WO2021088235A1 - 零点定位方法、系统、伺服电机及存储介质 - Google Patents

零点定位方法、系统、伺服电机及存储介质 Download PDF

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Publication number
WO2021088235A1
WO2021088235A1 PCT/CN2019/129089 CN2019129089W WO2021088235A1 WO 2021088235 A1 WO2021088235 A1 WO 2021088235A1 CN 2019129089 W CN2019129089 W CN 2019129089W WO 2021088235 A1 WO2021088235 A1 WO 2021088235A1
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Prior art keywords
motor
zero
encoder
collision
block
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PCT/CN2019/129089
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English (en)
French (fr)
Inventor
刘元江
石功磊
赵云峰
曹娟娟
王国元
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歌尔股份有限公司
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Publication of WO2021088235A1 publication Critical patent/WO2021088235A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/12—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means
    • G01D5/244—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains
    • G01D5/245—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable using electric or magnetic means influencing characteristics of pulses or pulse trains; generating pulses or pulse trains using a variable number of pulses in a train
    • G01D5/2451—Incremental encoders

Definitions

  • the present invention relates to the technical field of motor control, in particular to a zero-point positioning method, system, servo motor and storage medium.
  • servo motors In many areas of modern industrial production, position motions with high-precision errors of micrometers are required, and this function is mainly realized by servo motors.
  • servo motors usually use high-precision absolute encoders or incremental encoders. Among them, incremental encoders have become the mainstream due to their moderate cost and convenient operation. However, the accuracy of servo motors using incremental encoders is lower. low.
  • the moving block is set at a certain constant speed.
  • the servo motor will control the moving block to decelerate and stop.
  • the position of the moving block is set to zero.
  • the main purpose of the present invention is to provide a zero-point positioning method, system, servo motor and storage medium, aiming to solve the technical problem of large zero-point positioning error in the prior art.
  • the present invention provides a zero-point positioning method.
  • the method includes the following steps:
  • control the motor movement block When the collision is successful, control the motor movement block to run away from the limit block, and detect in real time whether the Z signal sent by the encoder is received;
  • the zero point position is determined according to the first encoder value and the second encoder value based on a preset algorithm.
  • the step of determining the zero point position according to the first encoder value and the second encoder value based on a preset algorithm includes:
  • the actual position is taken as the zero position.
  • the step of compensating the parking distance based on a sinusoidal S-curve algorithm to obtain the actual position of the motor moving block when it stops includes:
  • the current position of the motor motion block is recorded, and the current position is taken as the actual position when the motor motion block stops.
  • the sine S-curve algorithm is:
  • V p is a preset target speed
  • S p is the stopping distance
  • t is the running time
  • j (t) is a jerk of the motor motion block.
  • the step of performing collision detection on the motor moving block includes:
  • the method further includes:
  • the three-phase inverter module is controlled to turn off, so that the three-phase inverter module stops driving the motor moving block.
  • the step of reading the first encoder value from the encoder when the Z signal is detected includes:
  • N is a preset positive integer
  • the present invention also provides a zero-point positioning system
  • the zero-point positioning system includes:
  • the collision detection module is used to control the motor moving block to run toward the limit block, and to perform collision detection on the motor moving block;
  • the signal detection module is used to control the motor movement block to run away from the limit block when the collision is successful, and to detect in real time whether the Z signal sent by the encoder is received;
  • the encoder reading module is used to read the first encoder value from the encoder when the Z signal is detected, and control the motor motion block to decelerate, so as to read the motor motion block when the motor motion block stops.
  • Second encoder value Second encoder value
  • the distance compensation module is configured to determine the zero point position according to the first encoder value and the second encoder value based on a preset algorithm.
  • the present invention also provides a servo motor, the servo motor includes: a memory, a processor, and a zero point positioning program stored in the memory and running on the processor, the zero point The positioning program is configured to implement the steps of the zero-point positioning method.
  • the present invention also provides a storage medium with a zero-point positioning program stored on the storage medium, and the zero-point positioning program is executed by a processor to implement the steps of the zero-point positioning method.
  • the present invention controls the movement of the motor movement block toward the limit block, and performs collision detection on the motor movement block; when the collision is successful, controls the motor movement block to run away from the limit block, and detects whether the Z signal sent by the encoder is received in real time; When the Z signal is detected, the first encoder value is read from the encoder, and the motor motion block is controlled to decelerate to run to read the second encoder value when the motor motion block stops; based on the preset algorithm according to the first encoder value And the second encoder value determines the zero position.
  • the accurate positioning of the zero point is achieved through Z signal detection and distance compensation for the decelerating operation of the motor movement block, which eliminates the position sensor used in the traditional zero point positioning, reduces the cost of the zero point positioning error, and improves the use The accuracy of the servo motor of the incremental encoder.
  • FIG. 1 is a schematic diagram of a servo motor structure of a hardware operating environment involved in a solution of an embodiment of the present invention
  • FIG. 2 is a schematic flowchart of a first embodiment of a zero-point positioning method according to the present invention
  • FIG. 3 is a schematic flowchart of a second embodiment of a zero-point positioning method according to the present invention.
  • Fig. 4 is a functional block diagram of the first embodiment of the zero-point positioning system of the present invention.
  • FIG. 1 is a schematic diagram of a servo motor structure of a hardware operating environment involved in a solution of an embodiment of the present invention.
  • the servo motor may include: a processor 1001, such as a CPU, a communication bus 1002, a user interface 1003, a network interface 1004, and a memory 1005.
