A control method for a parallel groove clamp dismounting tool

Abstract

The present application relates to the technical field of live working tool control, and discloses a control method of parallel groove clamp dismounting tool, which comprises the following steps: a power management step, which carries out multi-stage isolation conversion and power distribution; a logic control step, which runs a multi-source feedback closed-loop control algorithm, dynamically allocates control weights based on real-time pressure and rotating speed, introduces load feedforward compensation, simultaneously combines a sliding time window to execute fault joint determination of mechanical sticking and overload, and generates a PWM control signal; a data interaction step, which realizes bidirectional wireless transmission of device state and remote control instruction; and an execution driving step, which drives the motor to run and collects sensor feedback signals in real time. Through software and hardware cooperation and segmented variable structure closed-loop regulation, the present application solves the defects of open loop and easy damage of existing tool control, realizes remote real-time monitoring of aerial work and autonomous shutdown protection under abnormal working conditions, and improves the safety and dismounting efficiency of live working.

Description

Technical Field

[0001] This invention relates to the field of live-line working tool control technology, specifically a control method for a parallel groove clamp disassembly tool. Background Technology

[0002] Parallel groove clamp removal tools are specialized portable devices used in power line operation and maintenance to disconnect conductor splice clamps. In live-line work or power outage maintenance scenarios on transmission and distribution lines, workers need to safely and non-destructively disconnect the parallel groove clamps to avoid conductor damage and safety hazards caused by traditional manual knocking or brute force removal.

[0003] Currently, most existing wire clamp removal tools on the market employ manual operation or simple open-loop electric drive, resulting in significant limitations in their overall architecture and control logic. Firstly, the existing tools' motor drive methods are relatively simple, unable to dynamically adjust the motor's output torque and speed according to the actual load. When encountering sudden high-resistance conditions such as severely corroded bolts or deformed clamps during actual operation, the lack of closed-loop regulation means the motor often continuously outputs maximum torque, easily leading to motor overheating and burnout or physical damage to the transmission mechanism. Secondly, power line maintenance often takes place in high-altitude, live-line environments, requiring operators to maintain a safe distance from the work site. However, existing tools generally lack remote data communication capabilities. This not only prevents operators from obtaining real-time information on the tool's current pressure, speed, and stroke position, but more critically, when the equipment experiences mechanical jamming, overload, or limit-reaching abnormalities at the remote end, the lack of local fault self-diagnosis and autonomous protection mechanisms prevents emergency intervention from being implemented remotely. This significantly increases the risk of equipment damage and operational failure.

[0004] Furthermore, in actual engineering projects, there are numerous specifications of parallel cable clamps, and different models of clamps require different disassembly forces and stroke parameters. The control system parameters of existing tools have poor adaptability, often requiring operators to rely on repeated blind adjustments based on personal experience when facing different working conditions. This not only leads to poor consistency in construction operations but also severely restricts overall emergency repair efficiency. In conclusion, existing control methods are insufficient to meet the practical engineering requirements of modern power grids for intelligent, highly reliable, and highly adaptive live-line working tools. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a control method for a parallel groove clamp disassembly tool, which solves the problems of easy damage and lack of safety protection caused by the use of open-loop control in existing parallel groove clamp disassembly tools for high-altitude live-line operations.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A control method for a wire clamp removal tool, the tool comprising a main unit and multiple circuit boards mounted on the main unit, wherein a battery is installed at the bottom of the main unit, and the control method comprising the following steps: The DC power supply is converted into multiple isolated DC power supplies of different voltage levels through a DC-DC isolation module and distributed to the various power modules of the disassembly tool. Run the preset control algorithm, collect feedback signals from peripheral devices, perform calculations and judgments, generate control signals, and establish a communication link; The device transmits data bidirectionally between the device and the external network through the communication link, receives control commands issued by the remote host computer and inputs them into the preset control algorithm, and at the same time sends the device status data processed by the preset control algorithm back to the external network. The system receives the control signal to drive the motor to perform the disassembly action, and simultaneously collects the feedback signal during the disassembly process, which is then transmitted back to the preset control algorithm as the peripheral feedback signal.

[0007] Preferably, the peripheral feedback signal includes the actual pressure value and the actual speed value transmitted back when the motor is running; The preset control algorithm includes a multi-source feedback closed-loop control algorithm, which includes: Simultaneously collect the actual pressure value and the actual rotation speed value; Based on the actual pressure value, the working condition is identified, and the disassembly process of the parallel groove clamp is divided into three working condition stages: no-load approach, thread engagement, and gland fitting. Based on the actual pressure value, the speed weight and pressure weight of the control signal are dynamically allocated, the comprehensive control error is calculated, and the control signal output to the motor is adjusted.

