Digital control and monitoring system and monitoring method for power equipment

Abstract

This application provides a digital control and monitoring system and method for power equipment, specifically relating to the field of digital control and monitoring technology for power equipment. The system includes an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, and a higher-level monitoring system. The embedded servo driver integrates a motion control module, a motor drive module, a communication interface, and a data acquisition unit. The motion control module executes pre-stored motion logic and sends commands to the motor drive module to drive the servo motor; the data acquisition unit collects the servo motor's operating parameters in real time. The embedded servo driver uploads the operating parameters to the higher-level monitoring system via the communication interface and receives its operation commands. The simplified mechanical transmission mechanism connects the servo motor's output shaft to the power equipment's actuators. This system effectively solves the problems of complex mechanical structures, low control accuracy, and lack of real-time status perception and diagnosis in traditional solutions, achieving simplified mechanical structures, improved control accuracy, and online intelligent monitoring and prediction of operating status.

Description

Technical Field

[0001] This invention relates to the field of digital control and monitoring technology for power equipment, and more specifically, to a digital control and monitoring system and method for power equipment. Background Technology

[0002] In the fields of power systems and industrial automation, the driving and control of power equipment (such as disconnecting switches and grounding switches) is rapidly developing towards digitalization and intelligence. The industry expects equipment to not only perform reliable opening and closing actions, but also achieve precise control, transparent status, and remote intelligent operation and maintenance. However, the driving and control of currently widely used traditional power equipment mainly relies on a purely mechanical solution consisting of motors, gearboxes, complex linkage mechanisms, and mechanical limit switches. This solution results in cumbersome equipment structures, difficult debugging and maintenance, and difficulty in real-time sensing of operating status and connection to digital networks, becoming a major bottleneck for the industry's intelligent upgrade.

[0003] To address the aforementioned issues, existing technologies primarily achieve partial improvements by optimizing mechanical design (such as improving linkage trajectories and using more wear-resistant materials) or adding independent sensors and controllers (such as additional position sensors, vibration probes, and connections to a PLC). However, these improvements do not alter the fundamental architecture of "mechanical transmission as the primary method and electrical control as a secondary method." Optimizing mechanical design cannot fundamentally simplify the structure, and the fragmented data acquisition, drive control, and fault diagnosis functions of the separately added sensors and control units are disconnected, resulting in low system integration, high costs, and inherent limitations in improving control accuracy and integrated intelligent diagnostics, making it difficult to achieve true deep electromechanical integration and unified management across all states.

[0004] In summary, how to simultaneously solve the technical problems of complex mechanical structures, low-precision control, and lack of real-time status perception and diagnostic capabilities through a highly integrated control core is a technical problem that urgently needs to be solved. Summary of the Invention

[0005] The main objective of this invention is to provide a digital control and monitoring system and method for power equipment, which at least solves the technical problems of complex mechanical structure, low control accuracy and lack of real-time status perception and diagnostic capabilities in traditional power equipment drive control schemes, thereby achieving simplified mechanical structure, improved control accuracy and online intelligent monitoring and prediction of operating status of the equipment.

[0006] To achieve the above objectives, this invention provides a digital control and monitoring system for power equipment. The system includes: an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, and a higher-level monitoring system. The embedded servo driver integrates a motion control module, a motor drive module, a communication interface, and a data acquisition unit. The servo motor is electrically connected to the embedded servo driver. The simplified mechanical transmission mechanism is connected between the output shaft of the servo motor and the actuator of the power equipment. The higher-level monitoring system is connected to the communication interface of the embedded servo driver via a communication network. The motion control module executes pre-stored motion logic and sends control commands to the motor drive module. The motor drive module drives the servo motor according to the control commands. The data acquisition unit collects the operating parameters of the servo motor in real time. The embedded servo driver uploads the operating parameters to the higher-level monitoring system via the communication interface and receives operation commands from the higher-level monitoring system.

[0007] Specifically, the embedded servo driver also includes a fault prediction module, which is connected to the data acquisition unit and is used to execute a fault prediction algorithm based on the operating parameters.

[0008] Specifically, the simplified mechanical transmission mechanism is a direct coupling or a single-stage reducer.

[0009] Specifically, the monitoring system further includes a digital status sensor group, which is installed on the device body of the power equipment. The digital status sensor group is used to collect status signals of the device body and send the status signals to the embedded servo driver.

[0010] Specifically, the embedded servo driver also integrates an adaptive control module, which is used to adjust the control parameters of the motion control module according to the operating parameters or environmental parameters collected by the data acquisition unit.

[0011] Specifically, the communication interface is an industrial fieldbus communication interface or an industrial Ethernet communication interface, and the communication network is a corresponding industrial fieldbus network or industrial Ethernet network.

[0012] Specifically, the embedded servo driver is also provided with an auxiliary signal input interface, the digital status sensor group is connected to the auxiliary signal input interface, and the data acquisition unit is also used to acquire the status signal through the auxiliary signal input interface.

[0013] On the other hand, the present invention provides a digital control and monitoring method for power equipment, the method comprising:

[0014] Receive operation instructions from the superior monitoring system;

[0015] The motion control module of the embedded servo driver executes the pre-stored motion logic according to the operation instructions and generates motor control instructions;

[0016] The motor drive module of the embedded servo driver drives the servo motor to operate according to the motor control command;

[0017] The servo motor and simplified mechanical transmission mechanism drive the actuators of the power equipment to move.

