A high-precision self-adaptive motion control device and method suitable for multiple mechanical configurations

Abstract

The application discloses a kind of high-precision self-adaptive motion control device and method suitable for multiple mechanical configurations, the device includes automatic feeding and discharging device, automatic measurement / pose adjustment docking device and control computing system, automatic feeding and discharging device is configured with gripper;Automatic measurement / pose adjustment docking device is equipped with pose adjustment support mechanism, auxiliary docking mechanism, middle measurement mechanism and feature measurement mechanism;Pose adjustment support mechanism has multi-axis movement ability, auxiliary docking mechanism integrates force sensing and displacement sensing element, middle measurement mechanism and the feature measurement mechanism are respectively carried with visual and ranging sensing component;Control computing system is electrically connected all mechanisms, for controlling to complete the visual measurement of to-be-measured cabin section, displacement calculation, control shaft movement.The device solves the problems existing in the prior art, such as fixed equipment tooling structure, narrow adaptation range and only basic component alignment detection can be completed, can be automatically adjusted according to the difference of product, improves the detection and docking efficiency.

Description

Technical Field

[0001] This invention relates to the field of precision assembly technology for parts and components, and specifically to a high-precision adaptive motion control device and method that adapts to multiple mechanical configurations. Background Technology

[0002] Cylindrical module components are fundamental building blocks of core equipment such as launch vehicles, spacecraft, and propulsion systems. Their docking and assembly precision, consistency, and safety directly determine the operational reliability and service life of the entire system. As aerospace equipment evolves towards multi-model, small-batch, high-precision, and lightweight designs, the mass production of cylindrical modules with varying diameters, lengths, and weights places extremely high demands on the automation level, multi-configuration adaptability, precision attitude adjustment accuracy, and flexible protection performance of module docking and assembly.

[0003] Traditional assembly methods rely heavily on manual hoisting, visual alignment, and manual fine-tuning, which have many drawbacks such as poor alignment accuracy, low assembly efficiency, high labor costs, and poor repeatability. In addition, manual assembly is prone to problems such as uneven force distribution, shearing of sealing rings, scratches on paint surfaces, and damage to components, which cannot meet the production standards of micron-level precision assembly for high-end aerospace equipment.

[0004] Currently, automated attitude adjustment and docking equipment has been gradually promoted in the industry, replacing manual assembly operations to a certain extent. Existing typical docking equipment mostly adopts a single measurement mode of monocular or binocular vision or measurement robot, combined with a six-degree-of-freedom attitude adjustment platform to achieve coaxial alignment and assembly of cylindrical components, which can complete basic automated attitude adjustment and docking operations and effectively improve basic assembly efficiency. However, existing equipment still has significant technical shortcomings: First, the equipment tooling structure is fixed, and the support and clamping mechanisms cannot adaptively adjust the spacing, which can only adapt to single or extremely narrow specifications of compartment products, and cannot be compatible with the general assembly of compartments of multiple sizes, weights, and configurations; Second, the measurement system is singular, which can only complete basic alignment detection of component end faces and axes, and lacks precise positioning functions for key assembly features such as compartment pin holes, lugs, and keyways, making it impossible to achieve high-precision matching of circumferential features, and making it difficult to further improve the assembly yield. Summary of the Invention

[0005] This invention provides a high-precision adaptive motion control device and method that adapts to multiple mechanical configurations, aiming to solve the problems existing in the background technology, such as fixed equipment tooling structure, narrow adaptation range, and the inability to complete the basic alignment detection of components.

[0006] The technical solution provided by this invention is as follows: This invention provides a high-precision adaptive motion control device that adapts to multiple mechanical configurations, including an automatic loading and unloading device, an automatic measurement / attitude adjustment docking device, and a control calculation system; The automatic loading and unloading device is equipped with grippers, which are used to grab different specifications of test compartments onto the automatic measurement / attitude adjustment docking device. The automatic measurement / attitude adjustment docking device is equipped with a base, on which are arranged an attitude adjustment support mechanism, an auxiliary docking mechanism, a central measurement mechanism, and a feature measurement mechanism that can slide along the base. The posture adjustment support mechanism has multi-axis motion capability, the auxiliary docking mechanism integrates force sensing and displacement sensing elements, and the middle measuring mechanism and the feature measuring mechanism are respectively equipped with vision and distance sensing components. The control and computing system is electrically connected to all mechanisms and is used to control and complete the visual measurement, displacement calculation, and control axis movement of the section under test.

[0007] Optionally, the posture adjustment support mechanism integrates an X-axis motion structure, a Y-axis motion structure, a Z-axis lifting structure, and an R-axis rotation structure; The X-axis motion structure is guided by the first linear slide rail and the first slider, and achieves linear movement by relying on the meshing of the first servo motor, the first reducer, the first gear, and the first rack. The Y-axis motion structure is guided by the second linear slide rail and the second slider, and uses the first ball screw and the second servo drive to complete the lateral displacement adjustment. The Z-axis lifting structure is guided by a first linear bearing and is used in conjunction with a first screw jack to achieve lifting drive. The R-axis rotation structure is guided by the third linear slide rail and the third slider, and uses a rotation drive module to drive the attitude adjustment drive wheel. The rotation drive module works with the second ball screw to achieve spacing adjustment.

[0008] Optionally, the auxiliary docking mechanism integrates an X-axis moving module, a Z-axis lifting module, and a measurement reference module; The X-axis moving module uses the first linear slide rail and the first slider as guides, and achieves precise X-axis sliding of the whole machine through the meshing of the third servo motor, the second reducer, the second gear, and the first rack. The Z-axis lifting module uses a second linear bearing for guidance, and works with a second screw jack and a rotating handwheel to complete the initial height adjustment. The measurement reference module integrates the force sensor, laser displacement sensor, and tail displacement detection module to collect data on the attitude and receiving force of the tail end face of the compartment.

[0009] Optionally, the central measuring mechanism includes an X-axis adjustment mechanism, a Y-axis telescopic mechanism, and a central measuring reference module; The X-axis adjustment module uses a fourth linear slide rail and a fourth slider as guides, and a third ball screw and a fourth servo motor as drives. The Y-axis telescopic module is guided by the fifth linear slide rail and the fifth slider, and driven by the fourth ball screw and the fifth servo motor. The central measurement reference module is equipped with a protective cover, which integrates a camera and a light source. Multiple sets of laser displacement sensors are evenly distributed on both sides at 90° intervals.

[0010] Optionally, the upper part of the base is provided with a first linear slide rail and a first slider, and a first rack is fixed on the side. The base is equipped with an attitude adjustment support mechanism base and an auxiliary docking mechanism base. Each base is equipped with a servo motor and a gear transmission structure. Through gear and rack meshing transmission, the attitude adjustment support mechanism and the auxiliary docking mechanism are driven to slide independently along the X-axis on the base.

[0011] Optionally, the feature measurement mechanism includes an X-axis adjustment module, a Y-axis telescopic module, and a feature measurement base module; The X-axis adjustment module shares the fourth linear slide rail with the X-axis adjustment module, and is independently configured with the fifth ball screw and the sixth servo drive to achieve autonomous sliding. The Y-axis telescopic module has the same structural design as the Y-axis telescopic module. The feature measurement basic module includes a visual measurement module and a feature calibration module. The visual measurement module integrates a camera and a light source and is equipped with an external protective cover. It is used to measure the shape features of the compartment lugs, pin holes, and pin grooves. The feature calibration module adopts a cylinder-driven quick-change calibration head structure to realize the alignment calibration of the pin hole assembly.

