A rubber piston comprehensive control system and method based on intelligent regulation and state sensing

Abstract

This invention provides a comprehensive control system and method for rubber pistons based on intelligent regulation and state perception, relating to the field of intelligent control technology for pistons and seals. The method includes: firstly, collecting the operating state parameters of the rubber piston; then, through feature extraction and data standardization processing, generating a standardized state feature set; next, identifying the current operating condition and assessing the health status based on the standardized state feature set, generating adaptive regulation commands and hierarchical protection decisions; then, adjusting the operating speed, stroke frequency, drive torque, valve group timing, and buffer parameters according to the adaptive regulation commands, while simultaneously generating operating feedback information; finally, combining the hierarchical protection decisions and operating feedback information to execute corresponding level protection actions, thereby achieving multi-dimensional state perception, intelligent operating condition identification, dynamic parameter adjustment, and hierarchical interlocking protection of the rubber piston, improving the operational stability of the mine backfilling system.

Description

Technical Field

[0001] This invention relates to the field of intelligent control technology for pistons and seals, and in particular to a comprehensive control system and method for rubber pistons based on intelligent regulation and state perception. Background Technology

[0002] Mine backfilling systems are a core component of green mining, goaf remediation, tailings disposal, and safe production. As backfilling processes evolve towards higher concentrations, longer distances, larger flow rates, continuous operation, and automation, key equipment at backfilling stations operates under complex conditions of high-pressure pulsation, high abrasion, and strong impact. Rubber pistons, as crucial actuators and sealing elements in piston pumps, buffer and pressure-stabilizing devices, isolation chambers, and reciprocating conveying units, directly determine the stability and safety of the conveying system.

[0003] Existing control methods for rubber pistons still have many shortcomings: Firstly, the perception of operational status is limited to a single dimension, mostly monitoring only single parameters such as pressure or flow rate, lacking multi-dimensional comprehensive perception of piston displacement, stroke deviation, temperature rise, vibration, wear degree, and seal leakage, making it difficult to identify early anomalies; Secondly, the control logic is crude, mostly based on fixed thresholds or manually set parameters, and cannot adaptively adjust according to the conveying concentration, working pressure, equipment load and piston wear status, resulting in control lag and insufficient control precision. Third, the ability to predict and diagnose faults is insufficient. Problems such as piston jamming, seal failure, overheating, abnormal wear, stroke imbalance, and pressure shock are often only discovered after the fault has escalated, which can easily lead to shutdown, pipeline blockage, media leakage, or component damage. Fourth, the safety interlocking and collaborative control capabilities are weak, and an integrated mechanism for perception, analysis, decision-making, execution and protection has not been formed. It is unable to achieve comprehensive protection such as graded load reduction, bypass switching and interlock shutdown under abnormal operating conditions.

[0004] Developing a comprehensive control system for rubber pistons with multi-parameter status perception, intelligent working condition identification, dynamic control and adjustment, and fault interlock protection functions is of significant engineering value for improving the operational stability and safety of mine backfilling systems.

[0005] Therefore, the present invention provides a comprehensive control system and method for rubber pistons based on intelligent regulation and state perception. Summary of the Invention

[0006] This invention discloses a comprehensive control system and method for rubber pistons based on intelligent regulation and state perception. It overcomes the problems of insufficient perception dimensions, low regulation accuracy, weak early warning capability, and imperfect protection mechanism in existing rubber piston control systems. It realizes real-time perception of multi-dimensional operating status of rubber pistons, intelligent identification of operating conditions and abnormal trends, dynamic adjustment of operating parameters, early warning of faults, and hierarchical interlocking protection, thereby improving the operational stability of mine filling systems, extending the service life of rubber pistons, and ensuring production safety.

[0007] This invention provides a comprehensive control system for a rubber piston based on intelligent regulation and state perception, comprising: The state perception module is used to collect the operating state parameters of the rubber piston, perform feature extraction and data standardization processing on the operating state parameters, and generate a standardized state feature set of the rubber piston. The integrated control module is used to identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and hierarchical protection decisions. The actuator module is used to adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and at the same time generate operation feedback information. The security protection module is used to execute protection actions at the corresponding level based on the hierarchical protection decision and the operation feedback information.

[0008] In one implementable manner, the state-aware module includes: The displacement sensing unit is located on the outer periphery of the connecting rod of the rubber piston and is used to collect the displacement deviation parameters and stroke deviation parameters of the rubber piston. The pressure-temperature composite sensing unit consists of several units, which are respectively set on the piston cavity wall and the corresponding position of the sealing pair of the rubber piston, and are used to collect the cavity pressure, inlet and outlet pressure difference parameters and sealing area temperature rise parameters of the rubber piston. The vibration sensing unit is installed in the drive end housing of the rubber piston and is used to collect the operating vibration amplitude and frequency band parameters of the rubber piston. The load acquisition unit is connected to the power supply circuit of the drive motor of the rubber piston and is used to acquire the drive current, torque and power parameters of the rubber piston. The leakage detection unit is installed on the outer periphery of the sealing pair of the rubber piston to collect the sealing leakage parameters of the rubber piston. The parameter processing unit is used to acquire the displacement deviation parameters, stroke deviation parameters, cavity pressure, inlet and outlet pressure difference parameters, sealing area temperature rise parameters, operating vibration amplitude, frequency band parameters, driving current, torque, power parameters, and sealing leakage parameters of the rubber piston, and generate the operating status parameters of the rubber piston.

[0009] In one implementable embodiment, the state-aware module further includes: The parameter processing unit is used to filter, denoise, and remove outliers from the operating status parameters. Based on the operating cycle of the rubber piston, the parameters after purification are synchronized in time and converted in unit, generating a unified set of synchronized and aligned dimensional parameters. The unified dimension parameter set is normalized, and the displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value and load fluctuation rate of the unified dimension parameter set are extracted. The displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate are normalized respectively to obtain the standardized state feature set of the rubber piston.

[0010] In one implementable manner, the integrated control module includes: The working condition identification unit is used to receive the standardized state feature set and identify the current working condition of the rubber piston based on the coupling characteristics of displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate. The status assessment unit is used to retrieve the historical operating data of the rubber piston, combine it with the standardized status feature set, use a multi-dimensional weighted formula to calculate the current health index of the rubber piston, construct the historical trend of the health index, and output the prediction result of the remaining operating time of the rubber piston. An adaptive control unit is used to generate the adaptive control command based on the current operating conditions and the predicted remaining operating time. The graded protection unit is used to generate the graded protection decision based on the current health index and the standardized state characteristics that exceed the corresponding preset range.