[0018] During the operation of the servo motor, the data acquisition unit of the embedded servo driver collects the operating parameters of the servo motor in real time;

[0019] The embedded servo driver uploads the operating parameters to the upper-level monitoring system through its communication interface.

[0020] Optionally, after the data acquisition unit acquires the operating parameters of the servo motor in real time, the monitoring method further includes a fault prediction step, which includes:

[0021] The fault prediction module of the embedded servo driver executes a fault prediction algorithm based on the operating parameters collected by the data acquisition unit.

[0022] When the fault prediction algorithm determines that the operating status is abnormal, it generates an early warning signal.

[0023] Optionally, before or simultaneously with the motion control module executing pre-stored motion logic and generating motor control commands according to the operation instructions, the monitoring method further includes an adaptive control step, which includes:

[0024] The adaptive control module of the embedded servo driver adjusts the control parameters of the motion control module based on the operating parameters or environmental parameters collected by the data acquisition unit.

[0025] This application provides a digital control and monitoring system and method for power equipment. The monitoring system includes an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, and a higher-level monitoring system. The embedded servo driver integrates a motion control module, a motor drive module, a communication interface, and a data acquisition unit. The motion control module executes pre-stored motion logic and sends commands to the motor drive module to drive the servo motor; the data acquisition unit collects the servo motor's operating parameters in real time. The embedded servo driver uploads the operating parameters to the higher-level monitoring system via the communication interface and receives its operation commands. The simplified mechanical transmission mechanism connects the servo motor's output shaft to the power equipment's actuators. This system solves the problems of complex mechanical structures, low control accuracy, and lack of real-time status perception and diagnostic capabilities in traditional solutions, achieving simplified mechanical structures, improved control accuracy, and online intelligent monitoring and prediction of operating status. Attached Figure Description

[0026] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0027] Figure 1 A connection diagram of the digital control and monitoring system for power equipment provided in this application;

[0028] Figure 2 A flowchart illustrating the digital control and monitoring method for power equipment provided in this application.

[0029] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concepts of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0031] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein.

[0032] In this invention, the terms "exemplary" or "for example" are used to indicate examples, illustrations, or descriptions. Any embodiment or design described as "exemplary" or "for example" in this application should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of terms such as "exemplary" or "for example" is intended to present the relevant concepts in a concrete manner.

[0033] This application provides a digital control and monitoring system and method for power equipment. The system includes an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, and a higher-level monitoring system. The embedded servo driver integrates multiple functional modules: a motion control module executes motion logic and sends commands, a motor drive module drives the servo motor, and a data acquisition unit collects operating parameters. Parameters are uploaded to the higher-level monitoring system via a communication interface, and commands are received. Combined with the simplified mechanical transmission mechanism, this achieves simplified mechanical structure, improved control accuracy, and online intelligent monitoring and prediction of operating status.

[0034] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0035] Figure 1 A schematic diagram of the digital control and monitoring system for power equipment provided in this application, such as... Figure 1 As shown, this embodiment provides a digital control and monitoring system for power equipment. The system includes: an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, and a higher-level monitoring system. The embedded servo driver integrates a motion control module, a motor drive module, a communication interface, and a data acquisition unit. The servo motor is electrically connected to the embedded servo driver. The simplified mechanical transmission mechanism is connected between the output shaft of the servo motor and the actuator of the power equipment. The higher-level monitoring system is connected to the communication interface of the embedded servo driver via a communication network. The motion control module executes pre-stored motion logic and sends control commands to the motor drive module. The motor drive module drives the servo motor according to the control commands. The data acquisition unit collects the operating parameters of the servo motor in real time. The embedded servo driver uploads the operating parameters to the higher-level monitoring system via the communication interface and receives operation commands from the higher-level monitoring system.

[0036] Specifically, the embedded servo driver also includes a fault prediction module, which is connected to the data acquisition unit and is used to execute a fault prediction algorithm based on the operating parameters.

[0037] Specifically, the simplified mechanical transmission mechanism is a direct coupling or a single-stage reducer.

[0038] Specifically, the monitoring system further includes a digital status sensor group, which is installed on the device body of the power equipment. The digital status sensor group is used to collect status signals of the device body and send the status signals to the embedded servo driver.

[0039] Specifically, the embedded servo driver also integrates an adaptive control module, which is used to adjust the control parameters of the motion control module according to the operating parameters or environmental parameters collected by the data acquisition unit.

[0040] Specifically, the communication interface is an industrial fieldbus communication interface or an industrial Ethernet communication interface, and the communication network is a corresponding industrial fieldbus network or industrial Ethernet network.

[0041] Specifically, the embedded servo driver is also provided with an auxiliary signal input interface, the digital status sensor group is connected to the auxiliary signal input interface, and the data acquisition unit is also used to acquire the status signal through the auxiliary signal input interface.

[0042] The digital control and monitoring system for power equipment provided by the present invention will be clearly and thoroughly described below with reference to a specific embodiment, so that those skilled in the art can implement it. This embodiment uses a digital control and monitoring system applied to a high-voltage disconnector as an example for illustration.

