Support response calibration and phased adaptive pressure compensation control method for heavy cutting

Abstract

The present application relates to heavy load processing equipment automatic control technical field, especially to a kind of heavy load cutting's support response calibration and phased adaptive pressure compensation control method, comprising: obtaining the reference ranging value of all ranging points, dividing several cutting zones, establishing ranging point set, freezing initial safety state;Each support hydraulic cylinder is calibrated in turn to obtain support response table, and the compatible calibration of double-cylinder parallel compatibility is carried out to two support hydraulic cylinders compatible in response direction in the same cutting zone to obtain parallel compatibility record;Active support set is obtained, and a plurality of single-cylinder or double-cylinder candidate pressure compensation groups meeting parallel compatibility record are formed in combination with support response table;The pressure command level of last verified pressure group is taken as starting point by controller, and prediction residual is calculated, selected candidate pressure compensation group is filtered out to output pressure compensation command, and the ranging point of current cutting zone is re-measured, and re-measurement is passed to be written into verified pressure group.The present application reduces the non-associated support adjustment of each support hydraulic cylinder, and reduces pressure compensation round.

Description

Technical Field

[0001] This invention relates to the field of automatic control technology for heavy-duty processing equipment, and in particular to a method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting. Background Technology

[0002] During the cutting process, the workpiece is affected by its own weight, cutting load, and cutting vibration, which may cause local sagging near the cutting zone. Existing equipment usually has multiple supporting hydraulic cylinders, but the actual range of action and response lag of each supporting hydraulic cylinder are different for different workpieces, different cutting positions, and different measuring points. If multiple hydraulic cylinders are adjusted simultaneously according to the overall load, individual measuring values, or empirical pressure, the pressure compensation may be applied to unrelated areas, or the next pressure compensation may continue to accumulate before the previous pressure compensation has stabilized.

[0003] The linkage between laser ranging and hydraulic support is a known engineering combination. However, existing solutions typically use target height or overall balance as the control result, failing to establish the measured response relationship of each support hydraulic cylinder to the current workpiece ranging point set, and also failing to use the sag retest and vibration verification after each pressure replenishment as the entry conditions for the next pressure replenishment. Therefore, it is necessary to organize single-cylinder calibration, cutting zone association, discrete pressure levels, cylinder-by-cylinder retest confirmation, and verified state rollback into an implementable control chain without changing the existing mechanical structure, sensors, and hydraulic circuits. Summary of the Invention

[0004] This invention aims to at least solve one of the technical problems existing in related technologies. To this end, this invention provides a support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting, which solves the technical problem of lag in pressure compensation operation response in the prior art, and improves the stability and positional accuracy of workpiece support during the cutting process.

[0005] This invention provides a method for calibration of support response and staged adaptive pressure compensation control for heavy-duty cutting, comprising the following steps: Heavy-duty cutting equipment is used, including a laser rangefinder, vibration sensor, cutting assembly, multiple support assemblies and controller, the support assemblies having support hydraulic cylinders; Before the cutting component starts cutting, the reference distance values ​​of all distance measurement points within the coverage area of ​​the laser rangefinder are obtained. The workpiece is divided into several cutting areas according to the position to be cut, and a set of distance measurement points is established for each cutting area. The initial safety state is frozen, including the pressure command level, allowable output range and allowable vibration state threshold of each supporting hydraulic cylinder. Each supporting hydraulic cylinder was individually calibrated to obtain a support response table; two supporting hydraulic cylinders with compatible response directions in the same cutting zone were subjected to dual-cylinder parallel compatibility calibration to obtain a parallel compatibility record. Start the cutting assembly, and form an active support set by the support hydraulic cylinders that generate effective distance changes for each cutting zone according to the support response table; form a number of candidate pressure replenishment groups according to the support response table and the active support set, which can be a single-cylinder candidate pressure replenishment group or a double-cylinder candidate pressure replenishment group that conforms to the parallel compatibility record; The controller starts with the pressure command level in the last verified pressure group recorded, and then calculates the predicted residual in combination with the candidate pressure replenishment group. Based on the predicted residual, the selected candidate pressure replenishment group is selected from the dual-cylinder candidate pressure replenishment group. The pressure replenishment command is output according to the selected candidate pressure replenishment group so that the corresponding support hydraulic cylinder performs pressure replenishment operation. Then, the distance measurement point of the current cutting area is re-measured. If the re-measurement is successful, it is written into the verified pressure group. If it fails, the original verified pressure group is maintained and downgraded to the single-cylinder candidate pressure replenishment group.

[0006] Further, obtaining the reference ranging values ​​for all ranging points within the coverage area of ​​the laser rangefinder includes the following steps: The laser rangefinder performs multiple stationary distance measurements at multiple distance measurement points. When the difference between two consecutive distance measurements at the same distance measurement point is less than or equal to the allowable repeatability difference, the result of the last stationary distance measurement is recorded as the reference distance measurement value, and the corresponding distance measurement point is marked as a valid distance measurement point. When the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the laser rangefinder rescans; after the laser rangefinder rescans, if the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the corresponding distance measurement point is marked as an invalid distance measurement point.