[0008] Preferably, when in the thread engagement stage, the dynamic allocation strategy for the speed weight and the pressure weight is as follows: The velocity weight decreases linearly as the actual pressure value increases; The pressure weight increases linearly as the actual pressure value increases.

[0009] Preferably, the control signal includes a PWM control signal; The multi-source feedback closed-loop control algorithm further includes load disturbance feedforward compensation logic, which includes: Based on the pressure change rate of the actual pressure value collected, a corresponding feedforward compensation amount is generated; The feedforward compensation amount is used to superimpose and adjust the PWM control signal output to the motor.

[0010] Preferably, the preset control algorithm further includes mechanical jamming fault determination logic; Mechanical jamming fault is determined to occur only when all three conditions are met simultaneously: the actual rotational speed is lower than the minimum allowable rotational speed, the actual pressure value collected is greater than the overload threshold, and the cumulative pressure change within the preset sliding time window is greater than the jamming pressure change threshold. When the mechanical jamming fault is detected, the control signal output to the motor is immediately blocked, the jamming fault code is transmitted back through the communication link, and the motor is controlled to reverse and retreat.

[0011] Preferably, the preset control algorithm further includes continuous overload protection determination logic; The continuous overload protection judgment logic uses the time window integration method to calculate the cumulative overload duration when the actual pressure value is greater than the maximum allowable pressure threshold. The shutdown protection is triggered and the output of the control signal to the motor is stopped only when the cumulative overload duration exceeds the set trip threshold.

[0012] Preferably, the preset control algorithm further includes a parameter adaptive mapping algorithm, which specifically includes: Receive the wire clamp specification code sent by the remote host computer through the communication link; Based on the wire clamp specification code, the corresponding baseline parameters are obtained by table lookup or interpolation. The baseline parameters are corrected by combining a preset environmental compensation factor to obtain the actual operating control parameters, and the actual operating control parameters are input into the preset control algorithm.

[0013] Preferably, the step of converting the DC power supply into multiple isolated DC power supplies of different voltage levels through a DC-DC isolation module and distributing them to the various power modules of the disassembly tool specifically includes: The input DC power supply is divided into two paths: The first path is converted to 12V DC power through the first isolation conversion module and output to the execution drive unit that drives the motor; The second path is converted to 5V DC power through the second isolation conversion module and output to the main control element running the preset control algorithm, the data interaction unit for bidirectional data transmission, and the sensor for collecting feedback signals from the peripheral devices.

[0014] Preferably, in the steps of running a preset control algorithm, collecting peripheral feedback signals and performing calculations and judgments to generate control signals and establish a communication link, the process of establishing a communication link specifically includes: A serial-to-WiFi module is used to access the external network. The serial-to-WiFi module supports two network working modes: STA mode and AP mode. The device status data transmitted back to the external network includes pressure values, motor speed, stroke position, and device fault codes.

[0015] Preferably, before running the preset control algorithm, a power-on self-test program for the disassembly tool is also included: After the disassembly tool is powered on, the output voltage after the DC power supply conversion, the working status of the logic control unit running the preset control algorithm, the communication status of the communication link, and the status of the motor are detected sequentially. When the self-test program does not detect a system fault, it enters standby mode; When a fault is detected, the output of the control signal is stopped, and the fault code is reported through the communication link.

[0016] This invention provides a control method for a grooved wire clamp disassembly tool. It has the following beneficial effects: 1. This invention uses a multi-source feedback closed-loop control algorithm to identify operating conditions and dynamically allocate control weights for speed and pressure based on real-time collected pressure and speed data. At the same time, it introduces feedforward compensation logic based on the pressure change rate to adjust the PWM output, enabling the disassembly tool to autonomously balance the motor speed and torque according to the actual physical resistance of the parallel groove clamp. This effectively suppresses system overshoot caused by sudden load changes and avoids equipment damage or wire damage caused by continuous maximum torque output of traditional open-loop motors.

[0017] 2. This invention introduces a fault joint judgment logic based on multi-dimensional state space and sliding time window integration, taking real-time speed stall, pressure over-limit state and time accumulation as comprehensive judgment conditions, and adding a parameter adaptive mapping algorithm before the execution step. This not only effectively filters out the misjudgment of shutdown caused by brief resistance fluctuations during disassembly, but also achieves precise yielding and protection against mechanical jamming and continuous overload. It can also automatically match the benchmark control parameters according to the remotely issued clamp specification code, solving the problem of inconsistent standards caused by manual blind adjustment.

