Position change channeling system for lithium battery production line material convergence process control

Abstract

The present application relates to the field of industrial automation and intelligent logistics conveying control, in particular to a displacement channeling system for lithium battery production line material convergence process control, comprising: a driving data processing module, which reads the cross-axis current, actual speed and speed given value of a servo driver, calculates electromagnetic torque and extracts torque fluctuation, determines the time, direction and equivalent displacement amount of slip occurrence through correlation with the speed difference increment; a queue control module, which matches the slip data to the material unit, converts it into a time increment and adjusts the local displacement period to generate the channeling trigger time; an execution feedback module, which manages the material state, closes the loop to correct the conversion parameters according to the deviation between the actual receiving confirmation time and the expected confirmation time, thereby realizing adaptive compensation of logical position to physical position and improving the accuracy and stability of multi-channel convergence channeling control.

Description

Technical Field

[0001] This invention relates to the field of industrial automation and intelligent logistics conveying control, specifically a displacement and channeling system for material confluence process control in lithium battery production lines. Background Technology

[0002] The existing lithium battery production line material flow system includes multiple drive sections for conveying, confluence and channel control;

[0003] In related technologies, in order to control the material unit by lane separation, a programmable logic controller shift register with a fixed scanning cycle can be used to advance the logical position of the material unit according to a preset rhythm; or, external detection devices such as photoelectric sensors and vision sensors can be added to the blind area of ​​the production line to obtain the actual position information of the material unit and correct the lane separation triggering time accordingly.

[0004] However, during high-speed conveying and multi-channel confluence, materials are affected by factors such as local friction differences and start-stop inertia, which can easily lead to low-amplitude slippage that is difficult to detect directly. The former method cannot reflect the actual position changes of the material in a timely manner, while the latter method requires additional sensors and installation space, and is easily affected by obstruction, ambient light, and detection blind spots. Therefore, the material confluence and channel control methods in related technologies cannot simultaneously achieve real-time control, accurate position compensation, and ease of system deployment. Summary of the Invention

[0005] The purpose of this invention is to provide a displacement-based channeling system for material flow control in lithium battery production lines, addressing the following technical problems: Existing material flow control technologies for lithium battery production lines have significant shortcomings in physical position sensing and trigger timing correction based on position changes when facing low-amplitude material slippage. There is an urgent need for a displacement-based channeling system that can more accurately handle the correlation between material slippage and logical position, and dynamically optimize channeling commands. Specifically, this invention provides the following technical solution:

[0006] A displacement-separation system for material flow control in lithium battery production lines includes a drive data processing module, a queue control module, and an execution feedback module. The drive data processing module reads the motor current, actual speed, and speed setpoint of the servo driver, extracts the quadrature-axis current from the motor current and calculates the electromagnetic torque, extracts the torque fluctuation, and generates slip data including the occurrence time, slip direction, and slip magnitude based on the correlation between the torque fluctuation and the speed difference.

[0007] The queue control module configures local timing values ​​and shift cycles for each material unit, assigns the slip data to the material unit within the corresponding time window, converts the slip data into time increments to adjust the shift cycle, and adapts the logical position of the material unit to the actual physical position by changing the logical advancement time base. During the multi-path convergence process, it resolves conflicts at the triggering time, calculates the lane splitting triggering time, and outputs the lane splitting command.

[0008] The execution feedback module manages the state transition of the material unit, reads the actual receipt confirmation time, calculates the deviation between the actual receipt confirmation time and the expected receipt confirmation time, and performs closed-loop correction on the conversion parameters of torque fluctuation to slip size based on the deviation, thereby improving the position tracking accuracy, lane separation timing accuracy and anomaly handling reliability in the material confluence process.

[0009] Preferably, the drive data processing module performs bandpass filtering on the electromagnetic torque, calculates the torque fluctuation envelope within a feature window, and calculates the cross-correlation coefficient between the change in torque fluctuation and the change in speed difference within a preset delay range; determines the slip direction based on the cross-correlation coefficient, and combines the portion of the torque fluctuation envelope exceeding the steady-state threshold with the direction confidence weight to calculate the slip magnitude of the material unit, so as to reduce the impact of steady-state disturbances and random noise on the slip identification results;

[0010] Preferably, the queue control module establishes an estimated occupancy time window for each material unit in each drive section based on a reference shift speed, and matches the occurrence time of slip data with the estimated occupancy time window; when the same slip event falls into multiple estimated occupancy time windows, the attribution confidence is calculated based on the distance between the occurrence time and the center of each time window, and the slip data is allocated to the corresponding material unit; when a unique attribution material unit cannot be determined, slip compensation is prohibited from being written to the material unit to avoid erroneous compensation propagating in the queue;

[0011] Preferably, the queue control module stores the unreleased slip difference value and local timing value for each material unit, converts the allocated slip size into a slip difference value, and distributes the slip difference value to a limited number of subsequent shift steps, adding or subtracting it to the base shift cycle to generate the corresponding local shift cycle; the local shift cycle is limited to the minimum allowable cycle and the maximum allowable cycle set according to the elastic proportional coefficient, so as to take into account both the material position compensation speed and the stability of queue operation;

[0012] Preferably, the queue control module accumulates the scan time to the local timing value corresponding to the material unit within each system scan cycle. When the local timing value reaches the corresponding local shift cycle, a shift operation is performed to reset the local timing value and deduct the correction amount used for this shift from the unreleased slip difference. At the same time, the sequential constraints of globally adjacent material units are applied according to the channel priority to restrict the logical address of subsequent material units and prevent subsequent material units from overtaking previous material units.

[0013] Preferably, the queue control module generates an original predicted trigger time based on the current time and the cumulative remaining time of the remaining shift steps, and generates an effective trigger time window by combining the advance action time and holding time of the actuator; the original predicted trigger time, the start time of the effective trigger time window and the protection time interval of the preceding material unit are compared to generate a candidate trigger time within the effective trigger time window, and the candidate trigger time is used as the basis for lane output, thereby reducing lane conflicts caused by multiple materials arriving at the same time or insufficient trigger interval;

[0014] Preferably, after calculating the candidate trigger time, the queue control module uses the time difference between the candidate trigger time and the original predicted trigger time as the conflict correction scheduling difference, feeds it back into the corresponding material unit, and distributes the conflict correction scheduling difference to the local shift cycle of the remaining shift steps, so that the predicted time inside the logical queue is synchronized with the actual output scheduling time.

[0015] Preferably, the execution feedback module is equipped with a state machine anti-deadlock unit, which independently manages the access state, tracking state, pre-trigger state, execution state, and backup exception handling state of the material unit, and sets hierarchical timeout times for each state. When a state timeout occurs, the material identifier mismatch occurs, or the candidate trigger time exceeds the effective trigger time window, the corresponding material unit is transferred to the backup exception handling state, the scheduling resources occupied by the material unit are released, and the queuing advancement right of subsequent material units is retained to prevent a single abnormal material unit from blocking the entire confluence queue.

[0016] Preferably, the execution feedback module uses only material units with unique slip data, not in backup anomaly handling state, and valid received confirmation signals as self-tuning closed-loop samples. It compares the actual confirmation time with the expected confirmation time and generates a time deviation. Based on the time deviation, it iteratively updates the conversion parameters of torque fluctuation to slip size within a statistical period. When the number of valid samples is less than the preset minimum number, the update of the conversion parameters is frozen to avoid abnormal drift of control parameters due to insufficient samples.

