Dual-axis synchronous calibration method, industrial operation device, and computer program product

Abstract

The application discloses a double-shaft synchronous calibration method, an industrial operation device and a computer program product, relates to the technical field of industrial operation devices, and the technical scheme of the application comprises the following steps: acquiring a real-time angle difference between a first rotating shaft and a second rotating shaft in a workpiece coordinate system; determining whether the real-time angle difference exceeds a preset first threshold value; if the real-time angle difference exceeds the first threshold value, performing a preset parameter transplantation operation, wherein the parameter transplantation operation comprises the following steps: identifying a leading shaft and a lagging shaft in the first rotating shaft and the second rotating shaft based on the real-time angle difference, and assigning at least part of current servo gain parameters of the leading shaft to the lagging shaft as target parameters; returning to the step of acquiring the real-time angle difference between the first rotating shaft and the second rotating shaft in the workpiece coordinate system and subsequent steps until the real-time angle difference is less than or equal to the first threshold value. The application can solve the technical problems that double-shaft synchronous calibration is time-consuming, the effect is poor, and the operation depends on external tools and professional personnel in the prior art.

Description

Technical Field

[0001] This application relates to the field of industrial operating equipment technology, and in particular to a dual-axis synchronous calibration method, industrial operating equipment, and computer program products. Background Technology

[0002] In industrial equipment with dual rotary axes, such as laser processing, precision assembly, and multi-axis industrial robots, the first and second rotary axes must maintain strict synchronous motion in the workpiece coordinate system. When the servo control characteristics of the two rotary axes are inconsistent due to factors such as power differences, different transmission methods, parameter drift, or load changes, an angular difference will occur between the two axes, resulting in product processing position deviation and significantly reducing product yield.

[0003] In related technologies, a common approach to solving this type of dual-axis asynchrony problem is to use external debugging tools, such as a computer with dedicated servo debugging software installed, connected to the servo driver, to manually or automatically tune the servo gain parameters (such as position loop gain and velocity loop gain) of each axis. This method has the following drawbacks: the adjustment process is time-consuming, and because each axis is tuned independently, it is difficult to achieve consistency between two axes with different dynamic response characteristics during coordinated motion; the angular difference between the two axes may still be large after adjustment, resulting in limited improvement in synchronization. Furthermore, this process relies on external debugging equipment and specially trained operators, making calibration inconvenient and difficult for on-site operators to perform anytime, anywhere. Summary of the Invention

[0004] The main purpose of this application is to provide a dual-axis synchronous calibration method, industrial operating equipment, and computer program product, aiming to solve the technical problems of long time consumption, poor effect, and reliance on external tools and professional personnel in the related technology of dual-axis synchronous calibration.

[0005] To achieve the above objectives, this application proposes a dual-axis synchronous calibration method, applicable to industrial operating equipment containing a first rotating axis and a second rotating axis that need to operate synchronously. The method includes: Obtain the real-time angular difference between the first rotation axis and the second rotation axis in the workpiece coordinate system; Determine whether the real-time angle difference exceeds a preset first threshold; If the value exceeds the limit, a preset parameter transfer operation is performed. The parameter transfer operation includes: identifying the leading axis and the lagging axis determined based on the real-time angle difference between the first rotation axis and the second rotation axis, and assigning at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis. The servo gain parameters include position loop gain parameters and / or velocity loop gain parameters. Return to the step of obtaining the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system, and subsequent steps, until the real-time angle difference is less than or equal to the first threshold.

[0006] In one embodiment, the method further includes: Obtain the current operating condition information of the industrial operating equipment, wherein the current operating condition information includes at least one of the target rotation speed, load torque, and running direction of the first rotating shaft and the second rotating shaft; After the real-time angle difference is less than or equal to the first threshold, the current operating condition information is associated with the servo gain parameters of the first and second rotating axes obtained after the return execution, and stored as a set of synchronous operating condition records in a gain mapping table. The gain mapping table is used to provide initial servo gain parameters for the first and second rotating axes under different operating conditions of the industrial operating equipment.

[0007] In one embodiment, the method further includes: When the industrial operating equipment is running, the gain mapping table is queried based on the real-time operating condition information to determine the servo gain parameters that match the real-time operating condition information; Based on the servo gain parameters that match the real-time operating information, the initial servo gain parameters of the first and second rotary axes are determined and applied.

[0008] In one embodiment, the parameter transfer operation further includes: Based on the current first servo gain parameter of the first rotation axis and the current second servo gain parameter of the second rotation axis, a virtual reference servo model is constructed, wherein the target servo gain parameter of the virtual reference servo model is between the first servo gain parameter and the second servo gain parameter. Calculate the parameter differences between the first servo gain parameter, the second servo gain parameter, and the target servo gain parameter; Based on the parameter difference, the servo gain parameter of the lagging axis is increased and the servo gain parameter of the leading axis is decreased, so that the servo gain parameters of both approach the target servo gain parameter.

[0009] In one embodiment, the method for constructing a virtual reference servo model is as follows: Obtain the first transfer function of the first rotation axis and the second transfer function of the second rotation axis; The first transfer function and the second transfer function are weighted and averaged to obtain the transfer function of the virtual reference servo model. Based on the transfer function of the virtual reference servo model, the target servo gain parameter is determined to construct the virtual reference servo model.

[0010] In one embodiment, the servo gain parameters include position loop gain parameters and velocity loop gain parameters; the parameter transfer operation includes at least one of the following: When the first rotation axis and / or the second rotation axis are in a first motion state, the position loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis; When the first rotation axis and / or the second rotation axis are in a second motion state, the position loop gain parameter and velocity loop gain parameter of the leading axis are both assigned as target parameters to the lagging axis, wherein the absolute value of the acceleration represented by the second motion state is greater than the absolute value of the acceleration represented by the first motion state. When the first rotation axis and / or the second rotation axis are in a third motion state, the velocity loop gain parameter of the leading axis is assigned as a target parameter to the lagging axis, wherein the absolute value of the acceleration represented by the third motion state is greater than the absolute value of the acceleration represented by the second motion state.

[0011] In one embodiment, the method further includes: The real-time angle difference, calculated in real time, is displayed on the touchscreen. In response to a manual calibration command input by the user via the touchscreen, the current servo gain parameter of the hysteresis axis is increased or decreased according to the sign of the real-time angle difference, until the real-time angle difference is less than or equal to the first threshold.

[0012] In one embodiment, the process of returning to the step of obtaining the real-time angular difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps further includes: Obtain the rate of change of the real-time angle difference over time; If the rate of change indicates that the rate of decrease of the real-time angle difference exceeds a preset first rate of change threshold, then the adjustment step of the servo gain parameter in the parameter transfer operation is reduced. If the rate of change indicates that the change in the real-time angle difference within a preset time period is less than a preset second rate of change threshold, then the adjustment step of the servo gain parameter in the parameter transfer operation is increased.

[0013] In one embodiment, prior to performing the parameter transfer operation, the method further includes: Confirm whether the operating status of the servo drives corresponding to the first and second rotary axes is normal to confirm whether there is a first hardware fault, and confirm whether the communication status of the encoders corresponding to the first and second rotary axes is normal to confirm whether there is a second hardware fault. If a hardware malfunction is detected in either the first or the second rotating axis, the parameter migration operation is stopped and a first alarm is issued. The hardware malfunction includes both the first and the second hardware malfunctions.

[0014] In one embodiment, the process of returning to the step of obtaining the real-time angular difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps further includes: Monitor the trend of the real-time angle difference after a single parameter transfer operation; If the real-time angle difference does not shrink in the preset convergence direction, but instead expands and the expansion exceeds the preset third threshold, the parameter transfer operation will be stopped and a second alarm will be issued.

[0015] In addition, to achieve the above objectives, this application also proposes an industrial operating device, which includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the dual-axis synchronous calibration method described above.

[0016] In addition, to achieve the above objectives, this application also proposes a storage medium, which is a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, it implements the steps of the dual-axis synchronous calibration method described above.

[0017] In addition, to achieve the above objectives, this application also provides a computer program product, which includes a computer program that, when executed by a processor, implements the steps of the dual-axis synchronous calibration method described above.

[0018] This application proposes a dual-axis synchronous calibration method, applicable to industrial operating equipment, specifically industrial operating equipment containing a first rotary axis and a second rotary axis that need to operate synchronously. The technical solution of this application involves obtaining the real-time angular difference between the first and second rotary axes in the workpiece coordinate system; determining whether the real-time angular difference of the industrial operating equipment exceeds a preset first threshold; if it does, performing a preset parameter transfer operation, wherein the industrial operating equipment parameter transfer operation includes: identifying the leading and lagging axes among the first and second rotary axes determined based on the real-time angular difference of the industrial operating equipment, and assigning at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis of the industrial operating equipment, the servo gain parameters of the industrial operating equipment including position loop gain parameters and / or velocity loop gain parameters; returning to the step of obtaining the real-time angular difference between the first and second rotary axes in the workpiece coordinate system and subsequent steps, until the real-time angular difference of the industrial operating equipment is less than or equal to the first threshold of the industrial operating equipment.

