the current material, and this state is continuously maintained for at least [time period missing]. At each sampling point, the thermal control module 13 determines the moment when the above conditions are first met as the candidate gel characteristic moment. When the candidate gel characteristic moment is within the preset allowable gel time range of the current material, it is determined as the valid gel characteristic moment.

[0095] If no effective gel characteristic moment is detected within the allowable gel time range, the thermodynamic control module 13 uses the reference gel time calibrated by rheological testing of the same batch of insulating potting materials as the alternative trigger moment and records any dielectric anomalies. The start and end times of the compensation time window are determined by adding preset start and end offsets to the effective gel characteristic moment or the alternative trigger moment, respectively. The start and end offsets are calibrated through rheological testing of the same batch of materials and thermal compensation testing of standard samples.

[0096] After entering the compensation time window, the actuators of each zone in the multi-zone curing equipment 30 enter an asymmetric temperature control state. In this embodiment, the zone actuators use infrared radiation heating tubes arranged in a ring array along the outer periphery of the conductive slip ring.

[0097] The thermal control module 13 is based on the global deformation azimuth angle Predicting deformation amplitude A pre-calibrated temperature difference-deformation response model is used to calculate the target temperature increment for each temperature zone. The temperature difference-deformation response model is used to describe the correspondence between the temperature increment for each temperature zone, the actual temperature asymmetry characteristic vector, the duration of the compensation time window, the gel characteristic moment, and the equivalent deformation vector after curing.

[0098] The thermal control module 13 calculates the target temperature distribution that can reduce the predicted deformation vector based on the temperature difference-deformation response model. The circumferential azimuth corresponding to the highest target temperature is determined by the compensated phase offset in the temperature difference-deformation response model, and is not fixed in advance to the opposite direction of the predicted deformation azimuth angle.

[0099] Temperature detection components in each temperature zone collect the temperature of the corresponding area in real time. The thermal control module 13 calculates the pulse width modulation duty cycle of the corresponding zone actuator through the temperature closed-loop controller based on the deviation between the target temperature and the actual control temperature of each temperature zone, so that the actual control temperature of each temperature zone follows the target temperature.

[0100] In one embodiment, the temperature closed-loop controller employs a proportional-integral-derivative (PID) controller, whose control parameters are tuned through step heating response tests in each temperature zone. The calculated pulse width modulation (PWM) duty cycle is output to the corresponding zone actuator after amplitude limiting to prevent the output of the zone actuator from exceeding the hardware allowable range.

[0101] The asymmetric temperature distribution causes the insulating potting material to undergo asymmetric curing shrinkage with controllable direction and extent within the compensation time window. The expected thermal micro-warpage vector formed by this curing shrinkage is opposite in direction to the predicted deformation vector, or it can reduce the deformation amplitude after the two are combined, thereby reducing the offset of the central axis of the conductive slip ring or the equivalent radial deformation of the ring channel after curing.

[0102] During thermal compensation, the thermal control module 13 continuously monitors the first-order rate of change of the time-series dielectric coupling impedance signal. As the curing reaction progresses, the degree of cross-linking of the insulating potting material gradually increases, and the rate of change of the impedance characteristic tends to stabilize. The thermal control module 13 defines the absolute value of the first-order rate of change of the smoothed dielectric coupling impedance signal as the convergence state characteristic value. .

[0103] when No less than The number of sampling points is below the steady-state rate of change threshold. At this point, the thermal control module 13 determines that the insulating potting material has entered the curing stage where thermal compensation sensitivity is reduced. Steady-state rate of change threshold. Calibration was performed based on the first-order differential noise of a fully cured reference sample. Determined based on sampling frequency and allowable truncation response time.

[0104] Under the same sampling frequency, filtering parameters, and oven temperature, signal acquisition module 11 acquires the dielectric coupling impedance signal of the fully cured reference sample and calculates the peak-to-peak value or standard deviation of its first-order differential sequence. Steady-state rate of change threshold. It can be set to 1.2 to 1.5 times the peak-to-peak value of the noise, or to a preset multiple of the standard deviation of the noise.

[0105] After the convergence condition is met, the thermal control module 13 gradually reduces the target temperature increment of each temperature zone according to the preset descent slope, so that the target temperature of each temperature zone is smoothly restored to the basic curing temperature. The pulse width modulation duty cycle of each zone actuator is automatically adjusted by the temperature closed-loop controller according to the deviation between the target temperature and the actual control temperature during the recovery process, so as to avoid thermal shock caused by sudden changes in the target temperature and reduce the risk of excessive deformation caused by continuous application of temperature difference during the deep curing stage.

[0106] To quantify the asymmetry of the circumferential temperature distribution within the compensation time window, the thermal control module 13 constructs an actual temperature asymmetry characteristic vector based on the actual control temperature of each temperature zone. The instantaneous horizontal component of this characteristic vector is obtained by multiplying the temperature increment of each temperature zone relative to the base curing temperature, the cosine of the corresponding temperature zone's installation angle, and the temperature zone weight, and then summing the results. The instantaneous vertical component is obtained by multiplying the temperature increment of each temperature zone relative to the base curing temperature, the sine of the corresponding temperature zone's installation angle, and the temperature zone weight, and then summing the results. The weights of each temperature zone are pre-calibrated based on the temperature zone coverage and the results of step heating response tests.

[0107] The thermal control module 13 continuously calculates the instantaneous components of the horizontal axis and the vertical axis according to the preset sampling period within the compensation time window, and calculates the time average value within the compensation time window respectively. The time average value is used to form the actual temperature asymmetry feature vector corresponding to the current conductive slip ring.

[0108] The actual temperature asymmetry feature vector is used to characterize the dominant orientation and degree of asymmetry of the circumferential temperature distribution within the compensation time window, and is not equivalent to the temperature gradient per unit spatial distance. The thermal control module 13 writes this feature vector and the compensation time window parameters into the slip ring assembly state vector for subsequent electrical performance testing and cross-batch parameter correction.

[0109] See attached document Figure 5 The present invention provides an embodiment of the principle of phase-locked extraction of electrical signals and iterative correction of the control model.