  • the communication bus 1002 is used to implement connection and communication between these components.
  • the user interface 1003 may include a display screen (Display) and an input unit such as a keyboard (Keyboard), and the optional user interface 1003 may also include a standard wired interface and a wireless interface.
  • the network interface 1004 may optionally include a standard wired interface and a wireless interface (such as a WI-FI interface).
  • the memory 1005 may be a high-speed RAM memory, or a non-volatile memory (non-volatile memory), such as a magnetic disk memory.
  • the memory 1005 may also be a storage device independent of the aforementioned processor 1001.
  • Fig. 1 does not constitute a limitation on the servo motor, and may include more or fewer components than shown in the figure, or a combination of certain components, or a different component arrangement.
  • the memory 1005 which is a computer storage medium, may include an operating system, a network communication module, a user interface module, and a zero-point positioning program.
  • the network interface 1004 is mainly used for data communication with an external network;
  • the user interface 1003 is mainly used for receiving user input instructions;
  • the servo motor uses the processor 1001 to call the zero point stored in the memory 1005 Locate the program and do the following:
  • control the motor movement block When the collision is successful, control the motor movement block to run away from the limit block, and detect in real time whether the Z signal sent by the encoder is received;
  • the zero point position is determined according to the first encoder value and the second encoder value based on a preset algorithm.
  • processor 1001 may call the zero-point positioning program stored in the memory 1005, and also perform the following operations:
  • the actual position is taken as the zero position.
  • processor 1001 may call the zero-point positioning program stored in the memory 1005, and also perform the following operations:
  • the current position of the motor motion block is recorded, and the current position is taken as the actual position when the motor motion block stops.
  • processor 1001 may call the zero-point positioning program stored in the memory 1005, and also perform the following operations:
  • the collision time is not less than the first preset time, and the collision position is not greater than the preset displacement, it is determined that the collision is successful.
  • processor 1001 may call the zero-point positioning program stored in the memory 1005, and also perform the following operations:
  • the three-phase inverter module is controlled to turn off, so that the three-phase inverter module stops driving the motor moving block.
  • processor 1001 may call the zero-point positioning program stored in the memory 1005, and also perform the following operations:
  • N is a preset positive integer
  • the motor motion block is controlled to run toward the limit block, and collision detection is performed on the motor motion block; when the collision is successful, the motor motion block is controlled to run away from the limit block, and real-time detection of whether the Z signal sent by the encoder is received ;
  • the Z signal is detected, read the first encoder value from the encoder, and control the motor motion block to decelerate to read the second encoder value when the motor motion block stops; based on the preset algorithm according to the first encoder The value and the second encoder value determine the zero position.
  • the accurate positioning of the zero point is achieved through Z signal detection and distance compensation for the decelerating operation of the motor movement block, which eliminates the position sensor used in the traditional zero point positioning, reduces the cost of the zero point positioning error, and improves the use The accuracy of the servo motor of the incremental encoder.
  • FIG. 2 is a schematic flowchart of the first embodiment of the zero-point positioning method of the present invention.
  • the zero-point positioning method includes the following steps:
  • S10 Control the motor motion block to run toward the limit block, and perform collision detection on the motor motion block;
  • the traditional zero point positioning method is to place the sensor near the zero point, move the motor motion block to a fixed direction at a constant speed, and decelerate to stop when the sensor is detected, and set the position when the motor motion block is completely stopped. Is zero.
  • the true zero point is not the same as the position where the motor motion block completely stops, resulting in a large error in the zero point positioning.
  • the sensor is eliminated, and the limit block, the encoder and the corresponding program control in the servo motor are used to achieve precise zero point positioning.
  • the collision detection is to detect whether the motor moving block collides with the limit block, and there are many detection methods.
  • the collision current, collision time, and collision displacement of the motor moving block are respectively detected; only when three conditions are met at the same time, that is, when the collision current is not less than the preset current, the collision
  • the time is not less than the first preset time and the collision position is not greater than the preset displacement, it is determined that the collision is successful, so as to ensure that the collision is sufficient.
  • the three-phase inverter module is the drive hardware of the motor, which is used to drive the motor to run.
  • the collision current is not less than the preset current and the collision time is not less than the first preset time, it means that the current is too large and the duration is long. At this time, it is necessary to control the three-phase inverter module to shut down to stop the three-phase inverter module from driving.
  • the motor movement block can effectively protect the three-phase inverter module.
  • the encoder may use an incremental encoder.
  • Incremental encoders directly use the principle of photoelectric conversion to output three sets of square wave pulses A, B and Z phases.
  • the phase difference between the two sets of pulses A and B is 90, so that the direction of rotation can be easily judged, and the Z phase is one per revolution. Pulse, used for zero point positioning.
  • the Nth Z signal when the Nth Z signal is detected, it is determined whether the time for detecting the Nth Z signal is greater than the second preset time; where N is a preset positive integer; if so, the three-phase inverse is controlled The variable module is closed; if not, the first encoder value is read from the encoder.
  • the position of the Z signal in a circle is the zero position.
  • the counting error caused by the loss of pulses of the incremental signal can be corrected in a circle.
  • the engineer can select the encoder value of the Nth Z signal as the first encoder value according to the specific hardware conditions of the servo motor.
  • the encoder fails, the signal cannot be found or the time to find the Nth Z signal is too long, in order to protect the drive hardware, the three-phase inverter module must also be turned off.
  • the decelerating operation of the motor motion block at this time refers to the decelerating operation of the motor motion block away from the limit block.
