CN118131606A - Deviation rectifying system based on linear sensor closed loop - Google Patents
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Abstract
The invention provides a deviation correcting system based on a linear sensor closed loop, which belongs to the technical field of closed loop deviation correcting, and comprises a setting module, a prediction parameter module and a deviation correcting module, wherein the system comprises the steps of acquiring and analyzing the physical characteristics of the linear sensor and the requirements of the deviation correcting system, establishing a reasonable closed loop monitoring circuit, analyzing by using historical deviation data, predicting the possible future deviation trend, adjusting deviation correcting control parameters according to the predicted deviation trend, generating a proper electric signal to be sent to an executing mechanism, receiving the electric signal by the executing mechanism and carrying out corresponding mechanical action, monitoring sensor feedback in real time by the system, evaluating physical deviation according to the action result of the executing mechanism, adjusting and optimizing to reduce the physical deviation, ensuring the action accuracy, realizing the improvement of the automatic control level, optimizing the production process and efficiency, improving the self-adaption capability and the predictability of the system, reducing the operation error caused by the deviation, and enabling the deviation correcting to be more accurate.
Description
Technical Field
The invention relates to the technical field of closed loop correction, in particular to a correction system based on a linear sensor closed loop.
Background
In existing web production lines, to ensure that the material is able to move accurately along a predetermined path, any offset in its travel must be monitored and corrected in real time. The cooperation of the sensor, the controller and the actuating mechanism in the deviation correcting control system is crucial, due to the diversity and complexity of the production process and the change of the production environment, a certain tiny deviation exists after deviation correction, meanwhile, the traditional closed-loop control system is slow in response speed, rapid adjustment of high speed or sudden change is difficult to effectively and practically perform, the precision of the control system is influenced by various factors, such as the precision of the sensor, the precision of the actuating mechanism, the design of a control algorithm and the like, and the precision and the stability of final control can be limited.
Accordingly, the present invention provides a linear sensor closed loop based correction system.
Disclosure of Invention
The deviation correcting system based on the linear sensor closed loop provided by the invention acquires and analyzes the physical characteristics of the linear sensor and the requirements of the deviation correcting system, establishes a reasonable closed loop monitoring circuit, analyzes by utilizing historical deviation data, predicts the possible future deviation trend, adjusts deviation correcting control parameters according to the predicted deviation trend to generate a proper electric signal to be sent to an actuating mechanism, the actuating mechanism receives the electric signal and carries out corresponding mechanical action, the system monitors sensor feedback in real time, evaluates physical deviation according to the action result of the actuating mechanism, adjusts and optimizes to reduce the physical deviation, ensures accurate action, realizes the improvement of automatic control level, optimizes the production process and efficiency, improves the self-adaption capability and predictability of the system, reduces operation errors caused by deviation, and ensures that the deviation correction is more accurate.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises:
And (3) a setting module: acquiring physical characteristics of a linear sensor and basic requirements of a deviation correcting system, and setting a closed-loop monitoring circuit of the linear sensor according to the physical characteristics and the basic requirements;
and a prediction parameter module: predicting the actual offset condition according to the historical offset condition of the closed loop monitoring circuit, adjusting the control parameter of the deviation correcting system according to the prediction result, and transmitting an electric signal corresponding to the adjusted control parameter to an executing mechanism;
And a deviation rectifying module: the executing mechanism performs mechanical action according to the received electric signals, and meanwhile, the system continuously monitors feedback of the linear sensor, determines physical deviation according to the executing result of the mechanical action, and adjusts and optimizes the physical deviation.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which is provided with a module, comprising:
a sensor selection unit: the method comprises the steps of determining the target of a deviation correcting system and the performance requirement of a production line corresponding to the deviation correcting system, and selecting the type of a linear sensor according to the target and the performance requirement and combining the physical characteristics of the linear sensor;
a first screening unit: determining an inherent error corresponding to each selected type from a type-error table, determining an error source of the inherent error, and carrying out first screening on the linear sensor by combining the error source and the production process of the production line;
a second screening unit: deep review is carried out on the first screening result and the cooperative working condition of the deviation correcting system component, potential integration problems of the deviation correcting system are determined, and second screening is carried out on the linear sensor according to the integration problems;
line construction unit: and matching the corresponding executing mechanism and the controller from the element library according to the sensor model of the second screening result, and constructing a closed-loop monitoring circuit.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which predicts a parameter module and comprises:
Prediction unit: determining a mode and a rule corresponding to coil offset by monitoring historical data of coils in a circuit in a closed loop, constructing an offset prediction model according to the historical offset rule, inputting real-time data to analyze the circuit offset condition, and predicting the circuit offset condition possibly occurring in a short time in the future based on an analysis result;
parameter adjustment unit: and adjusting control parameters of the deviation correcting system according to the difference value between the corresponding data of the predicted condition and the real-time data of the coiled material, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the executing mechanism.
