A Dynamic Calibration Method for Tank Support Limitation Based on Displacement Feedback

Abstract

This invention discloses a dynamic calibration method for tank support limits based on displacement feedback, relating to the field of industrial control technology. The method includes: acquiring the initial support position and initial limit clearance, and performing zero-position calibration and clearance calibration respectively to form a support zero-position reference and a limit clearance reference; performing dual-domain dead-zone compensation on the support zero-position reference and the limit clearance reference to obtain the support running offset and limit insertion amount, and dividing the support action boundary and the limit action boundary; limiting the trial control range of the PLC controller, triggering the PLC controller to issue a short-stroke action command to execute a short-stroke trial movement and record the tank feedback changes, eliminating idle stroke segments that do not produce tank feedback changes, and forming effective action boundaries; using the effective action boundaries to correct the support running offset and limit insertion amount, forming the support limit dynamic calibration result. This invention improves the stability, executability, and control consistency of the support limit dynamic calibration result by limiting the trial control range of the PLC controller.

Description

Technical Field

[0001] This invention relates to the field of industrial control technology, and in particular to a dynamic calibration method for tank support limit based on displacement feedback. Background Technology

[0002] With the increasing demand for continuous operation of large container equipment in chemical, metallurgical, energy and building materials production, the adjustment of the contact state between the equipment and the supporting limit components has gradually evolved from static correction to online attitude constraint and position correction during operation. Existing technologies use sensor measurement, actuator displacement adjustment and industrial controller command distribution to coordinate the management of contact state, lateral constraint state and operating attitude changes. The focus is on mechanical contact state identification, limit contact reliability maintenance, actuator micro-motion control and operating attitude closed-loop adjustment, so as to adapt to the problems of vibration disturbance, load change and installation error accumulation in the long-term operation of large container equipment.

[0003] However, existing technologies often use the change in the stroke of the actuator as the calibration boundary, which easily includes the idle stroke segment that does not cause a change in the tank feedback as the basis for correcting the support running offset and limit pressing amount. Although the short stroke control command has triggered the actuator to move, the tank has not yet generated an effective displacement response, making it difficult for the calibration boundary to accurately reflect the actual displacement response of the tank, affecting the consistency and executability of the dynamic calibration results of the support limit. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, this invention provides a dynamic calibration method for tank support limit based on displacement feedback to solve the problem that the calibration boundary is difficult to accurately reflect the true displacement response of the tank.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0007] This invention provides a dynamic calibration method for tank support limiting based on displacement feedback, comprising:

[0008] Obtain the initial support position and the initial limit gap, and perform zero-position calibration and gap calibration respectively to form the support zero-position reference and the limit gap reference;

[0009] Dual-domain dead zone compensation is performed on the support zero-position reference and the limit gap reference to obtain the support running offset and the limit push-in amount, and the support action boundary and the limit action boundary are divided.

[0010] By using the support action boundary and limit action boundary to define the trial control range of the PLC controller, the PLC controller is triggered to issue a short-stroke action command to execute a short-stroke trial movement and record the tank feedback changes. The idle stroke segment that does not produce a tank feedback change is eliminated to form an effective action boundary.

[0011] The effective action boundary is used to correct the support running offset and limit pressing amount, forming the support limit dynamic calibration result.

[0012] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the specific steps for forming the support zero-position reference and the limit gap reference are as follows:

[0013] Under the static support state of the tank, the support side position reading of the support contact part and the limit side clearance reading of the adjacent part of the limit block are collected to form the initial support position and the initial limit clearance.

[0014] The support contact area is pressed and reset at the initial support position to generate lift-off and fall-back readings.

[0015] The zero-scale reading and zero-position acquisition position are determined based on the fallback reading. The initial position of the support is calibrated using the zero-scale reading to form the support zero-position reference.

[0016] Based on the initial limit gap, the PLC controller sends an advance contact action command and a retraction stop action command to the limit actuator, controlling the limit block to complete the limit advance and retraction actions and generating advance and retraction readings;

[0017] The limit clearance readings that do not reach the initial limit clearance in the forward and reverse gear readings are discarded to form the limit clearance reference.

[0018] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the specific steps for obtaining the support running offset and limit pressing amount are as follows:

[0019] Based on the zero-position reference, the idle travel reading and return travel stagnation reading are located and eliminated from the position readings on the support side to obtain the support running offset;

[0020] Use the limit clearance reference to find the movement position where the initial limit clearance is located, and use it as the initial limit position;

[0021] The advance reading is zeroed out along the initial position of the limit switch to obtain a zero reading. The zero reading is used as the cutoff point. The advance reading between the cutoff point and the end position of the limit advance amount is retained to form the limit advance amount.

[0022] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the support action boundary is the action segment formed from the starting position of the support movement offset away from the zero position acquisition position to the ending position of the support movement offset away from the zero position acquisition position.

[0023] The limit action boundary is the action section extending from the starting position of the limit indentation when the limit side clearance reading reaches zero to the ending position of the limit indentation.

