CN112873264B - Industrial robot joint structure, robot control system and method - Google Patents
Industrial robot joint structure, robot control system and method Download PDFInfo
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- CN112873264B CN112873264B CN202110290485.2A CN202110290485A CN112873264B CN 112873264 B CN112873264 B CN 112873264B CN 202110290485 A CN202110290485 A CN 202110290485A CN 112873264 B CN112873264 B CN 112873264B
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- 239000011159 matrix material Substances 0.000 claims abstract description 19
- 230000007246 mechanism Effects 0.000 claims abstract description 11
- 239000003638 chemical reducing agent Substances 0.000 claims description 10
- 239000000853 adhesive Substances 0.000 claims description 6
- 238000005070 sampling Methods 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 abstract description 8
- 238000005259 measurement Methods 0.000 abstract description 6
- 238000010586 diagram Methods 0.000 description 14
- 230000006870 function Effects 0.000 description 12
- 238000009434 installation Methods 0.000 description 9
- 238000004590 computer program Methods 0.000 description 7
- 239000000470 constituent Substances 0.000 description 7
- 230000005540 biological transmission Effects 0.000 description 6
- 238000012545 processing Methods 0.000 description 4
- 208000019462 Occupational injury Diseases 0.000 description 3
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J17/00—Joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J13/00—Controls for manipulators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J13/00—Controls for manipulators
- B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
- B25J19/02—Sensing devices
- B25J19/021—Optical sensing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/10—Programme-controlled manipulators characterised by positioning means for manipulator elements
- B25J9/12—Programme-controlled manipulators characterised by positioning means for manipulator elements electric
- B25J9/126—Rotary actuators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1674—Programme controls characterised by safety, monitoring, diagnostic
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- Robotics (AREA)
- Mechanical Engineering (AREA)
- Human Computer Interaction (AREA)
- Manipulator (AREA)
Abstract
The invention discloses an industrial robot joint structure, a robot control system and a method, wherein the industrial robot joint structure comprises a servo motor, a robot joint matrix, a robot connecting rod and an encoder, wherein the servo motor is connected with the robot joint matrix, the robot joint matrix is connected with the robot connecting rod, and the encoder is connected with the servo motor; the device also comprises a grating ruler and a reading head, wherein the grating ruler adopts a linear grating; the grating ruler is arranged on the side edge of the robot connecting rod, so that coaxiality of the grating ruler and the robot connecting rod is ensured, and the roundness of the grating ruler is within the precision range; the reading head is arranged on the side edge of the robot joint matrix; the angle information of the joint is obtained through the relative movement between the grating ruler and the reading head. According to the invention, the real-time monitoring of each joint angle of the robot is realized, the two-way measurement of each joint angle information is realized through the encoder and the grating ruler, and the safety and the reliability of the robot are improved according to a hierarchical alarm mechanism based on joint angle errors and alarm time.
Description
Technical Field
The invention relates to the technical field of industrial robot safety control, in particular to an industrial robot joint structure, a robot control system and a method.
Background
With the rapid development of intelligent manufacturing, industrial robots are increasingly used in the industrial field. The safety of the industrial robot is mainly based on that encoders of six joint motors transmit angle information of each joint so as to further transmit pose information of the tail end of the robot, but if the encoders are in error transmission or fail, misoperation of the robot can be caused, and occupational injury is caused.
Disclosure of Invention
The technical problem to be solved by the invention is that the safety of the existing industrial robot is mainly based on that the encoders of six joint motors transmit the angle information of each joint so as to further transmit the pose information of the tail end of the robot, but if the encoder information transmission is wrong or the encoder fails, the malfunction of the robot can be caused, occupational injury is caused, and the serious safety problem exists.
