CN105415374A - Mechanical hand transmission unit on-line fault diagnosis system based on synergetic measurement - Google Patents
Mechanical hand transmission unit on-line fault diagnosis system based on synergetic measurement Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
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- B25J9/00—Programme-controlled manipulators
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Abstract
The invention discloses a mechanical hand transmission unit on-line fault diagnosis system based on synergetic measurement, and belongs to the field of fault diagnosis. The system comprises a vibration sensor, a data acquisition repeater, a robot RTU and an on-line fault diagnosis subsystem, wherein the vibration sensor acquires vibration acceleration and motion angular velocity data through adopting an acceleration sensor and a gyroscope, and transfers the acceleration and motion angular velocity data to the data acquisition repeater, the data is subjected to smooth filtering, and the data subjected to smooth filtering is transferred to the robot RTU through a Wi-Fi module; the robot RTU reads the motion control parameters of corresponding joints from a robot controller, calculates the space attitude data of the joints of a mechanical hand, and performs data fusion through using the kalman filtering algorithm; and the on-line fault diagnosis subsystem compares the initial two-dimensional inherent vibration characteristics, acquired during the ex-factory assessment and test stage of a mechanical hand product, of the joints of the mechanical hand with the current two-dimensional inherent vibration characteristics, and performs fault diagnosis. The mechanical hand transmission unit on-line fault diagnosis system has important functions in the field of fault diagnosis of variable speed servo mechanical hands.
Description
Technical field
The invention belongs to fault diagnosis field, relate to a kind of robotic transfer unit online system failure diagnosis based on cooperative.
Background technology
Make a general survey of Chinese assembling manufacturing industry, automatic flexible production system and intelligence manufacture are its development trends.Robot is electromechanical integration equipment, and they replace the mankind to bear the repetitive operation of a large amount of high accuracy, high strength, as the punching press in automobile production process, application, welding, polishing, carrying, general assembly etc.The industry mechanical arm that multiple degrees of freedom electromechanical integration joint is formed, due to the flexibility, able to programme and intelligent of its height, become backbone equipment and the basis of flexible production and intelligence manufacture, stability and the accuracy of industry mechanical arm are most important to process of manufacture.Robotic transfer unit is made up of servomotor, gearbox etc., under duty for a long time and repeatedly, the engaging piece of gear unit engenders that wearing and tearing, areal deformation, change emaciated face such as to fall at the fault state, and this causes the robust motion of manipulator, repetitive positioning accuracy changes.If can not Timeliness coverage trouble shooting, major accident may be cast.Therefore, invent and a set ofly can adapt to the variable motion of industry mechanical arm gear unit and can be significant to the online system failure diagnosis of manipulator on-line monitoring, fault diagnosis and early warning and alarming.
The present invention and application number are the application for a patent for invention of 201310567302.2, have following difference:
The system that 201310567302.2 patents of invention describe, do not explain the sensor that its data acquisition unit uses, and data acquisition unit is the part of robot; Data collection task of the present invention is completed by vibrating sensor, and outside the machine-independent robot system of sensor.
201310567302.2 the system that patent of invention describes, the composition of real time data information is not explained; The real time data that the present invention gathers is manipulator each joint vibration acceleration data, each joint motions angular velocity data of manipulator and robot controller motion control parameter.
The system that 201310567302.2 patents of invention describe, its local monitor unit does not explain the processing procedure of real time data information, and does not explain the comparative approach of data comparing unit; The present invention all elaborates to the processing method of gathered real time data and method for diagnosing faults.
Summary of the invention
The technical problem to be solved in the present invention is to provide the robotic transfer unit online system failure diagnosis based on cooperative, can vibration acceleration, the angular velocity of satellite motion in each joint of Real-Time Monitoring manipulator, and the motion control parameter of synchronous acquisition robot controller, realize the on-line fault diagnosis to the industry mechanical arm gear unit in compound movement and early warning.