[0024] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the specific steps of defining the trial control range of the PLC controller using the support action boundary and the limit action boundary are as follows:

[0025] The direction from the starting position to the ending position in the support action boundary is determined as the support operation offset direction. The action position that does not fall into the empty stroke reading and the return stroke retention reading is selected along the support operation offset direction to form the support side test section.

[0026] Within the limit action boundary, the limit side clearance reading is zeroed out in segments to form a limit side test segment;

[0027] The support-side test section and the limit-side test section are written into the PLC controller as the test control range of the PLC controller.

[0028] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the specific steps of triggering the PLC controller to issue a short-stroke action command to execute a short-stroke trial movement are as follows:

[0029] The action position of the PLC controller's trial control range is read to obtain the support trial action position and the limit trial action position;

[0030] The PLC controller is triggered by the position of the support test action to issue a short-stroke action command to the support actuator, which controls the support actuator to drive the support contact part to perform a short-distance movement along the support running offset direction and complete the reverse short-stroke convergence at the end of the support side test section, thus generating the support test stroke.

[0031] The limit actuator is activated by the PLC controller, which drives the limit block to the zero boundary position and then returns to the initial limit position, generating the limit trial stroke.

[0032] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the support actuator is a support-side action component controlled by a PLC controller, connected to the support contact part, and driving the support contact part to move.

[0033] The limit actuator is a limit-side action component controlled by a PLC controller, connected to a limit block, and driving the limit block to move.

[0034] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the reverse short-stroke convergence is achieved when, after the tank reaches the end reading position of the support-side test section, the PLC controller stops the short-stroke test movement and controls the tank to retreat to the support-side test section, thus completing the reverse short-stroke convergence.

[0035] As a preferred embodiment of the dynamic calibration method for tank support limit based on displacement feedback described in this invention, the tank feedback change includes the support-side tank feedback change generated relative to the initial support position within the support test stroke, and the limit side gap change generated relative to the initial limit gap within the limit test stroke.

[0036] As a preferred embodiment of the tank support limit dynamic calibration method based on displacement feedback described in this invention, the specific steps for forming the support limit dynamic calibration result are as follows:

[0037] The effective action boundary is used to screen out the action positions that cause tank feedback changes during the support trial stroke, and the start and end positions of the support running offset are corrected based on the start and end points of the action positions to form the corrected support running offset.

[0038] The limit test stroke is delineated and intercepted, and the advance and retraction readings at the zeroing boundary position and the restored initial limit gap position are retained to form the corrected limit push-in amount;

[0039] The corrected support running offset and the corrected limit push-in amount are combined into the support limit dynamic calibration result.

[0040] The beneficial effects of this invention are as follows: By limiting the trial control range of the PLC controller, the response relationship between the PLC controller's action output and the tank's displacement change is clarified. This effectively distinguishes between real effective actions and idle interference, reducing the situation where invalid strokes in minor movements of the support and limit sides are mixed into the calibration judgment. This shifts the basis for correcting support running offset and limit pressing amount from simple action commands to real feedback results, thereby reducing the risks of misadjustment, boundary drift, and action lag in dynamic calibration of support and limit. At the same time, short-range trial movement can expose the idle stroke of the support side and the clearance deviation of the limit side within a small action amplitude, making the effective action boundary closer to the actual response state of the tank. This avoids the mechanical idle stroke, contact lag, and backlash deviation of the support and limit actuators being mistakenly regarded as effective calibration basis, enhancing the identifiability and verifiability of the effective action boundary, and improving the stability, executability, and control consistency of dynamic calibration of support and limit. Attached Figure Description

[0041] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0042] Figure 1 This is a flowchart of a dynamic calibration method for tank support limit based on displacement feedback.

[0043] Figure 2 A flowchart for creating a support zero-position reference and a limit gap reference.

[0044] Figure 3 A flowchart for forming effective action boundaries.

[0045] Figure 4 A flowchart for generating dynamic calibration results for support limits.

[0046] Figure 5 A timing comparison diagram to support the operation offset action feedback.

[0047] Figure 6 Comparison chart for adjusting the advance / reverse return line based on the limit input amount. Detailed Implementation

[0048] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0049] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0050] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0051] Reference Figures 1-6 As one embodiment of the present invention, this embodiment provides a dynamic calibration method for tank support limiting based on displacement feedback, including the following steps:

[0052] S1. Obtain the initial support position and the initial limit gap, and perform zero-position calibration and gap calibration respectively to form the support zero-position reference and the limit gap reference.

[0053] S1.1. While the tank is in a static supported state, collect the support side position readings at the support contact points and the limit side clearance readings at the adjacent parts of the limit stop to form the initial support position and the initial limit clearance. Specifically,

[0054] When the tank is kept in a static support state and the support contact part is kept in pressure contact, the support side displacement sensor is fixed at the measurement position of the support seat near the support contact part. The probe of the support side displacement sensor faces the support contact part. The support side displacement sensor reads the displacement reading of the support contact part relative to the measurement position of the support seat, forming the support side position reading.

