CN110757882B - Full closed-loop control system and method based on sensorless servo press - Google Patents
Full closed-loop control system and method based on sensorless servo press Download PDFInfo
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Abstract
The invention belongs to the technical field of control technology and plastic forming, and particularly relates to a full closed-loop control system and method based on a sensorless servo press. The whole machine electric control system is provided with a process curve interpolation algorithm, a dynamics analysis and model establishment module, a nonlinear predictive controller and a robust controller, and a servo driver adopts a speed observer without a position sensor and a Luenberger observer. The difference between the forming process curve and the actual position of the sliding block is used as the input of a dynamics analysis and model building module, the output given torque is used as the parameter input of a robust controller, the nonlinear predictive controller replaces the function of PI in the robust controller, the output of the nonlinear predictive controller is the parameter input of the robust controller, the output of the robust controller is used as the input of a Luenberger observer, the accurate position control of the sliding block is finally realized, and the problem of overshoot of a position control mode of a traditional servo press is solved.
Description
Technical Field
The invention belongs to the technical field of control technology and plastic forming, and particularly relates to a full closed-loop control system and method based on a sensorless servo press.
Background
At this stage, servo motor power systems have been widely used in the field of metal forming, but in a very different manner. At present, the most common control mode of the slide position of the servo press is semi-closed loop control, namely an encoder is used as a sensor for closed-loop feedback of the crankshaft angle, a driving system consists of a servo motor and a servo driver, and the problem of the control mode is that the actual position of the slide is not used as a feedback object. The servo press comprises two power parts, a fine adjustment control unit and a main driving power system. The fine adjustment control unit can automatically adjust the die or set the die closing height in the working process of the servo press. The main driving force system performs feedback detection on the angle of an output shaft of the servo motor by an encoder of the servo motor of the press machine, and simultaneously performs feedback detection on the angle of the crankshaft by a photoelectric encoder connected to the crankshaft to form semi-closed loop control of a control system of the servo press machine. Some systems adopt a linear grating ruler sensor, but only carry out calibration or measurement of accuracy, and do not participate in the operation and feedback of a control system. For example, the invention patent application CN102320157 of the development center of optical-electro-mechanical technology, ltd, wisdom, usa, discloses a fully closed-loop control method, and a specific control process is explicitly written, but the control method of the servo press obviously has the following four defects: firstly, the control method of the bottom dead center adopts a comparison module and a threshold module, which can cause the condition that the actual position of the slide block exceeds the position of the bottom dead center, so that the workpiece is easy to wrinkle or break; secondly, only the bottom dead center is controlled, and the servo driver does not adjust other positions in the complete machine stroke range of the servo press machine, so that the speed and the efficiency of the stamping stroke are seriously influenced; thirdly, the angle collected at the crankshaft is used as the bottom dead center for control, and due to the multiple requirements of the assembly process, the movement clearance and the design tolerance of the servo press, the deviation between the angle and the crankshaft can occur in the actual movement process of the slide block, and the control method can not solve the precision problem; and fourthly, because the photoelectric encoder is adopted to feed back the position signal of the motor, the motor is easily influenced by electromagnetic interference and noise, the control of the servo driver is influenced, and the reliability of the system is also reduced. Fundamentally, the accuracy of the slide position control of the servo press is still not solved, and the system reliability is not very high.
Disclosure of Invention
The invention provides a full closed-loop control system and method based on a sensorless servo press machine, aiming at solving the defects of the prior art.