The invention provides a deviation rectifying system based on a linear sensor closed loop, a prediction unit comprises:
assume that the determination subunit: collecting historical data on a closed-loop monitoring line, extracting data features corresponding to the historical data in a historical period, extracting potential offset modes of coiled materials from the data features by using a data mining technology, and establishing corresponding preliminary assumptions according to the potential offset modes;
an initial disaggregation subunit: selecting relevant features in the preliminary hypothesis, quantizing each relevant feature to obtain quantized features, and summarizing the quantized features into quantized vectors, wherein each historical offset pattern recognition scheme adopts quantized vector representation, and an initial solution set of a whale algorithm is formed based on all quantized vectors;
Prediction case subunit: and acquiring real-time data in the current time period, judging the quality of each initial solution according to the whale algorithm by combining the real-time data, and generating a new solution by cross pairing the initial solutions with the first high quality and the second high quality according to the judging result to obtain a prediction condition.
The invention provides a deviation correcting system based on a linear sensor closed loop, which predicts a situation subunit and comprises:
Solution evaluation block: evaluating each solution in the initial solution set of the combined whale algorithm based on the fitting degree of the real-time data and the offset prediction model, and selecting a solution with first high quality and a solution with second high quality according to an evaluation result;
New solution determination block: dividing quantization vectors corresponding to the solutions with the first high quality and the second high quality according to a uniform crossing rule, selecting variation probability, randomly selecting point positions to perform bit inversion to perform variation operation on the divided quantization vectors, and finally combining the quantization vectors into a new quantization vector serving as a new solution;
Prediction block: and according to the future state of the new solution prediction deviation correcting system, evaluating the new solution again, and selecting the solution with the highest quality as a final prediction model to obtain a prediction condition.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises a parameter adjusting unit, a deviation rectifying unit and a deviation rectifying unit, wherein the parameter adjusting unit comprises:
a calculating subunit: determining a current regression matrix of the deviation correcting system according to the real-time data, and calculating the change rate of the control parameters in the period of time by combining the predicted output value in the predicted condition;
；
；
Wherein, Representing a control parameter vector; /(I)Representing the scale parameter coefficient,/>Representing integral parameter coefficients; /(I)Representing differential parameter coefficients; /(I)Representing the state feedback parameter coefficients; /(I)Representing dynamic compensation parameter coefficients; /(I)Representing a diagonal matrix; Gain representing the scaling parameter coefficients; /(I) A gain representing the integral parameter coefficient; /(I)A gain representing a differential parameter coefficient; /(I)Gain representing state feedback parameter coefficients; /(I)Gain representing dynamic compensation parameter coefficients; /(I)The parameter error amount at time t; /(I)Representing the accumulated error amount in 0~t periods; /(I)The prediction error amount at the time t is represented; /(I)Representing a state error at time t; /(I)Representing a dynamic compensation error at the time t; /(I)Representing the output error of the deviation correcting system; Representing a predicted output value of the deviation correcting system at the moment t; /(I) Representing the actual output value of the deviation correcting system at the moment t; representing a regression matrix of the deviation correcting system at the moment t;
a transmission subunit: and adjusting the control parameters by minimizing performance errors according to the calculated control parameter change rate and the gradient descent method, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the execution mechanism.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises a deviation rectifying module, wherein the deviation rectifying module comprises:
physical offset unit: the executing mechanism decodes the received electric signals and executes decoding results, so that the executing action process is monitored to identify the physical offset of the executing mechanism, and the physical offset is fed back to the controller;
and a comparison unit: the controller compares the physical offset with a preset target value range, calculates the required adjustment amount according to the physical offset exceeding the range, generates a deviation rectifying instruction corresponding to the physical offset, and generates a new electric signal;
And a circulation unit: and adjusting the corresponding physical quantity of the executing mechanism according to the new electric signal, and forming an offset elimination circulation process by using the monitoring, offset feedback and offset correction instructions after the execution of the physical quantity adjusting signal is finished until the physical offset is within a preset target value range.
The invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises a physical deviation unit, wherein the physical deviation unit comprises:
Decoding subunit: adopting a multi-stage decoding algorithm to decode the electric signal from two aspects of basic parameters and complex modes;
Evaluation subunit: in the process that the monitoring execution mechanism executes according to the decoding result, determining response data of the execution mechanism and deviation data between an actual position and an expected target, performing first evaluation on the accuracy of the action of the execution mechanism according to the deviation data, performing second evaluation on the action response time, and performing third evaluation on the impact effect of the action response;
optimization subunit: and integrating the first evaluation, the second evaluation and the third evaluation results to optimize the control strategy in the controller.
Compared with the prior art, the application has the following beneficial effects: the method comprises the steps of acquiring and analyzing physical characteristics of a linear sensor and the requirements of a deviation correcting system, establishing a reasonable closed-loop monitoring circuit, analyzing by utilizing historical deviation data, predicting a deviation trend possibly occurring in the future, adjusting deviation correcting control parameters according to the predicted deviation trend to generate a proper electric signal and sending the proper electric signal to an actuating mechanism, receiving the electric signal by the actuating mechanism and carrying out corresponding mechanical actions, monitoring the feedback of the sensor in real time by the system, evaluating the physical deviation according to the action result of the actuating mechanism, adjusting and optimizing to reduce the physical deviation, ensuring the action accuracy, realizing the improvement of the automatic control level, optimizing the production process and efficiency, improving the self-adaption capability and predictability of the system, reducing the operation errors caused by the deviation, and enabling the deviation correction to be more accurate.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and drawings.
The technical scheme of the invention is further described in detail through the drawings and the embodiments.