[0055] The support-side displacement sensor collects the support-side position readings at the support-side reading sampling period. The support-side reading sampling period is set based on the response time of the support-side displacement sensor and the minimum action time interval of the support actuator in the actual application scenario. The support-side reading sampling period is between one-half and one time the minimum action time interval of the support actuator, and is not less than the response time of the support-side displacement sensor. The value is determined based on the fact that at least one support-side position reading is obtained during the period when the support actuator completes one action, and does not exceed the response capability of the support-side displacement sensor.

[0056] After collecting the support side position readings, the support side position readings obtained from the same support seat measurement position are organized into a support side reading sequence according to the collection order.

[0057] If the difference between the support side position readings at adjacent sampling times within the number of consecutive sampling points with stable dwell does not exceed the dwell position determination limit, the support side position readings corresponding to the number of consecutive sampling points with stable dwell belong to the same dwell position. The support side position readings corresponding to the same dwell position are determined as valid support side position readings, and the support contact part position corresponding to the valid support side position reading is taken as the initial support position.

[0058] The criteria for determining the same location of stay are as follows:

[0059] The same dwell position is determined by both the dwell position determination limit and the number of consecutive sampling points for stable dwell.

[0060] The dwell position determination limit is set based on the resolution of the support-side displacement sensor and the standard deviation of the support-side reading sequence under static support conditions. The dwell position determination limit is set to two to three times the resolution of the support-side displacement sensor, and is verified in conjunction with the standard deviation of the support-side reading sequence. The determination is based on eliminating the influence of support-side displacement sensor reading jitter on the determination of the same dwell position.

[0061] The number of stable continuous sampling points is set based on the duration during which the support side position reading remains stable under static support conditions and the sampling period of the support side reading. The number of stable continuous sampling points is taken as one to two times the number of sampling points covered by the duration, and the value is based on the stable residence process after the support contact part is under pressure.

[0062] If a single-point jump occurs in the support-side position reading, and the support-side position readings before and after the jump still fall at the same dwell position, the support-side position reading corresponding to the single-point jump is deleted.

[0063] The tank is in a static support state, the limit block remains stationary, the limit side gap sensor is arranged at the measurement position near the limit block, the probe of the limit side gap sensor faces the adjacent surface of the tank, the limit side gap sensor measures the interval reading from the end face of the limit block to the adjacent surface of the tank to form the limit side gap reading.

[0064] The limit side clearance reading is taken from the end face of the limit block. An interval reading greater than zero indicates that the end face of the limit block is not in contact with the adjacent surface of the tank. An interval reading equal to zero indicates that the end face of the limit block is in contact with the adjacent surface of the tank. An interval reading less than zero indicates that the end face of the limit block has passed over the adjacent surface of the tank.

[0065] When the limit side clearance reading does not show an interval reading less than zero, retain the limit side clearance reading with an interval reading greater than zero. When the limit side clearance reading is greater than zero, there is an actual gap between the end face of the limit block and the adjacent surface of the tank. Record the actual gap between the end face of the limit block and the adjacent surface of the tank as the initial limit gap.

[0066] When the limit side clearance reading is less than zero and occurs during the initial limit clearance acquisition stage, the limit side clearance reading less than zero is marked as an abnormal initial acquisition reading and will not enter the initial limit clearance. However, when the limit side clearance reading continues to be less than zero after the advance reading reaches zero, the limit side clearance reading less than zero is retained as the pressure reading after the limit stop passes the adjacent surface of the tank, and is used to form the limit pressure amount in the future.

[0067] S1.2, Press and reset the support contact area at the initial support position to generate lift-off and fall-back readings, specifically,

[0068] The support actuator drives the support contact part to leave the tank support surface, and the support contact part changes from pressure contact to disengagement contact. The support side displacement sensor records the support side position reading at the moment of disengagement contact, and the support side position reading at the moment of disengagement contact forms the lifting-off reading.

[0069] The support actuator drives the support contact part to return to the tank support surface. The support contact part changes from disengagement to pressure contact. The support side displacement sensor records the support side position reading at the moment of re-pressure contact. The support side position reading at the moment of re-pressure contact forms the fall reading.

[0070] S1.3. Determine the zero-scale reading and zero-position acquisition location based on the fallback reading, and calibrate the initial position of the support using the zero-scale reading to form a support zero-position reference. Specifically,

[0071] Read the acquisition sequence and support side position readings corresponding to the fall-off readings one by one in the support side reading sequence. When the support side position reading corresponding to the fall-off reading is consistent with the support side position reading corresponding to the initial support position, record the support side position reading corresponding to the fall-off reading as the zero scale reading and the acquisition sequence position corresponding to the fall-off reading as the zero acquisition position.