[0011] One feasible approach also includes: The hierarchical protection decision-making levels are: early warning, load reduction, speed reduction, bypass switching, or interlocking shutdown.

[0012] In one implementable manner, the actuator module includes: The drive motor unit is connected to the transmission end of the rubber piston and is used to receive the running speed adjustment amount, stroke frequency adjustment amount and drive torque adjustment amount in the adaptive control command, and adjust the running speed, stroke frequency and drive torque of the rubber piston. The hydraulic buffer unit is connected to the buffer chamber of the rubber piston and is used to receive the buffer parameter adjustment amount in the adaptive control command, adjust the buffer section running time and buffer pressure, and absorb the pressure pulsation during the medium transportation process. The reversing valve group unit is installed in the medium inlet and outlet pipeline of the rubber piston, and is used to receive the valve group timing adjustment amount in the adaptive control command, and adjust the switching timing of the suction and discharge slurry valve group of the rubber piston. The bypass switching unit is connected in parallel with the inlet and outlet pipelines of the rubber piston and is used to receive the bypass conduction command issued by the safety protection module to switch the medium flow path to the bypass. The feedback generation unit is used to collect the actual operating parameters of the drive motor unit, the hydraulic buffer unit, the reversing valve group unit and the bypass switching unit, generate operating feedback information and send it to the safety protection module.

[0013] In one implementable manner, the security protection module includes: The early warning unit is used to trigger an audible and visual warning and push a reminder for sealing inspection or piston maintenance when the graded protection decision is at the pre-alarm level. The load limiting unit is used to send a load reduction ratio command to the drive motor unit of the actuator module when the graded protection decision is to reduce the load level. The deceleration unit is used to send a deceleration command to the drive motor unit of the actuator module when the graded protection decision is to decelerate. The bypass triggering unit is used to send a conduction command to the bypass switching unit of the actuator module when the hierarchical protection decision is to switch the level of bypass. The interlocking shutdown unit is used to send a shutdown command to the drive motor unit of the actuator module when the graded protection decision is at the interlocking shutdown level, and at the same time cut off the drive power of the rubber piston. The integrated decision-making unit is used to receive the operation feedback information. When the deviation between the actual operation parameters corresponding to each execution unit in the operation feedback information and the corresponding target adjustment amount in the adaptive control instruction exceeds a preset threshold, it feeds back the current level of the hierarchical protection decision to the integrated control module.

[0014] One feasible approach also includes: The human-computer interaction and remote monitoring module is used to receive the entire process of operation data, control commands and alarm information, and at the same time send the manually set target operation parameters to the integrated control module.

[0015] This invention provides a comprehensive control method for rubber pistons based on intelligent regulation and state perception, comprising: Step 1: Collect the operating state parameters of the rubber piston, perform feature extraction and data standardization on the operating state parameters, and generate a standardized state feature set of the rubber piston; Step 2: Identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and graded protection decisions; Step 3: Adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and generate operation feedback information at the same time; Step 4: Execute the corresponding level of protection action based on the hierarchical protection decision and the operation feedback information.

[0016] The beneficial effects achievable by this invention are as follows: 1. It upgrades monitoring from a single parameter to comprehensive monitoring of multiple parameters such as displacement, pressure, temperature, vibration, load, and wear, enhancing the accuracy of condition identification; 2. It can provide early warnings when the piston shows signs of early wear, jamming, overheating, or seal failure, reducing the risk of sudden shutdowns; 3. It establishes a closed-loop mechanism from perception to analysis to decision-making, execution, and finally protection, supporting abnormal interlock protection and reducing equipment damage and production accidents; 4. Through adaptive regulation and operating condition optimization, it reduces impact loads and abnormal wear, extending the life of key components; 5. The system has strong compatibility and can be interfaced with existing filling pumps, buffer devices, slurry conveying systems, and remote monitoring platforms, facilitating industrialization and promotion.

[0017] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0018] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0019] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the composition of a rubber piston integrated control system based on intelligent regulation and state perception in an embodiment of the present invention. Figure 2 This is a schematic diagram illustrating the workflow of a comprehensive control method for rubber pistons based on intelligent regulation and state perception, as described in an embodiment of the present invention. Detailed Implementation

[0020] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0021] Example 1: This example provides a comprehensive control system for rubber pistons based on intelligent control and state perception, such as... Figure 1 As shown, it includes: The state perception module is used to collect the operating state parameters of the rubber piston, perform feature extraction and data standardization processing on the operating state parameters, and generate a standardized state feature set of the rubber piston. The integrated control module is used to identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and hierarchical protection decisions. The actuator module is used to adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and at the same time generate operation feedback information. The security protection module is used to execute protection actions at the corresponding level based on the hierarchical protection decision and the operation feedback information.

[0022] In this example, the operating status parameters represent the raw physical quantities that reflect the operating status of the rubber piston, collected by various sensing units, including parameters such as displacement deviation, stroke deviation, cavity pressure, inlet and outlet pressure difference, temperature rise in the sealing area, operating vibration amplitude, drive current, torque, power, and sealing leakage.

[0023] In this example, feature extraction refers to the process of extracting core characteristic quantities from the original operating state parameters. Specifically, it extracts five key characteristic quantities that can reflect the piston's operating characteristics: displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate.

[0024] In this example, data standardization refers to the process of unifying and normalizing the dimensions of the extracted features, so that feature parameters with different physical meanings and magnitudes are converted into comparable logarithmic values ​​of a uniform specification.

[0025] In this example, the standardized state feature set represents a set of state feature data with uniform specifications formed after feature extraction and data standardization. It serves as the input data source for the integrated control module to perform operating condition identification and health assessment.

[0026] In this example, the current operating condition refers to the type of working state of the rubber piston during operation, including five categories: normal operating condition, heavy load operating condition, jamming risk condition, seal failure trend condition, and accelerated wear condition.

[0027] In this example, the health status represents a quantitative assessment of the overall operational health of the rubber piston, characterized by a health index. A higher value indicates a better piston operating condition and a lower risk of failure.

[0028] In this example, the adaptive control instruction represents the operating parameter adjustment instruction generated by the integrated control module based on the current operating conditions and health status. It is used to guide the actuator to dynamically adjust the piston's operating parameters to adapt to the current operating conditions.

[0029] In this example, the graded protection decision means that the integrated control module generates protection execution instructions based on the risk level of the health status and abnormal parameters, which includes five levels: pre-alarm, load reduction, deceleration, bypass switching, and interlock shutdown.

