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CN-121995736-A - Debugging method and system for high-precision mechanical and electrical equipment

CN121995736ACN 121995736 ACN121995736 ACN 121995736ACN-121995736-A

Abstract

The invention discloses a debugging method and system for high-precision mechanical and electrical equipment, which relate to the technical field of electrical equipment debugging and comprise the steps of deploying a multi-source heterogeneous sensor in the high-precision mechanical and electrical equipment, collecting displacement, temperature, vibration and current signals, generating multi-dimensional state data through time alignment and filtering processing, extracting time sequence characteristics of error disturbance based on the multi-dimensional state data, constructing a dynamic composite error characterization model, outputting a comprehensive positioning deviation estimated value, inputting the comprehensive positioning deviation estimated value into an electromechanical coupling virtual model in a high-fidelity digital twin platform, automatically optimizing to generate an initial control parameter set, driving the equipment to execute low-speed reciprocating motion by utilizing the initial control parameter set, collecting position response residual errors in a reversing stage, constructing a feedforward compensation function based on the position response residual errors, and integrating the feedforward compensation function and the initial control parameter set into an equipment bottom layer motion controller.

Inventors

  • TANG QI
  • YAO XIAOTING
  • DING LIBO
  • Lei Youliang
  • Yuan Zhuangyuan

Assignees

  • 广东聚力胜智能科技有限公司

Dates

Publication Date
20260508
Application Date
20260126

Claims (10)