The invention is realized by the following technical scheme:
a full closed-loop control system based on a sensorless servo press comprises a servo press, wherein the servo press is provided with a complete machine electric control system, the complete machine electric control system is in communication connection with a human-computer interaction platform and controls a servo driver, the servo driver is connected with a servo motor through a cable, the servo motor is rigidly connected with a speed reducing mechanism through a coupler, the speed reducing mechanism is connected with a connecting rod mechanism, the connecting rod mechanism drives a sliding block to move, balance cylinders are arranged on two sides of the sliding block, and the complete machine electric control system comprises a process curve interpolation algorithm, a dynamics analysis and model establishment module, a nonlinear prediction controller and a robust controller; the servo driver control method comprises a Luenberger observer; near slider position sensor of slider position installation, slider position sensor feeds back slider actual position information to whole electrical system, wherein:
a human-computer interaction platform: and inputting process curve key points, transmitting the process curve key points to the whole machine electric control system, and displaying key state information.
Kinetic analysis and modeling module: and establishing a kinematic and dynamic model of the servo press, inputting the difference between a forming process curve and the actual position of the slide block, outputting the given torque output by dynamic calculation, and inputting the given torque as a parameter of a robust controller.
A non-linear predictive controller: the method has the advantages that the function of PI in a robust controller is replaced, the absolute value of the difference between a given forming process curve and the actual position of a sliding block is used as an input parameter of a value function, and the optimal solution of the optimal quadratic form is solved; the nonlinear predictive controller output is a parameter input to a robust controller.
A robust controller: the input is the difference between a forming process curve and the actual position of the slide block, the given torque output by the dynamics analysis and model building module, the clearance generated by a connecting rod crank in the motion process of the slide block and the interference caused by the deformation of a press machine body, the smooth output with the interference is completed, and the output is the motor torque.
A Longberger observer: the input is the motor torque output by a robust controller, the pole of the servo motor is configured according to the state equation and the control principle of the servo motor to achieve considerable control effect, and the dynamic performance of rotating speed estimation can be controlled according to different set poles, so that the position of the sliding block can be accurately controlled.
Preferably, the robust controller adopts a sliding mode controller.
Preferably, the nonlinear predictive controller employs a generalized predictive control technique.
Preferably, the slider position sensor is installed in a range larger than an operation stroke of the slider.
Preferably, the slide block position sensor is a high-precision grating ruler or a magnetic linear position sensor.
Based on the full closed-loop control system of the sensorless servo press, a full closed-loop control method based on the sensorless servo press comprises the following steps:
the method comprises the following steps: inputting a process curve key point of the press machine on a human-computer interaction platform, transmitting the key point to a complete machine electric control system of the servo press machine, generating a forming process curve through a process curve interpolation algorithm in the complete machine electric control system, and inputting the difference between the forming process curve and the actual position of a sliding block as a control instruction position of the complete machine electric control system; the actual position of the slide block is collected by a slide block position sensor and then fed back to the whole electric control system.
Step two: in a dynamics analysis and model establishment module in an electric control system of the whole machine, taking the difference between a forming process curve and the actual position of a slide block as the input of a kinematics and dynamics model, and establishing a mathematical model of a servo press; the dynamics analysis and modeling module calculates and outputs a given torque based on dynamics, the given torque being an input to a robust controller.
Step three: and the absolute value of the difference between the forming process curve and the actual position of the slide block is used as an input parameter of a value function of the nonlinear predictive controller to realize the optimal solution of the optimal quadratic form, and the output of the nonlinear predictive controller is used as the parameter input of the robust controller.
Step four: the input of the robust controller is the difference between a forming process curve and the actual position of the slide block, the given torque output by the dynamics analysis and model building module, the clearance generated by a connecting rod crank in the motion process of the slide block and the interference caused by the deformation of a press machine body, and the output is the motor torque.
Step five: the motor torque output by the robust controller is used as the input of the Roberter observer, a position-sensorless control algorithm based on the Roberter observer is realized in a servo driver to drive the servo motor to operate, and finally, the accurate control on the position of the sliding block is realized.
In the second step, the output given torque is the motor torque or can be linearly converted into a torque result.