[0012] The present invention also provides a control method for the above-mentioned high-precision adaptive motion control device with multiple mechanical configurations, comprising the following steps: The control computing system receives the segment docking production task and reads the product model and structural parameters, controls the automatic loading and unloading device to adjust the opening and closing size of the grippers, and adjusts the spacing of the attitude adjustment support mechanism. The automatic loading and unloading device is controlled to transfer the product's docking compartment to the attitude adjustment support mechanism station, and the auxiliary docking mechanism is controlled to slide to the tail of each compartment. The end face attitude data is collected in real time and uploaded to the control calculation system. The attitude deviation is calculated by controlling the computing system and driving the attitude adjustment support mechanism to make fine adjustments so that the end face of each docking section is parallel to the reference plane of the docking device. The central measuring mechanism is extended, and laser ranging and visual detection are combined to calculate the center coordinates of each docking section, and the calculated data is sent to the control computing system. The control calculation system calculates the adjustment amount and controls the attitude adjustment support mechanism to adjust the attitude according to the adjustment amount, so that the central axis of each docking section coincides with the virtual axis of the docking device. The feature measurement mechanism measures the feature data of the section to be docked and sends the measurement data to the control calculation system, which then calculates the adjustment amount based on the measurement data. The attitude adjustment support mechanism is controlled to adjust according to the adjustment amount, so that the features of the front and rear compartments of the product are consistent. After passing the retest, all measuring mechanisms are reset, and the attitude adjustment support mechanism is controlled to perform feed docking. The docking load is monitored in real time by force sensors throughout the docking process to avoid squeezing and shearing damage. After docking is completed, the whole machine is reset.

[0013] Optionally, the control calculation system uses a PID algorithm to convert visual deviations into compensation amounts for each axis to achieve closed-loop attitude adjustment.

[0014] Optionally, the control and calculation system is equipped with a two-level force threshold protection mechanism. During the docking process, the docking axial force and torque data are collected in real time. When the docking force reaches the first-level threshold, the control and calculation system drives the attitude adjustment support mechanism to make fine adjustments to avoid shearing damage to the docking seal ring. When the docking force exceeds the limit and triggers the second-level threshold, the docking operation is immediately suspended and an alarm is triggered to achieve flexible protection and safety management of the product.

[0015] Compared with the prior art, the beneficial effects of the present invention are: The present invention provides a high-precision adaptive motion control device and method adaptable to multiple mechanical configurations. The device integrates an attitude adjustment support mechanism, a central measurement mechanism, a feature measurement mechanism, and an auxiliary docking mechanism. It adopts non-contact measurement methods and has the ability to measure spatial attitude and calculate the deviation value from the benchmark. Then, it performs automatic adjustment, which can realize the automatic attitude adjustment and docking of the product with 6 degrees of freedom. The measurement accuracy meets ±0.02mm, and the attitude axis accuracy is better than 0.05°. At the same time, each mechanism of the device has the ability to adapt to multiple mechanical configurations and can automatically adjust according to the differences of the product, thereby improving the detection and docking efficiency and enhancing the overall docking capability of the device. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the high-precision adaptive motion control device adapted to multiple mechanical configurations in an embodiment of the present invention; Figure 2 This is a schematic diagram of the automatic measurement / attitude adjustment docking device in an embodiment of the present invention; Figure 3 This is a schematic diagram of the base frame structure in an embodiment of the present invention; Figure 4 This is a schematic diagram of the posture adjustment support mechanism in an embodiment of the present invention; Figure 5 This is a schematic diagram of the auxiliary docking mechanism in an embodiment of the present invention; Figure 6This is a schematic diagram of the structure of the central measuring mechanism mentioned in the embodiment of the present invention. Figure 1 ; Figure 7 This is a schematic diagram of the structure of the central measuring mechanism mentioned in the embodiment of the present invention. Figure 2 ; Figure 8 This is a schematic diagram of the feature measurement mechanism in an embodiment of the present invention; Figure 9 This is a schematic diagram of the automatic loading and unloading device in an embodiment of the present invention.

[0017] The attached figures are labeled as follows: 1-Automatic measurement / attitude adjustment docking device, 11-Base, 110-Base frame, 111-Linear slide rail slider assembly, 1111-First linear slide rail, 1112-First slider, 112-First rack, 12-Attitude adjustment support mechanism, 121-Attitude adjustment support mechanism base, 122-X-axis motion structure, 1222-First servo motor, 1223-First gear, 123-Y-axis motion structure, 1231-Y-axis moving base, 1232-Second linear slide rail, 1233-Second slider, 1234-First ball screw, 1235-Fixed base, 1236-Moving Nut assembly, 1237-Second servo motor, 1238-First coupling, 124-Z-axis lifting structure, 1241-First linear bearing, 1242-First screw jack, 125-R-axis rotation structure, 1251-Base plate, 1252-Third linear slide rail, 1253-Third slider, 1254-Rotary drive module, 1255-Second ball screw, 13-Auxiliary docking mechanism, 131-Auxiliary docking mechanism base, 132-X-axis movement module, 1322-Third servo motor, 1323-Second gear, 133-Z-axis lifting module, 1331-Z-axis lifting... Lowering base, 1332-Second linear bearing, 1333-Second screw jack, 1334-Rotating handwheel, 1335-First fixed plate, 134-Measuring reference module, 14-Central measuring mechanism, 141-Measuring base, 1411-Second fixed plate, 1412-Adjustable fixed plate, 142-X-axis adjustment mechanism, 1421-Fourth linear slide rail, 1422-Slide rail limit block, 1423-Fourth slider, 1424-Third ball screw, 1425-Fourth servo motor, 143-Y-axis telescopic mechanism, 1431-Y-axis base plate, 1432-Fifth linear... 1433-Fifth slider, 1434-Fourth ball screw, 1435-Fifth servo motor, 144-Central measurement reference module, 15-Feature measurement mechanism, 151-X-axis adjustment module, 1511-Fifth ball screw, 1512-Sixth servo motor, 152-Y-axis telescopic module, 153-Feature measurement base module, 1531-Vision measurement module, 1532-Feature calibration module, 2-Automatic loading and unloading device, 21-Truss, 22-X-axis motion module, 23-Y-axis motion module, 24-Z-axis lifting module, 25-Gripper, 3-Control calculation system. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the present invention provided in conjunction with the accompanying drawings is intended merely to illustrate selected embodiments of the invention and is not intended to limit the scope of protection claimed by the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0020] It should be understood that in the description of embodiments of the present invention, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first," "second," etc., may explicitly or implicitly include one or more of the stated features.

[0021] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows for mutual communication; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention according to the specific circumstances.

[0022] See Figure 1 This invention provides a high-precision adaptive motion control device suitable for multiple mechanical configurations. The device comprises three parts: an automatic loading / unloading device 2, an automatic measurement / attitude adjustment docking device 1, and a control and computing system 3. These three parts cooperate and are electrically linked to complete the fully automated operation process of the cylindrical section, from automatic loading, attitude measurement, multi-axis attitude adjustment, feature calibration to precise docking and finished product unloading. The control and computing system 3, as the central brain of the entire device, achieves full-point electrical connection with all mechanical motion mechanisms and various sensing elements within the device, and is responsible for all tasks including signal acquisition, data processing, logical judgment, motion command issuance, and fault alarm.

[0023] The automatic loading and unloading device 2 is a front-end logistics unit. The core execution component is the gripper 25. The gripper 25 is used to pick up, transfer and place test sections of different diameters and lengths in the workshop. It can smoothly transfer the sections in the raw material area to the designated work station of the automatic measurement / adjustment docking device 1, and can also transfer the finished sections that have been docked to the unloading area.

[0024] The automatic measurement / attitude adjustment docking device 1 is the core operating unit of the entire equipment. This device uses the base 11 as the mounting and supporting structure for all components, such as... Figure 3As shown, the base 11 can be formed by welding standard rectangular square tubes and steel plates to form a base frame 110, which has high structural strength and small overall deformation, fully meeting the load-bearing requirements of heavy-duty compartments. The base frame 110 is equipped with an attitude adjustment support mechanism base 121 and an auxiliary docking mechanism base 131. Each base can be equipped with a servo motor and gears, and through overall cooperation, the attitude adjustment support mechanism 12 and the auxiliary docking mechanism 13 can operate independently along the X-axis on the docking device. The upper surface of the base 11 is covered with a linear guide rail slider assembly 111, which includes a first linear guide rail 1111 and a first slider 1112. A first rack 1113 is fixed along the length direction on the side, and the two form a standard linear transmission pair.