[0018] 3. This invention uses a DC-DC isolation conversion module to separate strong and weak current power supply, and adopts a serial port to WiFi module that supports both STA and AP network modes to establish a two-way communication link between the device and the external network. While eliminating power ripple interference caused by motor start-stop and ensuring stable operation of the underlying hardware, it also realizes real-time remote transmission of equipment status data and remote issuance of control commands in high-altitude operation scenarios, thereby improving the remote monitoring capability and safety of live-line construction operations. Attached Figure Description

[0019] Figure 1 This is a system architecture diagram of a parallel groove clamp disassembly system according to an embodiment of the present invention; Figure 2 This is a flowchart of a control method for a grooved clamp disassembly tool according to an embodiment of the present invention. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] See attached document Figure 1 This invention provides a wire clamp removal system, implemented based on the hardware architecture of the removal tool itself. The removal tool includes a main unit and multiple circuit boards mounted on the main unit, with a battery installed at the bottom of the main unit. Physically, the removal tool includes a power management unit, a logic control unit, a data interaction unit, and an execution drive unit.

[0022] The power management unit adopts a wide voltage input design and integrates a DC-DC isolation module to convert the DC power input from the battery into multiple isolated DC power supplies of different voltage levels, thereby providing stable and clean power support for all units and eliminating interference caused by power ripple and voltage fluctuations.

[0023] The logic control unit uses an STM32 series microcontroller as its main control core and is equipped with general-purpose input / output interfaces, analog-to-digital conversion channels, and serial communication interfaces. The logic control unit is responsible for relying on the pre-set control algorithm based on the allocated power supply, collecting feedback signals from peripherals, performing calculations and judgments, and converting abstract instructions into specific control signals.

[0024] The data interaction unit uses a USR-WIFI232-B2 serial-to-WiFi module, supporting both STA and AP network operating modes. One end of the data interaction unit connects to the logic control unit via a serial communication interface, while the other end connects wirelessly to an external network, enabling bidirectional data transmission between the device and the external network.

[0025] The actuator unit includes a motor driver chip, a DC motor, a mechanical transmission mechanism, and various peripheral sensors. These peripheral sensors include an encoder mounted on the DC motor output shaft, a pressure sensor mounted on the disassembly actuator, and limit switches.

[0026] See attached document Figure 2This invention provides a control method for a grooved wire clamp disassembly tool, comprising the following steps: S1, the power management step, provides stable power support for all subsequent units through wide voltage input, multi-stage DC-DC isolation conversion and power distribution; S2, the logic control step, relies on the power operation preset control algorithm provided by the power management step to collect peripheral feedback signals and perform calculations and judgments to generate specific control signals; S3, the data interaction step, relies on the serial communication link provided by the logic control step to receive control commands issued by the remote host computer and pass them to the logic control step. At the same time, it sends the device status data processed by the logic control step back to the user. S4 executes the drive step, receives control commands from the logic control step, and converts electrical signals into actual physical actions based on the power support provided by the power management step, driving the motor to run. At the same time, it collects feedback signals during the execution process and sends them back to the logic control step.

[0027] Before executing steps S1 to S4, the system performs a self-test procedure after power-on. The logic control unit sequentially detects the output voltage of the power management step, the operating status of the logic control step, the communication status of the data interaction step, and the motor status of the drive execution step.

[0028] When the self-test program detects a system fault, the logic control unit immediately stops all control signal outputs and sends the fault code to the remote host computer via the data interaction unit. When the self-test program does not detect a system fault, the logic control unit enters standby mode, waiting to receive control commands from the remote host computer. After receiving the control command and completing the disassembly of the parallel groove clamp, the logic control unit controls the execution drive unit to reset to its initial position and sends disassembly completion status information to the host computer via the data interaction unit, forming a complete work loop.

[0029] In this embodiment, the four steps are linked in real time. Step S1 is the hardware foundation and specifically includes the following sub-steps: S101, an external 9V to 36V wide-range DC power supply is connected to the power management unit via the XT60 high-current interface, and then splits into two independent power supply branches. The first DC power supply is input to the first isolation conversion module, specifically the URB2412YMD-10WR3 isolation conversion module in this embodiment, which outputs a 12V DC power supply after isolation conversion. The second DC power supply is input to the second isolation conversion module, specifically the URB2405YMD-10WR3 isolation conversion module in this embodiment, which outputs a 5V DC power supply after isolation conversion.

[0030] The S102 distributes the 12V DC power supply as a high-power branch. The 12V DC power supply is distributed to the motor driver chip, cooling fan, and high-power peripherals through the XT60 output interface and screw terminals.

[0031] S103 distributes the 5V DC power supply as a low-voltage power supply branch. The 5V DC power supply is distributed to the main control components through the PH2.0 pin header interface, specifically the main control microcontroller, serial-to-WiFi module, signal conditioning circuit, and sensor in this embodiment.