Drawings
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate the invention and together with the embodiments of the invention, serve to explain the invention. In the drawings:
Fig. 1 is a schematic structural diagram of a deviation rectifying system based on a linear sensor closed loop according to an embodiment of the present invention.
Detailed Description
The preferred embodiments of the present invention will be described below with reference to the accompanying drawings, it being understood that the preferred embodiments described herein are for illustration and explanation of the present invention only, and are not intended to limit the present invention.
Example 1:
An embodiment of the present invention provides a deviation rectifying system based on a closed loop of a linear sensor, as shown in fig. 1, including:
And (3) a setting module: acquiring physical characteristics of a linear sensor and basic requirements of a deviation correcting system, and setting a closed-loop monitoring circuit of the linear sensor according to the physical characteristics and the basic requirements;
and a prediction parameter module: predicting the actual offset condition according to the historical offset condition of the closed loop monitoring circuit, adjusting the control parameter of the deviation correcting system according to the prediction result, and transmitting an electric signal corresponding to the adjusted control parameter to an executing mechanism;
And a deviation rectifying module: the executing mechanism performs mechanical action according to the received electric signals, and meanwhile, the system continuously monitors feedback of the linear sensor, determines physical deviation according to the executing result of the mechanical action, and adjusts and optimizes the physical deviation.
In this embodiment, the closed loop monitoring circuit generally includes a sensor, a controller, an actuator and a feedback mechanism, the library of elements is a database containing all the possible components, for example, a deviation correction system for paper manufacture may be aimed at ensuring that the paper is flat on the production line without skewing, the corresponding performance requirements are high accuracy of correction errors and fast response time, in this example, the photoelectric sensor continuously monitors the edge of the paper, and if the paper is detected to deviate from a preset path, the sensor immediately sends data to the PLC controller. The controller analyzes the data and instructs the motorized governor to adjust the position of the sheet accordingly. The adjusted position is re-monitored by the sensor and fed back again to the controller to form a closed loop, ensuring that the sheet always remains moving on the correct path.
In this embodiment, the physical characteristics include range, sensitivity, precision, resolution, response time, and stability, and the basic requirements include control precision, response speed, stability range, data processing capability, and compatibility and reliability.
In this embodiment, the historical offset conditions include offset records, action response records, system performance changes, and equipment wear conditions.
In the embodiment, according to the performance requirement of the production line and the deviation rectifying target, the proper linear sensor model is screened out, after preliminary screening, the cooperative work effect between the sensor and other components of the deviation rectifying system is further considered, the integration and potential problems of the whole system are reviewed, the second deep screening is carried out, finally the sensor model is determined, and a proper executing mechanism and a proper controller are matched, so that a closed-loop monitoring circuit is constructed.
In the embodiment, a potential offset mode is determined through historical data, a preliminary hypothesis is generated, relevant features of the preliminary hypothesis are extracted, an initial solution set is obtained after quantization, quality evaluation is carried out on each solution in the initial solution set, and finally a final model is determined according to a new solution, so that a prediction condition is obtained.
The working principle and the beneficial effects of the technical scheme are as follows: the method comprises the steps of acquiring and analyzing physical characteristics of a linear sensor and the requirements of a deviation correcting system, establishing a reasonable closed-loop monitoring circuit, analyzing by utilizing historical deviation data, predicting a deviation trend possibly occurring in the future, adjusting deviation correcting control parameters according to the predicted deviation trend to generate a proper electric signal and sending the proper electric signal to an actuating mechanism, receiving the electric signal by the actuating mechanism and carrying out corresponding mechanical actions, monitoring the feedback of the sensor in real time by the system, evaluating the physical deviation according to the action result of the actuating mechanism, adjusting and optimizing to reduce the physical deviation, ensuring the action accuracy, realizing the improvement of the automatic control level, optimizing the production process and efficiency, improving the self-adaption capability and predictability of the system, reducing the operation errors caused by the deviation, and enabling the deviation correction to be more accurate.
Example 2:
The embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises a setting module, a deviation rectifying module and a deviation rectifying module, wherein the setting module comprises:
a sensor selection unit: the method comprises the steps of determining the target of a deviation correcting system and the performance requirement of a production line corresponding to the deviation correcting system, and selecting the type of a linear sensor according to the target and the performance requirement and combining the physical characteristics of the linear sensor;
a first screening unit: determining an inherent error corresponding to each selected type from a type-error table, determining an error source of the inherent error, and carrying out first screening on the linear sensor by combining the error source and the production process of the production line;
a second screening unit: deep review is carried out on the first screening result and the cooperative working condition of the deviation correcting system component, potential integration problems of the deviation correcting system are determined, and second screening is carried out on the linear sensor according to the integration problems;
line construction unit: and matching the corresponding executing mechanism and the controller from the element library according to the sensor model of the second screening result, and constructing a closed-loop monitoring circuit.
In this embodiment, production linearity requirements generally include production efficiency, product quality, system reliability, safety, flexibility, maintainability, and the like.
In this embodiment, the type-error table refers to a list of different sensor types and their corresponding inherent errors, which are unavoidable errors caused by the design, materials, manufacturing or use environment of the sensor, for example, resistance drift of the resistive sensor may occur due to temperature change, resulting in measurement errors.