  • the incremental encoder converts the displacement into a periodic electrical signal, and then converts this electrical signal into a count pulse, the number of pulses is used to indicate the magnitude of the displacement, so the value of the first encoder is And the second encoder value can calculate the displacement of the motor motion block in different time periods.
  • S40 Determine a zero point position according to the first encoder value and the second encoder value based on a preset algorithm.
  • the preset algorithm is used to compensate the parking distance through a reverse compensation method, eliminate the parking error of the motor moving block, thereby reducing the positioning error, and completing the precise positioning.
  • the motor motion block is controlled to run toward the limit block, and collision detection is performed on the motor motion block; when the collision is successful, the motor motion block is controlled to run away from the limit block, and real-time detection of whether the Z signal sent by the encoder is received ;
  • the Z signal is detected, read the first encoder value from the encoder, and control the motor motion block to decelerate to read the second encoder value when the motor motion block stops; based on the preset algorithm according to the first encoder The value and the second encoder value determine the zero position.
  • the accurate positioning of the zero point is achieved through Z signal detection and distance compensation for the decelerating operation of the motor movement block, eliminating the position sensor used in the traditional zero point positioning, reducing the cost while reducing the zero point positioning error, and improving the use The accuracy of the servo motor of the incremental encoder.
  • step S40 specifically includes the following steps:
  • S41 Determine the parking distance according to the difference between the second encoder value and the first encoder value
  • the second encoder value can be used to calculate the displacement of the motor motion block when it runs to deceleration.
  • the difference between the value and the first encoder value can determine the stopping distance of the motor moving block during deceleration.
  • S42 Compensate the parking distance based on a sinusoidal S-curve algorithm to obtain the actual position of the motor motion block when it stops;
  • the jerk of the motor motion block is obtained based on the sine S-curve algorithm according to the parking distance and the preset target speed; the motor motion block is controlled to run with the jerk toward the limit block; when the motor moves When the running distance of the block is the parking distance, the current position of the motor motion block is recorded, and the current position is taken as the actual position when the motor motion block stops.
  • sine S-curve algorithm is:
  • V p is a preset target speed
  • S p is the stopping distance
  • t is the running time
  • j (t) is a jerk of the motor motion block.
  • the jerk of the trapezoidal and parabolic acceleration curves is a step function, and there is a step transformation, which makes the speed change of the motor not stable enough.
  • the jerk of the sine acceleration curve is a sine function, which can be continuously derived, so sine The curve can better conform to the characteristic that the torque of the stepper motor decreases with the increase of speed, make full use of the effective torque of the motor, and at the same time can reduce the mechanical shock.
  • the zero return completion signal can also be sent to the encoder to synchronize the current sampling value of the encoder, and set the zero return state of the encoder, and wait for instructions from the host computer.
  • the acceleration/deceleration operation of the moving block of the motion path control motor is planned by the sinusoidal S-curve algorithm, while accurately and backwardly compensating the parking distance, the accuracy of the position is ensured, and precise positioning is realized.
  • the present invention further provides a zero-point positioning system.
  • Fig. 4 is a functional block diagram of the first embodiment of the zero-point positioning system of the present invention.
  • the zero-point positioning system includes:
  • the collision detection module 10 is used to control the motor motion block to run toward the limit block, and perform collision detection on the motor motion block;
  • the traditional zero-point positioning method is to place the sensor near the zero point, move the motor motion block to a fixed direction at a constant speed, and decelerate to stop when the sensor is detected, and set the position when the motor motion block is completely stopped. Is zero.
  • the true zero point is not the same as the position where the motor motion block completely stops, resulting in a large error in the zero point positioning.
  • the sensor is eliminated, and the limit block, the encoder and the corresponding program control in the servo motor are used to achieve precise zero point positioning.
  • the collision detection is to detect whether the motor moving block collides with the limit block, and there are many detection methods.
  • the collision current, collision time, and collision displacement of the motor moving block are respectively detected; only when three conditions are met at the same time, that is, when the collision current is not less than the preset current, the collision
  • the time is not less than the first preset time and the collision position is not greater than the preset displacement, it is determined that the collision is successful, so as to ensure that the collision is sufficient.
  • the three-phase inverter module is the drive hardware of the motor, which is used to drive the motor to run.
  • the collision current is not less than the preset current and the collision time is not less than the first preset time, it means that the current is too large and the duration is long. At this time, it is necessary to control the three-phase inverter module to shut down to stop the three-phase inverter module from driving.
  • the motor movement block can effectively protect the three-phase inverter module.
  • the signal detection module 20 is used to control the motor movement block to run away from the limit block when the collision is successful, and to detect in real time whether the Z signal sent by the encoder is received;
  • the encoder may use an incremental encoder.
  • Incremental encoders directly use the principle of photoelectric conversion to output three sets of square wave pulses A, B and Z phases.
  • the phase difference between the two sets of pulses A and B is 90, so that the direction of rotation can be easily judged, and the Z phase is one per revolution. Pulse, used for zero point positioning.
  • the encoder reading module 30 is used to read the first encoder value from the encoder when the Z signal is detected, and control the motor motion block to decelerate to run, so as to read when the motor motion block stops The second encoder value;
  • the Nth Z signal when the Nth Z signal is detected, it is determined whether the time for detecting the Nth Z signal is greater than the second preset time; where N is a preset positive integer; if so, the three-phase inverse is controlled The variable module is closed; if not, the first encoder value is read from the encoder.
  • the position of the Z signal in a circle is the zero position.