[0072] When the support side position reading corresponding to the fallback reading is inconsistent with the support side position reading corresponding to the initial support position, the acquisition sequence position corresponding to the fallback reading is retained, and the support side position reading corresponding to the initial support position is replaced by the support side position reading of the fallback reading to complete the initial support position calibration.

[0073] After completing the initial position calibration of the support, the initial position of the support, the zero scale reading, and the zero position acquisition position are collected to form the support zero position reference.

[0074] S1.4. Based on the initial limit clearance, the PLC controller sends an advance engagement command and a retraction stop command to the limit actuator, controlling the limit block to complete the limit advance and retraction actions and generating advance and retraction readings. Specifically,

[0075] The PLC controller takes the position corresponding to the initial gap of the limit switch as the starting position and the position where the limit side gap reading reaches zero as the forward stop position. It combines the approach direction of the limit block, the forward stop position, and the output port number of the limit actuator into a forward trigger action command.

[0076] The PLC controller sends a forward engagement command to the limit actuator via its output port. The limit actuator moves the limit block toward the adjacent surface of the tank. The limit side gap sensor records the limit side gap reading during the movement. The limit side gap readings, which decrease from the initial limit gap to zero, are arranged to form the forward engagement reading.

[0077] After the limit side clearance reading reaches zero for the first time during the advance reading, the PLC controller continues to control the limit actuator to move the limit block along the direction close to the adjacent surface of the tank. The limit side clearance reading continues to change from zero to the limit press-in termination position. Then, the PLC controller ends the advance trigger action command and switches the reversal stop action command through the output port of the limit actuator.

[0078] The retraction pause action command controls the limit actuator to release the contact state between the end face of the limit block and the adjacent surface of the tank, causing the limit block to retract away from the adjacent surface of the tank; the limit side gap sensor no longer records the limit side gap reading during the approach process, but records the gap recovery process after the zero reading is released, the limit side gap reading recovers to the initial limit gap and remains there, wherein the limit side gap reading during the gap recovery process is the retraction reading.

[0079] S1.5. Discard the limit clearance readings from the forward and reverse gear readings that have not reached the initial limit clearance, and form the limit clearance reference. Specifically,

[0080] The gear advance reading starts from the starting position corresponding to the initial limit gap. The portion of the limit gap reading that decreases to zero from the initial limit gap is retained. The retained gear advance reading is then entered into the limit gap reference.

[0081] The retraction reading is based on the gap recovery process after the zero reading is released. The portion of the limit side gap reading that recovers from the zero reading to the initial limit gap is retained, while the limit side gap reading that stops before recovering to the initial limit gap is deleted.

[0082] The advance reading retention section indicates the gap change when the limit stop is close to the adjacent surface of the tank, and the retraction reading retention section indicates the gap recovery after the limit stop moves away from the adjacent surface of the tank. The advance reading retention section and the retraction reading retention section together form the limit gap reference.

[0083] S2. Perform dual-domain dead zone compensation on the support zero-position reference and the limit gap reference to obtain the support running offset and the limit pressing amount, and divide the support action boundary and the limit action boundary.

[0084] S2.1 Perform dual-domain dead zone compensation on the support zero-position reference and the limit gap reference to obtain the support running offset and the limit push-in amount, specifically,

[0085] S2.1.1. Based on the support zero-position benchmark, locate and discard the idle travel reading and return travel stagnation reading from the support-side position readings to obtain the support running offset, specifically,

[0086] The position where the support actuator begins to move is marked as the starting point of the support action, and the position where the support side position reading first leaves the zero scale reading is marked as the starting point of the support displacement.

[0087] Mark the support side position reading that remains at zero scale reading between the support action start point and the support displacement start point as an empty travel reading and delete it.

[0088] The position where the support actuator falls back to the stop position is marked as the support fall-back endpoint, and the position where the support side position reading returns to the zero scale reading is marked as the zero fall-back position.

[0089] The support-side position readings that do not reach the zero mark from the zero position to the support fall-off endpoint are marked as return stagnation readings and deleted.

[0090] After deleting the empty travel readings and return travel stagnation readings, the remaining support side position readings are referenced with the zero scale reading as the zero point. The displacement changes of the support contact part from leaving the zero scale reading to returning to the zero scale reading are retained in the order of collection to form the support running offset.

[0091] S2.1.2. Use the limit clearance reference to find the operating position where the initial limit clearance is located, and use it as the initial limit position. Specifically,

[0092] Read the limit side clearance readings one by one from the beginning of the advance reading retention section. Find the limit actuator position where the limit side clearance reading is equal to the initial limit clearance and the limit side clearance reading of the next acquisition sequence is less than the initial limit clearance. Take the limit actuator position where the limit side clearance reading begins to leave the initial limit clearance as the initial limit position.

[0093] If there are two or more limit actuator positions in the advance reading retention section that are equal to the initial limit gap, then the end limit actuator position before entering the continuous decreasing reading segment will be taken as the initial limit position.