In this embodiment, the first screening is a preliminary selection of linear sensors based on a type-error table, involving consideration of specific conditions (e.g., temperature, humidity, electromagnetic interference, etc.) in the production process, excluding those sensors that fail to meet accuracy requirements in a particular production environment.
In this embodiment, the deep review is a detailed analysis of the first screening result, so as to detect how each sensor cooperates with other parts of the deviation correcting system, including compatibility of software and hardware, convenience of debugging and maintenance, cost effectiveness, and the like, and possible integration problems may be caused including poor matching of components, software conflicts, signal interference, and the like.
In this embodiment, the second screening is performed on the sensor according to the conclusion after deep evaluation, and on a more detailed level, the most suitable sensor model is selected according to the overall design of the deviation correcting system.
The working principle and the beneficial effects of the technical scheme are as follows: according to the performance requirements of the production line and the deviation rectifying targets, the proper linear sensor model is screened out, after preliminary screening, the cooperative work effect between the sensor and other components of the deviation rectifying system is further considered, the integration and potential problems of the whole system are reviewed, the second deep screening is carried out, finally the sensor model is determined, a proper executing mechanism and a proper controller are matched, a closed loop monitoring circuit is constructed, the precision of the deviation rectifying system is ensured, the position deviation of materials on the production line is corrected in real time, the sensor selection and the system integration are optimized, the quick response is carried out, and the risk of production interruption is reduced.
Example 3:
the embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, and a prediction parameter module comprises:
Prediction unit: determining a mode and a rule corresponding to coil offset by monitoring historical data of coils in a circuit in a closed loop, constructing an offset prediction model according to the historical offset rule, inputting real-time data to analyze the circuit offset condition, and predicting the circuit offset condition possibly occurring in a short time in the future based on an analysis result;
parameter adjustment unit: and adjusting control parameters of the deviation correcting system according to the difference value between the corresponding data of the predicted condition and the real-time data of the coiled material, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the executing mechanism.
In this embodiment, the web offset pattern refers to a pattern of behavior of the web in the manufacturing process that deviates from an ideal trajectory, including periodic offset, trending offset, and random offset.
In this embodiment, the historical deviation law is the statistical characteristics and regularity of the deviation pattern obtained by analyzing the historical data, such as the frequency, amplitude, rate of trending deviation, etc. of the periodic deviation in the historical data.
In this embodiment, the inputs to the offset prediction model typically include real-time production data and historical offset data, the data types including, but not limited to, sensor readings, web speed, tension, and environmental conditions, among others; the model output is a prediction of the roll deflection over a period of time in the future, and is a probability distribution, a specific parameter of a certain deflection trend, or an estimate of the deflection.
In this embodiment, the line deviation refers to the change in the position of the web relative to the ideal position during the production process, the change in the direction, size, shape, etc. of the deviation.
In this embodiment, the control parameters are variables that the correction system uses to adjust the device to correct for the offset, typically including motor speed, tension control, guide, pressure setting.
In this embodiment, the parameter adjustment process is to compare the predicted coil track with the actual track, calculate the difference between the predicted coil track and the actual track, adjust the control parameter according to the difference by using PID control, convert the adjusted parameter into a control electrical signal, and transmit the control electrical signal to an actuator (such as a motor and a hydraulic system) to implement physical adjustment.
The working principle and the beneficial effects of the technical scheme are as follows: according to the method, a deviation prediction model is constructed according to the deviation mode and rule of coiled materials, which are analyzed according to the historical data of a closed-loop monitoring line, so that the line deviation situation which possibly occurs in the future is predicted, the control parameters of a deviation correcting system are adjusted by calculating data difference values based on the prediction result and the real-time data of the coiled materials, new control electric signals are generated and transmitted to an executing mechanism to perform corresponding operation, the deviation which possibly occurs in the materials can be accurately predicted in advance, preventive adjustment is timely performed, large deviation of the production line is avoided, automatic parameter adjustment is performed, manual intervention is reduced, and the automation level of the system is improved.
Example 4:
The embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, a prediction unit comprises:
assume that the determination subunit: collecting historical data on a closed-loop monitoring line, extracting data features corresponding to the historical data in a historical period, extracting potential offset modes of coiled materials from the data features by using a data mining technology, and establishing corresponding preliminary assumptions according to the potential offset modes;
an initial disaggregation subunit: selecting relevant features in the preliminary hypothesis, quantizing each relevant feature to obtain quantized features, and summarizing the quantized features into quantized vectors, wherein each historical offset pattern recognition scheme adopts quantized vector representation, and an initial solution set of a whale algorithm is formed based on all quantized vectors;
Prediction case subunit: and acquiring real-time data in the current time period, judging the quality of each initial solution according to the whale algorithm by combining the real-time data, and generating a new solution by cross pairing the initial solutions with the first high quality and the second high quality according to the judging result to obtain a prediction condition.
In this embodiment, historical data refers to all data collected over a period of time on the closed loop monitoring line, including but not limited to sensor readings, machine conditions, environmental variables (e.g., temperature, humidity), production parameters (e.g., speed, pressure), and the like.