The invention aims to provide an industrial robot joint structure, a robot control system and a method, wherein a high-precision grating ruler is arranged at each joint of a robot body, the grating ruler adopts a linear grating and is matched with a reading head, and angle information of the joint is obtained through relative movement between the grating ruler and the reading head; according to the invention, the real-time monitoring of each joint angle of the robot is realized, the two-way measurement of each joint angle information is realized through the encoder and the grating ruler, and the safety and the reliability of the robot are improved according to a hierarchical alarm mechanism based on joint angle errors and alarm time length; the system and the method are not used for improving the precision of the robot, but are used for improving the safety and reliability of the robot. The robot grading alarm mechanism thought based on the alarm time length information and the joint angle information provides a new thought for maintenance of the robot.
The invention is realized by the following technical scheme:
in a first aspect, the invention provides an industrial robot joint structure, which comprises a servo motor, a robot joint matrix, a robot connecting rod and an encoder, wherein the servo motor is connected with the robot joint matrix, the robot joint matrix is connected with the robot connecting rod, and the encoder is connected with the servo motor;
the device also comprises a grating ruler and a reading head, wherein the grating ruler adopts a linear grating; the grating ruler is arranged on the side (left side) of the robot connecting rod, the installation position needs to ensure clean and foreign matters-free, and the coaxiality of the grating ruler and the robot connecting rod and the roundness of the grating ruler are ensured to be in the precision range; the reading head is arranged on the side edge of the robot joint matrix; the distance between the grating ruler and the reading head can ensure that data reading is normal; and obtaining the angle information of the joint through the relative movement between the grating ruler and the reading head.
The working principle is as follows: the safety of the existing industrial robot mainly depends on that encoders of six joint motors transmit angle information of each joint so as to further transmit pose information of the tail end of the robot, but if the encoder information transmission is wrong or the encoder fails, misoperation of the robot can be caused, occupational injury is caused, and serious safety problem exists. At present, the grating ruler is installed at each joint of the robot basically by utilizing the high-precision characteristic of the grating ruler to improve the precision of the robot, but the safety and reliability of the robot are not improved, so that the invention utilizes the linear grating, and the problem that if a circular grating is adopted, each joint of the robot needs to be disassembled for installation, so that the geometric precision of each joint is easily lost; the invention adopts the linear grating, and only needs to be attached to the side of the robot connecting rod, so that the robot joint is not required to be disassembled, and the geometric accuracy of the robot is not influenced. The grating ruler is thin and has certain flexibility, so that the linear grating can be tightly attached to the connecting rod of the robot during installation, and the straight bending is realized. The grating ruler adopts a Ransha QUANTIC self-adhesive incremental grating ruler, the precision is +/-5 mu m/m- +/-15 mu m/m, the maximum length can reach 10m, the grating ruler can adapt to industrial robots of different types, the grating ruler is arranged on the connecting rod side of the robot, the installation position needs to ensure clean and foreign matters, the coaxiality of the grating ruler and the connecting rod needs to be ensured to be less than or equal to 0.001mm, the roundness of the grating ruler is less than or equal to 0.001mm, and the reading head is arranged on the joint matrix side of the robot, and the angle information of the joint is obtained through the relative movement between the grating ruler and the reading head; the invention has certain innovation and practicability, and can solve the safety problem caused by the information transmission error of the motor encoder or the failure of the encoder of the robot.
Preferably, the grating ruler adopts a Ranshao QUANTIC self-adhesive incremental grating ruler, the precision is +/-5 mu m/m- +/-15 mu m/m, the maximum length can reach 10m, and the grating ruler can be suitable for industrial robots of different models.
Preferably, the grating ruler is arranged on the side edge of the robot connecting rod, so that coaxiality of the grating ruler and the robot connecting rod and roundness of the grating ruler are ensured to be within a precision range; wherein the coaxiality of the grating ruler and the robot connecting rod is less than or equal to 0.001mm, and the roundness of the grating ruler is less than or equal to 0.001mm.
Preferably, the robot joint comprises a robot joint body, a servo motor and a speed reducer, wherein the speed reducer and the servo motor are arranged in the robot joint body, and the servo motor is connected with the robot joint body through the speed reducer.