[0094] S2.1.3. The advance reading is zeroed out along the initial limit position to obtain a zero reading. This zero reading is used as the cutoff point. The advance reading between the cutoff point and the end position of the limit advance is retained to form the limit advance amount. Specifically,

[0095] The gear advance reading starts from the initial position of the limit switch and the limit side clearance reading, which decreases from the initial limit clearance to zero, is used to complete the zeroing interception.

[0096] The position where the first zero reading appears during gear shifting is marked as the cutoff point. Gear shifting readings before the cutoff point do not enter the limit input amount. Gear shifting readings between the cutoff point and the end position of the limit input amount are retained as the limit input amount.

[0097] When the gear advance reading does not show a zero reading, the gear advance reading remains within the limit gap reference and does not form a limit press-in amount.

[0098] S2.2, Define the support action boundary and the limit action boundary, specifically as follows:

[0099] The position where the support side position reading first leaves the zero scale reading is the starting position of the support action, and the position where the support side position reading returns to the zero scale reading is the ending position of the support action. The support action boundary is the action segment formed by the starting position of the support operation offset from the zero acquisition position to the ending position of the return to the zero acquisition position.

[0100] The limit action boundary is the action section extending from the starting position of the limit indentation when the limit side clearance reading reaches zero to the ending position of the limit indentation.

[0101] S3. By using the support action boundary and limit action boundary to define the trial control range of the PLC controller, the PLC controller is triggered to issue a short-stroke action command to execute a short-stroke trial movement and record the tank feedback changes. The idle stroke segment that does not produce a tank feedback change is eliminated to form an effective action boundary.

[0102] S3.1. The experimental control range of the PLC controller is defined by using the support action boundary and the limit action boundary. Specifically,

[0103] S3.1.1. The direction from the starting position to the ending position in the support action boundary is determined as the support running offset direction. Along the support running offset direction, the action positions that do not fall into the empty stroke reading and return stroke dwell reading are selected to form the support-side test section. Specifically,

[0104] Within the support action boundary, the acquisition sequence corresponding to the start position of the support action is earlier than the acquisition sequence corresponding to the end position of the support action. The direction of the acquisition sequence from the start position to the end position of the support action is denoted as the support operation offset direction.

[0105] The movement positions in the support movement boundary are checked one by one. If the movement position corresponds to the position of the empty travel reading, the support side test section is not entered. If the movement position corresponds to the position of the return travel stagnation reading, the support side test section is not entered.

[0106] When the action position does not correspond to the position of the empty travel reading and does not correspond to the position of the return travel dwell reading, it enters the support side test section. The action position entering the support side test section retains the support side position reading and the collection sequence, and is arranged from the side of the support action start position to the side of the support action end position to form the support side test section.

[0107] S3.1.2. Within the limit action boundary, the limit side clearance reading is segmented to zero, forming a limit side test segment, specifically as follows:

[0108] Within the limit action boundary, the starting position of the limit press-in amount, the ending position of the limit press-in amount, and the limit side clearance reading are retained. The advance reading before the boundary point belongs to the zeroing process of the limit initial clearance to zero reading and does not enter the limit action boundary.

[0109] The position where the first zero reading is obtained during the gear shift is marked as the zeroing boundary position. When the limit side clearance reading does not show a zero reading, the limit action boundary remains in a state of pending verification and does not form a limit side trial section.

[0110] When the limit side clearance reading is zero, the operating position from the initial limit clearance position to the zeroing boundary position is retained. The retained operating position carries the limit side clearance reading, the gear advance reading and the zeroing boundary position, forming the limit side trial section.

[0111] S3.1.3 Write the support-side test segment and the limit-side test segment into the PLC controller. The PLC controller registers the support-side test segment and the limit-side test segment respectively. Configure the support-side test segment under the action number of the support actuator and configure the limit-side test segment under the action number of the limit actuator. This ensures that the action position in the support-side test segment can only trigger the support actuator and the action position in the limit-side test segment can only trigger the limit actuator, forming a test control interval that includes the registration items of the support-side test segment and the limit-side test segment.

[0112] S3.2, Trigger the PLC controller to issue a short-stroke action command to execute a short-stroke trial movement and record the tank feedback changes, specifically,

[0113] S3.2.1 The action position of the PLC controller's trial control range is read to obtain the support trial action position and the limit trial action position. Specifically,

[0114] Within the trial control range, the PLC controller identifies the actuator action number carried by each action position. Action positions whose actuator action number matches the support actuator action number and retains the support running offset direction are designated as support trial action positions. Action positions whose actuator action number matches the limit actuator action number and are located before the zeroing boundary position are designated as limit trial action positions. Action positions whose actuator action number does not match either the support actuator action number or the limit actuator action number are skipped by the PLC controller, and the PLC controller does not issue short-stroke action commands to the support actuator and the limit actuator.