[0110] After the curing process is completed, the main control unit 10 sends a transfer command to the production line conveyor mechanism 80, causing the material carrier 50 carrying the conductive slip ring to enter the electrical performance testing equipment 40. The electrical performance testing equipment 40 includes a servo-driven test bench and an incremental photoelectric encoder. After the conductive slip ring is mounted on the servo-driven test bench, it rotates continuously at a preset constant speed; the incremental photoelectric encoder synchronously outputs an angle pulse signal corresponding to the mechanical rotation angle.

[0111] The signal acquisition module 11 employs a four-wire micro-resistance measurement circuit to detect the dynamic contact resistance of the conductive slip ring's test channel. A constant current source applies a constant DC test current to the test channel through a set of current leads, while an independently configured voltage detection lead acquires the voltage drop signal across the test contact. The voltage drop signal is amplified by a differential amplifier or instrumentation amplifier and then converted from analog to digital to obtain the timing dynamic contact resistance signal of the conductive slip ring under constant-speed rotation. Because the current leads and voltage detection leads are independent, the influence of lead resistance and contact resistance on the micro-resistance measurement results is reduced.

[0112] When there is eccentricity or unilateral local deformation inside the conductive slip ring, the dynamic contact resistance usually exhibits a periodic component dominated by one revolution; when there is elliptical deformation of the ring track, a periodic component dominated by two revolutions usually appears; when there is multi-lobe deformation or circumferential periodic defects, higher-order periodic components of the corresponding order may appear. The feedback correction module 14 extracts the corresponding periodic resistance characteristics based on the amplitude and phase of different order harmonics.

[0113] The time-series dynamic contact resistance signal may also contain environmental electromagnetic interference, mechanical friction noise, and random contact fluctuations. To improve the stability of periodic feature extraction, the feedback correction module 14 converts the time-sampled dynamic contact resistance signal into an angle-domain contact resistance sequence based on mechanical rotation angle sampling, according to the angle pulse signal output by the incremental photoelectric encoder.

[0114] The signal acquisition module 11 uses the timestamp generated by the system clock to correlate each resistor sampling point with the mechanical angle output by the incremental photoelectric encoder. The electrical performance testing equipment 40 drives the conductive slip ring to rotate continuously for multiple complete cycles. The feedback correction module 14 resamples the sampling data in each rotation cycle to a unified angle grid and performs multi-cycle synchronous averaging on the data at the same angle position to attenuate random noise that is out of sync with the mechanical rotation.

[0115] Feedback correction module 14 performs multi-order phase-locked harmonic extraction on the angle-domain contact resistance sequence. For the first... The h-th harmonic is fed back to the mechanical rotation frequency. The feedback correction module 14 generates a sinusoidal reference carrier and a cosine reference carrier with the same frequency as the h-th harmonic. These are then discretely multiplied and periodically integrated with the angle-domain contact resistance sequence to obtain the h-th harmonic. The orthogonal components of the first harmonic. Harmonic order. It includes at least 1 and 2, and can be extended to preset higher harmonics depending on the structure of the conductive slip ring and the type of defect to be identified.

[0116] Feedback correction module 14 calculates the corresponding amplitude based on the orthogonal components of each harmonic. and phase A harmonic is only identified as a valid harmonic when the ratio of its amplitude to the noise amplitude exceeds a preset threshold and the phase dispersion over multiple consecutive rotation cycles is below the preset threshold. Valid harmonics with larger amplitudes are used to characterize the main periodic resistance fluctuation modes of the current conductive slip ring, while other harmonics that meet the validity criteria are retained and participate in the construction of the residual resistance harmonic observation vector.

[0117] The feedback correction module 14 uses the mechanical zero position of the incremental photoelectric encoder as the phase reference for each harmonic to obtain the phase of each effective harmonic in the coordinate system of the electrical performance testing equipment 40. Before testing, the angular relationship between the zero position of the test fixture and the fixed mechanical positioning zero position of the material carrier 50 is obtained through calibration. The feedback correction module 14 performs a coordinate inverse rotation based on this angular relationship to transform the azimuth characteristics of each effective harmonic to the local polar coordinate system of the carrier.

[0118] For the first harmonic, the conversion result represents the directional residual periodic resistance orientation; for the second harmonic, the non-directional principal axis orientation is determined based on half of the second harmonic phase, and the principal axis orientation is limited to the range of 0 to 180 degrees. The second harmonic itself cannot distinguish between two opposite directions that are 180 degrees apart. When it is necessary to determine the directional compensation orientation, a joint judgment can be made by combining the first harmonic phase, the known excitation direction in the temperature range, or the mechanical detection results.

[0119] To reduce the impact of surface contamination, brush pressure dispersion, and wiring status on test results, the feedback correction module 14 can perform forward and reverse rotation tests separately, or correlate and verify the dynamic contact resistance harmonic characteristics with the results of circular runout, roundness, or radial displacement detection. When the phase of a certain harmonic is repeatable in multiple consecutive rotation cycles, it is determined as a stable residual periodic resistance characteristic.

[0120] The feedback correction module 14 constructs a residual resistance harmonic characteristic vector based on the amplitude and phase of each effective harmonic. When a resistance harmonic-mechanical deformation calibration model is not established, this characteristic vector is only used to characterize the amplitude and orientation of periodic resistance fluctuations and does not directly represent mechanical deformation. When a resistance harmonic-mechanical deformation calibration model has been established, and the phase-locked harmonic results and mechanical testing results meet preset consistency conditions, the feedback correction module 14 calculates an equivalent residual deformation vector based on the residual resistance harmonic characteristic vector, which is used for mechanical deformation diagnosis and product quality evaluation. Cross-batch parameter correction uniformly uses the residual resistance harmonic characteristic vector as the feedback output.

[0121] To enable cross-batch control parameter correction, the feedback correction module 14 uses a recursive least squares algorithm to perform online identification of the thermal compensation response model. The thermal compensation response model establishes a mapping relationship between the production process state and the residual resistance harmonic characteristics after curing. Model inputs include the predicted deformation transverse component, the predicted deformation longitudinal component, the transverse and longitudinal components of the actual temperature asymmetry characteristic vector, the duration of the compensation time window, the deviation of the gel characteristic time from the reference gel time, and the current temperature control parameters. The model output is the residual resistance harmonic observation vector composed of the orthogonal components of each effective harmonic.