  • the counting error caused by the loss of pulses of the incremental signal can be corrected in a circle.
  • the engineer can select the encoder value of the Nth Z signal as the first encoder value according to the specific hardware conditions of the servo motor.
  • the encoder fails, the signal cannot be found or the time to find the Nth Z signal is too long, in order to protect the drive hardware, the three-phase inverter module must also be turned off.
  • the decelerating operation of the motor motion block at this time refers to the decelerating operation of the motor motion block away from the limit block.
  • the incremental encoder converts the displacement into a periodic electrical signal, and then converts this electrical signal into a count pulse, the number of pulses is used to indicate the magnitude of the displacement, so the value of the first encoder is And the second encoder value can calculate the displacement of the motor motion block in different time periods.
  • the distance compensation module 40 is configured to determine a zero point position according to the first encoder value and the second encoder value based on a preset algorithm.
  • the preset algorithm is used to compensate the parking distance through a reverse compensation method, eliminate the parking error of the motor moving block, thereby reducing the positioning error, and completing the precise positioning.
  • the motor motion block is controlled to run toward the limit block, and collision detection is performed on the motor motion block; when the collision is successful, the motor motion block is controlled to run away from the limit block, and real-time detection of whether the Z signal sent by the encoder is received ;
  • the Z signal is detected, read the first encoder value from the encoder, and control the motor motion block to decelerate to read the second encoder value when the motor motion block stops; based on the preset algorithm according to the first encoder The value and the second encoder value determine the zero position.
  • the accurate positioning of the zero point is achieved through Z signal detection and distance compensation for the decelerating operation of the motor movement block, eliminating the position sensor used in the traditional zero point positioning, reducing the cost while reducing the zero point positioning error, and improving the use The accuracy of the servo motor of the incremental encoder.
  • the embodiment of the present invention also provides a storage medium, the storage medium stores a zero-point positioning program, and when the zero-point positioning program is executed by a processor, the following operations are implemented:
  • control the motor movement block When the collision is successful, control the motor movement block to run away from the limit block, and detect in real time whether the Z signal sent by the encoder is received;
  • the zero point position is determined according to the first encoder value and the second encoder value based on a preset algorithm.
  • the actual position is taken as the zero position.
  • the current position of the motor motion block is recorded, and the current position is taken as the actual position when the motor motion block stops.