[0043] 1. Overall structure and connection relationships of the digital control and monitoring system for power equipment provided in this embodiment.

[0044] The digital control and monitoring system for power equipment provided in this embodiment includes: an embedded servo driver, a servo motor, a simplified mechanical transmission mechanism, a digital status sensor group, and a higher-level monitoring system.

[0045] The embedded servo driver, serving as the control core of the entire system, has a power input terminal, a motor power output terminal, a communication interface, and an auxiliary signal input interface on its housing. The power input terminal is connected to an external AC 380V or DC 220V power supply network via a power cable to power the various modules within the embedded servo driver. The motor power output terminal is electrically connected to the three-phase power input terminal of the servo motor via a three-phase power cable, providing drive power to the servo motor and transmitting control signals. The communication interface is specifically a PROFINET industrial Ethernet communication interface. The auxiliary signal input interface includes multiple analog input channels and digital input channels.

[0046] The servo motor is a permanent magnet synchronous servo motor with an absolute encoder. The output shaft of the servo motor is mechanically connected to the input shaft of the simplified mechanical transmission mechanism via a keyway and a flat key.

[0047] In this embodiment, the simplified mechanical transmission mechanism is a single-stage reducer. The input end (high-speed shaft) of this single-stage reducer is rigidly connected to the output shaft of the servo motor via a coupling. The output end (low-speed shaft) of this single-stage reducer is fixedly connected to the insulating support of the high-voltage disconnect switch (i.e., the actuator of the power equipment) via a flange and bolts, thereby converting the rotational motion of the servo motor into the rotational opening and closing action of the insulating support. The advantage of using a single-stage reducer is to increase the output torque and reduce the speed. Furthermore, compared to traditional multi-stage linkage mechanisms, its structure is greatly simplified, reducing the number of moving parts and improving transmission efficiency and reliability.

[0048] The digital status sensor group is installed on the equipment body of the high-voltage disconnect switch, specifically including a vibration acceleration sensor and an infrared temperature sensor. The vibration acceleration sensor is fixedly mounted on the bearing housing of the disconnect switch's rotating mechanism via a magnetic base, and is used to collect vibration signals from the equipment body. The infrared temperature sensor is aligned with the conductive contacts of the disconnect switch via a bracket, and is used to collect temperature signals from the contacts. The signal output lines of the vibration acceleration sensor and the infrared temperature sensor are respectively connected to one analog input channel in the auxiliary signal input interface of the embedded servo driver, thereby sending the vibration signal and temperature signal (collectively referred to as status signals) characterizing the equipment body status to the embedded servo driver.

[0049] The upper-level monitoring system is a computer monitoring platform deployed in the substation's main control room. The upper-level monitoring system connects to the PROFINET industrial Ethernet communication interface of the embedded servo drive via an industrial Ethernet cable with an RJ45 connector, forming a communication network. This connection allows the upper-level monitoring system to send remote operation commands (such as "closing" and "opening") to the embedded servo drive and receive operating parameters and status signals uploaded by the embedded servo drive.

[0050] 2. Internal module functions and data interaction of the embedded servo driver

[0051] The embedded servo driver integrates a motion control module, a motor drive module, a communication interface module, a data acquisition unit, a fault prediction module, and an adaptive control module. These modules interact with each other via an internal bus.

[0052] In this embodiment, the embedded servo driver uses a main control board integrating a microprocessor (such as an ARM Cortex-M series or DSP), memory, and necessary peripheral interface circuits as its core hardware platform. The motion control module, the control algorithm section of the motor drive module, the logic processing section of the data acquisition unit, the fault prediction module, and the adaptive control module are essentially software programs or firmware running on the microprocessor, and are different software functional units divided according to their functions. The power output section of the motor drive module and the sensor signal conditioning and sampling section of the data acquisition unit are dedicated hardware circuits connected to the microprocessor. Each module interacts with data through the microprocessor's internal bus or shared memory. Specifically:

[0053] (1) Motion Control Module: Essentially, this is a real-time control task or software routine running on a microprocessor. This module reads pre-stored motion curve parameters (position-velocity-time curves) from non-volatile memory and receives operation commands (such as "close the circuit breaker") parsed from the communication interface module. The software routine runs at a fixed control cycle (e.g., 1ms), executes a proportional-integral-derivative control algorithm by calling mathematical library functions, calculates the deviation between the target position and the actual position fed back by the encoder, and finally outputs the speed command V_cmd and torque limit Torque_limit in digital form. The output is a data packet passed to the motor drive module software.

[0054] (2) Motor drive module: This is a functional unit that combines hardware and software.

[0055] Hardware components include an insulated gate bipolar transistor power bridge, gate drive circuit, current sampling circuit (such as Hall sensor + ADC), encoder interface circuit, etc.

[0056] The software / firmware portion consists of a high-priority interrupt service routine or low-level driver task with a shorter execution cycle (e.g., 100μs). It receives V_cmd and Torque_limit from the motion control module and executes the field-oriented control algorithm chain: it reads the three-phase currents I_a, I_b, and I_c from the ADC, performs Clark transformation, Park transformation, PI controller operations, and inverse Park transformation in the software, ultimately generating space vector pulse width modulation waveform data and writing it to the register of the hardware PWM generator. This controls the switching action of the power bridge, driving the servo motor.