[0030] In this example, the operating speed represents the linear velocity of the rubber piston reciprocating within the piston cavity, and is a core operating parameter affecting conveying efficiency and wear rate.

[0031] In this example, the stroke frequency represents the number of reciprocating motions completed by the rubber piston per unit time, which directly determines the flow rate and cycle time of the slurry delivery.

[0032] In this example, the driving torque represents the driving torque applied to the rubber piston by the driving mechanism, which is used to overcome the resistance of the medium and frictional resistance, and reflects the load level of the equipment.

[0033] In this example, the valve group timing indicates the opening and closing switching time nodes of the slurry medium suction and discharge valve group, which needs to be matched with the reciprocating motion rhythm of the piston to ensure conveying efficiency and pressure stability.

[0034] In this example, the buffer parameter represents the running time and pressure set value of the buffer mechanism during the piston reversing stage, which is used to absorb pressure pulsations and reduce reversing shocks.

[0035] In this example, the operational feedback information represents the actual operational parameter data collected after the actuator completes parameter adjustment. This data is used to verify the control effect and provide a basis for adjusting the level of safety protection.

[0036] In this example, the protection action refers to the protective operation performed by the safety protection module for different risk levels, including graded protection actions such as early warning prompts, load reduction, operation deceleration, bypass switching, and interlock shutdown.

[0037] The working principle and beneficial effects of the above technical solution are as follows: The state perception module collects full-dimensional operating state parameters of the rubber piston, such as displacement, pressure, temperature, vibration, load, and leakage, through multiple types of sensor units. It then sequentially performs data standardization processing, including signal filtering and noise reduction, timing synchronization, key feature extraction, and dimensional normalization, generating a standardized state feature set with uniform specifications and transmitting it to the integrated control module. The integrated control module identifies the piston's current operating condition based on the multi-parameter coupled features in the feature set, calculates a weighted health index to complete a health status assessment, and generates differentiated adaptive control commands and graded protection decisions by matching the operating condition with the health level. After receiving the adaptive control command, the actuator module adjusts the piston's running speed, stroke frequency, drive torque, valve group switching sequence, and buffer parameters accordingly, and simultaneously collects the actual operating data after adjustment to generate operating feedback information for feedback. The safety protection module combines the verification results of hierarchical protection decisions and operating feedback to initiate corresponding level protection actions. This not only achieves comprehensive perception of the multi-source state of the rubber piston and precise adaptive control of operating conditions, but also constructs a hierarchical interlocking safety protection mechanism, which can effectively identify early anomalies, reduce the risk of failure and downtime, reduce abnormal piston wear, and improve the operational stability and service life of the mine filling and conveying system.

[0038] Example 2: Based on Example 1, the integrated control system for a rubber piston based on intelligent control and state perception includes a state perception module comprising: The displacement sensing unit is located on the outer periphery of the connecting rod of the rubber piston and is used to collect the displacement deviation parameters and stroke deviation parameters of the rubber piston. The pressure-temperature composite sensing unit consists of several units, which are respectively set on the piston cavity wall and the corresponding position of the sealing pair of the rubber piston, and are used to collect the cavity pressure, inlet and outlet pressure difference parameters and sealing area temperature rise parameters of the rubber piston. The vibration sensing unit is installed in the drive end housing of the rubber piston and is used to collect the operating vibration amplitude and frequency band parameters of the rubber piston. The load acquisition unit is connected to the power supply circuit of the drive motor of the rubber piston and is used to acquire the drive current, torque and power parameters of the rubber piston. The leakage detection unit is installed on the outer periphery of the sealing pair of the rubber piston to collect the sealing leakage parameters of the rubber piston. The parameter processing unit is used to acquire the displacement deviation parameters, stroke deviation parameters, cavity pressure, inlet and outlet pressure difference parameters, sealing area temperature rise parameters, operating vibration amplitude, frequency band parameters, driving current, torque, power parameters, and sealing leakage parameters of the rubber piston, and generate the operating status parameters of the rubber piston.

[0039] In this example, the displacement deviation parameter represents the offset between the actual moving position of the rubber piston and the theoretical reference position, and is used to reflect the straightness deviation of the piston movement and abnormal guiding conditions.

[0040] In this example, the stroke deviation parameter represents the difference between the actual stroke length of a single reciprocating motion of the rubber piston and the rated stroke, which is used to reflect the risk of stroke abnormalities and piston limit failure.

[0041] In this example, the cavity pressure represents the pressure value of the medium inside the piston cavity where the rubber piston is located, which is used to reflect the load level and pressure fluctuation state of the equipment operation.

[0042] In this example, the inlet and outlet pressure difference parameter represents the pressure difference between the medium at the inlet and outlet of the piston cavity, which is used to reflect changes in conveying resistance and sealing pressure bearing capacity.

[0043] In this example, the temperature rise parameter of the sealing area represents the temperature rise at the rubber piston sealing pair position, which is used to reflect the frictional heating state of the seal and the abnormal wear trend of the seal.

[0044] In this example, the operating vibration amplitude represents the intensity of mechanical vibration during the operation of the rubber piston, and is used to reflect the piston impact, uneven wear and motion imbalance.

[0045] In this example, the frequency band parameter represents the frequency distribution characteristics of the rubber piston vibration signal, which is used to distinguish abnormal vibrations caused by different factors and identify different fault types such as impact and wear.

[0046] In this example, the drive current parameter represents the operating current value of the rubber piston drive motor, which is used to indirectly reflect the change in load resistance during piston operation.

[0047] In this example, torque represents the magnitude of the driving torque output by the drive mechanism to the rubber piston, which is used to characterize the piston's ability to overcome the resistance of the medium and frictional resistance.

[0048] In this example, the power parameter represents the operating power value of the drive motor, which is used to comprehensively reflect the operating load level and energy consumption status of the rubber piston.

[0049] In this example, the sealing leakage parameter represents the amount of medium leaking from the rubber piston seal pair, which directly reflects the sealing performance and degree of failure of the seal pair.