In this embodiment, the preliminary assumption is an inference based on data analysis to predict system behavior that may occur in a particular situation, e.g., if the analysis finds that the system is shifted whenever the temperature and pressure reach a particular value, then an assumption may be made that this particular temperature and pressure combination may be a precursor to the system shifting; the parameter vector is a concrete numerical representation constructed for applying this preliminary hypothesis in a pattern recognition system, comprising several parameters, each representing a key factor in the hypothesis, such as the temperature and pressure values in the above example, the function of the parameter vector being to transform the hypothesis into a mathematical model that can be processed by the algorithm.
In this embodiment, the data features refer to meaningful information obtained by analyzing the historical data, such as statistical information (mean, variance, etc.), trends and periodicity in time series analysis, major frequency components in frequency domain analysis, and the like.
In this embodiment, the process of extracting potential migration patterns is to use data mining techniques including, for example, cluster analysis, principal Component Analysis (PCA), regression analysis, etc., to find the regularity of the migration in the coil production process from complex historical data.
In this embodiment, the relevant features are those features directly related to the offset pattern of the web, including the readings of specific sensors, changes in line speed, changes in material properties, etc., and the difference between the data features and the relevant features is that all quantization indexes extracted from the historical data may be referred to as data features, but not all data features are closely related to the problem to be solved, so the relevant features are selected from all data features, and they have a significant correlation with the predicted variable. The process of converting the data features into related features includes screening features which are obviously related to the systematic shift phenomenon from the numerous data features, converting the data features, such as by means of logarithmic conversion, normalization and the like, combining a plurality of data features to form a new feature, reducing the number of features by using Principal Component Analysis (PCA), linear Discriminant Analysis (LDA) and other technologies, and simultaneously retaining the features with the most information quantity.
In this embodiment, the quantization process refers to the conversion of these relevant features into numerical form that can be calculated and compared, using normalization or normalization.
In this embodiment, the quantized vector is a series of normalized mathematical representations that can be used as inputs in an algorithm, e.g., if there are 5 correlation features, all of which are converted to values between 0 and 1, the quantized vector being。
In this embodiment, the process of determining the quality of the solution is to use a whale algorithm to evaluate the effectiveness of the historical offset pattern solution represented by each quantized vector. The whale algorithm is a heuristic optimization algorithm that searches the solution space for the optimal solution by simulating whale predation behavior. The quality of the solution is based on its assessment of the accuracy of the actual bias condition predictions.
In this embodiment, the crossover pair generates a new solution by taking the two solutions with the highest quality (i.e., the quantized vectors with the highest prediction accuracy) and generating a new quantized vector solution by crossover operation in the algorithm.
The working principle and the beneficial effects of the technical scheme are as follows: the potential deviation mode is determined through historical data, a preliminary hypothesis is generated, relevant characteristics of the preliminary hypothesis are extracted, an initial solution set is obtained after quantization, quality evaluation is carried out on each solution in the initial solution set, a final model is finally determined according to the new solution, a prediction condition is obtained, the position of a coiled material can be controlled more accurately, deviation is reduced, the optimized deviation correcting system can reduce material waste, and the speed and the quality of production lines are improved.
Example 5:
the embodiment of the invention provides a deviation correcting system based on a linear sensor closed loop, which comprises a prediction condition subunit, wherein the prediction condition subunit comprises the following components:
Solution evaluation block: evaluating each solution in the initial solution set of the combined whale algorithm based on the fitting degree of the real-time data and the offset prediction model, and selecting a solution with first high quality and a solution with second high quality according to an evaluation result;
New solution determination block: dividing quantization vectors corresponding to the solutions with the first high quality and the second high quality according to a uniform crossing rule, selecting variation probability, randomly selecting point positions to perform bit inversion to perform variation operation on the divided quantization vectors, and finally combining the quantization vectors into a new quantization vector serving as a new solution;
Prediction block: and according to the future state of the new solution prediction deviation correcting system, evaluating the new solution again, and selecting the solution with the highest quality as a final prediction model to obtain a prediction condition.
In this embodiment, the evaluation process of the solutions refers to how to evaluate the performance of each possible solution (which refers to one possible setting or configuration of the correction system) in the optimization problem, and based on the real-time data and the predetermined deviation prediction model, the system calculates the fitting degree of each solution, that is, the matching degree of the solution to the data.
In this embodiment, the uniform crossing rule is a method of selecting parent genes, which is used to generate offspring, involves quantization vectors of two "parent" solutions, and divides and reorganizes these vectors according to a rule, unlike single-point or two-point crossing, which uniformly crosses at each element position with equal probability select an element of one of the two parent vectors to compose the offspring.
In this embodiment, the variation probability refers to the probability that a solution is selected and randomly changed in a variation phase of the genetic algorithm, by introducing additional randomness to prevent the algorithm from converging prematurely to a locally optimal solution rather than to a globally optimal solution, such asThe set variation probability is 0.1, namely, the probability of 10% of each parameter is changed, and the compiled result is probably/>。
In this embodiment, the quantization vector is partitioned by cutting the digital representation of one solution (i.e., the quantization vector) according to a certain rule for reorganization with the corresponding portion of the other solution. The variation is based on the random selection of some positions on the quantized vector to change the values (e.g. bit inversion) with a certain probability, thereby generating new solutions, such asAfter performing the crossover rule with a, a new vector is derived such as/>。
In this embodiment, the new solution predicts the future state of the correction system by predicting the future behavior of the correction system after the new solution is obtained, i.e., how the system will respond to different inputs and environmental conditions, evaluating the performance of the new solution by running a simulation or applying a mathematical model, and finally selecting the solution with the best predicted performance for guiding the actual operation of the correction system.