Technical scheme of the present invention:
Based on the robotic transfer unit online system failure diagnosis of cooperative, involving vibrations sensor, data collecting relay, robot RTU (RemoteTerminalUnit remote-terminal unit) and on-line fault diagnosis subsystem;
The instrument that vibrating sensor is developed for adopting MEMS (Micro-Electro-MechanicalSystem MEMS) acceleration transducer and MEMS gyro instrument, volume is little, security is high, compact conformation, be easy to install, adopt CAN (ControllerAreaNetwork controller local area network) bus carry out data transmission.Vibrating sensor comprises MCU (MicrocontrollerUnit micro-control unit), acceleration sensor module, gyro module, power module, Signal-regulated kinase and CAN module, vibrating sensor is fixedly mounted on each joint of manipulator, acceleration sensor module gathers the vibration acceleration data of three axles, gyro module gathers the angular velocity of satellite motion data of three axles, Signal-regulated kinase carries out anti-aliasing filter to the vibration acceleration data-signal of three axles and the angular velocity of satellite motion data-signal of three axles, MCU carries out analog-to-digital conversion and data management to carrying out the signal that anti-aliasing filter obtains, power module completes voltage transitions and power management, the number of vibrating sensor is determined by manipulator degrees-of-freedom number, each vibrating sensor successively by gathered data via CAN module transfer to data collecting relay,
Data collecting relay comprises digital signal processing module, CAN module, power module, memory module, Wi-Fi module, RS232 and RS485, data collecting relay is arranged on the pedestal place of robot, by the data that each joint vibrating sensor of CAN module receiver tool hand gathers, digital signal processing module is to the smoothing filtering process of vibration acceleration data received, power module completes voltage transitions and power management, the initial data collected by vibrating sensor and the vibration acceleration data after processing are saved to memory module, and transfer to robot RTU by Wi-Fi module, RS232 is used as configuration interface, RS485 facilitates on-line debugging.
Robot RTU is robot internet of things data acquisition unit, the carrying vibrating sensor data in each joint of manipulator and the real-time collaborative acquisition tasks of motion control parameter, realizes the key that motion transient fault vibration information catches.Robot RTU comprises MCU, ethernet module, power module, memory module, Wi-Fi module, RS232 and RS485, robot RTU is arranged in robot control cabinet, with the communication of data collecting relay setting up wireless networks, EPA is adopted to be connected with the robot controller in robot control cabinet, robot RTU receives the vibrating sensor data in each joint of manipulator successively by Wi-Fi module, and synchronously reads the motion control parameter of corresponding joint from robot controller; In addition, utilize the location algorithm of gyroscope and acceleration transducer to obtain the spatial attitude data in each joint of manipulator, recycling Kalman filtering algorithm carries out data fusion to the gesture stability parameter in spatial attitude data and motion control parameter; Spatial attitude data after vibration acceleration data, fusion treatment and other motion control parameter are saved to memory module, and transfer to the on-line fault diagnosis subsystem of PC host computer via ethernet module; RS232 is used as configuration interface, and RS485 facilitates on-line debugging, and power module completes voltage transitions and power management.
On-line fault diagnosis subsystem comprises database, cooperative data capture unit, data pre-processing unit, data characteristics extraction unit, failure diagnosis unit and early warning and alarming unit, cooperative data capture unit utilizes spatial attitude data correction vibration acceleration data, by vibration acceleration data by servo-actuated coordinate system transformation under reference frame, data characteristics extraction unit is from its time and frequency domain characteristics information of pretreated vibration acceleration extracting data, and then obtain the time and frequency domain characteristics information be associated with robot movement speed parameter, the time and frequency domain characteristics information be associated with robot movement speed parameter is called two-dimentional intrinsic vibration performance, manipulator each joint that intrinsic for the two dimension in each joint vibration performance and test phase gather by failure diagnosis unit intrinsic vibration performance of two dimension performs an analysis comparison, makes fault diagnosis.