[0050] The working principle and beneficial effects of the above technical solution are as follows: A displacement sensing unit is deployed on the outer periphery of the connecting rod of the rubber piston to collect real-time data on the piston's positional offset and stroke length during its movement; several pressure-temperature composite sensing units are respectively arranged on the piston cavity wall and corresponding positions of the sealing pair to synchronously collect the internal medium pressure, inlet-outlet pressure difference, and temperature changes in the sealing area; a vibration sensing unit is installed on the drive end housing to capture the intensity and frequency characteristics of the mechanical vibration generated by the piston's operation; a load acquisition unit is connected to the drive motor power supply circuit to collect the motor's electrical parameters and convert them into load-related data; a leakage detection unit is set on the outer periphery of the sealing pair to monitor medium leakage at the sealing position; and a parameter processing unit uniformly collects the raw parameters output by all the above sensing units, and after data aggregation and integration, generates complete rubber piston operating status parameters, providing raw data support for subsequent data processing and control decisions. A multi-source sensing system covering six dimensions—motion, pressure, thermal state, vibration, load, and sealing—has been constructed to replace the traditional single-parameter monitoring method. This system comprehensively captures the operating characteristics and early abnormal signals of the rubber piston, significantly improving the completeness and accuracy of state sensing and providing a reliable data foundation for subsequent working condition identification, health assessment, and intelligent control.

[0051] Example 3: Based on Example 2, the state sensing module of the integrated control system for rubber pistons based on intelligent control and state perception further includes: The parameter processing unit is used to filter, denoise, and remove outliers from the operating status parameters. Based on the operating cycle of the rubber piston, the parameters after purification are synchronized in time and converted in unit, generating a unified set of synchronized and aligned dimensional parameters. The unified dimension parameter set is normalized, and the displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value and load fluctuation rate of the unified dimension parameter set are extracted. The displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate are normalized respectively to obtain the standardized state feature set of the rubber piston.

[0052] In this example, filtering refers to the smoothing and filtering operation of interference fluctuations in the original operating state parameters, which is used to reduce signal noise caused by electromagnetic and mechanical disturbances on site and preserve the true trend of parameter changes.

[0053] In this example, denoising refers to the processing operation of removing random noise mixed in with the original signal, which is used to improve the purity of the sensing data and avoid noise interference causing deviations in state judgment.

[0054] In this example, outlier removal refers to the process of identifying and removing jump data that deviates from the normal range in the original parameters. This is used to eliminate invalid outlier values ​​caused by sensor malfunctions or transient interference, thus ensuring data validity.

[0055] In this example, the running beat represents the periodic pattern of the rubber piston completing a single reciprocating motion. It serves as the time reference for the timing synchronization of multi-source sensor data and is used to align the sampling time points of different parameters.

[0056] In this example, the purified parameters represent the running status parameters after filtering, denoising, and outlier removal, which have removed interference and invalid data. These parameters are the basis for subsequent time-series synchronization and feature extraction.

[0057] In this example, the unified dimensional parameter set represents a collection of various operating status parameters that are aligned in time dimension and have unified measurement units after time synchronization and unit conversion, ensuring that different parameters can be compared and analyzed under the same benchmark.

[0058] In this example, the peak displacement represents the maximum value of the rubber piston's displacement within a single operating cycle, used to characterize the piston's stroke limit and range of motion.

[0059] In this example, the pressure pulsation amplitude represents the fluctuation range of the cavity pressure within a single operating cycle, that is, the difference between the maximum and minimum pressure values, which is used to reflect the degree of pressure impact during media transport.

[0060] In this example, the temperature rise rate represents the rate at which the temperature of the sealing area rises over time. It is used to characterize the frictional heat generation intensity of the sealing pair and to predict the risk of overheating and abnormal wear.

[0061] In this example, the peak-to-peak value of vibration represents the difference between the maximum and minimum values ​​of the vibration signal within a single operating cycle. It is used to characterize the overall vibration intensity of the piston operation and reflect abnormal states such as impact and uneven wear.

[0062] In this example, load volatility represents the degree of fluctuation of the driving load within a single operating cycle, which is used to characterize the stability of the driving load and reflect the changes in piston running resistance.

[0063] The working principle and beneficial effects of the above technical solution are as follows: After receiving the original operating status parameters summarized by the parameter processing unit, the parameter processing unit first eliminates electromagnetic interference, signal jumps, and invalid abnormal data by filtering, denoising, and outlier removal operations to obtain clean and reliable purified parameters. Then, using the reciprocating cycle of the rubber piston as the time reference, the multi-source purified parameters are time-series aligned and units converted to eliminate sampling time differences and dimensional differences between different sensing units, generating a unified dimensional parameter set with synchronized time and uniform measurement units. Subsequently, five core state feature quantities—displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate—are extracted from the unified dimensional parameter set to condense key information characterizing the piston's operating status. Finally, normalization processing is performed on the five feature quantities to convert features with different physical properties and different numerical magnitudes into comparable data of a uniform scale, outputting a standardized state feature set that can be directly called and analyzed by the integrated control module. This processing flow eliminates data errors caused by industrial site interference, ensuring the temporal consistency and comparability of multi-source sensor data. On the other hand, it refines core state information through feature extraction, reduces data redundancy, and normalizes the data to provide standardized input for subsequent operating condition identification and health assessment model calculations, effectively improving the accuracy and reliability of subsequent control decisions.

[0064] Example 4: Based on Example 1, the integrated control module of the rubber piston integrated control system based on intelligent regulation and state perception includes: The working condition identification unit is used to receive the standardized state feature set and identify the current working condition of the rubber piston based on the coupling characteristics of displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate. The status assessment unit is used to retrieve the historical operating data of the rubber piston, combine it with the standardized status feature set, use a multi-dimensional weighted formula to calculate the current health index of the rubber piston, construct the historical trend of the health index, and output the prediction result of the remaining operating time of the rubber piston. An adaptive control unit is used to generate the adaptive control command based on the current operating conditions and the predicted remaining operating time. The graded protection unit is used to generate the graded protection decision based on the current health index and the standardized state characteristics that exceed the corresponding preset range.

[0065] In this example, historical operating data represents a collection of historical data stored in the system, including the state parameters, health index, operating condition records, and fault information of the rubber piston during its past operation. This data forms the basis for conducting health trend analysis and fault prediction.

[0066] In this example, the current health index is a numerical indicator that quantifies the current health of the rubber piston by combining a weighted calculation of real-time standardized state feature set. The value ranges from zero to one hundred, and the higher the value, the better the piston's operating condition and the lower the risk of failure.

[0067] In this example, the historical trend of the health index represents the change curve formed by connecting the health indices at different time points in chronological order, which is used to reflect the evolution pattern and deterioration rate of the health status of the rubber piston.

[0068] In this example, the remaining runtime prediction result represents the estimated duration that the rubber piston can maintain normal operation under the current working conditions, which is derived from the historical trend of the health index. It is used to guide the formulation of operation and maintenance plans and the adjustment of operation strategies.