[0019] Since the calibration process in this embodiment is entirely automated by the controller, it eliminates the need for external debugging tools or manual tuning by professionals, significantly improving the convenience of the calibration operation. Furthermore, by directly assigning the servo gain parameters of the leading axis to the lagging axis, the lagging axis can quickly obtain effective parameters verified through actual operation. Compared to the traditional method of independently tuning each axis, this avoids the lengthy process of repeated trial and error and gradual approximation, thereby significantly shortening the time required for the dual-axis angle difference to converge to within the target threshold.

[0020] Furthermore, because related technologies involve independently tuning the servo parameters of the two axes, even if each axis has good response characteristics, differences in dynamic characteristics between the two axes may still exist, leading to angular deviations during coordinated motion. This application's embodiment uses a "parameter transfer" method, allowing the lagging axis to directly adopt the servo gain parameters of the leading axis. Therefore, the servo control characteristics of both axes tend to be consistent, eliminating motion response differences caused by different control parameters at their root. Consequently, after calibration, the angular difference between the two axes in the workpiece coordinate system can be controlled within a very small preset threshold range, resulting in a substantial improvement in synchronization accuracy. Attached Figure Description

[0021] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 A flowchart illustrating the biaxial synchronous calibration method of this application; Figure 2 This is a schematic diagram of the device structure of the hardware operating environment involved in the dual-axis synchronous calibration method in the embodiments of this application.

[0024] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] It should be understood that the specific embodiments described herein are merely illustrative of the technical solutions of this application and are not intended to limit this application.

[0026] For ease of understanding, the following explains some key terms in this embodiment: The dual-axis synchronous calibration method refers to adjusting the control parameters of two rotating axes in industrial operating equipment to maintain a preset synchronous relationship during operation, thereby reducing or eliminating angular deviation between them.

[0027] The first and second rotating axes refer to two rotating components in industrial operating equipment that need to move in coordination. Typically, one rotating axis is designated as the master axis and the other as the driven axis, with a master-slave relationship between them.

[0028] The workpiece coordinate system refers to a coordinate system established with the workpiece as a reference in industrial operating equipment. Under this coordinate system, the motion state and relative position of the rotating axis can be accurately measured and represented.

[0029] Real-time angular difference refers to the instantaneous angular deviation between the first and second rotary axes in the workpiece coordinate system during the operation of industrial equipment. This angular difference reflects the accuracy of the synchronous operation of the two axes.

[0030] The first threshold is a preset value used to determine whether the real-time angle difference exceeds the allowable range. When the real-time angle difference exceeds this threshold, it indicates that the synchronization of the two axes has deviated from the acceptable range and calibration is required.

[0031] Parameter transfer operation refers to a servo gain parameter adjustment strategy. This operation involves transferring part or all of the servo gain parameter of one rotary axis to another rotary axis to achieve convergence of the servo response characteristics of the two axes, thereby improving synchronization.

[0032] Leading axis and lagging axis refer to the rotating axis whose speed or position is ahead (leading axis) and whose speed or position is behind (lagging axis) in the process of dual-axis synchronous operation, based on the magnitude and direction of the real-time angle difference.

[0033] Servo gain parameters are key parameters used in servo control systems to adjust the system's response characteristics. These include position loop gain parameters and velocity loop gain parameters. Position loop gain parameters affect the accuracy and stiffness of position tracking, while velocity loop gain parameters affect the speed and stability of velocity response. Adjusting these parameters can alter the dynamic response characteristics of the rotary axis.

[0034] This embodiment provides a dual-axis synchronous calibration method applied to industrial operating equipment comprising a first rotary axis and a second rotary axis. In this equipment, the first and second rotary axes are configured to operate synchronously, and the second rotary axis is set as the driven rotary axis of the first rotary axis. For example, in a multi-axis linkage machine tool, the spindle is responsible for the main machining motion, while the driven axis cooperates to complete auxiliary or compensating motions to ensure machining accuracy. Please refer to... Figure 1 , Figure 1 The flowchart provided for the biaxial synchronous calibration method of this application includes: Step S100: Obtain the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system; Step S200: Determine whether the real-time angle difference exceeds a preset first threshold. Step S300: If the value exceeds the limit, a preset parameter transfer operation is performed. The parameter transfer operation includes: identifying the leading axis and the lagging axis determined based on the real-time angle difference between the first rotation axis and the second rotation axis, and assigning at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis. The servo gain parameters include position loop gain parameters and / or velocity loop gain parameters. Step S400: Return to the step of obtaining the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps until the real-time angle difference is less than or equal to the first threshold.

[0035] During the execution of the method, it is first necessary to obtain the real-time angular difference between the first and second rotation axes in the workpiece coordinate system. This real-time angular difference can be obtained in several ways. For example, an encoder installed on each rotation axis can be used to collect the absolute or relative position information of the two axes in real time, and then the controller can calculate the angular deviation between them. As another implementation method, a vision sensor can be used to track specific marker points on the workpiece in real time, and the real-time angular difference between the two axes can be indirectly calculated based on the relative position changes of the marker points.

[0036] After acquiring the real-time angle difference, the system determines whether this difference exceeds a preset first threshold. This first threshold is a configurable parameter, and its setting is typically determined based on the accuracy requirements and process tolerances of the industrial operating equipment. For example, it can be set to 0.01 degrees or 0.05 degrees. If the real-time angle difference is less than or equal to the first threshold, the two axes are considered to be in a synchronized state, and no further calibration is required. If the real-time angle difference exceeds the first threshold, it indicates that the synchronization of the two axes has deviated from the allowable range, and a calibration process needs to be initiated.

[0037] If the real-time angle difference exceeds a first threshold, a preset parameter transfer operation is executed. The core of this parameter transfer operation lies in identifying the leading and lagging axes. A leading axis is a rotational axis whose angular position or velocity leads that of another axis in synchronous motion; a lagging axis is a rotational axis whose angular position or velocity lags behind that of another axis. For example, the leading and lagging axes can be determined by comparing the real-time angular positions or real-time velocities of the two axes.

[0038] After identifying the lead and lag axes, the parameter transfer operation assigns at least a portion of the current servo gain parameters of the lead axis as target parameters to the lag axis. For example, the current position loop gain parameter value of the lead axis can be directly copied and applied to the position loop gain parameter of the lag axis. Alternatively, the current velocity loop gain parameter value of the lead axis can be copied and applied to the velocity loop gain parameter of the lag axis. This direct transfer method aims to make the response characteristics of the lag axis closer to those of the lead axis, thereby reducing the dynamic differences between the two.

[0039] Servo gain parameters include position loop gain parameters and / or velocity loop gain parameters. Position loop gain parameters primarily affect the servo system's response speed and accuracy to position commands, while velocity loop gain parameters affect the servo system's response speed and stability to velocity commands. During parameter porting, position loop gain parameters, velocity loop gain parameters, or both can be selectively ported according to actual needs. For example, in some applications, only adjusting the position loop gain may be necessary to improve static synchronization accuracy; while in other applications, adjusting both the position and velocity loop gains simultaneously may be required to optimize dynamic synchronization performance.

[0040] After the parameter migration operation is executed, the system returns to the step of obtaining the real-time angle difference between the first and second rotation axes in the workpiece coordinate system, and then proceeds with subsequent steps. This process continues to loop until the real-time angle difference is less than or equal to a first threshold. For example, after each parameter migration, the system remeasures the angle difference and determines whether further adjustments are needed based on the new angle difference. This iterative adjustment mechanism ensures that the synchronization of the two axes gradually converges to a preset accuracy range.

[0041] This embodiment of the dual-axis synchronous calibration method monitors the angular difference between the first and second rotary axes in the workpiece coordinate system in real time, dynamically identifies the leading and lagging axes based on this angular difference, and then transfers the servo gain parameters of the leading axis to the lagging axis, achieving rapid and adaptive calibration of dual-axis synchronization in industrial operating equipment. This method effectively solves the problems of long calibration time, limited synchronization effect, and reliance on external tools and professionals in traditional calibration methods, significantly improving product yield and equipment operating efficiency in applications such as laser processing, precision assembly, and multi-axis industrial robots.

[0042] In some embodiments described above, this application proposes a method for achieving synchronous calibration by real-time monitoring of the dual-axis angle difference and iteratively adjusting servo gain parameters. However, in actual industrial operation, industrial equipment often needs to operate under various different conditions, such as different target speeds, load torques, or operating directions. If the iterative calibration process is performed from scratch every time the operating conditions change, it may lead to low calibration efficiency, increased time costs for equipment startup and operating condition switching, and an inability to effectively accumulate and utilize historical calibration experience.