[0057] (3) Data acquisition unit: This is a collection of hardware acquisition circuits and data processing software that integrate analog and digital interfaces.

[0058] Hardware components include analog input channels (auxiliary signal input interfaces for connecting external sensors), analog signal conditioning circuits, analog-to-digital converters, and digital communication interfaces (such as EnDat and SSI) for connecting servo motor encoders.

[0059] The software component is responsible for scheduling, acquiring, and preprocessing data. It configures the ADC to sample at regular intervals, reads encoder data, filters and calibrates the raw sampled values, and runs the torque observer algorithm (based on the motor model and the acquired current and position) to calculate the real-time torque T_est. It packages the processed operating parameters such as current, position, and torque, along with status signals (vibration, temperature) acquired from the auxiliary interface, into a shared memory area for use by the fault prediction module and the communication interface module.

[0060] (4) Fault Prediction Module: Essentially, this is a data analysis and logical judgment software task running on a microprocessor. This task periodically (e.g., every 10ms) reads the latest operating parameters (mainly torque T_est) from the shared memory area of ​​the data acquisition unit. It implements specific judgment logic, such as threshold comparison (determining whether T_est continuously exceeds T_threshold_alert) and trend analysis algorithms (performing linear regression analysis on the historical torque queue, calculating the slope, and comparing it with S_threshold). The output of this module is the generation of structured early warning signal data.

[0061] (5) Adaptive Control Module: Essentially, it is a parameter management software task running on a microprocessor. This task monitors specific parameters (such as winding temperature Temp_winding) provided by the data acquisition unit. It internally stores or can calculate a mapping relationship (such as a temperature-current relationship table). Based on the current parameters, it obtains the adjusted control parameter values ​​(such as the new maximum allowable current I_q_max or torque limit Torque_limit) by looking up the table or by calculation, and transmits them to the motion control module through the software interface, thereby affecting the behavior of the motion control module in generating subsequent instructions.

[0062] Specifically, the motion control module pre-stores motion logic and position-velocity-time curves for the opening and closing operations of the high-voltage disconnector. The motion control module receives a "closing" operation command from the upper-level monitoring system via the communication interface module. The motion control module parses this operation command, calls the pre-stored "closing" motion curve, and generates corresponding motor control commands (including target position sequence, speed profile, and torque limit). These motor control commands are then sent to the motor drive module.

[0063] The motor drive module generates a three-phase pulse width modulation signal based on the received motor control command using a field-oriented control algorithm. This signal drives the servo motor to operate precisely through the motor power output terminal, thereby causing the servo motor to rotate according to a preset motion curve.

[0064] The data acquisition unit collects the operating parameters of the servo motor in real time, including the three-phase current of the motor collected by the internal current sensor, the real-time output torque calculated based on the current and motor model by the internal algorithm, and the actual position fed back by the absolute encoder of the servo motor. Simultaneously, the data acquisition unit also collects vibration signals from the vibration acceleration sensor and temperature signals from the infrared temperature sensor through the auxiliary signal input interface. All collected operating parameters and status signals are packaged and processed by the data acquisition unit.

[0065] The fault prediction module is connected to the data acquisition unit and is used to execute a fault prediction algorithm based on the operating parameters collected in real time by the data acquisition unit. The specific fault prediction algorithms include a threshold comparison algorithm and a trend analysis algorithm. For the threshold comparison algorithm, the fault prediction module compares the torque data collected in real time by the data acquisition unit with a preset torque protection threshold (e.g., 150% of the rated torque). When the real-time torque continuously exceeds this threshold for 100 milliseconds, an "over-torque fault" warning signal is immediately generated and sent to the motion control module, which then commands the motor drive module to stop driving. For the trend analysis algorithm, the fault prediction module stores the steady-state torque values ​​at the completion of the last 100 "closing" operations and calculates their linear regression trend. When the analysis finds that the torque value shows a continuous upward trend and the slope exceeds a preset slope threshold, a warning signal of "torque slowly increasing, mechanical lubrication recommended" is generated.

[0066] The adaptive control module is used to adjust the control parameters of the motion control module based on the operating parameters or environmental parameters collected by the data acquisition unit. For example, the adaptive control module monitors the servo motor winding temperature collected by the data acquisition unit. When the winding temperature rises, the adaptive control module reduces the value of the torque limit parameter in the motion control module according to a preset temperature-current relationship table to prevent the motor from overheating, thereby providing protection and maintaining stable control performance.

[0067] The communication interface module (PROFINET interface) is responsible for uploading the operating parameters (current, torque, position) and status signals (vibration, temperature) packaged by the data acquisition unit, as well as the early warning signals generated by the fault prediction module, to the upper-level monitoring system. Simultaneously, the communication interface module also receives operation commands and parameter setting commands from the upper-level monitoring system and forwards them to the motion control module.