[0069] In this example, the weighted calculation of the health index is as follows: displacement stability weight 20%, pressure stability weight 20%, temperature rise weight 15%, vibration weight 15%, load weight 15%, and sealing leakage weight 15%; the health index H ∈ [0, 100], H > 80 is normal, 60 ≤ H ≤ 80 is slightly deteriorated, 40 ≤ H < 60 is moderately deteriorated, and H < 40 is severely deteriorated; the remaining operating time is extrapolated based on the linear fitting of the deterioration rate of the continuous cycle health index; the working condition discrimination boundary is: displacement peak exceeding the rated value by 110% is a risk of jamming, temperature rise rate > 0.8℃ / min is a trend of sealing failure, and load fluctuation rate > 25% is a condition of accelerated wear.

[0070] The working principle and beneficial effects of the above technical solution are as follows: Through multi-unit collaboration, state assessment and command output are completed. During operation, the working condition identification unit receives a standardized state feature set and, based on the coupling and linkage law of five types of features—displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate—matches a preset working condition benchmark model to determine the current working condition of the rubber piston. This multi-parameter joint judgment replaces the traditional single-parameter judgment method, effectively reducing the probability of misjudgment and improving the accuracy of state identification. Simultaneously, the state assessment unit retrieves historical operating data of the rubber piston stored in the system and, combined with the real-time standardized state feature set, calculates the current health index through multi-dimensional weighted calculation. It also connects the health indices of different time periods to construct a historical trend of health index changes, and outputs a prediction result of the remaining operating time through trend extrapolation. This combines real-time quantitative health assessment with long-term deterioration trend prediction. This system promotes the transformation of fault early warning from post-event handling to pre-event prediction, providing reliable data support for planned operation and maintenance. The adaptive control unit uses the identified current operating conditions and the predicted remaining operating time as dual decision-making bases to match the corresponding control strategy and generate adaptive control commands. It takes into account the operational adaptability of the current operating conditions and the wear control requirements of long-term service, which can slow down the deterioration rate of the piston and extend the service life of core components while ensuring the efficiency of conveying operations. The graded protection unit combines the risk level corresponding to the current health index with the out-of-limit abnormal parameters in the standardized state feature set to match the corresponding protection level, generating differentiated graded protection decisions. This ensures that the protection action is both in line with the overall health status of the piston and matches the specific abnormal type, avoiding over-protection that interferes with the production rhythm or under-protection that causes equipment damage. Ultimately, it achieves a simultaneous improvement in system control accuracy and protection reliability.

[0071] Example 5: Based on Example 4, the comprehensive control system for rubber pistons based on intelligent control and state perception further includes: The hierarchical protection decision-making levels are: early warning, load reduction, speed reduction, bypass switching, or interlocking shutdown.

[0072] In this example, the pre-alarm refers to the early warning level triggered by early, minor anomalies. It is used to push fault information to maintenance personnel to remind them to carry out inspections and maintenance in advance. It is a non-intrusive, light protection level.

[0073] In this example, load reduction refers to the load reduction level for moderate abnormal execution. By reducing the piston drive output and operating load, the rate of failure deterioration is slowed down. It belongs to the damage reduction protection level under the premise of maintaining production.

[0074] In this example, deceleration indicates a reduction in the operating speed for abnormally heavy operations. By reducing the reciprocating speed of the piston, impact and friction losses are reduced, further controlling the development of the fault. This is a level of enhanced protection to reduce damage.

[0075] In this example, bypass switching represents a flow path switching level performed for more serious anomalies. By switching the media delivery path to the bypass pipeline, the faulty piston unit is isolated, preventing the fault from affecting the entire delivery system. It belongs to the protection level of fault isolation.

[0076] In this example, interlocked shutdown refers to the level of forced shutdown implemented for high-risk faults. By cutting off the piston drive power and interlocking to stop the equipment operation, the fault condition is completely terminated. It belongs to the ultimate protection level to avoid equipment damage and safety accidents.

[0077] The working principle and beneficial effects of the above technical solution: This five-level gradient progressive protection mechanism changes the traditional protection mode of passively shutting down only after a system failure occurs. It reduces the probability of sudden shutdown through early warning and avoids excessive interference with the production rhythm by a single shutdown strategy through graded handling. It can minimize the impact of abnormal operating conditions on production efficiency while ensuring the safe operation of equipment, and achieve multiple optimizations of equipment life, production continuity and operation and maintenance costs.

[0078] Example 6: Based on Example 1, the integrated control system for a rubber piston based on intelligent control and state perception includes an actuator module comprising: The drive motor unit is connected to the transmission end of the rubber piston and is used to receive the running speed adjustment amount, stroke frequency adjustment amount and drive torque adjustment amount in the adaptive control command, and adjust the running speed, stroke frequency and drive torque of the rubber piston. The hydraulic buffer unit is connected to the buffer chamber of the rubber piston and is used to receive the buffer parameter adjustment amount in the adaptive control command, adjust the buffer section running time and buffer pressure, and absorb the pressure pulsation during the medium transportation process. The reversing valve group unit is installed in the medium inlet and outlet pipeline of the rubber piston, and is used to receive the valve group timing adjustment amount in the adaptive control command, and adjust the switching timing of the suction and discharge slurry valve group of the rubber piston. The bypass switching unit is connected in parallel with the inlet and outlet pipelines of the rubber piston and is used to receive the bypass conduction command issued by the safety protection module to switch the medium flow path to the bypass. The feedback generation unit is used to collect the actual operating parameters of the drive motor unit, the hydraulic buffer unit, the reversing valve group unit and the bypass switching unit, generate operating feedback information and send it to the safety protection module.

[0079] In this example, the running speed adjustment amount represents the numerical range by which the running speed of the rubber piston needs to be adjusted in the adaptive control command, and it is the quantitative basis for the drive motor unit to adjust the piston movement speed.

[0080] In this example, the stroke frequency adjustment amount represents the numerical range that needs to be adjusted in the adaptive control command for the number of piston reciprocations per unit time, which is used to guide the drive motor unit to adjust the piston reciprocating cycle.

[0081] In this example, the drive torque adjustment amount represents the numerical range by which the drive output torque needs to be adjusted in the adaptive control command, which is used to match the piston's drive force requirements under different load conditions.

[0082] In this example, the operating speed represents the linear velocity of the rubber piston reciprocating within the piston cavity, which directly affects the medium transport efficiency and the piston friction loss rate.

[0083] In this example, the stroke frequency represents the number of times the rubber piston completes a full reciprocating motion per unit time, and it is the core parameter that determines the slurry conveying flow rate and the system operating cycle.

[0084] In this example, the driving torque represents the rotational torque applied to the rubber piston by the drive mechanism through the transmission end, which is used to overcome the resistance of the medium and frictional resistance, and reflects the load-bearing capacity of the equipment.