[0007] Furthermore, after freezing the initial safety state, the cutting component is only allowed to update the verified pressure group when the retest passes during cutting.

[0008] Furthermore, the support response table includes the support hydraulic cylinder identifier, the ranging point where an effective ranging change occurs, the ranging change direction of each ranging point, the response coefficient, the response stabilization time, and the order of response contribution; The order of response contribution is as follows: the hydraulic cylinder with the larger absolute value of the response coefficient is ranked first; if the absolute values ​​of the response coefficients are the same, the one with the shorter response settling time is ranked first.

[0009] Furthermore, each supporting hydraulic cylinder is calibrated individually to obtain a support response table, including the following steps: The controller acquires the current safe pressure control command and pressure output threshold of the support hydraulic cylinder to be calibrated. Based on the current safe pressure control command and pressure command level, the controller determines the pressure increment, and the support hydraulic cylinder gradually issues calibration commands according to the pressure increment. After the supporting hydraulic cylinder outputs a pressure increment each time according to the calibration command, the laser rangefinder collects the calibration distance values ​​of all distance measurement points. Based on the calibration distance values ​​and the reference distance values, the distance change of each distance measurement point is calculated. When the distance change exceeds the allowable repeatability difference, it is determined that the corresponding distance measurement point has a valid distance change, and the direction and amount of distance change are recorded. For the ranging point that produces an effective ranging change, the response coefficient is calculated based on the ranging change and the pressure increment; If the change in distance measurement at the same distance measurement point is less than the allowable repeatability difference in two consecutive measurements, record the time elapsed from the issuance of the calibration command to the moment when the change in distance measurement at the corresponding distance measurement point does not exceed the allowable repeatability difference, and use this time as the response stabilization time of the support hydraulic cylinder. When ranging loss, continuous fluctuation of ranging change, or abnormal vibration occurs, the single-cylinder calibration is determined to be invalid, and the support hydraulic cylinder is restored to the pressure before the single-cylinder calibration was performed.

[0010] Furthermore, the parallel compatibility record includes the identifier of the paired support hydraulic cylinder, the direction of pressure increment, and the pressure command level.

[0011] Furthermore, a parallel compatibility calibration is performed on two supporting hydraulic cylinders with compatible response directions within the same cutting zone to obtain a parallel compatibility record, including the following steps: After completing the single-cylinder calibration, select two supporting hydraulic cylinders that are in the same cutting area, have the same effective distance measuring point, and have the same direction of distance measurement change. The controller simultaneously outputs pressure command levels to the two selected support hydraulic cylinders. After the support hydraulic cylinder with the longer response stabilization time completes its response, the laser rangefinder collects the measured changes of the two cylinders at each ranging point. When the difference between the measured change of the two cylinders and the calibrated change of each of the two supporting hydraulic cylinders is less than or equal to the allowable repeatability difference, and the vibration state is within the allowable vibration state threshold, it is recorded as a parallel compatible record.

[0012] Furthermore, forming several candidate pressure replenishment groups includes the following steps: After the cutting component enters a cutting zone, according to the support response table, the support hydraulic cylinders that produce effective distance changes in the distance measurement point set of the corresponding cutting zone are added to the active support set, and the support hydraulic cylinders that do not produce effective distance changes do not participate in the pressure replenishment operation of the corresponding cutting zone. If the active support set is empty, the controller will not output a pressure replenishment command, but will maintain the verified pressure group and issue an alarm signal; The laser rangefinder collects the current distance measurement value of each distance measurement point in the corresponding cutting area in real time, and determines whether the distance measurement is valid based on the current distance measurement value and the reference distance measurement value. Vibration sensors monitor the vibration state of the workpiece in real time; When the ranging is effective, the vibration state is within the allowable vibration state threshold, and the active support set is not empty, the controller forms a candidate pressure compensation group.

[0013] Further, the selected candidate pressure replenishment groups are screened based on the predicted residuals, including the following steps: The controller calculates the predicted residuals of each candidate pressure replenishment group for each ranging point in the current cutting area; The formula for calculating the prediction residual is as follows: in, The predicted residual of the j-th ranging point after the application of candidate pressure group G; For the j-th ranging point, calculate the current local sag residual relative to the reference ranging value before performing candidate pressure compensation; The response coefficient of the i-th supporting hydraulic cylinder to the j-th measuring point, obtained from single-cylinder calibration; is the pressure command level increment of the i-th supporting hydraulic cylinder in the candidate pressure replenishment group G; G is a single-cylinder candidate pressure replenishment group or a dual-cylinder candidate pressure replenishment group with parallel compatibility records; Candidate pressure compensation groups that do not meet the allowable output range are eliminated, and then candidate pressure compensation groups that do not meet the pressure compensation direction setting conditions are eliminated. The remaining candidate pressure compensation groups form a set of candidate pressure compensation groups. The conditions for setting the pressure compensation direction are: the predicted residual of each measuring point corresponding to several candidate pressure compensation groups is greater than or equal to the current local sag residual; the workpiece change direction predicted by each candidate pressure compensation group exceeds the reference direction; and the predicted distance change exceeds the allowable repeatability difference. The candidate pressure replenishment groups are selected based on the candidate pressure replenishment group selection formula; The formula for selecting the candidate pressure replenishment group is: in, The selected candidate pressure relief group; Candidate pressure replenishment group; This is the set of candidate pressure replenishment groups. This indicates the number of distance measurement points.