[0025] like Figure 2 As shown, the attitude adjustment support mechanism 12, auxiliary docking mechanism 13, central measuring mechanism 14, and feature measuring mechanism 15 are arranged sequentially above the base 11. All four mechanisms can independently slide on the surface of the base 11 using the linear guide slider assembly 111 and the first rack 1113, with a range of motion covering the entire working area. The attitude adjustment support mechanism 12 possesses complete multi-axis motion capabilities and serves as the main load-bearing structure and attitude adjustment actuator for the module. The auxiliary docking mechanism 13 integrates two types of precision components: force sensors and displacement sensors, primarily responsible for detecting the attitude of the module's tail end face and real-time monitoring of the force throughout the docking process. The central measuring mechanism 14 and feature measuring mechanism 15 are equipped with high-definition vision components and high-precision ranging sensors, respectively, with clearly defined functions. The central measuring mechanism 14 focuses on detecting the module's axis and coaxiality, while the feature measuring mechanism 15 is responsible for detecting and calibrating the module's pin holes, lugs, pin slots, and other external features. The entire system, relying on hardware integration and system control, eliminates the traditional manual assembly mode, achieving automated precision docking of multi-configuration modules.

[0026] like Figure 4 As shown, the attitude adjustment support mechanism 12 is the core execution component for realizing the attitude adjustment of the cabin section. It includes the attitude adjustment support mechanism base 121, which integrates four major motion units: X-axis motion structure 122, Y-axis motion structure 123, Z-axis lifting structure 124, and R-axis rotation structure 125. The four sets of structures work together to realize six degrees of freedom of all-round attitude adjustment of the cabin section, perfectly adapting to the support and attitude adjustment needs of cylindrical cabin sections of different sizes and weights. It is also the key structure for the whole set of equipment to adapt to products with multiple mechanical configurations.

[0027] The X-axis motion structure 122 is the lateral movement unit of the entire mechanism, using a mature linear slide rail slider assembly 111 as the guide structure, ensuring smooth operation and high positioning accuracy. The power system consists of a first servo motor 1222 paired with a first reducer. The first servo motor 1222 provides stable power, while the first reducer amplifies torque and reduces speed. A transmission gear is installed at the power output end, and the first gear 1223 meshes with the first rack 1113 on the side of the base 11. This gear and rack transmission method drives the attitude adjustment support mechanism 12 to move linearly along the length of the base, completing the coarse adjustment of the compartment's X-axis position. The support point position can be flexibly adjusted according to the compartment length. Preferably, the X-axis motion structure 122 uses two sets of linear slide rail slider assemblies 111, each fixed to the base 11. An attitude adjustment support mechanism base 121 is designed on the first slider 1112. The head of the attitude adjustment support mechanism base 121 is fixed with a first servo motor 109, which transmits power to the first gear 1223 via the first reducer, and then meshes with the fixed first rack 1113 to achieve linear motion.

[0028] The Y-axis motion structure 123 includes a Y-axis moving base 1231, and second linear slide rails 1232 symmetrically distributed and fixed on the Y-axis moving base 1231. Six second sliders 1233 are arranged on the second linear slide rails 1232. The top of the second sliders 1233 is connected to the base plate 1251 of the R-axis rotation structure 125. A set of first ball screws 1234 is installed in the middle of the Y-axis moving base 1231. Fixed bases 1234 are installed at both ends of the first ball screws 1234. The moving nut pair 1236 in the middle of the first ball screws 1234 is connected and fixed to the base plate 1251 of the R-axis rotation structure 125. The second servo motor 1237 is connected to the first ball screw 1234 through a reducer and a first coupling 1238 to provide power.

[0029] The Z-axis lifting structure 124 is guided by four first linear bearings 1241 and powered by a first screw jack 1242. The first screw jack 1242 can be a turbine trapezoidal screw jack. The base of the first screw jack 1242 is fixed on the support mechanism base 121, and the extended end of the first screw jack 1242 is connected to the Y-axis moving base 1231 by screws.

[0030] The Z-axis lifting structure 124 performs vertical height adjustment. A first linear bearing 1241 serves as the lifting guide, effectively reducing friction and ensuring smooth, unhindered lifting. The power source is a first screw jack 1242, which has a self-locking function, ensuring a stable height lock after adjustment and preventing slippage due to the compartment's weight. When the screw jack 1242 operates, guided by the first linear bearing 1241, it drives the mechanism to complete vertical Z-axis lifting, adapting to the support height of compartments with different diameters and ensuring the compartment center is at the standard operating height.

[0031] The R-axis rotation structure 125 can use a steel plate as the base plate 1251. Two third linear slide rails 1252 are symmetrically installed on both sides of the base plate 1251. Each slide rail is equipped with four third sliders 1253. The third sliders are connected to the base of the rotation drive module 1254. An attitude adjustment drive wheel is fixed on the upper part of the base of the rotation drive module 1254. The rotation drive module 1254 can be powered by a reducer connected to a servo motor. Two sets of rotating drive modules 1254 can be configured. The two sets of rotating drive modules 1254 are connected and cooperate with a second ball screw 1255 to achieve spacing adjustment, and have the ability to support rotation for products with different diameters.

[0032] like Figure 5 As shown, the auxiliary docking mechanism 13 includes an auxiliary docking mechanism base 131, on which are mounted an X-axis movement module 132, a Z-axis lifting module 133, and a measurement reference module 134, enabling adjustment of the stern position of the compartment, adjustment of the height, and acquisition of attitude and force data. The structure and function of each module are as follows: The X-axis moving module 132 is guided by the first linear slide rail 1111 and the first slider 1112. An auxiliary docking mechanism base 131 is mounted on the top of the first slider 1112. The power components include a third servo motor 1322, a second reducer, and a second gear 1323. The third servo motor 1322 outputs power, which is reduced in speed by the second reducer and then driven by the second gear 1323 meshing with the first rack 1113. This drives the auxiliary docking mechanism base 131 and the entire structure above it to complete precise X-axis sliding on the base 11, allowing it to move to the tail inspection area of ​​different length sections.

[0033] The Z-axis lifting module 133 includes a Z-axis lifting base 1331, which is fixedly mounted on the auxiliary docking mechanism base 131. The lifting guide uses a second linear bearing 1332, which can be fixed at the four corners of the Z-axis lifting base 1331. The power component can be a second screw jack 1333, which can be a worm gear trapezoidal screw jack fixed in the middle of the Z-axis lifting base 1331. The input end of the second screw jack 1333 is connected to a rotary handwheel 1334. The operator rotates the rotary handwheel 1334 to drive the second screw jack 1333, coordinating with the second linear bearing 1332 to complete the initial height adjustment of the mechanism. First fixing plates 1334 are fixed to both sides of the Z-axis lifting module 133, serving as travel limiters and anti-collision protection.

[0034] The measurement reference module 134 is the core detection unit. It can use a steel plate as the reference frame, and force sensors, laser displacement sensors, and tail displacement detection modules are designed inside the reference frame to realize the measurement of data on the tail end face of the compartment. The laser displacement sensor and the tail displacement detection module are responsible for collecting the attitude and displacement data of the tail end face of the compartment, while the force sensor collects the force data during the docking process in real time. All collected data are uploaded to the control computing system 3.

[0035] like Figure 6 , Figure 7 As shown, the central measuring mechanism 14 includes a measuring base 141, an X-axis adjustment mechanism 142, a Y-axis telescopic mechanism 143, and a central measuring reference module 144. It is mainly used for detecting the center coordinates and coaxiality of the central section. The structure and function of each component are as follows: The measuring base 141 is the mounting base of the entire mechanism. The top is fixed with a second fixing plate 1411 for mounting the X-axis adjustment mechanism 142; the bottom is fixed with an adjustable fixing plate 1412 for leveling the entire mechanism and fine-tuning its position.