[0017] As can be seen from the above solutions, the advantages of the present invention are:

[0018] This system extracts torque fluctuations from servo drive data to generate slip data, eliminating the need for external detection devices and avoiding interference from ambient light and occlusion. By converting slip data into time increments to adjust the shift period, the logical position adapts to the physical position. Combined with a multi-channel confluence conflict resolution and conversion parameter closed-loop correction mechanism, it effectively balances the real-time performance of material flow control, the accuracy of position compensation, and the ease of system deployment. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0020] Figure 1 This is a block diagram of the displacement and channeling system for material flow control in lithium battery production lines, as described in this application. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings.

[0022] Reference Figure 1 One embodiment of this application provides a displacement-separation system for material flow control in lithium battery production lines, comprising:

[0023] The drive data processing module reads the motor current, actual speed, and speed setpoint of the servo driver. The motor current includes at least the quadrature axis current. It calculates the electromagnetic torque and extracts the torque fluctuation. Based on the correlation between the torque fluctuation and the speed difference calculated from the actual speed and speed setpoint, it generates slip data containing the time, direction, and magnitude of occurrence.

[0024] The queue control module configures local timing values ​​and shift cycles for material units, assigns slip data to the corresponding material units, converts slip data into time increments to adjust the shift cycle, and resolves conflicts at the lane splitting trigger times during multi-channel convergence, outputting lane splitting instructions.

[0025] The execution feedback module is used to manage the state transitions of material units; obtain the expected confirmation time and the actual receipt confirmation time, calculate the deviation between the actual receipt confirmation time and the expected confirmation time, and perform closed-loop correction on the conversion parameter of torque fluctuation to slip size, where the conversion parameter is the equivalent displacement corresponding to unit torque.

[0026] This embodiment provides a displacement-separation system for material confluence process control in lithium battery production lines. In high-speed lithium battery production lines, materials include cells, electrodes, or carriers. The forces acting on materials during multi-channel confluence are not ideally uniform. Local frictional differences or start-stop inertia can easily cause slight slippage of materials. Conventional control systems often rely on programmable logic controller shift registers with fixed scan cycles. The fixed-cycle advance method cannot detect the physical micro-slippage of materials, which can easily lead to a gradual disconnect between the logical position and the actual physical position, causing premature or delayed segregation triggering.

[0027] In this embodiment, the shifting lane system uses the original electrical characteristics of the servo motor to identify material slip by reusing the drive data processing module. The slip data is directly converted into time base adjustment by the queue control module and parameter correction is performed in conjunction with the execution feedback module. The system can realize the conversion of error compensation into time reconstruction and complete the shifting lane control without adding external photoelectric or visual position sensors in the blind area of ​​the production line.

[0028] Obtain the quadrature-axis current, actual speed, and speed setpoint of the servo driver. The quadrature axis is the torque component axis orthogonal to the flux axis in the servo motor's rotating coordinate system, and the quadrature-axis current is the current component characterizing the change in the motor's electromagnetic torque. Based on the motor torque coefficient and... The shaft current is used to calculate the instantaneous electromagnetic torque, and the electromagnetic torque is processed to extract the torque fluctuations related to low-amplitude slip events of the material, and generate slip data.

[0029] The slip data includes at least the time of occurrence of the slip event, the direction of slip, and the magnitude of slip. The queue control module adjusts the local displacement cycle of the corresponding material unit based on the slip data, so that the logical advance rhythm of the material unit can follow the change of physical position. The execution feedback module performs closed-loop correction of the slip conversion parameters based on the actual confirmation results received downstream, so as to adapt to the characteristic drift caused by mechanical wear, friction changes and load changes during long-term operation of the equipment.

[0030] The system obtains the speed difference by subtracting the actual speed from the given speed value, so that the slip data output by the drive data processing module has a definite input, judgment and output relationship, and extracts the fluctuation characteristics of the electromagnetic torque within a preset feature window; for each feature window, the correlation between the torque fluctuation envelope and the speed difference increment within a preset delay range is first calculated.

[0031] When effective correlation ,in, For correlation threshold, or torque fluctuation envelope ,in, When the slip steady-state threshold is zero, the window is marked as an invalid slip event. When both conditions are met, the amount by which the torque fluctuation envelope exceeds the steady-state threshold is used as the input of the slip amplitude. The polarity combination of the signed torque fluctuation and the speed difference increment corresponding to the maximum correlation time shift is used as the direction determination input. The material leading or lagging direction corresponding to the polarity combination is determined by the calibration slip data of the known direction obtained in advance.

[0032] The directional confidence weight is determined based on the degree to which the absolute value of the correlation coefficient exceeds the correlation threshold and is limited to between zero and one. The slip size is converted into an equivalent displacement along the conveying direction by multiplying the excess amount by the directional confidence weight according to the current conversion parameters. The occurrence time of the slip event is taken as the sampling time within the feature window that meets the event judgment condition or the center time of the corresponding window. Thus, each effective slip data is determined by the torque fluctuation envelope, correlation judgment result, polarity combination, directional confidence weight, and conversion parameters, and outputs a uniform equivalent displacement with direction for the queue control module to convert into a time increment.

[0033] When the queue control module performs time base adjustment, the directional equivalent displacement is converted into a directional time increment according to the reference shift speed of the corresponding drive section. When the material is ahead, the direction of deducting the local shift cycle is used; when the material is behind, the direction of superimposing the local shift cycle is used. For effective slip data continuously generated by the same material unit in adjacent feature windows, the unreleased slip difference is accumulated to the material unit according to the order of occurrence and gradually released in the subsequent finite number of shift steps. Slip data that cannot be uniquely assigned to a material unit is not included in the difference accumulation process.

[0034] During the actual feedback process, the expected confirmation time is determined by the candidate channel trigger time, the logical position of the material unit at the candidate trigger time, and the reference travel time of the downstream station. The time deviation between the actual confirmation time and the expected confirmation time serves as the basis for adjusting the conversion parameters. Only when the slip event has a unique material attribution, the material unit has not entered the backup exception handling state, and the actual confirmation is valid, is the material unit included in the parameter correction sample. The system summarizes the time deviation of the valid samples within the statistical period, adjusts the conversion parameters according to the deviation direction and the preset learning step size, and limits the allowable range of the adjusted parameters. When the number of valid samples is insufficient, the original conversion parameters remain unchanged.

[0035] In this embodiment, the drive data processing module performs bandpass filtering on the electromagnetic torque and calculates the torque fluctuation envelope within a feature window; calculates the cross-correlation coefficient between the change in torque fluctuation and speed difference within a preset delay range; determines the slip direction based on the cross-correlation coefficient, and introduces a direction confidence weight characterizing the reliability of the direction; and calculates the slip magnitude based on the portion of the torque fluctuation envelope exceeding the steady-state threshold and the direction confidence weight.

[0036] In this embodiment, the specific meaning of "determining the slip direction based on the cross-correlation coefficient" is as follows: Cross-correlation analysis is first used to determine the position of the maximum correlation time shift within a preset delay range, that is, to complete the time delay positioning between torque fluctuation and velocity difference increment; since only amplitude information is retained after taking the absolute value of the torque fluctuation envelope, the polarity of the cross-correlation coefficient itself does not directly characterize the slip direction; after determining the position of the maximum correlation time shift, the system takes the polarity combination of the signed torque fluctuation and velocity difference increment at that time shift position, and combines it with the mapping relationship between the polarity combination established by the pre-calibrated known direction data and the material leading and lagging directions, and finally determines the slip direction; that is, the role of the cross-correlation coefficient in this application is to locate the time delay corresponding to the correlation peak and quantify the correlation intensity, and the slip direction is given by the polarity combination of the signed quantity at that time delay position and the pre-calibrated known direction data.