[0122] The temperature zone control parameters include the global target temperature difference gain, the compensation phase offset, and the temperature increment correction coefficient for each temperature zone. To avoid numerical jumps in the compensation phase offset around 0 degrees and 360 degrees, the phase parameter is represented by the cosine and sine components of the compensation phase offset in the thermal compensation response model, and the compensation phase offset is recovered through a bivariate arctangent function.

[0123] The basic temperature range control parameters for the current product model are pre-calibrated using the temperature difference-deformation response model, without zero initialization. A recursive least squares algorithm is used to identify incremental responses outside the basic model. Initial incremental response model parameter vector. Set as the zero vector, initial error covariance matrix Set as a diagonal matrix with diagonal elements having a value of 1000.

[0124] For the residual resistance harmonic observation vector, the first... Each scalar component, the thermal compensation response model is based on the input state vector of the current production batch. The model parameter vector of the previous production batch Calculate the predicted value and use the actual observed value. The difference between the predicted value and the actual value is used as the recursive update error. Before entering the recursive operation, each component in the input state vector is normalized according to the preset range of the corresponding parameter.

[0125] The iterative update formula for the recursive least squares algorithm is as follows: ; ; ; In the formula, Indicates the production batch number; Indicates the first Algorithm gain matrix for production batch; Indicates the first Error covariance matrix of production batch; Indicates the first In the production batch and the first The thermal compensation response model parameter vector corresponding to each resistance harmonic observation component; Indicates the first Normalized input state vector for production batch; Represents the input state vector Transpose of; Indicates the first The first in the residual resistance harmonic observation vector of the production batch A scalar component; This represents the forgetting factor, which ranges from 0.95 to 1.0. Represents the identity matrix.

[0126] The harmonic order range for recursive identification is pre-set to be from the 1st to the 2nd order. The two orthogonal components of each order harmonic are arranged in a fixed order to form the residual resistance harmonic observation vector. For the first First harmonic, the two orthogonal components are respectively from and express, observation vector One of the scalar components. The feedback correction module 14 sets up a recursive least squares identification channel for each scalar component. When a certain harmonic does not meet the validity condition, the corresponding orthogonal component does not participate in the parameter update of the current production batch.

[0127] For the second harmonic, the feedback correction module 14 determines the elliptic principal axis orientation based on the second harmonic phase and constructs the corresponding two-dimensional orthogonal component using double-angle coordinates to avoid numerical jumps in the principal axis orientation at the boundary between 0 degrees and 180 degrees.

[0128] Each production batch includes one or more conductive slip rings processed under the same equipment parameters, material batches, and curing procedures. When the same production batch includes multiple conductive slip rings, the feedback correction module 14 performs outlier removal and statistical averaging on the residual resistance harmonic observation vectors of each conductive slip ring, and uses the processed batch average result as the observation data for this recursive update.

[0129] After updating the model parameters for the current production batch, the feedback correction module 14 calculates the impact of changes in the global target temperature difference gain, compensation phase offset, and temperature increment correction coefficient of each temperature zone on the residual resistance harmonic observation vector based on the updated thermal compensation response model, forming a sensitivity matrix between the temperature zone control parameters and the residual resistance harmonic observation.

[0130] The feedback correction module 14 aims to reduce the predicted residual resistance harmonic observation vector for the next production batch by calculating the temperature zone control parameter correction amount through constrained least squares operation. This correction amount includes the global target temperature difference gain correction amount, the compensation phase offset correction amount, and the temperature increment correction amount for each temperature zone.

[0131] The calculated temperature control parameter correction amount must meet the upper and lower limits of the parameter and the maximum change in a single batch. When the correction result exceeds the allowable range, the feedback correction module 14 limits it to the boundary value of the corresponding parameter and sends the constrained temperature control parameter to the thermal control module 13 for use in the next production batch.

[0132] When the condition number of the sensitivity matrix exceeds a preset threshold, the number of valid samples is insufficient, the input state change amplitude of consecutive production batches is lower than a preset identification threshold, or there is a sensor malfunction in the current production batch, the feedback correction module 14 will not perform the current model parameter update and temperature control parameter correction. When the updated temperature control parameters cause an increase in the residual resistance harmonic amplitude for multiple consecutive production batches, the main control unit 10 will stop automatic iteration and revert to the temperature control parameters that most recently met the product quality requirements.

[0133] As production batches increase, the thermal compensation response model is continuously revised based on production process data and electrical performance test results, allowing the temperature control parameters to gradually adapt to changes in equipment status, material batches, and product structure, thereby reducing the periodic fluctuations in the dynamic contact resistance of the conductive slip ring. Furthermore, given the established resistance harmonic-mechanical deformation calibration model, it can also reduce the equivalent residual deformation corresponding to the periodic resistance characteristics.

[0134] See attached document Figure 6 , Figure 6 This invention illustrates the principle of adaptive compensation for thermal micro-warpage based on in-situ dielectric monitoring, closed-loop temperature control of the temperature zone, and truncation of the compensation time window in a further embodiment of the present invention.

[0135] After mechanical assembly and coordinate system alignment are completed, the material carrier 50 carrying the conductive slip ring enters the heating chamber of the multi-temperature zone curing equipment 30, and the main control unit 10 controls the system to perform thermal micro-warping compensation.

[0136] The signal acquisition module 11 applies a high-frequency detection micro-level to adjacent detection electrode pairs through a spring probe interface mounted on the material carrier 50, and acquires the timing dielectric coupling impedance signal between adjacent detection electrode pairs. The frequency of the high-frequency detection micro-level is set in the range of 10kHz to 1MHz, and the amplitude is on the order of millivolts, in order to reduce the influence of the detection electric field on the curing process of the insulating potting material and to avoid dielectric breakdown.

[0137] The signal acquisition module 11 includes a high-frequency excitation source, a known sampling impedance, a differential voltage acquisition circuit, and a phase detection circuit. The signal acquisition module 11 calculates the dielectric coupling impedance based on the voltage amplitude across the detection electrode pair, the current amplitude flowing through the sampling impedance, and the phase difference between the voltage and current. The structure of adjacent detection electrode pairs, the baseline calibration method of the detection circuit, and the parasitic impedance compensation method are also considered. Figure 4 The corresponding implementation method is the same.

