A method and system for the coordinated control of manufacturing process node status in smart factories

Abstract

This invention discloses a method and system for the coordinated control of manufacturing process node states in smart factories, relating to the field of smart factory technology. It includes a transitional virtual mapping module, used to instantiate a virtual feedforward node in the system control topology that is synchronized in real time with the kinematic state of the physical workpiece when the workpiece leaves the upstream control node and does not contact the downstream execution node; and a fault feedforward decision module, used to instantiate a virtual feedforward node that dynamically tracks the momentum state of the workpiece when it is in a physically uncontrollable transition phase, and to feed forward a virtual collision warning to this node using the speed of light in the network when a sudden fault occurs in the downstream execution node. This forces the faulty node to shield its rigid emergency stop logic and adaptively reconstruct the compliant impedance parameters of the impact direction, transforming the destructive impact into active retreat and kinetic energy absorption.

Description

Technical Field

[0001] This invention relates to the field of smart factory technology, specifically to a method and system for the coordinated management and control of manufacturing process nodes in a smart factory. Background Technology

[0002] In the discrete manufacturing and continuous material handling systems of modern smart factories, cyber-physical systems (CPS) are widely used to coordinate the sequential actions of multiple manufacturing execution nodes. Materials or workpieces are typically transferred between different processing nodes via gravity chutes, air-bearing tracks, and magnetic levitation catapult tracks, achieving highly dynamic physical transfer without mechanical connections. This high-speed transfer process relies on an underlying industrial communication network for state synchronization. After completing processing, the upstream control node releases the workpiece and imparts initial kinetic energy. Under the combined action of gravitational acceleration and initial inertia, the workpiece slides freely along the transfer track to the downstream execution node. The downstream execution node captures the workpiece's arrival signal through photoelectric sensors or position encoders, and then drives the mechanical gripper and platform for precise position interception and secondary clamping. The state machine data of the entire manufacturing process is periodically polled and action scheduled by a global programmable logic controller (PLC).

[0003] Existing linkage control systems suffer from a fatal state-command temporal deadlock defect when the workpiece is in a physically irreversible free-sliding transition state. When the workpiece detaches from the upstream control node and is flying downstream due to irreversible physical inertia, if a sudden hardware failure such as mechanical jamming or servo malfunction occurs at the downstream execution node, the existing control system will immediately trigger a global emergency stop mechanism based on conventional safety logic. This causes the drive shaft of the downstream execution node to be immediately de-energized and triggers a mechanical brake to lock itself in place. However, the emergency stop digital command issued by the system cannot cancel the physical momentum already carried by the workpiece in mid-air. Ultimately, this results in the high-value workpiece, in a high-speed sliding state, violently impacting the faulty downstream node, which is in an absolutely rigid locked state. This leads to severe consequences, including workpiece shattering and scrapping, and devastating structural deformation of the precision actuator due to the secondary impact. Summary of the Invention

[0004] The purpose of this invention is to provide a method and system for the coordinated management and control of manufacturing process nodes in smart factories, so as to solve the problems mentioned in the background art.

[0005] To address the aforementioned technical problems, this invention provides the following technical solution: a manufacturing process node status linkage control system for smart factories, comprising a transitional virtual mapping module, used to instantiate a virtual feedforward node in the system control topology that is synchronized in real time with the kinematic state of the physical workpiece when the workpiece leaves the upstream control node and does not contact the downstream execution node; a fault feedforward decision module, used to extract the workpiece momentum data from the virtual feedforward node and send it to the downstream execution node at a network communication speed higher than the running speed of the physical workpiece when a sudden hardware failure is detected in the downstream execution node; and a compliant impedance reconstruction module, used to receive the workpiece momentum data, cut off the default rigid emergency stop locking circuit of the downstream execution node, and adjust the end stiffness and damping parameters of the actuator according to the material fragility of the workpiece to prepare for physical collisions.

