Multi-dimensional running parameter fusion health assessment method for key components of equipment

Abstract

The application relates to the technical field of equipment state monitoring, and discloses a multi-dimensional operation parameter fusion health evaluation method for key components of equipment. Torque instructions, angular position feedback, driving power, component temperature and vibration speed in a complete displacement control action are collected according to original time stamps, a control power process is formed by torque instructions and angular velocity feedback, asynchronous parameters are mapped to common process nodes, energy response trajectories of electric input energy, thermal energy storage and vibration energy consumption are constructed, a health reference surface is established according to healthy components, a degradation envelope amount is updated according to a trajectory deviation amount, and a running control instruction of running or shutdown maintenance is formed by comparing the degradation envelope amount with a failure threshold. The application compares multi-dimensional parameters with different action lengths, load processes and sampling rates according to consistent mechanical work stages, reduces the influence of working condition changes and sampling misplacement on evaluation results, and adapts the evaluation results to equipment action permission and maintenance management.

Description

Technical Field

[0001] This application relates to the field of equipment condition monitoring technology, specifically to a multi-dimensional operating parameter fusion health assessment method for key equipment components. Background Technology

[0002] Closed-loop electric actuators widely employ servo controllers, encoders, power metering units, temperature sensors, and vibration sensors to monitor the operating status of key force-transmitting components. Existing health assessments typically extract features such as current, power, torque residuals, temperature rise, and vibration amplitude within a fixed time window or complete operating range, and then provide status results through threshold comparison, weighted fusion, statistical distance, or health templates. Such methods can reflect the overall changes in parameters, but usually require the sampling channels to have a close time reference, or require the stroke, load, speed curves, and duration of the compared actions to be basically consistent.

[0003] In flexible operation scenarios, the same critical force-transmitting component may perform complete displacement control actions with varying durations and load build-up processes. Furthermore, the controller's internal parameters and external parameters such as temperature and vibration may employ different sampling periods and transmission links. Even if each channel is interpolated to the same clock time, the resulting samples may be at different mechanical work stages; comparing only the total amount of motion can weaken the representation of local friction, jamming, or efficiency changes. Changes in operating conditions and component degradation can both cause variations in power, temperature rise, and vibration, thus easily leading to fluctuations in health status. This makes it difficult to conduct consistent and interpretable health assessments of the multidimensional operating parameters of critical force-transmitting components under varying operating conditions and asynchronous sampling. Summary of the Invention

[0004] This application provides a multi-dimensional operating parameter fusion health assessment method for key components of equipment to solve the technical problem of difficulty in aligning and assessing multi-dimensional parameters of key force transmission components under variable operating conditions and asynchronous sampling.

[0005] The first aspect of this application provides a multi-dimensional operating parameter fusion health assessment method for key equipment components, which includes the following in the online health assessment process of key force transmission components of closed-loop electric drive actuators: Collect torque commands, angular feedback, drive power, component temperature, and vibration velocity for each complete displacement control action using the original timestamp; Angular velocity feedback is obtained from angular position feedback. The absolute value of the product of torque command and angular velocity feedback is taken and integrated to form cumulative control work and total control work. The control work process is generated by the ratio of the two, the process rate and process mapping time are determined, and the drive power, component temperature and vibration speed are mapped to common process nodes. Based on the electrical input energy, thermal storage energy, and vibration energy consumption formed at the process mapping time, the local rate of change of each energy relative to the control work process is calculated, and the energy response trajectory is formed by normalizing the total control work. A health reference surface is established based on the energy response trajectory of the same type of healthy component, as well as the control work process, process rate, and total control work. The trajectory deviation is formed based on the energy response trajectory and the health reference surface. The larger value between the degradation envelope of the previous complete displacement control action and the trajectory deviation is taken to update the degradation envelope. By comparing the degradation envelope with the failure threshold, an operation control command is generated with a value that allows the system to run or to be shut down for maintenance.

[0006] The second aspect of this application provides an electronic device, including a memory and a processor. The memory stores a computer program, and when the computer program is executed by the processor, it causes the processor to perform the steps of the above-described method for multi-dimensional operating parameter fusion health assessment of key components of the device.

[0007] The third aspect of this application provides a computer-readable storage medium storing computer instructions for causing a computer to execute the aforementioned multi-dimensional operating parameter fusion health assessment method for key components of a device.