[0014] Furthermore, based on the selected candidate pressure replenishment group, a pressure replenishment command is output to cause the corresponding support hydraulic cylinder to perform a pressure replenishment operation, thereby re-measuring the measuring point of the current cutting area. If the re-measuring passes, it is written into the verified pressure group; if it fails, the original verified pressure group is retained and downgraded to a single-cylinder candidate pressure replenishment group. This includes the following steps: Before performing the pressure replenishment operation, the controller calculates the leading local droop residual of each measuring point in the cutting area to be cut, and confirms the maximum leading local droop residual among multiple leading local droop residuals. After performing the pressure replenishment operation, the controller calculates the local droop residual of each measuring point in the cutting area after the cutting operation, and confirms the maximum local droop residual of multiple local droop residuals. The conditions for passing the retest are: the maximum local droop residual at the rear is less than the maximum local droop residual at the front, no reverse change exceeding the allowable repeatability difference occurs at any distance measurement point, and the vibration state is within the allowable vibration state threshold. If the retest fails, the selected candidate pressure replenishment group will not be written into the verified pressure group, the pressure replenishment operation of the subsequent dual-cylinder candidate pressure replenishment group will be frozen and restored to the verified pressure group before the pressure replenishment operation was performed, and it will be downgraded to a single-cylinder candidate pressure replenishment group.

[0015] The above-described one or more technical solutions in the embodiments of the present invention have at least one of the following technical effects: By calibrating each support hydraulic cylinder individually, a support response table was established, consisting of support hydraulic cylinder identification, distance measurement point response relationship, response coefficient, and response stabilization time. This table accurately reflects the actual support effect of each support hydraulic cylinder on different distance measurement points, solving the problem of inaccurate pressure compensation caused by relying solely on experience or overall load adjustment in existing technologies. This allows the pressure compensation force to be precisely applied to the cutting area that needs support.

[0016] A phased adaptive pressure compensation control strategy is adopted, which gradually increases the pressure compensation starting from the last recorded verified pressure set. After each pressure compensation, a droop retest and vibration check are performed. Only if the retest passes is the verified pressure set updated; otherwise, the original verified pressure set is maintained. This avoids the accumulation of the next pressure compensation before the previous pressure compensation has stabilized, solves the technical problems of lag response and error accumulation in pressure compensation operation, and improves the dynamic stability of workpiece support during the cutting process.

[0017] By performing dual-cylinder parallel compatibility calibration on two supporting hydraulic cylinders with compatible response directions within the same cutting zone, and only including dual-cylinder combinations that pass compatibility verification into the candidate pressure replenishment group, the actual effect of dual-cylinder parallel pressure replenishment can be known in advance. This avoids excessive or insufficient support caused by excessive deviation from expectations after the superposition of the responses of the two hydraulic cylinders, and ensures the predictability and stability of combined pressure replenishment.

[0018] The pressure replenishment effect of each candidate pressure replenishment group is predicted by using a residual calculation formula. Candidate pressure replenishment groups are then selected based on conditions set according to the pressure replenishment direction. This ensures that the selected pressure replenishment group reduces local sag residuals and avoids ineffective pressure replenishment adjustments. Simultaneously, if a retest fails after pressure replenishment, subsequent dual-cylinder pressure replenishment is automatically frozen and restored to the verified pressure group before pressure replenishment. This achieves automatic rollback of ineffective adjustments and improves the fault tolerance of the cutting process.

[0019] It integrates vibration sensors to monitor the workpiece vibration status in real time during the cutting process. Whether the vibration status is within the allowable threshold is used as a necessary condition for pressure compensation candidate and retesting. When the vibration exceeds the threshold, pressure compensation is paused in time and the abnormality is recorded. This can avoid the decrease in cutting accuracy caused by excessive vibration and improve the stability and safety of the cutting process.

[0020] This invention does not require changes to the existing mechanical structure, sensor configuration, and hydraulic circuit of heavy-duty cutting equipment. It can improve support accuracy simply by optimizing the control process, adapting to different workpiece specifications and different cutting paths. It has good compatibility and practicality, and reduces the cost of equipment modification and upgrade.

[0021] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 This is a flowchart of a support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting provided by the present invention.

[0024] Figure 2 This is a schematic diagram of a heavy-duty cutting equipment.

[0025] Figure label: 1. Cutting assembly; 2. Support assembly; 3. Workpiece; 4. Controller. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. The following embodiments are used to illustrate this invention but should not be used to limit the scope of this invention.