[0068] 3. Workflow of the digital control and monitoring system for power equipment provided in this embodiment

[0069] When a closing operation is required, the upper-level monitoring system sends a "closing" command to the embedded servo drive via industrial Ethernet. The motion control module of the embedded servo drive, based on this command, calls a pre-stored smooth closing curve to generate motor control commands. The motor drive module drives the servo motor to rotate; the torque is increased through a single-stage reducer, driving the insulating support of the high-voltage disconnect switch to smoothly rotate to the closing position. Throughout the entire process, the data acquisition unit continuously collects motor current, calculates torque, and monitors the actual position. The fault prediction module analyzes the torque data in real time, providing overload protection and trend warnings. The adaptive control module fine-tunes control parameters based on motor temperature. All these operating parameters, status signals, and warning information are uploaded to the upper-level monitoring system in real time via the PROFINET interface, enabling maintenance personnel to fully grasp the equipment status, simplify the mechanical structure, improve control precision, and achieve online intelligent monitoring and prediction of operating status.

[0070] Figure 2 A flowchart illustrating the digital control and monitoring method for power equipment provided in this application is shown below. Figure 2 As shown in this embodiment, the digital control and monitoring method for power equipment is applied to... Figure 1 The digital control and monitoring system for power equipment described in the embodiment includes the following method:

[0071] S101: Receives operation instructions from the superior monitoring system;

[0072] S102: The motion control module of the embedded servo driver executes the pre-stored motion logic according to the operation instructions and generates motor control instructions;

[0073] S103: The motor drive module of the embedded servo driver drives the servo motor to operate according to the motor control command;

[0074] S104: The servo motor and the simplified mechanical transmission mechanism drive the actuators of the power equipment to move;

[0075] S105: During the operation of the servo motor, the data acquisition unit of the embedded servo driver collects the operating parameters of the servo motor in real time.

[0076] S106: The embedded servo driver uploads the operating parameters to the upper-level monitoring system through its communication interface.

[0077] Optionally, after the data acquisition unit collects the operating parameters of the servo motor in real time, the monitoring method further includes a fault prediction step, which includes: a fault prediction module of the embedded servo driver executing a fault prediction algorithm based on the operating parameters collected by the data acquisition unit; and generating a warning signal when the fault prediction algorithm determines that the operating state is abnormal.

[0078] Optionally, before or simultaneously with the motion control module executing pre-stored motion logic and generating motor control instructions according to the operation instructions, the monitoring method further includes an adaptive control step, which includes: the adaptive control module of the embedded servo driver adjusting the control parameters of the motion control module according to the operating parameters or environmental parameters collected by the data acquisition unit.

[0079] The following is combined with Figure 1 The described monitoring system embodiment provides a detailed explanation of the digital control and monitoring method for power equipment provided by the present invention. This method is applied to the aforementioned digital control and monitoring system for power equipment.

[0080] S101: Receives operation instructions from the superior monitoring system.

[0081] Specifically, the human-machine interface of the higher-level monitoring system (such as a substation computer monitoring platform) receives the "close" command issued by the operator. The higher-level monitoring system encapsulates this "close" command according to a pre-agreed communication protocol (such as the PROFINET IO protocol), generating a network data frame containing the target device address, instruction code (e.g., "0x01" representing closure), and necessary verification data. The higher-level monitoring system sends this network data frame to the PROFINET industrial Ethernet communication interface of the embedded servo drive via an industrial Ethernet network. After receiving the network data frame, the communication interface module of the embedded servo drive decodes and verifies it, extracts the instruction code "0x01," parses it as the "close" operation instruction, and passes it to the main control logic inside the embedded servo drive.

[0082] This step establishes a remote control channel, enabling maintenance personnel to remotely and accurately issue action intention commands to the power equipment drive unit, replacing traditional local button or hard-wired control and laying the foundation for digital centralized control.

[0083] S102: The motion control module of the embedded servo driver executes the pre-stored motion logic according to the operation instructions and generates motor control instructions.

[0084] Specifically, upon receiving a "closing" operation command, the motion control module of the embedded servo driver retrieves the "closing motion curve" pre-configured for the high-voltage disconnector, associated with the command, from non-volatile memory. This "closing motion curve" is a function describing the change of the target angle over time as the insulating support (actuator) moves from the open to the closed position. Its specific parameters include: total motion time T_total (e.g., 3 seconds), initial acceleration time T_acc (e.g., 0.5 seconds), constant speed time T_const, final deceleration time T_dec, and the final target angle Position_target (e.g., 90 degrees). The motion control module compares the actual angle Position_actual, fed back by the current servo motor encoder, with the target angle Position_target(t) calculated by the "closing motion curve" in each control cycle (e.g., 1 millisecond), obtaining the angle deviation e(t) = Position_target(t) - Position_actual. The motion control module uses a proportional-integral-derivative (PID) control algorithm to calculate the angle deviation e(t), generating a speed command V_cmd(t) = Kp * e(t) + Ki * ∫e(t)dt + Kd * de(t) / dt. Simultaneously, based on curve parameters and system inertia, the motion control module calculates a torque limit value Torque_limit. Finally, the motion control module encapsulates the speed command V_cmd(t) and the torque limit value Torque_limit into a continuous sequence of motor control commands and sends it to the motor drive module.

[0085] This step transforms high-level, abstract operation commands ("closing") into a set of precise, executable low-level motion control commands, enabling refined and programmable control of the power equipment's operation process (such as speed, position, and torque), replacing the coarse control method of traditional mechanical limit switches.

[0086] S103: The motor drive module of the embedded servo driver drives the servo motor to operate according to the motor control command.