In a second aspect, the invention also provides a robot control system based on joint angle information, which comprises the industrial robot joint structure; the robot control system further comprises a robot control cabinet and a robot body, wherein six groups of joint motor drivers are arranged in the robot control cabinet; the robot body is provided with six groups of robot joint motors and encoders thereof; the encoder is connected with the servo motor, the encoder is connected with the joint motor driver, and the servo motor is connected with the joint motor driver; adjacent joint motor drivers are connected through a driver network port;
the robot control system comprises a robot control cabinet, six groups of joint motor drivers, a network switch, a PLC controller and a high-speed counter module, wherein the six groups of joint motor drivers in the robot control cabinet are connected with the network switch through a control cabinet network port by virtue of one group of joint motor drivers, the network switch is connected with the PLC controller, and the PLC controller is connected with the high-speed counter module; the high-speed counter module is correspondingly connected with the grating scales (namely, a first joint grating scale, a second joint grating scale, a third joint grating scale, a fourth joint grating scale, a fifth joint grating scale and a sixth joint grating scale) corresponding to each joint.
The motor driver of each joint of the control system is respectively connected with each shutdown motor and the encoder thereof through power connection and signal connection; the multichannel network switch is connected with the robot control cabinet through a real-time Ethernet; the high-performance PLC controller with the motion control function is connected with the multichannel network switch through the real-time Ethernet and reads the data of each encoder; the PLC is connected with the high-speed counter module, and the high-speed counter module is connected with the grating ruler so as to read the data of the grating ruler; the PLC is connected with the touch screen through a real-time Ethernet, and displays the acquired information on the touch screen in real time and allows an operator to operate the device system.
Preferably, the six groups of robot joint motors and six groups of joint motor drivers are sequentially recorded as a first joint motor, a first joint motor driver, a second joint motor driver, a third joint motor driver, a fourth joint motor driver, a fifth joint motor driver, a sixth joint motor driver; the net mouth of going up of first joint motor driver connects the net mouth of putting down of second joint motor driver, the net mouth of going up of second joint motor driver connects the net mouth of putting down of third joint motor driver, the net mouth of going up of third joint motor driver connects the net mouth of putting down of fourth joint motor driver, the net mouth of putting down of fifth joint motor driver is connected to the net mouth of putting down of fourth joint motor driver, the net mouth of putting down of sixth joint motor driver is connected to the net mouth of putting up of fifth joint motor driver, the net mouth of putting up of sixth joint motor driver passes through the switch board net mouth and connects the network switch. Therefore, the connecting wires are saved, and meanwhile, the communication connection among the six joint motor groups is realized.
Preferably, the internet access port of the joint 6 motor driver is connected with a network switch through the Ethernet by means of the network port of the control cabinet;
the network switch is connected with the PLC controller through the Ethernet.
Preferably, the intelligent control system further comprises a touch screen, and the PLC is connected with the touch screen through Ethernet.
In a third aspect, the present invention also provides a control method based on the robot control system, the method comprising the steps of:
step 1: embedding grating scales into 6 joints of the robot, and obtaining angle information of the joints through relative movement between the grating scales and a reading head;
step 2: the PLC controller with the motion control function reads the angle information of each reading head in real time through the multichannel network switch and stores the angle information in the PLC controller;
step 3: the PLC with motion control function reads the encoder information of each joint of the robot in real time, and simultaneously controls the starting, suspending, emergency stopping and the like of the motors of each joint by using the PLC;
step 4: the angle values of the six joint grating rulers are respectively marked as Ai, the angle values of the 6 joint encoders are respectively marked as Bi, the angle difference value corresponding to the grating rulers and the encoders of each joint is Ci= |ai-Bi|, and the angle relative error is Di = Ci/Ai, wherein i is 1, 2, 3, 4, 5 and 6 respectively;
step 5: calibrating the angle information of the grating ruler and the angle information of the encoder to obtain a calibration result Di, wherein Di is less than or equal to 1/1000;
step 6: setting a relative error threshold E and an alarm duration threshold T, and setting a hierarchical alarm mechanism as follows:
A. when Di is less than or equal to E, E is a relative error threshold, the robot completely works normally, the alarm level is 4, and other operations are not needed by operators;
B. when a relative error Di of a joint angle is larger than E, the alarm level is 3, and an operator needs to be alerted without other operations; meanwhile, if the alarm time length exceeds T, the alarm level is increased to 2 levels, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention;
C. when the angle relative error Di of the two joints exceeds E, the alarm level is 2, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention; meanwhile, if the alarm time length of any joint exceeds T, the alarm level is automatically lifted to be 1 level, the system intervention is automatically started, and the robot operation is automatically and immediately stopped, so that the safety of equipment and operators is ensured;
D. when the relative errors Di of the angles of at least 3 joints exceed E, the alarm level is 1 level, the system intervention is automatically started, and the robot is automatically and immediately stopped to run, so that the safety of equipment and operators is ensured.