[0027] The following is combined with Figure 1 and Figure 2 The present invention describes a method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting, comprising the following steps: The heavy-duty cutting equipment includes a laser rangefinder, a vibration sensor, a cutting assembly 1, multiple support assemblies 2 and a controller 4. The support assemblies have support hydraulic cylinders, the laser rangefinder is set on the top surface of the base, and the vibration sensor can be set on the support platform of the support assembly. Before cutting, the cutting component 1 acquires the reference distance values ​​of all distance measurement points within the coverage area of ​​the laser rangefinder, divides the workpiece 3 into several cutting areas according to the position to be cut, and establishes a set of distance measurement points for each cutting area; freezes the initial safety state, including the pressure command level, allowable output range and allowable vibration state threshold of each supporting hydraulic cylinder; Each supporting hydraulic cylinder was individually calibrated to obtain a support response table; two supporting hydraulic cylinders with compatible response directions in the same cutting zone were subjected to dual-cylinder parallel compatibility calibration to obtain a parallel compatibility record. Start the cutting assembly, and form an active support set by the support hydraulic cylinders that generate effective distance changes for each cutting zone according to the support response table; form a number of candidate pressure replenishment groups according to the support response table and the active support set, which can be a single-cylinder candidate pressure replenishment group or a double-cylinder candidate pressure replenishment group that conforms to the parallel compatibility record; The controller starts with the pressure command level in the last verified pressure group recorded, and then calculates the predicted residual in combination with the candidate pressure replenishment group. Based on the predicted residual, the selected candidate pressure replenishment group is selected from the dual-cylinder candidate pressure replenishment group. The pressure replenishment command is output according to the selected candidate pressure replenishment group so that the corresponding support hydraulic cylinder performs pressure replenishment operation. Then, the distance measurement point of the current cutting area is re-measured. If the re-measurement is successful, it is written into the verified pressure group. If it fails, the original verified pressure group is maintained and downgraded to the single-cylinder candidate pressure replenishment group.

[0028] Further, obtaining the reference ranging values ​​for all ranging points within the coverage area of ​​the laser rangefinder includes the following steps: The laser rangefinder performs multiple stationary distance measurements at multiple distance measurement points. When the difference between two consecutive distance measurements at the same distance measurement point is less than or equal to the allowable repeatability difference, the result of the last stationary distance measurement is recorded as the reference distance measurement value, and the corresponding distance measurement point is marked as a valid distance measurement point. When the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the laser rangefinder rescans; after the laser rangefinder rescans, if the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the corresponding distance measurement point is marked as an invalid distance measurement point.

[0029] Preferably, invalid ranging points are not involved in the subsequent pressure compensation judgment and support adjustment process. The controller directly records the abnormality at the position. After all ranging points are scanned and marked, the reference ranging values ​​of all valid ranging points are integrated and stored to provide a reference for real-time ranging value comparison and support pressure adjustment in subsequent cutting operations.

[0030] Furthermore, after freezing the initial safety state, the cutting component is only allowed to update the verified pressure group when the retest passes during cutting. If the retest result shows that the distance deviation corresponding to the current support pressure exceeds the allowable range, the system calls the pre-stored reference response coefficient of the corresponding distance point to correct the support pressure until the deviation meets the requirements, and then maintains the pressure output to ensure the processing accuracy and support stability of heavy-duty cutting operations.

[0031] Furthermore, the support response table includes the support hydraulic cylinder identifier, the ranging point where an effective ranging change occurs, the ranging change direction of each ranging point, the response coefficient, the response stabilization time, and the order of response contribution; The order of response contribution is as follows: the hydraulic cylinder with the larger absolute value of the response coefficient is ranked first; if the absolute values ​​of the response coefficients are the same, the one with the shorter response settling time is ranked first.

[0032] Ideally, the response contribution sequence avoids the superposition error of support deformation caused by simultaneous adjustment of multiple cylinders, thereby improving the accuracy and stability of pressure compensation control.

[0033] Furthermore, each supporting hydraulic cylinder is calibrated individually to obtain a support response table, including the following steps: The controller acquires the current safe pressure control command and pressure output threshold of the support hydraulic cylinder to be calibrated. Based on the current safe pressure control command and pressure command level, the controller determines the pressure increment, and the support hydraulic cylinder gradually issues calibration commands according to the pressure increment. After the supporting hydraulic cylinder outputs a pressure increment each time according to the calibration command, the laser rangefinder collects the calibration distance values ​​of all distance measurement points. Based on the calibration distance values ​​and the reference distance values, the distance change of each distance measurement point is calculated. When the distance change exceeds the allowable repeatability difference, it is determined that the corresponding distance measurement point has a valid distance change, and the direction and amount of distance change are recorded. For the ranging point that produces an effective ranging change, the response coefficient is calculated based on the ranging change and the pressure increment; If the change in distance measurement at the same distance measurement point is less than the allowable repeatability difference in two consecutive measurements, record the time elapsed from the issuance of the calibration command to the moment when the change in distance measurement at the corresponding distance measurement point does not exceed the allowable repeatability difference, and use this time as the response stabilization time of the support hydraulic cylinder. When ranging loss, continuous fluctuation of ranging change, or abnormal vibration occurs, the single-cylinder calibration is determined to be invalid, and the support hydraulic cylinder is restored to the pressure before the single-cylinder calibration was performed.