[0032] S104 connects LED indicators in parallel to the output terminals of the two DC-DC isolation conversion modules. The on / off state of the LEDs indicates the power-on status of the corresponding output circuit. Voltage test points are reserved on the PCB board of the power management unit to measure the input and output voltages of the two modules. Furthermore, a resistor-based voltage divider sampling circuit is installed in the bypass circuit at the output terminal to step down the 12V and 5V output voltages according to a set ratio, converting them into low-voltage analog electrical signals that can be safely read by the microcontroller's analog-to-digital conversion channel.

[0033] S105 executes the data validity constraint logic. When the main control microcontroller detects that the 5V or 12V output voltage exceeds the allowable operating range through the resistor voltage divider sampling circuit, the system directly discards all sensor sampling data collected in the current control cycle, does not perform closed-loop calculation, and marks the sampling state of the current cycle as invalid. The allowable operating range is determined based on the electrical tolerance characteristics of the subsequent chips. In this embodiment, the allowable operating range for the 5V low-voltage circuit is set to 4.75V to 5.25V, and the allowable operating range for the 12V high-voltage circuit is set to 10.8V to 13.2V.

[0034] In this embodiment, step S2 serves as the main control computing center, completing signal processing and closed-loop computation, and specifically includes the following sub-steps: S201, the STM32 series microcontroller in the logic control unit, immediately executes the system initialization program after receiving power, sequentially configuring the general-purpose input / output interface, timer, analog-to-digital converter acquisition channel, and serial communication interface. After configuration, the microcontroller reads preset control algorithm parameters from its internal Flash memory. These preset control algorithm parameters include motor speed parameters, disassembly stroke parameters, pressure threshold parameters, and fault judgment threshold parameters.

[0035] S202, define the current control cycle as... The previous control cycle was The microcontroller synchronously acquires the actual pressure value fed back by the drive unit in the current cycle through the analog-to-digital converter acquisition channel and general-purpose input / output interface. and actual speed value The pressure change rate and speed change rate are calculated separately. For detailed mathematical expressions, please refer to the correlation and coupling algorithm between each step in the following text.

[0036] S203, construct a dynamic weight allocation model based on working condition identification. The disassembly process of the parallel groove clamp is physically divided into three stages: unloaded approach, thread engagement, and gland contact. A pressure stage threshold is set. and ,in Less than When the actual pressure falls within different ranges, the microcontroller dynamically allocates speed control weights and pressure control weights. During the thread engagement stage, the speed weight decreases linearly as the actual pressure value increases, while the pressure weight increases linearly as the actual pressure value increases. Based on this, the comprehensive control error is calculated. For a detailed mathematical expression, please refer to the correlation and coupling algorithm between each step below.

[0037] S204 introduces load disturbance feedforward compensation logic based on pressure change rate. Based on the pressure change rate of the collected actual pressure value, a corresponding feedforward compensation amount is generated to intervene in the PWM output in advance. For detailed mathematical expressions, please refer to the correlation and coupling algorithm between each step below.

[0038] S205 calculates the PWM duty cycle increment and the current cycle duty cycle output to the execution drive unit. Using incremental proportional-integral-derivative (PID) arithmetic combined with feedforward compensation, the microcontroller outputs the corresponding duty cycle PWM control signal and direction control signal to the motor drive chip, completing closed-loop control.

[0039] S206 executes the mechanical jamming fault determination logic. The microcontroller allocates a space of length [length missing] in its internal RAM. A circular queue that caches the most recent data in real time. The pressure and speed value sequences for each control cycle. When simultaneously satisfying: A. Stalling occurs when the current speed is below the minimum permissible speed; B. The current pressure is greater than the overload threshold; C. When the cumulative pressure change within the sliding window exceeds the set threshold, it is determined to be a mechanical jamming fault. Mechanical jamming is a secondary shutdown protection fault. After jamming is determined, the microcontroller blocks the PWM output, reports the jamming fault code, and triggers the reverse yielding subroutine to control the motor to run in reverse by a preset angle, such as 30°, to release mechanical stress.

[0040] S207 executes the continuous overload protection judgment logic. The sliding time window integration method is used to calculate the cumulative duration of pressure exceeding the limit; specific integration conditions are detailed in the algorithm section below. When the cumulative overload duration exceeds the set trip threshold, it is determined to be a continuous overload, triggering shutdown protection and reporting a fault.

[0041] S208 performs supplementary fault classification judgment for the entire machine. If a DC-DC output failure, main control hardware malfunction, or multiple consecutive reconnection failures of the serial-to-WiFi module are detected, it is judged as a Level 3 fatal fault. All motor outputs are cut off and the system power supply is maintained at a minimum. Any disassembly is prohibited, and fatal fault codes are reported cyclically through the data interaction unit. When communication fails, local LED indicator lights provide an alarm. Level 1 alarms are for recoverable conditions such as minor speed deviations. The system only performs closed-loop correction and does not interrupt operation.