[0085] In this example, the buffer parameter adjustment amount represents the numerical range that the buffer mechanism's operating parameters need to be adjusted according to the adaptive control command, and it serves as a quantitative basis for adjusting the buffering effect of the hydraulic buffer unit.

[0086] In this example, the buffer run duration represents the length of time the buffer mechanism intervenes during the piston reversal process. The longer the duration, the smoother the reversal process and the smaller the impact load.

[0087] In this example, the buffer pressure refers to the working pressure value set inside the hydraulic buffer chamber, which is used to counteract the inertial force and media reaction force of the piston reversal and weaken the impact load during the reversal process.

[0088] In this example, the absorption medium transport process represents the process by which the buffer mechanism dissipates pressure fluctuations generated during slurry transport, thereby smoothing out pressure oscillations within the pipeline.

[0089] In this example, pressure pulsation refers to the periodic pressure fluctuations caused by piston reversal and valve group switching during the medium transportation process, which is an important cause of piston impact and wear of the sealing pair.

[0090] In this example, the valve group timing adjustment amount represents the time range that needs to be adjusted at the valve group switching time node issued in the adaptive control command, which is used to calibrate the synchronization matching degree between the valve group action and the piston movement.

[0091] In this example, the switching sequence of the suction and discharge valve group indicates the order in which the suction valve and discharge valve open and close. It needs to be precisely matched with the reciprocating motion of the piston to ensure normal suction and discharge operations.

[0092] In this example, the bypass activation command is an execution command issued by the safety protection module to control the bypass pipeline to activate, which is used to trigger the bypass switching unit to complete the switching of the medium flow path.

[0093] The working principle and beneficial effects of the above technical solution are as follows: During operation, the drive motor unit receives the speed adjustment, stroke frequency adjustment, and drive torque adjustment from the adaptive control commands, and adjusts the speed, stroke frequency, and drive torque of the rubber piston accordingly. This allows for dynamic matching of drive force and operating rhythm based on real-time load conditions, avoiding insufficient power under heavy loads or ineffective energy consumption and excessive wear under light loads. The hydraulic buffer unit synchronously receives buffer parameter adjustments, correspondingly adjusting the buffer segment duration and buffer pressure. This actively absorbs pressure pulsations during media transport, effectively mitigating reversing impacts in coordination with the piston's operating rhythm. It also reduces the abrasive damage to the piston body and sealing surfaces caused by pressure fluctuations, extending the service life of components. The reversing valve group unit receives valve group timing adjustments, precisely... The switching sequence of the slurry suction and discharge valve groups is adjusted to precisely match the opening and closing actions of the valve groups with the reciprocating rhythm of the piston. This ensures slurry delivery efficiency while reducing pressure shocks and media backflow caused by asynchronous valve actions. The bypass switching unit receives bypass activation commands from the safety protection module under abnormal operating conditions, quickly switching the media flow path to the bypass pipeline. This achieves online isolation of the faulty piston unit, preventing localized failures from interrupting the overall delivery process and balancing equipment protection with production continuity. The feedback generation unit collects real-time operating parameters from the drive motor unit, hydraulic buffer unit, reversing valve group unit, and bypass switching unit, integrates and generates operational feedback information, and sends it to the safety protection module. This provides real-time data for control effect verification and dynamic adjustment of protection levels, forming a closed-loop feedback mechanism at the execution end. The entire actuator achieves dynamic and precise adjustment of multi-dimensional operating parameters, ensuring the adaptability and stability of piston operation under different operating conditions. It also reduces equipment wear and improves control accuracy through buffer optimization and feedback closed-loop, while the bypass switching function balances production continuity and equipment protection requirements under abnormal operating conditions.

[0094] Example 7: Based on Example 1, the safety protection module of the comprehensive control system for rubber pistons based on intelligent control and state perception includes: The early warning unit is used to trigger an audible and visual warning and push a reminder for sealing inspection or piston maintenance when the graded protection decision is at the pre-alarm level. The load limiting unit is used to send a load reduction ratio command to the drive motor unit of the actuator module when the graded protection decision is to reduce the load level. The deceleration unit is used to send a deceleration command to the drive motor unit of the actuator module when the graded protection decision is to decelerate. The bypass triggering unit is used to send a conduction command to the bypass switching unit of the actuator module when the hierarchical protection decision is to switch the level of bypass. The interlocking shutdown unit is used to send a shutdown command to the drive motor unit of the actuator module when the graded protection decision is at the interlocking shutdown level, and at the same time cut off the drive power of the rubber piston. The integrated decision-making unit is used to receive the operation feedback information. When the deviation between the actual operation parameters corresponding to each execution unit in the operation feedback information and the corresponding target adjustment amount in the adaptive control instruction exceeds a preset threshold, it feeds back the current level of the hierarchical protection decision to the integrated control module.

[0095] In this example, the preset threshold represents the maximum allowable deviation between the actual operating parameters and the target value of the adaptive control command, which is set in advance by the system. It serves as the criterion for determining whether the control effect meets the standard and whether the protection level needs to be adjusted.

[0096] In this example, the current level represents the protection level of the currently executing hierarchical protection decision. It is used to feed back the current system's multi-control variable conflict coordination rules to the integrated control module: priority is given to ensuring the piston reciprocating rhythm matches the buffer pressure and valve group timing, then adjusting the operating speed and stroke frequency; a health index of 70-80 triggers a pre-alarm, 50-70 triggers load reduction, 30-50 triggers deceleration, 10-30 triggers bypass switching, and <10 triggers interlock shutdown. After the level is fed back, the integrated control module recalculates the adaptive control commands. If the abnormality persists, the protection level is automatically upgraded; once the parameters return to normal, protection is gradually deactivated. This protection status provides a basis for the dynamic adjustment of the protection strategy.