[0138] For the current insulating potting material, the main control unit 10 pre-determines the operating frequency of dielectric detection through frequency scanning, and calibrates the direction of change of impedance amplitude or impedance phase near the gelation stage through rheological and impedance tests. The thermodynamic control module 13 performs first-order and second-order difference operations on the smoothed impedance characteristic sequence. When the second-order difference undergoes a sign change in a preset direction, the first-order difference meets the change direction threshold corresponding to the current material, and this state is maintained continuously for no less than a preset number of sampling points, the thermodynamic control module 13 determines the moment when the above conditions are first met as the candidate gelation characteristic moment.

[0139] When a candidate gel characteristic moment falls within the preset allowable gel time range for the current material, the thermodynamic control module 13 determines it as a valid gel characteristic moment. For materials whose dielectric coupling impedance amplitude increases near the gel stage, the gel characteristic moment can be determined according to the following conditions: ; In the formula, Indicates the characteristic moment of gelation; This indicates the first valid moment on the timeline when the judgment condition is met; This represents a smoothed timing dielectric coupling impedance signal; This indicates the solidification time. In discrete signal processing, the zero-crossing position of the second-order difference is determined by judging whether the sign of the second-order difference between adjacent sampling points changes in a preset direction.

[0140] For materials whose dielectric coupling impedance amplitude decreases near the gelation stage, the first-order change direction condition is adjusted to a negative change condition; for materials with more significant impedance phase changes, the impedance phase sequence is used instead of the impedance amplitude sequence to perform the same differential judgment. The change direction, judgment threshold, and allowable gelation time range for each material are predetermined based on the comparison results of rheological and impedance tests.

[0141] When no effective gel characteristic moment is detected within the allowable gel time range, the thermal control module 13 uses the reference gel time obtained by rheological testing of the same batch of insulating potting materials as the alternative trigger moment and records the dielectric detection anomaly.

[0142] The start and end times of the compensation time window are determined by adding preset start and end offsets to the effective gel characteristic time or the alternative trigger time. The start and end offsets are calibrated through rheological tests of the same batch of materials and thermal compensation tests of standard samples.

[0143] After entering the compensation time window, the actuators of each zone in the multi-temperature zone curing equipment 30 switch to an asymmetric temperature control state. In this embodiment, the zone actuators use infrared radiation heating tubes arranged in a ring array along the outer periphery of the conductive slip ring.

[0144] The thermal control module 13 is based on the global deformation azimuth angle Predicting deformation amplitude Based on the temperature difference-deformation response model and the current temperature range control parameters, calculate the first... Target temperature increment for each temperature zone The target temperature increment is based on the first... Installation angle of each temperature zone The relationship between the target compensation orientation and the material is assigned and limited to the maximum temperature difference allowed by the insulating potting material process.

[0145] No. Target temperature for each temperature zone Based on the curing temperature With target temperature increment The results are obtained by adding them together. The temperature detection component collects the data for the first... The actual controlled temperature of each temperature zone The thermal control module 13 determines the target temperature based on the thermal control module 13. With actual control temperature The deviation between them is used to calculate the pulse width modulation duty cycle of the corresponding partition actuator. .

[0146] In this embodiment, the thermal control module 13 employs a proportional-integral-derivative (PID) controller to perform closed-loop temperature regulation. The parameters of the PID controller are tuned through step heating response tests in each temperature zone, and the calculated pulse width modulation duty cycle is obtained. After being limited, the output is sent to the corresponding partition executor.

[0147] The asymmetric temperature distribution in each temperature zone causes the insulating potting material to undergo asymmetric shrinkage of controllable direction and extent during gelation and subsequent curing. The crosslinking reaction rate and volume shrinkage degree change accordingly in the higher temperature regions, causing the insulating potting material to form a directional thermal micro-warping effect under the constraint of the conductive slip ring structure.

[0148] The thermal control module 13 selects the target temperature distribution based on the temperature difference-deformation response model, ensuring that the expected thermal micro-warpage vector obtained from the standard sample calibration is in the opposite direction to the predicted deformation vector, or reducing the amplitude of the combined expected thermal micro-warpage vector and the predicted deformation vector. This reduces the central axis offset, annular radial deformation, or related periodic fluctuations in dynamic contact resistance after curing. This compensation method achieves deformation adjustment through material shrinkage during the curing process, eliminating the need to apply mechanical corrective loads to the conductive slip ring.

[0149] During thermal compensation, the thermal control module 13 continuously calculates the first-order rate of change of the time-series dielectric coupling impedance signal. As the cross-linking degree of the insulating potting material increases, the rate of change of the impedance characteristic gradually stabilizes. The thermal control module 13 defines the absolute value of the first-order rate of change of the smoothed dielectric coupling impedance signal as the convergence state characteristic value. .

[0150] When convergence state characteristics No less than The number of sampling points is below the steady-state rate of change threshold. At that time, the thermal control module 13 determines that the insulating potting material has entered the curing stage where thermal compensation sensitivity is reduced. The cutoff judgment conditions are as follows: ; In the formula, Indicates the steady-state rate of change threshold; This represents the number of sampling points that continuously satisfy the steady-state judgment condition. It is determined based on the sampling frequency of the dielectric impedance signal and the allowable truncation response time.

[0151] Steady-state rate of change threshold Calibration is performed based on the rate-of-change noise of the dielectric impedance detection channel. Under the same sampling frequency, filtering parameters, and oven temperature conditions, the signal acquisition module 11 acquires the dielectric coupling impedance signal of the fully cured reference sample and calculates the peak-to-peak value or standard deviation of the noise in the first-order differential sequence of this signal. Steady-state rate-of-change threshold. It can be set to 1.2 to 1.5 times the peak-to-peak value of the first-order differential noise, or set to a preset multiple of the standard deviation of the first-order differential noise.

[0152] Meeting the cutoff criteria indicates that the insulating potting material has entered a stage where its thermal compensation sensitivity has significantly decreased, but it does not mean that the material has completely lost its deformation capacity. The thermal control module 13 gradually reduces the target temperature increment of each temperature zone to zero according to a preset descent slope, so that the target temperature of each temperature zone smoothly recovers to the basic curing temperature. The pulse width modulation duty cycle of each zone actuator is automatically adjusted by the proportional-integral-derivative controller according to the deviation between the target temperature and the actual control temperature, so as to avoid thermal shock caused by sudden changes in the target temperature and reduce the risk of excessive deformation caused by continuous application of temperature difference during the deep curing stage.