[0036] The X-axis adjustment mechanism 142 uses a fourth linear slide rail 1421 as a motion guide to achieve overall X-axis position adjustment of the mechanism. Slide rail limit blocks 1422 are installed at both ends of the fourth linear slide rail 1421 to limit the maximum travel of the mechanism and prevent damage from overtravel. Four fourth sliders 1423 are mounted on the fourth linear slide rail 1421 and connected to the Y-axis base plate 1431 of the Y-axis telescopic mechanism 143 by screws. Simultaneously, a set of third ball screw 1424 adjustment components is installed on the second fixed plate 1411 and connected to the reducer / fourth servo motor 1425 via a coupling to provide power.

[0037] The Y-axis telescopic mechanism 143 includes a Y-axis base plate 1431, a fifth linear slide rail 1432 as a motion guide, a fifth slider 1433 on the fifth linear slide rail 1432, and a fifth servo motor 1435 and a fourth ball screw 1434 as driving components mounted on the Y-axis base plate 1431. The fifth servo motor 1435 drives the fourth ball screw 1434 to rotate, thereby driving the Y-axis telescopic mechanism 143 to complete the Y-axis telescopic movement, allowing the detection component to move closer to or away from the measured surface of the compartment. Preferably, four fifth sliders 1433 can be fixed on the Y-axis base plate 1431, the fifth linear slide rail 1432 is connected to the frame of the telescopic part, and the fourth ball screw 1434 is fixed to one side of the Y-axis base plate 1431.

[0038] The central measurement reference module 144 can be fitted with a protective cover to provide dust and collision protection. The protective cover integrates a camera and a light source; the camera can be a vision camera, and the light source can be a ring light source, forming a vision inspection unit. Sensors are evenly distributed along a 90° circumference on both sides of the protective cover, consisting of a first set of laser displacement sensors and a second set of laser displacement sensors. The vision camera and ring light source 142, in conjunction with the two sets of laser displacement sensors, perform fusion detection to accurately calculate the center coordinates of the compartment and the coaxiality of the end face.

[0039] like Figure 8 As shown, the feature measurement mechanism 15 can be composed of an X-axis adjustment module 151, a Y-axis telescopic module 152, and a feature measurement base module 153. It performs detection and calibration on the external features of the compartment pin holes, lugs, pin grooves, etc. The structure and function of each module are as follows: The X-axis adjustment module 151 can be mounted on the measuring base 141 of the central measuring mechanism 14. It shares the same set of linear slide rails (i.e., the fourth linear slide rail 1421) as a guide component with the central measuring mechanism 14. At the same time, it is independently configured with the fifth ball screw 1511 and the sixth servo motor 1512, and can autonomously complete the X-axis sliding. Its motion logic is independent of the central measuring mechanism 14.

[0040] The mechanical structure, transmission form, and drive components of the Y-axis telescopic module 152 are consistent with those of the Y-axis telescopic mechanism 143 of the central measuring mechanism 14, ensuring that the motion accuracy of the two mechanisms is consistent.

[0041] The feature measurement basic module 153 is divided into two units: the visual measurement module 1531 and the feature calibration module 1532. The visual measurement module 1531 integrates a camera and light source internally and is equipped with a protective cover externally. It is responsible for collecting images of the external features of the compartment lugs, pin holes, pin grooves, etc., and completing the detection of feature dimensions and positions. The feature calibration module 1532 is fixed by an L-shaped mounting plate. The power component is a calibration drive cylinder. The calibration drive cylinder drives the quick-change calibration head to achieve precise alignment calibration of the compartment pin hole assembly position.

[0042] like Figure 9 As shown, the automatic loading and unloading device 2 relies on the truss 21 to complete the automated handling and transfer of compartments. The truss 21 integrates an X-axis motion module 22, a Y-axis motion module 23, a Z-axis lifting module 24, and a gripper 25. The three sets of motion modules are used to realize the three-dimensional material transfer.

[0043] The gripper 25 can accommodate various specifications of compartment products with diameters ranging from φ100mm to φ500mm and lengths from 500mm to 6500mm. The overall transfer speed of the truss 21 can be steplessly adjusted within the range of 0 to 1.5m / s, and the cycle time for a single complete material transfer can be controlled within 90s. The entire system can complete the unmanned transfer operation of compartments from the raw material area to the docking station, and finished compartments from the docking station to the unloading area.

[0044] In one example embodiment, the device provided by the present invention can use a Siemens S7-1200G2 PLC as the core controller of the control computing system 3, and is equipped with a PROFINET IRT real-time industrial Ethernet bus. 1. Motion control: The CPU1217G2 supports 32-axis synchronous servo control, connecting the servo drivers of each X / Y / Z / R axis to the real-time bus to achieve multi-axis synchronous linkage with a communication delay of ≤1ms; 2. Sensor signal acquisition: Analog signals from force sensors and laser displacement sensors are input to the PLC analog input module, and industrial cameras transmit image data via Ethernet IP communication; 3. Software program: TIA Portal programming is used, with built-in standard PID function blocks to realize visual deviation closed-loop correction, a two-level force threshold determination logic subroutine is built, and a database of different specifications of compartment size parameters is stored. The present invention also provides a complete control method based on the above-mentioned device, the specific process of which is as follows: (1) The control computing system 3 receives the segment docking production task, reads the product model and structural parameters, outputs instructions to control the automatic loading and unloading device 2 to adjust the opening and closing size of the gripper 25, and at the same time adjusts the support spacing of each component inside the attitude adjustment support mechanism 12 to complete the pre-adjustment of the mechanism before loading.

[0045] (2) Control the automatic loading and unloading device 2 to transfer the product to be docked compartment to the bearing position of the attitude adjustment support mechanism 12; control the auxiliary docking mechanism 13 to slide along the base 11 to the tail of the compartment, collect the position and attitude data of the tail end face of the compartment in real time through the internal laser displacement sensor and the tail displacement detection module, and upload the data to the control calculation system 3.

[0046] (3) The attitude deviation data is calculated by the control calculation system 3, and the adjustment command is output to drive the attitude adjustment support mechanism 12 to fine adjust the attitude so that the end face of the docking section is parallel to the reference plane of the docking device.

[0047] (4) The Y-axis telescopic mechanism 134 of the central measuring mechanism 14 extends out, and the laser ranging and visual detection results are fused together with the visual camera, the ring light source, the first set of laser displacement sensors, and the second set of laser displacement sensors to calculate the center coordinates of the compartment and transmit the calculation data to the control calculation system 3.

[0048] (5) The control calculation system 3 calculates the axis adjustment amount based on the center coordinate deviation, drives the attitude adjustment support mechanism 12 to complete the attitude adjustment, so that the center axis of the section to be docked coincides with the virtual axis of the docking device.

[0049] (6) The control feature measurement mechanism 15 starts working and detects feature data such as the lugs, pin holes, and pin grooves of the compartment through the vision measurement module 1531. The data is uploaded to the control calculation system 3, and the attitude adjustment amount is calculated again through the control calculation system 3.

[0050] (7) The R-axis rotation structure 125 of the attitude adjustment support mechanism 12, based on the attitude adjustment amount, drives the attitude adjustment support roller to rotate, drives the compartment to rotate circumferentially, completes the alignment according to the adjustment amount, and ensures that the assembly features of the front and rear compartments are consistent.

[0051] (8) After the equipment has completed the retest and the results are qualified, the central measuring mechanism 14 and the feature measuring mechanism 15 are all reset. The attitude adjustment support mechanism 12 is controlled to drive the compartment to perform the feeding and docking action. During the docking process, the docking load is monitored throughout by the force sensor to avoid problems such as squeezing, shearing, and damage to the sealing ring of the compartment. After the docking operation is completed, all mechanisms of the whole machine are reset in sequence, waiting for the next batch of operation tasks.