[0043] In this regard, this application further proposes that, based on the above-mentioned dual-axis synchronous calibration method, it also includes acquiring the current operating condition information of the industrial operating equipment. The current operating condition information includes at least one of the target rotational speed, load torque, and running direction of the first and second rotating axes. After the real-time angle difference is less than or equal to a first threshold, the current operating condition information is associated with the servo gain parameters of the first and second rotating axes finally obtained after the return execution, and stored as a set of synchronous operating condition records in a gain mapping table. The gain mapping table is used to provide initial servo gain parameters for the first and second rotating axes under different operating conditions of the industrial operating equipment.

[0044] Specifically, current operating condition information refers to key parameters of industrial equipment under specific operating conditions, which directly affect the dynamic response and synchronization performance of the first and second rotating axes. Current operating condition information may include, but is not limited to, target speed, load torque, and direction of travel. For example, the target speed can be obtained by reading the command value set by the equipment controller (such as a PLC or motion controller); the load torque can be measured in real time by a torque sensor mounted on the rotating axis, or estimated by the servo drive based on parameters such as motor current and speed; the direction of travel can be determined based on control commands or direction signals fed back by the encoder. This information is typically acquired through industrial communication buses or dedicated sensor interfaces. This step aims to comprehensively capture the characteristics of the operating environment at the time of calibration.

[0045] In detail, when the above iterative calibration process successfully converges, meaning the real-time angle difference has decreased to within a preset first threshold, it indicates that the current servo gain parameters can effectively achieve dual-axis synchronization. At this point, the system binds the captured current operating condition information with the servo gain parameters (including position loop gain parameters and / or velocity loop gain parameters) of the first and second rotation axes finally determined in this calibration. This binding forms a set of "synchronization operating condition records" and is stored in a preset gain mapping table. The gain mapping table can be implemented using a database, lookup table, or hash table, and its core function is to establish a mapping relationship between operating condition information and corresponding optimized servo gain parameters.

[0046] In other words, the gain mapping table acts as a knowledge base, storing and managing verified, optimal servo gain parameter configurations for different operating conditions. When industrial equipment starts up or needs to switch to a new operating condition, the system can query the gain mapping table based on the current or target operating condition information. If a record matching the current operating condition exists in the table, the corresponding servo gain parameters are directly extracted and applied as the initial servo gain parameters for the first and second rotary axes. This mechanism allows the equipment to skip the iterative calibration process from scratch and directly load verified parameters when facing known operating conditions, thus achieving fast and efficient startup and operating condition switching.

[0047] Through the above technical solution, this application effectively solves the problem of low efficiency in repeated calibration of industrial operating equipment under different operating conditions. Specifically, after each successful calibration, the current operating condition information is associated with the final optimized servo gain parameters and stored in a gain mapping table. This allows the system to accumulate experience in optimal parameter configuration under different operating conditions. When the equipment operates again in or switches to a recorded operating condition, the corresponding initial servo gain parameters can be directly queried from the gain mapping table and applied, thus avoiding the time-consuming iterative calibration process from scratch. This significantly shortens the time required for equipment startup and operating condition switching, improves production efficiency and equipment response speed, and enhances the intelligence and adaptability of the dual-axis synchronous system, enabling it to maintain high-precision synchronous operation under varying operating conditions.

[0048] In some of the embodiments described above in this application, although it is proposed to associate the calibrated servo gain parameters with the operating condition information and store them in the gain mapping table, how to efficiently utilize these pre-stored parameters to quickly provide suitable initial servo gain parameters for the first and second rotary axes during actual operation of industrial equipment, thereby ensuring the synchronization performance of the two axes under different operating conditions, remains a problem that needs to be solved.

[0049] In response, this application further proposes that, during the operation of industrial equipment, a gain mapping table is queried based on real-time acquired operating information to determine the servo gain parameters that match the real-time operating information; and based on the servo gain parameters that match the real-time operating information, the initial servo gain parameters of the first and second rotary axes are determined and applied.

[0050] Specifically, during the operation of industrial equipment, the system continuously acquires the equipment's current operating condition information in real time. This real-time operating condition information typically includes, but is not limited to, key parameters such as the target rotational speed, actual load torque, and operating direction of the first and second rotating axes. This information can be monitored and collected in real time by sensors within the equipment (e.g., encoders for acquiring speed and direction, and torque sensors for acquiring load). Subsequently, the system uses this real-time operating condition information to query a pre-established gain mapping table. The gain mapping table stores servo gain parameters, calibrated for different operating conditions, applicable to the first and second rotating axes. The query process can employ various matching algorithms, such as exact matching, fuzzy matching, or interpolation / extrapolation-based matching methods, to find the operating condition record that is closest to or completely consistent with the current real-time operating condition information.

[0051] After retrieving servo gain parameters that match the real-time operating conditions, the system extracts initial servo gain parameters applicable to both the first and second rotary axes. These parameters may include position loop gain parameters and / or velocity loop gain parameters. Subsequently, the system configures and applies these determined initial servo gain parameters to the servo drives controlling the first and second rotary axes. In this way, the servo system can immediately adopt optimized control parameters at the start of equipment operation or when operating conditions change, rather than relying on general or default settings.

[0052] Through the above technical solution, during the operation of industrial equipment, the system can dynamically query and determine the servo gain parameters that best match the current operating conditions from the gain mapping table based on real-time acquired operating condition information. Based on this, initial servo gain parameters are quickly determined and applied for the first and second rotary axes, enabling the dual axes to rapidly obtain near-optimal control parameters upon startup or changes in operating conditions. This significantly improves the synchronization accuracy and response speed of the dual axes under different operating conditions, effectively avoids synchronization deviations caused by changes in operating conditions, reduces reliance on real-time online calibration, and thus improves the overall operating efficiency and stability of the equipment, reducing production losses caused by synchronization problems.

[0053] In some embodiments described above in this application, a parameter transfer method is proposed that identifies the leading and lagging axes and directly assigns the servo gain parameters of the leading axis to the lagging axis. However, in its implementation, this one-way parameter transfer method may cause drastic changes in the servo gain parameters of the lagging axis, especially when the initial parameters of the leading and lagging axes differ significantly. This may lead to system instability, oscillation, or overshoot, thereby affecting the stability and accuracy of dual-axis synchronous calibration.

[0054] To address this, this application further proposes constructing a virtual reference servo model during parameter transfer operations, based on the current first servo gain parameter of the first rotation axis and the current second servo gain parameter of the second rotation axis. This virtual reference servo model is an idealized, intermediate-state servo system model. It does not correspond to the actual physical axes but is a theoretical model calculated to guide the parameter adjustment of the actual axes. Specifically, the target servo gain parameter of the virtual reference servo model is set between the first servo gain parameter and the second servo gain parameter of the second rotation axis. This means that the target parameter will not be an extreme value for either axis but rather a balance point between them. For example, it could be the arithmetic mean, weighted average, or an intermediate value calculated using a certain optimization algorithm for the current parameters of the two axes. The purpose is to ensure that during the adjustment process, neither axis completely converges to the other, but rather both converge towards a compromise, more optimized state.

[0055] Based on this, the parameter differences between the first servo gain parameter, the second servo gain parameter, and the target servo gain parameter are calculated. This parameter difference refers to the numerical difference between the current servo gain parameter of each rotation axis and the target servo gain parameter of the virtual reference servo model, typically obtained through simple subtraction. Subsequently, based on the parameter differences, the servo gain parameter of the lagging axis is increased and the servo gain parameter of the leading axis is decreased, so that the servo gain parameters of both approaches the target servo gain parameter. Specifically, if the parameter of the lagging axis is lower than the target parameter, its gain is increased; if the parameter of the leading axis is higher than the target parameter, its gain is decreased. The adjustment step size or magnitude can be proportional to the parameter difference, or dynamically adjusted using methods such as PID control.

[0056] By introducing a virtual reference servo model and bidirectionally adjusting the servo gain parameters of the leading and lagging axes through the above technical solution, the drastic parameter changes and system instability problems that may occur with traditional unidirectional parameter transfer are avoided. The servo gain parameters of the two rotary axes no longer converge unidirectionally towards the parameters of the leading axis, but instead converge together towards a virtual reference target parameter that lies between the two. This makes the parameter adjustment process smoother and more gradual, effectively suppressing oscillations or overshoots that may occur during calibration, thereby significantly improving the stability and accuracy of dual-axis synchronous calibration. Simultaneously, because the parameter adjustment is bidirectional, the system can reach synchronization faster and more robustly, reducing calibration time and lowering the mechanical stress on industrial equipment during calibration, thus extending the equipment's service life.