10. The control method according to claim 9, characterized in that the calibration procedure of step 5 comprises the sub-steps of:
step 51, starting the robot, controlling each joint of the robot to rotate in a single joint, wherein the rotation angle is consistent with the travel of the unidirectional grating ruler of the joint, and acquiring the angle value of the joint motor encoder as reference data;
step 52, converting the angle value of the motor encoder and the grating number of the grating ruler read by the PLC to obtain an angle value corresponding to each grating, and completing preliminary calibration;
and step 53, controlling each joint of the robot to perform single joint movement again, taking the angle of each joint motor encoder as a theoretical value, taking the angle sampling resolution as the minimum resolution of the motor encoder as a standard, taking the angle of the grating ruler as an actual value, considering the joint error of the robot in the zero joint position as 0, generating an error table of the joint of the robot, and inputting the error table into a system variable, thereby finishing the precise calibration.
Compared with the prior art, the invention has the following advantages and beneficial effects:
1. the invention adopts the linear grating, and only needs to be attached to the side of the robot connecting rod, so that the robot joint is not required to be disassembled, and the geometric accuracy of the robot is not influenced. The grating ruler is thin and has certain flexibility, so that the linear grating can be tightly attached to the connecting rod of the robot during installation, and the straight bending is realized. The grating ruler adopts a Ransha QUANTIC self-adhesive incremental grating ruler, the precision is +/-5 mu m/m- +/-15 mu m/m, the maximum length can reach 10m, the grating ruler can adapt to industrial robots of different types, the grating ruler is arranged on the connecting rod side of the robot, the installation position needs to ensure clean and foreign matters, the coaxiality of the grating ruler and the connecting rod needs to be ensured to be less than or equal to 0.001mm, the roundness of the grating ruler is less than or equal to 0.001mm, and the reading head is arranged on the joint matrix side of the robot, and the angle information of the joint is obtained through the relative movement between the grating ruler and the reading head; the invention has certain innovation and practicability, and can solve the safety problem caused by the information transmission error of the motor encoder or the failure of the encoder of the robot.
2. According to the invention, the real-time monitoring of each joint angle of the robot is realized, the two-way measurement of each joint angle information is realized through the encoder and the grating ruler, and the safety and the reliability of the robot are improved according to a hierarchical alarm mechanism based on joint angle errors and alarm time. The system and the method are not used for improving the precision of the robot, but are used for improving the safety and reliability of the robot.
3. According to the system and the method, the grating ruler is added on the robot body, so that the two-way measurement and the information comparison of the angle information of the grating ruler and the encoder are realized, and the safety and the reliability of the robot are improved; the robot grading alarm mechanism thought based on the alarm time length information and the joint angle information provides a new thought for maintenance of the robot.
Drawings
The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention. In the drawings:
fig. 1 is a schematic structural view of an industrial robot joint structure according to the present invention.
Fig. 2 is a schematic connection diagram of a robot control system based on joint angle information according to the present invention.
Fig. 3 is a schematic diagram of an overall logic framework of the control method based on the robot control system.
Fig. 4 is a block diagram of an alarm level determination of the present invention.
FIG. 5 is a schematic diagram of a software system interface corresponding to the method of the present invention.