[0052] The method will now be described in detail using the aforementioned apparatus. The detailed steps of the method are as follows: (1) Before the equipment is officially started, the control computing system 3 first receives the segment docking production task issued by the host computer, automatically retrieves and analyzes the complete model parameters, external dimensions, weight specifications, assembly process standards and other core data of the segment to be processed, so as to complete the pre-adaptive pre-adjustment operation of the entire equipment. For cylindrical segment products with different diameters, lengths and weights, the control computing system 3 first issues adjustment instructions to the automatic loading and unloading device 2, drives the X-axis motion module 22, Y-axis motion module 23 and Z-axis lifting module 24 on the truss 21 structure to make coordinated fine adjustments, accurately adjust the opening and closing distance and clamping stroke of the end gripper 25, so that the clamping range of the gripper 25 accurately matches the outer diameter of the current segment (adapted to the full specification range of φ100mm~φ500mm), and at the same time relies on the adaptive clamping structure of the gripper 25 to ensure uniform clamping force and avoid the problems of clamping deformation and paint scratches of thin-walled segments. Simultaneously, the control computing system 3 synchronously controls the attitude adjustment support mechanism 12 of the automatic measurement / attitude adjustment docking device 1 to complete the configuration adaptation adjustment. The sixth servo motor 1512 drives the fifth ball screw 1511 to operate, and with the guiding effect of the third linear slide rail 1252 and the third slider 1253, the two sets of rotary drive modules 1254 adaptively adjust the support spacing. Combined with the transmission fine adjustment function of the second ball screw 1255, the support point position of the attitude adjustment support mechanism 12 is completely adapted to the length and diameter parameters of the current compartment. In addition, the control computing system 3 pre-calibrates the initial zero point position of each motion axis, resets all measurement mechanisms and docking mechanisms, eliminates the displacement deviation caused by equipment standby, and provides a precise initial mechanical reference for subsequent loading, attitude adjustment, measurement, and docking operations, completely solving the technical shortcomings of traditional equipment tooling fixation and inability to adapt to multi-configuration products.

[0053] (2) After completing the pre-adjustment and configuration adaptation of the equipment, the transfer command is issued through the control calculation system 3 to start the automatic loading and unloading device 2 to perform the compartment transfer operation. The X-axis motion module 22, Y-axis motion module 23 and Z-axis lifting module 24 mounted on the truss 21 achieve precise three-dimensional spatial displacement, and move smoothly with stepless speed regulation from 0 to 1.5 m / s. The compartment to be docked in the raw material area is smoothly transferred to the core working position of the attitude adjustment support mechanism 12. During the transfer process, the multi-module linkage buffer control is used to prevent compartment shaking, collision and deviation, and ensure the stability and safety of the transfer. After the compartment is accurately positioned, the X-axis motion structure 122 and Z-axis lifting structure 124 of the attitude adjustment support mechanism 12 are initially locked and positioned to complete the product position fixation. Subsequently, the auxiliary docking mechanism 13 is driven to initiate the station adaptation movement. Precise guidance is achieved using the first linear slide rail 1111 and the first slider 1112 laid on the base 11. The third servo motor 1322, in conjunction with the second reducer, second gear 1323, and the first rack 112 of the base 11, meshes with the mechanism, driving the auxiliary docking mechanism 13 to slide precisely along the X-axis. The displacement stroke is automatically matched according to the section length parameters, precisely moving to the tail end face detection station of the section to be docked. Once in position, the Z-axis lifting module 133 of the auxiliary docking mechanism 13 performs a secondary height fine-tuning through the second screw jack 1333 and the rotating handwheel 1334. This ensures that the built-in laser displacement sensor, tail displacement detection module, and tail end face maintain a standard detection distance and vertical posture. Real-time posture data such as flatness, tilt, and displacement deviation of the tail end face are collected from all directions, and the massive amount of high-frequency detection data is transmitted and uploaded to the control and computing system 3 in real time, providing raw data support for subsequent attitude calculation and adjustment correction.

[0054] (3) After receiving the original attitude data of the tail end face of the compartment uploaded by the auxiliary docking mechanism 13 through the control computing system 3, it can rely on the built-in high-precision data calculation model to perform real-time calculation and analysis on multi-dimensional data such as end face tilt deviation, spatial attitude offset, and flatness error, accurately calculate the deviation between the current attitude of the compartment and the equipment reference plane, and clarify the attitude compensation adjustment parameters of each axis X, Y, Z, and R. After the deviation calculation is completed, the control computing system 3 outputs closed-loop adjustment commands to drive the attitude adjustment support mechanism 12 to complete the fine attitude fine-tuning through multi-axis linkage. The X-axis motion structure 122 uses a first servo motor 1222 and a first reducer 1223 in conjunction with a gear and rack meshing to achieve fine-tuning of lateral displacement and correct the X-axis position deviation of the compartment. The Y-axis motion structure 123 relies on a second servo motor 1237 to drive a first ball screw 1234 for transmission, and works with a second linear guide rail 1232 to smoothly guide and complete the Y-axis horizontal deviation correction of the compartment. The Z-axis lifting structure 124 uses a first screw jack 1242 to precisely control the lifting height and compensate for the vertical height error of the compartment. The R-axis rotation structure 125 uses a rotation drive module 1254 to fine-tune the circumferential angle of the compartment and correct the end face tilt deviation. All axes work together and are fine-tuned step by step. The PID closed-loop control algorithm is used throughout the process to correct the adjustment amount in real time, gradually eliminating the parallelism error between the end face of the compartment and the reference plane of the equipment. Finally, the overall end face of the compartment to be docked is completely parallel to the reference plane of the docking device, ensuring the basic assembly accuracy of the docking end face of the compartment and avoiding problems such as uneven end face fit and local extrusion stress during subsequent docking.

[0055] (4) After completing the parallelism correction of the end face of the compartment, the central measuring mechanism 14 is started by the control calculation system 3 to carry out the precise detection of the center axis of the compartment, providing core data support for coaxiality adjustment. First, the X-axis adjustment mechanism 142 of the central measuring mechanism 14 is controlled to move, and the third ball screw 1424 is driven by the fourth servo motor 1425. Relying on the precise guidance of the fourth linear slide rail 1421 and the fourth slider 1423, the X-axis position of the measuring mechanism is finely adjusted so that the detection unit is aligned with the detection area in the middle of the compartment. Then, the Y-axis telescopic mechanism 143 is driven to extend, and the fourth ball screw 1434 is driven by the fifth servo motor 1435 to push the central measuring reference module 144 close to the outer circular surface of the compartment. After reaching the preset detection position, it is locked and positioned. After the inspection operation is initiated, the high-definition visual camera inside the measurement reference module 144 in the control center works in conjunction with the ring light source to acquire a panoramic image of the central part of the compartment. Simultaneously, two sets of laser displacement sensors evenly distributed at 90° angles on both sides of the protective cover are activated to collect distance data of the outer circle of the compartment from multiple dimensions, achieving multi-source data fusion detection of visual imaging and laser ranging. Through cross-validation of multi-dimensional data, the current three-dimensional coordinates of the compartment's center, the actual position of the central axis, and the coaxiality deviation with the equipment's virtual reference axis are accurately calculated. All calculated data are transmitted synchronously to the control calculation system 3 in real time to complete the accurate verification of the compartment's center attitude, providing accurate data basis for subsequent axis alignment adjustment.

[0056] (5) After receiving the center coordinates and axis deviation data of the compartment uploaded by the central measuring mechanism 14 through the control calculation system 3, the system accurately calculates the spatial position adjustment compensation of the X, Y, and Z axes and the attitude fine-tuning of the R axis by combining the preset standard virtual docking axis parameters of the equipment, and forms a multi-axis collaborative attitude adjustment command. Subsequently, the system drives the attitude adjustment support mechanism 12 to perform high-precision axis alignment adjustment. Among them, the X-axis motion structure 122 and the Y-axis motion structure 123 correct the axis offset error in the horizontal direction of the compartment through servo precision transmission; the Z-axis lifting structure 124 precisely fine-tunes the support height through the screw jack to eliminate the axis deviation in the vertical direction; the cooperation of each axis realizes the accurate correction of the overall spatial position of the compartment. The attitude adjustment process adopts PID closed-loop feedback control throughout, converts the visual detection deviation into the motion compensation of each axis in real time, dynamically corrects the adjustment error, and eliminates the problem of over-adjustment or under-adjustment in a single adjustment. Through multiple rounds of closed-loop iteration involving testing, calculation, and adjustment, the actual center axis of the module to be docked was finally made to completely coincide with the standard virtual axis of the docking device, controlling the coaxiality error within the micrometer-level precision range. This met the core process requirements for high-precision coaxial docking of aerospace modules, fundamentally improving the accuracy and consistency of docking assembly.