[0006] According to the above technical solution, the transitional virtual mapping module includes: a detachment trigger submodule, used to confirm that the workpiece has entered the physically uncontrollable region and generate a trigger signal through the end sensor signal of the upstream control node; and a state parameter inheritance submodule, used to receive the trigger signal and encapsulate the initial mass, initial velocity and trajectory vector of the workpiece into a data packet of the virtual feedforward node. The fault feedforward decision module includes: an abnormal state interruption submodule, used to capture the hardware abnormal code of the downstream execution node and suspend the normal linkage instruction; and a collision intervention calculation submodule, used to calculate the remaining time for the workpiece to reach the downstream execution node and the expected impact kinetic energy based on the data packet of the virtual feedforward node. The compliant impedance reconstruction module includes: a hardware protection unbinding submodule, used to shield the servo motor brake signal and power-off holding mechanism of the downstream execution node; and a targeted attitude adaptive submodule, used to switch the mechanical structure of the downstream execution node to a kinetic energy absorption unloading posture that matches the workpiece material.

[0007] A method for coordinated status control of manufacturing process nodes in a smart factory includes the following steps: Step S1: Construct virtual nodes. The system monitors the physical position transfer status of the workpiece on the manufacturing line. When the workpiece completely leaves the physical clamp of the upstream control node and enters the free sliding transition state, the central controller generates the corresponding virtual feedforward node in the control topology diagram and assigns it initial physical attributes. Step S2: Monitor node failures. The central controller polls the underlying device health status of downstream execution nodes in real time. Once a mechanical jamming error frame of a downstream execution node is captured, the system immediately blocks the issuance of the global emergency stop broadcast message. Step S3, Feedforward physical parameters: The system extracts the real-time kinematic properties of the workpiece encapsulated in the virtual feedforward node, and writes the workpiece's mass and velocity properties directly to the underlying driver memory of the faulty downstream execution node via industrial Ethernet, bypassing the regular task queue. Step S4: Release the rigid lock. After receiving the feedforward command, the driver of the downstream execution node analyzes the characteristics of the impending physical impact and controls the brake locking action of the bottom active suppression electromagnetic brake, so that the mechanical shaft affected by the fault is released from the absolute position rigid holding mode. Step S5: Perform compliant absorption. Based on the inherent material characteristics of the workpiece, the controller dynamically adjusts the mechanical impedance parameters in the force direction of the downstream execution node. By reducing the control stiffness of the robotic arm joint and increasing the dissipation damping, the node compliantly yields when it is hit by the workpiece, unloading the workpiece's kinetic energy and guiding it to a safe waste area.

[0008] According to the above technical solution, step S1 specifically includes: Step S1-1: Obtain the initial velocity v0 and workpiece mass m at the moment the workpiece leaves the upstream control node; Step S1-2, according to the displacement formula Calculate the position coordinates of the virtual feedforward node, where S is the physical distance the workpiece travels in the transition state, t is the duration after being out of control, and a is the physical component of the workpiece's gravitational acceleration along the transition track. The significance of this formula is to dynamically calibrate the virtual spatial position of the virtual feedforward node in the software topology map in real time based on classical kinematics principles.

[0009] According to the above technical solution, step S2 specifically includes: Step S2-1: The downstream execution node monitors the real-time current I_real of its own motor through the current sensor inside the servo driver. Step S2-2: The abnormal state is determined using the judgment formula E_diff=|I_real-I_ref|, where E_diff is the absolute value of the current deviation and I_ref is the reference current pre-calibrated by the downstream execution node in the normal no-load standby state. When E_diff is greater than the safe current threshold set by the system and the duration exceeds the set clock cycle, it is determined that the downstream execution node has a mechanical jamming fault. The principle of this formula is to use the current change characteristics to eliminate conventional electromagnetic interference noise and accurately confirm the sudden fault of rigid failure at the hardware level.