[0008] The beneficial effects of this application are as follows: By retaining the original timestamps of each acquisition channel and characterizing the progress of the complete displacement control action by the proportion of cumulative control work to total control work, this application can map multi-dimensional operating parameters with different durations and sampling rates to a consistent mechanical work stage. The energy absorbed by the drive side, changes in component heat storage, and structural vibration dissipation are converted through physical calculations, local differentiation, and normalization of total control work to form a three-dimensional energy response trajectory. This trajectory is then compared with the health reference surface under the corresponding conditions of control work progress, progress rate, and total control work, which can reduce the impact of changes in operating conditions and channel misalignment on the evaluation results. The degraded envelope retains any significant trajectory deviations that have already occurred and, based on the experimentally calibrated failure threshold, generates operational control commands for operation or shutdown maintenance, ensuring that the health assessment results are adapted to equipment operation permits and maintenance management. Attached Figure Description

[0009] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0010] Figure 1 A flowchart illustrating the multi-dimensional operational parameter fusion health assessment method for key equipment components provided in this application embodiment; Figure 2 A schematic diagram illustrating the process of constructing control function processes and mapping asynchronous operation parameters provided in this application embodiment; Figure 3 A schematic diagram illustrating a scenario for online health assessment of key force transmission components of a closed-loop electric drive actuator provided in this application embodiment; Figure 4 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application. Detailed Implementation

[0011] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this application.

[0012] It should be noted that, in the description of this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. The terms "first," "second," etc., in this application are used to distinguish similar objects and are not used to describe a specific order or sequence.

[0013] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0014] like Figure 1 As shown, the multi-dimensional operating parameter fusion health assessment method for key components of equipment includes the following steps in the online health assessment of key force transmission components of a closed-loop electric drive actuator: Step S1: Collect torque commands, angular feedback, drive power, component temperature and vibration velocity for each complete displacement control action according to the original timestamp; Step S2: Obtain angular velocity feedback from angular position feedback, take the absolute value of the product of torque command and angular velocity feedback and integrate it to form cumulative control work and total control work, generate control work process based on the ratio of the two, determine the process rate and process mapping time, and map drive power, component temperature and vibration speed to common process node. Step S3: Based on the process mapping time, the electrical input energy, thermal storage energy, and vibration energy consumption are generated. The local rate of change of each energy relative to the control work process is calculated, and the energy response trajectory is formed by normalizing the total control work. Step S4: Establish a health reference surface based on the energy response trajectory of the same type of healthy component, as well as the control work process, process rate, and total control work. Based on the trajectory deviation between the energy response trajectory and the health reference surface, take the larger value between the degradation envelope of the previous complete displacement control action and the trajectory deviation to update the degradation envelope. Step S5: Compare the degradation envelope with the failure threshold to generate an operation control command with a value that allows the machine to run or be shut down for maintenance.

[0015] In one embodiment of this application, step S1 includes the following steps: Step S101: In the online health assessment of the key force transmission components of the closed-loop electric drive actuator, the equipment controller establishes an action sequence number at the beginning of each complete displacement control action. Specifically, a complete displacement control action is defined by the existing action states of the equipment controller. The start time of the action is when the displacement control command takes effect and the action execution flag changes from inactive to active. The end time of the action is when the equipment controller confirms that the target position has been reached, the speed has entered a stopped state, and the action completion flag is set. Records that maintain position without generating a displacement control command are not assigned an action number. The action number is incremented according to the order in which the actions begin and is written into all the acquisition records generated by that action. This is used to distinguish consecutive complete displacement control actions and to ensure that the five-channel data within the same action have a consistent action attribution.

[0016] Step S102: Collect torque commands and angular position feedback according to the native timestamp of each acquisition channel. The torque commands come from the servo controller, and the angular position feedback comes from the coaxial encoder. The original timestamp is the time information recorded when each acquisition channel forms the original sample, without being resampled, averaged, or rewritten using a common time grid. The torque command is the target torque command output by the servo controller, measured in Newton-meters, and can be read from the periodic data area of ​​the servo driver control register or the real-time control bus. The angular position feedback is the angular position measurement value given by the coaxial encoder, measured in radians, which can be obtained by reading the encoder count and converting it according to the encoder resolution.

[0017] Step S103: Acquire the drive power according to the native timestamp of the drive power acquisition channel. The drive power is the non-negative absorption power measured at the DC bus input terminal, and the feedback component is returned to zero. Specifically, drive power is the input power formed by the voltage and current at the DC bus input terminal at the same sampling moment, measured in watts. The positive direction of power is defined as the DC bus supplying energy to the driver. When the current direction indicates that the driver is feeding energy back to the DC bus, the corresponding drive power is set to zero. Voltage and current can be obtained synchronously by isolated voltage sampling circuits and isolated current sampling circuits, or they can be obtained from a driver metering interface with DC bus power output.

[0018] Step S104: Collect component temperature and vibration velocity according to the original timestamp of each acquisition channel. The component temperature comes from the temperature sensor at the housing measuring point of the key force transmission component, and the vibration velocity comes from the vibration velocity transmitter at the same housing measuring point. The component temperature is the output value of a contact temperature sensor fixed at a measuring point on the housing of the critical force-transmitting component, which can be acquired using a resistance temperature detector (RTD) or a thermocouple. The vibration velocity is the measured value output by a vibration velocity transmitter along a specified monitoring direction, measured in meters per second. In this embodiment, the "same housing measuring point" refers to a pre-determined measurement area within the same housing, where the temperature sensor and vibration velocity transmitter are respectively installed on adjacent rigid mounting surfaces within this area. During calibration and online evaluation, the measuring point area, monitoring direction, fastening method, and cable fixing method remain consistent.