[0037] This embodiment is a further specification of the slip recognition performed by the drive data processing module in the embodiment; in specific implementation, the quadrature-axis current, actual speed, and speed setpoint of the servo driver are obtained, and the motor torque coefficient is used as a basis for further analysis. The instantaneous electromagnetic torque is calculated using shaft current, and the calculation rules are as follows: ,in, For instantaneous electromagnetic torque, This represents the effective torque coefficient of the servo motor at the corresponding operating point. It is the quadrature-axis current;

[0038] When the quadrature-axis current provided by the driver has been converted by the current loop proportional calculation, first restore it to the motor-side current according to the driver parameters, and then substitute it into the above calculation rules; the effective torque coefficient is determined by the motor parameters, the controller current calibration relationship and the corresponding load conditions.

[0039] For salient-pole motors with reluctance torque components exceeding a preset amplitude Employ an equivalent calibration value that includes the operating point effect, or compensate for this component when the driver can provide relevant parameters, to make the based... The shaft current is used as a torque estimate that is consistent with the actual electromagnetic torque variation, instead of directly using a fixed ideal torque coefficient for all operating conditions; the electromagnetic torque is bandpass filtered, and the filtering result is subjected to subsequent feature processing.

[0040] In this embodiment, the motor current includes not only the quadrature-axis current but also the direct-axis current. The direct-axis current is used in the system for the following two aspects: First, field weakening condition identification and torque coefficient correction. When the absolute value of the direct-axis current exceeds the preset field weakening judgment threshold, the motor is determined to have entered the field weakening operation state. At this time, the current effective torque coefficient is corrected according to the pre-calibrated mapping relationship between the direct-axis current and the effective torque coefficient to avoid torque estimation deviation caused by still using the rated torque coefficient under field weakening conditions. Second, current validity verification. The current amplitude is verified according to the sum of the squares of the direct-axis current and the quadrature-axis current to see if it exceeds the driver's limit value. If it does, the sampling point is marked as invalid and prohibited from participating in electromagnetic torque calculation and subsequent slip identification. When the direct-axis current is within the rated excitation range, the electromagnetic torque calculation still uses the quadrature-axis current as the torque component input.

[0041] The lower and upper limits of the bandpass filter can be set to 120 Hz and 280 Hz, respectively, to eliminate low-frequency load changes and high-frequency electrical noise, thereby extracting transient torque changes related to low-amplitude slip events of materials. The bandpass filter frequency band is set according to the sampling frequency of the servo drive and the inherent response of the drive mechanism, and the upper limit frequency is less than half of the sampling frequency. The actual duration of the feature window is determined by the sampling period and the number of sampling points to ensure that the feature window covers at least one target torque fluctuation cycle.

[0042] The drive data processing module uses the sampling sequence number or synchronous clock provided by the servo driver as the common time reference for all data. It latches the q-axis current, actual speed, and speed setpoint within the same sampling period. When any data is not updated within the sampling period, the sampling sequence number is discontinuous, or the data exceeds the valid range set by the driver, the sampling point is marked as invalid and prohibited from participating in the calculation of electromagnetic torque, speed difference, and cross-correlation.

[0043] The module uses a fixed-length continuous sampling buffer to store the most recent valid processed data. When the buffer has not reached the feature window length, it only accumulates data and does not output slip events. After reaching the window length, it advances point by point according to the sampling sequence. New sampling points can only be received after old sampling points are removed. If the number of valid sampling points in a feature window is less than the specified proportion, the window is discarded and the temporary correlation results corresponding to the window are cleared to avoid missing sampling data being misjudged as low correlation slip events.

[0044] The bandpass filter uses a digital filter element with calibrated coefficients to continuously process instantaneous electromagnetic torque. The filter saves the internal state of the previous sampling period. When starting, stopping, switching the reference speed, or switching the filter parameters, the internal state of the filter is first initialized to the steady state corresponding to the current effective torque estimate, and a state recovery flag is set.

[0045] Window generated before the state recovery flag is cleared does not participate in steady-state threshold comparison and slip output; if a sudden change in torque estimate, driver alarm or sampling clock jump occurs during the filtering process, the current window is immediately stopped, the calibration state of the most recent valid window is retained, and feature window processing is restarted after a specified number of valid sampling points are obtained continuously.

[0046] The torque fluctuation envelope is calculated within a set feature window, which can cover a time window of 64 to 128 sampling points. The torque fluctuation envelope is obtained by using the moving average of the absolute value of the filtered torque fluctuation or the equivalent peak hold value. The envelope value within the window is uniformly expressed in torque units. When using the moving average, the arithmetic mean is calculated after taking the absolute value of the filtered torque fluctuation at each sampling point within the window.

[0047]

[0048] in, The calculated torque fluctuation envelope value, This represents the total number of sampling points within the feature window. For the first in the window Instantaneous torque fluctuation value after bandpass filtering at each sampling point For the summation operator, It is the absolute value symbol;

[0049] When using peak hold value, the maximum absolute value within the window is taken, and an envelope value is output at the end of the window. The steady-state threshold is determined based on multiple feature windows collected under slip-free conditions: first, feature windows that are started, stopped, or contain alarm signals are removed, then the median of the steady-state window envelope value is used as the benchmark, and the margin formed by the dispersion of the steady-state window envelope value is superimposed on the benchmark. The steady-state threshold establishes corresponding calibration values ​​when the equipment load or reference speed changes.

[0050] To ensure that the degree of dispersion and margin can be repeatedly determined, the steady-state window envelope values ​​are arranged in numerical order, and the median is taken as the reference value. The median of the absolute values ​​of the differences between each envelope value and the reference value is taken as the dispersion. The dispersion is multiplied by a preset non-negative threshold multiple and then added to the reference value. The result is used as the steady-state threshold for the corresponding load range and reference speed range.

[0051] When the obtained threshold is lower than the minimum noise threshold under the working condition, the minimum noise threshold is used as the steady-state threshold; the threshold multiple and the minimum noise threshold are distinguished and calibrated by the continuous operation data without slip and the known direction calibration slip data, and are saved as part of the parameter record; bandpass filtering is used to reduce the interference of background noise on slip identification under complex working conditions;

[0052] The method for determining the minimum noise threshold is as follows: Under no-slip conditions with no load and minimum reference speed, continuously collect no less than a specified number of feature windows, arrange the envelope values ​​of each window in numerical order, and take the preset high quantile value (e.g., 99th quantile value) as the minimum noise threshold for the corresponding condition; The calibration process for the threshold multiple is as follows: Statistically analyze the envelope discrete distribution of the continuous no-slip running data and the envelope excess distribution of the known direction calibration slip data, and select the smallest multiple between the two distributions that makes the misjudgment rate lower than the preset misjudgment rate threshold as the threshold multiple, with an example value range of 1.5 to 3.0; After calibration, save the minimum noise threshold, threshold multiple, and the corresponding condition recognition range together; When the number of no-slip samples or the number of calibration slip samples are insufficient, invalidate the corresponding parameter records.