[0087] Specifically, the motor drive module receives motor control commands from the motion control module, which include the target speed V_cmd(t) and torque limit Torque_limit. The motor drive module first acquires the real-time currents I_a, I_b, and I_c of the three-phase windings of the servo motor using internal current sensors. Employing a field-oriented control algorithm, the motor drive module transforms the currents (I_a, I_b, I_c) in the three-phase stationary coordinate system to the direct-axis current I_d and quadrature-axis current I_q in the two-phase rotating coordinate system using Clark and Park transformations. The motor drive module compares the target speed V_cmd(t) with the actual motor speed ω_actual fed back from the servo motor encoder and calculates the command value I_q_ref of the quadrature-axis current using a speed loop proportional-integral controller. Simultaneously, the direct-axis current command I_d_ref is typically set to zero to achieve maximum torque-to-current ratio control. The motor drive module then compares I_d_ref and I_q_ref with the feedback I_d and I_q, and calculates the voltage commands V_d_ref and V_q_ref in the two-phase rotating coordinate system using a current loop proportional-integral controller. Next, V_d_ref and V_q_ref are transformed back to the two-phase stationary coordinate system through inverse Park transformation. Then, six PWM waves with specific duty cycles are generated using space vector pulse width modulation technology to control the switching state of the power bridge of the insulated gate bipolar transistor inside the driver. This generates the required voltage and current of the required magnitude and frequency on the three-phase windings of the servo motor, driving the servo motor to rotate at the target speed V_cmd(t) while ensuring that the output torque does not exceed Torque_limit.

[0088] This step precisely converts the digitized motor control commands into the electrical power required to drive the physical motion of the servo motor. Through advanced control algorithms, it ensures the speed, smoothness, and accuracy of the motor response, making it a key execution step for achieving high-precision motion control.

[0089] S104: The servo motor and the simplified mechanical transmission mechanism drive the actuator of the power equipment to move.

[0090] Specifically, the output shaft of the driven servo motor begins to rotate. The output shaft of the servo motor is rigidly connected to the high-speed input shaft of a single-stage reducer (a simplified mechanical transmission mechanism in this embodiment) via a key connection. The rotational motion and torque output by the servo motor are transmitted to the single-stage reducer. A pair of gears (e.g., helical gears) inside the single-stage reducer mesh to convert the high-speed, low-torque input into a low-speed, high-torque output. The low-speed output shaft of the single-stage reducer is fixedly connected to the base of the insulating support of the high-voltage disconnector (i.e., the actuator of the power equipment) via flanges and bolts. Therefore, the low-speed, high-torque rotational motion output by the single-stage reducer directly drives the insulating support to rotate smoothly and precisely around its axis from the open position (e.g., 0 degrees) to the closed position (e.g., 90 degrees), completing the opening and closing operation.

[0091] The purpose and effect of this step is to reliably transmit and convert the precise electrically controlled rotary motion of the servo motor into the mechanical actions required by the actuators of the electrical equipment through a highly simplified mechanical transmission chain. The simplified mechanical transmission mechanism (such as a single-stage reducer) significantly reduces intermediate links, backlash, and deformation in the motion chain, improving the rigidity, efficiency, and reliability of the entire transmission system. This allows the precise electrical control of the preceding steps to ultimately manifest as the precise movements of the equipment itself.

[0092] S105: During the operation of the servo motor, the data acquisition unit of the embedded servo driver collects the operating parameters of the servo motor in real time.

[0093] Specifically, during the entire S103 process of driving the servo motor from startup acceleration, constant speed operation to deceleration and stop, the data acquisition unit synchronously performs multiple data acquisition tasks at a fixed sampling period (e.g., 100 microseconds). The data acquisition unit acquires the instantaneous current values ​​I_u(t), I_v(t), and I_w(t) flowing through the U, V, and W phase windings of the motor in real time using Hall effect current sensors connected to the three-phase power lines of the servo motor. The data acquisition unit also receives serial data packets fed back from the servo motor's built-in absolute encoder via a digital interface (e.g., EnDat2.2) and parses the real-time mechanical angle θ_m(t) of the servo motor rotor. The data acquisition unit, based on the acquired three-phase currents I_u(t), I_v(t), and I_w(t) and the motor's position information, and combining the mathematical model parameters of the permanent magnet synchronous motor pre-stored in the driver (such as stator resistance Rs, d-axis inductance Ld, q-axis inductance Lq, and permanent magnet flux linkage Ψf), estimates the real-time electromagnetic torque T_est(t) output by the servo motor at the current moment through real-time calculation (e.g., using a torque observer algorithm based on motor equations). The aforementioned currents I_u(t), I_v(t), I_w(t), actual mechanical angle θ_m(t), and estimated torque T_est(t) together constitute the real-time acquired operating parameters of the servo motor.

[0094] This step acquires the most direct electrical and mechanical state quantities of the drive core (servo motor) in a comprehensive and high-frequency manner while the equipment is performing its actions. These operating parameters are the most original and realistic physical quantities reflecting the equipment's load, health status, and energy consumption, providing an indispensable data foundation for subsequent status monitoring, fault diagnosis, and performance optimization, thus achieving "transparency" in the equipment's operating status.

[0095] S106: The embedded servo driver uploads the operating parameters to the upper-level monitoring system through its communication interface.