[0019] In step S105, the five parameters—torque command, angular position feedback, drive power, component temperature, and vibration velocity—retain their original timestamps and are sorted by action sequence number and time within the action.

[0020] Specifically, each acquisition module uses a monotonic clock provided by the device controller. Acquisition modules not directly using this monotonic clock record their clock offset relative to it upon data access. The device controller first uses this offset to convert the native timestamp of the corresponding channel to its monotonic time base, then subtracts the start time of the corresponding action to obtain the time within the action. The unit of the time within the action is seconds. The above conversion result is used as a derived time for sorting and subsequent calculations; the native timestamp in the original sample is retained and not overwritten. The clock offset is updated upon device startup and reconnection of the acquisition modules.

[0021] Furthermore, valid samples are collected and cached near the start and end of the action, enabling each channel to complete interpolation within the full displacement control action range.

[0022] In one embodiment of this application, such as Figure 2 As shown, step S2 includes the following steps: Step S201: Perform piecewise linear interpolation on the torque command and angular position feedback according to the original timestamp so that the two are paired at the integration time. Calculate the time change rate of the angular position feedback to obtain the angular velocity feedback. In steps S201 and S202, the integral time is an ordered time node after the torque command and angular position feedback completion time are paired. Angular velocity feedback represents the rate of change of angular position feedback relative to the time within the action, in radians per second.

[0023] Specifically, the torque command and angular position feedback, converted using the same time base, are merged and sorted to form an integral time sequence. When a channel lacks an original sample at the integral time, piecewise linear interpolation is performed using two adjacent original samples from that channel. For coaxial encoders employing cyclic counting, the angular position feedback is continuously expanded based on the adjacent counting change directions to avoid unrealistic angle abrupt changes when crossing the counting start point. The angular velocity feedback at the internal integral time is determined by the change in angular position feedback on both adjacent sides and the corresponding time span. The start point of the action uses the first adjacent interval after the start point, and the end point of the action uses the last adjacent interval before the end point.

[0024] Step S202: Take the absolute value of the product of the torque command and the angular velocity feedback, integrate it from the start of the action to form the cumulative control work, and integrate it over the entire displacement control action range to form the total control work. Specifically, the formulas for calculating the cumulative control work and the total control work are as follows: in, Indicates the first A complete displacement control action from the start of the action to the moment within the action. The cumulative control work, measured in joules; Indicates the first The total control work of a complete displacement control action is expressed in joules.

[0025] Indicates the first The complete displacement control action at the integral time Torque command; Indicates the first The complete displacement control action at the integral time Angular velocity feedback.

[0026] Indicates the first A complete displacement control action range; Indicates the action sequence number; Indicates the time within the action; This indicates the integration time. In step S202, The ordered time nodes after matching the completion time of the corresponding torque command and angular position feedback; in step S302. These correspond to ordered time nodes formed according to the original sample sequence after the driving power or vibration velocity is converted using the same time base.

[0027] Furthermore, the absolute command mechanical work between adjacent integration moments is accumulated using a trapezoidal method. Each interval uses the absolute value of the product of the torque command at both ends of the interval and the angular velocity feedback, combined with the corresponding time interval to form the control work increment for that interval. The accumulated control work increases interval by interval from zero at the start of the action, with the total control work taken as the accumulated result at the end of the action. The equipment controller executes step S203 only for complete displacement control actions where the angular position feedback changes non-zero within the action interval and the total control work is positive, keeping the action from being considered a complete displacement control action for evaluation.

[0028] Step S203: Generate the control work process from the ratio of cumulative control work to total control work, and calculate the process rate; Among them, the control work process represents the proportion of the cumulative control work to the total control work, and the process rate represents the rate of change of the control work process relative to the time within the action.

[0029] Step S204: For consecutive identical dwell records of accumulated control power, only the last time is retained, and the process mapping time is obtained based on the retained records; Specifically, the calculation formulas for the control function process, the process rate, and the process mapping time are as follows: in, Indicates the first A complete displacement control action within the action time The control process; Indicates the first A complete displacement control action within the action time The process rate.

[0030] Indicates the first Control power process in a complete displacement control action The corresponding process mapping time; This represents the inverse function of the control process obtained based on the retained records; This indicates the control process.

[0031] Furthermore, continuous identical cumulative control work means that the cumulative control work of adjacent records has the same value at the numerical resolution used by the device controller to record the cumulative control work. After deleting records within the dwell interval except for the last time, the control work progress in the retained sequence monotonically increases with the time within the action. When a common process node is located between two adjacent retained records, piecewise linear inverse interpolation is performed according to the control work progress and time within the action of the two records to obtain the process mapping time. The last time of the retained dwell interval can include the component temperature changes and vibration velocity decay that occur during the dwell period in the corresponding process mapping time.