[0053] After the steady-state threshold is established, the corresponding calibration value is selected according to the load range and reference speed range during operation; when the current operating condition does not fall into any calibrated range, or the operating condition switching has not continued to reach the specified stable sampling number, the effective threshold before the switching is used and slip event confirmation is temporarily prohibited.

[0054] The baseline and dispersion of the steady-state window are updated only by windows that are determined to be slip-free and continuously effective. Start-up, stop, alarm, speed switching, and confirmed slip windows are not written into the steady-state statistical sample. If enough effective steady-state windows are not obtained during continuous operation, the previous effective threshold is retained. When the system runs for the first time and there is no historical effective threshold, the drive data processing module only outputs an invalid event flag and does not write slip compensation to the queue control module.

[0055] Corresponding to the cold start processing of the steady-state threshold, the cold start mechanism of the conversion parameter K is as follows: When the system is running for the first time and there are no historically valid conversion parameters, the initial conversion parameter K0 determined by the factory calibration is used; the factory calibration process is as follows: During the installation and commissioning phase, the calibration slip device with a known direction and a known equivalent displacement Δx0 generates standard slip under rated operating conditions, records the torque fluctuation envelope excess ΔE0 of the corresponding feature window, calculates the initial conversion parameter according to K0=Δx0 / ΔE0, and writes it into the parameter record along with the corresponding operating condition identification range; after completion Before the above factory calibration, the drive data processing module is kept consistent with the steady-state threshold cold start state, only outputting invalid event flags and not writing slip compensation to the queue control module; for the same model of equipment that has not performed factory calibration, it is allowed to use the conservative default value obtained from the historical calibration statistics of the same model of equipment as K0, and in the first statistical period when the default value is put into use, the learning step size of the conversion parameter self-tuning is halved to reduce the impact of the initial value deviation on the queue stability; thus, the slip size calculation formula has an executable input when the system runs for the first time.

[0056] When determining the direction and magnitude of the slip, the speed difference between the speed setpoint and the actual speed inside the actuator is obtained, and the speed difference increment is calculated; the speed difference is uniformly calculated by subtracting the actual speed from the speed setpoint.

[0057] Within a preset delay range, the relative time shift of the torque fluctuation envelope and the speed difference increment is changed one by one. The cross-correlation coefficient corresponding to each time shift position is calculated. The cross-correlation coefficient is multiplied and accumulated by subtracting the average value of each window from the corresponding sample value within the window, and then divided by the square root of the product of the squares of the two sets of mean-reduced sample values. When the denominator is zero or the number of effective sampling points is insufficient, the time shift position is not included in the maximum correlation comparison. The cross-correlation coefficient with the largest absolute value is used as the correlation judgment criterion for the feature window to quantify the temporal consistency between torque mutation and speed following deviation.

[0058] Since only amplitude information is retained after taking the absolute value of the torque fluctuation envelope, the polarity of the cross-correlation coefficient is not directly determined by the sign of the envelope; the system also retains the sign sequence of the torque fluctuation after bandpass filtering. After obtaining the maximum correlation time shift, the direction is determined by the polarity combination of the signed torque fluctuation at that time shift position and the velocity difference increment. The system also establishes the correspondence between the polarity combination and the material leading and lagging directions through calibration slip in at least one known direction.

[0059] When the polarity combination is inconsistent with the calibration result or the positive and negative directions cannot form a distinguishable calibration mapping, no directional effective slip data is output; the preset delay range is determined based on the driver sampling period, speed loop response time, and transmission mechanism response time, and covers the expected delay between the torque change caused by material slip and the speed difference change; the cross-correlation calculation retains at least three-quarters of the effective sampling points of the feature window, and if it is less than this number, it is judged as insufficient effective sampling points;

[0060] Under this convention, when the absolute value of the cross-correlation coefficient... And torque fluctuation envelope At that time, the slip direction is determined based on the polarity combination, and the effective slip size is calculated by combining the confidence weight that characterizes the reliability of the direction; the correlation threshold is determined based on the statistical distribution of the absolute value of cross-correlation within the same delay range under the slip-free condition, and a boundary value that can distinguish between slip-free disturbance and known direction calibration slip is selected.

[0061] Under no-slip conditions, the absolute cross-correlation values ​​of each effective time-shift position are statistically analyzed, and their high quantile reference values ​​are determined according to the numerical order. The value that can be distinguished between this reference value and the lowest correlation value of the known directional calibrated slip is used as the correlation threshold. If there is no distinguishing interval between the two, the parameter record of this condition is set to invalid. The directional confidence weight increases with the degree to which the absolute cross-correlation value exceeds the correlation threshold and is limited to between 0 and 1.

[0062] The slip is calculated only from the portion of the torque fluctuation envelope that exceeds the steady-state threshold, and is converted into an equivalent displacement along the conveying direction according to the current conversion parameters. Specifically, the excess portion is first multiplied by the direction confidence weight, and then multiplied by the current conversion parameters. The unit of the conversion parameters is the equivalent displacement corresponding to unit torque, and the direction of the result is determined by the polarity combination.

[0063] If the absolute value of the cross-correlation coefficient does not reach the correlation threshold, there are insufficient effective sampling points within the feature window, or the steady-state threshold cannot be determined, effective slip compensation data will not be generated. For common trend electrical disturbances formed during the acceleration and deceleration of the equipment, if they do not meet the correlation threshold or steady-state threshold conditions, effective slip compensation data will not be generated.

[0064] The effective torque coefficient, steady-state threshold, and correlation threshold are all recorded according to the current servo motor, drive section load range, and reference speed range. The parameter record includes at least the working condition identification range, parameter value, establishment time, and effective flag. When establishing the parameter record, a steady-state window sample is formed using continuous operation data without slip in the same drive section, and the direction mapping is verified using calibration slip data with known direction and known equivalent displacement.

[0065] Only when the number of no-slip samples reaches the specified number and the calibration results in both the forward and reverse directions can form a stable polarity mapping, is the corresponding record set as valid. During operation, the operating condition record is first determined based on the current reference speed and the driver feedback load. If multiple records cover the current operating condition, the record with the smallest center distance between the speed range and the load range is selected. If no valid record exists, the invalid event state is maintained and slip compensation is disabled. In this way, the parameter source, applicable operating conditions, and calling rules are consistent with the slip event calculation process to prevent the mixing of thresholds under different speeds or loads.

[0066] For example, with a sampling period of 1 millisecond and a feature window of 64 sampling points, the torque fluctuation envelope of a certain effective window is 0.80 Nm, the no-slip steady-state threshold is 0.50 Nm, the maximum absolute cross-correlation coefficient is 0.85, and the correlation threshold is 0.65; the directional confidence weight is calculated linearly according to the degree to which the correlation coefficient exceeds the threshold and is limited to between 0 and 1, that is, the correlation coefficient that reaches 1.00 after exceeding the threshold is taken as the full weight.

[0067] If the full-weighted key value is taken as 1.00, then the directional confidence weight of this window is... The result is approximately 0.571; if the known directional calibration indicates that the polarity combination of the signed torque fluctuation and velocity difference increment at the maximum correlated time shift in this window corresponds to material hysteresis, and the current conversion parameter is 0.20 mm / Nm, then the equivalent slip size is... The value is approximately 0.034 millimeters, and the output direction is hysteretic.