The invention has the beneficial effects that:
the control precision problem of the slide block of the servo press is fundamentally solved, full closed-loop control of the servo press from a servo motor to the slide block of a final actuating mechanism is realized, the control precision of the absolute position of the slide block is improved from 0.1mm to 0.01mm, and the repeated positioning precision can be improved by one order of magnitude on the basis of the original control precision.
And secondly, the speed and the position of the slide block can be accurately controlled within the full stroke range of the press, and the influence of the conditions such as gear clearance, machine body deformation and the like is overcome.
And thirdly, the feedback of a position encoder of the motor is cancelled, and the reliability and the anti-interference performance of the control system are greatly improved.
And fourthly, the problem that the position control mode of the traditional servo press is overshot is solved.
Drawings
FIG. 1 is a schematic diagram of the basic architecture of a fully closed loop for a servo press according to the present invention.
Fig. 2 is a frame diagram of a full closed loop control method for a sensorless based servo press.
In the figure, 1 a whole machine electric control system, 2 a man-machine interaction platform, 3 a servo driver, 4 a servo motor, 5 a balance cylinder, 6 a slide block and 7 a slide block position sensor.
Detailed Description
The following embodiments of the present invention are provided, and it should be noted that the present invention is not limited to the following embodiments, and all equivalent changes based on the technical solutions of the present invention are within the protection scope of the present invention.
The invention adopts a brand new control method, which is a full closed-loop position control method of a servo press based on a sensorless. The system hardware architecture diagram of the servo press adopted by the method is shown in figure 1, a position sensor of a servo motor 4 is not adopted any more, model reconstruction is carried out according to detected current and voltage signals, and the current motor position, speed and torque value can be estimated.
The invention relates to a sensorless-based full-closed-loop servo control system of a servo press, which comprises a servo press, wherein the servo press is provided with a complete machine electric control system 1, the complete machine electric control system 1 is a control core of the whole system, and can be used for controlling a logic unit of the press and processing signals. The whole machine electric control system 1 is in communication connection with the human-computer interaction platform 2 and can perform interactive communication, the human-computer interaction platform 2 can input process curve key points, the process curve key points are transmitted to the whole machine electric control system 1, and key state information is displayed. The whole machine electric control system 1 is connected with and controls the servo driver 3, the servo driver 3 is connected with the servo motor 4 through a cable, the servo motor 4 is rigidly connected with the speed reducing mechanism through a coupler, an output shaft of the speed reducing mechanism is connected with the crankshaft unit, the tail end of the crank and the common end of the connecting rod mechanism are combined into a whole through a pin shaft in a three-point mode, and the connecting rod at the lower end is connected with the mechanical device in the sliding block 6 through a spherical. And balancing cylinders 5 are arranged on two sides of the sliding block 6. The above is the existing structure of the servo press, and the structure and principle thereof are not described in detail herein.
The invention installs the position sensor 7 of the slide block near the position of the slide block 6, the position sensor 7 of the slide block is installed in the range larger than the running stroke of the slide block 6, can detect its position accurately. Preferably, a high-precision grating ruler or a magnetic linear position sensor is arranged near the position of the sliding block 6 to provide feedback information of the actual position of the sliding block, and the feedback information of the actual position of the sliding block can be directly acquired into the whole electronic control system 1. The invention cancels the motor position sensor at the position of the prior servo motor 4, and further adds a control algorithm without a position sensor in the servo driver 3.
The whole machine electric control system 1 is internally provided with a process curve interpolation algorithm, and the key points of the input process curve realize generation of a forming process curve by using the process curve interpolation algorithm.
The whole machine electric control system 1 is provided with a dynamics analysis and model establishment module, and the dynamics analysis and model establishment module can establish a kinematics and dynamics model of the servo press by utilizing Lagrange's theorem of theoretical mechanics, Hamilton principle, Jacobian matrix and the like. The input of the dynamics analysis and model building module is the difference between a forming process curve and the actual position of the slide block, the output is given torque output by dynamics calculation, namely motor torque or the result of linear conversion into torque, and the given torque output is used as the input of a robust controller.