In the drawings, the reference numerals and corresponding part names:
1-servo motor, 2-robot joint base body, 3-robot connecting rod, 4-encoder, 5-grating ruler, 6-reading head, 7-reducer, 8-robot control cabinet, 9-robot body, 10-network switch, 11-PLC controller, 12-touch screen, 13-high-speed counter module, 101-first joint motor, 102-second joint motor, 103-third joint motor, 104-fourth joint motor, 105-fifth joint motor, 106-sixth joint motor, 901-first joint motor driver, 902-second joint motor driver, 903-third joint motor driver, 904-fourth joint motor driver, 905-fifth joint motor driver, 906-sixth joint motor driver, 501-first joint grating ruler, 502-second joint grating ruler, 503-third joint grating ruler, 504-fourth joint grating ruler, 505-fifth joint grating ruler, 506-sixth joint grating ruler.
Detailed Description
Hereinafter, the terms "comprises" or "comprising" as may be used in various embodiments of the present invention indicate the presence of inventive functions, operations or elements, and are not limiting of the addition of one or more functions, operations or elements. Furthermore, as used in various embodiments of the invention, the terms "comprises," "comprising," and their cognate terms are intended to refer to a particular feature, number, step, operation, element, component, or combination of the foregoing, and should not be interpreted as first excluding the existence of or increasing likelihood of one or more other features, numbers, steps, operations, elements, components, or combinations of the foregoing.
In various embodiments of the invention, the expression "or" at least one of a or/and B "includes any or all combinations of the words listed simultaneously. For example, the expression "a or B" or "at least one of a or/and B" may include a, may include B or may include both a and B.
Expressions (such as "first", "second", etc.) used in the various embodiments of the invention may modify various constituent elements in the various embodiments, but the respective constituent elements may not be limited. For example, the above description does not limit the order and/or importance of the elements. The above description is only intended to distinguish one element from another element. For example, the first user device and the second user device indicate different user devices, although both are user devices. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of various embodiments of the present invention.
It should be noted that: if it is described to "connect" one component element to another component element, a first component element may be directly connected to a second component element, and a third component element may be "connected" between the first and second component elements. Conversely, when one constituent element is "directly connected" to another constituent element, it is understood that there is no third constituent element between the first constituent element and the second constituent element.
The terminology used in the various embodiments of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the various embodiments of the invention. As used herein, the singular is intended to include the plural as well, unless the context clearly indicates otherwise. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments of the invention belong. The terms (such as those defined in commonly used dictionaries) will be interpreted as having a meaning that is the same as the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein in connection with the various embodiments of the invention.
For the purpose of making apparent the objects, technical solutions and advantages of the present invention, the present invention will be further described in detail with reference to the following examples and the accompanying drawings, wherein the exemplary embodiments of the present invention and the descriptions thereof are for illustrating the present invention only and are not to be construed as limiting the present invention.
Example 1
As shown in fig. 1, the industrial robot joint structure comprises a servo motor 1, a robot joint matrix 2, a robot connecting rod 3 and an encoder 4, wherein the servo motor 1 is connected with the robot joint matrix 2, the robot joint matrix 2 is connected with the robot connecting rod 3, and the encoder 4 is connected with the servo motor 1;
the device also comprises a grating ruler 5 and a reading head 6, wherein the grating ruler 5 adopts a linear grating, the grating ruler 5 is arranged on the left side of the side edge of the robot connecting rod 3, the installation position needs to ensure clean and foreign matters-free, and the coaxiality of the grating ruler 5 and the robot connecting rod 3 and the roundness of the grating ruler 5 are ensured to be within the precision range; the reading head 6 is arranged on the side edge of the robot joint matrix 2; the distance between the grating ruler 5 and the reading head 6 can ensure that data reading is normal; the angle information of the joint is obtained through the relative movement between the grating ruler 5 and the reading head 6.
In the embodiment, the grating ruler 5 adopts a Ranshao QUANTIC self-adhesive incremental grating ruler, the precision is +/-5 mu m/m- +/-15 mu m/m, the maximum length can reach 10m, and the device can be suitable for industrial robots of different models.