[0032] Step S205: Perform piecewise linear interpolation of drive power, component temperature and vibration speed at the common process node according to the process mapping time.

[0033] The common process nodes are a set of control process positions used by all complete displacement control actions. Common process nodes include 0s and 1s, set at equal intervals. The number of nodes is no greater than the minimum effective number of samples for the lowest sampling rate channel in all calibration actions, and is selected within this upper limit to satisfy the controller's storage capacity.

[0034] Specifically, the system collects and caches the most recent sample before the start of the action and the most recent sample after the end of the action. When there is no record of component temperature or vibration velocity at exactly the same moment at the action boundary, boundary interpolation is performed only using the most recent sample surrounding the action boundary, without extrapolation beyond the time interval defined by the most recent sample. Drive power, component temperature, and vibration velocity are all mapped according to the same process mapping time, and their respective parameter names are retained after mapping.

[0035] It should be noted that the cumulative control work is obtained by accumulating the absolute value of mechanical power represented by torque command and angular velocity feedback over time, and remains non-decreasing during forward drive, reverse drive, and braking phases. Representing the control work progress as the proportion of cumulative control work to total control work allows for the conversion of complete displacement control actions with different durations, speed curves, and load establishment processes into a common operating progress of 0 to 1. Dwell time records only retain the final moment, ensuring a single value for the process mapping time, while also preserving heat accumulation and vibration changes during dwell times. Therefore, multi-sampling rate channels can establish correspondences according to the same mechanical work stages, reducing stage mismatches caused by simply aligning according to clock time, and minimizing normal transient offsets caused by differences in action duration.

[0036] In one embodiment of this application, step S3 includes the following steps: Step S301: The equivalent heat capacity and equivalent vibration damping are calibrated by electrothermal pulse test and controlled vibration attenuation test of the same type of healthy component, respectively. Among them, equivalent heat capacity This is a positive calibration parameter that converts the component temperature difference into thermal energy storage, measured in joules per Kelvin. Equivalent vibration damping. These are positive calibration parameters used to convert the squared time integral of vibration velocity into vibration energy consumption, measured in Newton-seconds per meter. These two parameters only serve the purpose of physical energy conversion and dimensional unification; they are not used as adjustable fusion weights for the health status.

[0037] Specifically, when calibrating the equivalent heat capacity, a healthy component of the same model is fixed according to the actual installation method, and the temperature at the shell measuring point is continuously observed until the temperature does not show a continuous change exceeding the repeatability fluctuation range of the temperature measurement. An electric heating element capable of measuring input power is installed in this shell area, and a short-duration electric heating pulse is applied. The heating voltage, heating current, and component temperature are collected simultaneously to obtain the pulse input heat and the corresponding temperature rise. The equivalent heat capacity is taken as the conversion value between the input heat and the corresponding temperature rise. The pulse duration is selected to be a time interval that allows for a distinguishable temperature rise and ensures that the obtained conversion value passes the repeatability check of the test bench, in order to limit the influence of environmental heat dissipation on the conversion result. The test is repeated within the operating temperature range specified in the equipment specifications, and the average value of each conversion value that passes the repeatability check is used.

[0038] When calibrating the equivalent vibration damping, a healthy component of the same model is installed on a support and fastening structure consistent with the equipment, and a controlled pulse excitation is applied along the specified monitoring direction of the vibration velocity transmitter. The excitation device simultaneously measures the applied force and the velocity of the excitation end in the same direction, and continuously records the vibration velocity from the start of excitation until the vibration response decays to the measurement noise range. The measurement noise range is the output fluctuation range measured by the vibration velocity transmitter when the structure is stationary before excitation under the same installation, measuring point, and acquisition conditions. The mechanical energy input to the test bench is obtained based on the applied force and the velocity of the excitation end. Under the condition that the structure is stationary at both the start and end times of the test and the start and end positions are consistent, the input mechanical energy is used as the measured energy consumption of this response. The equivalent vibration damping is taken as the converted value of this measured energy consumption and the square time integral of the vibration velocity over the entire recording interval. The controlled excitation is repeated, and the average value of each converted value that passes the repeatability check of the test bench is used.

[0039] Furthermore, equivalent heat capacity and equivalent vibration damping are only used for key force-transmitting components of the same model, and are limited to the installation structure, temperature range, and vibration response range covered by the calibration test. Calibration and online evaluation use the same measuring points, monitoring directions, and installation stiffness. When changing the housing structure, measuring point location, sensor monitoring direction, or component model, the corresponding calibration must be re-performed.