The method of operation based on the robotic transfer unit online system failure diagnosis of cooperative is as follows:
Basis is characterized as with manipulator each joint original two-dimensional intrinsic vibration that the examination of manipulator product export and test phase gather, at manipulator normal operating phase, by the vibration acceleration data in each joint of system Real-time Collection robotic transfer unit of the present invention and the motion control parameter of angular velocity of satellite motion data and robot controller, and then comparison that the original two-dimensional intrinsic vibration feature in each joint and the intrinsic vibration performance of current two dimension performed an analysis, according to discrepancy threshold, variation tendency threshold value, duration, the comprehensive analyzing and diagnosing of the characteristic parameters such as feature band, make early warning or warning.
Beneficial effect of the present invention is the motion control parameter by cooperative robot controller, realizes the application of method for diagnosing faults on speed change master-slave manipulator under reference frame; Utilize the gesture stability parameter of Kalman filtering algorithm to the spatial attitude data obtained and synchronous acquisition to carry out data fusion, improve the accuracy of fault diagnosis; CAN makes the wiring of vibrating sensor simple, reliable, and Wi-Fi wireless telecommunications make the position of robot RTU unrestricted, outside the machine-independent people's control system of online system failure diagnosis of the present invention, are convenient to practical engineering application.
Accompanying drawing explanation
Fig. 1 is system architecture schematic diagram of the present invention.
Fig. 2 is vibrating sensor structure chart of the present invention.
Fig. 3 is data collecting relay structure chart of the present invention.
Fig. 4 is robot RTU structure chart of the present invention.
Fig. 5 is on-line fault diagnosis subsystem structure figure of the present invention.
In figure: 1 vibrating sensor; 2 traversing joints; 3 vertical movable joint; 4 data collecting relays; 5 robot controllers; 6 on-line fault diagnosis subsystems; 7 robot control cabinets; 8 robot RTU.
Detailed description of the invention
The specific embodiment of the present invention is described in detail below in conjunction with summary of the invention and Figure of description.
Based on the robotic transfer unit online system failure diagnosis of cooperative composition as shown in Figure 1, involving vibrations sensor, data collecting relay, robot RTU, on-line fault diagnosis subsystem four parts.Vibrating sensor is fixedly installed to each joint of manipulator, adopts CAN to carry out communication between vibrating sensor and data collecting relay; Data collecting relay is arranged on the pedestal place of robot, carries out communication with robot RTU setting up wireless networks; Robot RTU is arranged in robot control cabinet, is connected respectively by EPA with on-line fault diagnosis subsystem and robot controller.On-line fault diagnosis subsystem runs on PC host computer.
(1) vibrating sensor
The composition of vibrating sensor as shown in Figure 2, comprising: MCU, acceleration sensor module, gyro module, power module, Signal-regulated kinase, CAN module.MCU adopts PIC single chip microcomputer dsPIC33EP64GP502, the 3-axis acceleration sensor that acceleration sensor module adopts is ADXL335, the three-axis gyroscope that gyro module adopts is ITG3050, power module adopts two panels TPS78233 to realize voltage transitions and power management, adopt the integrated CAN of PIC single chip microcomputer to carry out data transmission, CAN module adopts VP230 typical circuit.Vibrating sensor is the secondary meter based on ADXL335 and ITG3050 exploitation, takes magnetic-disc mounting means to be fixed on each joint of manipulator.Each vibrating sensor is powered by data collecting relay, has 4 lead-out wires, comprises each 1 of power and ground, bus signal line 2.The output of ADXL335 is analog signal, and the second-order low-pass filter circuit that 3-axis acceleration signal is transferred to Signal-regulated kinase respectively carries out anti-aliasing filter, then the analog-to-digital conversion module being transferred to PIC single chip microcomputer carries out synchronous acquisition; The cut-off frequency of filter circuit is 1KHz, adopts precision operational-amplifier AD8603.The output of ITG3050 is data signal, passes through I
2c is connected with PIC single chip microcomputer.In native system, the number of vibrating sensor is determined by manipulator degrees-of-freedom number, and gathered data are transferred to data collecting relay via CAN by each vibrating sensor successively.