[0010] According to the above technical solution, step S3 specifically includes: Step S3-1: The virtual feedforward node calculates the remaining warning time T_rem based on the fixed network communication delay and the controller's processing delay; Step S3-2, using the kinetic energy evaluation formula The expected impact kinetic energy is calculated, where E_k is the dynamic impact kinetic energy of the workpiece at the moment of impact with the downstream execution node, m is the workpiece mass, v0 is the initial velocity of departure, a is the acceleration along the track, t_current is the physical time that has been gliding, and T_rem is the remaining warning time from the issuance of the feedforward command to the generation of mechanical response at the downstream node. This formula is used to quantitatively quantify the destructive potential carried by the impending physical collision, providing a basic quantitative input basis for the subsequent adjustment of dynamic impedance parameters.

[0011] According to the above technical solution, step S4 specifically includes: Step S4-1: After receiving the data packet containing the expected impact kinetic energy E_k, the underlying driver of the downstream execution node loads the preset workpiece material fragility coefficient C_fragile, where C_fragile is a dimensionless parameter calibrated at the factory, and its value is positively correlated with the physical fragility of the workpiece. Step S4-2, execute the instruction switching judgment logic: set the kinetic energy damage threshold E_safe, and trigger the operation based on the judgment formula E_k*C_fragile>E_safe. When the formula condition is met, a compliant reconstruction intervention instruction is generated to forcibly shut down the electromagnetic brake relay control circuit that was originally caused by the fault interruption. The significance of this formula is to assess whether the current collision kinetic energy combined with the workpiece material is sufficient to cause substantial damage, and to ensure that the default rigid protection mechanism of the system is cut off only when a real threat occurs.

[0012] According to the above technical solution, step S5 specifically includes: Step S5-1: Based on the impedance control principle, establish a second-order linear mechanical equivalent model of the downstream execution node in the impact direction; Step S5-2: The mechanical response characteristics of the node are dynamically adjusted using the impedance control formula F_impact=K*X+D*V, where F_impact is the resistance applied to the workpiece by the downstream execution node in the impact direction, K is the equivalent elastic stiffness coefficient in the impact direction, X is the actual displacement of the node in the impact direction, D is the equivalent viscous damping coefficient in the impact direction, and V is the instantaneous linear velocity of the node's yielding motion. The system actively lowers the value of parameter K and simultaneously increases the value of parameter D, so that the node produces a slow and gentle yielding displacement X when it is impacted by the workpiece. The physical principle of this formula is to convert the destructive transient impact kinetic energy into controlled damped dissipated internal energy, and completely realize the soft landing and force relief protection of the workpiece under fault conditions.

[0013] Compared with existing technologies, the beneficial effects achieved by this invention are as follows: This invention completely solves the state-instruction spatiotemporal deadlock problem caused by sudden downstream failures during irreversible physical transitions in smart factory production lines. Through innovative virtual state mapping and advanced light-speed feedforward mechanisms, the system can intervene in advance within a millisecond-level window before a physical collision occurs, without adding any physical buffer sensors in the transition zone. By cutting off the fixed mechanical brake locking circuit and introducing impedance adaptive adjustment based on material characteristics, the faulty equipment terminal not only does not stiffen under impact, but can also flexibly yield to the impact kinetic energy of the workpiece. This not only completely avoids the pulverization and scrapping of high-value, fragile workpieces, but also greatly reduces secondary impact damage to the core mechanical shafts of precision downstream nodes, significantly reducing downtime maintenance costs and economic losses in flexible manufacturing production lines. Attached Figure Description

[0014] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a flowchart illustrating the present invention. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some 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.