In this embodiment, the grating ruler 5 is installed at the side of the robot connecting rod 3, so as to ensure that the coaxiality of the grating ruler 5 and the robot connecting rod 3 and the roundness of the grating ruler 5 are within the precision range; wherein the coaxiality of the grating ruler 5 and the robot connecting rod 3 is less than or equal to 0.001mm, and the roundness of the grating ruler 5 is less than or equal to 0.001mm.
In this embodiment, the robot joint base body 2 further comprises a speed reducer 7, the speed reducer 7 and the servo motor 1 are arranged in the robot joint base body 2, and the servo motor 1 is connected with the robot joint base body 2 through the speed reducer 7.
The working principle is as follows: according to the invention, the high-precision grating ruler is embedded into 6 joints of the robot, and the grating ruler utilizes the linear grating, so that the fact that if a circular grating is adopted, all joints of the robot need to be disassembled and installed is considered, and the geometric precision of all joints is easy to lose; the invention adopts the linear grating, and only needs to be attached to the side of the robot connecting rod, so that the robot joint is not required to be disassembled, and the geometric accuracy of the robot is not influenced. The grating ruler is thin and has certain flexibility, so that the linear grating can be tightly attached to the connecting rod of the robot during installation, and the straight bending is realized. The grating ruler adopts a Ransha QUANTIC self-adhesive incremental grating ruler, the precision is +/-5 mu m/m- +/-15 mu m/m, the maximum length can reach 10m, the grating ruler can adapt to industrial robots of different types, the grating ruler is arranged on the connecting rod side of the robot, the installation position needs to ensure clean and foreign matters, the coaxiality of the grating ruler and the connecting rod needs to be ensured to be less than or equal to 0.001mm, the roundness of the grating ruler is less than or equal to 0.001mm, and the reading head is arranged on the joint matrix side of the robot, and the angle information of the joint is obtained through the relative movement between the grating ruler and the reading head; the invention has certain innovation and practicability, and can solve the safety problem caused by the information transmission error of the motor encoder or the failure of the encoder of the robot.
Example 2
As shown in fig. 1 and 2, the difference between the present embodiment and embodiment 1 is that the present embodiment provides a robot control system based on joint angle information, which includes an industrial robot joint structure described in embodiment 1;
the robot control system further comprises a robot control cabinet 8 and a robot body 9, wherein six groups of joint motor drivers are arranged in the robot control cabinet 8; the robot body 9 is provided with six groups of robot joint motors and encoders thereof; the encoder 4 is connected with the servo motor 1, the encoder 4 is connected with the joint motor driver, and the servo motor 1 is connected with the joint motor driver; adjacent joint motor drivers are connected through a driver network port;
the robot control system further comprises a network switch 10, a PLC (programmable logic controller) 11 and a high-speed counter module 13, wherein six groups of joint motor drivers in the robot control cabinet 8 are connected with the network switch 10 through a control cabinet network port by means of one group of joint motor drivers, the network switch 10 is connected with the PLC 11, and the PLC 11 is connected with the high-speed counter module 13; the high-speed counter module 13 is correspondingly connected with the grating scales 5 corresponding to the joints (i.e., a first joint grating scale 501, a second joint grating scale 502, a third joint grating scale 503, a fourth joint grating scale 504, a fifth joint grating scale 505, and a sixth joint grating scale 506).
In the present embodiment, six groups of robot joint motors and six groups of joint motor drivers are sequentially denoted as a first joint motor 101, a first joint motor driver 901, a second joint motor 102, a second joint motor driver 902, a third joint motor 103, a third joint motor driver 903, a fourth joint motor 104, a fourth joint motor driver 904, a fifth joint motor 105, a fifth joint motor driver 905, a sixth joint motor 106, a sixth joint motor driver 906; the upper net mouth of the first joint motor driver 901 is connected with the lower net mouth of the second joint motor driver 902, the upper net mouth of the second joint motor driver 902 is connected with the lower net mouth of the third joint motor driver 903, the upper net mouth of the third joint motor driver 903 is connected with the lower net mouth of the fourth joint motor driver 904, the upper net mouth of the fourth joint motor driver 904 is connected with the lower net mouth of the fifth joint motor driver 905, the upper net mouth of the fifth joint motor driver 905 is connected with the lower net mouth of the sixth joint motor driver 906, and the upper net mouth of the sixth joint motor driver 906 is connected with the network switch 10 through the net mouth of the control cabinet. Therefore, the connecting wires are saved, and meanwhile, the communication connection among the six joint motor groups is realized.