  • the collision time is not less than the first preset time, and the collision position is not greater than the preset displacement, it is determined that the collision is successful.
  • the three-phase inverter module is controlled to turn off, so that the three-phase inverter module stops driving the motor moving block.
  • N is a preset positive integer
  • the technical solution of the present invention essentially or the part that contributes to the existing technology can be embodied in the form of a software product, and the computer software product is stored in a storage medium (such as ROM/RAM) as described above. , Magnetic disks, optical disks), including several instructions to make a terminal device (which can be a mobile phone, a computer, a server, an air conditioner, or a network device, etc.) execute the method described in each embodiment of the present invention.
  • a terminal device which can be a mobile phone, a computer, a server, an air conditioner, or a network device, etc.

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Abstract

一种零点定位方法、系统、伺服电机及存储介质。通过控制电机运动块朝向限位块运行，并对电机运动块进行碰撞检测（S10）；当碰撞成功时，控制电机运动块背离限位块运行，并实时检测是否接收到编码器发送的Z信号（S20）；在检测到Z信号时从编码器读取第一编码器值，并控制电机运动块减速运行，以读取电机运动块停止时的第二编码器值（S30）；基于预设算法根据第一编码器值及第二编码器值确定零点位置（S40）。其中，通过Z信号检测及对电机运动块减速运行的距离补偿实现对零点的精确定位，取消了传统零点定位时使用的位置传感器，在降低成本的同时减小了零点定位的误差，提高了使用增量式编码器的伺服电机的精度。

Description

零点定位方法、系统、伺服电机及存储介质 技术领域
本发明涉及电机控制技术领域，尤其涉及一种零点定位方法、系统、伺服电机及存储介质。
背景技术
在现代工业生产的很多领域中，都需要高精度误差为微米的位置动作，该功能主要依靠伺服电机实现。目前伺服电机通常使用高精度绝对式编码器或增量式编码器，其中，增量式编码器因其成本适中，操作方便等优势成为主流，但是使用增量式编码器的伺服电机的精度较低。
为了提高伺服电机的精度，通常需要精确地对零点进行定位。现有技术中大部分使用外接的定位传感器，如霍尔传感器、光电开关等位置传感器，将传感器放置在零点附近作为伺服电机回零点的定位基准，具体地为，将运动块以某一恒定速度向着某方向运行，行进过程中如果位置传感器检测到运动块，伺服电机就控制运动块减速停止，当运动块完全停止时，运动块所处的位置就设定为零点。
上述回零点方法，在检测到位置传感器开始减速停止时，受到电机转速控制误差、传感器响应误差以及机械传动结构几大因素的影响(如加工装配误差，结构磨合程度等)，会造成停止位置误差较大，很难将误差控制在微米的范围内，无法满足一些高精度要求的行业的生产要求。
发明内容
本发明的主要目的在于提供一种零点定位方法、系统、伺服电机及存储介质，旨在解决现有技术中零点定位误差较大的技术问题。
为实现上述目的，本发明提供一种零点定位方法，所述方法包括以下步骤：
控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测 是否接收到编码器发送的Z信号；
在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
优选地，所述基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置的步骤，包括：
根据所述第二编码器值与所述第一编码器值的差值确定停车距离；
基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置；
将所述实际位置作为零点位置。
优选地，所述基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置的步骤，包括：
基于正弦S曲线算法根据所述停车距离及预设目标速度获取所述电机运动块的加加速度；
控制所述电机运动块以所述加加速度朝向限位块运行；
当所述电机运动块的运行距离为所述停车距离时，记录所述电机运动块的当前位置，并将所述当前位置作为所述电机运动块停止时的实际位置。
优选地，所述正弦S曲线算法为：
Figure PCTCN2019129089-appb-000001
其中，V p为预设目标速度，S p为所述停车距离，t为运行时间，j(t)为所述电机运动块的加加速度。
优选地，所述对所述电机运动块进行碰撞检测的步骤，包括：
分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；
当所述碰撞电流不小于预设电流且当所述碰撞时间不小于第一预设时间时，控制三相逆变模块关闭，以使所述三相逆变模块停止驱动所述电机运动块。
优选地，所述分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测的步骤之后，所述方法还包括：
当所述碰撞时间不小于第一预设时间时，控制三相逆变模块关闭，以使 所述三相逆变模块停止驱动所述电机运动块。
优选地，所述在检测到所述Z信号时从所述编码器读取第一编码器值的步骤，包括：
在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；
若是，则控制所述三相逆变模块关闭；
若否，从所述编码器读取第一编码器值。
此外，为实现上述目的，本发明还提供一种零点定位系统，所述零点定位系统包括：
碰撞检测模块，用于控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
信号检测模块，用于当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
编码器读取模块，用于在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
距离补偿模块，用于基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