[0096] Specifically, the communication interface module (PROFINET interface) of the embedded servo drive periodically (e.g., every 10 milliseconds) performs a data upload task. The communication interface module reads the latest set of operating parameters from the shared memory of the data acquisition unit, including three-phase currents I_u, I_v, I_w, actual mechanical angle θ_m, and estimated torque T_est. Following the PROFINET IO device protocol specification, the communication interface module fills these operating parameters into a specific output data frame, adding a serial number and timestamp. Subsequently, the communication interface module transmits the encapsulated data frame as an electrical signal to the industrial Ethernet network via the Ethernet PHY chip at the physical layer. This data frame is transmitted via a network switch to the upper-level monitoring system, which acts as the PROFINET IO controller. The communication processing unit of the upper-level monitoring system receives and parses the data frame, extracts the operating parameters contained within, and updates them to its real-time database and the corresponding display elements in the graphical human-machine interface for monitoring, recording, and analysis by maintenance personnel.

[0097] This step establishes a data uplink channel from the device edge to the control center, transmitting the underlying operating parameters collected in step S105 to the remote monitoring center in real time and reliably. This enables the device's operating status to be centrally visualized and recorded remotely, which is a prerequisite for realizing remote device monitoring, historical data backtracking, and centralized intelligent analysis, completing a key leap from local intelligence to cloud-edge collaboration.

[0098] Specific implementation examples of optional fault prediction steps:

[0099] After the data acquisition unit collects the operating parameters of the servo motor in real time, the monitoring method also includes a fault prediction step. This step is executed by the fault prediction module of the embedded servo driver. Based on the operating parameters collected by the data acquisition unit, the fault prediction module mainly executes two fault prediction algorithms. The first is a threshold comparison algorithm: the fault prediction module compares the electromagnetic torque T_est(t) estimated in real time by the data acquisition unit with a preset torque protection threshold T_threshold_alert (e.g., 130% of the rated torque). If T_est(t) > T_threshold_alert for N consecutive sampling periods (e.g., N=10, corresponding to 1 millisecond), the fault prediction module immediately generates an "overload warning" signal. The second is a trend analysis algorithm: after each "closing" action is completed and the servo motor enters the steady-state holding phase, the fault prediction module records the average value T_steady(k) of the estimated torque at that moment, where k represents the k-th operation. The fault prediction module maintains a torque history queue of length M (e.g., M=100). After each new T_steady(k) is recorded, the fault prediction module performs a linear regression analysis on all data in the queue to calculate the slope of torque change with the number of operations. If the calculated slope is greater than a preset positive slope threshold S_threshold, the fault prediction module generates a "torque slow increase warning" signal, indicating that mechanical friction may be increasing. The generated warning signal is appended with a timestamp and type identifier and uploaded to the upper-level monitoring system along with the operating parameters via the communication interface module.

[0100] Optionally, the specific implementation steps of the trend analysis algorithm are as follows:

[0101] Step a: Data preparation. After each "closing" or "opening" action is completed and the servo motor enters the steady-state holding phase, the fault prediction module records the average value of the estimated electromagnetic torque T_est(t) within a fixed time window (e.g., 100 milliseconds) before and after that moment, which is denoted as the steady-state torque value T_steady(k) for this operation, where k is the operation sequence number.

[0102] Step b: Historical queue maintenance. The fault prediction module maintains a first-in, first-out queue of length M to store the steady-state torque values ​​T_steady(k) of the most recent M valid operations. The queue length M can be set according to the equipment maintenance cycle and experience; for example, M=100 represents analyzing the most recent 100 operations.

[0103] Step c: Trend slope calculation. Each time a new T_steady(k) is added to the queue, the fault prediction module performs a univariate linear regression analysis on all M data points in the queue. The operation sequence number k (or time sequence number) is used as the independent variable X, and the corresponding steady-state torque value T_steady(k) is used as the dependent variable Y. The least squares method is used to fit the linear regression equation Y = Slope * X + Intercept. The calculated regression coefficient Slope represents the average trend of steady-state torque with the number of operations. The formula for calculating Slope is:

[0104] Slope = [ M*Σ(XY) - ΣX*ΣY ] / [ M*Σ(X 2 ) - (ΣX) 2 ].

[0105] Step d: Anomaly Detection and Early Warning. The calculated slope (Slope) is compared with a preset positive slope threshold (S_threshold). The slope threshold (S_threshold) is set based on statistical results of long-term operation data of the same model of equipment under normal and healthy conditions; for example, it can be set to 0.1 N·m / operation. This threshold indicates that a slow, natural increase in torque is permissible, but exceeding this value indicates an anomaly. If Slope > S_threshold, the fault prediction module determines that the torque shows an abnormal upward trend and immediately generates a "torque slow increase early warning" signal. This signal includes information such as the warning type, the current slope value, and the calculation timestamp.

[0106] This fault prediction step gives the system preliminary intelligent diagnostic capabilities. By monitoring and analyzing the thresholds and trends of real-time operating parameters (especially torque), it can identify abnormal signs in the early stages of equipment performance degradation or minor mechanical jamming and issue early warnings. This transforms the maintenance mode from "post-fault repair" to "early warning maintenance," significantly improving equipment availability and safety.