[0034] Ideally, after completing the single-cylinder calibration of all supporting hydraulic cylinders, all valid calibration results are summarized and organized to generate a support response table that matches the current workpiece and working conditions, providing a data basis for the subsequent formation of candidate pressure replenishment groups.

[0035] Furthermore, the parallel compatibility record includes the identifier of the paired support hydraulic cylinder, the direction of pressure increment, and the pressure command level.

[0036] Specifically, the parallel compatibility calibration of two supporting hydraulic cylinders with compatible response directions in the same cutting zone is performed to obtain a parallel compatibility record, including the following steps: After completing the single-cylinder calibration, select two supporting hydraulic cylinders that are in the same cutting area, have the same effective distance measuring point, and have the same direction of distance measurement change. The controller simultaneously outputs pressure command levels to the two selected support hydraulic cylinders. After the support hydraulic cylinder with the longer response stabilization time completes its response, the laser rangefinder collects the measured changes of the two cylinders at each ranging point. When the difference between the measured change of the two cylinders and the calibrated change of each of the two supporting hydraulic cylinders is less than or equal to the allowable repeatability difference, and the vibration state is within the allowable vibration state threshold, it is recorded as a parallel compatible record.

[0037] Preferably, if the difference between the measured change of the two cylinders and the calibrated change of each of the two supporting hydraulic cylinders exceeds the allowable repeatability difference or the vibration state exceeds the allowable threshold, it indicates that there is hydraulic coupling interference when the two supporting hydraulic cylinders operate simultaneously. The combination of the two supporting hydraulic cylinders is recorded as parallel incompatible, and the control command output for simultaneous operation is avoided in the subsequent cutting and pressure compensation control.

[0038] Furthermore, forming several candidate pressure replenishment groups includes the following steps: After the cutting component enters a cutting zone, according to the support response table, the support hydraulic cylinders that produce effective distance changes in the distance measurement point set of the corresponding cutting zone are added to the active support set, and the support hydraulic cylinders that do not produce effective distance changes do not participate in the pressure replenishment operation of the corresponding cutting zone. If the active support set is empty, the controller will not output a pressure replenishment command, but will maintain the verified pressure group and issue an alarm signal; The laser rangefinder collects the current distance measurement value of each distance measurement point in the corresponding cutting area in real time, and determines whether the distance measurement is valid based on the current distance measurement value and the reference distance measurement value. Vibration sensors monitor the vibration state of the workpiece in real time; When the ranging is effective, the vibration state is within the allowable vibration state threshold, and the active support set is not empty, the controller forms a candidate pressure compensation group.

[0039] Preferably, the candidate pressure replenishment group provides a decision-making basis for subsequent pressure replenishment operations. When performing pressure replenishment operations, dual-cylinder candidate pressure replenishment groups are selected first. After selecting a dual-cylinder candidate pressure replenishment group from multiple dual-cylinder candidate pressure replenishment groups and verifying that the group does not have a parallel incompatibility mark, it is determined as the execution group for this pressure replenishment operation, and pressure replenishment commands are output to the two supporting hydraulic cylinders of the group. If all dual-cylinder candidate pressure replenishment groups have parallel incompatibility marks, the supporting hydraulic cylinder with the largest difference from the current supporting pressure is selected from the single-cylinder candidate pressure replenishment group as the pressure replenishment execution object, and a single-cylinder pressure replenishment command is output. In this way, while ensuring pressure replenishment efficiency, the support instability problem caused by hydraulic coupling interference is avoided to the greatest extent, and the support stability of the workpiece is guaranteed during the cutting process.

[0040] Preferably, the controller takes the pressure control command of each support hydraulic cylinder in the most recently verified pressure group as a starting point, and selects the pressure command level for each support hydraulic cylinder in the pressure increase direction, pressure decrease direction, or holding direction; the increase / decrease direction is determined by the sign of the local droop residual and the response coefficient of the support hydraulic cylinder at the corresponding measuring point. The candidate pressure replenishment group includes only one support hydraulic cylinder, or includes two active hydraulic cylinders with established parallel compatible records and whose candidate pressure increment direction and pressure command level are consistent with the records.

[0041] Further, the selected candidate pressure replenishment groups are screened based on the predicted residuals, including the following steps: The controller calculates the predicted residuals of each candidate pressure replenishment group for each ranging point in the current cutting area; The formula for calculating the prediction residual is as follows: in, The predicted residual of the j-th ranging point after the application of candidate pressure group G; For the j-th ranging point, calculate the current local sag residual relative to the reference ranging value before performing candidate pressure compensation; The response coefficient of the i-th supporting hydraulic cylinder to the j-th measuring point, obtained from single-cylinder calibration; is the pressure command level increment of the i-th supporting hydraulic cylinder in the candidate pressure replenishment group G; G is a single-cylinder candidate pressure replenishment group or a dual-cylinder candidate pressure replenishment group with parallel compatibility records; Candidate pressure compensation groups that do not meet the allowable output range are eliminated, and then candidate pressure compensation groups that do not meet the pressure compensation direction setting conditions are eliminated. The remaining candidate pressure compensation groups form a set of candidate pressure compensation groups. The conditions for setting the pressure compensation direction are: the predicted residual of each measuring point corresponding to several candidate pressure compensation groups is greater than or equal to the current local sag residual; the workpiece change direction predicted by each candidate pressure compensation group exceeds the reference direction; and the predicted distance change exceeds the allowable repeatability difference. The candidate pressure replenishment groups are selected based on the candidate pressure replenishment group selection formula; The formula for selecting the candidate pressure replenishment group is: in, The selected candidate pressure relief group; Candidate pressure replenishment group; This is the set of candidate pressure replenishment groups. This indicates the number of distance measurement points.