此外，为实现上述目的，本发明还提供一种伺服电机，所述伺服电机包括：存储器、处理器及存储在所述存储器上并可在所述处理器上运行的零点定位程序，所述零点定位程序配置为实现所述的零点定位方法的步骤。
此外，为实现上述目的，本发明还提供一种存储介质，所述存储介质上存储有零点定位程序，所述零点定位程序被处理器执行时实现所述的零点定位方法的步骤。
本发明通过控制电机运动块朝向限位块运行，并对电机运动块进行碰撞 检测；当碰撞成功时，控制电机运动块背离限位块运行，并实时检测是否接收到编码器发送的Z信号；在检测到Z信号时从编码器读取第一编码器值，并控制电机运动块减速运行，以读取电机运动块停止时的第二编码器值；基于预设算法根据第一编码器值及第二编码器值确定零点位置。其中，通过Z信号检测及对电机运动块减速运行的距离补偿实现对零点的精确定位，取消了传统零点定位时使用的位置传感器，在降低成本的同时减小了零点定位的误差，提高了使用增量式编码器的伺服电机的精度。
附图说明
图1是本发明实施例方案涉及的硬件运行环境的伺服电机结构示意图；
图2为本发明零点定位方法第一实施例的流程示意图；
图3为本发明零点定位方法第二实施例的流程示意图；
图4为本发明零点定位系统第一实施例的功能模块图。
本发明目的的实现、功能特点及优点将结合实施例，参照附图做进一步说明。
具体实施方式
应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
参照图1，图1为本发明实施例方案涉及的硬件运行环境的伺服电机结构示意图。
如图1所示，该伺服电机可以包括：处理器1001，例如CPU，通信总线1002、用户接口1003，网络接口1004，存储器1005。其中，通信总线1002用于实现这些组件之间的连接通信。用户接口1003可以包括显示屏(Display)、输入单元比如键盘(Keyboard)，可选用户接口1003还可以包括标准的有线接口、无线接口。网络接口1004可选的可以包括标准的有线接口、无线接口(如WI-FI接口)。存储器1005可以是高速RAM存储器，也可以是稳定的存储器(non-volatile memory)，例如磁盘存储器。存储器1005可选的还可以是独立于前述处理器1001的存储装置。
本领域技术人员可以理解，图1中示出的结构并不构成对伺服电机的限 定，可以包括比图示更多或更少的部件，或者组合某些部件，或者不同的部件布置。
如图1所示，作为一种计算机存储介质的存储器1005中可以包括操作系统、网络通信模块、用户接口模块以及零点定位程序。
在图1所示的伺服电机中，网络接口1004主要用于与外部网络进行数据通信；用户接口1003主要用于接收用户的输入指令；所述伺服电机通过处理器1001调用存储器1005中存储的零点定位程序，并执行以下操作：
控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
进一步地，处理器1001可以调用存储器1005中存储的零点定位程序，还执行以下操作：
根据所述第二编码器值与所述第一编码器值的差值确定停车距离；
基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置；
将所述实际位置作为零点位置。
进一步地，处理器1001可以调用存储器1005中存储的零点定位程序，还执行以下操作：
基于正弦S曲线算法根据所述停车距离及预设目标速度获取所述电机运动块的加加速度；
控制所述电机运动块以所述加加速度朝向限位块运行；
当所述电机运动块的运行距离为所述停车距离时，记录所述电机运动块的当前位置，并将所述当前位置作为所述电机运动块停止时的实际位置。
进一步地，处理器1001可以调用存储器1005中存储的零点定位程序，还执行以下操作：
分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；
当所述碰撞电流不小于预设电流，所述碰撞时间不小于第一预设时间且所述碰撞位置不大于预设位移时判定碰撞成功。
进一步地，处理器1001可以调用存储器1005中存储的零点定位程序，还执行以下操作：
当所述碰撞电流不小于预设电流且所述碰撞时间不小于第一预设时间时，控制三相逆变模块关闭，以使所述三相逆变模块停止驱动所述电机运动块。
进一步地，处理器1001可以调用存储器1005中存储的零点定位程序，还执行以下操作：
在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；
若是，则控制所述三相逆变模块关闭；
若否，从所述编码器读取第一编码器值。
本实施例通过控制电机运动块朝向限位块运行，并对电机运动块进行碰撞检测；当碰撞成功时，控制电机运动块背离限位块运行，并实时检测是否接收到编码器发送的Z信号；在检测到Z信号时从编码器读取第一编码器值，并控制电机运动块减速运行，以读取电机运动块停止时的第二编码器值；基于预设算法根据第一编码器值及第二编码器值确定零点位置。其中，通过Z信号检测及对电机运动块减速运行的距离补偿实现对零点的精确定位，取消了传统零点定位时使用的位置传感器，在降低成本的同时减小了零点定位的误差，提高了使用增量式编码器的伺服电机的精度。
基于上述硬件结构，提出本发明零点定位方法实施例。
参照图2，图2为本发明零点定位方法第一实施例的流程示意图。
在第一实施例中，所述零点定位方法包括以下步骤：
S10：控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
可以理解的是，传统的零点定位方法是将传感器放置在零点附近，将电机运动块以某一恒定速度向着固定方向运动，当检测到传感器就减速停止，将电机运动块完全停止时的位置设置为零点。但是由于电机运动块停止需要 时间，并会运行一段距离，因此，真正的零点与电机运动块完全停止的位置并不相同，导致零点定位存在较大误差。本实施例取消了传感器，利用伺服电机中的限位块、编码器及相应的程序控制实现精确的零点定位。
应理解的是，所述朝向限位块运行指向限位块的方向运行，本实施例中不限定具体运行路径。
需要说明的是，所述碰撞检测是对电机运动块是否碰撞到限位块进行检测，其检测方式有很多种。作为一优选实施例，在进行碰撞检测时分别对电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；只有同时满足三个条件，即当所述碰撞电流不小于预设电流，所述碰撞时间不小于第一预设时间且所述碰撞位置不大于预设位移时才判定碰撞成功，以保证碰撞充分。
在具体实现中，三相逆变模块是电机的驱动硬件，用于驱动电机运行。当碰撞电流不小于预设电流且碰撞时间不小于第一预设时间时，说明电流过大并且持续时间较长，此时需要控制三相逆变模块关闭，以使三相逆变模块停止驱动电机运动块，如此可以有效保护三相逆变模块。
S20：当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
应理解的是，所述背离限位块运行指向限位块的方向的反方向运行，本实施例中不限定具体运行路径。
需要说明的是，为了控制产品成本及方便用户操作，所述编码器可以使用增量式编码器。增量式编码器是直接利用光电转换原理输出三组方波脉冲A、B和Z相，A、B两组脉冲相位差90，从而可方便的判断出旋转方向，而Z相为每转一个脉冲，用于零点定位。
S30：在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
具体地，在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；若是，则控制所述三相逆变模块关闭；若否，从所述编码器读取第一编码器值。