[0107] Specific implementation examples of optional adaptive control steps:

[0108] Before or simultaneously with the motion control module executing pre-stored motion logic and generating motor control commands based on operation instructions, the monitoring method also includes an adaptive control step. This step is executed by the adaptive control module of the embedded servo driver. The adaptive control module dynamically adjusts the control parameters of the motion control module based on the operating parameters or environmental parameters collected by the data acquisition unit. For example, the adaptive control module monitors the winding temperature Temp_winding, provided by the data acquisition unit and measured by a thermistor installed on the servo motor windings. The adaptive control module internally stores a temperature-current relationship table, which defines the maximum allowable quadrature-axis current I_q_max corresponding to different winding temperature ranges. When the adaptive control module detects that the current winding temperature Temp_winding falls into a certain temperature range (e.g., 70℃ ≤ Temp_winding < 80℃), it looks up the table to obtain the corresponding I_q_max value. Then, the adaptive control module sends this I_q_max value to the motion control module as a new basis for the output limiting of the internal PID controller when generating motor control commands, or directly as a basis for correcting the torque limit value Torque_limit. In this way, when the motor temperature rises, the system will automatically reduce the maximum allowable output torque to prevent the motor from being damaged due to overheating, while ensuring control performance that allows for continuous operation within a safe temperature rise range.

[0109] This adaptive control step endows the control system with a certain degree of environmental adaptability and self-protection capability. By dynamically adjusting key control parameters (such as current / torque limits) based on real-time monitored parameters (such as temperature), the system can adapt to changes in operating conditions, optimize control performance while ensuring equipment safety, and improve the robustness and reliability of the system under different operating conditions.

[0110] Those skilled in the art will understand that all or some of the steps, systems, and functional modules / units in the methods disclosed above can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0111] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0112] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A digital control and monitoring system for power equipment, characterized in that, The system includes: An embedded servo driver, which integrates a motion control module, a motor drive module, a communication interface, and a data acquisition unit. A servo motor, which is electrically connected to the embedded servo driver; A simplified mechanical transmission mechanism is provided, which connects the output shaft of the servo motor to the actuating component of the power equipment. A higher-level monitoring system is connected to the communication interface of the embedded servo driver via a communication network; The motion control module is used to execute pre-stored motion logic and send control commands to the motor drive module. The motor drive module is used to drive the servo motor according to the control command; The data acquisition unit is used to collect the operating parameters of the servo motor in real time; The embedded servo driver is used to upload the operating parameters to the upper-level monitoring system through the communication interface, and to receive operation instructions from the upper-level monitoring system.

2. The digital control and monitoring system for power equipment according to claim 1, characterized in that, The embedded servo driver also integrates a fault prediction module, which is connected to the data acquisition unit and is used to execute a fault prediction algorithm based on the operating parameters.

3. The digital control and monitoring system for power equipment according to claim 1, characterized in that, The simplified mechanical transmission mechanism is a direct coupling or a single-stage reducer.

4. The digital control and monitoring system for power equipment according to claim 1, characterized in that, The monitoring system also includes a digital status sensor group, which is installed on the device body of the power equipment. The digital status sensor group is used to collect status signals of the device body and send the status signals to the embedded servo driver.

5. The digital control and monitoring system for power equipment according to claim 1, characterized in that, The embedded servo driver also integrates an adaptive control module, which is used to adjust the control parameters of the motion control module according to the operating parameters or environmental parameters collected by the data acquisition unit.

6. The digital control and monitoring system for power equipment according to claim 1, characterized in that, The communication interface is an industrial fieldbus communication interface or an industrial Ethernet communication interface, and the communication network is a corresponding industrial fieldbus network or industrial Ethernet network.

7. The digital control and monitoring system for power equipment according to claim 4, characterized in that, The embedded servo driver is also provided with an auxiliary signal input interface, the digital status sensor group is connected to the auxiliary signal input interface, and the data acquisition unit is also used to acquire the status signal through the auxiliary signal input interface.

8. A method for digital control and monitoring of power equipment, characterized in that, The monitoring method is applied to the monitoring system according to any one of claims 1-7, and the monitoring method includes: Receive operation instructions from the superior monitoring system; The motion control module of the embedded servo driver executes the pre-stored motion logic according to the operation instructions and generates motor control instructions; The motor drive module of the embedded servo driver drives the servo motor to operate according to the motor control command; The servo motor and simplified mechanical transmission mechanism drive the actuators of the power equipment to move. During the operation of the servo motor, the data acquisition unit of the embedded servo driver collects the operating parameters of the servo motor in real time; The embedded servo driver uploads the operating parameters to the upper-level monitoring system through its communication interface.

9. The monitoring method according to claim 8, characterized in that, After the data acquisition unit acquires the operating parameters of the servo motor in real time, the monitoring method further includes a fault prediction step, which includes: The fault prediction module of the embedded servo driver executes a fault prediction algorithm based on the operating parameters collected by the data acquisition unit. When the fault prediction algorithm determines that the operating status is abnormal, it generates an early warning signal.

10. The monitoring method according to claim 8, characterized in that, Before or simultaneously with the motion control module executing pre-stored motion logic and generating motor control commands according to the operation instructions, the monitoring method further includes an adaptive control step, which includes: The adaptive control module of the embedded servo driver adjusts the control parameters of the motion control module based on the operating parameters or environmental parameters collected by the data acquisition unit.

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