In this embodiment, the internet access of the motor driver 906 of the joint 6 is connected to the network switch 10 through the ethernet by means of the network port of the control cabinet;
the network switch 10 is connected to the PLC controller 11 through an ethernet network.
In this embodiment, the touch screen 12 is further included, and the PLC controller 11 is connected to the touch screen 12 through ethernet.
The working principle is as follows: the motor driver of each joint of the control system is respectively connected with each shutdown motor and the encoder thereof through power connection and signal connection; the multichannel network switch is connected with the robot control cabinet and the grating ruler respectively through a real-time Ethernet; the high-performance PLC controller with the motion control function is connected with the multichannel network switch through the real-time Ethernet and reads the data of each encoder; the PLC is connected with the high-speed counter module which is connected with the grating ruler (a plurality of high-speed counter modules are required to be configured, and because one module cannot read 6 grating ruler data and all modules are not drawn in the process of illustration in the figure), so that the reading of the grating ruler data is completed; the PLC is connected with the touch screen through a real-time Ethernet, and displays the acquired information on the touch screen in real time and allows an operator to operate the device system.
Example 3
As shown in fig. 1 to 5, the difference between the present embodiment and embodiment 2 is that the present embodiment provides a control method based on the robot control system, the control method is based on a robot control system based on joint angle information described in embodiment 2, and based on a connection schematic diagram (as shown in fig. 2) of the robot control system based on joint angle information described in embodiment 2, the control system and method control logic schematic diagram are as shown in fig. 3, and the method includes the following steps:
step 1: embedding grating scales into 6 joints of the robot, and obtaining angle information of the joints through relative movement between the grating scales and a reading head;
step 2: the PLC controller with the motion control function reads the angle information of each reading head in real time through the multichannel network switch and stores the angle information in the PLC controller;
step 3: the PLC with motion control function reads the encoder information of each joint of the robot in real time, and simultaneously controls the starting, suspending, emergency stopping and the like of the motors of each joint by using the PLC;
step 4: the angle values of the six joint grating rulers are respectively marked as Ai, the angle values of the 6 joint encoders are respectively marked as Bi, the angle difference value corresponding to the grating rulers and the encoders of each joint is Ci= |ai-Bi|, and the angle relative error is Di = Ci/Ai, wherein i is 1, 2, 3, 4, 5 and 6 respectively;
step 5: calibrating the angle information of the grating ruler and the angle information of the encoder to obtain a calibration result Di, wherein Di is less than or equal to 1/1000;
step 6: a relative error threshold E and an alarm duration threshold T are set, and an alarm level decision block diagram is shown in fig. 4. The hierarchical alarm mechanism is set as follows:
A. when Di is less than or equal to E, E is a relative error threshold, the robot completely works normally, the alarm level is 4, and other operations are not needed by operators;
B. when a relative error Di of a joint angle is larger than E, the alarm level is 3, and an operator needs to be alerted without other operations; meanwhile, if the alarm time length exceeds T, the alarm level is increased to 2 levels, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention, for example, the robot can stop operating immediately when a 'manual intervention' button is clicked on a corresponding software system interface;
C. when the angle relative error Di of the two joints exceeds E, the alarm level is 2, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention, for example, the robot can stop operating immediately when a 'manual intervention' button is clicked on a corresponding software system interface; meanwhile, if the alarm time length of any joint exceeds T, the alarm level is automatically lifted to be 1 level, the system intervention is automatically started, and the robot operation is automatically and immediately stopped, so that the safety of equipment and operators is ensured;
D. when the relative errors Di of the angles of at least 3 joints exceed E, the alarm level is 1 level, the system intervention is automatically started, and the robot is automatically and immediately stopped to run, so that the safety of equipment and operators is ensured; for example, the "system intervention" button on the corresponding software system interface may be automatically clicked, and the robot may be automatically and immediately stopped.