[0153] See attached document Figure 7 The present invention provides a further embodiment of the principles for multi-order resistance harmonic extraction, thermal compensation response model identification, and temperature zone control parameter iterative correction.

[0154] After thermal micro-warping compensation and base curing are completed, the material carrier 50 transports the conductive slip ring to the electrical performance testing equipment 40. The electrical performance testing equipment 40 includes a servo-driven test bench and an incremental photoelectric encoder. The conductive slip ring is mounted on the servo-driven test bench and rotates continuously at a preset constant speed; the incremental photoelectric encoder synchronously outputs an angular pulse signal corresponding to the mechanical rotation angle of the conductive slip ring.

[0155] The signal acquisition module 11 uses a four-wire micro-resistance measurement circuit to acquire the dynamic contact resistance of the channel under test. A constant current source applies a constant DC test current to the channel under test through a set of current leads, and an independently set voltage detection lead acquires the voltage drop signal across the contact. The voltage drop signal is amplified by a differential amplifier or instrumentation amplifier and then converted from analog to digital to obtain the timing dynamic contact resistance signal under constant speed rotation of the conductive slip ring.

[0156] When a conductive slip ring has eccentricity or unilateral local deformation, the dynamic contact resistance may exhibit a periodic component that is predominantly once per revolution; when the slip ring is elliptical, a periodic component that is predominantly twice per revolution may appear; when there is multi-lobed deformation or circumferential periodic defect, a higher-order periodic component of the corresponding order may appear.

[0157] The feedback correction module 14 converts the time-sampled dynamic contact resistance signal into an angle-domain contact resistance sequence based on the angle pulse signal output by the incremental photoelectric encoder. The signal acquisition module 11 associates the contact resistance sampling points with the corresponding mechanical rotation angles based on the timestamps generated by the system clock, in order to reduce data misalignment and phase deviation between different sampling links.

[0158] The electrical performance testing equipment 40 drives the conductive slip ring to rotate continuously for multiple complete cycles. The feedback correction module 14 resamples the sampling data of each rotation cycle to a uniform angle grid and synchronously averages the sampling values ​​at the same angle position to reduce the impact of environmental electromagnetic interference, mechanical friction noise and random contact fluctuations on the periodic feature extraction results.

[0159] Feedback correction module 14 performs multi-order phase-locked harmonic extraction on the angle-domain contact resistance sequence. For the first... The first harmonic, feedback correction module 14 generates the first harmonic with the mechanical rotation frequency. The sinusoidal and cosine reference carriers of the same frequency as the first harmonic are used, and discrete mixing and periodic integration are performed with the contact resistance sequence in the angle domain, respectively, to obtain the first harmonic. The two orthogonal components of a harmonic. Harmonic order. It includes at least 1 and 2, and can be extended to preset higher harmonics depending on the conductive slip ring structure and the type of defect to be identified.

[0160] The specific dimensionality reduction extraction formula is as follows: ; ; ; ; In the formula, This represents the total number of discrete sampling points within a single rotation cycle. Indicates the discrete sampling point number; Indicates the first The contact resistance value corresponding to each sampling point; Indicates the first The mechanical rotation angle corresponding to each sampling point; and These represent the sinusoidal mixing integral component and the cosine mixing integral component, respectively; Indicates the first Harmonic amplitude of dynamic contact resistance; Indicates the first Phase of dynamic contact resistance harmonics.

[0161] Harmonic amplitude This is used to represent the degree of periodic resistance fluctuations of the corresponding order. Only after establishing the resistance harmonic-mechanical deformation calibration model can the harmonic amplitude be converted into the equivalent mechanical deformation amplitude according to the corresponding calibration relationship.

[0162] The feedback correction module 14 determines the amplitude signal-to-noise ratio and the phase stability over multiple consecutive rotations of each harmonic. Only when the ratio of the corresponding harmonic amplitude to the noise amplitude exceeds a preset threshold, and the phase dispersion over multiple consecutive rotation cycles is lower than a preset threshold, is the harmonic determined to be a valid harmonic.

[0163] The feedback correction module 14 uses the mechanical zero position of the incremental photoelectric encoder as the phase reference for each order of harmonics, and performs a coordinate reverse rotation according to the calibration angle between the zero position of the test fixture and the fixed mechanical positioning zero position of the material carrier 50, so as to convert the phase characteristics of each effective harmonic to the local polar coordinate system of the carrier.

[0164] For the first harmonic, the conversion result represents the directional residual periodic resistance orientation; for the second harmonic, the non-directional principal axis orientation is determined based on half of the second harmonic phase, and the principal axis orientation is limited to the range of 0 to 180 degrees. The second harmonic cannot distinguish between two opposite directions that are 180 degrees apart. When a directional compensation orientation is required, the feedback correction module 14 combines the first harmonic phase, the known excitation direction in the temperature range, or the mechanical detection result to make a judgment.

[0165] The feedback correction module 14 constructs a residual resistance harmonic characteristic vector based on the amplitude and phase of each effective harmonic. When the resistance harmonic-mechanical deformation calibration model is not established, the residual resistance harmonic characteristic vector only characterizes the amplitude and orientation of the periodic resistance fluctuations and does not directly represent the mechanical deformation.

[0166] With the established resistance harmonic-mechanical deformation calibration model, the feedback correction module 14 calculates the equivalent residual deformation vector based on the residual resistance harmonic characteristic vector and the calibration model. For a first-order periodic resistance characteristic, the corresponding equivalent eccentric or unilateral deformation orientation can be obtained from the calibration model; for a second-order periodic resistance characteristic, the corresponding equivalent elliptic principal axis orientation can be obtained.

[0167] To reduce the impact of surface contamination, brush pressure dispersion, and wiring status on the test results, the feedback correction module 14 can perform forward and reverse rotation tests respectively, or correlate and verify the dynamic contact resistance harmonic characteristics with the test results of circular runout, roundness, or radial displacement. When the phase-locked harmonic phase is repeatable in multiple consecutive rotation cycles, the corresponding characteristic is determined as a stable residual periodic resistance characteristic; when the phase-locked harmonic results and mechanical test results meet the preset consistency conditions, the equivalent residual deformation is calculated through the resistance harmonic-mechanical deformation calibration model.