  1. 1. A debugging method for high-precision mechanical and electrical equipment is characterized by comprising the following steps: disposing a multi-source heterogeneous sensor in high-precision mechanical and electrical equipment, collecting displacement, temperature, vibration and current signals, and generating multi-dimensional state data through time alignment and filtering; Extracting time sequence features of error disturbance based on multidimensional state data, constructing a dynamic composite error characterization model, and outputting a comprehensive positioning deviation estimated value; Inputting the comprehensive positioning deviation estimated value into an electromechanical coupling virtual model in a high-fidelity digital twin platform, and automatically optimizing to generate an initial control parameter set; The method comprises the steps of executing low-speed reciprocating motion by using initial control parameter set driving equipment, collecting position response residual errors in a reversing stage, and constructing a feedforward compensation function based on the position response residual errors to identify friction and hysteresis nonlinear characteristics on line; integrating the feedforward compensation function and the initial control parameter set into a motion controller at the bottom layer of the equipment to form a closed-loop debugging strategy and start the equipment to operate so as to acquire tracking errors; And calculating a disturbance uncertainty index according to the time evolution characteristic of the tracking error, dynamically adjusting the parameter updating step length of the digital twin model and the correction amplitude of the feedforward compensation function based on the disturbance uncertainty index, and performing iterative execution until the tracking error is converged within a preset micron-level precision threshold.
  2. 2. The method for debugging high-precision mechanical and electrical equipment according to claim 1, wherein the disposing of the multi-source heterogeneous sensor on the high-precision mechanical and electrical equipment is characterized by collecting displacement, temperature, vibration and current signals, and generating multidimensional state data through time alignment and filtering processing, and the method comprises the following specific steps: The driving end, the load end and the key structure supporting point of the equipment motion shaft are respectively provided with a high-resolution optical encoder, a thermocouple, a triaxial accelerometer and a Hall current sensor; All sensors are triggered by a unified hardware clock to realize synchronous sampling, and an original displacement signal, a temperature signal, a vibration signal and a current signal are obtained; Respectively carrying out low-pass filtering on the original signals to inhibit high-frequency electromagnetic interference, and additionally carrying out sliding median filtering on the vibration signals to remove transient impact noise; and (3) strictly aligning the four types of signals after filtering according to sampling time to form a synchronous multidimensional state data sequence.
  3. 3. The debugging method for high-precision mechanical and electrical equipment according to claim 2, wherein the method is characterized by extracting time sequence features of error disturbance based on multidimensional state data, constructing a dynamic composite error characterization model, and outputting a comprehensive positioning deviation estimated value, and comprises the following specific steps of: calculating the difference between the instruction position and the filtered displacement signal to obtain an instantaneous positioning error; Setting a sliding time window with a fixed length, and respectively extracting statistical characteristics including an error mean value, a temperature rise rate, vibration energy and a current harmonic distortion rate from an instantaneous positioning error, a temperature signal, a vibration signal and a current signal in the sliding time window; Combining the statistical features into feature vectors, and inputting a nonlinear mapping function, wherein the nonlinear mapping function is realized by a radial basis function network and is used for outputting a comprehensive positioning deviation estimated value reflecting the current composite disturbance intensity; wherein the vibration energy The calculation formula of (2) is as follows: ; Wherein, the The duration of the sliding time window is indicated, Is shown at the moment The three-dimensional vibration signal vector is collected, Representing the euclidean norm of the vector, The energy intensity of the structural vibration per unit time is characterized and used for quantifying the disturbance level caused by mechanical looseness or resonance.
  4. 4. The method for debugging high-precision mechanical and electrical equipment according to claim 3, wherein the step of inputting the comprehensive positioning deviation estimated value into the electromechanical coupling virtual model in the high-fidelity digital twin platform and automatically optimizing to generate an initial control parameter set comprises the following specific steps: Establishing a multi-physical field coupling virtual model containing motor electromagnetic dynamics, mechanical transmission chain rigidity, thermal expansion displacement effect and structural modal characteristics in a digital twin platform; injecting the comprehensive positioning deviation estimated value as an external disturbance item into the output end of the multi-physical field coupling virtual model to simulate the dynamic response of the actual equipment under the current operation working condition; Defining a control parameter vector to be optimized, wherein the control parameter vector comprises a proportional gain, a differential gain, a notch filter center frequency and a track look-ahead window length; adopting a Bayesian optimization algorithm to perform iterative search in a parameter space so as to minimize the mean square error between the virtual model output track and the reference track; in each iteration, the Bayesian optimization builds a Gaussian process agent model based on the historical evaluation result, and selects the next most promising error reduction parameter combination for simulation evaluation; converging the obtained parameter combination to be used as an initial control parameter set; wherein, the expression of the track tracking mean square error J (p) is: ; Wherein, the Representing the currently evaluated control parameter vector, A reference trajectory is represented and a reference trajectory is represented, Expressed in parameters The analog displacement output by the lower digital twin model, The total duration of a single test trace is indicated, For measuring parameters The virtual tracking performance is an objective function of Bayesian optimization.
  5. 5. The method for debugging high-precision mechanical and electrical equipment according to claim 4, wherein the driving equipment using the initial control parameter set executes low-speed reciprocating motion, collects position response residual errors in a reversing stage, and based on the position response residual errors, online identifies friction and hysteresis nonlinear characteristics, and constructs a feedforward compensation function, and the method comprises the following specific steps: Downloading the initial control parameter set to a bottom layer motion controller of the equipment, and controlling a single motion axis to execute multiple complete reciprocating strokes along positive and negative directions at a speed lower than 1 millimeter per second; intercepting instantaneous positioning errors in a fixed time interval before and after each speed zero crossing point to form a position response residual error sequence of a reversing stage; based on the position response residual sequence of the reversing stage and the corresponding speed signal, jointly fitting internal parameters of the LuGre friction model and the Bouc-Wen hysteresis model; The model parameters are updated online by adopting a recursive least square method, so that the compensation function can be adaptively adjusted along with equipment wear or temperature change; constructing a feedforward compensation function taking real-time displacement and speed as input and output as a compensation moment command; The internal state evolution equation of the LuGre friction and Bouc-Wen hysteresis combined model is as follows: ; Wherein, the Representing the current displacement of the object, Indicating the current speed of the vehicle, Representing a hysteresis of the internal state variable, 、 、 Is a hysteresis shape parameter to be identified; Wherein the feedforward compensation torque The calculation formula of (2) is as follows: ; Wherein, the 、 、 Respectively representing static friction rigidity, damping friction coefficient and viscous friction coefficient, which are real parameters obtained through on-line identification; the said Directly to the control output for counteracting structural positional deviations caused by friction and hysteresis.