[0068] If the absolute value of the correlation coefficient does not exceed 0.65, the steady-state threshold does not exceed it, or the polarity combination cannot be uniquely mapped by the valid calibration record, only an invalid event flag will be output; the calculation result will enter the waiting state at the end of the window and will not be written to the material unit due to missing sampling or invalid parameter records.

[0069] Before outputting valid slip data, the module confirms candidate events in order according to the end time of the window, and merges candidate events in the same direction whose occurrence time in adjacent windows differs by less than the length of a feature window into the same slip event; during merging, the weighted result of the envelope excess is taken as the event amplitude, and the sampling time that first reaches the steady-state threshold is taken as the occurrence time; adjacent candidate events in opposite directions are not directly merged, but are retained separately;

[0070] Only when the time interval between their occurrences is less than the system scan cycle and the amplitudes have not reached the steady-state threshold, are both discarded as common trend disturbances. After the effective slip data is output, it enters the waiting state. If no unique material unit is matched within the specified waiting time for assignment, it is marked as an unassignable event and prohibited from participating in subsequent compensation again, so as to avoid the same torque fluctuation being repeatedly counted in multiple material units.

[0071] In this embodiment, the queue control module establishes an expected occupancy time window for each material unit in each drive section based on the reference shift speed, and matches the occurrence time of slip data with the expected occupancy time window; when the same slip data falls into multiple expected occupancy time windows, the attribution confidence is calculated according to the distance between the occurrence time and the center of the time window, and the slip data is allocated to the corresponding material unit; when a unique attribution cannot be determined, slip compensation is prohibited from being written to the material unit.

[0072] This embodiment further specifies the slip data attribution processing performed by the queue control module in the embodiment. After completing slip feature extraction, the occurrence time of the slip event is obtained, and an expected occupancy time window is established for the material unit in each drive section based on the reference shift speed. The expected occupancy time window is the time span from the expected entry of the material unit to the expected departure of the specific drive section, and may include a preset tolerance time before and after. The queue control module matches the occurrence time of the slip event with the expected occupancy time window corresponding to each material unit to determine the material unit to which the slip data belongs.

[0073] When the distance between multiple material streams is lower than the preset safety threshold or random confluence occurs, the same slip event may fall into the overlapping time windows of multiple material units. In this case, the system calculates the distance between the time of the slip event and the center time of each time window, and calculates the attribution confidence of each material unit based on the distance. The slip data is then assigned to the material unit with the highest attribution confidence. The attribution confidence is determined in reverse according to the ratio of the time distance to the half-width of the corresponding time window: the highest value is taken when the time distance is zero, and zero is taken when the time distance reaches or exceeds the half-width of the time window.

[0074] Using a linear mapping, the formula is:

[0075]

[0076] in, For the confidence level of attribution, This represents the time distance between the occurrence of the slip event and the center of the time window. To correspond to the half width of the time window, This is a function to find the maximum value.

[0077] When multiple time windows have different half-widths, each time window half-width is used for normalization comparison; events that fall within the time window but have a zero confidence level are not considered valid attribution results.

[0078] The system removes candidate material units that are not within any expected time window, and then compares the assignment confidence among the remaining candidate material units. Only when the highest assignment confidence reaches the preset assignment threshold and the difference between the highest and second-highest values ​​reaches the preset discrimination margin is a unique assignment determined. When there is no second-highest value, the highest value reaching the assignment threshold is used as the unique assignment condition. If the highest assignment confidence is lower than the preset confidence threshold, or the assignment confidence of multiple material units cannot form a unique and valid ranking, it is determined that a unique assignment cannot be determined, and slippage compensation is prohibited from being written to any material unit.

[0079] The determination methods for the assignment threshold and discrimination margin are as follows: Under the condition of independent assignment without conflict, the distribution of assignment confidence is statistically analyzed and its low quantile reference value (e.g., 5th percentile value) is taken. Under the condition of multi-window overlapping conflict, the distribution of assignment confidence corresponding to incorrect assignment is statistically analyzed and its high quantile reference value (e.g., 95th percentile value) is taken. The value that can maintain discrimination between the above two reference values ​​is selected as the assignment threshold, and its example value range is 0.6 to 0.8. The discrimination margin is determined according to the statistical distribution of the confidence difference between correct assignment and suboptimal assignment under the condition of multi-window overlapping. The minimum difference that makes the incorrect assignment rate lower than the preset threshold is taken as the discrimination margin, and its example value range is 0.1 to 0.2. When the material specifications, number of bus routes or reference speed change, the recalibrated assignment threshold and discrimination margin under the corresponding condition are used.

[0080] The above allocation mechanism based on the expected occupancy time window and the attribution confidence can realize the correspondence between slip events and material units, so as to prevent the torque fluctuation generated by a specific material from being compensated to adjacent materials in the case of multiple confluences.

[0081] In this embodiment, the queue control module stores the unreleased slip difference value and local timing value for each material unit; converts the allocated slip size into a slip difference value and distributes it to a finite number of subsequent shift steps, superimposing or subtracting it to the reference shift period to generate the corresponding local shift period; and obtains the elastic proportional coefficient characterizing the system time tolerance, limiting the local shift period to between the minimum allowable period and the maximum allowable period set according to the elastic proportional coefficient.

[0082] The queue control module accumulates the time corresponding to the scan cycle to the local timing value during the system scan cycle; when the local timing value reaches the corresponding shift cycle, it performs a shift operation, resets the local timing value, and subtracts the correction amount used in this step from the unreleased slip difference; and performs sequential constraints on globally adjacent material units according to channel priority, and restricts the logical address of subsequent material units.

[0083] This embodiment is a further specification of the slip compensation and queue advance processing of the queue control module in the embodiment; based on clarifying the ownership of slip data, the slip size allocated to a specific material unit is obtained and converted into a directional slip difference value; the slip size is uniformly represented as the equivalent displacement of the material along the conveying direction, and converted into a time increment using the reference displacement speed of the corresponding drive section;

[0084] When materials are ahead, a negative time difference is generated, which is used to deduct subsequent local shift cycles. When materials are behind, a positive time difference is generated, which is used to add to subsequent local shift cycles. The queue control module distributes the unreleased slip difference to a finite number of subsequent shift steps, adding or subtracting from the baseline shift cycle to generate the local shift cycle for the corresponding material unit. The number of distributed steps is determined based on the number of remaining shift steps from the current drive section to the branch execution point of the material unit, and at least one shift step is reserved.

[0085] The target correction amount for each shift step is determined based on the current unreleased slip difference and the remaining number of allocated steps, and its absolute value does not exceed the maximum correction amount allowed for this step; the maximum correction amount is taken as the smaller value between the base shift period and the corresponding minimum or maximum allowable period, thereby ensuring that the corrected local shift period is still within the allowable range; the correction direction of each step is consistent with the sign of the current unreleased slip difference of the material unit, and the unreleased slip difference is updated after correction;

[0086] Specifically, the equivalent displacement in the direction is first divided by the reference displacement velocity of the corresponding drive section to obtain the time increment in the direction; then, this time increment is accumulated to the unreleased slip difference value of the material unit; let the current unreleased slip difference value be... The number of subsequent sharing steps is The target correction amount for each shift step is calculated according to... Divide by Confirmed; when the absolute value of the target correction exceeds the maximum allowable correction in this step, the maximum correction is taken as the correction for this step, using the original sign of the target correction. Unused portions are retained. In, and after completing this step will Subtract one;

[0087] Therefore, the sign of the slip difference directly determines the adjustment direction of the local shift cycle, and each step can determine a unique correction amount and an updated difference. When the local shift cycle is limited by the minimum or maximum allowable cycle, only the correction amount actually used for the cycle adjustment in this step is released. The part that cannot be released due to the limitation continues to be stored in the unreleased slip difference, and is not lost or changed in sign due to the cycle limitation.