[0042] Preferably, the reference direction is the normal direction of the workpiece surface before cutting.

[0043] Preferably, the controller first eliminates candidate pressure compensation groups where the pressure control command of any candidate pressure group exceeds the allowable output threshold of the supporting hydraulic cylinder; then it eliminates candidate pressure compensation groups where the predicted residual at any measuring point is not lower than the local droop residual, or where the predicted change of the workpiece after applying the pressure control command crosses the reference direction and exceeds the allowable repeatability difference. For the retained candidate pressure compensation groups, the controller determines the selection value of the candidate pressure compensation group according to the candidate pressure compensation group selection formula, first selecting the candidate pressure compensation group with the smaller maximum predicted residual; when the maximum predicted residuals are the same, the candidate pressure compensation group with the smaller sum of the absolute values ​​of the candidate pressure increments of each supporting hydraulic cylinder is selected. If there are no retained candidate pressure compensation groups, the controller does not output parallel pressure compensation, but retains the verified pressure group.

[0044] Furthermore, based on the selected candidate pressure replenishment group, a pressure replenishment command is output to cause the corresponding support hydraulic cylinder to perform a pressure replenishment operation, thereby re-measuring the measuring point of the current cutting area. If the re-measuring passes, it is written into the verified pressure group; if it fails, the original verified pressure group is retained and downgraded to a single-cylinder candidate pressure replenishment group. This includes the following steps: Before performing the pressure replenishment operation, the controller calculates the leading local droop residual of each measuring point in the cutting area to be cut, and confirms the maximum leading local droop residual among multiple leading local droop residuals. After performing the pressure replenishment operation, the controller calculates the local droop residual of each measuring point in the cutting area after the cutting operation, and confirms the maximum local droop residual of multiple local droop residuals. The conditions for passing the retest are: the maximum local droop residual at the rear is less than the maximum local droop residual at the front, no reverse change exceeding the allowable repeatability difference occurs at any distance measurement point, and the vibration state is within the allowable vibration state threshold. If the retest fails, the selected candidate pressure replenishment group will not be written into the verified pressure group, the pressure replenishment operation of the subsequent dual-cylinder candidate pressure replenishment group will be frozen and restored to the verified pressure group before the pressure replenishment operation was performed, and it will be downgraded to a single-cylinder candidate pressure replenishment group.

[0045] Preferably, the controller simultaneously sends the control commands of each candidate pressure replenishment group within the selected candidate pressure replenishment group to the control interface of the corresponding supporting hydraulic cylinder, and waits for the longest response stabilization time in the selected candidate pressure replenishment group before re-acquiring the set of ranging points and vibration status of the current cutting area. If the maximum local droop residual measured again is lower than the maximum local droop residual before execution, no ranging point has undergone a reverse change exceeding the allowable repeatability difference, and the vibration status is within the allowable vibration status threshold, then the pressure control commands of the selected candidate pressure replenishment group are written into the verified pressure group. The verified pressure group includes the current pressure control commands of each supporting hydraulic cylinder and their verification status. It is the unique starting state of the next candidate pressure replenishment group and also the controlled pressure state that can be called when switching cutting areas.

[0046] If the selected candidate pressure replenishment group fails the retest, the vibration state becomes unstable, or the ranging data is invalid, the controller will not write the selected candidate pressure replenishment group and will freeze subsequent parallel candidate pressure replenishment actions. The controller will retain the most recently verified pressure group before this action; when the corresponding support hydraulic cylinder interface supports cancellation, the output pressure control command will be restored to the previously recorded pressure control command. After the ranging data and vibration state are restored to validity, the controller will downgrade the candidate pressure replenishment group to a single-cylinder candidate pressure replenishment action according to the response contribution order and retest each cylinder; if the candidate pressure replenishment fails to improve the local sagging residual, the ranging data remains invalid, or there is no active support set after a number of consecutive attempts determined by the safe operation strategy, the controller will output a pause cutting command or an alarm command.

[0047] When the cutting component enters the next cutting zone, the controller re-searches the support response table based on the set of ranging points in that cutting zone and generates a new active support set. The generation of a candidate pressure replenishment group for the next cutting zone is only allowed if the baseline ranging value for the next cutting zone is valid, the support response table is valid, and the currently verified pressure group is valid.