[0057] In some embodiments described above in this application, dual-axis synchronization is calibrated by identifying the leading and lagging axes and transferring some servo gain parameters of the leading axis to the lagging axis, or by constructing a virtual reference servo model and making the servo gain parameters of both axes approach the target parameters. However, if the dynamic characteristics of the first and second rotation axes are not fully considered when constructing the virtual reference servo model, the determined target servo gain parameters may not accurately reflect the actual needs of the system, thereby affecting the convergence, stability, and final synchronization accuracy of the parameter adjustment.

[0058] In response, this application further proposes a method for constructing a virtual reference servo model as follows: obtaining a first transfer function of a first rotation axis and a second transfer function of a second rotation axis; performing a weighted average of the first and second transfer functions to obtain the transfer function of the virtual reference servo model; and determining the target servo gain parameter based on the transfer function of the virtual reference servo model to construct the virtual reference servo model.

[0059] A transfer function is a mathematical model describing the dynamic characteristics of a system, representing the relationship between the system's input and output. For rotating shafts in industrial operating equipment, their transfer functions reflect the dynamic response characteristics of a servo system composed of motors, drives, and mechanical loads, such as inertia, damping, and stiffness. These transfer functions can be obtained through system identification methods. Specifically, a preset test signal (such as a step signal, a swept frequency signal, or a pseudo-random binary sequence) can be applied individually to each rotating shaft, and its output response (such as speed and position) can be measured in real time. Then, system identification algorithms (such as least squares method, subspace identification method, or frequency response method) are used to process the collected input and output data to fit their respective transfer function models. These models are typically represented in the Laplace transform domain (s-domain) or Z-transform domain (z-domain), accurately characterizing the dynamic behavior of each rotating shaft.

[0060] The weighted averaging operation aims to comprehensively consider the dynamic characteristics of the first and second rotation axes to generate a virtual reference model that represents the balance or compromise between them. This operation is achieved by linearly combining the transfer functions of the two rotation axes with different weighting coefficients. For example, if the transfer function of the first rotation axis is G1(s) and the transfer function of the second rotation axis is G2(s), then the transfer function G_ref(s) of the virtual reference servo model can be expressed as G_ref(s) = w1 G1(s) + w2 G2(s), where w1 and w2 are weighting coefficients, and w1+w2=1. The weighting coefficients can be set based on actual application requirements. For example, they can be set to 0.5 to achieve equal weighting, or they can be dynamically adjusted according to the power, inertia, importance in the synchronization system, or the quality of their dynamic characteristics of each rotating axis to ensure that the virtual reference model better matches the actual synchronization goal.

[0061] Once the transfer function of the virtual reference servo model is obtained, its corresponding servo gain parameters can be designed or determined based on this transfer function. These parameters include, but are not limited to, position loop gain parameters and / or velocity loop gain parameters, which will serve as common targets for adjusting the lead and lag axes during parameter transfer operations. In practice, classical control theory methods, such as root locus methods, frequency response methods (e.g., Bode plot, Nyquist plot analysis), or PID parameter tuning methods (e.g., the Ziegler-Nichols method), can be used to calculate and determine a set of servo gain parameters that enable the virtual reference model to achieve the desired dynamic response characteristics (e.g., response speed, overshoot, stability margin) based on the virtual reference servo model's transfer function G_ref(s). These determined parameters are the target servo gain parameters. In this way, the virtual reference servo model not only possesses clear dynamic characteristics but also has matching control parameters, thus providing a clear and reasonable convergence target for subsequent parameter tuning.

[0062] Through the above technical solution, this application clarifies the specific method for constructing a virtual reference servo model and its target servo gain parameters. By obtaining the transfer functions of the first and second rotation axes and weighted averaging them to obtain the transfer function of the virtual reference servo model, it is ensured that the constructed virtual reference model can comprehensively reflect the actual dynamic characteristics of the two rotation axes. Based on this, the target servo gain parameters are determined according to the transfer function of the virtual reference servo model, so that these target parameters are no longer empirically or arbitrarily set, but reasonable values ​​derived from the actual physical characteristics of the system. This effectively solves the problems of poor convergence, insufficient stability, or low synchronization accuracy that may be caused by improper setting of target parameters during dual-axis synchronous calibration. This method provides a scientific, stable, and representative convergence target for adjusting the servo gain parameters of the leading and lagging axes, thereby significantly improving the efficiency, accuracy, and robustness of dual-axis synchronous calibration, and is especially suitable for industrial operating equipment where the dynamic characteristics of the two rotation axes differ.

[0063] In some of the above embodiments, when the real-time angular difference between the first and second rotational axes exceeds a preset threshold, dual-axis synchronous calibration is achieved by identifying the leading and lagging axes and assigning at least a portion of the current servo gain parameters of the leading axis to the lagging axis. However, in actual industrial operation, industrial equipment may be in different motion states, such as low-speed stable operation, medium-speed acceleration operation, or high-speed emergency stop. Under these different motion states, the sensitivity and adjustment requirements of the position loop gain parameters and speed loop gain parameters of the servo system may differ. Indiscriminate parameter transfer may lead to low calibration efficiency, or even cause system oscillation or response lag under certain operating conditions, affecting synchronization accuracy and equipment stability.

[0064] To address this, this application further proposes a scheme for selectively transferring servo gain parameters based on motion states. Specifically, the servo gain parameters include position loop gain parameters and velocity loop gain parameters. The parameter transfer operation includes at least one of the following: when the first rotation axis and / or the second rotation axis are in a first motion state, the position loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis; when the first rotation axis and / or the second rotation axis are in a second motion state, both the position loop gain parameter and the velocity loop gain parameter of the leading axis are assigned as target parameters to the lagging axis, wherein the absolute value of the acceleration represented by the second motion state is greater than the absolute value of the acceleration represented by the first motion state; when the first rotation axis and / or the second rotation axis are in a third motion state, the velocity loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis, wherein the absolute value of the acceleration represented by the third motion state is greater than the absolute value of the acceleration represented by the second motion state.

[0065] Servo gain parameters are key parameters used in servo control systems to adjust the system's response characteristics, typically including position loop gain parameters and speed loop gain parameters. These parameters directly affect the dynamic performance, stability, and ability to suppress external disturbances of the servo system. Position loop gain parameters are primarily used to control the position tracking error of the servo motor, determining the system's response speed and positioning accuracy to position commands. Higher position loop gain usually means faster response speed and smaller steady-state error, but may also increase the risk of system oscillation. In practical applications, position loop gain parameters typically include proportional gain, integral gain, and derivative gain; adjusting these parameters can optimize the system's position tracking performance. Speed ​​loop gain parameters are primarily used to control the speed tracking error of the servo motor, determining the system's response speed to speed commands, speed smoothness, and resistance to load changes. Higher speed loop gain usually provides stronger resistance to load disturbances and faster speed response, but may also affect system stability. Speed ​​loop gain parameters are also often composed of proportional gain, integral gain, and derivative gain, used for fine-tuning speed control performance.

[0066] This application refines the parameter transfer strategy based on the different motion states of industrial operating equipment. The first motion state typically refers to the operating condition where the industrial equipment is running at low acceleration or near-uniform speed. In this state, the main goal of the system is to maintain accurate position tracking and small steady-state error. For example, when the equipment is performing slow positioning or uniform linear motion, the absolute value of its acceleration is relatively small. When the equipment is in this first motion state, the position loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis. The aim is to adjust the position loop gain parameter of the lagging axis so that its position response characteristics are consistent with those of the leading axis, thereby quickly eliminating position deviation and improving synchronization accuracy.

[0067] The second motion state refers to the operating condition where industrial equipment is running at moderate acceleration. In this state, the system needs to maintain good position tracking capability as well as a certain level of speed response and disturbance rejection capability. For example, when the equipment is performing moderate-speed acceleration / deceleration or curvilinear interpolation, the absolute value of its acceleration falls between the first and third motion states. When the equipment is in this second motion state, the position loop gain parameters and velocity loop gain parameters of the leading axis are both assigned as target parameters to the lagging axis. By simultaneously adjusting the position loop and velocity loop gain parameters of the lagging axis, it can better follow the leading axis in both position and velocity response, thereby achieving more comprehensive synchronization performance optimization.

[0068] The third motion state refers to the operating condition where industrial equipment is running at high acceleration. In this state, the system requires extremely high speed response and stability to cope with rapid acceleration and deceleration, sudden stops, or high-dynamic load changes. For example, when the equipment is undergoing rapid start-up, sudden stop, or high-speed reciprocating motion, the absolute value of its acceleration is significantly higher than in the second motion state. When the equipment is in this third motion state, the speed loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis. By adjusting the speed loop gain parameter of the lagging axis, its speed response characteristics are matched with those of the leading axis, thereby effectively suppressing speed fluctuations and dynamic errors during high-speed motion and ensuring the synchronous stability of the system under high dynamic conditions.