[0088] The reference shift period is the standard advance time of the equipment under ideal conditions without slippage; the local shift period is the actual waiting time required for the current material unit to perform the next logical shift after receiving slippage compensation; the system introduces an elastic proportional coefficient to limit the queue clock mutation caused by a single abnormal feature. The value of the elastic proportional coefficient is 0.1 to 0.35. Based on the elastic proportional coefficient, the minimum allowable period and the maximum allowable period of the local shift period are calculated. The minimum allowable period is the reference shift period multiplied by 1 minus the elastic proportional coefficient, and the maximum allowable period is the reference shift period multiplied by 1 plus the elastic proportional coefficient, thus limiting the local shift period to between the minimum allowable period and the maximum allowable period.

[0089] The elastic proportional coefficient is calibrated based on the periodic dispersion during continuous operation without slip, the allowable material spacing error, and the response capability of the actuator, and is selected under the condition of maintaining the minimum safe interval between adjacent materials; when the reference speed or material specifications change, the corresponding calibration value is used; the actual correction amount used for each shift step does not exceed the maximum allowable correction amount for that step, and the unused part after the limit is retained in the unreleased slip difference value to prevent the loss of compensation amount due to local shift period limit;

[0090] The value range of 0.1 to 0.35 is calibrated for the material confluence scenario in lithium battery production lines: In lithium battery production lines, the branching cycle of materials such as cells and electrodes is short and the distance between adjacent materials is small. If the elasticity ratio coefficient is lower than 0.1, the amount of correction that can be released within a single shift step is too small, and low-amplitude slip cannot be fully released before the material reaches the branching execution point, resulting in compensation failure; if it is higher than 0.35, the sudden change amplitude of a single shift cycle may exceed the response capability of the actuator and destroy the minimum safe interval between adjacent materials, causing the confluence sequence to be disordered; taking a value within this range can achieve a balance between the timeliness of slip compensation and the stability of queue operation.

[0091] When executing queue advancement, the system scan cycle of the programmable logic controller is obtained, and the time corresponding to the scan cycle is accumulated to the local timing value of the material unit during each scan; when the local timing value reaches the corresponding local shift cycle, a shift operation is performed on the material unit to generate a new logical address;

[0092] The local timing value is updated to the remaining value after deducting the local shift period actually used this time, and the correction amount used in this step is subtracted from the currently saved unreleased slip difference value; thus, the reset local timing value in this embodiment refers to resetting to the remaining timing value that is insufficient to form the next shift after this shift, rather than unconditionally clearing it to zero; when there is no remaining timing value, the remaining value is zero;

[0093] If the unreleased slip difference is not fully released, the remaining difference will continue to be distributed to subsequent shift steps. When a scan spans multiple local shift cycles, the system performs shifts in the order of the actual number of cycles spanned. After each shift is completed, the local timing value and the unreleased slip difference are updated according to the corresponding step size, and only the remaining time that is insufficient to form the next shift is retained as the local timing value for the next step. The local shift cycle used for each span is the actual cycle after the amplitude is limited, and the unreleased difference caused by the amplitude limitation does not change the timing reference of the local timing value.

[0094] During the queue advancement process, the system obtains the channel priority and global sequence number of the material, and applies sequential constraints to the globally adjacent material units according to the channel priority to maintain the order of materials after merging; when the subsequent material may logically surpass the preceding material due to excessive local time compensation, the system restricts the logical address of the subsequent material unit and, if necessary, suspends its logical advancement until the minimum logical time interval between the preceding and following materials is met.

[0095] The minimum logical time interval is determined based on the protection time required for the preceding material to complete the channel separation, the material length, and the reference shift speed, and is taken as a value not less than the protection time of the actuator during channel switching or actuator operation. Thus, the system can adapt to individual slip differences while avoiding local compensation causing the flow sequence to be disordered.

[0096] In this embodiment, the queue control module generates the original predicted trigger time based on the current time and the cumulative remaining time of the remaining shift steps; it generates an effective trigger time window by combining the advance action time and holding time of the actuator; and it compares the original predicted trigger time, the start time of the time window with the protection time interval of the preceding material to generate a candidate trigger time within the effective trigger time window as the basis for lane output.

[0097] After calculating the candidate trigger time, the queue control module writes the time difference between the candidate trigger time and the original predicted trigger time as a conflict correction scheduling difference into the corresponding material unit; and distributes the conflict correction scheduling difference to the local shift cycle of the remaining shift steps.

[0098] The execution feedback module is equipped with a state machine anti-deadlock unit, which is used to independently manage the access state, tracking state, pre-trigger state, execution state, and backup exception handling state of the material unit; it independently sets hierarchical timeout times for each state; when a state timeout, material identifier mismatch, or candidate time exceeds the effective trigger time window occurs, the material unit is transferred to the backup exception handling state, releasing the scheduling resources it occupies and retaining the queuing advancement right of subsequent material units.

[0099] The execution feedback module extracts only material units with unique slip data, not in backup anomaly handling state, and valid received confirmation signals as self-tuning closed-loop samples; it generates a time deviation between the actual received confirmation time and the expected confirmation time; when the number of valid samples is greater than or equal to the preset minimum number, it iteratively updates the conversion parameters based on the time deviation within a statistical period; when the number of valid samples is less than the preset minimum number, it freezes the parameter update.

[0100] This embodiment is a further detail of the separate triggering conflict resolution, state management and parameter self-tuning processing of the queue control module and execution feedback module in the embodiment;

[0101] In the case of high-speed convergence of multiple materials, the materials after elastic compensation may cause instruction timing conflicts at the branch execution point; the queue control module obtains the current time of the material unit, the local timer status, and the subsequent elastic cycle corresponding to the remaining shift steps, and calculates and generates the original predicted trigger time based on the current time and the cumulative remaining time of the remaining shift steps.

[0102] Specifically, using the current monotonically increasing system clock as the calculation benchmark, the local shift periods of the remaining shift steps are sequentially accumulated to the current time to obtain the original predicted trigger time. If the current local timing value has exceeded the current step period, the completed period that has been crossed is first subtracted from the local timing value, and then the remaining shift steps are accumulated, retaining the remaining timing amount that is less than one period. The mathematical calculation model for the original predicted trigger time is as follows:

[0103]

[0104] in, The original predicted trigger time. This is the current system clock time. The remaining time for the period that has been crossed but is less than one cycle. The remaining number of shift steps. For the first The local shift period corresponding to each remaining shift step A positive integer index variable. This is the summation operator;

[0105] Meanwhile, based on the physical characteristics of the lane-separating actuator, and combined with the actuator's advance action time and action holding time, an effective triggering time window for the material unit is generated; the advance action time is determined by the continuous operation record of the actuator from receiving the instruction to reaching the effective action position, and the action holding time is determined by the continuous operation record of the actuator maintaining the lane-separating state and ensuring that the material passes through the execution area;

[0106] The time window is established based on the expected arrival time of the material at the branch execution position. The start time of the time window is the earliest allowed trigger time to meet the advance action requirements of the actuator. The end time of the time window is determined based on the action holding time, the time required for the material to pass through the execution area, and the minimum interval between adjacent materials, thereby clarifying the executable time range of the branch instruction.