[0168] Cross-batch parameter correction uniformly uses the residual resistance harmonic characteristic vector as the feedback output. The feedback correction module 14 uses a recursive least squares algorithm to perform online identification of the thermal compensation response model. The thermal compensation response model is used to describe the mapping relationship between the production process state, temperature control parameters, and the residual resistance harmonic characteristics after curing.

[0169] The input state vector of the thermal compensation response model includes the predicted deformation transverse component, the predicted deformation longitudinal component, the transverse and longitudinal components of the actual temperature asymmetry feature vector, the duration of the compensation time window, the deviation of the gel characteristic time from the reference gel time, and the current temperature control parameters; the model output is the residual resistance harmonic observation vector composed of the orthogonal components of each effective phase-locked harmonic.

[0170] For each scalar component in the residual resistance harmonic observation vector, the feedback correction module 14 sets the corresponding recursive least squares identification channel and updates the thermal compensation response model parameters according to the input state vector of the current production batch and the actual observation value.

[0171] The basic temperature control parameters of the current product model are pre-calibrated using a temperature difference-deformation response model without zero initialization. The recursive least squares algorithm is used to identify incremental responses outside the basic model. Its initial model parameter vector is set to a zero vector, and the initial error covariance matrix is ​​set to a diagonal matrix with diagonal elements of 1000.

[0172] After updating the model parameters for the current production batch, the feedback correction module 14 calculates the impact of changes in the global target temperature difference gain, compensation phase offset, and temperature increment correction coefficients of each temperature zone on the residual resistance harmonic observation vector based on the updated thermal compensation response model, and forms a sensitivity matrix between the temperature zone control parameters and the residual resistance harmonic observation.

[0173] The feedback correction module 14 aims to reduce the predicted residual resistance harmonic observation vector for the next production batch by calculating the temperature zone control parameter correction amount through constrained least squares operation. The temperature zone control parameter correction amount includes the global target temperature difference gain correction amount, the compensation phase offset correction amount, and the temperature increment correction amount for each temperature zone.

[0174] The feedback correction module 14 applies upper and lower limit constraints and single-batch maximum change constraints to the temperature zone control parameter correction amount, and sends the constrained temperature zone control parameters to the thermal control module 13. When processing the next production batch, the thermal control module 13 adjusts the asymmetry of the target temperature distribution according to the updated global target temperature difference gain, adjusts the circumferential orientation of the target temperature distribution according to the compensation phase offset, and adjusts the target temperature of the corresponding temperature zone according to the temperature increment correction coefficient of each temperature zone.

[0175] When the condition number of the sensitivity matrix exceeds a preset threshold, the number of valid samples is insufficient, the change amplitude of the input state vector in consecutive production batches is lower than a preset identification threshold, or there is a sensor malfunction in the current production batch, the feedback correction module 14 will not perform the current model parameter update and temperature control parameter correction. When the updated temperature control parameters cause an increase in the residual resistance harmonic amplitude in multiple consecutive production batches, the main control unit 10 will stop automatic iteration and revert to the temperature control parameters that most recently met the product quality requirements.

[0176] As production batches increase, the thermal compensation response model is continuously revised based on production process data and electrical performance test results, allowing the temperature control parameters to adapt to changes in equipment status, batches of insulating potting materials, and product structure, thereby reducing the periodic fluctuations in the dynamic contact resistance of the conductive slip ring. Furthermore, given the established resistance harmonic-mechanical deformation calibration model, it can also reduce the equivalent residual deformation corresponding to the periodic resistance characteristics.

[0177] The temperature difference-deformation response model was established through standard sample experiments. Standard samples with the same structure and material system as the conductive slip ring to be produced were divided into multiple groups. Each group was subjected to the same basic curing procedure and different asymmetric temperature distributions with different directions, amplitudes and durations.

[0178] After curing, the central axis offset or annular radial deformation of each standard sample was measured using a roundness measuring device, a radial displacement measuring device, or a coordinate measuring machine. Based on the correspondence between the actual temperature asymmetry characteristic vector, the duration of the compensation time window, the gel characteristic moment, and the measured deformation change, a temperature difference-deformation response model was fitted.

[0179] The temperature difference-deformation response model is only used within the range of the basic curing temperature, maximum temperature difference, compensation time window duration, and product structure covered by the standard sample verification. When the calculated target temperature condition exceeds the model calibration range, the thermal control module 13 will limit the target temperature to the calibration range boundary, or stop asymmetric thermal compensation and output a recalibration prompt.

[0180] The resistance harmonic-mechanical deformation calibration model was also established through standard sample testing. The first eccentricity component, the second ellipticity component, and the higher-order deformation components to be detected of the standard sample were obtained using roundness measuring equipment or radial displacement measuring equipment, and the corresponding dynamic contact resistance harmonics were collected under the same rotational speed, test current, and brush preload conditions.

[0181] Based on the relationship between the mechanical deformation component and the amplitude, phase, and corresponding mechanical orientation of the resistance harmonics, a resistance harmonic-mechanical deformation calibration model is obtained. When the test results of the standard sample show that a certain order resistance harmonic does not have repeatability or correlation with the corresponding mechanical deformation component that meets the preset requirements, the resistance harmonic is not converted into a mechanical deformation variable, but is only used as an evaluation index of the electrical performance quality of the conductive slip ring.

[0182] This embodiment uses a conductive slip ring with four independent assembly channels as the engineering application basis, and details the closed-loop control and data processing logic of the main control unit in the multi-station flow process. The physical arrangement angles of the four independent assembly channels of the conductive slip ring in the local polar coordinate system of the vehicle are set to 0 degrees, 90 degrees, 180 degrees and 270 degrees, respectively.

[0183] During assembly by the servo crimping device, the signal acquisition module synchronously records mechanical and displacement signals at high frequency. The vector mapping module performs discrete integration on the force and displacement curves of each channel to extract the crimping work feature values ​​of the corresponding channels. The feature values ​​of the current samples are 10.5 joules, 9.8 joules, 8.2 joules, and 10.0 joules. The system then performs asymmetric feature vector synthesis calculation, and the crimping work offset components of the horizontal and vertical axes are calculated as follows: ; ; The vector mapping module calls a pre-defined linear structural mechanics transformation matrix. In the initial state of this batch, the calibration gain coefficient is set to 2.0 micrometers per joule. From this, the physical components of the predicted deformation are calculated: the lateral predicted deformation component is 4.6 micrometers, and the longitudinal predicted deformation component is -0.4 micrometers. Further derivation of the predicted deformation amplitude and vector azimuth angle follows: ; ; The calculated deformation amplitude of 4.62 micrometers and azimuth angle of 355 degrees were simultaneously incorporated into the assembly state feature vector matrix of the sample.