[0069] By employing the aforementioned technical solution, and selectively choosing the type of servo gain parameters (position loop only, velocity loop only, or both) for the advanced axis based on the specific motion state of the industrial operating equipment, this application achieves more refined and adaptive parameter calibration. Under low-acceleration motion, prioritizing the adjustment of the position loop gain parameters helps to quickly eliminate positional deviations and improve positioning accuracy. Under medium-acceleration motion, simultaneously adjusting the position and velocity loop gain parameters balances system response speed and stability. Under high-acceleration motion, focusing on adjusting the velocity loop gain parameters effectively suppresses speed fluctuations and ensures smooth dynamic response. This motion state-based parameter transfer strategy avoids blind or over-adjustment, significantly improving the efficiency and accuracy of dual-axis synchronous calibration, effectively preventing oscillations or hysteresis that may occur under different operating conditions, thereby ensuring stable synchronous operation of the industrial operating equipment across the entire operating range.

[0070] In some embodiments described above in this application, a method for calibrating dual-axis synchronous operation through automatic parameter transfer is proposed. However, in certain industrial operating scenarios, a purely automated calibration process may not fully meet the high requirements for calibration accuracy, convergence speed, or operational flexibility. For example, in the initial stages of equipment commissioning or when facing complex and changing operating conditions, operators may require more intuitive feedback and more refined intervention methods to make fine adjustments based on actual observation and experience, thereby ensuring that the dual-axis synchronous calibration achieves the best results.

[0071] In response, this application further proposes a dual-axis synchronous calibration method, which further includes: displaying the real-time angle difference obtained by real-time calculation on a touch screen; responding to a manual calibration command input by the user through the touch screen, increasing the current servo gain parameter of the hysteresis axis and / or decreasing the current servo gain parameter of the hysteresis axis according to the sign of the real-time angle difference, until the real-time angle difference is less than or equal to a first threshold.

[0072] Real-time angle difference is a key indicator for measuring the synchronization performance of the first and second rotary axes. Displaying it on a touchscreen aims to provide operators with intuitive, real-time feedback on the synchronization status. In practice, industrial operating equipment is typically equipped with a Human-Machine Interface (HMI) or industrial panel PC, whose display can serve as a touchscreen. The real-time angle difference data can be calculated by a servo controller or programmable logic controller (PLC) and transmitted to the touchscreen via an industrial communication network (e.g., EtherCAT, Profinet, or Modbus TCP / IP). The application on the touchscreen can dynamically update and display this angle difference in various forms, such as numerical values, trend graphs, bar charts, or color coding (e.g., green for good synchronization, yellow for approaching the threshold, and red for exceeding the threshold) to visually indicate the synchronization status, allowing operators to clearly understand the current synchronization deviation of the two axes.

[0073] This allows users to actively trigger or participate in the calibration process after observing real-time angular differences, providing flexibility and control for manual intervention. The touchscreen interface can be designed with dedicated function buttons or sliders such as "Manual Calibration," "Gain Adjustment," or "Fine-tuning." When the user clicks these buttons or drags the sliders via the touchscreen, the touchscreen application generates a corresponding command signal. This command signal is sent to the servo controller or main controller via a communication interface (e.g., Modbus TCP / IP, OPC UA, or proprietary protocol). The command can include the direction of adjustment (e.g., increasing or decreasing servo gain) and the magnitude of adjustment (e.g., step size or percentage).

[0074] The core logic of manual calibration involves adjusting the servo gain parameter of the lagging axis (increasing or decreasing it based on the sign of the real-time angle difference) to change its response speed and thus reduce the angle difference with the leading axis. When the system receives a manual calibration command, it first determines whether the current real-time angle difference is positive or negative. For example, if the real-time angle difference is defined as "first rotation axis angle minus second rotation axis angle," and the difference is positive, it indicates that the first rotation axis is ahead of the second rotation axis, making the second rotation axis a lagging axis. To make the second rotation axis catch up, the system increases its servo gain parameter (e.g., position loop gain Kp, velocity loop gain Kv) according to the command, making its response faster. Conversely, if the real-time angle difference is negative, it indicates that the second rotation axis is ahead of the first rotation axis, making the first rotation axis a lagging axis. To make the first rotation axis catch up, the system increases its current servo gain parameter according to the command. The adjustment step size can be a preset fixed value or dynamically determined based on the strength of the user's input command (e.g., the length of time a button is pressed or the range of the slider drag) to achieve fine-tuning.

[0075] A clear calibration target is set, and the manual calibration process can be stopped or considered complete when this target is reached. The system continuously monitors the absolute value of the real-time angle difference. After each manual adjustment of the servo gain parameters, the system recalculates and evaluates the real-time angle difference. When the absolute value of the real-time angle difference drops below a preset first threshold, the system can automatically stop further gain adjustments or display a calibration completion message on the touchscreen, instructing the user to stop manual operation. This ensures the effectiveness and targeting of the calibration process, avoiding over-adjustment.

[0076] The above technical solution displays the angle difference in real time on the touchscreen, allowing operators to intuitively understand the current status and calibration progress of the dual-axis synchronization. When automatic parameter transfer may not fully meet the precise synchronization requirements under specific working conditions, users can manually increase or decrease the servo gain parameter of the lagging axis based on real-time feedback and calibration commands. This human-computer interaction makes the calibration process more flexible and controllable, especially suitable for scenarios requiring high-precision synchronization or fine-tuning under complex and variable working conditions. It overcomes the limitations of purely automatic calibration in some cases, improves the success rate of calibration and the final synchronization accuracy, while reducing the extreme requirements for the robustness of the system's automatic adjustment algorithm, thus enhancing the system's adaptability and reliability.

[0077] In some embodiments described above in this application, the leading and lagging axes of the first and second rotation axes are identified, and the servo gain parameters of the leading axis are transferred to the lagging axis to reduce the real-time angle difference between the first and second rotation axes. However, if the adjustment step size of the servo gain parameters remains fixed during the iterative process of parameter transfer, the calibration process may converge slowly, or overshoot and oscillation may occur when approaching synchronization, affecting the efficiency and stability of the calibration.

[0078] In response, this application further proposes that, during the process of returning to execute the step of obtaining the real-time angle difference between the first and second rotation axes in the workpiece coordinate system and subsequent steps, the following additional steps are included: obtaining the rate of change of the real-time angle difference over time; if the rate of change indicates that the rate of decrease of the real-time angle difference exceeds a preset first rate of change threshold, then reducing the adjustment step size of the servo gain parameter in the parameter transfer operation; if the rate of change indicates that the change amplitude of the real-time angle difference within a preset time period is less than a preset second rate of change threshold, then increasing the adjustment step size of the servo gain parameter in the parameter transfer operation.

[0079] Specifically, the system can periodically collect real-time angular difference data between the first and second rotation axes in the workpiece coordinate system. By performing differential operations on these continuously collected real-time angular difference data—for example, calculating the difference between the current real-time angular difference and the previous real-time angular difference, and then dividing by the corresponding time interval—the rate of change of the real-time angular difference over time can be obtained. This rate of change can intuitively reflect the decreasing or increasing trend and speed of the real-time angular difference, providing a basis for subsequent adaptive adjustments. To improve the accuracy of the rate of change calculation and its anti-interference capability, digital filtering techniques, such as moving average filtering or Kalman filtering, can also be used to smooth the original angular difference data before calculating the rate of change.

[0080] When the rate of decrease in real-time angle difference is too rapid—that is, when the absolute value of its rate of change exceeds a preset first rate of change threshold—it indicates that the current parameter transfer operation may be too aggressive, posing a risk of system overshoot or oscillations near the target value. In this case, to ensure the smoothness and stability of the calibration process, the system will automatically reduce the adjustment step size of the servo gain parameter. For example, the current adjustment step size can be multiplied by a decay coefficient less than 1 (such as 0.5 or 0.8), or a preset fixed value can be subtracted from the current step size. The setting of the first rate of change threshold should comprehensively consider the dynamic response characteristics of the industrial operating equipment, the desired convergence speed, and the system stability requirements, and is usually determined through experimental testing or simulation optimization.

[0081] Conversely, if the change in real-time angle difference is very small within a preset time period, i.e., the absolute value of its rate of change is less than a preset second rate of change threshold, this may mean that the current parameter transfer operation step size is too small, leading to slow convergence of the calibration process, or even getting stuck in a local optimum. To accelerate the calibration process and improve efficiency, the system will increase the adjustment step size of the servo gain parameter. For example, the current adjustment step size can be multiplied by an amplification factor greater than 1 (such as 1.2 or 1.5), or a preset fixed value can be added to the current step size. The preset time period is introduced to avoid misjudgment of step adjustment due to instantaneous fluctuations and to ensure the stability of the judgment. The setting of the second rate of change threshold aims to balance convergence speed and system stability, ensuring that synchronization is achieved as quickly as possible while maintaining stability.