The whole electric control system 1 further includes a non-linear predictive controller and a robust controller.
The nonlinear predictive controller adopts the technical scheme of generalized predictive control, mainly realizes the replacement of PI in a robust controller, and realizes the rolling time domain optimization and the optimal output selection in the full range as far as possible. The nonlinear predictive controller can increase linear constraint, input the difference between the forming process curve and the actual position of the slide block, and use the absolute value of the difference between the given forming process curve and the actual position of the slide block as the input parameter of the value function, so as to realize the optimal solution of the optimal quadratic form, and avoid overshoot in the position control of the servo press. The nonlinear predictive controller output is used as a parameter input of a robust controller.
The purpose of the robust controller is to maintain the stability and robustness of the system as much as possible. And inputting the difference between the forming process curve and the actual position of the slide block, the given torque output by the dynamics analysis and model establishment module, the clearance generated by the connecting rod crank in the motion process of the slide block 6 and the interference caused by the body deformation of the press into a robust controller to finish smooth output with interference, and outputting the torque as motor torque. The robust controller adopts a sliding mode controller, because the robustness in sliding mode control is strong, the control result at the periphery of the sliding mode surface can be converged on the sliding mode surface finally, and different control rates can be selected to obtain different convergence speeds.
The control method of the servo driver 3 comprises a Roberter observer, and motor torque output by a robust controller is used as input of the Roberter observer. The lunberg observer is a motor control algorithm without a motor position sensor, can configure poles of the lunberg observer to achieve a considerable control effect according to a state equation of the servo motor 4 and a control principle, and can control the dynamic performance of the rotation speed estimation according to different set poles. Therefore, a position-sensorless control algorithm based on the Lorber observer is realized in the servo driver 3, the servo motor 4 is further controlled through controlling the output current, and finally the position of the sliding block 6 is accurately controlled.
The invention discloses a full closed-loop control method based on a sensorless servo press, which is realized in the full closed-loop control system based on the sensorless servo press and specifically comprises the following steps:
the method comprises the following steps: inputting a process curve key point of the press by a user of the servo press on the man-machine interaction platform 2, transmitting the key point to the whole machine electric control system 1 of the servo press, generating a smooth press forming process slide block motion curve by a piecewise polynomial curve interpolation algorithm to form a forming process curve, and inputting the difference between the forming process curve and the actual position of the slide block as a control instruction position of the whole machine electric control system 1 of the servo press; the actual position of the slide block is collected by a slide block position sensor 7 and then fed back to the whole electric control system 1.
Step two: in a dynamics analysis and model establishment module in the whole machine electric control system 1, the difference between a forming process curve and the actual position of a sliding block is used as the input of a kinematics and dynamics model, the kinematics and dynamics model establishment comprises the steps of establishing a mathematical model of a servo press by utilizing Lagrange's theorem, Hamilton's theorem, Jacobian matrix and the like, selecting a reasonable degree of freedom of 1 by combining geometric constraint and complete constraint relation, and directly simplifying an expression of a crank connecting rod into a form of a mathematical equation by utilizing a crank angle.
The dynamics analysis and modeling module calculates and outputs a given torque according to dynamics, wherein the output given torque is a motor torque or can be linearly converted into a torque result, and the output given torque is used as an input of a robust controller. The following were used:
t is the sum of the kinetic energy of the transmission part of the servo press, L is the sum of the potential energy of the transmission part of the servo press, theta is the crank angle or the selected key angle of the servo press, and tau is given torque output by calculation.
Step three: the absolute value of the difference between the forming process curve and the actual position of the sliding block is used as an input parameter of a value function of the nonlinear predictive controller, so that the optimal solution of the optimal quadratic form can be realized, and the output of the nonlinear predictive controller is used as the parameter input of the robust controller.
