Multi-signal synchronous acquisition converter and multi-motor synchronous linkage control system

Abstract

The utility model discloses a multi-signal synchronous acquisition converter and a multi-motor synchronous linkage control system, and the converter comprises a housing, a plurality of encoder signal input interfaces, a plurality of encoder signal output interfaces, and an industrial Ethernet communication interface, the first-stage microprocessor and the second-stage microprocessor are arranged in the shell; wherein the first-stage microprocessor is used for synchronously acquiring signals of a plurality of encoders, realizing clock zero point alignment, and performing alignment processing on position zero points, rotation directions and change resolutions of the encoders; and the second-stage microprocessor is connected with the first-stage microprocessor and is used for processing the encoder signals subjected to synchronous acquisition and alignment processing, outputting the encoder signals in the form of industrial Ethernet signals after addresses are merged, and receiving and executing instructions from a user interface window of a rear-end synchronous controller at the same time.

Description

Technical Field

[0001] The utility model relates to the field of automatic control, in particular to a multi-signal synchronous acquisition converter and a multi-motor synchronous linkage control system. Background Art

[0002] In the field of intelligent manufacturing, automated production control has become a key means to improve production efficiency and quality. Among them, multi-motor synchronous linkage motion control, as one of the core technologies of automated production control, is widely used in the mechanical transmission parts of various production lines. This kind of motion control not only requires mechanical motion sensing sensors to provide accurate closed-loop feedback to meet the safety requirements of automated intelligent coordinated production, but also needs to support digital remote monitoring and data uploading to support the digital remote cloud access requirements of production machinery sensing.

[0003] The absolute encoder, as an important position sensing sensor, plays a key role in the perception of rotational angle or linear motion position changes. There are usually two options for its installation position: one is to directly install it on the motion actuator, such as the tail of the motor, to directly sense the angle change of the motor rotor and provide a feedback closed-loop for the actuator drive; the other is to install it at the end of the mechanical transmission to directly sense the final motion effect after mechanical transmission.

[0004] In the scenario of multi-motor linkage synchronous control, due to the differences in actuators or loads, achieving the synchronous effect of the motion results becomes the key. This requires the position zeros of each motion coordinate to be aligned in the mechanical motion results, that is, it is necessary to rely on the sensor installed at the mechanical end to provide zero alignment and comparison of the feedback closed-loop. This encoder installed at the mechanical end is usually called the second encoder.

[0005] However, in the prior art, most systems do not install the second encoder, but only rely on the encoder on the actuator motor as the feedback signal, and compare the signals collected by the driver for motion control synchronization networking. This approach has two major problems: one is the error in the process of mechanical motion result transmission, and the other is the time delay error in signal transmission. The uncertainty of these two errors makes it impossible to accurately reflect the true synchronous state.

[0006] Although some prior art adopts the second encoder and transmits the signals of each encoder to the multi-motion synchronous controller through the bus networking method for feedback comparison, due to the characteristics of bus transmission, there are the sequence of address sorting and the alternating online of space-time occupancy during signal transmission, resulting in crowded online resources and increased signal delay, thus seriously affecting the time accuracy of synchronous control.

[0007] Therefore, developing a new control system that can accurately achieve multi-motor linkage synchronous control and overcome the above technical defects has important practical application value. Utility Model Content

[0008] To achieve the above object, an embodiment of the present application provides a multi-signal synchronous acquisition converter, including: a housing, a plurality of encoder signal input interfaces, output interfaces, and industrial Ethernet communication interfaces provided on the housing, and a first-stage microprocessor and a second-stage microprocessor provided in the housing;

[0009] Among them, the first-stage microprocessor is used to synchronously acquire a plurality of encoder signals, achieve clock zero alignment, and perform alignment processing on the position zero point, rotation direction, and change resolution of each encoder;

[0010] The second-stage microprocessor is connected to the first-stage microprocessor, and is used to process the encoder signals after synchronous acquisition and alignment processing, merge the addresses and output them in the form of industrial Ethernet signals, and at the same time receive and execute instructions from the user interface window of the backend synchronous controller.

[0011] Optionally, the converter includes at least two first-stage microprocessors, and each first-stage microprocessor is respectively communicatively connected to the second-stage microprocessor.

[0012] Optionally, each first-stage microprocessor includes a power input interface and a signal input interface.