  6. 6. The method for debugging high-precision mechanical and electrical equipment according to claim 5, wherein the step of integrating the feedforward compensation function and the initial control parameter set into the bottom layer motion controller of the equipment to form a closed-loop debugging strategy and starting the equipment to operate and obtain tracking errors comprises the following specific steps: Configuring a standard feedback control law in the motion controller, wherein the output of the standard feedback control law is the sum of a proportional term and a differential term; adding the output of the feedforward compensation function and the output of the feedback control law to form a total control instruction and drive a servo driver; The equipment runs according to a preset standard test track, and records the actual displacement and the instruction position in real time; and calculating the difference between the two as a tracking error, and caching the complete error sequence of the last several running periods.
  7. 7. The method for debugging high-precision mechanical and electrical equipment according to claim 6, wherein the method is characterized in that the disturbance uncertainty index is calculated according to the time evolution characteristic of the tracking error, the parameter update step length of the digital twin model and the correction amplitude of the feedforward compensation function are dynamically adjusted based on the disturbance uncertainty index, and the method is iteratively executed until the tracking error is converged within a preset micron-level precision threshold, and comprises the following specific steps of: Calculating standard deviation and variation coefficients in a sliding window for a plurality of cached periodic tracking error sequences; weighting and fusing the two to form a disturbance uncertainty index; Setting a high uncertainty threshold and a low uncertainty threshold, judging that the system is in a high disturbance state when the disturbance uncertainty index is higher than the high threshold, reducing the updating step length of control parameters in the digital twin model at the moment, and limiting the correction amplitude of feedforward compensation function parameters; When the disturbance uncertainty index is lower than a low threshold, the system is judged to be stable, and at the moment, the updating step length and the correction amplitude are increased, so that the convergence process is accelerated; repeatedly executing parameter updating, compensation function correction and equipment operation until the maximum tracking error of three continuous periods is smaller than a preset micron-level precision threshold; Wherein the disturbance uncertainty index The calculation formula of (2) is as follows: ; Wherein, the Indicating the latest The standard deviation of the tracking error of each period reflects the absolute amplitude of the error fluctuation, Representing the coefficient of variation, defined as Wherein For the average tracking error, the relative degree of dispersion of the error with respect to its mean value is measured, For the preset weight coefficient, the method is used for adjusting the specific gravity of the absolute fluctuation and the relative dispersion in uncertainty evaluation.
  8. 8. A debugging system for high-precision mechanical and electrical equipment, based on the debugging method for high-precision mechanical and electrical equipment according to any one of claims 1-7, which is characterized by comprising the following steps: The system comprises a multi-source sensing fusion module, a dynamic error modeling module, a digital twin optimization module, a nonlinear feedforward compensation module, a closed loop debugging execution module and a self-adaptive iteration regulation and control module; The multi-source sensing fusion module is used for deploying an optical encoder, a thermocouple, a triaxial accelerometer and a Hall current sensor at the driving end, the load end and the key structure supporting point of a motion shaft of the equipment, realizing synchronous sampling through a unified hardware clock, carrying out low-pass filtering and sliding median filtering processing on original displacement, temperature, vibration and current signals, and outputting a time-aligned multi-dimensional state data sequence; The dynamic error modeling module is used for calculating instantaneous positioning errors based on multidimensional state data, extracting error mean values, temperature rise rates, vibration energy and current harmonic distortion rates in a sliding time window as time sequence features, inputting feature vectors into a radial basis neural network to construct a dynamic composite error characterization model, and outputting comprehensive positioning deviation estimated values; The digital twin optimizing module is used for establishing an electromechanical coupling virtual model comprising motor electromagnetic dynamics, transmission chain rigidity, thermal expansion effect and structural modes in the high-fidelity digital twin platform, taking the comprehensive positioning deviation estimated value as disturbance input, adopting a Bayesian optimizing algorithm to automatically optimize in a control parameter space, and generating an initial control parameter set for minimizing a virtual track tracking error; The nonlinear feedforward compensation module is used for driving equipment to execute low-speed reciprocating motion by utilizing an initial control parameter set, collecting position response residual errors in a reversing stage, identifying LuGre friction and Bouc-Wen hysteresis model parameters on line based on the residual errors and speed signals, constructing a feedforward compensation function taking displacement and speed as input, and outputting a compensation moment instruction; The closed loop debugging execution module is used for integrating the feedforward compensation function and the initial control parameter set into the bottom layer motion controller of the equipment to form a feedback and feedforward parallel closed loop control strategy, driving the equipment to run according to a standard test track and collecting tracking errors between actual displacement and instruction positions in real time; The adaptive iteration regulation and control module is used for calculating a disturbance uncertainty index according to the time evolution characteristic of the tracking error, the index is formed by weighting and fusing an error standard deviation and a variation coefficient, the parameter updating step length of the digital twin model and the correction amplitude of a feedforward compensation function are dynamically adjusted according to the index, the disturbance is conservatively adjusted in high disturbance, the convergence is accelerated in low disturbance, and the iteration is carried out until the tracking error is stably converged within a preset micron-level precision threshold.
  9. 9. A computer device comprises a memory and a processor, wherein the memory stores a computer program, and the computer device is characterized in that the processor realizes the steps of the debugging method for high-precision mechanical and electrical equipment according to any one of claims 1-7 when executing the computer program.
  10. 10. A computer-readable storage medium, on which a computer program is stored, characterized in that the computer program, when being executed by a processor, implements the steps of the method for debugging high-precision mechatronic devices according to any one of claims 1-7.