[0040] Step S302: At the common process node, the driving power from the start of the action to the process mapping time is integrated to form electrical input energy, the component temperature difference between the time and the start of the action is multiplied by the equivalent heat capacity to form thermal storage energy, and the square integral of the vibration velocity in the same interval is multiplied by the equivalent vibration damping to form vibration energy consumption. Specifically, the calculation formulas for the electrical input energy, the thermal storage energy, and the vibration energy consumption are as follows: in, Indicates the first A complete displacement control action, from the start of the action to the control process... Electrical input energy at the corresponding process mapping moment, in joules; Indicates the first A complete displacement control action in the control process The thermal energy stored is calculated by converting the temperature difference of the components into equivalent heat capacity, and the unit is joules. Indicates the first A complete displacement control action, from the start of the action to the control process... The vibration energy consumption at the corresponding process mapping moment, in joules.

[0041] Indicates the first The complete displacement control action at the integral time Drive power; Indicates the first A complete displacement control action at the process mapping time Component temperature; Indicates the first The temperature of the component at the starting point of a complete displacement control action; Indicates the first The complete displacement control action at the integral time The vibration velocity.

[0042] Furthermore, the electrical input energy is accumulated in a trapezoidal manner along the same time base corresponding to the original timestamp of the drive power. Since the feedback component of the drive power has been removed in step S103, the electrical input energy is a non-negative cumulative amount. Vibration energy consumption is accumulated in a trapezoidal manner along the same time base corresponding to the original timestamp of the vibration velocity, multiplied by the equivalent vibration damping; therefore, vibration energy consumption is also a non-negative cumulative amount. Thermal energy storage is calculated by subtracting the component temperature at the start of the action from the component temperature at the process mapping time; when the component cools down during operation, the thermal energy storage is allowed to be negative, representing a reduction in heat storage relative to the start of the action.

[0043] Step S303: Perform finite difference on adjacent common process nodes, calculate the local rate of change of electrical input energy, thermal storage energy and vibration energy consumption relative to the control work process, and form the energy response trajectory in the aforementioned order after normalization of total control work. Specifically, the formula for calculating the energy response trajectory is as follows: in, Indicates the first A complete displacement control action in the control process The energy response trajectory is a three-dimensional dimensionless column vector arranged in the order of electrical input energy, thermal storage energy, and vibration energy consumption.

[0044] Indicates the first The electrical input energy of a complete displacement control action relative to the control work process The local rate of change; Indicates the first The thermal energy stored in a complete displacement control action is relative to the control work process. The local rate of change; Indicates the first The vibration energy consumption of a complete displacement control action relative to the control work process The local rate of change.

[0045] Specifically, finite difference is implemented between every two adjacent common process nodes. The local rate of change is assigned to the next node by dividing the energy increment of the two nodes by the control work process increment, with the starting point being the local rate of change of the first node interval. The three energy components use the same node rules. Subsequently, the three local rates of change are normalized with the total control work, maintaining a fixed order of electrical input energy, thermal storage energy, and vibration energy consumption, forming an energy response trajectory that can be compared node by node with the health reference surface. The three components of the energy response trajectory represent the local distribution rate of the three types of energy relative to the unit total control work within the control work process interval defined by the adjacent common process nodes, and are not equivalent to the single energy total of any original acquisition parameter or complete action.

[0046] It should be noted that the integral of the driving power reflects the electrical energy absorbed by the driving side, the component temperature difference, converted through equivalent heat capacity, reflects the heat storage change at the corresponding measuring point on the shell, and the square integral of the vibration velocity, converted through equivalent vibration damping, reflects the structural vibration dissipation in the specified direction. These three are first unified to Joules, then the control work process is locally differentiated and normalized with the total control work, resulting in a three-dimensional energy distribution trajectory independent of the total energy scale of the action. This process preserves both the location of energy changes during the action and the differences between the three physical domains of electricity, heat, and vibration, allowing changes in local friction, heat accumulation, or vibration dissipation to be represented within the corresponding process intervals. Compared to using only the total energy of the complete action, this reduces the averaging of local changes in the total cumulative energy of the entire action and improves the comparability between different action energy scales.

[0047] In one embodiment of this application, step S4 includes the following steps: Step S401: Before commissioning, collect the energy response trajectory within the rated total control power and process rate range of the same type of healthy component; The rated total control power and process rate range are jointly determined by the equipment specifications, permissible displacement control program, and rated load. Before commissioning, select healthy components of the same model that have completed assembly, lubrication, and sensor installation acceptance, and confirm their status based on independent controller position tracking, permissible temperature rise, and vibration checks. These checks are based on the permissible limits specified in the corresponding equipment acceptance documents, and the health status is not determined in reverse based on the health reference surface to be established.

[0048] Specifically, the calibration actions cover different combinations of displacement, velocity, acceleration, and load allowed by the device controller, ensuring that each common process node has a corresponding process rate sample, and that the total control power covers the range from the lower limit to the upper limit of the device's allowed total control power. Each calibration action is processed according to steps S1 to S3 to obtain the corresponding energy response trajectory.