[0013] Optionally, the converter further includes a mode setting selection switch and a confirmation trigger switch, where the mode setting selection switch is used to set the zeroing alignment mode, and the confirmation trigger switch is used to trigger the signal input microprocessor in the set mode.

[0014] Optionally, the sealing level of the converter is not less than IP67.

[0015] On the other hand, the present application also discloses a multi-motor synchronous linkage control system, including the multi-signal synchronous acquisition industrial Ethernet converter in the foregoing embodiment, and the system includes:

[0016] A real-time sensing sensor installed at the mechanical end of each motion axis, the sensor is used to generate synchronous sensor signals and achieve zero alignment through clock synchronization technology;

[0017] The converter is used to receive and process signals from multiple encoders, and merge the processed signals into one address for one-time transmission.

[0018] By adopting the above technical solutions, compared with the prior art, it has at least the following beneficial effects:

[0019] The device provided by this application includes the processing of multiple encoder input signals collected on-site, and intelligent processing by a microprocessor. It realizes the synchronous data acquisition of the second encoder for mechanical motion feedback at the process site, completes the zero alignment of the mechanical position coordinates and the clock alignment of data acquisition, which provides a synchronous basis for the subsequent synchronous controller to align the coordinates in time and space of the sensors. In addition, the intelligent preprocessing and combined address transmission of multiple encoder signals can save online resources and controller computing capacity resources. Especially in the synchronous calculation and control of multiple motion actuators in intelligent manufacturing, it can achieve parallel input of sampling time, zero alignment, and real-time synchronous motion control without time difference for clock alignment. Description of the Drawings

[0020] To more clearly illustrate the technical solutions in the embodiments of this application, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of this application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0021] Figure 1 It is a schematic diagram of the interface of a multi-signal synchronous acquisition converter provided by an exemplary embodiment of this application;

[0022] Figure 2 It is a schematic diagram of the structure of a multi-signal synchronous acquisition converter provided by an exemplary embodiment of this application.

[0023] Reference Signs:

[0024] 1, the first power supply interface;

[0025] 2, the second power supply interface;

[0026] 3, the mode setting strobe switch;

[0027] 4, the first encoder signal input interface;

[0028] 5, the first industrial Ethernet communication interface;

[0029] 6, the second industrial Ethernet communication interface;

[0030] 7, the confirmation trigger switch;

[0031] 8, the second encoder signal input interface. Detailed Embodiments

[0032] To make the objectives, technical solutions, and advantages of this application clearer, the following will further describe the embodiments of this application in detail in conjunction with the drawings.

[0033] The utility model is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the utility model, but do not limit the utility model in any form. It should be pointed out that for those of ordinary skill in the art, several changes and improvements can be made without departing from the concept of the utility model. These all belong to the protection scope of the utility model.

[0034] The present application provides a multi-signal synchronous acquisition converter, comprising: a shell, a plurality of encoder signal input interfaces, output interfaces and industrial Ethernet communication interfaces arranged on the shell, and a first-level microprocessor and a second-level microprocessor arranged in the shell; wherein the first-level microprocessor is used to synchronously acquire a plurality of encoder signals, realize clock zero point alignment, and perform alignment processing on the position zero point, rotation direction and change resolution of each encoder; the second-level microprocessor is connected to the first-level microprocessor, and is used to process the encoder signals after synchronous acquisition and alignment processing, and output them in the form of industrial Ethernet signals after merging addresses, and simultaneously receive and execute instructions from the user interface window of the back-end synchronization controller.

[0035] Specifically, the above-mentioned multiple encoder signal input interfaces, output interfaces and industrial Ethernet communication interfaces, as well as the first-level microprocessor and the second-level microprocessor arranged in the shell, are all arranged on a PCB circuit board, and each input interface, output interface and processor are connected by metal wires on the circuit board.

[0036] The converter provided by the present application includes multiple encoder input signal processing collected on site, and microprocessor intelligent processing, which realizes the synchronous data collection of the second encoder of mechanical motion feedback at the process site, completes the zero point alignment of the mechanical position coordinates, and the clock alignment of data acquisition, which provides the synchronization basis for the subsequent synchronous controller to align the coordinates in the time and space of the sensor. In addition, the intelligent preprocessing of multiple encoder signals merges the address transmission, which can save online resources and controller computing capacity resources; especially in the synchronous calculation and control of intelligent manufacturing multi-motion actuators, it can realize the parallel input of sampling time, zero point alignment, clock alignment and real-time synchronous motion control without time difference.