(2) data collecting relay
The composition of data collecting relay as shown in Figure 3, comprising: digital signal processing module, CAN module, power module, memory module, Wi-Fi module, RS232 and RS485.Data collecting relay take STM320F28335 as core, integrated CAN function on sheet, CAN module adopts VP230 typical circuit, power module adopts LM2576-5, LM2576-3.3 and LM1117-3.3 to realize voltage transitions and power management, memory module adopts 24W256 to realize external data storage, adopt the Wi-Fi module RN171 of MICROCHIP, RS232 is used as configuration interface, and RS485 facilitates on-line debugging.Data collecting relay takes magnetic-disc mounting means to be fixed on the pedestal place of robot, by the vibrating sensor data in each joint of CAN speed receiver tool hand.Digital signal processing module in the time window set by robot RTU to the gathered smoothing filtering operation of vibration acceleration data, be specially every 5 data, remove 1 maximum, 1 minimum of a value, get the valid data of average as this group data of remaining 3 data, then by array backward translation one do same process, by that analogy, until data processing is complete.Vibration acceleration data after two class initial data of vibrating sensor and process are saved to memory module, and transfer to robot RTU by Wi-Fi module and make further data fusion and signal transacting.
(3) robot RTU
Robot RTU is robot Internet of Things remote-terminal unit, and its composition as shown in Figure 4, comprising: MCU, ethernet module, power module, memory module, Wi-Fi module, RS232, RS485.MCU adopts PIC32MX695F512L, ethernet module adopts W5100, power module adopts WDY05S05 and AMS1117-3.3 to realize voltage transitions and power management, memory module adopts IS61WV10248BLL, Wi-Fi module adopts the RN171 of MICROCHIP, RS232 is used as configuration interface, and RS485 facilitates on-line debugging.Robot RTU is arranged in robot control cabinet, with the communication of data collecting relay setting up wireless networks, adopts EPA to be connected with robot controller.Robot RTU receives vibration acceleration data and the angular velocity of satellite motion data in each joint of manipulator successively, and the motion control parameter of corresponding joint is read by Modbus protocol synchronization between robot RTU and robot controller ground, be specially and a time window is set intercepts and the data storing both vibrating sensor and robot controller.In addition, the location algorithm of gyroscope and acceleration transducer is utilized to obtain the spatial attitude data in each joint of manipulator, recycling Kalman filtering algorithm carries out data fusion to the gesture stability parameter in spatial attitude data and motion control parameter, to obtain movable joint spatial attitude data more accurately.Spatial attitude data after vibration acceleration data and fusion treatment and other motion control parameter are saved to memory module, and then the vibration acceleration data obtained based on motion control parameter, then data complete for integration are transferred to the on-line fault diagnosis subsystem of PC host computer via EPA.
(4) on-line fault diagnosis subsystem
The composition of on-line fault diagnosis subsystem as shown in Figure 5, comprising: database, cooperative data capture unit, data pre-processing unit, data characteristics extraction unit, failure diagnosis unit, early warning and alarming unit.On-line fault diagnosis subsystem realizes the storage administration of data by connecting MySQL database, have the functions such as data backup, data convert, data processing and data display, data processing method is the core of this subsystem.In the time window set by robot RTU, cooperative data capture unit utilizes the spatial attitude data correction vibration acceleration data in motion control parameter, will be the vibration acceleration data under reference frame with the vibration acceleration data transformation under moving coordinate system.Data pre-processing unit utilizes LMD (decomposition of Localmeandecomposition local mean value) method to process the vibration acceleration data under reference frame, therefrom isolate pure FM signal and envelope signal, finally obtain the time-frequency distributions of vibration acceleration data.Data characteristics extraction unit from its time and frequency domain characteristics information of pretreated vibration acceleration extracting data, and then obtains two-dimentional intrinsic vibration performance.The intrinsic vibration performance of two dimension in joint each in this time window examine and the two-dimentional intrinsic vibration performance in each joint of manipulator that test phase gathers performs an analysis comparison with dispatching from the factory by failure diagnosis unit, according to the comprehensive analysis to characteristic parameters such as discrepancy threshold, variation tendency threshold value, duration, feature bands, make diagnosis.Early warning and alarming unit sends early warning or warning message according to diagnostic result by host computer.