[0049] Step S402: Perform piecewise linear interpolation based on the control work process, process rate, and total control work to establish a healthy reference surface for outputting a three-dimensional dimensionless column vector. The health reference surface is a calibration model that takes control work process, process rate, and total control work as inputs and outputs a three-dimensional dimensionless column vector. Each calibration action forms a reference sample at each common process node. For repeated actions under the same calibration conditions, the average value of the three trajectory components is taken respectively.

[0050] Specifically, a three-dimensional mesh is established according to the control work process, process rate, and total control work, and linear interpolation is performed on the three output components within each adjacent mesh cell. When the online query point is located within a mesh cell, the corresponding three-dimensional output is obtained using the vertex samples of that mesh cell. The calibration action covers the rated action combination allowed to be executed by the device controller, and the online evaluation only queries the health reference surface within the calibration value range of each input dimension, without extrapolating across the calibration boundary.

[0051] Step S403: Determine the process rate at the time of process mapping on the common process node, and query the health reference plane using the process rate and total control power. Specifically, each public process node uses the node's control power process, the process rate corresponding to the process mapping time, and the total control power of the current complete displacement control action to query, so that the health reference plane output corresponds to the current action in terms of three conditions: running progress, local process speed, and action energy scale.

[0052] Step S404: Integrate the Euclidean distance between the energy response trajectory and the health reference plane along the control work process to form the trajectory deviation, and take the larger value between the degenerate envelope of the previous complete displacement control action and the current trajectory deviation to update the degenerate envelope. Specifically, the calculation formulas for the trajectory deviation and the degenerate envelope are as follows: in, This represents a healthy reference surface that takes the control work process, process rate, and total control work as inputs and outputs a three-dimensional dimensionless column vector. This represents a three-dimensional dimensionless column vector obtained by querying the health reference surface based on the current control power process, process rate, and total control power.

[0053] Indicates the first The trajectory deviation of a complete displacement control action is a dimensionless quantity. Indicates Euclidean distance; and These represent the start and end points of the control process, respectively.

[0054] Indicates as of the date The degenerate envelope of a complete displacement control action is a dimensionless quantity. It represents the degenerate envelope of the previous complete displacement control action.

[0055] Furthermore, at the same common process node, the differences between the three components of the energy response trajectory and the three components of the health reference surface are calculated separately, and Euclidean distances are formed. Trapezoidal accumulation is used along adjacent common process nodes to obtain the trajectory deviation of the entire control power process. Starting from the second evaluated action, only the degenerate envelope of the previous action and the current trajectory deviation are compared, and the larger value is retained. No additional time decay or operating condition weights are introduced.

[0056] Step S405: The degenerate envelope of the first complete displacement control action being evaluated corresponds to the trajectory deviation.

[0057] It should be noted that taking a larger historical value can prevent a large deviation that has already been confirmed from being overwritten by a smaller result due to subsequent light loads or short-term actions.

[0058] In one embodiment of this application, step S5 includes the following steps: Step S501: The failure threshold is calibrated by accelerated wear test and normal working condition verification test of key force transmission components. The degradation envelope when it first fails to meet the acceptance requirements of controller position tracking is used as the calibration point, and the separable boundary between unfailed and failed samples is used for verification. The acceptance requirements for controller position tracking shall adopt the qualified conditions for displacement control actions that have been determined in the equipment product specifications, factory acceptance specifications or commissioning acceptance documents, including at least the allowable limits for steady-state position error and tracking error during the action process. The specific limits shall be determined based on the equipment specifications and controller parameters.

[0059] Specifically, the accelerated wear test uses multiple key force transmission components of the same model. The load and speed of each specimen's single action are maintained within the rated load and rated speed range, and the test cycle is shortened by increasing the frequency of action cycles. The complete displacement control action used for evaluation is performed at pre-set intervals with a consistent number of action cycles across all specimens. Position tracking results are checked simultaneously after each evaluation. Records that meet the acceptance requirements are marked as non-failed samples, while records that fail to meet the acceptance requirements the first time and subsequent records are marked as failed samples.

[0060] Furthermore, the failure threshold is a positive dimensionless calibration parameter that distinguishes between non-failed and failed samples. For each specimen, the degradation envelope value at the first time the controller position tracking acceptance requirements are not met is taken as the failure-side calibration point, and the degradation envelope value at the last time the acceptance requirements are met before that moment is taken as the non-failed-side sample. After summing all specimens, if the maximum non-failure value is less than the minimum failure value, the median value between the two is taken as the failure threshold. If the two types of samples overlap, no arbitrary value is set within the overlapping range; instead, the sensor installation, action coverage, sample marking, and test consistency are checked before recalibration.

[0061] Normal operating condition verification tests use healthy components of the same model and perform the same data acquisition and evaluation process as in online applications within the rated operating range covered by the healthy reference plane. Verification includes verifying that the degradation envelope of the healthy component is on the non-failure side of the failure threshold, and that the failed sample in the accelerated wear test is on the failure side. Only when both verification conditions are met simultaneously is the failure threshold written into the calibration parameter area of ​​the equipment controller.