[0037] See also Figure 1 The utility model provides a schematic diagram of the interface included in a multi-signal synchronous acquisition converter. The interface of the converter is arranged on the housing, and is provided with a first power interface 1 and a second power interface 2 for powering the converter and the encoder. A mode setting selection switch 3, exemplarily, the switch is an 8421 encoding switch. And a confirmation trigger switch 7 corresponding to the mode setting.

[0038] The first encoder signal input interface 4 and the second encoder signal input interface 8 are used to receive encoder signals. The first industrial Ethernet communication interface 5 and the second industrial Ethernet communication interface 6 are used for signal output (e.g., profinet or Ethercat).

[0039] Further, please refer to Figure 2 , the converter provided in this embodiment has an internal circuit design that synchronously and parallely collects multiple encoder signals, combines the processed signals into one address for one-time transmission, and has a structure with two built-in microprocessors (MCUs). Among them, the functional objectives of the first-level microprocessors (MCU1 and MCU2) are to synchronously collect multiple sensor encoder signals, align the clock zeros, and in the first-level microprocessors (MCU1 and MCU2), the first-level microprocessors will also perform alignment processing on the position zeros, rotation directions, and change resolutions of each encoder to ensure seamless docking and comparison of data between different encoders. This function is implemented by an 8421 coding switch, and the user sets a zero alignment mode and inputs it to the first-level microprocessors. Preferably, a button switch is also provided to trigger signal input to the first-level microprocessors (MCU1 and MCU2) in a certain set mode for zero alignment after digital calculation of the collected signals of each encoder. And the memory EEPROM remembers the set zero alignment parameters.

[0040] According to specific implementation situations, the converter may include at least two first-level microprocessors, and each first-level microprocessor is respectively communicatively connected to the second-level microprocessor. This configuration can improve the efficiency of data collection and processing, and at the same time increase the redundancy and reliability of the system.

[0041] Each first-level microprocessor is provided with a power input interface and a signal input interface to receive external power and encoder signals.

[0042] The second-level microprocessor MCU3 is connected to the first-level microprocessors and is used to receive the encoder signals after synchronous collection and alignment processing. It further processes these signals, such as data integration, format conversion, etc., and finally combines the processed data into one address and outputs it in the form of an industrial Ethernet signal. The second-level microprocessor is also responsible for receiving instructions from the user interface window of the backend synchronous controller and performing corresponding operations, such as adjusting collection parameters, changing output formats, etc.

[0043] Specifically, the functional objective of the second-level microprocessor MCU3 is to process the signals of multiple sensor encoders after synchronous acquisition and zero alignment according to the on-site process requirements. For example, it can perform timely comparison of two encoder signals on-site, generate and send warning signals for asynchronous situations backward. The second-level microprocessor also serves as the merged address and communication protocol for sending signals backward, such as the industrial Ethernet signal profinet or Ethercat. The second microprocessor is also the instruction receiver and executor for the user interface window of the backend synchronization controller. The EEPROM remembers the instruction requirements of the user interface window and maintains consistency in the future.

[0044] On the other hand, the present application also provides a multi-motor synchronous linkage control system, including the multi-signal synchronous acquisition industrial Ethernet converter described in the foregoing embodiment. The system includes: real-time sensing sensors installed at the mechanical ends of each motion axis, which are used to generate synchronous sensor signals and achieve zero alignment through clock synchronization technology; the converter is used to receive and process signals from multiple encoders, and merge the processed signals into one address for one-time transmission.

[0045] The sensors are installed at the mechanical ends of each motion axis and are used to sense and record the position information of the mechanical ends in real time. The synchronous sensor signals generated by them achieve zero alignment through clock synchronization technology, ensuring the consistency and accuracy of data.

[0046] The converter receives signals from multiple sensors. After synchronous acquisition, alignment processing, and data integration, the processed data is merged into one address and transmitted to the backend synchronization controller at one time through the industrial Ethernet communication interface.

[0047] The backend synchronization controller performs synchronous control on each motor according to the received data, realizing the efficient and precise linkage of multiple motors.

[0048] The following further elaborates on the present application in combination with the usage steps.