[0057] (6) After completing the center axis alignment of the compartment, in order to solve the defect that traditional equipment cannot achieve precise matching of circumferential features, the control feature measurement mechanism 15 carries out the key assembly feature detection operation of the compartment. The feature measurement mechanism 15 drives the fifth ball screw 1511 through the independent sixth servo motor 1512, and completes the X-axis autonomous sliding with the fourth linear slide rail 1421 shared with the middle measurement mechanism 14. The detection station is accurately positioned according to the preset positions of the compartment pin holes, lugs, and keyways. Then the Y-axis telescopic module 152 extends precisely, driving the feature measurement base module 153 to approach the key assembly area of ​​the compartment. During the detection process, the vision measurement module 1531 uses a high-definition camera with a dedicated light source to acquire high-precision images of key features such as the shape of the compartment lugs, the diameter of the pin holes, and the position of the keyways. The control calculation system 3 extracts feature coordinates, angles, and position deviation data through image algorithms. At the same time, the cylinder of the feature calibration module 1532 drives the quick-change calibration head to extend, complete the precise alignment and verification of feature points, and further verify the matching error of the assembly features. All feature detection and verification data are uploaded to the control computing system 3. The control computing system 3 combines the feature parameters of the two sections to be docked to accurately calculate the compensation adjustment amount for the circumferential rotation of the sections, providing data support for accurate matching of circumferential features.

[0058] (7) The control and calculation system 3 outputs precise rotation adjustment commands based on the circumferential deviation data obtained by the feature measurement mechanism 15, driving the R-axis rotation structure 125 of the attitude adjustment support mechanism 12 to perform circumferential attitude adjustment. The R-axis rotation structure 125 completes adaptive fine-tuning of the spacing through the third linear slide rail 1252 and the third slider 1253. It works in conjunction with the two sets of rotating drive modules 1254 and the second ball screw 1255 to precisely drive the attitude adjustment drive wheel to rotate at low speed. Relying on the frictional force of the roller and the outer circle of the compartment, the compartment is driven to smoothly complete the circumferential rotation fine-tuning. During the attitude adjustment process, the control and calculation system 3 receives the dynamic detection data of the feature measurement mechanism 15 in real time, continuously iterates and corrects the rotation angle, accurately compensates for the circumferential feature position deviation, and gradually eliminates assembly problems such as misalignment of pin holes, misalignment of lugs, and mismatch of keyways in the front and rear compartments. After multiple rounds of closed-loop fine-tuning, all key assembly features of the front and rear sections to be docked were finally made to correspond completely and match in a consistent manner, achieving high-precision matching of circumferential features. This completely solved the shortcoming of traditional equipment that could only complete basic alignment and could not achieve precise feature assembly, and greatly improved the yield rate of section docking and assembly.

[0059] (8) After completing the full-dimensional attitude adjustment operations of the end face parallelism, axis coaxiality, and circumferential feature matching of the compartment, the equipment starts the fully automatic retest process. The central measuring mechanism 14 and the feature measuring mechanism 15 perform a second check on all assembly datum, attitude parameters, and feature matching accuracy to ensure that all accuracy indicators meet the process standards of ±0.02mm measurement accuracy and 0.05° attitude axis accuracy. After the retest is qualified, the control calculation system 3 first drives all measuring mechanisms to reset. The Y-axis telescopic mechanism 143 and Y-axis telescopic module 152 of the central measuring mechanism 14 and the feature measuring mechanism 15 retract, and the motion mechanism of each axis returns to the initial standby position to avoid interference and collision between the measuring structure and the compartment during the docking process. Then, the control system 3 drives the attitude adjustment support mechanism 12 to feed at a low speed and smoothly, driving the compartment to be docked to complete the precise fitting docking. During the entire docking process, the high-precision force sensor built into the auxiliary docking mechanism 13 collects the axial docking force and torsional torque data in real time at high frequency. The flexible and safe docking is achieved by relying on the two-level force threshold protection mechanism preset by the control system 3. When the docking force reaches the first-level threshold, the control system 3 automatically drives the attitude adjustment support mechanism 12 to make minor adjustments to the attitude, eliminating docking jamming and uneven force distribution, and effectively avoiding shearing damage to the sealing ring and extrusion damage to components. When the docking force abnormally exceeds the limit and triggers the second-level threshold, the equipment immediately suspends the docking operation and activates an audible and visual alarm to prevent product scrapping and equipment damage. After the compartments are fully docked and locked in place, the docking assembly is confirmed to be qualified. All motion mechanisms, measuring mechanisms, and sensing modules of the whole machine are reset in sequence, completing the single compartment precision docking operation. The equipment then enters standby mode, waiting for the next batch of production task instructions, realizing fully unmanned, high-precision, and high-safety automated assembly operations.

[0060] The entire control method relies on the deep integration of hardware structure, sensor detection, algorithm control, and safety protection. The entire process requires no manual intervention, which not only realizes the automated assembly of multi-configuration modules, but also ensures assembly accuracy, work efficiency and product safety, and is fully adapted to the precision assembly production needs of high-end aerospace equipment.

[0061] In other embodiments, the control computing system 3 can employ a PID algorithm to achieve closed-loop attitude adjustment. The vision camera 141 and the laser displacement sensor 130 acquire visual deviation and position deviation signals. The control computing system 3 uses a PID algorithm to calculate the deviation signals, converting the deviation values ​​into compensation amounts for each servo motion axis. It continuously sends adjustment commands to each axis to dynamically correct the cabin attitude, achieving full closed-loop high-precision attitude adjustment and ensuring a smooth and continuous attitude adjustment process.

[0062] In other embodiments, the control computing system 3 has a built-in two-level force threshold protection mechanism. During the docking operation, the force sensor 129 collects docking axial force and torque data in real time and executes safety protection logic in different levels: When the receiving force reaches the first-level threshold, it is determined to be a slight attitude deviation. The control calculation system 3 drives the attitude adjustment support mechanism 12 to complete the micro-attitude fine adjustment, correct the docking angle, and prevent the docking seal ring from being sheared and damaged.

[0063] When the receiving force continues to rise and triggers the secondary threshold, it is determined to be an abnormal force. The system immediately suspends all docking and feeding actions, triggers an alarm signal, and terminates the current operation. This mechanism achieves flexible protection of the compartments and overall safety control, preventing damage to products and equipment.

[0064] It should be noted that the control computing system 3 is the core hub of the entire high-precision adaptive motion control device that adapts to multiple mechanical configurations. Different models can be matched to different application scenarios: For mass production conditions with small and medium production capacity and conventional accuracy requirements (attitude axis accuracy 0.05°, positioning accuracy ±0.02mm), Siemens S7-1200G2 series PLC can be selected. The CPU1216G2 and CPU1217G2 of this series can support up to 16-axis and 32-axis motion control respectively. It is equipped with PROFINETIRT real-time Ethernet, with low communication latency, supports DSC dynamic servo control function, and can decentralize position loop calculation to servo drive, which greatly improves dynamic attitude adjustment response speed. The built-in standard PID function block can directly realize closed-loop calculation of visual deviation and position deviation. The analog interface can seamlessly connect to the analog signals of force sensor 129 and laser displacement sensor 130. The matching Portal software is easy to program and is suitable for stable operation of small and medium-sized compartment docking equipment. For medium to large production capacity and higher precision requirements, you can also choose the Huazhong HNC-848Di bus-type CNC system, STMicroelectronics STM32F767 high-performance MCU or Texas Instruments TMS320F2812DSP as the core control unit or Mitsubishi MELSECIQ-R series.