需要说明的是，Z信号在一圈内位置是零位，通过读取Z信号，可以在一圈内修正增量信号因脉冲丢失而产生的计数误差。本实施例中，工程人员可以根据伺服电机的具体硬件情况选取第N个Z信号时编码器的值作为第一 编码器值。
当然，如果编码器出现故障，找不到信号或者找到第N个Z信号的时间过长时，为了保护驱动硬件，同样需要关闭三相逆变模块。
应当理解的是，此时电机运动块减速运行，是指电机运动块背离限位块减速运行。
在具体实现中，由于增量式编码器是将位移转换成周期性的电信号，再把这个电信号转变成计数脉冲，用脉冲的个数表示位移的大小，因此，通过第一编码器值及第二编码器值可以计算电机运动块在不同时间段的位移。
S40：基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
需要说明的是，从接收到第N个Z信号开始停车，到电机运动块完全停止，这期间存在一段停车距离。所述预设算法用于通过反向补偿方式对停车距离进行回补，消除电机运动块的停车误差，从而减少定位误差，完成精确定位。
本实施例通过控制电机运动块朝向限位块运行，并对电机运动块进行碰撞检测；当碰撞成功时，控制电机运动块背离限位块运行，并实时检测是否接收到编码器发送的Z信号；在检测到Z信号时从编码器读取第一编码器值，并控制电机运动块减速运行，以读取电机运动块停止时的第二编码器值；基于预设算法根据第一编码器值及第二编码器值确定零点位置。其中，通过Z信号检测及对电机运动块减速运行的距离补偿实现对零点的精确定位，取消了传统零点定位时使用的位置传感器，在降低成本的同时减小了零点定位的误差，提高了使用增量式编码器的伺服电机的精度。
进一步地，如图3所示，基于第一实施例提出本发明零点定位方法第二实施例，在本实施例中，步骤S40具体包括以下步骤：
S41：根据所述第二编码器值与所述第一编码器值的差值确定停车距离；
具体地，由于通过第一编码器值可以计算出找到第N个Z信号时电机运动块的位移，通过第二编码器值可以计算出电机运动块运行至减速时的位移，通过第二编码器值与所述第一编码器值的差值可以确定电机运动块减速过程中的停车距离。
S42：基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置；
具体地，基于正弦S曲线算法根据所述停车距离及预设目标速度获取所述电机运动块的加加速度；控制所述电机运动块以所述加加速度朝向限位块运行；当所述电机运动块的运行距离为所述停车距离时，记录所述电机运动块的当前位置，并将所述当前位置作为所述电机运动块停止时的实际位置。
其中，所述正弦S曲线算法为：
Figure PCTCN2019129089-appb-000002
其中，V p为预设目标速度，S p为所述停车距离，t为运行时间，j(t)为所述电机运动块的加加速度。
需要说明的是，梯形、抛物线形加速曲线其加加速度为阶跃函数，存在阶跃变换，使得电机速度变化不够平稳，而正弦加速曲线，其加加速度为正弦函数，可连续求导，因此正弦曲线能更好地符合步进电机力矩随速度升高而减小的特点，充分地利用电机的有效转矩，同时能够减弱机械冲击。通过正弦S曲线算法控制电机运动块加减速，可以实现电机的平稳可靠的运行。
S43：将所述实际位置作为零点位置。
可理解的是，在对停车距离进行补偿后，电机运动块停止的实际位置才是真正的零点位置。在零点定位完成后，还可以向编码器发送回零完成信号，以同步编码器的当前采样值，并设置编码器的回零状态，等待上位机指令。
本实施例通过正弦S曲线算法规划运动路径控制电机动块的加减速运行，在对停车距离精准反向补偿的同时，保障了位置的准确性，实现了精准定位。
本发明进一步提供一种零点定位系统。
参照图4，图4为本发明零点定位系统第一实施例的功能模块图。
本实施例中，所述零点定位系统包括：
碰撞检测模块10，用于控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
可以理解的是，传统的零点定位方法是将传感器放置在零点附近，将电机运动块以某一恒定速度向着固定方向运动，当检测到传感器就减速停止，将电机运动块完全停止时的位置设置为零点。但是由于电机运动块停止需要 时间，并会运行一段距离，因此，真正的零点与电机运动块完全停止的位置并不相同，导致零点定位存在较大误差。本实施例取消了传感器，利用伺服电机中的限位块、编码器及相应的程序控制实现精确的零点定位。
应理解的是，所述朝向限位块运行指向限位块的方向运行，本实施例中不限定具体运行路径。
需要说明的是，所述碰撞检测是对电机运动块是否碰撞到限位块进行检测，其检测方式有很多种。作为一优选实施例，在进行碰撞检测时分别对电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；只有同时满足三个条件，即当所述碰撞电流不小于预设电流，所述碰撞时间不小于第一预设时间且所述碰撞位置不大于预设位移时才判定碰撞成功，以保证碰撞充分。
在具体实现中，三相逆变模块是电机的驱动硬件，用于驱动电机运行。当碰撞电流不小于预设电流且碰撞时间不小于第一预设时间时，说明电流过大并且持续时间较长，此时需要控制三相逆变模块关闭，以使三相逆变模块停止驱动电机运动块，如此可以有效保护三相逆变模块。
信号检测模块20，用于当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
应理解的是，所述背离限位块运行指向限位块的方向的反方向运行，本实施例中不限定具体运行路径。
需要说明的是，为了控制产品成本及方便用户操作，所述编码器可以使用增量式编码器。增量式编码器是直接利用光电转换原理输出三组方波脉冲A、B和Z相，A、B两组脉冲相位差90，从而可方便的判断出旋转方向，而Z相为每转一个脉冲，用于零点定位。
编码器读取模块30，用于在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
具体地，在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；若是，则控制所述三相逆变模块关闭；若否，从所述编码器读取第一编码器值。
需要说明的是，Z信号在一圈内位置是零位，通过读取Z信号，可以在一圈内修正增量信号因脉冲丢失而产生的计数误差。本实施例中，工程人员 可以根据伺服电机的具体硬件情况选取第N个Z信号时编码器的值作为第一编码器值。
当然，如果编码器出现故障，找不到信号或者找到第N个Z信号的时间过长时，为了保护驱动硬件，同样需要关闭三相逆变模块。
应当理解的是，此时电机运动块减速运行，是指电机运动块背离限位块减速运行。
在具体实现中，由于增量式编码器是将位移转换成周期性的电信号，再把这个电信号转变成计数脉冲，用脉冲的个数表示位移的大小，因此，通过第一编码器值及第二编码器值可以计算电机运动块在不同时间段的位移。
距离补偿模块40，用于基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
需要说明的是，从接收到第N个Z信号开始停车，到电机运动块完全停止，这期间存在一段停车距离。所述预设算法用于通过反向补偿方式对停车距离进行回补，消除电机运动块的停车误差，从而减少定位误差，完成精确定位。
本实施例通过控制电机运动块朝向限位块运行，并对电机运动块进行碰撞检测；当碰撞成功时，控制电机运动块背离限位块运行，并实时检测是否接收到编码器发送的Z信号；在检测到Z信号时从编码器读取第一编码器值，并控制电机运动块减速运行，以读取电机运动块停止时的第二编码器值；基于预设算法根据第一编码器值及第二编码器值确定零点位置。其中，通过Z信号检测及对电机运动块减速运行的距离补偿实现对零点的精确定位，取消了传统零点定位时使用的位置传感器，在降低成本的同时减小了零点定位的误差，提高了使用增量式编码器的伺服电机的精度。