[0097] In this example, The working principle and beneficial effects of the above technical solution are as follows: During operation, the early warning unit triggers a light-based early warning and pushes a maintenance reminder after receiving the pre-alarm level decision. This can prompt manual intervention in the early stages of minor piston abnormalities, moving the fault handling point forward and preventing the abnormality from continuing to deteriorate. The load limiting unit sends a load reduction ratio command to the drive motor unit after receiving the load reduction level decision, proportionally reducing the operating load to slow the rate of fault development while maintaining basic production, balancing production continuity and equipment damage reduction requirements. The deceleration unit sends a deceleration command after receiving the deceleration level decision, further reducing the piston's movement speed, weakening impact and friction losses, and enhancing the fault suppression effect. The bypass triggering unit sends a conduction command after receiving the bypass switching level decision, isolating the faulty piston unit online and preventing the spread of local faults from interrupting the overall conveying process. The interlock shutdown unit simultaneously sends a shutdown command and cuts off the drive power supply after receiving the interlock shutdown level decision, forcibly terminating high-risk operating conditions, preventing irreversible damage to core components, and eliminating safety accidents. The integrated decision-making unit receives operational feedback information in real time, compares actual parameters with target values ​​of control commands, and when the deviation exceeds a preset threshold, it feeds back the current level of graded protection decision to the integrated control module. This supports dynamic adjustment of the protection strategy, avoiding insufficient or excessive protection. The entire module, through gradient-progressive execution logic and a closed-loop verification mechanism, changes the traditional, passive shutdown approach after a system failure, achieving full-gradient protection. This ensures equipment operational safety while reducing the impact of abnormal operating conditions on production efficiency and improving protection accuracy.

[0098] Example 8: Based on Example 1, the comprehensive control system for a rubber piston based on intelligent control and state perception further includes: The human-computer interaction and remote monitoring module is used to receive the entire process of operation data, control commands and alarm information, and at the same time send the manually set target operation parameters to the integrated control module.

[0099] The working principle and beneficial effects of the above technical solution are as follows: The human-machine interaction and remote monitoring module serves as the interaction hub between the system and the operation and maintenance end. During operation, it collects real-time operational data, control commands, and alarm information from the entire process, completing data visualization, event archiving, and historical trend organization, supporting on-site status viewing and remote fault tracing. Operation and maintenance personnel can use this module to set target operating parameters and protection benchmarks, which are then sent to the integrated control module as a basis for decision-making, flexibly adapting to different conveying conditions. This module bridges the gap between manual configuration and automatic control, reducing on-site inspection load, improving operation and maintenance response efficiency, and providing data support for equipment lifecycle management and process optimization.

[0100] Example 9: This example provides a comprehensive control method for rubber pistons based on intelligent regulation and state perception, such as... Figure 2 As shown, it includes: Step 1: Collect the operating state parameters of the rubber piston, perform feature extraction and data standardization on the operating state parameters, and generate a standardized state feature set of the rubber piston; Step 2: Identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and graded protection decisions; Step 3: Adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and generate operation feedback information at the same time; Step 4: Execute the corresponding level of protection action based on the hierarchical protection decision and the operation feedback information.

[0101] In this example, the operating status parameters represent the raw physical quantities that reflect the operating status of the rubber piston, collected by various sensing units, including parameters such as displacement deviation, stroke deviation, cavity pressure, inlet and outlet pressure difference, temperature rise in the sealing area, operating vibration amplitude, drive current, torque, power, and sealing leakage.

[0102] In this example, feature extraction refers to the process of extracting core characteristic quantities from the original operating state parameters. Specifically, it extracts five key characteristic quantities that can reflect the piston's operating characteristics: displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate.

[0103] In this example, data standardization refers to the process of unifying and normalizing the dimensions of the extracted features, so that feature parameters with different physical meanings and magnitudes are converted into comparable logarithmic values ​​of a uniform specification.

[0104] In this example, the standardized state feature set represents a set of state feature data with uniform specifications formed after feature extraction and data standardization. It serves as the input data source for the integrated control module to perform operating condition identification and health assessment.

[0105] In this example, the current operating condition refers to the type of working state of the rubber piston during operation, including five categories: normal operating condition, heavy load operating condition, jamming risk condition, seal failure trend condition, and accelerated wear condition.

[0106] In this example, the health status represents a quantitative assessment of the overall operational health of the rubber piston, characterized by a health index. A higher value indicates a better piston operating condition and a lower risk of failure.

[0107] In this example, the adaptive control instruction represents the operating parameter adjustment instruction generated by the integrated control module based on the current operating conditions and health status. It is used to guide the actuator to dynamically adjust the piston's operating parameters to adapt to the current operating conditions.

[0108] In this example, the graded protection decision means that the integrated control module generates protection execution instructions based on the risk level of the health status and abnormal parameters, which includes five levels: pre-alarm, load reduction, deceleration, bypass switching, and interlock shutdown.

[0109] In this example, the operating speed represents the linear velocity of the rubber piston reciprocating within the piston cavity, and is a core operating parameter affecting conveying efficiency and wear rate.

[0110] In this example, the stroke frequency represents the number of reciprocating motions completed by the rubber piston per unit time, which directly determines the flow rate and cycle time of the slurry delivery.

[0111] In this example, the driving torque represents the driving torque applied to the rubber piston by the driving mechanism, which is used to overcome the resistance of the medium and frictional resistance, and reflects the load level of the equipment.

[0112] In this example, the valve group timing indicates the opening and closing switching time nodes of the slurry medium suction and discharge valve group, which needs to be matched with the reciprocating motion rhythm of the piston to ensure conveying efficiency and pressure stability.

[0113] In this example, the buffer parameter represents the running time and pressure set value of the buffer mechanism during the piston reversing stage, which is used to absorb pressure pulsations and reduce reversing shocks.

[0114] In this example, the operational feedback information represents the actual operational parameter data collected after the actuator completes parameter adjustment. This data is used to verify the control effect and provide a basis for adjusting the level of safety protection.

[0115] In this example, the protection action refers to the protective operation performed by the safety protection module for different risk levels, including graded protection actions such as early warning prompts, load reduction, operation deceleration, bypass switching, and interlock shutdown.

[0116] The working principle and beneficial effects of the above technical solution are as follows: The state perception module collects full-dimensional operating state parameters of the rubber piston, such as displacement, pressure, temperature, vibration, load, and leakage, through multiple types of sensor units. It then sequentially performs data standardization processing, including signal filtering and noise reduction, timing synchronization, key feature extraction, and dimensional normalization, generating a standardized state feature set with uniform specifications and transmitting it to the integrated control module. The integrated control module identifies the piston's current operating condition based on the multi-parameter coupled features in the feature set, calculates a weighted health index to complete a health status assessment, and generates differentiated adaptive control commands and graded protection decisions by matching the operating condition with the health level. After receiving the adaptive control command, the actuator module adjusts the piston's running speed, stroke frequency, drive torque, valve group switching sequence, and buffer parameters accordingly, and simultaneously collects the actual operating data after adjustment to generate operating feedback information for feedback. The safety protection module combines the verification results of hierarchical protection decisions and operating feedback to initiate corresponding level protection actions. This not only achieves comprehensive perception of the multi-source state of the rubber piston and precise adaptive control of operating conditions, but also constructs a hierarchical interlocking safety protection mechanism, which can effectively identify early anomalies, reduce the risk of failure and downtime, reduce abnormal piston wear, and improve the operational stability and service life of the mine filling and conveying system.