The nonlinear predictive controller adopts the technical scheme of generalized predictive control, and has the functions of mainly replacing PI in a robust controller, realizing rolling time domain optimization and selecting optimal output in a full range as far as possible, and providing enough constraint conditions for position control so that overshoot does not occur in the position control of the servo press.
Step four: the robust controller adopts a sliding mode controller, the input is the difference between a forming process curve and the actual position of the slide block, the given torque output by the dynamic analysis and model building module, the clearance generated by a connecting rod crank in the motion process of the slide block 6 and the interference caused by the deformation of the press machine body, and the output is the motor torque. The robust controller has the function of keeping the stability and robustness of the system as much as possible, meanwhile, the robust controller can input the clearance generated by the connecting rod crank in the motion process of the sliding block 6 and the body deformation of the press machine into the robust controller as interference, smooth output with interference is finished, and the implementation process is also carried out in the whole electric control system 1.
Step five: the motor torque output by the robust controller is used as the input of the Robert observer, a position-sensorless control algorithm based on the Robert observer is realized in the servo driver 3, the servo motor 4 is further controlled by controlling the output current, and finally, the position of the sliding block 6 is accurately controlled.
The lunberger observer is a motor control algorithm of an existing motor-free position sensor, and can be realized in the following manner:
the equation of state of an induction machine can be written as
px＝Ax+Bu (2)
y＝Cx (3)
Wherein x ═ isα，isβ，ψrα，ψrβ]，u＝[usα，usβ]，y＝[iaα，isβ](ii) a Six variables isα、isβ、ψrα、ψrβ、usα、usβSequentially obtaining alpha phase current, beta phase current, alpha phase flux linkage, beta phase flux linkage, alpha phase voltage and beta phase voltage under a two-phase static coordinate system; p represents a differential operator;
wherein
LrRotor inductance, LsStator inductance, LmMutual inductance, RsStator resistance, RrRotor resistance, ωrThe rotor speed.
Selecting a full-order observer model which takes stator current and rotor flux linkage as state variables to construct an induction motor as follows:
wherein
g1＝(k-1)*(a11+a22)，
g2＝(k-1)*ωr，
g4＝-ωr*(k-1)*a22，
eiαsRepresenting the difference between the alpha phase current estimate and the actual measured value, eiβsRepresenting the difference between the estimated value of beta phase current and the actual detection value, and k represents the k step.
The above, denoted as "^" representation estimate,
an estimate of the rotor speed is indicated.
Finally, a position-sensorless control algorithm based on a Lorber observer is realized in the servo driver 3, and the position of the sliding block 6 is accurately controlled.
The full closed-loop servo control method of the servo press based on the sensor can accurately control the position of the slide block 6 of the servo press without overshoot; the dynamic performance of the sliding block 6 in the operation process is greatly improved, and the efficiency of the control method is far higher than that of the existing control method; compared with the existing motor feedback signal, the EMC performance and the anti-interference capability of the system are improved, and the control cost of the servo motor 4 is greatly reduced; due to the adoption of the robust controller, the stability and the robustness of the system are greatly improved.
The above-described embodiment is only one of the preferred embodiments of the present invention, and general changes and substitutions by those skilled in the art within the technical scope of the present invention are included in the protection scope of the present invention.