[0042] S209 executes an adaptive mapping algorithm for parameters. To adapt to different specifications of parallel groove clamps and complex operating environments, the logic control unit receives clamp specification codes from a remote host computer via a data interaction unit. The microcontroller, based on the clamp specification code, retrieves the corresponding reference parameters from its internal memory through table lookup or interpolation. Target speed. and target pressure The combined values ​​are stored in the MCU code in advance. Based on the actual operating control parameters obtained, the corresponding target values ​​are selected and input into the control algorithm. This algorithm effectively avoids manual blind tuning.

[0043] Furthermore, to ensure the effective execution of the aforementioned multi-source feedback closed-loop control algorithm and fault joint judgment logic, in this embodiment, the preset control algorithm parameters, various judgment thresholds, and control coefficients are acquired and stored in the following ways: For the stress stage threshold , Threshold for change in stagnant pressure and tripping threshold The resistance characteristics of the parallel groove clamp under different corrosion conditions were pre-calibrated by those skilled in the art through offline disassembly tensile testing and fatigue statistics; the minimum allowable speed was determined in advance. With load overload threshold It is obtained by equivalent conversion based on the rated speed and maximum stall current parameters on the nameplate of the selected DC motor.

[0044] For incremental PID control parameters , , and feedforward gain coefficient The initial tuning was performed using the Ziegler-Nichols step response method, and fine-tuning was conducted based on the on-site load operation conditions; the total number of cycles for the hysteresis assessment sliding window was determined. Total number of cycles of the overload assessment sliding window The environmental compensation factor is determined based on the system sampling frequency and the response delay time of the mechanical transmission system, with high-frequency sensor noise being filtered out. The environmental compensation factor is extracted through a pre-established empirical function mapping table of the relationship between ambient temperature and lubricating grease viscosity.

[0045] All the thresholds and coefficients obtained from the above calibration are pre-stored in the non-volatile memory inside the STM32 series microcontroller, such as Flash, and are loaded into the random access memory (RAM) for operation during system power-on initialization.

[0046] In this embodiment, step S3 completes the uplink and downlink data forwarding, specifically including the following sub-steps: The S301, USR-WIFI232-B2 serial-to-WiFi module automatically loads preset WiFi configuration parameters after power-on. The preset WiFi configuration parameters include service set identifier, network access password, network working mode, and target server address.

[0047] S302 selects the corresponding operating mode and communication protocol according to the preset configuration parameters. When operating in STA mode, it connects to an external wireless router to access the Internet; when operating in AP mode, it creates a local wireless network for terminals to connect directly. The module supports three communication protocol modes: TCP client, TCP server, and UDP. When the connection with the remote host computer is lost, the module automatically attempts to re-establish the connection according to the preset reconnection interval, which is set to 3 to 5 seconds in this embodiment.

[0048] The S303 microcontroller encapsulates measured pressure, speed, and stroke status data according to a preset communication protocol. This protocol uses a data frame format including a frame header, valid data segments, and a cyclic redundancy check (CRC) code to prevent data tampering and malfunctions caused by strong electromagnetic interference. The data is packaged and sent via the serial communication interface. The data interaction unit receives serial port data, converts it into WiFi network data packets, and sends it to the remote host computer. In the downlink direction, the data interaction unit receives control command data packets from the remote host computer, converts them into serial port data, and sends them to the microcontroller's serial communication interface. The microcontroller then parses the data and inputs it into the control algorithm.

[0049] In this embodiment, step S4 performs physical drive and feedback acquisition. The core principle of step S4 is to convert the weak digital logic level output by the microcontroller into physical electrical energy to drive the high-power DC motor through the H-bridge power amplifier circuit, while simultaneously capturing mechanical state parameters in real time through an external sensor network, forming a mechatronic closed-loop control link. Specifically, it includes the following sub-steps: S401, the execution drive unit receives the PWM control signal and direction control signal issued by the logic control step through the general-purpose input / output interface. In this embodiment, the motor drive chip can be a TB6612FNG or L298N chip with a built-in H-bridge topology. The microcontroller outputs a combination of high and low level signals as direction control signals through two general-purpose input / output ports. For example, a combination of one high and one low level controls the forward or reverse operation of the DC motor, and a combination of two low or two high level signals controls the braking and stopping of the DC motor. The motor drive chip adjusts the average voltage output to both ends of the DC motor according to the duty cycle of the PWM control signal, and switches the output current direction according to the current high and low level combination signal.

[0050] The S402 motor driver chip outputs the regulated current to the DC motor. The DC motor then drives the parallel groove clamp disassembly actuator via a mechanical transmission mechanism to perform a physical disassembly action.