[0082] By dynamically acquiring the rate of change of the real-time angle difference over time and adaptively adjusting the adjustment step size of the servo gain parameter based on this rate of change, this application effectively solves the problems of slow convergence speed or unstable calibration caused by fixed step size adjustment. When the real-time angle difference decreases too quickly, reducing the adjustment step size can avoid system overshoot and oscillation, ensuring the smoothness of the calibration process; when the real-time angle difference changes slowly, increasing the adjustment step size can accelerate convergence and improve calibration efficiency. This adaptive adjustment mechanism enables the dual-axis synchronous calibration method to intelligently optimize parameter adjustment strategies according to the actual operating state, thereby achieving faster, more accurate, and more stable dual-axis synchronous calibration.

[0083] In dual-axis synchronous calibration methods, precise synchronization of the two axes is achieved by real-time monitoring of the angular difference between the first and second rotary axes and adjusting the servo gain parameters. However, if there is a failure in critical hardware such as the servo driver or encoder before the parameter transfer operation, subsequent parameter adjustments may not only fail to effectively solve the synchronization problem, but may also lead to system instability or even increase the risk of equipment damage, thus affecting the reliability and safety of the calibration process.

[0084] To address this, this application further proposes that, before performing the parameter migration operation, it also includes confirming whether the operating status of the servo drives corresponding to the first and second rotary axes is normal to confirm whether a first hardware fault exists, and confirming whether the communication status of the encoders corresponding to the first and second rotary axes is normal to confirm whether a second hardware fault exists. If a hardware malfunction is detected in either the first or second rotary axis, the parameter migration operation is stopped and a first alarm is issued, wherein the hardware malfunction includes both the first and second hardware faults.

[0085] Specifically, confirming the normal operating status of the servo drives corresponding to the first and second rotary axes is crucial to rule out synchronization issues caused by drive failures and ensure the effectiveness of subsequent parameter migration. The servo drive is the core component controlling the rotational axis movement, and its operating status directly affects the axis's performance. The system can determine its operating status by reading diagnostic information, status registers, or fault codes within the servo drive. For example, servo drives typically provide various fault indicators such as overcurrent, overvoltage, undervoltage, overload, encoder feedback anomalies, and excessively high internal drive temperature. The system can periodically query this status information or perform a comprehensive status check before initiating the parameter migration operation. Normal operation usually means no active fault alarms and that the drive is enabled.

[0086] Simultaneously, confirming the normal communication status of the encoders corresponding to the first and second rotating axes is crucial to rule out inaccurate or lost position feedback caused by encoder communication abnormalities. Encoders are used to accurately measure the real-time position and speed of the rotating axes and feed this information back to the servo drive and controller. Encoder communication status can be confirmed in various ways. For example, for incremental encoders, one can check whether the pulse output of its A / B phase signals is continuous and within the expected frequency range; for absolute encoders, one can check whether the data frames of its serial communication (such as SSI, BiSS, EnDat, etc.) are complete, the checksum is correct, and the data update frequency is normal. Abnormal communication status may manifest as data loss, data errors, communication timeouts, or no encoder output.

[0087] Once a hardware malfunction is detected in either the first or second rotating axis (i.e., a first or second hardware fault), the system will immediately halt the parameter migration operation and issue a first alarm. Stopping the parameter migration operation can be achieved by setting a control flag; this flag is activated when a fault is detected, preventing the execution of the parameter migration logic. The first alarm can be issued in various ways, such as displaying an error message on the industrial equipment's operating interface, issuing an alarm via an audible and visual alarm, sending a notification to a remote monitoring system, or logging a fault. The alarm message should clearly indicate the fault type and the affected rotating axis for rapid problem localization.

[0088] By pre-checking the operational and communication status of the servo drives and encoders corresponding to the first and second rotary axes before performing the parameter migration operation, this method can effectively identify potential first and second hardware faults. Once any hardware malfunction is detected, the system immediately stops the parameter migration operation and issues a first alarm. This avoids blindly adjusting servo gain parameters under hardware failure conditions, thus preventing further equipment damage, calibration failure, or system instability that may result from improper adjustments. This preventative check mechanism significantly improves the reliability and safety of the dual-axis synchronous calibration process, ensuring that the parameter migration operation is performed in a healthy and stable hardware environment, thereby improving the calibration success rate and the overall operating efficiency of industrial equipment.

[0089] In some embodiments described above, a method for achieving dual-axis synchronous calibration by iteratively adjusting servo gain parameters is proposed. This method obtains the real-time angular difference between the first and second rotational axes and performs parameter migration operations based on whether it exceeds a preset threshold, aiming to gradually reduce the angular difference. However, in actual parameter migration operations, due to system dynamics, external interference, or improper parameter settings, the real-time angular difference may fail to shrink in the expected convergence direction, instead widening or even diverging. If this anomaly is not detected and addressed promptly, it may lead to calibration failure or even damage to industrial equipment, affecting production efficiency and equipment lifespan.

[0090] To address this, this application further proposes a scheme for effectively monitoring and handling anomalies during the step of returning to obtain the real-time angular difference between the first and second rotation axes in the workpiece coordinate system, as well as subsequent steps. Specifically, this scheme includes monitoring the changing trend of the real-time angular difference after a single parameter transfer operation.

[0091] In the specific implementation process, after completing a parameter transfer operation, the system continuously collects and analyzes the real-time angle difference data between the first and second rotation axes. By comparing the angle difference before and after the parameter transfer, or by calculating the slope of the angle difference over time, it can be determined whether the angle difference tends to decrease or increase. For example, a short time window can be set, within which the real-time angle difference is sampled multiple times, and its average value or rate of change is calculated to accurately reflect the immediate effect after parameter transfer. This monitoring mechanism aims to provide immediate feedback to assess the effectiveness of the current parameter adjustment.

[0092] If monitoring results show that the real-time angle difference does not decrease according to the preset convergence direction, but instead increases and the increase exceeds the preset third threshold, it indicates that the current parameter migration operation may have a negative impact or cause system instability. The "preset convergence direction" typically refers to the absolute value of the real-time angle difference gradually decreasing to zero or close to zero. When the absolute value of the real-time angle difference increases instead of decreasing after parameter migration, and the increase exceeds the preset third threshold, an abnormal condition is triggered. This third threshold can be determined based on the specific requirements of the industrial operating equipment, the system stability margin, and the acceptable error range. For example, it can be set as a percentage of the initial angle difference or a fixed angle value.

[0093] Once the above-mentioned anomaly is detected, the system will immediately stop the current parameter migration operation and issue a second alarm. Stopping the parameter migration operation means that subsequent servo gain parameter adjustments will no longer be performed to prevent the problem from worsening. The second alarm can be implemented in various forms, such as displaying error messages on the operating interface, issuing audible and visual alarms, or sending an abnormal signal to the upper control system.

[0094] Through the above technical solution, this application can effectively avoid the real-time angle difference divergence problem caused by improper parameter adjustment or external interference during dual-axis synchronous calibration. By monitoring the angle difference change trend after parameter transfer in real time and setting reasonable anomaly judgment conditions, once the calibration process is found to deviate from the expected convergence direction and show a significant increase, the system can promptly stop the operation and issue an alarm. This not only protects industrial operating equipment from potential mechanical damage and improves the safety of equipment operation, but also avoids invalid calibration attempts, thereby improving the reliability and efficiency of the calibration process. This solution provides a robust anomaly handling mechanism for dual-axis synchronous calibration, ensuring the stability and controllability of the calibration process.

[0095] The following example will provide a more detailed explanation of the above technical solution: In an industrial operating device A, such as a high-precision laser cutting machine, there are a first rotary axis and a second rotary axis. These two axes need to maintain strict synchronization in the workpiece coordinate system, with the second rotary axis being the driven axis of the first. After prolonged operation of device A, due to mechanical wear, temperature changes, or servo driver parameter drift, an angular difference may develop between the first and second rotary axes, causing the laser cutting path to deviate and affecting product quality.

[0096] In an industrial operating device A, such as a high-precision laser cutting machine, there are a first rotary axis and a second rotary axis. These two axes need to maintain strict synchronization in the workpiece coordinate system, with the second rotary axis being the driven axis of the first. After prolonged operation of device A, due to mechanical wear, temperature changes, or servo driver parameter drift, an angular difference may develop between the first and second rotary axes, causing the laser cutting path to deviate and affecting product quality.

[0097] Before initiating the synchronous calibration process, the system first performs a pre-check. It verifies the operational status of the servo drives corresponding to the first and second rotary axes to rule out any primary hardware faults. Simultaneously, the system checks the communication status of the encoders corresponding to the first and second rotary axes to confirm the presence of any secondary hardware faults. If a hardware malfunction, such as a servo drive or encoder failure, is detected on either rotary axis, the system immediately halts subsequent parameter migration operations and issues a primary alarm, such as displaying "Hardware fault, please check servo drive or encoder connection" on the user interface. This step ensures that the calibration operation is performed only when the hardware is functioning correctly, avoiding unnecessary parameter adjustments.