[0049] 1. In the application scenario, there is a linkage synchronization control of multiple motion actuators. Absolute encoders are installed at the mechanical ends, and the output signals are high-speed point-to-point serial RS485 signals.

[0050] 2. The signals of multiple absolute encoders at the on-site process site are connected to the first encoder signal input interface 4 and the second encoder signal input interface 8 of the device of the present invention. Refer to Figure 1 .

[0051] 3. The working power supply of the converter and encoder of this device is connected through the power input interface 1. During the first commissioning after the installation of the absolute encoder, it is necessary to align the zero point of the signal of each absolute encoder in the device of the present utility model. Due to different requirements for the rotation direction and resolution of the encoder, there are various setting mode combinations. In the 8421 coding switch setting mode, and during the first commissioning, manually move each mechanical actuator to a mechanically specified position. After the device of the present utility model is powered on for the first time, press the setting trigger switch 7.

[0052] 4. After the first-level microprocessors (MCU1 and MCU2) receive the setting mode combination code, they call out the preset zero-point alignment setting method. After receiving the setting trigger switch signal, they perform a reverse digital coordinate rotation calculation on the signal of each received absolute encoder to the preset zero position. The above process aligns the zero-point positions of the signal coordinates of each absolute encoder connected to the device of the present utility model.

[0053] 5. After setting the initialization zero-point alignment of multiple encoders, the mode selection switch is toggled back to the 0 state and enters the working state.

[0054] 6. In the working state of the device of the present utility model, the encoder signal reading is a parallel signal acquisition, and clock point marks are added in the first-level microprocessors MCU1 and MCU2. In this way, the clock alignment of the signal acquisition of each encoder is achieved, and there is a unified delay during the subsequent transmission process. This delay can be reflected on the clock point marks.

[0055] 7. After the first-level microprocessor processes the signal, it transmits and centralizes it to the second-level microprocessor, and calculates the positional relationship between two or more encoders that need to be synchronized. When a large deviation occurs, a deviation warning signal is generated.

[0056] 8. All encoder signals that have been intelligently processed by the device of the present utility model, as well as the synchronous over-tolerance warning signal, are combined into one address and sent to the subsequent receiving device according to the communication protocol of industrial Ethernet. For example, profinet or Ethercat.

[0057] As can be seen from this embodiment, the multi-signal synchronous acquisition converter provided in this embodiment includes the processing of multiple encoder input signals collected on-site, and intelligent processing by the microprocessor. It realizes the synchronous data acquisition of the second encoder for mechanical motion feedback at the process site, completes the zero alignment of the mechanical position coordinates and the clock alignment of data acquisition, and provides a synchronous basis for the subsequent synchronous controller to align the coordinates of the sensor in time and space. Moreover, the intelligent preprocessing and combined address transmission of multiple encoder signals can save on-line resources and the computing capacity resources of the controller. Especially in the synchronous calculation and control of multiple motion actuators in intelligent manufacturing, it can realize the parallel input of the sampling time, and the real-time synchronous motion control with zero time difference for zero alignment and clock alignment.

[0058] The converter is also equipped with a mode setting gating switch and a confirmation trigger switch. The mode setting gating switch is used to set the zero alignment mode, and users can select different alignment modes according to actual needs. The confirmation trigger switch is used to trigger the signal to be input into the microprocessor in the set mode to start the data acquisition and processing process.

[0059] Zero alignment of the encoder position and clock alignment of the encoder signal acquisition. The zero alignment reference coordinate system for multi-motor synchronous linkage control is remotely digitized.

[0060] The converter of the present utility model is designed with a highly protected housing, and its sealing level is not lower than IP67, ensuring normal operation even in harsh industrial environments. It can collect multiple absolute encoder signals on-site, and remotely digitize the coordinate establishment of the absolute position of the second encoder.

[0061] Point-to-point fast active serial parallel communication, synchronous without time difference, short signal delay, and on-site conversion to Ethernet.

[0062] The converter of the present utility model realizes a truly synchronous coordinate system by aligning the data acquisition clock and synchronizing the time coordinates.

[0063] During debugging, initialize the zero alignment of the encoder data position coordinates. The absolute encoder does not lose the zero point and maintains long-term synchronous coordinate alignment. This saves the technical labor costs of expensive on-site debugging and maintenance.