[0117] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A comprehensive control system for a rubber piston based on intelligent regulation and state perception, characterized in that, include: The state perception module is used to collect the operating state parameters of the rubber piston, perform feature extraction and data standardization processing on the operating state parameters, and generate a standardized state feature set of the rubber piston. The integrated control module is used to identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and hierarchical protection decisions. The actuator module is used to adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and at the same time generate operation feedback information. The security protection module is used to execute protection actions at the corresponding level based on the hierarchical protection decision and the operation feedback information.

2. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 1, characterized in that, The state awareness module includes: The displacement sensing unit is located on the outer periphery of the connecting rod of the rubber piston and is used to collect the displacement deviation parameters and stroke deviation parameters of the rubber piston. The pressure-temperature composite sensing unit consists of several units, which are respectively set on the piston cavity wall and the corresponding position of the sealing pair of the rubber piston, and are used to collect the cavity pressure, inlet and outlet pressure difference parameters and sealing area temperature rise parameters of the rubber piston. The vibration sensing unit is installed in the drive end housing of the rubber piston and is used to collect the operating vibration amplitude and frequency band parameters of the rubber piston. The load acquisition unit is connected to the power supply circuit of the drive motor of the rubber piston and is used to acquire the drive current, torque and power parameters of the rubber piston. The leakage detection unit is installed on the outer periphery of the sealing pair of the rubber piston to collect the sealing leakage parameters of the rubber piston. The parameter processing unit is used to acquire the displacement deviation parameters, stroke deviation parameters, cavity pressure, inlet and outlet pressure difference parameters, sealing area temperature rise parameters, operating vibration amplitude, frequency band parameters, driving current, torque, power parameters, and sealing leakage parameters of the rubber piston, and generate the operating status parameters of the rubber piston.

3. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 2, characterized in that, The state awareness module further includes: The parameter processing unit is used to filter, denoise, and remove outliers from the operating status parameters. Based on the operating cycle of the rubber piston, the parameters after purification are synchronized in time and converted in unit, generating a unified set of synchronized and aligned dimensional parameters. The unified dimension parameter set is normalized, and the displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value and load fluctuation rate of the unified dimension parameter set are extracted. The displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate are normalized respectively to obtain the standardized state feature set of the rubber piston.

4. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 1, characterized in that, The integrated control module includes: The working condition identification unit is used to receive the standardized state feature set and identify the current working condition of the rubber piston based on the coupling characteristics of displacement peak value, pressure pulsation amplitude, temperature rise rate, vibration peak value, and load fluctuation rate. The status assessment unit is used to retrieve the historical operating data of the rubber piston, combine it with the standardized status feature set, use a multi-dimensional weighted formula to calculate the current health index of the rubber piston, construct the historical trend of the health index, and output the prediction result of the remaining operating time of the rubber piston. An adaptive control unit is used to generate the adaptive control command based on the current operating conditions and the predicted remaining operating time. The graded protection unit is used to generate the graded protection decision based on the current health index and the standardized state characteristics that exceed the corresponding preset range.

5. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 4, characterized in that, Also includes: The hierarchical protection decision-making levels are: early warning, load reduction, speed reduction, bypass switching, or interlocking shutdown.

6. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 1, characterized in that, The actuator module includes: The drive motor unit is connected to the transmission end of the rubber piston and is used to receive the running speed adjustment amount, stroke frequency adjustment amount and drive torque adjustment amount in the adaptive control command, and adjust the running speed, stroke frequency and drive torque of the rubber piston. The hydraulic buffer unit is connected to the buffer chamber of the rubber piston and is used to receive the buffer parameter adjustment amount in the adaptive control command, adjust the buffer section running time and buffer pressure, and absorb the pressure pulsation during the medium transportation process. The reversing valve group unit is installed in the medium inlet and outlet pipeline of the rubber piston, and is used to receive the valve group timing adjustment amount in the adaptive control command, and adjust the switching timing of the suction and discharge slurry valve group of the rubber piston. The bypass switching unit is connected in parallel with the inlet and outlet pipelines of the rubber piston and is used to receive the bypass conduction command issued by the safety protection module to switch the medium flow path to the bypass. The feedback generation unit is used to collect the actual operating parameters of the drive motor unit, the hydraulic buffer unit, the reversing valve group unit and the bypass switching unit, generate operating feedback information and send it to the safety protection module.

7. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 1, characterized in that, The security protection module includes: The early warning unit is used to trigger an audible and visual warning and push a reminder for sealing inspection or piston maintenance when the graded protection decision is at the pre-alarm level. The load limiting unit is used to send a load reduction ratio command to the drive motor unit of the actuator module when the graded protection decision is to reduce the load level. The deceleration unit is used to send a deceleration command to the drive motor unit of the actuator module when the graded protection decision is to decelerate. The bypass triggering unit is used to send a conduction command to the bypass switching unit of the actuator module when the hierarchical protection decision is to switch the level of bypass. The interlocking shutdown unit is used to send a shutdown command to the drive motor unit of the actuator module when the graded protection decision is at the interlocking shutdown level, and at the same time cut off the drive power of the rubber piston. The integrated decision-making unit is used to receive the operation feedback information. When the deviation between the actual operation parameters corresponding to each execution unit in the operation feedback information and the corresponding target adjustment amount in the adaptive control instruction exceeds a preset threshold, it feeds back the current level of the hierarchical protection decision to the integrated control module.

8. The integrated control system for a rubber piston based on intelligent regulation and state perception as described in claim 1, characterized in that, Also includes: The human-computer interaction and remote monitoring module is used to receive the entire process of operation data, control commands and alarm information, and at the same time send the manually set target operation parameters to the integrated control module.

9. A comprehensive control method for a rubber piston based on intelligent regulation and state perception, characterized in that, include: Step 1: Collect the operating state parameters of the rubber piston, perform feature extraction and data standardization on the operating state parameters, and generate a standardized state feature set of the rubber piston; Step 2: Identify the current working condition of the rubber piston and assess its health status based on the standardized state feature set, and generate adaptive control commands and graded protection decisions; Step 3: Adjust the running speed, stroke frequency, driving torque, valve group timing and buffer parameters of the rubber piston according to the adaptive control command, and generate operation feedback information at the same time; Step 4: Execute the corresponding level of protection action based on the hierarchical protection decision and the operation feedback information.

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