[0051] The S403 encoder, mounted on the output shaft of the DC motor, collects the motor's speed and angle in real time, converts the collected signals into quadrature A / B phase pulse signals, and outputs them to the advanced timer interface of the logic control unit for quadrature decoding. The pressure sensor mounted on the actuator collects the physical pressure during the disassembly and extrusion process in real time, and outputs the analog signal to the analog-to-digital conversion channel of the microcontroller.

[0052] S404 performs fault protection auxiliary actions. Limit switches installed at both ends of the actuator trigger a hardware-level signal output to the microcontroller's external interrupt pin when they reach their extreme positions. When the microcontroller detects a limit interrupt trigger or pressure over-limit, it immediately stops the PWM output before the main loop task to prevent rigid collision damage to the mechanical structure due to over-travel. Furthermore, the cooling fan configured in the actuator drive unit continues to run after system power-on, providing air cooling for the motor drive chip and power devices.

[0053] In this embodiment, the aforementioned external peripherals, such as limit switches, pressure sensors, encoders, and status indicator lights, are all connected to the circuit board of the execution drive unit in a plug-and-play manner through multiple sets of PH2.0 pin header interfaces.

[0054] In the control method of this invention, S1 power management, S2 logic control, S3 data interaction, and S4 execution drive are not simply executed sequentially, but rather form a closed-loop control architecture with real-time bidirectional linkage. Its core data association coupling algorithm and mathematical calculations are fully expressed as follows: The rate of change of pressure is calculated according to formula (1). Equation (1): ; The rate of change of rotational speed is calculated according to formula (2). Equation (2): ; In the formula, Indicates the first Control the rate of pressure change during the control cycle. Indicates the first Control cycle measured pressure, This indicates the measured pressure in the previous control cycle; Indicates the first The rate of change of rotational speed during the control cycle. Indicates the first Control cycle measured speed, This indicates the measured rotational speed in the previous control cycle.

[0055] By calculating the period difference, the load change trend is quantified in real time, providing dynamic data support for subsequent feedforward compensation and solving the problem that single-point sampling is easily affected by high-frequency noise interference.

[0056] Dynamic weight allocation and calculation of integrated control error: During the thread engagement stage, the speed weight and pressure weight are calculated according to equations (3) and (4), respectively. Equation (3): ; Equation (4): ; The pressure weight is derived from the speed weight, and the two exhibit a complementary linear relationship to ensure that the final calculated comprehensive control error meets expectations.

[0057] The overall control error is calculated according to formula (5). Equation (5): ; In the formula, Indicates the first Comprehensive control error during the control cycle Indicates the preset target speed. Indicates the preset target pressure; Indicates speed weight, Indicates pressure weight. and This indicates the preset pressure stage threshold.

[0058] Dynamically matching the control requirements of different physical stages of disassembly solves the technical pain point that fixed control parameters cannot simultaneously take into account both rapid approach under no-load conditions and high-precision force control for clamping.

[0059] The load disturbance feedforward compensation is calculated according to equation (6). Equation (6): ; In the formula, Indicates the first Feedforward compensation for periodic load disturbance. This represents the feedforward gain coefficient. This function represents the sign of the input; it outputs 1 when the input is greater than 0, -1 when the input is less than 0, and 0 when the input is equal to 0. This represents the nonlinear adjustment index. In this embodiment... The range of values ​​for the engineering parameters is set to 0.5 to 1.5.

[0060] By intervening in advance in the PWM output, the speed drop or pressure overshoot caused by sudden changes in resistance when removing rusted bolts or breaking through the thread engagement point can be effectively suppressed.

[0061] The duty cycle increment and the final duty cycle are calculated according to equations (7) and (8). Equation (7): ; Equation (8): ; In the formula, Indicates the increment of PWM duty cycle. , , These represent the proportional, integral, and differential coefficients, respectively. This indicates the overall control error for this cycle. and These represent the combined control errors of the previous control cycle and the two previous control cycles, respectively. This indicates the amount of load disturbance feedforward compensation for this cycle. This indicates the PWM duty cycle for the current period. This indicates the PWM duty cycle of the previous cycle.

[0062] It achieves precise closed-loop control of force and position, avoiding motor burnout or wire damage caused by the continuous output of maximum torque by the open-loop system.

[0063] The cumulative change in the mechanical jamming judgment condition is calculated according to formula (9). Equation (9): ; In the formula, Indicates the threshold value for changes in stagnant pressure; This represents the total number of cycles in the lag evaluation sliding window, i.e., the total number of sampling points buffered in the circular queue. Indicates the summation index within the time window. Indicates the first The measured pressure during the control cycle, Indicates the first The measured pressure of the control cycle. It is only judged as stuck when the speed drop, pressure over-limit and cumulative change conditions of equation (9) are met simultaneously.