[0016] Please see Figure 1 This invention provides a technical solution: a manufacturing process node status linkage control system for smart factories, including a transitional virtual mapping module, used to instantiate a virtual feedforward node in the system control topology that is synchronized in real time with the kinematic state of the physical workpiece when the workpiece leaves the upstream control node and does not contact the downstream execution node; a fault feedforward decision module, used to extract the workpiece momentum data in the virtual feedforward node and send it to the downstream execution node at a network communication speed higher than the running speed of the physical workpiece when a sudden hardware failure is detected in the downstream execution node; and a compliant impedance reconstruction module, used to receive the workpiece momentum data, cut off the default rigid emergency stop locking circuit of the downstream execution node, and adjust the end stiffness and damping parameters of the actuator according to the material fragility of the workpiece to prepare for physical collisions. The transitional virtual mapping module includes: a detachment trigger submodule, which is used to confirm that the workpiece has entered the physically uncontrollable region and generate a trigger signal through the end sensor signal of the upstream control node; and a state parameter inheritance submodule, which is used to receive the trigger signal and encapsulate the initial mass, initial velocity and trajectory vector of the workpiece into a data packet of the virtual feedforward node. The fault feedforward decision module includes: an abnormal state interruption submodule, which is used to capture the hardware abnormal code of the downstream execution node and suspend the regular linkage instructions; and a collision intervention calculation submodule, which is used to calculate the remaining time for the workpiece to reach the downstream execution node and the expected impact kinetic energy based on the data packets of the virtual feedforward node. The compliant impedance reconstruction module includes: a hardware protection unbinding submodule, used to shield the servo motor brake signal and power-off holding mechanism of the downstream execution node; and a targeted attitude adaptation submodule, used to switch the mechanical structure of the downstream execution node to a kinetic energy absorption unloading posture that matches the workpiece material. A method for coordinated status control of manufacturing process nodes in a smart factory includes the following steps: Step S1: Construct virtual nodes. The system monitors the physical position transfer status of the workpiece on the manufacturing line. When the workpiece completely leaves the physical clamp of the upstream control node and enters the free sliding transition state, the central controller generates the corresponding virtual feedforward node in the control topology diagram and assigns it initial physical attributes. Step S2: Monitor node failures. The central controller polls the underlying device health status of downstream execution nodes in real time. Once a mechanical jamming error frame of a downstream execution node is captured, the system immediately blocks the issuance of the global emergency stop broadcast message. Step S3, Feedforward physical parameters: The system extracts the real-time kinematic properties of the workpiece encapsulated in the virtual feedforward node, and writes the workpiece's mass and velocity properties directly to the underlying driver memory of the faulty downstream execution node via industrial Ethernet, bypassing the regular task queue. Step S4: Release the rigid lock. After receiving the feedforward command, the driver of the downstream execution node analyzes the characteristics of the impending physical impact and controls the brake locking action of the bottom active suppression electromagnetic brake, so that the mechanical shaft affected by the fault is released from the absolute position rigid holding mode. Step S5: Perform compliant absorption. Based on the inherent material characteristics of the workpiece, the controller dynamically adjusts the mechanical impedance parameters in the force direction of the downstream execution node. By reducing the control stiffness of the robotic arm joint and increasing the dissipation damping, the node undergoes compliant yielding when it is hit by the workpiece, unloading the kinetic energy of the workpiece and guiding it to the safe waste area. Step S1 specifically includes: Step S1-1: Obtain the initial velocity v0 and workpiece mass m at the moment the workpiece leaves the upstream control node; Step S1-2, according to the displacement formula Calculate the position coordinates of the virtual feedforward node, where S is the physical distance the workpiece travels in the transition state, t is the duration after being out of control, and a is the physical component of the gravitational acceleration of the workpiece along the transition track. The significance of this formula is to dynamically calibrate the virtual spatial position of the virtual feedforward node in the software topology map in real time based on the classical kinematics principle. This step establishes a continuous tracking mechanism independent of physical sensors. When the workpiece is in a physical blind zone dominated by gravity or inertia, the control system actively visualizes a pure data carrier in the communication network to receive all the workpiece's motion attributes. This operation fills the information flow gap during equipment handover, ensuring that the control system always has a grasp of the workpiece's dynamics. Conventional technologies typically rely on the passive triggering of downstream physical sensors to re-capture the target. This solution takes a different approach, breaking free from the limitations of physical detection and relying on the relay flow of virtual states to maintain uninterrupted global monitoring during the window period when there are no hardware monitoring methods.