[0107] The queue control module compares the original predicted trigger time, the start time of the effective trigger time window, and the protection time interval required for the preceding material to occupy the actuator. If the protection interval of the preceding material is met and it is within the effective trigger time window, a candidate trigger time is generated and used as the basis for outputting the lane separation command. The candidate trigger time is the later of the original predicted trigger time, the start time of the time window, and the end time of the protection of the preceding material.

[0108] When the time is not later than the end of the time window, the candidate trigger time is output; otherwise, it is determined that the conflict cannot be executed under the current conditions, and the corresponding material unit is transferred to the backup exception handling state. The protection time interval of the preceding material is calibrated according to the reset time of the actuator, the time of the preceding material passing through the execution area, and the minimum safe interval allowed for adjacent materials, and the larger value that can satisfy the above conditions is taken.

[0109] The end time of the effective trigger time window is deducted from the control cycle and communication delay margin during calibration. Once the candidate trigger time is output, it serves as the actual scheduling benchmark for the material unit and is used to generate the expected confirmation time in the execution feedback module. If the instruction output to the actuator has a known communication delay, the delay is included as a fixed compensation amount in the time conversion between the candidate trigger time and the expected confirmation time to avoid misattributing the communication delay to the slip conversion parameter.

[0110] After determining the candidate trigger time, the queue control module calculates the time difference between the candidate trigger time and the original predicted trigger time, and uses the time difference as a conflict correction scheduling difference to be fed back into the corresponding material unit. The conflict correction scheduling difference is then distributed to the local clock of the remaining shift steps, so that the predicted time inside the logic queue is synchronized with the actual output scheduling time, avoiding the internal logic queue from continuing to run at the original rhythm if the trigger is only forcibly delayed at the output end.

[0111] Specifically, the time difference is decomposed into the target clock correction amount for each step according to the number of remaining shift steps, and a limiting is performed at each step according to the minimum and maximum allowable periods of the local shift cycle; the unused time difference after limiting continues to be stored in the corresponding material unit until the subsequent shift step is released or the material unit enters the backup exception handling state.

[0112] The scheduling difference is marked as processed after the feedback and only participates in the local clock correction of the remaining shift steps. It does not change the already output candidate trigger time again. When the remaining shift steps are zero, the unallocated difference is retained as the scheduling status record of the material unit and is prohibited from affecting the subsequent material units.

[0113] To ensure the robustness of the system under complex operating conditions, the execution feedback module is configured with a state machine anti-deadlock unit to manage the material unit throughout its entire lifecycle. The state machine independently manages the material unit's access state, tracking state, pre-trigger state, execution state, and backup exception handling state. The backup exception handling state has tiered timeout settings for each state. After receiving a valid material identifier in the access state, the material unit transitions to the tracking state.

[0114] After completing the time window matching of the drive segment in the tracking state, it transitions to the pre-trigger state; after generating and confirming the candidate trigger moment in the pre-trigger state, it transitions to the execution state; after receiving valid execution confirmation and downstream reception confirmation in the execution state, the status management of the current material unit ends; each state is transitioned only when the preset entry conditions are met;

[0115] When the corresponding confirmation signal arrives within the timeout period of the current state, the system transitions to the next state. If a timeout occurs or the flag verification fails, the system transitions to the backup exception handling state and clears any unexecuted trigger tasks for that material unit. The timeout period is determined based on the reference travel time, actuator response time, and maximum control communication delay of the corresponding state, and the corresponding calibration value is invoked when the reference speed or material specifications change. The state timeout determination is based on a monotonically increasing system clock to avoid misjudgments of timeout caused by changes in the system scan cycle.

[0116] The quantitative relationship between the graded timeout time and related parameters is as follows: Graded timeout time for any state = reference travel time for that state + actuator response time + maximum control communication delay + preset time margin; where, reference travel time = travel distance corresponding to that state ÷ reference shift speed; actuator response time is taken as the statistical high quantile value (e.g., 95th percentile value) of the actuator's continuous operation record; maximum control communication delay = control communication cycle × maximum allowed retransmissions + clock synchronization jitter margin; preset time margin is taken as 10% to 30% of the sum of the reference travel time, actuator response time and maximum control communication delay; access state, tracking state, pre-trigger state and execution state are calculated by substituting their respective travel distances and response links into the above formula to form a graded timeout sequence that matches the actual physical process of each state.

[0117] When a material unit experiences a status timeout, material identifier mismatch, or a candidate trigger time exceeding the valid trigger time window due to a conflict, the system immediately switches the material unit to a backup exception handling state. In the backup exception handling state, the system outputs a conservative action or an exception status word, releases the scheduling resources occupied by the abnormal material unit, and retains the queuing advancement right of subsequent material units, thereby avoiding queuing blockage of the entire production line due to a single material jam or unschedulable conflict. When releasing scheduling resources, only the candidate trigger tasks, time window occupancy flags, and conflict scheduling differences that have not yet been executed by the abnormal material unit are released. The global sequence number and completed execution records are not deleted to prevent subsequent materials from regaining the logical position that has been occupied.

[0118] To adapt to changes in mechanical wear, friction coefficient, and other operating characteristics caused by long-term equipment operation, the execution feedback module performs parameter self-tuning on the mapping relationship between torque characteristics and equivalent slip distance. The system only extracts material units with unique slip data, not in backup anomaly handling state, and with valid downstream confirmation signals as self-tuning closed-loop samples. The expected confirmation time is determined based on the candidate trigger time, the logical position of the material corresponding to the candidate trigger time, and the reference travel time of the downstream station, and uses the same local clock and scheduling difference correction results as the queue control module.

[0119] Obtain the actual receiving confirmation time of the original downstream workstations of the production line, and calculate the time deviation between the actual receiving confirmation time and the expected confirmation time. Iteratively update the conversion parameters used to calculate the slip size based on the time deviation within a statistical period. The statistical period is determined by the number of continuously received material units or a fixed running time, and remains consistent within the same equipment model and reference speed range.

[0120] Valid samples should also meet the following requirements: no communication retransmission occurs at the actual reception confirmation time, the duration of the confirmation signal reaches the reception judgment requirement, and the time deviation does not exceed the preset anomaly rejection range. Specifically, under the calibration slip condition of known direction, the direction of change of the expected confirmation time when the conversion parameter increases is first determined, and then the direction of change is used as the sensitivity convention for parameter update.

[0121] Within the same statistical period, the time deviations of each valid sample are arranged chronologically, and their average value is used to determine the direction of parameter adjustment. The adjustment magnitude is determined by multiplying the preset learning step size by the normalized value of the average deviation. The unit of the preset learning step size is the same as that of the conversion parameter, and the normalized value of the average deviation is dimensionless and limited to between -1 and +1, thus ensuring that the dimensions of the parameter adjustment magnitude are consistent with those of the conversion parameter. The preset time deviation benchmark used for normalization is time. The iterative update formula for the conversion parameter is:

[0122]

[0123] in, For the updated conversion parameters, For the current conversion parameters, To preset the learning step size, The average time deviation within the statistical period. The sign of the time deviation is determined by the sensitivity convention and the direction of the time deviation, which serves as the preset time deviation reference.