[0064] Distinguish between normal transient impacts and real mechanical jamming, avoid erroneous shutdowns caused by simple threshold judgments, and ensure the continuity of high-altitude operations.

[0065] The integral of the continuous overload protection time window is calculated according to equation (10). Equation (10): ; In the formula, Indicates the cumulative duration of overload. Indicates the single control cycle time. This indicates the total number of cycles in the overload assessment sliding window. This is an indicator function that outputs 1 when the condition within the parentheses is true and 0 when the condition is false. Indicates the maximum allowable pressure threshold; This represents the summation index within the overload assessment window. Indicates the first Measured pressure during the control cycle.

[0066] By integrating over a time window to filter out brief spikes and overloads, shutdown protection is triggered only for continuous overloads, further improving equipment safety and fault tolerance.

[0067] All the control algorithms, adaptive mapping, and fault determination data processing logic mentioned in this invention are performed locally by the embedded control system and do not rely on the AIGC large model or real-time inference of cloud computing power; the specification code and compensation factor issued by the host computer are optional configuration inputs.

[0068] Furthermore, in order to verify the actual application effect of the control method and linkage architecture of the present invention, this embodiment has produced multiple physical prototypes based on the above system architecture and provides a specific working test process and performance data verification.

[0069] In the specific workflow: First, the system connects to an external 9V to 36V DC power supply via the XT60 high-current interface, which is then divided into two inputs to the URB2412YMD-10WR3 and URB2405YMD-10WR3 DC-DC isolation conversion modules respectively. The former converts the power to 12V DC, which is then distributed to the motor driver chip, cooling fan, and high-power peripherals of the execution drive unit; the latter converts the power to 5V DC, which is then distributed to the STM32 microcontroller, USR-WIFI232-B2 module, and various sensors and signal conditioning circuits. LED indicators are connected in parallel at both output terminals to indicate the power-on status, and voltage test points are reserved on the PCB board for debugging.

[0070] Secondly, after the system powers on, a self-test program is executed first. The logic control unit sequentially checks the output voltage of the power management unit, its own operating status, the communication status of the data interaction unit, and the motor status of the drive unit. If the self-test fails, all control signal outputs are immediately stopped, and a fault code is sent to the remote host computer via the USR-WIFI232-B2 module using a TCP client or similar mode. If the self-test passes, the STM32 microcontroller sequentially configures the general-purpose input / output interface, timer, analog-to-digital converter acquisition channel, and serial communication interface, and reads the preset speed, stroke, and threshold parameters from the internal Flash memory, and the system enters standby mode.

[0071] Subsequently, upon receiving the disassembly command from the host computer via the WiFi network, the microcontroller, based on the collected analog pressure signal, limit digital signal, and encoder pulse signal, and combined with the aforementioned closed-loop control algorithm, generates PWM control signals and direction control signals. These signals are output to the actuator chip via a general-purpose input / output interface to drive the DC motor to perform the disassembly action. During this process, the cooling fan continuously runs for air cooling. When a limit switch is triggered or the pressure value exceeds the limit, the system immediately stops the PWM output. After the disassembly action is completely completed, the actuator unit is reset to its initial position and sends disassembly completion status information to the host computer.

[0072] Based on the above control system architecture, this invention selected four prototype wire clamp removal tools, labeled as wire clamp removal tool 1 to wire clamp removal tool 4, for actual operational performance testing. The test data covers the microcontroller's underlying response time and the overall execution time of the mechanical mechanism. Specific test data records are shown in Table 1. Table 1. Actual Operation Performance Test Data of Parallel Groove Clamp Removal Tool According to the test results in Table 1, the control method and system architecture provided by this invention have a high response speed in terms of underlying hardware control. Moreover, each prototype has a high degree of consistency in action when performing the complex mechanical closed-loop process of pressing, unlocking, and loosening. The single one-click fully automatic operation time is stable at 18 seconds, which can safely, efficiently and reliably complete the automated disassembly of the parallel groove clamp.

Claims

1. A control method for a wire clamp removal tool, the removal tool comprising a main unit and multiple circuit boards mounted on the main unit, wherein a battery is installed at the bottom of the main unit, characterized in that, The control method includes the following steps: The DC power supply is converted into multiple isolated DC power supplies of different voltage levels through a DC-DC isolation module and distributed to the various power modules of the disassembly tool. Run the preset control algorithm, collect feedback signals from peripheral devices, perform calculations and judgments, generate control signals, and establish a communication link; The device transmits data bidirectionally between the device and the external network through the communication link, receives control commands issued by the remote host computer and inputs them into the preset control algorithm, and at the same time sends the device status data processed by the preset control algorithm back to the external network. The system receives the control signal to drive the motor to perform the disassembly action, and simultaneously collects the feedback signal during the disassembly process, which is then transmitted back to the preset control algorithm as the peripheral feedback signal.