[0017] Step S2 specifically includes: Step S2-1: The downstream execution node monitors the real-time current I_real of its own motor through the current sensor inside the servo driver. Step S2-2: Use the judgment formula E_diff=|I_real-I_ref| to determine the abnormal state, where E_diff is the absolute value of the current deviation and I_ref is the reference current pre-calibrated by the downstream execution node in the normal no-load standby state. When E_diff is greater than the safe current threshold set by the system and the duration exceeds the set clock cycle, it is determined that the downstream execution node has a mechanical jamming fault. The principle of this formula is to use the current change characteristics to eliminate conventional electromagnetic interference noise and accurately confirm the sudden fault of rigid failure at the hardware level. Step S3 specifically includes: Step S3-1: The virtual feedforward node calculates the remaining warning time T_rem based on the fixed network communication delay and the controller's processing delay; Step S3-2, using the kinetic energy evaluation formula The expected impact kinetic energy is calculated, where E_k is the dynamic impact kinetic energy of the workpiece at the moment of collision with the downstream execution node, m is the workpiece mass, v0 is the initial velocity of separation, a is the acceleration along the track, t_current is the physical time that has been gliding, and T_rem is the remaining warning time from the issuance of the feedforward command to the generation of mechanical response at the downstream node. This formula is used to quantitatively quantify the destructive potential carried by the impending physical collision, providing a basic quantitative input basis for the subsequent adjustment of dynamic impedance parameters. This step cleverly utilizes the significant objective difference between the transmission speed of industrial Ethernet electronic signals and the speed of macroscopic physical objects. The system directly transmits the kinetic energy potential quantification carried by virtual nodes through the conventional task scheduling queue, delivering it ahead of time to the already malfunctioning receiver. Traditional linkage control often focuses its computing power on figuring out how to forcibly stop an out-of-control target. This solution directly acknowledges the inviolability of physical inertia and instead uses all computing resources to provide early warning to the attacked party, gaining extremely valuable millisecond-level response time for subsequent intervention actions.

[0018] Step S4 specifically includes: Step S4-1: After receiving the data packet containing the expected impact kinetic energy E_k, the underlying driver of the downstream execution node loads the preset workpiece material fragility coefficient C_fragile, where C_fragile is a dimensionless parameter calibrated at the factory, and its value is positively correlated with the physical fragility of the workpiece. Step S4-2, execute instruction switching judgment logic: set kinetic energy damage threshold E_safe, trigger operation based on judgment formula E_k*C_fragile>E_safe. When the formula condition is met, generate compliant reconstruction intervention instruction to forcibly close the electromagnetic brake relay control circuit originally caused by fault interruption. The significance of this formula is to assess whether the current collision kinetic energy combined with the workpiece material is sufficient to cause substantial damage, and to ensure that the system's default rigid protection mechanism is cut off only when a real threat occurs. Step S5 specifically includes: Step S5-1: Based on the impedance control principle, establish a second-order linear mechanical equivalent model of the downstream execution node in the impact direction; Step S5-2: The mechanical response characteristics of the node are dynamically adjusted using the impedance control formula F_impact=K*X+D*V, where F_impact is the resistance applied to the workpiece by the downstream execution node in the impact direction, K is the equivalent elastic stiffness coefficient in the impact direction, X is the actual displacement of the node in the impact direction, D is the equivalent viscous damping coefficient in the impact direction, and V is the instantaneous linear velocity of the node's yielding motion. The system actively lowers the value of parameter K and simultaneously increases the value of parameter D, so that the node produces a slow and gentle yielding displacement X when it is impacted by the workpiece. The physical principle of this formula is to convert the destructive transient impact kinetic energy into controlled damped dissipated internal energy, and completely realize the soft landing and force relief protection of the workpiece under fault conditions.

[0019] The aforementioned unlocking and absorption processes jointly reconstruct the underlying safety response philosophy of industrial equipment. Faced with sudden failures and impending impacts, the system forcibly intervenes and disconnects the power-off brake protection mechanism built into the drive. Considering the vulnerability of the workpiece approaching, it instructs the damaged mechanical structure to proactively reduce joint stiffness. Existing safety mechanisms rely on in-situ locking to prevent unpredictable secondary dangers. This solution reverses this rigid locking mechanism, causing the faulty equipment to deform and yield in the direction of impact, thus proactively paralyzing the equipment and mitigating the dual crises of high-volume material crushing and precision bearing breakage.