Claims (1)
1. based on a robotic transfer unit online system failure diagnosis for cooperative, it is characterized in that, this online system failure diagnosis involving vibrations sensor, data collecting relay, robot RTU and on-line fault diagnosis subsystem;
Vibrating sensor is develop based on MEMS acceleration transducer and MEMS gyro instrument, adopts CAN to carry out data transmission, vibrating sensor comprises MCU, acceleration sensor module, gyro module, power module, Signal-regulated kinase and CAN module, vibrating sensor is fixedly mounted on each joint of manipulator, acceleration sensor module gathers the vibration acceleration data of three axles, gyro module gathers the angular velocity of satellite motion data of three axles, Signal-regulated kinase carries out anti-aliasing filter to the vibration acceleration data-signal of three axles and the angular velocity of satellite motion data-signal of three axles, MCU carries out analog-to-digital conversion and data management to carrying out the signal that anti-aliasing filter obtains, power module completes voltage transitions and power management, the number of vibrating sensor is determined by manipulator degrees-of-freedom number, each vibrating sensor successively by gathered data via CAN module transfer to data collecting relay,
Data collecting relay comprises digital signal processing module, CAN module, power module, memory module, Wi-Fi module, RS232 and RS485, data collecting relay is arranged on the pedestal place of robot, by the data that each joint vibrating sensor of CAN module receiver tool hand gathers, digital signal processing module is to the smoothing filtering process of vibration acceleration data received, power module completes voltage transitions and power management, the initial data collected by vibrating sensor and the vibration acceleration data after processing are saved to memory module, and transfer to robot RTU by Wi-Fi module, RS232 is used as configuration interface, RS485 is used for on-line debugging,
Robot RTU is robot internet of things data acquisition unit, the carrying vibrating sensor data in each joint of manipulator and the real-time collaborative acquisition tasks of motion control parameter; Robot RTU comprises MCU, ethernet module, power module, memory module, Wi-Fi module, RS232 and RS485, robot RTU is arranged in robot control cabinet, with the communication of data collecting relay setting up wireless networks, EPA is adopted to be connected with the robot controller in robot control cabinet, robot RTU receives the vibrating sensor data in each joint of manipulator successively by Wi-Fi module, and synchronously reads the motion control parameter of corresponding joint from robot controller; Utilize the location algorithm of gyroscope and acceleration transducer to obtain the spatial attitude data in each joint of manipulator, recycling Kalman filtering algorithm carries out data fusion to the gesture stability parameter in spatial attitude data and motion control parameter; Spatial attitude data after vibration acceleration data, fusion treatment and other motion control parameter are saved to memory module, and transfer to the on-line fault diagnosis subsystem of PC host computer via ethernet module; RS232 is used as configuration interface, and RS485 is used for on-line debugging, and power module completes voltage transitions and power management;
On-line fault diagnosis subsystem comprises database, cooperative data capture unit, data pre-processing unit, data characteristics extraction unit, failure diagnosis unit and early warning and alarming unit, cooperative data capture unit utilizes spatial attitude data correction vibration acceleration data, by vibration acceleration data by servo-actuated coordinate system transformation under reference frame; Data characteristics extraction unit is from its time and frequency domain characteristics information of pretreated vibration acceleration extracting data, obtain the time and frequency domain characteristics information be associated with robot movement speed parameter, the time and frequency domain characteristics information be associated with robot movement speed parameter is called two-dimentional intrinsic vibration performance; The each joint of manipulator of intrinsic for the two dimension in each joint vibration performance and the test phase collection intrinsic vibration performance of two dimension performs an analysis comparison by failure diagnosis unit, makes fault diagnosis.
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