Claims (7)
1. The utility model provides a based on full closed-loop control system of sensorless servo press, including servo press, servo press has complete machine electrical system, complete machine electrical system is connected with the communication of human-computer interaction platform, complete machine electrical system control servo driver action, servo driver passes through cable junction servo motor, servo motor passes through shaft coupling rigid connection reduction gears, reduction gears links to each other with link mechanism, link mechanism drives the slider and moves from top to bottom, slider both sides installation balancing cylinder, its characterized in that: the whole machine electric control system comprises a process curve interpolation algorithm, a dynamics analysis and model building module, a nonlinear predictive controller and a robust controller; the servo driver is internally provided with a Luenberger observer; and a slide block position sensor is arranged near the slide block position, and feeds back the actual position information of the slide block to the whole electric control system, wherein:
a human-computer interaction platform: inputting process curve key points, transmitting the process curve key points to a whole machine electric control system, and displaying key state information;
kinetic analysis and modeling module: establishing a kinematics and dynamics model of the servo press, inputting the difference between a forming process curve and the actual position of a slide block, outputting the given torque output by dynamics calculation, and inputting the given torque as a parameter of a robust controller;
a non-linear predictive controller: the method has the advantages that the function of PI in a robust controller is replaced, the absolute value of the difference between a given forming process curve and the actual position of a sliding block is used as an input parameter of a value function, and the optimal solution of the optimal quadratic form is solved; the output of the nonlinear predictive controller is the parameter input of the robust controller;
a robust controller: the input is the difference between a forming process curve and the actual position of the slide block, the given torque output by the dynamics analysis and model establishment module, the interference caused by the clearance generated by a connecting rod crank in the motion process of the slide block and the deformation of a press machine body, the smooth output with the interference is completed, and the output is the motor torque;
a Longberger observer: the input is the motor torque output by a robust controller, the pole of the servo motor is configured according to the state equation and the control principle of the servo motor to achieve considerable control effect, and the dynamic performance of rotating speed estimation can be controlled according to different set poles, so that the position of the sliding block can be accurately controlled.
2. The full closed-loop control system based on the sensorless servo press according to claim 1, wherein: the robust controller adopts a sliding mode controller.
3. The full closed-loop control system based on the sensorless servo press according to claim 1, wherein: the nonlinear predictive controller employs a generalized predictive control technique.
4. The full closed-loop control system based on the sensorless servo press according to claim 1, wherein: the slide block position sensor is arranged in a range larger than the running stroke of the slide block.
5. The full closed-loop control system based on the sensorless servo press according to claim 1, wherein: the slide block position sensor is a high-precision grating ruler or a magnetic linear position sensor.
6. The full closed-loop control system based on the sensorless servo press as claimed in any one of claims 1 to 5, a full closed-loop control method based on the sensorless servo press, comprising the steps of:
the method comprises the following steps: inputting a process curve key point of the press machine on a human-computer interaction platform, transmitting the key point to a complete machine electric control system of the servo press machine, generating a forming process curve through a process curve interpolation algorithm in the complete machine electric control system, and inputting the difference between the forming process curve and the actual position of a sliding block as a control instruction position of the complete machine electric control system; the actual position of the sliding block is collected by a sliding block position sensor and then fed back to the whole machine electric control system;
step two: in a dynamics analysis and model establishment module in an electric control system of the whole machine, taking the difference between a forming process curve and the actual position of a slide block as the input of a kinematics and dynamics model, and establishing a mathematical model of a servo press; the dynamics analysis and model establishment module calculates and outputs a given torque according to dynamics, and the given torque is used as the input of the robust controller;
step three: the absolute value of the difference between the forming process curve and the actual position of the sliding block is used as an input parameter of a value function of the nonlinear predictive controller to realize the optimal solution of the optimal quadratic form, and the output of the nonlinear predictive controller is used as the parameter input of the robust controller;
step four: the input of the robust controller is the difference between a forming process curve and the actual position of the slide block, the given torque output by the dynamics analysis and model building module, the clearance generated by a connecting rod crank in the motion process of the slide block and the interference caused by the deformation of a press machine body, and the output is the motor torque;
step five: the motor torque output by the robust controller is used as the input of the Roberter observer, a position-sensorless control algorithm based on the Roberter observer is realized in a servo driver to drive the servo motor to operate, and finally, the accurate control on the position of the sliding block is realized.
7. The full closed-loop control method based on the sensorless servo press machine as claimed in claim 6, wherein: in the second step, the output given torque is the motor torque or can be linearly converted into a torque result.
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