[0098] After confirming that the hardware is operating normally, the control system of device A initiates the dual-axis synchronous calibration method. First, the system acquires the real-time angular difference between the first and second rotary axes in the workpiece coordinate system. For example, it calculates the actual positions of the two axes using pulse signals fed back from a high-precision encoder, converts them into angular values, and then calculates the difference between them.

[0099] The system then determines whether this real-time angle difference exceeds a preset first threshold. Let's assume the first threshold is set to 0.05 degrees. If the real-time angle difference is 0.1 degrees, it is determined to exceed the threshold.

[0100] If the real-time angle difference exceeds a first threshold, the system will execute a preset parameter transfer operation. During this operation, the system first identifies the leading and lagging axes based on the real-time angle difference. For example, if the angle value of the first rotation axis is greater than that of the second rotation axis, the first rotation axis is identified as the leading axis, and the second rotation axis as the lagging axis.

[0101] Parameter transfer operations can be performed using different strategies. One strategy is that the system assigns at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis. These servo gain parameters include position loop gain parameters and / or velocity loop gain parameters. For example, if the first rotation axis is a leading axis, the system reads its current position loop gain parameters and velocity loop gain parameters and uses them as target values ​​to adjust the position loop gain parameters and velocity loop gain parameters of the second rotation axis (lagging axis) to bring them closer to the parameters of the first rotation axis.

[0102] Another more refined parameter transfer method involves constructing a virtual reference servo model based on the current first servo gain parameter of the first rotation axis and the current second servo gain parameter of the second rotation axis. For example, the system can obtain the first transfer function of the first rotation axis and the second transfer function of the second rotation axis, and then perform a weighted average of these two transfer functions to obtain the transfer function of the virtual reference servo model. Based on this virtual reference servo model's transfer function, a target servo gain parameter is determined, which lies between the first and second servo gain parameters. Next, the system calculates the parameter differences between the first and second servo gain parameters and the target servo gain parameter. Based on these parameter differences, the system increases the servo gain parameter of the lag axis and decreases the servo gain parameter of the lead axis, respectively, so that the servo gain parameters of both axes approach the target servo gain parameter. This method avoids the overshoot or oscillation problems that may result from simply assigning the lead axis parameter entirely to the lag axis, making the dynamic response characteristics of the two axes more consistent.

[0103] During the parameter transfer process, the system will also selectively adjust the servo gain parameters based on the motion state of the first and / or second rotation axes. For example: When the first rotation axis and / or the second rotation axis are in the first motion state (e.g., low-speed uniform motion with a small absolute value of acceleration), the system mainly assigns the position loop gain parameter of the leading axis as the target parameter to the lagging axis.

[0104] When the first rotation axis and / or the second rotation axis are in a second motion state (e.g., acceleration or deceleration, with the absolute value of the acceleration being greater than that in the first motion state), the system will assign the position loop gain parameter and velocity loop gain parameter of the leading axis as target parameters to the lagging axis.

[0105] When the first and / or second rotating axes are in the third motion state (e.g., high-speed emergency stop or rapid acceleration, with the absolute value of acceleration greater than that in the second motion state), the system mainly assigns the velocity loop gain parameter of the leading axis as the target parameter to the lagging axis.

[0106] This phased and type-based gain adjustment strategy enables the calibration process to better adapt to the synchronization requirements of the equipment under different dynamic operating conditions.

[0107] After the parameter migration operation is executed, the system returns to the step of obtaining the real-time angle difference between the first and second rotation axes in the workpiece coordinate system, and then proceeds with subsequent steps, forming a closed-loop iterative process. During this iteration, the system monitors the rate of change of the real-time angle difference over time. If the rate of change indicates that the decrease in the real-time angle difference exceeds a preset first rate of change threshold (e.g., convergence is too fast), the system reduces the adjustment step size of the servo gain parameter in the parameter migration operation to avoid overshoot and oscillation. Conversely, if the rate of change indicates that the change in the real-time angle difference within a preset time period is less than a preset second rate of change threshold (e.g., convergence is too slow), the system increases the adjustment step size of the servo gain parameter in the parameter migration operation to accelerate the convergence speed.

[0108] Simultaneously, the system monitors the trend of real-time angle difference changes after a single parameter transfer operation. If the real-time angle difference does not shrink in the preset convergence direction but instead expands and the expansion exceeds the preset third threshold, the system will determine that the calibration process is abnormal, immediately stop the parameter transfer operation, and issue a second alarm prompt, such as displaying "Synchronization calibration abnormal, please check system configuration." This effectively prevents system instability caused by incorrect parameter adjustments.

[0109] The entire iterative process continues until the real-time angle difference is less than or equal to the first threshold. At this point, the synchronization of the first and second rotation axes meets the requirements.

[0110] Once the real-time angle difference is less than or equal to a first threshold, the system acquires the current operating condition information of device A, such as the target speed, load torque, and running direction of the first and second rotating axes. Then, the system associates this current operating condition information with the servo gain parameters of the first and second rotating axes obtained after a return execution, storing this as a set of synchronized operating condition records in a gain mapping table. This gain mapping table is used to provide initial servo gain parameters for the first and second rotating axes under different operating conditions of device A. For example, when device A runs again under the same or similar speed and load, the system can query the gain mapping table based on the real-time operating condition information to determine the servo gain parameters that match the real-time operating condition information, and based on this, determine and apply the initial servo gain parameters of the first and second rotating axes. This avoids a time-consuming calibration process every time the device starts or its operating conditions change, improving the device's startup efficiency and operational stability.

[0111] Furthermore, to provide a more flexible calibration method, the system can also display the real-time angle difference calculated in real time on the touchscreen. When user A inputs a manual calibration command via the touchscreen, the system responds to the command, increasing the current servo gain parameter of the hysteresis axis according to the sign of the real-time angle difference, until the real-time angle difference is less than or equal to a first threshold. This allows on-site operators to perform convenient fine-tuning without the need for external debugging tools and specialized software.

[0112] Compared to existing technologies that rely on external calibration tools and professional personnel to independently tune each axis, this method directly optimizes the coordinated motion characteristics of the two axes by acquiring the angular difference between them in real time and performing parameter transfer based on this difference. In particular, by identifying the leading and lagging axes and adjusting the servo gain parameters of the lagging axis accordingly, or by constructing a virtual reference servo model to bring the parameters of the two axes closer to an ideal intermediate value, it can more effectively eliminate the dynamic response differences between the two axes and significantly improve synchronization accuracy. Simultaneously, integrating the calibration process into the equipment control system and supporting the associated storage and application of operating condition information and gain parameters, as well as providing a touchscreen manual calibration function, greatly simplifies the operation process, reduces reliance on professional skills and external equipment, and allows field operators to perform calibration anytime, anywhere, improving the convenience and efficiency of calibration.

[0113] This application provides an industrial operating device, which includes: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, which are executed by the at least one processor to enable the at least one processor to perform the dual-axis synchronous calibration method in any of the above embodiments.

[0114] The following is for reference. Figure 2 It shows a structural schematic diagram of an industrial operating device suitable for implementing the embodiments of this application. Figure 2 The industrial operating equipment shown is merely an example and should not impose any limitation on the functionality and scope of use of the embodiments of this application.

[0115] like Figure 2As shown, the industrial operating equipment may include a processing unit 1001 (e.g., a central processing unit, a graphics processing unit, etc.), which can perform various appropriate actions and processes according to a program stored in a read-only memory 1002 or a program loaded from a storage device 1003 into a random access memory 1004. The random access memory 1004 also stores various programs and data required for the operation of the industrial operating equipment. The processing unit 1001, the read-only memory 1002, and the random access memory 1004 are interconnected via a bus 1005. An input / output interface 1006 is also connected to the bus. Typically, the following systems can be connected to the input / output interface 1006: input devices 1007 including, for example, touchscreens, touchpads, keyboards, mice, image sensors, microphones, accelerometers, gyroscopes, etc.; output devices 1008 including, for example, liquid crystal displays (LCDs), speakers, vibrators, etc.; storage devices 1003 including, for example, magnetic tapes, hard disks, etc.; and communication devices 1009. Communication device 1009 allows industrial operating equipment to communicate wirelessly or wiredly with other equipment to exchange data. Although the figures show industrial operating equipment with various systems, it should be understood that implementation or possession of all the systems shown is not required. More or fewer systems may be implemented alternatively.

[0116] Specifically, according to the embodiments disclosed in this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments disclosed in this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from storage device 1003, or installed from read-only memory 1002. When the computer program is executed by processing device 1001, it performs the functions defined in the methods of the embodiments disclosed in this application.