The working principle and the beneficial effects of the technical scheme are as follows: and evaluating each solution in the initial solution set, dividing, mutating and recombining the solutions with the first high quality and the second high quality as evaluation results to form a new solution, evaluating the new solution again, selecting the solution with the highest quality, predicting and reducing energy consumption through optimizing configuration, and improving the overall sustainability of the system.
Example 6:
the embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, and a parameter adjusting unit comprises:
a calculating subunit: determining a current regression matrix of the deviation correcting system according to the real-time data, and calculating the change rate of the control parameters in the period of time by combining the predicted output value in the predicted condition;
；
；
Wherein, Representing a control parameter vector; /(I)Representing the scale parameter coefficient,/>Representing integral parameter coefficients; /(I)Representing differential parameter coefficients; /(I)Representing the state feedback parameter coefficients; /(I)Representing dynamic compensation parameter coefficients; /(I)Representing a diagonal matrix; Gain representing the scaling parameter coefficients; /(I) A gain representing the integral parameter coefficient; /(I)A gain representing a differential parameter coefficient; /(I)Gain representing state feedback parameter coefficients; /(I)Gain representing dynamic compensation parameter coefficients; /(I)The parameter error amount at time t; /(I)Representing the accumulated error amount in 0~t periods; /(I)The prediction error amount at the time t is represented; /(I)Representing a state error at time t; /(I)Representing a dynamic compensation error at the time t; /(I)Representing the output error of the deviation correcting system; Representing a predicted output value of the deviation correcting system at the moment t; /(I) Representing the actual output value of the deviation correcting system at the moment t; representing a regression matrix of the deviation correcting system at the moment t;
a transmission subunit: and adjusting the control parameters by minimizing performance errors according to the calculated control parameter change rate and the gradient descent method, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the execution mechanism.
In this embodiment, real-time data from sensors and monitoring systems is gathered, which may include web position, speed, tension, etc.; using the real-time data and the historical data, applying a regression analysis method (e.g., linear regression, polynomial regression) to estimate a regression matrix describing the behavior of the correction system, the regression matrix being capable of converting an input variable (e.g., coil current offset information) into an output variable (e.g., a desired control electrical signal); and calculating the change rate of the control parameter by combining the predicted output value, and calculating the change rate of the control parameter according to the predicted output value provided by the prediction model and the regression matrix.
In this embodiment, the rate of change indicates how the control parameter should change over time in order to reach the predicted ideal position.
In this embodiment, the gradient descent is an optimization algorithm for adjusting parameters step by step to minimize the performance error (the difference between the actual position and the predicted position), initializing the control parameters and calculating the error, calculating the gradient (partial derivative) of the error with respect to each control parameter, updating the control parameters according to the gradient direction, i.e. adjusting the parameter values along the direction in which the error decreases most rapidly, setting the learning rate (step size), determining the magnitude of the parameter adjustment at each iteration, repeating the above steps until the performance error falls within an acceptable range or reaches a preset number of iterations.
In this embodiment, the control electrical signal is transmitted to an actuator, such as a servo motor, of the deskewing system to perform an adjustment action to correct the web offset.
The working principle and the beneficial effects of the technical scheme are as follows: the current state of the deviation correcting system is determined by monitoring data in real time, the change trend and the change rate of the control parameters are calculated by using the prediction output value provided by the prediction module, the performance error is optimized by adopting a gradient descent method, namely, the control parameters are adjusted according to the error gradient, so that the purpose of minimizing the error is achieved, the performance error is minimized, the adjustment of the control parameters is more accurate, and the deviation correcting accuracy is improved.
Example 7:
The embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, which comprises:
physical offset unit: the executing mechanism decodes the received electric signals and executes decoding results, so that the executing action process is monitored to identify the physical offset of the executing mechanism, and the physical offset is fed back to the controller;
and a comparison unit: the controller compares the physical offset with a preset target value range, calculates the required adjustment amount according to the physical offset exceeding the range, generates a deviation rectifying instruction corresponding to the physical offset, and generates a new electric signal;
And a circulation unit: and adjusting the corresponding physical quantity of the executing mechanism according to the new electric signal, and forming an offset elimination circulation process by using the monitoring, offset feedback and offset correction instructions after the execution of the physical quantity adjusting signal is finished until the physical offset is within a preset target value range.
In this embodiment, the decoding process is that the electric signals received by the executing mechanism are usually encoded signals sent by the controller, and include specific instructions required for executing deviation correction, and the decoding process is that the electric signals are converted into executable commands or actions by the circuit inside the executing mechanism or matched with the executing mechanism according to a predetermined protocol, and the decoding result is that the type, direction, amplitude and the like of the actions need to be executed by the mechanism.
In this embodiment, the physical offset is the deviation between the actual position and the expected position due to mechanical error, frictional resistance, temperature variation, material fatigue or other external factors, including deviations in linearity or angle, such as a slight displacement in the straight axis direction or a slight rotation angle variation of the rotating assembly, when the actuator performs the corrective action.