[0020] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0021] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A manufacturing process node status linkage control system for smart factories, characterized in that: It includes a transitional virtual mapping module, which is used to instantiate a virtual feedforward node in the system control topology that is synchronized in real time with the kinematic state of the physical workpiece when the workpiece leaves the upstream control node and does not contact the downstream execution node. The fault feedforward decision module is used to extract the workpiece momentum data in the virtual feedforward node and send it to the downstream execution node at a network communication speed higher than the physical workpiece running speed when a sudden hardware failure is detected in the downstream execution node; the compliant impedance reconstruction module is used to receive the workpiece momentum data, cut off the default rigid emergency stop locking circuit of the downstream execution node, and adjust the end stiffness and damping parameters of the actuator according to the material fragility of the workpiece to prepare for physical collision.

2. The manufacturing process node status linkage control system for smart factories according to claim 1, characterized in that: The transitional virtual mapping module includes: a detachment trigger submodule, used to confirm that the workpiece has entered the physically uncontrollable region and generate a trigger signal through the end sensor signal of the upstream control node; and a state parameter inheritance submodule, used to receive the trigger signal and encapsulate the initial mass, initial velocity and trajectory vector of the workpiece into a data packet of the virtual feedforward node. The fault feedforward decision module includes: an abnormal state interrupt submodule, which is used to capture the hardware abnormal code of the downstream execution node and suspend the regular linkage instructions; The collision intervention calculation submodule is used to calculate the remaining time for the workpiece to reach the downstream execution node and the expected impact kinetic energy based on the data packets of the virtual feedforward node. The compliant impedance reconstruction module includes: a hardware protection unbinding submodule, used to shield the servo motor brake signal and power-off holding mechanism of the downstream execution node; and a targeted attitude adaptive submodule, used to switch the mechanical structure of the downstream execution node to a kinetic energy absorption unloading posture that matches the workpiece material.

3. A method for coordinated control of manufacturing process node status in smart factories, characterized in that: The method, when applied to the system of claim 2, includes the following steps: Step S1: Construct virtual nodes. The system monitors the physical position transfer status of the workpiece on the manufacturing line. When the workpiece completely leaves the physical clamp of the upstream control node and enters the free sliding transition state, the central controller generates the corresponding virtual feedforward node in the control topology diagram and assigns it initial physical attributes. Step S2: Monitor node failures. The central controller polls the underlying device health status of downstream execution nodes in real time. Once a mechanical jamming error frame of a downstream execution node is captured, the system immediately blocks the issuance of the global emergency stop broadcast message. Step S3, Feedforward physical parameters: The system extracts the real-time kinematic properties of the workpiece encapsulated in the virtual feedforward node, and writes the workpiece's mass and velocity properties directly to the underlying driver memory of the faulty downstream execution node via industrial Ethernet, bypassing the regular task queue. Step S4: Release the rigid lock. After receiving the feedforward command, the driver of the downstream execution node analyzes the characteristics of the impending physical impact and controls the brake locking action of the bottom active suppression electromagnetic brake, so that the mechanical shaft affected by the fault is released from the absolute position rigid holding mode. Step S5: Perform compliant absorption. Based on the inherent material characteristics of the workpiece, the controller dynamically adjusts the mechanical impedance parameters in the force direction of the downstream execution node. By reducing the control stiffness of the robotic arm joint and increasing the dissipation damping, the node compliantly yields when it is hit by the workpiece, unloading the workpiece's kinetic energy and guiding it to a safe waste area.