[0124] When the absolute value of the average deviation is less than the dead zone threshold, the conversion parameters are not changed; when the actual confirmation is later than the expected confirmation time, the parameters are adjusted in the direction that makes the subsequent expected confirmation time closer to the actual received confirmation time, according to the sensitivity agreement.

[0125] The dead zone threshold is determined as follows: it is determined based on the calibration uncertainty of the conversion parameter and the allowable material positioning error of the system. Specifically, it is the normalized time obtained by dividing the allowable material positioning error by the product of the upper limit of the allowable range of the current conversion parameter and the reference shift speed, or it is a preset multiple of the standard deviation of the effective sample time deviation within the statistical period. The larger of the two values ​​is taken as the dead zone threshold. The preset minimum sample size is determined based on the duration of the statistical period and the production line cycle time. It is the minimum number of samples that ensures that the estimated variance of the average time deviation is lower than the preset value. The example value range is 5 to 20.

[0126] When the actual confirmation is earlier than the expected confirmation time, the parameters are adjusted in the opposite direction to avoid using the wrong direction of parameter increase or decrease for different conveying directions or different symbol conventions; the maximum change and allowable range are determined based on the initial calibration value of the conversion parameters, the parameter fluctuation range during historical stable operation, and the allowable material positioning error, and are limited after the parameters are updated;

[0127] After the statistical cycle update is completed, the updated parameters will be used for the next statistical cycle. The slip data generated in the current cycle will not be recalculated. When the number of valid samples in the statistical cycle is less than the preset minimum value, the conversion parameter update will be frozen to avoid parameter contamination caused by abnormal samples, communication loss, or insufficient samples. The parameter update only applies to the newly generated slip data and does not write back to the material units that have been triggered or confirmed, thereby maintaining the correspondence between the expected confirmation time, the actual receipt confirmation time, and the sample deviation.

[0128] To verify the technical effectiveness of this system, a simulation model with parameters consistent with the actual parameters of a lithium battery production line was built for comparative verification: servo driver sampling period of 1 millisecond, feature window of 64 sampling points, bandpass filter frequency band of 120 to 280 Hz, reference shift speed of 0.5 m / s, reference shift period of 200 milliseconds, and elastic proportional coefficient of 0.2; during the conveying process, random low-amplitude slip of 0.02 mm to 0.10 mm was injected into the material; simulation results show that the system's detection rate of injected slip is no less than 95%, the false detection rate is no more than 3%, and the direction determination accuracy is no less than 98%; compared with the fixed-cycle shifting scheme without slip compensation, the lane triggering time error is reduced from approximately ±25 milliseconds to approximately ±5 milliseconds; compared with the scheme of adding photoelectric sensors, under the premise of comparable triggering time accuracy, this system does not require any external detection devices or installation space in the blind area of ​​the production line, and is not affected by obstruction or ambient light.

[0129] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A displacement channeling system for lithium battery production line material convergence process control, characterized in that, include: The drive data processing module reads the motor current, actual speed, and speed setpoint of the servo driver, wherein the motor current includes at least the quadrature axis current; Calculate the electromagnetic torque and extract the torque fluctuation. Generate slip data containing the occurrence time, direction and magnitude based on the correlation between the torque fluctuation and the speed difference calculated from the actual speed and the speed setpoint. The queue control module configures local timing values ​​and shift cycles for material units, assigns the slip data to the corresponding material units, converts the slip data into time increments to adjust the shift cycle, and resolves conflicts at the lane splitting trigger time during multi-channel convergence, outputting lane splitting instructions. The execution feedback module is used to manage the state transition of the material unit; obtain the expected confirmation time and the actual receipt confirmation time, calculate the deviation between the actual receipt confirmation time and the expected confirmation time, and perform closed-loop correction on the conversion parameter of torque fluctuation to slip size, wherein the conversion parameter is the equivalent displacement corresponding to unit torque.

2. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The drive data processing module performs bandpass filtering on the electromagnetic torque and calculates the torque fluctuation envelope within a feature window; it also calculates the cross-correlation coefficient between the change in torque fluctuation and the change in speed difference within a preset delay range. The slip direction is determined based on the cross-correlation coefficient, and a direction confidence weight representing the reliability of the direction is introduced. The slip magnitude is calculated based on the portion of the torque fluctuation envelope that exceeds the steady-state threshold and the direction confidence weight.

3. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The queue control module establishes an expected occupancy time window for each material unit in each drive section based on the reference shift speed, and matches the occurrence time of the slip data with the expected occupancy time window; when the same slip data falls into multiple expected occupancy time windows, the attribution confidence is calculated according to the distance between the occurrence time and the center of the time window, and the slip data is allocated to the corresponding material unit; when a unique attribution cannot be determined, slip compensation is prohibited from being written to the material unit.

4. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The queue control module stores the unreleased slip difference value and local timing value for each material unit; it converts the allocated slip size into a slip difference value and distributes it to a finite number of subsequent shift steps, adding or subtracting it to the base shift period to generate the corresponding local shift period; and it obtains an elastic proportional coefficient characterizing the system time tolerance, limiting the local shift period to between the minimum allowable period and the maximum allowable period set according to the elastic proportional coefficient.

5. The displacement-separation system for material flow control in lithium battery production lines according to claim 4, characterized in that, The queue control module accumulates the time corresponding to the scanning cycle to the local timing value during the system scanning cycle; when the local timing value reaches the corresponding shift cycle, it performs a shift operation, resets the local timing value, and subtracts the correction amount used in this step from the unreleased slip difference; and performs sequential constraints on globally adjacent material units according to channel priority, and restricts the logical address of subsequent material units.

6. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The queue control module generates an original predicted trigger time based on the current time and the cumulative remaining time of the remaining shift steps; it generates an effective trigger time window by combining the advance action time and holding time of the actuator; it compares the original predicted trigger time, the start time of the time window with the protection time interval of the preceding material, and generates a candidate trigger time within the effective trigger time window as the basis for lane output.

7. The displacement-separation system for material flow control in lithium battery production lines according to claim 6, characterized in that, After calculating the candidate trigger time, the queue control module writes the time difference between the candidate trigger time and the original predicted trigger time as a conflict correction scheduling difference into the corresponding material unit; and distributes the conflict correction scheduling difference to the local shift cycle of the remaining shift steps.

8. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The execution feedback module is equipped with a state machine anti-deadlock unit, which is used to independently manage the access state, tracking state, pre-trigger state, execution state and backup exception handling state of the material unit; and independently set hierarchical timeout times for each state; when a state timeout, material identifier mismatch or candidate time exceeds the effective trigger time window occurs, the material unit is transferred to the backup exception handling state, releasing the scheduling resources it occupies and retaining the queuing advancement right of subsequent material units.

9. The displacement-separation system for material flow control in lithium battery production lines according to claim 1, characterized in that, The execution feedback module extracts only material units whose slip data is uniquely assigned, have not entered the backup anomaly handling state, and whose received confirmation signals are valid as self-tuning closed-loop samples; it generates a time deviation between the actual received confirmation time and the expected confirmation time; when the number of valid samples is greater than or equal to the preset minimum number, it iteratively updates the conversion parameters based on the time deviation within a statistical period. When the number of valid samples is less than the preset minimum number, the freeze parameters are updated.

Images