In this embodiment, the controller calculates the adjustment amount and generates the corresponding deviation correcting instruction, where the controller compares the physical deviation fed back by the actuator with a preset target value range. If a physical offset is detected that is outside of the allowable range, a calculation is required of how much adjustment is needed to correct the offset.
In this embodiment, the offset cancellation loop is a closed loop feedback control process, by monitoring the actual states of the executing mechanism and the coiled material in real time, comparing the monitored actual states with the theoretical expected states, calculating the physical offset, calculating the required adjustment according to the offset, generating a correction instruction, executing the adjustment action by the executing mechanism according to the received correction electric signal, monitoring the state of the executing mechanism again, ensuring that the physical offset is corrected to the inside of the preset target value range, and if the monitoring result does not meet the expected value, continuing the loop unit until the offset is successfully cancelled.
The working principle and the beneficial effects of the technical scheme are as follows: the controller compares the offset with a target value, calculates an adjustment amount, sends out a deviation rectifying instruction, adjusts the offset by a new electric signal, forms closed-loop control, ensures that the offset is within the target value, shortens the fault response time, and improves the overall production efficiency and the equipment utilization rate.
Example 8:
the embodiment of the invention provides a deviation rectifying system based on a linear sensor closed loop, a physical deviation unit, comprising:
Decoding subunit: adopting a multi-stage decoding algorithm to decode the electric signal from two aspects of basic parameters and complex modes;
Evaluation subunit: in the process that the monitoring execution mechanism executes according to the decoding result, determining response data of the execution mechanism and deviation data between an actual position and an expected target, performing first evaluation on the accuracy of the action of the execution mechanism according to the deviation data, performing second evaluation on the action response time, and performing third evaluation on the impact effect of the action response;
optimization subunit: and integrating the first evaluation, the second evaluation and the third evaluation results to optimize the control strategy in the controller.
In this embodiment, the basic parameter decoding process is that the decoding algorithm will first extract basic control instructions in the electrical signal, where these instructions generally include parameters of basic actions that the executing mechanism needs to execute, such as simple motion characteristics of speed, direction, angle, time, etc.; the complex pattern analysis process is that after the basic parameters are decoded, the algorithm further analyzes more complex control sequences possibly contained in the electrical signal, which may be programmed process patterns, preset action sequences responding to specific situations, etc.
In this embodiment, the response data is actual action response information generated by the executing mechanism after receiving the control instruction, including dynamic parameters such as presented position, speed, acceleration and the like, and various sensor readings; the deviation data refers to the difference between the actual response position and the preset target position, and is a key index for measuring the accuracy of the executing mechanism, which may be generated due to the accuracy of the control signal, the performance of the equipment and external factors.
In this embodiment, a complex control algorithm (which may include, but is not limited to, adaptive control, fuzzy logic, neural networks, etc.) is employed to optimize the control strategy in the controller based on the results of the three evaluations.
The working principle and the beneficial effects of the technical scheme are as follows: the actuating mechanism decodes the electric signal through a multi-stage decoding algorithm, then evaluates the execution accuracy, response time and impact effect in the operation process, the controller comprehensively evaluates the actions of the actuating mechanism according to the evaluation results, and then timely updates the control strategy according to evaluation information to optimize the system performance, so that the deviation data is reduced, the response time is improved, and the impact of the actions on other parts of the system is reduced.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (8)
1. Deviation rectifying system based on linear sensor closed loop, characterized by comprising:
And (3) a setting module: acquiring physical characteristics of a linear sensor and basic requirements of a deviation correcting system, and setting a closed-loop monitoring circuit of the linear sensor according to the physical characteristics and the basic requirements;
and a prediction parameter module: predicting the actual offset condition according to the historical offset condition of the closed loop monitoring circuit, adjusting the control parameter of the deviation correcting system according to the prediction result, and transmitting an electric signal corresponding to the adjusted control parameter to an executing mechanism;
And a deviation rectifying module: the executing mechanism performs mechanical action according to the received electric signals, and meanwhile, the system continuously monitors feedback of the linear sensor, determines physical deviation according to the executing result of the mechanical action, and adjusts and optimizes the physical deviation.
2. The linear-sensor-closed-loop-based rectification system of claim 1, wherein the setup module comprises:
a sensor selection unit: the method comprises the steps of determining the target of a deviation correcting system and the performance requirement of a production line corresponding to the deviation correcting system, and selecting the type of a linear sensor according to the target and the performance requirement and combining the physical characteristics of the linear sensor;
a first screening unit: determining an inherent error corresponding to each selected type from a type-error table, determining an error source of the inherent error, and carrying out first screening on the linear sensor by combining the error source and the production process of the production line;
a second screening unit: deep review is carried out on the first screening result and the cooperative working condition of the deviation correcting system component, potential integration problems of the deviation correcting system are determined, and second screening is carried out on the linear sensor according to the integration problems;
line construction unit: and matching the corresponding executing mechanism and the controller from the element library according to the sensor model of the second screening result, and constructing a closed-loop monitoring circuit.