此外，本发明实施例还提出一种存储介质，所述存储介质上存储有零点定位程序，所述零点定位程序被处理器执行时实现如下操作：
控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电 机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
进一步地，所述零点定位程序被处理器执行时还实现如下操作：
根据所述第二编码器值与所述第一编码器值的差值确定停车距离；
基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置；
将所述实际位置作为零点位置。
进一步地，所述零点定位程序被处理器执行时还实现如下操作：
基于正弦S曲线算法根据所述停车距离及预设目标速度获取所述电机运动块的加加速度；
控制所述电机运动块以所述加加速度朝向限位块运行；
当所述电机运动块的运行距离为所述停车距离时，记录所述电机运动块的当前位置，并将所述当前位置作为所述电机运动块停止时的实际位置。
进一步地，所述零点定位程序被处理器执行时还实现如下操作：
分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；
当所述碰撞电流不小于预设电流，所述碰撞时间不小于第一预设时间且所述碰撞位置不大于预设位移时判定碰撞成功。
进一步地，所述零点定位程序被处理器执行时还实现如下操作：
当所述碰撞电流不小于预设电流且所述碰撞时间不小于第一预设时间时，控制三相逆变模块关闭，以使所述三相逆变模块停止驱动所述电机运动块。
进一步地，所述零点定位程序被处理器执行时还实现如下操作：
在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；
若是，则控制所述三相逆变模块关闭；
若否，从所述编码器读取第一编码器值。
本发明计算机可读存储介质的具体实施例与上述零点定位方法各实施例基本相同，在此不作赘述。
需要说明的是，在本文中，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者系统不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者系统所固有的要素。在没有更多限制的情况下，由语句“包括一个……”限定的要素，并不排除在包括该要素的过程、方法、物品或者系统中还存在另外的相同要素。
上述本发明实施例序号仅仅为了描述，不代表实施例的优劣。
通过以上的实施方式的描述，本领域的技术人员可以清楚地了解到上述实施例方法可借助软件加必需的通用硬件平台的方式来实现，当然也可以通过硬件，但很多情况下前者是更佳的实施方式。基于这样的理解，本发明的技术方案本质上或者说对现有技术做出贡献的部分可以以软件产品的形式体现出来，该计算机软件产品存储在如上所述的一个存储介质(如ROM/RAM、磁碟、光盘)中，包括若干指令用以使得一台终端设备(可以是手机，计算机，服务器，空调器，或者网络设备等)执行本发明各个实施例所述的方法。
以上仅为本发明的优选实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

  1. 一种零点定位方法，其特征在于，所述零点定位方法包括以下步骤：
    控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
    当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
    在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
    基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
  2. 如权利要求1所述的零点定位方法，其特征在于，所述基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置的步骤，包括：
    根据所述第二编码器值与所述第一编码器值的差值确定停车距离；
    基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置；
    将所述实际位置作为零点位置。
  3. 如权利要求2所述的零点定位方法，其特征在于，所述基于正弦S曲线算法对所述停车距离进行补偿，获得所述电机运动块停止时的实际位置的步骤，包括：
    基于正弦S曲线算法根据所述停车距离及预设目标速度获取所述电机运动块的加加速度；
    控制所述电机运动块以所述加加速度朝向限位块运行；
    当所述电机运动块的运行距离为所述停车距离时，记录所述电机运动块的当前位置，并将所述当前位置作为所述电机运动块停止时的实际位置。
  4. 如权利要求3所述的零点定位方法，其特征在于，所述正弦S曲线算法为：
    Figure PCTCN2019129089-appb-100001
    其中，V p为预设目标速度，S p为所述停车距离，t为运行时间，j(t)为所述电机运动块的加加速度。
  5. 如权利要求1～4中任一项所述的零点定位方法，其特征在于，所述对所述电机运动块进行碰撞检测的步骤，包括：
    分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测；
    当所述碰撞电流不小于预设电流，所述碰撞时间不小于第一预设时间且所述碰撞位置不大于预设位移时判定碰撞成功。
  6. 如权利要求5所述的零点定位方法，其特征在于，所述分别对所述电机运动块的碰撞电流、碰撞时间及碰撞位移进行检测的步骤之后，所述方法还包括：
    当所述碰撞电流不小于预设电流且所述碰撞时间不小于第一预设时间时，控制三相逆变模块关闭，以使所述三相逆变模块停止驱动所述电机运动块。
  7. 如权利要求6所述的零点定位方法，其特征在于，所述在检测到所述Z信号时从所述编码器读取第一编码器值的步骤，包括：
    在检测到第N个Z信号时判断检测到所述第N个Z信号的时间是否大于第二预设时间；其中，N为预设正整数；
    若是，则控制所述三相逆变模块关闭；
    若否，从所述编码器读取第一编码器值。
  8. 一种零点定位系统，其特征在于，所述零点定位系统包括：
    碰撞检测模块，用于控制电机运动块朝向限位块运行，并对所述电机运动块进行碰撞检测；
    信号检测模块，用于当碰撞成功时，控制所述电机运动块背离所述限位块运行，并实时检测是否接收到编码器发送的Z信号；
    编码器读取模块，用于在检测到所述Z信号时从所述编码器读取第一编码器值，并控制所述电机运动块减速运行，以读取所述电机运动块停止时的第二编码器值；
    距离补偿模块，用于基于预设算法根据所述第一编码器值及所述第二编码器值确定零点位置。
  9. 一种伺服电机，其特征在于，所述伺服电机包括：存储器、处理器及存储在所述存储器上并可在所述处理器上运行的零点定位程序，所述零点定位程序配置为实现如权利要求1至7中任一项所述的零点定位方法的步骤。
  10. 一种存储介质，其特征在于，所述存储介质上存储有零点定位程序，所述零点定位程序被处理器执行时实现如权利要求1至7中任一项所述的零点定位方法的步骤。
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