[0065] In actual operation, the workflow of the control computing system 3 runs through the entire process of the equipment: First, it receives production tasks and analyzes the compartment parameters, outputting commands to adjust the initial positions of the gripper 25 and the attitude adjustment support mechanism 12; then, it continuously collects detection data from the laser displacement sensor 130, the tail displacement detection module 131, the first group of laser displacement sensors 143, the second group of laser displacement sensors 144, and the vision camera 141, and converts the attitude deviation and position deviation into compensation amounts for each servo axis through the built-in PID algorithm, dynamically driving the X-axis motion structure 105, the Y-axis motion structure 106, the Z-axis lifting structure 107, and the R-axis rotation structure 108 to complete closed-loop attitude adjustment; After entering the docking phase, the system reads the force data of force sensor 129 in real time, triggering the first and second level force threshold protection mechanisms. In case of slight deviation, the drive mechanism is fine-tuned, and in case of serious abnormality, the system stops in an emergency and sounds and lights an alarm. After the operation is completed, the system controls all mechanisms to reset step by step according to the preset logic, and records the measurement data, operating status and fault information of this operation. The entire set of operating logic is stably implemented based on the hardware and software functions of the selected controller. Although different models of controllers have different architectures, buses and programming methods, they can all meet the core technical indicators of multi-configuration adaptation, high-precision attitude adjustment and flexible and safe docking of this device. The model can be flexibly selected according to the equipment scale, cost budget and intelligent needs.

[0066] The three-dimensional coordinate calculation steps for the center of the circle in step (4) include: 1. An industrial camera captures a complete image of the outer circle of the compartment, and an image algorithm extracts the pixels of the outer circle contour and fits the center of the circle to a pixel coordinate system.

[0067] 2. Four sets of radial distance data are simultaneously collected by 90° laser displacement sensors on both sides, and the visual contour fitting error is corrected by weighting.

[0068] 3. Using the device's hand-eye calibration matrix, the pixel center and laser ranging data are converted into three-dimensional coordinates in the device's mechanical coordinate system. The coaxiality deviation with the virtual reference axis is calculated and output to the control calculation system to complete the attitude adjustment calculation.

[0069] In one example, this device uses segmented adaptive PID closed-loop control logic to complete automatic attitude correction of the cabin section. Through multiple rounds of iterative "measurement-deviation calculation-servo adjustment-retest verification", it achieves high-precision autonomous attitude adjustment of the cabin section with six degrees of freedom. The entire process requires no manual intervention. The specific implementation steps are as follows: Step 1: Visual Image Acquisition and Cabin Contour Pixel Feature Extraction. The central measuring mechanism incorporates an industrial camera with a ring light source, continuously acquiring grayscale images of the central cross-section of the cabin under test at a fixed sampling frequency of 10Hz. The control calculation system has a built-in image preprocessing subroutine. First, a Gaussian filtering algorithm is used to eliminate image noise caused by ambient stray light and laser reflection. Then, an adaptive grayscale threshold segmentation technique is used to distinguish the cabin's metal cylinder from the equipment background area, extracting the complete outer contour pixel set of the cylinder. Subsequently, the center position of the cabin in the image pixel coordinate system is solved based on the least squares circle fitting method, obtaining the original pixel coordinate data that is only applicable to the image plane. This pixel coordinate cannot be directly used for equipment motion control; a conversion calculation from the pixel coordinate system to the equipment's mechanical coordinate system is required.

[0070] Step Two: Pixel Coordinates to Equipment 3D Mechanical Coordinates Conversion and Attitude Deviation Calculation. Before leaving the factory, the equipment undergoes a complete calibration process, storing camera intrinsic parameters, lens distortion correction parameters, and hand-eye transformation relationships of the measuring mechanism in the control calculation system database. The data conversion process is divided into two levels: First, relying on the laser displacement sensor to collect the vertical distance from the camera to the section cylinder in real time, and combining this with the lens distortion coefficient to correct the pixel center coordinates, eliminating positional errors caused by optical imaging; Second, calling the pre-stored hand-eye calibration transformation parameters to convert the corrected image 2D coordinates into 3D coordinates of the section center under the overall machine mechanical reference coordinate system. The system retrieves the virtual reference axis standard coordinates calibrated at the factory, compares the measured cylinder coordinates with the standard reference coordinates, and calculates the linear offset deviations of the section in the X, Y, and Z directions. Simultaneously, combining the section end face tilt data collected by the laser displacement sensor of the auxiliary docking mechanism, the R-axis circumferential rotation angle deviation is calculated, forming a four-axis attitude deviation dataset, which serves as the input basis for the PID controller.

[0071] Step 3: Based on the deviation amplitude, the adaptive PID adjustment parameters are matched in stages. Conventional fixed parameter PID control has the defects of low adjustment efficiency for large deviations and easy oscillation of the mechanism for small deviations. This device sets up a three-stage deviation range matching mechanism. The system automatically switches between proportional, integral and derivative control parameters according to the real-time deviation amplitude of a single axis to achieve adaptive adjustment: 1. Large deviation condition (single axis offset greater than 0.5mm): The coarse adjustment control mode is activated, the proportional adjustment coefficient is increased to quickly reduce the attitude deviation, and the integral calculation stage is locked at the same time to avoid servo axis overtravel impact caused by integral saturation. 1. For moderate deviation conditions (single-axis offset between 0.05mm and 0.5mm): A smooth transition adjustment mode is activated, employing a moderate proportional coefficient, a micro-integral coefficient, and a standard derivative coefficient, balancing adjustment response speed and mechanism operational stability. 2. For minor deviation conditions (single-axis offset less than or equal to 0.05mm): A micrometer-level fine-tuning mode is activated, appropriately reducing the proportional coefficient to avoid overshoot, enabling micro-integral calculations to eliminate static residual position errors, and simultaneously increasing the derivative suppression coefficient to reduce minor mechanical vibrations in the transmission mechanism, ensuring a positioning accuracy requirement of ±0.02mm. During the initial commissioning phase, the equipment can automatically perform a step response test, completing the tuning of the basic PID parameters for each axis and storing them locally. Subsequent continuous production of multiple specification sections requires no manual modification of control parameters.

[0072] Step 4: Calculate servo adjustment compensation amounts independently for each axis, and superimpose the inter-axis coupling compensation system. Independent PID calculation units are configured for the X, Y, and Z linear motion axes and the R rotary axis. Inter-axis coupling compensation logic is also added to counteract the mutual interference errors generated by the linkage of ball screws and linear guides during multi-axis synchronous motion. An integral amplitude limiting protection mechanism is added to the calculation process to limit the upper limit of the cumulative integral value, preventing long-term deviations from causing excessive single-cycle feed of the servo axis and equipment collisions. After calculation, the linear displacement or rotation angle compensation amount corresponding to each servo axis's single adjustment is output and sent to the servo drive unit for execution.

[0073] Step 5: Multi-axis synchronous micro-attitude correction, smooth drive to avoid product damage. The control calculation system sends adjustment commands synchronously to the four-axis servo drive via the PROFINET IRT real-time industrial Ethernet bus, driving the attitude adjustment support mechanism to complete the micro-adjustment of the compartment attitude: the X, Y, and Z axes achieve micro-displacement correction of the cylinder in the horizontal and vertical directions through ball screws; the R axis relies on the low-speed rotation of the rotary drive module to correct the circumferential tilt angle of the compartment. To prevent the paint from being scratched and the thin-walled cylinder from being squeezed and deformed due to violent movement of the compartment, the system sets a maximum single-axis adjustment stroke limit of 0.1mm, and all servo movements are equipped with acceleration and deceleration buffer control to ensure smooth and gentle attitude adjustment.

[0074] Step Six: Iterative Retesting and Verification, Layered Judgment of Attitude Adjustment Completion or Fault Warning. After a single attitude adjustment is completed, the equipment automatically restarts the vision and laser multi-source joint measurement process, repeating the aforementioned image acquisition, coordinate conversion, and deviation calculation procedures. Based on the new deviation data, a compliance judgment is performed: 1. Accuracy Compliance Condition: When the linear deviations of the X, Y, and Z axes do not exceed 0.02mm, and the R-axis rotation angle deviation does not exceed 0.05°, the cabin attitude correction is deemed qualified. The system clears the integral accumulated data of each axis, terminates the PID closed-loop attitude adjustment process, and automatically jumps to the cabin pin hole and lug feature measurement process; 2. Accuracy Failure Condition: The latest round of attitude deviation data is re-input into the PID controller, and the parameter matching, compensation calculation, and servo adjustment process are executed cyclically for continuous iterative correction; 3. Fault Protection Condition: The system limits the maximum number of iterative correction rounds to 20 rounds. If the accuracy still fails to meet the process standard after 20 consecutive retests, the equipment immediately stops all motion actions and outputs an audible and visual alarm, prompting the operator to complete the position calibration of the industrial camera and laser displacement sensor or the mechanical origin reset operation of the equipment.