[0048] This method predicts the combined effect of adjacent discrete pressure levels based on the measured response coefficients of the current task, without extrapolating the response coefficients to uncalibrated pressure ranges or directly extrapolating the single-cylinder response to combinations without dual-cylinder parallel compatibility calibration. For different workpiece specifications, support arrangements, or cutting paths, the controller re-executes the reference scan, single-cylinder calibration, and required dual-cylinder parallel compatibility calibration before each cutting task. If a valid reference record, valid support response table, or parallel compatibility record of the target dual cylinders cannot be obtained, the corresponding parallel pressure compensation branch is not entered, and a safe pressure state is maintained, requiring manual verification or pausing the cutting process.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for calibration of support response and staged adaptive pressure compensation control in heavy-duty cutting, characterized in that, Includes the following steps: Heavy-duty cutting equipment is used, including a laser rangefinder, vibration sensor, cutting assembly, multiple support assemblies and controller, the support assemblies having support hydraulic cylinders; Before the cutting component starts cutting, the reference distance values ​​of all distance measurement points within the coverage area of ​​the laser rangefinder are obtained. The workpiece is divided into several cutting areas according to the position to be cut, and a set of distance measurement points is established for each cutting area. The initial safety state is frozen, including the pressure command level, allowable output range and allowable vibration state threshold of each supporting hydraulic cylinder. Each supporting hydraulic cylinder was individually calibrated to obtain a support response table; two supporting hydraulic cylinders with compatible response directions in the same cutting zone were subjected to dual-cylinder parallel compatibility calibration to obtain a parallel compatibility record. Start the cutting assembly, and according to the support response table, form a set of movable supports by the support hydraulic cylinders that generate effective distance changes for each cutting zone; Several candidate pressure replenishment groups are formed based on the support response table and the active support set. The candidate pressure replenishment groups are either single-cylinder candidate pressure replenishment groups or dual-cylinder candidate pressure replenishment groups that conform to the parallel compatibility record. The controller starts with the pressure command level in the last verified pressure group recorded, and then calculates the predicted residual in combination with the candidate pressure replenishment group. Based on the predicted residual, the selected candidate pressure replenishment group is selected from the dual-cylinder candidate pressure replenishment group. The pressure replenishment command is output according to the selected candidate pressure replenishment group so that the corresponding support hydraulic cylinder performs pressure replenishment operation. Then, the distance measurement point of the current cutting area is re-measured. If the re-measurement is successful, it is written into the verified pressure group. If it fails, the original verified pressure group is maintained and downgraded to the single-cylinder candidate pressure replenishment group.

2. The method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting according to claim 1, characterized in that, Obtaining the reference distance values ​​for all distance measuring points within the coverage area of ​​the laser rangefinder includes the following steps: The laser rangefinder performs multiple stationary distance measurements at multiple distance measurement points. When the difference between two consecutive distance measurements at the same distance measurement point is less than or equal to the allowable repeatability difference, the result of the last stationary distance measurement is recorded as the reference distance measurement value, and the corresponding distance measurement point is marked as a valid distance measurement point. When the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the laser rangefinder rescans; after the laser rangefinder rescans, if the difference between two consecutive distance measurements at the same distance measurement point exceeds the allowable repeatability difference, the corresponding distance measurement point is marked as an invalid distance measurement point.

3. The method for support response calibration and staged adaptive pressure compensation control in heavy-duty cutting according to claim 2, characterized in that, After freezing the initial safety state, the cutting component is only allowed to update the verified pressure group when the retest passes during cutting.

4. The support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting according to claim 3, characterized in that, The support response table includes the support hydraulic cylinder identification, the distance measurement point where an effective distance measurement change occurs, the direction of distance measurement change at each distance measurement point, the response coefficient, the response stabilization time, and the order of response contribution. The order of response contribution is as follows: the hydraulic cylinder with the larger absolute value of the response coefficient is ranked first; if the absolute values ​​of the response coefficients are the same, the one with the shorter response settling time is ranked first.

5. The support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting according to claim 4, characterized in that, The support response table is obtained by calibrating each support hydraulic cylinder individually, including the following steps: The controller acquires the current safe pressure control command and pressure output threshold of the support hydraulic cylinder to be calibrated. Based on the current safe pressure control command and pressure command level, the controller determines the pressure increment, and the support hydraulic cylinder gradually issues calibration commands according to the pressure increment. After the supporting hydraulic cylinder outputs a pressure increment each time according to the calibration command, the laser rangefinder collects the calibration distance values ​​of all distance measurement points. Based on the calibration distance values ​​and the reference distance values, the distance change of each distance measurement point is calculated. When the distance change exceeds the allowable repeatability difference, it is determined that the corresponding distance measurement point has a valid distance change, and the direction and amount of distance change are recorded. For the ranging point that produces an effective ranging change, the response coefficient is calculated based on the ranging change and the pressure increment; If the change in distance measurement at the same distance measurement point is less than the allowable repeatability difference in two consecutive measurements, record the time elapsed from the issuance of the calibration command to the moment when the change in distance measurement at the corresponding distance measurement point does not exceed the allowable repeatability difference, and use this time as the response stabilization time of the support hydraulic cylinder. When ranging loss, continuous fluctuation of ranging change, or abnormal vibration occurs, the single-cylinder calibration is determined to be invalid, and the support hydraulic cylinder is restored to the pressure before the single-cylinder calibration was performed.