[0064] Under the condition of zero alignment of the position zero point and clock zero point, multi-level sub-task processing is carried out. The signal is converted to industrial Ethernet, and the information is sent by combining addresses. Remote digitization is realized, and Ethernet on-line resources and Ethernet hardware costs are saved.

[0065] Quickly calculate the synchronous relationship on-site, calculate the information sensitive to synchronous deviation and alarm information with large deviation, and improve the redundancy safety of multi-motor synchronous control.

[0066] The utility model device and method of the present application are for the synchronous linkage control of multiple motion actuators, realizing on-site real-time perception, associating with fast in-situ edge process calculation, and optimizing and compressing data packets for output on an industrial Ethernet with one address. It can realize the real-time perception and monitoring of multiple mechanical motion actuators in intelligent manufacturing, the intelligent perception of all-power mechanical equipment, the alignment of spatial and temporal coordinate zeros, the realization of industrial Ethernet networking and digital remote transmission, and help solve existing technical defects. At the same time, the determinability of mechanical position synchronous control can reduce the possibility of equipment damage and achieve safe production. Due to the perception and remote digitization of mechanical motion, intelligent maintenance and scientific management of equipment status can be realized, facilitating the big data collection, supervision, and recording of the factory's underlying machinery, and enabling managers to analyze big data and continuously improve production process efficiency and equipment maintenance management.

[0067] The above description is only some preferred embodiments of the present disclosure and an explanation of the applied technical principles. Those skilled in the art should understand that the scope of the utility model involved in the embodiments of the present disclosure is not limited to the technical solutions formed by the specific combination of the above technical features. It should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the above utility model concept. For example, the technical solutions formed by mutually replacing the above features with the (but not limited to) technical features with similar functions disclosed in the embodiments of the present disclosure.

[0068] After considering the specification and practicing the utility model disclosed herein, those skilled in the art will easily think of other implementation schemes of the present application. The present application aims to cover any variations, uses, or adaptive changes of the present application, which follow the general principles of the present application and include the common general knowledge or conventional technical means in the technical field not disclosed in the present application.

[0069] It should be understood that the present application is not limited to the precise structure already described and shown in the drawings, and various modifications and changes can be made without departing from its scope. The scope of the present application is only limited by the appended claims.

[0070] It should be understood that the term "plurality" mentioned herein refers to two or more. "And / or" describes the association relationship of associated objects and indicates that three relationships can exist. For example, A and / or B can represent: A exists alone, A and B exist simultaneously, and B exists alone. The character " / " generally represents an "or" relationship between the associated objects before and after.

[0071] The above are only the preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application shall be included within the protection scope of the present application.

Claims

1. A multi-signal synchronous acquisition converter, characterized in that, Comprising: A housing, a plurality of encoder signal input interfaces, output interfaces, and industrial Ethernet communication interfaces provided on the housing, and a first-stage microprocessor and a second-stage microprocessor provided inside the housing; Wherein, the first-stage microprocessor is used to synchronously collect a plurality of encoder signals, achieve clock zero alignment, and perform alignment processing on the position zero points, rotation directions, and change resolutions of each encoder; The second-stage microprocessor is connected to the first-stage microprocessor, and is used to process the encoder signals after synchronous collection and alignment processing, merge the addresses and output them in the form of industrial Ethernet signals, and at the same time receive and execute instructions from the user interface window of the backend synchronization controller.

2. The converter according to claim 1, characterized in that, The converter includes at least two first-stage microprocessors, and each first-stage microprocessor is respectively communicatively connected to the second-stage microprocessor.

3. The converter according to claim 2, characterized in that, Each of the first-stage microprocessors includes a power input interface and a signal input interface.

4. The converter according to claim 3, characterized in that, The converter further includes a mode setting gating switch and a confirmation trigger switch, wherein the mode setting gating switch is used to set the zeroing alignment mode, and the confirmation trigger switch is used to trigger the signal input microprocessor in the set mode.

5. The converter according to any one of claims 1 to 4, characterized in that, The sealing level of the converter is not less than IP67.

6. A multi-motor synchronous linkage control system, comprising the multi-signal synchronous acquisition converter according to any one of claims 1 to 5, characterized in that, The system includes: Real-time sensing sensors installed at the mechanical ends of each motion axis, the sensors are used to generate synchronous sensor signals and achieve zero alignment through clock synchronization technology; A converter for receiving and processing signals from multiple encoders, and merging the processed signals into one address for one-time transmission.

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