[0062] Step S502: The device controller compares the degradation envelope with the failure threshold. If the degradation envelope is less than the failure threshold, the operation control command is set to runnable; otherwise, it is set to stop for maintenance. Specifically, the formula for determining the operation control command is as follows: in, Indicates the first The operation control command for a complete displacement control action has only the value of either "running" or "stopping for maintenance". This indicates the failure threshold.

[0063] Step S503: The operation control command is written into the equipment monitoring and maintenance interface. When the operation control command is enabled, the equipment controller maintains permission for the next complete displacement control action. When the operation control command is shut down for maintenance, the equipment controller prohibits the next complete displacement control action after the current complete displacement control action is completed and issues a maintenance request.

[0064] Specifically, after the current complete displacement control action ends and the degenerate envelope is updated, the equipment controller generates a run control command and writes the run control command, action number, and generation time as a single record into the equipment monitoring and maintenance interface. The run control command is associated with the action number that generated it and is used to control the permission status of the next complete displacement control action. If the action is allowed to run, the permission bit for the next action remains valid; if it is for shutdown and maintenance, the permission bit for the next action is cleared, and a maintenance request is sent to the maintenance interface. Changing the permission for the next action only after the current action has ended avoids interrupting the planned action during displacement control.

[0065] like Figure 3 The diagram illustrates the component layout and data interaction during the online health assessment of key force-transmitting components in a closed-loop electric drive actuator. A servo controller provides torque commands, a coaxial encoder provides angular position feedback, and the DC bus input measures drive power. Temperature sensors and vibration velocity transmitters are installed in the measurement area of ​​the key force-transmitting component housing to collect component temperature and vibration velocity data, respectively. The temperature sensor and vibration velocity transmitter are mounted on adjacent rigid mounting surfaces within the same housing measurement area. These multi-dimensional operating parameters are input to the equipment controller and used for the online health assessment of the key force-transmitting components. The equipment controller determines the operating control commands based on the degradation envelope and failure threshold obtained from the assessment and writes these commands to the equipment monitoring and maintenance interface. When the operating control command is "operational," it allows the maintenance of the next complete displacement control action. When the operating control command is "shutdown for maintenance," it prohibits the next action after the current complete displacement control action is completed and issues a maintenance request.

[0066] like Figure 4 As shown, this application provides an electronic device, which includes a memory 601 and a processor 602. The memory 601 stores a computer program. When the computer program is executed by the processor 602, the processor 602 executes a multi-dimensional operating parameter fusion health assessment method for key components of the device as described in any of the above embodiments.

[0067] Memory 601 may be an electronic memory such as flash memory, EEPROM (Electrically Erasable Programmable Read-Only Memory), EPROM, hard disk, or ROM. Memory 601 has storage space 603 for program code 604 for performing any of the method steps described above. For example, storage space 603 for program code may include various program codes 604 for implementing the various steps in the methods described above. This program code can be read from or written to one or more computer program products. These computer program products include program code carriers such as hard disks, CDs, memory cards, or floppy disks. The program code may be compressed, for example, in a suitable form. When run by a computing processing device, this code causes the computing processing device to perform the various steps in the methods described above. This program code can be read from or written to one or more computer program products. These computer program products include program code carriers such as hard disks, CDs, memory cards, or floppy disks. The program code may be compressed, for example, in a suitable form. When this code is run by a computing device, it causes the computing device to perform the various steps in the multidimensional operational parameter fusion health assessment method for key device components described above.

[0068] This application also provides a computer-readable storage medium storing a computer program thereon; when the computer program is executed by a processor, it implements the multi-dimensional operating parameter fusion health assessment method for key components of equipment as described in any embodiment of this application.

[0069] A portion of this application can be applied as a computer program product, such as computer program instructions, which, when executed by a computer, can invoke or provide the methods and / or technical solutions according to this application through the operation of the computer. Those skilled in the art will understand that the forms in which computer program instructions exist in a computer-readable medium include, but are not limited to, source files, executable files, installation package files, etc. Correspondingly, the ways in which computer program instructions are executed by a computer include, but are not limited to: the computer directly executing the instructions, or the computer compiling the instructions and then executing the corresponding compiled program, or the computer reading and executing the instructions, or the computer reading and installing the instructions and then executing the corresponding installed program. Here, the computer-readable medium can be any available computer-readable storage medium or communication medium accessible to a computer.