6. The support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting according to claim 5, characterized in that, The parallel compatibility record includes the identifier of the paired support hydraulic cylinder, the direction of pressure increment, and the pressure command level.

7. The method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting according to claim 6, characterized in that, To obtain a parallel compatibility record, two supporting hydraulic cylinders with compatible response directions within the same cutting zone are subjected to dual-cylinder parallel compatibility calibration, which includes the following steps: After completing the single-cylinder calibration, select two supporting hydraulic cylinders that are in the same cutting area, have the same effective distance measuring point, and have the same direction of distance measurement change. The controller simultaneously outputs pressure command levels to the two selected support hydraulic cylinders. After the support hydraulic cylinder with the longer response stabilization time completes its response, the laser rangefinder collects the measured changes of the two cylinders at each ranging point. When the difference between the measured change of the two cylinders and the calibrated change of each of the two supporting hydraulic cylinders is less than or equal to the allowable repeatability difference, and the vibration state is within the allowable vibration state threshold, it is recorded as a parallel compatible record.

8. The method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting according to claim 7, characterized in that, The process of forming several candidate pressure replenishment groups includes the following steps: After the cutting component enters a cutting zone, according to the support response table, the support hydraulic cylinders that produce effective distance changes in the distance measurement point set of the corresponding cutting zone are added to the active support set, and the support hydraulic cylinders that do not produce effective distance changes do not participate in the pressure replenishment operation of the corresponding cutting zone. If the active support set is empty, the controller will not output a pressure replenishment command, but will maintain the verified pressure group and issue an alarm signal; The laser rangefinder collects the current distance measurement value of each distance measurement point in the corresponding cutting area in real time, and determines whether the distance measurement is valid based on the current distance measurement value and the reference distance measurement value. Vibration sensors monitor the vibration state of the workpiece in real time; When the ranging is effective, the vibration state is within the allowable vibration state threshold, and the active support set is not empty, the controller forms a candidate pressure compensation group.

9. The support response calibration and staged adaptive pressure compensation control method for heavy-duty cutting according to claim 8, characterized in that, The candidate pressure replenishment group is selected based on the predicted residuals, including the following steps: The controller calculates the predicted residuals of each candidate pressure replenishment group for each ranging point in the current cutting area; The formula for calculating the prediction residual is as follows: in, The predicted residual of the j-th ranging point after the application of candidate pressure group G; For the j-th ranging point, calculate the current local sag residual relative to the reference ranging value before performing candidate pressure compensation; The response coefficient of the i-th supporting hydraulic cylinder to the j-th measuring point, obtained from single-cylinder calibration; is the pressure command level increment of the i-th supporting hydraulic cylinder in the candidate pressure replenishment group G; G is a single-cylinder candidate pressure replenishment group or a dual-cylinder candidate pressure replenishment group with parallel compatibility records; Candidate pressure compensation groups that do not meet the allowable output range are eliminated, and then candidate pressure compensation groups that do not meet the pressure compensation direction setting conditions are eliminated. The remaining candidate pressure compensation groups form a set of candidate pressure compensation groups. The conditions for setting the pressure compensation direction are: the predicted residual of each measuring point corresponding to several candidate pressure compensation groups is greater than or equal to the current local sag residual; the workpiece change direction predicted by each candidate pressure compensation group exceeds the reference direction; and the predicted distance change exceeds the allowable repeatability difference. The candidate pressure replenishment groups are selected based on the candidate pressure replenishment group selection formula; The formula for selecting the candidate pressure replenishment group is: in, The selected candidate pressure relief group; Candidate pressure-reinforcing group; This is the set of candidate pressure replenishment groups. This indicates the number of distance measurement points.

10. The method for support response calibration and staged adaptive pressure compensation control for heavy-duty cutting according to claim 1, characterized in that, Based on the selected candidate pressure replenishment group, a pressure replenishment command is output to cause the corresponding support hydraulic cylinder to perform pressure replenishment operation. Then, the measuring point of the current cutting area is re-measured. If the re-measurement passes, it is written into the verified pressure group; if it fails, the original verified pressure group is retained and downgraded to a single-cylinder candidate pressure replenishment group. The process includes the following steps: Before performing the pressure replenishment operation, the controller calculates the leading local droop residual of each measuring point in the cutting area to be cut, and confirms the maximum leading local droop residual among multiple leading local droop residuals. After performing the pressure replenishment operation, the controller calculates the local droop residual of each measuring point in the cutting area after the cutting operation, and confirms the maximum local droop residual of multiple local droop residuals. The conditions for passing the retest are: the maximum local droop residual at the rear is less than the maximum local droop residual at the front, no reverse change exceeding the allowable repeatability difference occurs at any distance measurement point, and the vibration state is within the allowable vibration state threshold. If the retest fails, the selected candidate pressure replenishment group will not be written into the verified pressure group, the pressure replenishment operation of the subsequent dual-cylinder candidate pressure replenishment group will be frozen and restored to the verified pressure group before the pressure replenishment operation was performed, and it will be downgraded to a single-cylinder candidate pressure replenishment group.

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