4. The method for coordinated control of manufacturing process node status in a smart factory according to claim 3, characterized in that: Step S1 specifically includes: Step S1-1: Obtain the initial velocity v0 and workpiece mass m at the moment the workpiece leaves the upstream control node; Step S1-2, according to the displacement formula Calculate the position coordinates of the virtual feedforward node, where S is the physical distance the workpiece travels in the transition state, t is the duration after being out of control, and a is the physical component of the workpiece's gravitational acceleration along the transition track. The significance of this formula is to dynamically calibrate the virtual spatial position of the virtual feedforward node in the software topology map in real time based on classical kinematics principles.

5. The method for coordinated control of manufacturing process node status in a smart factory according to claim 4, characterized in that: Step S2 specifically includes: Step S2-1: The downstream execution node monitors the real-time current I_real of its own motor through the current sensor inside the servo driver. Step S2-2: The abnormal state is determined using the judgment formula E_diff=|I_real-I_ref|, where E_diff is the absolute value of the current deviation and I_ref is the reference current pre-calibrated by the downstream execution node in the normal no-load standby state. When E_diff is greater than the safe current threshold set by the system and the duration exceeds the set clock cycle, it is determined that the downstream execution node has a mechanical jamming fault. The principle of this formula is to use the current change characteristics to eliminate conventional electromagnetic interference noise and accurately confirm the sudden fault of rigid failure at the hardware level.

6. The method for coordinated control of manufacturing process node status in a smart factory according to claim 5, characterized in that: Step S3 specifically includes: Step S3-1: The virtual feedforward node calculates the remaining warning time T_rem based on the fixed network communication delay and the controller's processing delay; Step S3-2, using the kinetic energy evaluation formula The expected impact kinetic energy is calculated, where E_k is the dynamic impact kinetic energy of the workpiece at the moment of impact with the downstream execution node, m is the workpiece mass, v0 is the initial velocity of departure, a is the acceleration along the track, t_current is the physical time that has been gliding, and T_rem is the remaining warning time from the issuance of the feedforward command to the generation of mechanical response at the downstream node. This formula is used to quantitatively quantify the destructive potential carried by the impending physical collision, providing a basic quantitative input basis for the subsequent adjustment of dynamic impedance parameters.

7. The method for coordinated control of manufacturing process node status in a smart factory according to claim 6, characterized in that: Step S4 specifically includes: Step S4-1: After receiving the data packet containing the expected impact kinetic energy E_k, the underlying driver of the downstream execution node loads the preset workpiece material fragility coefficient C_fragile, where C_fragile is a dimensionless parameter calibrated at the factory, and its value is positively correlated with the physical fragility of the workpiece. Step S4-2, execute the instruction switching judgment logic: set the kinetic energy damage threshold E_safe, and trigger the operation based on the judgment formula E_k*C_fragile>E_safe. When the formula condition is met, a compliant reconstruction intervention instruction is generated to forcibly shut down the electromagnetic brake relay control circuit that was originally caused by the fault interruption. The significance of this formula is to assess whether the current collision kinetic energy combined with the workpiece material is sufficient to cause substantial damage, and to ensure that the default rigid protection mechanism of the system is cut off only when a real threat occurs.

8. The method for coordinated control of manufacturing process node status in a smart factory according to claim 7, characterized in that: Step S5 specifically includes: Step S5-1: Based on the impedance control principle, establish a second-order linear mechanical equivalent model of the downstream execution node in the impact direction; Step S5-2: The mechanical response characteristics of the node are dynamically adjusted using the impedance control formula F_impact=K*X+D*V, where F_impact is the resistance applied to the workpiece by the downstream execution node in the impact direction, K is the equivalent elastic stiffness coefficient in the impact direction, X is the actual displacement of the node in the impact direction, D is the equivalent viscous damping coefficient in the impact direction, and V is the instantaneous linear velocity of the node's yielding motion. The system actively lowers the value of parameter K and simultaneously increases the value of parameter D, so that the node produces a slow and gentle yielding displacement X when it is impacted by the workpiece. The physical principle of this formula is to convert the destructive transient impact kinetic energy into controlled damped dissipated internal energy, and completely realize the soft landing and force relief protection of the workpiece under fault conditions.

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