[0115] S3.2.2, The PLC controller is triggered by the position of the support test action to issue a short-stroke action command to the support actuator. This command controls the support actuator to move the support contact part a short distance along the support running offset direction and complete a reverse short-stroke convergence at the end of the support-side test section, generating the support test stroke. Specifically,

[0116] After the support probe movement position reaches the trigger position of the support actuator output port of the PLC controller, the PLC controller programs the support probe movement position, support running offset direction, support side probe end reading position and reverse short stroke convergence position into a short stroke movement instruction, and sends it to the support actuator through the support actuator output port.

[0117] The support actuator causes the support contact part to move a short distance, and the tank moves with the support contact part in the direction of support operation offset to the end reading position of the test section on the support side.

[0118] After the tank reaches the end reading position of the support side test section, the PLC controller stops the short-distance movement of the support in the direction of offset and controls the support actuator to move the support contact part in the opposite direction to the adjacent action position within the support side test section. After the support contact part moves in the opposite direction, the tank falls back with its own weight, and the support side position reading is restored to the corresponding reading of the adjacent action position within the support side test section, completing the reverse short stroke convergence.

[0119] The support test stroke is calculated by combining the support test position, the support side position reading during the short-distance movement, and the support side position reading after the reverse short-stroke convergence.

[0120] S3.2.3 Activate the limit actuator using the PLC controller, driving the limit stop block to the zero boundary position and then back to the initial limit position, generating a limit test stroke. Specifically,

[0121] The limit probe position and the zeroing boundary position are combined into a limit advance section. The PLC controller configures the limit advance section as the jog advance command of the limit actuator.

[0122] The jog drive command activates the limit actuator and pushes the limit block closer to the adjacent surface of the tank. Simultaneously, the limit side clearance reading drops from the initial limit clearance to zero.

[0123] After the zero reading appears, the PLC controller cancels the jog drive command and switches the output direction of the limit actuator to the retraction direction. The limit actuator drives the limit stop block to disengage from the adjacent surface of the tank. The limit side clearance sensor records the limit side clearance reading after the zero reading is released.

[0124] After the limit side clearance reading returns to the initial limit clearance, the PLC controller stops the retraction action and uses the limit side clearance reading in the limit advance section after the zero reading is removed as the limit test stroke.

[0125] It should be noted that, in this embodiment, the support actuator is a support-side servo electric cylinder controlled by a PLC controller. The telescopic end of the support-side servo electric cylinder is connected to the support contact part and drives the support contact part to complete lifting, lowering, and short-distance movement. The limit actuator is a limit-side servo electric cylinder controlled by a PLC controller. The telescopic end of the limit-side servo electric cylinder is connected to the limit stop block and drives the limit stop block to complete forward engagement, reverse stop, and limit probing movement.

[0126] S3.3 Fix the tank displacement sensor at a measurement position near the tank, with the probe of the tank displacement sensor facing the outer wall of the tank. During the support test stroke, the tank displacement sensor records the real-time position reading of the outer wall of the tank relative to the initial support position. When the real-time position reading deviates from the reading corresponding to the initial support position, the difference between the real-time position reading and the reading corresponding to the initial support position is the tank feedback change on the support side.

[0127] During the limit test stroke, the limit side gap sensor records the real-time position change of the limit side gap reading relative to the initial limit gap, and uses the gap difference between the limit side gap reading and the initial limit gap as the limit side gap change.

[0128] The changes in tank feedback on the support side and the changes in clearance on the limiting side together constitute the changes in tank feedback.

[0129] S3.4 Mark the movement position where the support side position reading is still at the initial support position and the movement position where the limit side clearance reading is still at the initial limit clearance as the idle segment.

[0130] The position where the support-side position reading begins to leave the initial support position is recorded as the effective support start point. The position where the support-side position reading maintains the tank feedback change is recorded as the effective support end point. The effective support start point to the effective support end point form the effective support action section.

[0131] After the limit side clearance reading leaves the initial limit clearance, it enters the zero-advance reading segment. The zero-advance reading segment decreases as the limit side clearance reading approaches the zero boundary position and ends at the zero boundary position. The zero-advance reading segment constitutes the effective action segment of the limit.

[0132] The effective support action section retains the action position that causes tank feedback changes during the support test stroke, and the effective limit action section retains the action position that causes limit side clearance changes during the limit test stroke. The effective support action section and the effective limit action section are recorded in the PLC controller to form the effective action boundary.

[0133] S4. Use the effective action boundary to correct the support running offset and limit pressing amount to form the support limit dynamic calibration result.

[0134] S4.1. Utilize the effective motion boundary to screen out the motion positions that cause tank feedback changes during the support trial stroke, and use the start and end points of these motion positions to correct the start and end positions of the support running offset, forming the corrected support running offset. Specifically,

[0135] The PLC controller checks the support side position readings at each action position within the support test stroke. If the support side position reading remains at the action position corresponding to the initial support position, it is determined that the action position has not generated tank feedback change and will not participate in the corrected support running offset.