2. The control method for a grooved wire clamp disassembly tool according to claim 1, characterized in that, The peripheral feedback signal includes the actual pressure value and actual speed value transmitted back when the motor is running; The preset control algorithm includes a multi-source feedback closed-loop control algorithm, which includes: Simultaneously collect the actual pressure value and the actual rotation speed value; Based on the actual pressure value, the working condition is identified, and the disassembly process of the parallel groove clamp is divided into three working condition stages: no-load approach, thread engagement, and gland fitting. Based on the actual pressure value, the speed weight and pressure weight of the control signal are dynamically allocated, the comprehensive control error is calculated, and the control signal output to the motor is adjusted.

3. The control method for a grooved wire clamp disassembly tool according to claim 2, characterized in that, When the thread engagement stage is in progress, the dynamic allocation strategy for the speed weight and the pressure weight is as follows: The velocity weight decreases linearly as the actual pressure value increases; The pressure weight increases linearly as the actual pressure value increases.

4. The control method for a grooved wire clamp disassembly tool according to claim 2, characterized in that, The control signal includes a PWM control signal; The multi-source feedback closed-loop control algorithm further includes load disturbance feedforward compensation logic, which includes: Based on the pressure change rate of the actual pressure value collected, a corresponding feedforward compensation amount is generated; The feedforward compensation amount is used to superimpose and adjust the PWM control signal output to the motor.

5. The control method for a grooved wire clamp disassembly tool according to claim 2, characterized in that, The preset control algorithm also includes mechanical jamming fault determination logic; Mechanical jamming fault is determined to occur only when all three conditions are met simultaneously: the actual rotational speed is lower than the minimum allowable rotational speed, the actual pressure value collected is greater than the overload threshold, and the cumulative pressure change within the preset sliding time window is greater than the jamming pressure change threshold. When the mechanical jamming fault is detected, the control signal output to the motor is immediately blocked, the jamming fault code is transmitted back through the communication link, and the motor is controlled to reverse and retreat.

6. The control method for a grooved wire clamp disassembly tool according to claim 2, characterized in that, The preset control algorithm also includes continuous overload protection judgment logic; The continuous overload protection judgment logic uses the time window integration method to calculate the cumulative overload duration when the actual pressure value is greater than the maximum allowable pressure threshold. The shutdown protection is triggered and the output of the control signal to the motor is stopped only when the cumulative overload duration exceeds the set trip threshold.

7. The control method for a parallel groove clamp disassembly tool according to claim 1, characterized in that, The preset control algorithm further includes a parameter adaptive mapping algorithm, which specifically includes: Receive the wire clamp specification code sent by the remote host computer through the communication link; Based on the wire clamp specification code, the corresponding baseline parameters are obtained by table lookup or interpolation. The baseline parameters are corrected by combining a preset environmental compensation factor to obtain the actual operating control parameters, and the actual operating control parameters are input into the preset control algorithm.

8. The control method for a grooved wire clamp disassembly tool according to claim 1, characterized in that, The process of converting DC power into multiple isolated DC power supplies of different voltage levels via a DC-DC isolation module and distributing them to the various power modules of the disassembly tool specifically includes: The input DC power supply is divided into two paths: The first path is converted to 12V DC power through the first isolation conversion module and output to the execution drive unit that drives the motor; The second path is converted to 5V DC power through the second isolation conversion module and output to the main control element running the preset control algorithm, the data interaction unit for bidirectional data transmission, and the sensor for collecting feedback signals from the peripheral devices.

9. The control method for a grooved wire clamp disassembly tool according to claim 1, characterized in that, In the steps of running a preset control algorithm, collecting feedback signals from peripheral devices and performing calculations and judgments to generate control signals and establish a communication link, the process of establishing a communication link specifically includes: A serial-to-WiFi module is used to access the external network. The serial-to-WiFi module supports two network working modes: STA mode and AP mode. The device status data transmitted back to the external network includes pressure values, motor speed, stroke position, and device fault codes.

10. The control method for a grooved wire clamp disassembly tool according to claim 1, characterized in that, Before running the preset control algorithm, a power-on self-test program for the disassembly tool is also included: After the disassembly tool is powered on, the output voltage after the DC power supply conversion, the working status of the logic control unit running the preset control algorithm, the communication status of the communication link, and the status of the motor are detected sequentially. When the self-test program does not detect a system fault, it enters standby mode; When a fault is detected, the output of the control signal is stopped, and the fault code is reported through the communication link.

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