[0070] The technical solutions provided in this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A multi-dimensional operational parameter fusion health assessment method for key equipment components, characterized in that, In the online health assessment of key force-transmitting components of a closed-loop electric drive actuator, the method includes: Collect torque commands, angular position feedback, drive power, component temperature, and vibration velocity for each complete displacement control action using the original timestamp; Angular velocity feedback is obtained from angular position feedback. The absolute value of the product of torque command and angular velocity feedback is taken and integrated to form cumulative control work and total control work. The control work process is generated by the ratio of the two, the process rate and process mapping time are determined, and the drive power, component temperature and vibration speed are mapped to common process nodes. Based on the electrical input energy, thermal storage energy, and vibration energy consumption formed at the process mapping time, the local rate of change of each energy relative to the control work process is calculated, and the energy response trajectory is formed by normalizing the total control work. A health reference surface is established based on the energy response trajectory of the same type of healthy component, as well as the control work process, process rate, and total control work. The trajectory deviation is formed based on the energy response trajectory and the health reference surface. The larger value between the degradation envelope of the previous complete displacement control action and the trajectory deviation is taken to update the degradation envelope. By comparing the degradation envelope with the failure threshold, an operation control command is generated with a value that allows the system to run or to be shut down for maintenance.

2. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The acquisition of torque commands, angular feedback, drive power, component temperature, and vibration velocity includes: In the online health assessment of key force transmission components of the closed-loop electric drive actuator, the equipment controller establishes an action sequence number at the start of a complete displacement control action and collects the parameters according to the original timestamp. Torque command and angular position feedback are respectively from servo controller and coaxial encoder. Drive power is non-negative absorbed power measured at DC bus input terminal with feedback component returned to zero. Component temperature and vibration velocity are respectively from temperature sensor and vibration velocity transmitter at the same housing measuring point. The parameters retain the original timestamp and are sorted by action sequence number and time within the action.

3. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The formation of the cumulative control work and the total control work includes: Piecewise linear interpolation is performed on the torque command and angular position feedback according to the original timestamp, so that the two are paired at the integration time. The angular velocity feedback is obtained by calculating the rate of change of the angular position feedback over time. The absolute value of the product of the torque command and the angular velocity feedback is taken, and the cumulative control work is formed by integrating from the start of the action. The total control work is formed by integrating over the entire displacement control action range.

4. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The determination of the control process, process rate, and process mapping time includes: The control work process is generated by the ratio of cumulative control work to total control work, and the process rate is calculated. For consecutive identical dwell times of the cumulative control power, only the last time is retained. The process mapping time is obtained according to the retained records. Piecewise linear interpolation is performed on the drive power, component temperature and vibration speed at the common process node according to the process mapping time.

5. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The formation of the electrical input energy, thermal storage energy, vibration energy dissipation, and energy response trajectory includes: The equivalent heat capacity and equivalent vibration damping were calibrated by electrothermal pulse test and controlled vibration attenuation test of the same type of healthy component, respectively. At the common process node, the driving power from the start of the action to the process mapping time is integrated to form electrical input energy, the component temperature difference between this time and the start of the action is multiplied by the equivalent heat capacity to form thermal storage energy, and the square integral of the vibration velocity in the same interval is multiplied by the equivalent vibration damping to form vibration energy consumption. Finite differences are made between adjacent common process nodes to calculate the local rate of change of the three energies relative to the control work process. After normalization of the total control work, the energy response trajectory is formed in the aforementioned order.

6. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The establishment of the health benchmark includes: Before commissioning, energy response trajectories are collected within the rated total control power and process rate range of healthy components of the same model. Piecewise linear interpolation is performed according to control power process, process rate and total control power to establish a healthy reference surface for outputting a three-dimensional dimensionless column vector.

7. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The formation of the trajectory deviation and the degenerate envelope includes: The process rate is determined at the common process node according to the process mapping time. The health reference surface is queried with the process rate and the total control power. The Euclidean distance between the energy response trajectory and the health reference surface is integrated along the control power process to form the trajectory deviation. The degenerate envelope is updated by taking the larger value between the degenerate envelope of the previous complete displacement control action and the current trajectory deviation. The degenerate envelope of the first complete displacement control action evaluated is taken as the corresponding trajectory deviation.

8. The multi-dimensional operational parameter fusion health assessment method for key equipment components according to claim 1, characterized in that, The formation of the failure threshold and operation control commands includes: The failure threshold is calibrated through accelerated wear tests and normal operating condition verification tests of key force transmission components. The degradation envelope when it first fails to meet the acceptance requirements of controller position tracking is used as the calibration point, and the separable boundary between unfailed and failed samples is used for verification. When the degradation envelope is less than the failure threshold, the equipment controller sets the operation control command to runnable; otherwise, it sets it to stop for maintenance and writes it into the equipment monitoring and maintenance interface. The operation control command is to allow the next complete displacement control action to continue when the current complete displacement control action is completed, and to issue a maintenance request when the machine is stopped for maintenance.

9. An electronic device, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program, and when the computer program is executed by the processor, the processor causes the processor to perform the steps of the multi-dimensional operating parameter fusion health assessment method for key components of equipment as described in any one of claims 1 to 8.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer instructions for causing the computer to execute the multi-dimensional operating parameter fusion health assessment method for key components of equipment as described in any one of claims 1 to 8.

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