[0117] The industrial operating equipment provided in this application, employing the dual-axis synchronous calibration method described in the above embodiments, can solve the technical problems of long processing time, poor results, and reliance on external tools and professional personnel in related technologies for dual-axis synchronous calibration. Compared with the prior art, the beneficial effects of the industrial operating equipment provided in this application are the same as those of the dual-axis synchronous calibration method provided in the above embodiments, and other technical features of this industrial operating equipment are the same as those disclosed in the previous embodiment of the dual-axis synchronous calibration method, and will not be repeated here.

[0118] It should be understood that the various parts disclosed in the embodiments of this application can be implemented using hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0119] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0120] This application provides a computer-readable storage medium having computer-readable program instructions (i.e., a computer program) stored thereon, which are used to execute the dual-axis synchronous calibration method in the above embodiments.

[0121] The computer-readable storage medium provided in this application embodiment may be, for example, a USB flash drive, but is not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems or devices, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fibers, portable compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this embodiment, the computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system or device. The program code contained on the computer-readable storage medium may be transmitted using any suitable medium, including but not limited to: wires, optical cables, RF (Radio Frequency), etc., or any suitable combination thereof.

[0122] The aforementioned computer-readable storage medium may be included in industrial operating equipment; or it may exist independently and not assembled into industrial operating equipment.

[0123] The aforementioned computer-readable storage medium carries one or more programs. When these programs are executed by an industrial operating device, the industrial operating device: acquires the real-time angular difference between a first rotation axis and a second rotation axis in the workpiece coordinate system; determines whether the real-time angular difference exceeds a preset first threshold; if it does, executes a preset parameter transfer operation, wherein the parameter transfer operation includes: identifying the leading axis and the lagging axis determined based on the real-time angular difference between the first and second rotation axes, and assigning at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis, the servo gain parameters including position loop gain parameters and / or velocity loop gain parameters; returning to the step of acquiring the real-time angular difference between the first and second rotation axes in the workpiece coordinate system and subsequent steps, until the real-time angular difference is less than or equal to the first threshold. Computer program code for performing the operations of the embodiments of this application can be written in one or more programming languages ​​or a combination thereof. These programming languages ​​include object-oriented programming languages—such as Java, Smalltalk, and C++—and conventional procedural programming languages—such as the "C" language or similar programming languages. The program code can execute entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network—including a local area network (LAN) or a wide area network (WAN)—or it can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0124] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of methods and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0125] The modules described in the embodiments of this application can be implemented in software or hardware. The names of the modules do not necessarily limit the functionality of the unit itself.

[0126] The readable storage medium provided in this application embodiment is a computer-readable storage medium that stores computer-readable program instructions (i.e., a computer program) for executing the above-described dual-axis synchronous calibration method. This solves the technical problems in related technologies, such as long processing time, poor performance, and reliance on external tools and professionals for dual-axis synchronous calibration. Compared with the prior art, the beneficial effects of the computer-readable storage medium provided in this application embodiment are the same as those of the dual-axis synchronous calibration method provided in the above embodiments, and will not be repeated here.

[0127] The above are only some embodiments of this application and do not limit the patent scope of this application. All equivalent structural transformations made under the technical concept of this application and using the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included in the patent protection scope of this application.

Claims

1. A dual-axis synchronous calibration method, characterized in that, The method, applicable to industrial operating equipment containing a first rotating shaft and a second rotating shaft that need to operate synchronously, includes: Obtain the real-time angular difference between the first rotation axis and the second rotation axis in the workpiece coordinate system; Determine whether the real-time angle difference exceeds a preset first threshold; If the value exceeds the limit, a preset parameter transfer operation is performed. The parameter transfer operation includes: identifying the leading axis and the lagging axis determined based on the real-time angle difference between the first rotation axis and the second rotation axis, and assigning at least a portion of the current servo gain parameters of the leading axis as target parameters to the lagging axis. The servo gain parameters include position loop gain parameters and / or velocity loop gain parameters. Return to the step of obtaining the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps, until the real-time angle difference is less than or equal to the first threshold. The parameter transfer operation also includes: Based on the current first servo gain parameter of the first rotation axis and the current second servo gain parameter of the second rotation axis, a virtual reference servo model is constructed, wherein the target servo gain parameter of the virtual reference servo model is between the first servo gain parameter and the second servo gain parameter. Calculate the parameter differences between the first servo gain parameter, the second servo gain parameter, and the target servo gain parameter; Based on the parameter difference, the servo gain parameter of the lagging axis is increased and the servo gain parameter of the leading axis is decreased, so that the servo gain parameters of both approach the target servo gain parameter. The process of returning to the step of obtaining the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps also includes: Obtain the rate of change of the real-time angle difference over time; If the rate of change indicates that the rate of decrease of the real-time angle difference exceeds a preset first rate of change threshold, then the adjustment step of the servo gain parameter in the parameter transfer operation is reduced. If the rate of change indicates that the change in the real-time angle difference within a preset time period is less than a preset second rate of change threshold, then the adjustment step of the servo gain parameter in the parameter transfer operation is increased.

2. The dual-axis synchronous calibration method as described in claim 1, characterized in that, The method further includes: Obtain the current operating condition information of the industrial operating equipment, wherein the current operating condition information includes at least one of the target rotation speed, load torque, and running direction of the first rotating shaft and the second rotating shaft; After the real-time angle difference is less than or equal to the first threshold, the current operating condition information is associated with the servo gain parameters of the first and second rotating axes obtained after the return execution, and stored as a set of synchronous operating condition records in a gain mapping table. The gain mapping table is used to provide initial servo gain parameters for the first and second rotating axes under different operating conditions of the industrial operating equipment.

3. The dual-axis synchronous calibration method as described in claim 2, characterized in that, The method further includes: When the industrial operating equipment is running, the gain mapping table is queried based on the real-time operating condition information to determine the servo gain parameters that match the real-time operating condition information; Based on the servo gain parameters that match the real-time operating information, the initial servo gain parameters of the first and second rotary axes are determined and applied.

4. The dual-axis synchronous calibration method as described in claim 1, characterized in that, The method for constructing a virtual reference servo model is as follows: Obtain the first transfer function of the first rotation axis and the second transfer function of the second rotation axis; The first transfer function and the second transfer function are weighted and averaged to obtain the transfer function of the virtual reference servo model. Based on the transfer function of the virtual reference servo model, the target servo gain parameter is determined to construct the virtual reference servo model.

5. The dual-axis synchronous calibration method as described in claim 1, characterized in that, The servo gain parameters include position loop gain parameters and velocity loop gain parameters; the parameter transfer operation includes at least one of the following: When the first rotation axis and / or the second rotation axis are in a first motion state, the position loop gain parameter of the leading axis is assigned as the target parameter to the lagging axis; When the first rotation axis and / or the second rotation axis are in a second motion state, the position loop gain parameter and velocity loop gain parameter of the leading axis are both assigned as target parameters to the lagging axis, wherein the absolute value of the acceleration represented by the second motion state is greater than the absolute value of the acceleration represented by the first motion state. When the first rotation axis and / or the second rotation axis are in a third motion state, the velocity loop gain parameter of the leading axis is assigned as a target parameter to the lagging axis, wherein the absolute value of the acceleration represented by the third motion state is greater than the absolute value of the acceleration represented by the second motion state.

6. The dual-axis synchronous calibration method as described in claim 1, characterized in that, The method further includes: The real-time angle difference, calculated in real time, is displayed on the touchscreen. In response to a manual calibration command input by the user via the touchscreen, the current servo gain parameter of the hysteresis axis is increased or decreased according to the sign of the real-time angle difference, until the real-time angle difference is less than or equal to the first threshold.

7. The dual-axis synchronous calibration method as described in claim 1, characterized in that, Before performing the parameter transfer operation, the following is also included: Confirm whether the operating status of the servo drives corresponding to the first and second rotary axes is normal to confirm whether there is a first hardware fault, and confirm whether the communication status of the encoders corresponding to the first and second rotary axes is normal to confirm whether there is a second hardware fault. If a hardware malfunction is detected in either the first or the second rotating axis, the parameter migration operation is stopped and a first alarm is issued. The hardware malfunction includes both the first and the second hardware malfunctions.

8. The dual-axis synchronous calibration method as described in claim 1, characterized in that, The process of returning to the step of obtaining the real-time angle difference between the first rotation axis and the second rotation axis in the workpiece coordinate system and subsequent steps also includes: Monitor the trend of the real-time angle difference after a single parameter transfer operation; If the real-time angle difference does not shrink in the preset convergence direction, but instead expands and the expansion exceeds the preset third threshold, the parameter transfer operation will be stopped and a second alarm will be issued.

9. An industrial operating device, characterized in that, The industrial operating equipment includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the dual-axis synchronous calibration method as described in any one of claims 1 to 8.

10. A computer program product, characterized in that, The computer program product includes a computer program that, when executed by a processor, implements the steps of the dual-axis synchronous calibration method as described in any one of claims 1 to 8.

Images