[0136] The tank displacement sensor records the real-time position reading of the outer wall of the tank during the support test stroke. The position where the real-time position reading changes relative to the initial support position is retained as the position where the tank feedback change occurs on the support side.

[0137] The earliest action position among the action positions that generate tank feedback changes is defined as the correction start position, and the last action position among the action positions that generate tank feedback changes is defined as the correction end position. The correction start position and correction end position replace the start position and end position of the support running offset to form the corrected support running offset.

[0138] Reference Figure 5 , Figure 5 The top section shows the relationship between the position of the supporting actuator, the position reading on the supporting side, and the feedback changes from the tank on the supporting side, as well as the changes in the data collection point number. Figure 5 Below is a magnified view of the effective action zone.

[0139] The effective action section of the support retains the action position that generates feedback changes from the tank on the support side during the support trial stroke, and excludes the position corresponding to the empty stroke reading and the position corresponding to the return stroke stagnation reading. This is used to determine the correction start position and correction end position, and to correct the support running offset accordingly.

[0140] S4.2. The limit test stroke is delimited and truncated, retaining the advance and retraction readings at the zeroing boundary position and the restored initial limit gap position, forming the corrected limit push-in amount. Specifically,

[0141] Within the limit test stroke, the action position where the limit side clearance reading in the forward gear reading reaches zero is marked as the corrected pressing position, and the action position where the limit side clearance reading in the reverse gear reading returns to the initial limit clearance is marked as the corrected retraction position.

[0142] In the forward gear reading, the limit side clearance reading before the corrected pressing position still belongs to the clearance change before zeroing and does not enter the corrected limit pressing amount. In the reverse gear reading, the limit side clearance reading after the corrected retraction position has been restored to the initial limit clearance and does not enter the corrected limit pressing amount.

[0143] The forward gear reading before the zero reading of the limit side clearance is removed from the corrected pressing position is retained as the effective pressing change. The reading change after the zero reading in the retraction reading belongs to the limit block release contact process. The reading change of the limit side clearance from the zero reading to the initial limit clearance in the retraction reading belongs to the clearance recovery process. The release contact process and the clearance recovery process are not included in the effective pressing change, but are only used to limit the corrected retraction position.

[0144] The effective change in the push-in and the corrected retraction position together constitute the corrected limit push-in amount.

[0145] Reference Figure 6 , Figure 6 The top section shows the relationship between the forward and reverse gear readings and the corrected limit push-in reference line as the limit actuator's position changes. Figure 6 Below is a magnified view of the effective change in pressure after reaching zero reading.

[0146] Figure 6 The enlarged view of the effective change of the push-in shows the effective push-in range (between ① and ③) after reaching zero reading, and marks the point of maximum difference between the forward and reverse readings (②) and the corrected limit push-in amount.

[0147] Wherein, ① and ③ represent the starting position and ending position of the effective change of the push-in, respectively. The corrected limit push-in amount does not include the gap change before the zeroing boundary position, nor does it include the gap recovery process of the limit side gap reading recovering from zero to the initial limit gap.

[0148] S4.3 Configure the corrected support running offset and the corrected limit press-in amount to the PLC controller. The PLC controller updates the subsequent action position of the support actuator with the corrected support running offset and updates the subsequent action position of the limit actuator with the corrected limit press-in amount, thus forming the dynamic calibration result of the support limit.

[0149] This embodiment also provides a computer device applicable to the dynamic calibration method for tank support limit based on displacement feedback, including: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to realize the dynamic calibration method for tank support limit based on displacement feedback as proposed in the above embodiment.

[0150] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0151] This embodiment also provides a storage medium storing a computer program. When executed by a processor, the program implements the displacement feedback-based dynamic calibration method for tank support limits as proposed in the above embodiments. The storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0152] In summary, this invention clarifies the response relationship between the PLC controller's action output and the tank's displacement changes by limiting the PLC controller's trial control range. It effectively distinguishes between actual effective actions and idle interference, reducing the incorporation of invalid strokes from minor movements of the support and limit sides into calibration judgments. This shifts the basis for correcting support travel offset and limit pressure from simple action commands to actual feedback results, thereby reducing the risks of misadjustment, boundary drift, and action lag in dynamic calibration of support and limit. Simultaneously, short-range trial movements expose idle strokes on the support side and clearance deviations on the limit side within small action amplitudes, making the effective action boundary closer to the actual response state of the tank. This prevents mechanical idle strokes, contact lags, and backlash deviations of the support and limit actuators from being mistakenly considered as valid calibration criteria, enhancing the identifiability and verifiability of the effective action boundary and improving the stability, executability, and control consistency of dynamic calibration of support and limit.