Description

Debugging method and system for high-precision mechanical and electrical equipment Technical Field The invention relates to the technical field of electric equipment debugging, in particular to a debugging method and system for high-precision mechanical and electric equipment. Background The debugging technology of electric equipment refers to the technical process that after mechanical and electric integrated equipment (especially an electromechanical system comprising servo drive, motion control and sensing feedback) is installed or maintained, the control performance, the motion precision, the stability and the reliability of the equipment reach the design index requirements through a series of systematic testing, parameter setting, performance verification and error compensation means. Therefore, how to improve the intelligent level and safety of electrical equipment debugging by using advanced technical means is one of the problems to be solved in the current urgent need. In the field of electrical equipment debugging, traditional calibration and compensation are mostly based on static or quasi-static assumptions, dynamic characteristics of disturbance evolving along with time cannot be described, so that the precision of equipment is rapidly degraded after long-time operation, and in micrometer/nanometer-level motion, nonlinear effects such as friction, hysteresis, dead zones and the like become main bottlenecks for limiting repeated positioning precision, and a conventional linear controller has almost no capability on such structural disturbance, and particularly, creeping or overshoot is easy to occur in a low-speed reversing stage. Disclosure of Invention The present invention has been made in view of the above-described problems occurring in the prior art. Therefore, the invention provides a debugging method for high-precision mechanical and electrical equipment, which solves the problems that the traditional calibration and compensation are based on static or quasi-static assumption, dynamic characteristics of disturbance evolving along with time cannot be described, so that the equipment is rapidly degraded in precision after long-time operation, and in micrometer/nanometer-level motion, nonlinear effects such as friction, hysteresis, dead zone and the like become main bottlenecks for limiting repeated positioning precision, and a conventional linear controller has little capability on such structural disturbance, and particularly, creeping or overshoot is easy to occur in a low-speed reversing stage. In order to solve the technical problems, the invention provides the following technical scheme: in a first aspect, the present invention provides a method for debugging high-precision mechanical and electrical equipment, including: disposing a multi-source heterogeneous sensor in high-precision mechanical and electrical equipment, collecting displacement, temperature, vibration and current signals, and generating multi-dimensional state data through time alignment and filtering; Extracting time sequence features of error disturbance based on multidimensional state data, constructing a dynamic composite error characterization model, and outputting a comprehensive positioning deviation estimated value; Inputting the comprehensive positioning deviation estimated value into an electromechanical coupling virtual model in a high-fidelity digital twin platform, and automatically optimizing to generate an initial control parameter set; The method comprises the steps of executing low-speed reciprocating motion by using initial control parameter set driving equipment, collecting position response residual errors in a reversing stage, and constructing a feedforward compensation function based on the position response residual errors to identify friction and hysteresis nonlinear characteristics on line; integrating the feedforward compensation function and the initial control parameter set into a motion controller at the bottom layer of the equipment to form a closed-loop debugging strategy and start the equipment to operate so as to acquire tracking errors; And calculating a disturbance uncertainty index according to the time evolution characteristic of the tracking error, dynamically adjusting the parameter updating step length of the digital twin model and the correction amplitude of the feedforward compensation function based on the disturbance uncertainty index, and performing iterative execution until the tracking error is converged within a preset micron-level precision threshold. The invention relates to a debugging method for high-precision mechanical and electrical equipment, which is a preferable scheme, wherein the multi-source heterogeneous sensor is deployed on the high-precision mechanical and electrical equipment to collect displacement, temperature, vibration and current signals, and multidimensional state data is generated through time alignment and filtering processing, and the method comp