[0075] Step 7: After the attitude adjustment is completed, the integral data is cleared to ensure the consistency of multi-configuration product adjustment. After the attitude adjustment of a single section is qualified, the control calculation system automatically clears the cumulative PID integral data of each servo axis, eliminates the error residue generated in the previous workpiece adjustment process, avoids fixed attitude deviation when switching production of sections with different diameters and lengths, and ensures the accuracy, stability and consistency of adaptive attitude adjustment of all specifications of sections.

[0076] The above description is merely the preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A high-precision adaptive motion control device adaptable to multiple mechanical configurations, characterized in that, Includes automatic loading and unloading devices, automatic measurement / orientation docking devices, and control and computing systems; The automatic loading and unloading device is equipped with grippers, which are used to grab different specifications of test compartments onto the automatic measurement / attitude adjustment docking device. The automatic measurement / attitude adjustment docking device is equipped with a base, on which are arranged an attitude adjustment support mechanism, an auxiliary docking mechanism, a central measurement mechanism, and a feature measurement mechanism that can slide along the base. The posture adjustment support mechanism has multi-axis motion capability, the auxiliary docking mechanism integrates force sensing and displacement sensing elements, and the central measuring mechanism and the feature measuring mechanism are respectively equipped with vision and distance sensing components. The control and computing system is electrically connected to all mechanisms and is used to control and complete the visual measurement, displacement calculation, and control axis movement of the section under test.

2. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to claim 1, characterized in that, The posture adjustment support mechanism integrates an X-axis motion structure, a Y-axis motion structure, a Z-axis lifting structure, and an R-axis rotation structure. The X-axis motion structure is guided by the first linear slide rail and the first slider, and achieves linear movement by relying on the meshing of the first servo motor, the first reducer, the first gear, and the first rack. The Y-axis motion structure is guided by the second linear slide rail and the second slider, and uses the first ball screw and the second servo drive to complete the lateral displacement adjustment. The Z-axis lifting structure is guided by a first linear bearing and is used in conjunction with a first screw jack to achieve lifting drive. The R-axis rotation structure is guided by the third linear slide rail and the third slider, and uses a rotation drive module to drive the attitude adjustment drive wheel. The rotation drive module works with the second ball screw to achieve spacing adjustment.

3. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to claim 1, characterized in that, The auxiliary docking mechanism integrates an X-axis movement module, a Z-axis lifting module, and a measurement reference module. The X-axis moving module uses the first linear slide rail and the first slider as guides, and achieves precise X-axis sliding of the whole machine through the meshing of the third servo motor, the second reducer, the second gear, and the first rack. The Z-axis lifting module uses a second linear bearing for guidance, and works with a second screw jack and a rotating handwheel to complete the initial height adjustment. The measurement reference module integrates the force sensor, laser displacement sensor, and tail displacement detection module to collect data on the attitude and receiving force of the tail end face of the compartment.

4. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to claim 1, characterized in that, The central measuring mechanism includes an X-axis adjustment mechanism, a Y-axis telescopic mechanism, and a central measuring reference module; The X-axis adjustment module uses a fourth linear slide rail and a fourth slider as guides, and a third ball screw and a fourth servo motor as drives. The Y-axis telescopic module is guided by the fifth linear slide rail and the fifth slider, and driven by the fourth ball screw and the fifth servo motor. The central measurement reference module is equipped with a protective cover, which integrates a camera and a light source. Multiple sets of laser displacement sensors are evenly distributed on both sides at 90° intervals.

5. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to any one of claims 1-4, characterized in that, The upper part of the base is provided with a first linear slide rail and a first slider, and a first rack is fixed on the side. The base is equipped with an attitude adjustment support mechanism base and an auxiliary docking mechanism base. Each base is equipped with a servo motor and a gear transmission structure. Through gear and rack meshing transmission, the attitude adjustment support mechanism and the auxiliary docking mechanism are driven to slide independently along the X-axis on the base.

6. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to claim 4, characterized in that, The feature measurement mechanism includes an X-axis adjustment module, a Y-axis telescopic module, and a feature measurement basic module; The X-axis adjustment module shares the fourth linear slide rail with the X-axis adjustment module, and is independently configured with the fifth ball screw and the sixth servo drive to achieve autonomous sliding. The Y-axis telescopic module has the same structural design as the Y-axis telescopic module. The feature measurement basic module includes a visual measurement module and a feature calibration module. The visual measurement module integrates a camera and a light source and is equipped with an external protective cover. It is used to measure the shape features of the compartment lugs, pin holes, and pin grooves. The feature calibration module adopts a cylinder-driven quick-change calibration head structure to achieve pin hole assembly alignment calibration.

7. The high-precision adaptive motion control device for adapting to multiple mechanical configurations according to claim 4, characterized in that, The automatic loading and unloading device uses a truss to automatically transport and transfer products. The truss integrates an X-axis motion module, a Y-axis motion module, a Z-axis lifting module, and the grippers. The grippers are compatible with various specifications of compartment products with diameters of φ100mm to φ500mm and lengths of 500mm to 6500mm. The truss transfer speed is infinitely adjustable within the range of 0 to 1.5m / s, and the single transfer cycle is controlled within 90s.

8. A control method based on the high-precision adaptive motion control device for adapting multiple mechanical configurations as described in any one of claims 1 to 7, characterized in that, Includes the following steps: The control computing system receives the segment docking production task and reads the product model and structural parameters, controls the automatic loading and unloading device to adjust the opening and closing size of the grippers, and adjusts the spacing of the attitude adjustment support mechanism. The automatic loading and unloading device is controlled to transfer the product's docking compartment to the attitude adjustment support mechanism station, and the auxiliary docking mechanism is controlled to slide to the tail of each compartment. The end face attitude data is collected in real time and uploaded to the control calculation system. The attitude deviation is calculated by controlling the computing system and driving the attitude adjustment support mechanism to make fine adjustments so that the end face of each docking section is parallel to the reference plane of the docking device. The central measuring mechanism is extended, and laser ranging and visual detection are combined to calculate the center coordinates of each docking section, and the calculated data is sent to the control computing system. The control calculation system calculates the adjustment amount and controls the attitude adjustment support mechanism to adjust the attitude according to the adjustment amount, so that the central axis of each docking section coincides with the virtual axis of the docking device. The feature measurement mechanism measures the feature data of the section to be docked and sends the measurement data to the control calculation system, which then calculates the adjustment amount based on the measurement data. The attitude adjustment support mechanism is controlled to adjust according to the adjustment amount, so that the features of the front and rear compartments of the product are consistent. After passing the retest, all measuring mechanisms are reset, and the attitude adjustment support mechanism is controlled to perform feed docking. The docking load is monitored in real time by force sensors throughout the docking process to avoid squeezing and shearing damage. After docking is completed, the whole machine is reset.

9. The control method according to claim 8, characterized in that, The control and calculation system uses a PID algorithm to convert visual deviations into compensation amounts for each axis, thereby achieving closed-loop attitude adjustment.

10. The control method according to claim 8, characterized in that, The control and calculation system is equipped with a two-level force threshold protection mechanism. During the docking process, the docking axial force and torque data are collected in real time. When the docking force reaches the first-level threshold, the control and calculation system drives the attitude adjustment support mechanism to make fine adjustments to avoid shearing damage to the docking seal ring. When the docking force exceeds the limit and triggers the second-level threshold, the docking operation is immediately suspended and an alarm is triggered to achieve flexible protection and safety management of the product.

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