[0153] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A dynamic calibration method for tank support limit based on displacement feedback, characterized in that: include, Obtain the initial support position and the initial limit gap, and perform zero-position calibration and gap calibration respectively to form the support zero-position reference and the limit gap reference; Dual-domain dead zone compensation is performed on the support zero-position reference and the limit gap reference to obtain the support running offset and the limit push-in amount, and the support action boundary and the limit action boundary are divided. By using the support action boundary and limit action boundary to define the trial control range of the PLC controller, the PLC controller is triggered to issue a short-stroke action command to execute a short-stroke trial movement and record the tank feedback changes. The idle stroke segment that does not produce a tank feedback change is eliminated to form an effective action boundary. The effective action boundary is used to correct the support running offset and limit pressing amount, forming the support limit dynamic calibration result.

2. The dynamic calibration method for tank support limiting based on displacement feedback as described in claim 1, characterized in that: The specific steps for forming the supporting zero-position reference and the limiting gap reference are as follows: Under the static support state of the tank, the support side position reading of the support contact part and the limit side clearance reading of the adjacent part of the limit block are collected to form the initial support position and the initial limit clearance. The support contact area is pressed and reset at the initial support position to generate lift-off and fall-back readings. The zero-scale reading and zero-position acquisition position are determined based on the fallback reading. The initial position of the support is calibrated using the zero-scale reading to form the support zero-position reference. Based on the initial limit gap, the PLC controller sends an advance contact action command and a retraction stop action command to the limit actuator, controlling the limit block to complete the limit advance and retraction actions and generate advance readings and retraction readings; The limit clearance readings that do not reach the initial limit clearance in the forward and reverse gear readings are discarded to form the limit clearance reference.

3. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 2, characterized in that: The specific steps for obtaining the support running offset and limit push-in amount are as follows: Based on the zero-position reference, the idle travel reading and return travel stagnation reading are located and eliminated from the position readings on the support side to obtain the support running offset; Use the limit clearance reference to find the movement position where the initial limit clearance is located, and use it as the initial limit position; The advance reading is zeroed out along the initial position of the limit switch to obtain a zero reading. The zero reading is used as the cutoff point. The advance reading between the cutoff point and the end position of the limit advance amount is retained to form the limit advance amount.

4. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 3, characterized in that: The support action boundary is the action segment formed by the starting position from the zero-position acquisition position to the ending position from the zero-position acquisition position during the support operation offset; The limit action boundary is the action section extending from the starting position of the limit indentation when the limit side clearance reading reaches zero to the ending position of the limit indentation.

5. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 4, characterized in that: The specific steps for defining the trial control range of the PLC controller using support action boundaries and limit action boundaries are as follows: The direction from the starting position to the ending position in the support action boundary is determined as the support operation offset direction. The action position that does not fall into the empty stroke reading and the return stroke retention reading is selected along the support operation offset direction to form the support side test section. Within the limit action boundary, the limit side clearance reading is zeroed out in segments to form a limit side test segment; The support-side test section and the limit-side test section are written into the PLC controller as the test control range of the PLC controller.

6. The dynamic calibration method for tank support limiting based on displacement feedback as described in claim 5, characterized in that: The specific steps for triggering the PLC controller to issue a short-stroke action command to execute a short-stroke trial movement are as follows: The action position of the PLC controller's trial control range is read to obtain the support trial action position and the limit trial action position; The PLC controller is triggered by the position of the support test action to issue a short-stroke action command to the support actuator, which controls the support actuator to drive the support contact part to perform a short-distance movement along the support running offset direction and complete the reverse short-stroke convergence at the end of the support side test section, thus generating the support test stroke. The limit actuator is activated by the PLC controller, which drives the limit block to the zero boundary position and then returns to the initial limit position, generating the limit trial stroke.

7. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 6, characterized in that: The support actuator is a support-side moving component that is controlled by a PLC controller, connected to the support contact part, and drives the support contact part to move. The limit actuator is a limit-side action component controlled by a PLC controller, connected to a limit stop, and driving the limit stop to move.

8. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 6, characterized in that: The reverse short-stroke convergence occurs when, after the tank reaches the end reading position of the support-side test section, the PLC controller stops the short-stroke test movement and controls the tank to retreat back to the support-side test section, thus completing the reverse short-stroke convergence.

9. The dynamic calibration method for tank support limit based on displacement feedback as described in claim 8, characterized in that: The tank feedback changes include the support-side tank feedback changes generated relative to the initial support position during the support test stroke, and the limit-side clearance changes generated relative to the initial limit clearance during the limit test stroke.

10. The dynamic calibration method for tank support limiting based on displacement feedback as described in claim 9, characterized in that: The specific steps for forming the dynamic calibration result of the support limit are as follows: The effective action boundary is used to screen out the action positions that cause tank feedback changes during the support trial stroke, and the start and end positions of the support running offset are corrected based on the start and end points of the action positions to form the corrected support running offset. The limit test stroke is delineated and intercepted, and the advance and retraction readings at the zeroing boundary position and the restored initial limit gap position are retained to form the corrected limit push-in amount; The corrected support running offset and the corrected limit push-in amount are combined into the support limit dynamic calibration result.

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