[0184] The material carrier enters the multi-zone curing equipment along the conveyor line. Positioning sensors detect a 5-degree counter-clockwise physical deflection of the carrier during transport. The thermal control module immediately performs a spatial rotation matrix transformation, resulting in a global deformation azimuth angle of 360 degrees, equivalent to a 0-degree baseline. This calculation indicates that the dominant release direction of residual stress in the assembly is precisely aligned with the first temperature zone of the multi-zone curing equipment. During the curing heating cycle, the signal acquisition module continuously extracts the timing characteristics of the dielectric coupling impedance of the potting material at a 100 kHz micro-level detection frequency.

[0185] When the system detects that the second-order difference sequence of impedance crosses zero and the first-order difference is positive and remains stable for 50 consecutive sampling cycles, the thermal control module determines that the polymer chain segments inside the potting compound have reached the critical point of gel cross-linking, and then triggers the asymmetric thermal compensation time window. Based on the calibration of the basic physical properties, this material requires a 2-degree Celsius spatial temperature gradient to eliminate 1-micron structural eccentricity. The system calculates the target maximum temperature increment as 9.2 degrees Celsius based on the deformation amplitude.

[0186] Based on a base curing temperature of 80 degrees Celsius, the thermal control module reconstructs the boundary conditions of the multi-temperature zone thermal field distribution. It dynamically raises the first temperature zone at 0 degrees to 89.2 degrees Celsius, locks the third temperature zone at 180 degrees Celsius at 80 degrees Celsius, and sets the adjacent second and fourth temperature zones at 84.6 degrees Celsius following a smooth fluid dynamics transition curve. High-precision platinum resistance thermometers in each temperature zone provide real-time feedback on the local cavity heat flux density. The main controller outputs a high-frequency pulse width modulation duty cycle using a proportional-integral-differential algorithm to maintain this asymmetric thermal field distribution.

[0187] This spatial temperature gradient causes the crosslinking reaction rate of the potting compound in the 0-degree direction to be higher than that on the opposite side, inducing anisotropic gel shrinkage stress, which precisely counteracts the eccentric residual tendency introduced by the previous pressing. When the first-order rate of change of dielectric impedance decays to within the steady-state noise threshold, the thermal compensation program is automatically cut off, and each temperature zone smoothly returns to the 80-degree Celsius insulation baseline.

[0188] The cured conductive slip ring enters the electrical performance constant-speed rotation test bench and operates at a constant angular velocity of 60 revolutions per minute. The feedback correction module performs Fourier series expansion on the contact impedance waveform, extracts the key indicators affecting the stability of signal transmission, the first-order harmonic amplitude is 15 milliohms, and the initial phase is measured as 8 degrees. The system substitutes this phase angle into the carrier zero calibration matrix for reverse rotation compensation, eliminates the measurement error introduced by the 5-degree carrier deflection in the previous stage, and corrects the actual failure phase to the 3-degree azimuth in the local polar coordinate system. Then the residual resistance harmonic observation vector is decomposed: ; ; The feedback correction module summarizes the observation data of all samples in the current batch to construct a mean vector, injects it into the state equation of the recursive least squares algorithm, and performs weight update of thermodynamic incremental parameters: ; If the algorithm determines that there is still systematic deformation residual after applying a 9.2 degree Celsius bias, it indicates that a微小 drift has occurred in the material batch properties or the mechanical stiffness of the equipment. The system then adaptively adjusts the global target temperature difference gain of the next batch from 2.0 degrees Celsius per micrometer to 2.15 degrees Celsius per micrometer, completing the online evolution of the manufacturing closed loop.

[0189] To verify the engineering effectiveness of the multi-station closed-loop control and dielectric thermal response compensation logic, in-line production testing is performed on a specific model of multi-channel slip ring. The experiment is divided into three process control groups, 300 consecutively produced samples are extracted from each group, and a total of 900 sample data are collected. The assessment dimensions are locked as the first-order harmonic amplitude of dynamic contact resistance, mechanical equivalent eccentricity and first delivery acceptance qualification rate. A first-order harmonic amplitude lower than 20 milliohms is defined as qualified.

[0190] Table 1: Comparison table of engineering performance of 3 production control schemes for conductive slip rings Analysis of test data and Figure 8 and Figure 9 show that the multi-physics strong coupling characteristic of each manufacturing link directly determines the electrical stability of the end product. Due to the lack of an intervention mechanism for assembly residual stress in the conventional control group, the physical eccentricity rises to 12.4 micrometers, which causes the average harmonic amplitude to exceed the limit, and the overall yield is only 72.0%. The open-loop compensation group guides directional micro-shrinkage of materials through feedforward vector mapping and static thermal bias, reducing the eccentricity to 6.8 micrometers. However, limited by the slight variation of physical properties of polymer materials across batches, the fixed parameter model has under-compensation or over-compensation blind areas, resulting in an out-of-tolerance extreme value of 26.4 milliohms, which confirms that static open-loop control cannot cope with nonlinear dynamic drift in the manufacturing process.

[0191] To address the aforementioned shortcomings, this system constructs an asymmetric temperature gradient distribution within the multi-temperature-zone curing chamber, resulting in a fluid thermodynamic profile exhibiting strong directional stretching characteristics. The temporally varying impedance surface forms a bright confluence zone in three-dimensional space, precisely identifying the coupling boundary between the second-order difference zero-crossing point and the high-level temperature field gradient. This physical watershed establishes the precise coordinates for the opening of the thermal compensation time window, enabling deep microscopic control through the coordinated intervention of electrical, thermal, and mechanical fields. The introduction of in-situ dielectric monitoring completely locks the optimal intervention point for gel crosslinking, avoiding secondary deformation caused by blindly applying thermal stress.