3. The linear-sensor-closed-loop-based correction system of claim 1, wherein the predictive parameter module comprises:
Prediction unit: determining a mode and a rule corresponding to coil offset by monitoring historical data of coils in a circuit in a closed loop, constructing an offset prediction model according to the historical offset rule, inputting real-time data to analyze the circuit offset condition, and predicting the circuit offset condition possibly occurring in a short time in the future based on an analysis result;
parameter adjustment unit: and adjusting control parameters of the deviation correcting system according to the difference value between the corresponding data of the predicted condition and the real-time data of the coiled material, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the executing mechanism.
4. A linear sensor closed loop based correction system according to claim 3, characterized in that the prediction unit comprises:
assume that the determination subunit: collecting historical data on a closed-loop monitoring line, extracting data features corresponding to the historical data in a historical period, extracting potential offset modes of coiled materials from the data features by using a data mining technology, and establishing corresponding preliminary assumptions according to the potential offset modes;
an initial disaggregation subunit: selecting relevant features in the preliminary hypothesis, quantizing each relevant feature to obtain quantized features, and summarizing the quantized features into quantized vectors, wherein each historical offset pattern recognition scheme adopts quantized vector representation, and an initial solution set of a whale algorithm is formed based on all quantized vectors;
Prediction case subunit: and acquiring real-time data in the current time period, judging the quality of each initial solution according to the whale algorithm by combining the real-time data, and generating a new solution by cross pairing the initial solutions with the first high quality and the second high quality according to the judging result to obtain a prediction condition.
5. The linear-sensor-closed-loop-based correction system of claim 4, wherein the predicted situation subunit comprises:
Solution evaluation block: evaluating each solution in the initial solution set of the combined whale algorithm based on the fitting degree of the real-time data and the offset prediction model, and selecting a solution with first high quality and a solution with second high quality according to an evaluation result;
New solution determination block: dividing quantization vectors corresponding to the solutions with the first high quality and the second high quality according to a uniform crossing rule, selecting variation probability, randomly selecting point positions to perform bit inversion to perform variation operation on the divided quantization vectors, and finally combining the quantization vectors into a new quantization vector serving as a new solution;
Prediction block: and according to the future state of the new solution prediction deviation correcting system, evaluating the new solution again, and selecting the solution with the highest quality as a final prediction model to obtain a prediction condition.
6. A linear sensor closed loop based correction system according to claim 3, characterized by a parameter adjustment unit comprising:
a calculating subunit: determining a current regression matrix of the deviation correcting system according to the real-time data, and calculating the change rate of the control parameters in the period of time by combining the predicted output value in the predicted condition;
；
；
Wherein, Representing a control parameter vector; /(I)Representing the scale parameter coefficient,/>Representing integral parameter coefficients; /(I)Representing differential parameter coefficients; /(I)Representing the state feedback parameter coefficients; /(I)Representing dynamic compensation parameter coefficients; /(I)Representing a diagonal matrix; /(I)Gain representing the scaling parameter coefficients; /(I)A gain representing the integral parameter coefficient; /(I)A gain representing a differential parameter coefficient; /(I)Gain representing state feedback parameter coefficients; /(I)Gain representing dynamic compensation parameter coefficients; /(I)The parameter error amount at time t; Representing the accumulated error amount in 0~t periods; /(I) The prediction error amount at the time t is represented; /(I)Representing a state error at time t; /(I)Representing a dynamic compensation error at the time t; /(I)Representing the output error of the deviation correcting system; /(I)Representing a predicted output value of the deviation correcting system at the moment t; /(I)Representing the actual output value of the deviation correcting system at the moment t; /(I)Representing a regression matrix of the deviation correcting system at the moment t;
a transmission subunit: and adjusting the control parameters by minimizing performance errors according to the calculated control parameter change rate and the gradient descent method, generating new control electric signals for the adjusted control parameters, and transmitting the new control electric signals to the execution mechanism.
7. The linear-sensor-closed-loop-based rectification system of claim 1, wherein the rectification module comprises:
physical offset unit: the executing mechanism decodes the received electric signals and executes decoding results, so that the executing action process is monitored to identify the physical offset of the executing mechanism, and the physical offset is fed back to the controller;
and a comparison unit: the controller compares the physical offset with a preset target value range, calculates the required adjustment amount according to the physical offset exceeding the range, generates a deviation rectifying instruction corresponding to the physical offset, and generates a new electric signal;
And a circulation unit: and adjusting the corresponding physical quantity of the executing mechanism according to the new electric signal, and forming an offset elimination circulation process by using the monitoring, offset feedback and offset correction instructions after the execution of the physical quantity adjusting signal is finished until the physical offset is within a preset target value range.
8. The linear-sensor-closed-loop-based rectification system of claim 6, wherein the physical offset unit comprises:
Decoding subunit: adopting a multi-stage decoding algorithm to decode the electric signal from two aspects of basic parameters and complex modes;
Evaluation subunit: in the process that the monitoring execution mechanism executes according to the decoding result, determining response data of the execution mechanism and deviation data between an actual position and an expected target, performing first evaluation on the accuracy of the action of the execution mechanism according to the deviation data, performing second evaluation on the action response time, and performing third evaluation on the impact effect of the action response;
optimization subunit: and integrating the first evaluation, the second evaluation and the third evaluation results to optimize the control strategy in the controller.
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