To address the difficulty of directly applying finite element simulation trajectories to actual spinning machines, as well as the discrepancy between simulation data and equipment execution in the spinning process, this paper proposes a trajectory mapping method based on simulation trajectory extraction and data-driven error compensation. First, based on secondary development in ABAQUS, a discrete shell is introduced and combined with coordinate transformation to achieve accurate extraction of the roller center trajectory, and the simulated trajectory is converted into a discrete coordinate sequence. Subsequently, a roller trajectory acquisition and visualization system is developed, and machine motion data are collected and visualized for comparative analysis via the Modbus-RTU protocol. On this basis, to address the systematic deviation between simulated and actual execution trajectories, a trajectory error compensation method based on the projection method and Gaussian Process Regression is proposed. By modeling normal-direction errors and applying normal-direction compensation, smooth and stable optimization of the original simulation trajectory is achieved. Finally, experimental validation is conducted on a single-roller spinning machine, and the variation in trajectory deviation before and after compensation is comparatively analyzed. The results show that the proposed method effectively reduces trajectory execution errors, decreasing the average error from 0.503 mm to 0.229 mm, and significantly improves trajectory matching accuracy. This study provides an effective technical pathway for high-precision transformation of simulation trajectories to actual equipment in spinning processes and offers important support for the transition from experience-driven to model-driven spinning manufacturing.

Spacecraft recovery technology is crucial in the field of aerospace, in which the parachute plays a key role in slowing down the descent speed of the spacecraft and realizing a smooth landing. In order to construct a dynamically adjustable parachute deployment strategy, it is necessary to measure the parachute dynamic load accurately in real-time. However, the existing sensor measurement scheme makes it difficult to meet the measurement requirements due to its large structure and complex wiring. In order to meet the current demand for real-time measurement of parachute cords dynamic load, a miniature measuring instrument is designed. According to the function and technical requirements of the miniature measuring instrument, the hardware modules of the acquisition system are selected and designed, and the integration debugging and performance optimization of the microcontroller module, A/D sampling module, signal acquisition circuit, and power supply module are carried out. The software of the parachute cords tension acquisition system based on the miniature measuring instrument is developed. The Load Cell is modeled by using SolidWorks 2022 and statically analyzed by using Ansys 2022 R1 Workbench finite element analysis software. Then the final structure of the Load Cell and the pasting position of the strain gauge are determined through the results analysis as well as experimental verification. The hardware module of the signal acquisition system for the miniature measuring instrument is then encapsulated. The force value of the miniature measuring instrument is calibrated and tested many times by using the microcomputer-controlled electronic universal testing machine. The experimental results show that the designed miniature measuring instrument has accurate data, strong stability, and good real-time performance, which meets the demand for real-time accurate measurement of miniature measuring instruments, and can provide reliable data for parachute cords parameter validation and stepless unfolding design.

Virtual commissioning of discrete assembly lines lacks a unified stage representation and an integrated verification mechanism for PLC control states, virtual execution results, and physical workpiece states, making it difficult to determine whether the control program drives the actual equipment according to the prescribed process sequence. To address this issue, a PLC–vision bilateral stage consistency verification method is proposed. Structured PLC control states are mapped to virtual actions in Unity, and execution-confirmed virtual execution stages are generated based on action-completion feedback. On the physical side, YOLO11 object detection is integrated with process-region mapping and temporal constraints to generate vision-derived physical-stage events. The virtual and physical stages are then compared using unified stage semantics to identify consistent operation, physical-state lag, physical-state lead, missing visual events, and invalid stage transitions. Experiments were conducted at a representative station of a discrete assembly line using a single workpiece and a fixed operating path. The visual-stage event recognition method achieved an F1-score of 98.33%, with an average event-generation latency of 104.21 ms. In 140 tests covering normal and controlled abnormal operating conditions, all system decisions agreed with the predefined condition labels. The proposed method extends conventional one-way verification of PLC-driven virtual models to bilateral verification between virtual execution results and physical workpiece states, thereby providing an effective technical approach for control-program commissioning and operating-state verification in discrete assembly lines.

Spacecraft recovery technology is crucial in the field of aerospace, in which the parachute plays a key role in slowing down the descent speed of the spacecraft and realizing a smooth landing. In order to construct a dynamically adjustable parachute deployment strategy, it is necessary to measure the parachute dynamic load accurately in real time. However, the existing sensor measurement scheme is difficult to meet the measurement requirements due to its large structure and complex wiring. In order to meet the current demand for real-time measurement of parachute cords dynamic load, a miniature measuring instrument is designed.According to the function and technical requirements of the miniature measuring instrument, the hardware modules of the acquisition system are selected and designed, and the integration debugging and performance optimization of the microcontroller module, A/D sampling module, signal acquisition circuit and power supply module are carried out. The software of the parachute cords tension acquisition system based on the miniature measuring instrument is developed. The elastomer is modeled by using SolidWorks and statically analyzed by using AnsysWorkbench finite element analysis software. Then the final structure of the elastomer and the pasting position of the strain gage are determined through the results analysis as well as experimental verification. The hardware module of the signal acquisition system for the miniature measuring instrument is then encapsulated. The force value of the miniature measuring instrument is calibrated and tested many times by using the microcomputer-controlled electronic universal testing machine. The experimental results show that the designed miniature measuring instrument has accurate data, strong stability and good real-time performance, which meets the demand for real-time accurate measurement of miniature measuring instrument, and can provide reliable data for parachute cords parameter validation and stepless unfolding design.