[0192] Driven by the closed-loop algorithm, the recursive least squares method demonstrates an excellent convergence evolution path in continuous production batches. The parameter state points rapidly converge from the initial divergent state along a multidimensional spiral, entering a high-density central gravity region after a finite number of batches, establishing a steady-state formation of adaptive weights. The high-dimensional quality distribution projection clearly shows that the sample contact resistance harmonics of traditional processes exhibit a broad and discretely distributed shallow hill-like base, while the closed-loop evolution group of this scheme converges extremely towards the low impedance region, forming a sharp peak shape. The mean value of the first harmonic is completely suppressed to an extremely low level of 12.6 milliohms, ultimately achieving an industrial-grade high yield of 98.0%. From the perspectives of data visualization and statistics, this rigorously demonstrates the substantial breakthrough of the closed-loop adaptive mechanism in overcoming the limits of product consistency.

[0193] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-station intelligent production control system for conductive slip rings, characterized in that, include: Servo pressing equipment, multi-temperature zone curing equipment, electrical performance testing equipment, conveying mechanisms, material carriers, and main control units; The material carrier carrying the conductive slip ring moves between the servo pressing equipment, the multi-temperature zone curing equipment, and the electrical performance testing equipment via the conveying mechanism; The main control unit is communicatively connected to the servo pressing device, the multi-temperature zone curing device, the electrical performance testing device, and the conveying mechanism, respectively. The main control unit includes a signal acquisition module, a vector mapping module, a thermal control module, and a feedback correction module; The signal acquisition module acquires the timing mechanical signals and timing displacement signals during the pressing stage, the timing dielectric coupling impedance signal during the curing stage, and the timing dynamic contact resistance signal during the testing stage. The vector mapping module synthesizes a pressure-bonded asymmetric feature vector based on the time-series mechanical signal and the time-series displacement signal, and outputs a predicted deformation vector by inputting the structural mechanics transformation model. The thermal control module determines the gel characteristic moment and compensation time window based on the time-series dielectric coupling impedance signal, calculates the target temperature of each temperature zone based on the predicted deformation vector within the compensation time window, and outputs temperature distribution control commands. The feedback correction module extracts the harmonic features of the time-series dynamic contact resistance signal to construct a residual resistance harmonic feature vector, and performs thermal compensation response model identification based on the residual resistance harmonic feature vector to calculate the temperature zone control parameter correction amount.

2. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The vector mapping module uses the time-series displacement signal as the integration variable to integrate the time-series mechanical signal to obtain the crimping work characteristic value of each independent assembly channel. Combining the physical arrangement angle of each independent assembly channel in the local polar coordinate system of the vehicle, the crimping work characteristic value of each independent assembly channel is vector synthesized to obtain the crimping asymmetric characteristic vector.

3. The intelligent production control system for multi-station machining of conductive slip rings according to claim 2, characterized in that: The system also includes a positioning and identification sensor; the positioning and identification sensor is communicatively connected to the main control unit; the positioning and identification sensor detects the physical deflection angle of the material carrier relative to the global coordinate system when it arrives at the multi-temperature zone curing equipment; the thermal control module rotates the predicted deformation vector in the local polar coordinate system of the carrier according to the physical deflection angle, transforms the predicted deformation vector to the global coordinate system, and outputs the global deformation azimuth angle.

4. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The signal acquisition module applies a high-frequency detection micro-level to adjacent detection electrodes to acquire the time-series dielectric coupling impedance signal; the thermodynamic control module smooths the time-series dielectric coupling impedance signal and then performs first-order and second-order difference operations. When the sign of the second-order difference operation result changes in a predetermined direction and the first-order difference operation result meets the preset change direction threshold and continuously maintains the preset number of sampling points, the corresponding time is determined as the gel characteristic time.

5. The intelligent production control system for multi-station machining of conductive slip rings according to claim 4, characterized in that: Within the compensation time window, the thermal control module calculates the first-order rate of change of the timing dielectric coupling impedance signal. When the absolute value of the first-order rate of change is continuously lower than the steady-state rate of change threshold, a convergence condition satisfaction signal is generated. After receiving the convergence condition satisfaction signal, the thermal control module reduces the target temperature increment of each temperature zone according to a preset descent slope, and controls each temperature zone to return to the basic curing temperature.

6. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The thermodynamic control module is equipped with a temperature difference response model, which maps the quantitative relationship between temperature increment of temperature zone, duration of compensation time window, gel characteristic moment and equivalent deformation vector; the thermodynamic control module calculates the target temperature corresponding to each temperature zone based on the predicted deformation vector and the temperature difference response model.

7. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The feedback correction module converts the time-series dynamic contact resistance signal into an angle-domain contact resistance sequence based on the angle pulse signal output by the incremental photoelectric encoder, and extracts the first and second phase-locked harmonics related to the mechanical rotation cycle; the feedback correction module constructs the residual resistance harmonic feature vector based on the amplitude and phase of each phase-locked harmonic that meet the validity conditions.

8. The intelligent production control system for multi-station machining of conductive slip rings according to claim 7, characterized in that: The input state vector of the thermal compensation response model includes the predicted deformation lateral component, the predicted deformation longitudinal component, the lateral and longitudinal components of the actual temperature asymmetry feature vector, the duration of the compensation time window, the deviation of the gel characteristic moment from the reference gel time, and the current temperature zone control parameters. The feedback correction module uses the recursive least squares algorithm to identify the thermal compensation response model online, and combines constrained least squares operation to calculate the global target temperature difference gain correction, the compensation phase offset correction, and the temperature increment correction for each temperature zone.

9. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The system also includes a carrier tag reading component. The material carrier is equipped with a fixed mechanical positioning zero point and a unique identification tag. The main control unit establishes a local polar coordinate system of the carrier based on the fixed mechanical positioning zero point, and establishes a slip ring assembly state vector corresponding to the physical conductive slip ring according to the unique identification tag. The main control unit calls the slip ring assembly state vector according to the reading result of the carrier tag reading component.

10. The intelligent production control system for multi-station machining of conductive slip rings according to claim 1, characterized in that: The multi-temperature zone curing equipment has independent heating zones distributed in a circumferential array, and each independent heating zone is equipped with a zone actuator and a temperature detection component; the main control unit adjusts the pulse width modulation duty cycle of the corresponding zone actuator through a temperature closed-loop controller according to the deviation between the target temperature and the actual control temperature collected by the temperature detection component.

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