Specifically, the calibration process of step 5 includes the following sub-steps:
step 51, starting the robot, controlling each joint of the robot to rotate in a single joint, wherein the rotation angle is consistent with the travel of the unidirectional grating ruler of the joint, and acquiring the angle value of the joint motor encoder as reference data;
step 52, converting the angle value of the motor encoder and the grating number of the grating ruler read by the PLC to obtain an angle value corresponding to each grating, and completing preliminary calibration;
and step 53, controlling each joint of the robot to perform single joint movement again, taking the angle of each joint motor encoder as a theoretical value, taking the angle sampling resolution as the minimum resolution of the motor encoder as a standard, taking the angle of the grating ruler as an actual value, considering the joint error of the robot in the zero joint position as 0, generating an error table of the joint of the robot, and inputting the error table into a system variable, thereby finishing the precise calibration.
The information is displayed on a touch screen of a software system, the display frequency is 1 time/s, a display interface schematic diagram is shown in fig. 5, and the system can manually set different relative error thresholds E and alarm duration thresholds T according to different use scenes.
When the robot starts to work, the 'monitoring start' button is clicked to monitor the state of the robot in real time, the 'monitoring stop' button is clicked after the monitoring is finished, and the system automatically stores the real-time data of the encoder and the grating ruler of each joint operated at the time in the touch screen in a TXT format (the data recording frequency is 10 times/s) when the monitoring is stopped. When the abnormal condition of the invention occurs to the robot, an operator controls the robot according to the grading alarm mechanism.
According to the invention, the real-time monitoring of each joint angle of the robot is realized, the two-way measurement of each joint angle information is realized through the encoder and the grating ruler, and the safety and the reliability of the robot are improved according to the hierarchical alarm mechanism based on the joint angle error and the alarm time length. The system and method are not used for robot precision improvement, but are used for safety and reliability improvement.
According to the system and the method, the grating ruler is added on the robot body, so that the two-way measurement and the information comparison of the angle information of the grating ruler and the encoder are realized, and the safety and the reliability of the robot are improved; the robot grading alarm mechanism thought based on the alarm time length information and the joint angle information provides a new thought for maintenance of the robot.
It will be appreciated by those skilled in the art that embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media including, but not limited to, magnetic disk storage, CD-ROM, optical storage, and the like, having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus systems, and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flowchart illustrations and/or block diagrams, and combinations of flows and/or blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The foregoing description of the embodiments has been provided for the purpose of illustrating the general principles of the invention, and is not meant to limit the scope of the invention, but to limit the invention to the particular embodiments, and any modifications, equivalents, improvements, etc. that fall within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (8)
1. A control method of a robot control system is characterized in that the method is based on the robot control system based on joint angle information;
a robot control system based on joint angle information includes an industrial robot joint structure; the robot control system further comprises a robot control cabinet (8) and a robot body (9), wherein six groups of joint motor drivers are arranged in the robot control cabinet (8); the robot body (9) is provided with six groups of robot joint motors and encoders thereof; the encoder (4) is connected with the servo motor (1), the encoder (4) is connected with the joint motor driver, and the servo motor (1) is connected with the joint motor driver; adjacent joint motor drivers are connected through a driver network port;
the robot control system further comprises a network switch (10), a PLC (programmable logic controller) controller (11) and a high-speed counter module (13), wherein six groups of joint motor drivers in the robot control cabinet (8) are connected with the network switch (10) through a control cabinet network port by means of one group of joint motor drivers, the network switch (10) is connected with the PLC controller (11), and the PLC controller (11) is connected with the high-speed counter module (13); the high-speed counter module (13) is correspondingly connected with the grating ruler (5) corresponding to each joint;
the industrial robot joint structure comprises a servo motor (1), a robot joint matrix (2), a robot connecting rod (3) and an encoder (4), wherein the servo motor (1) is connected with the robot joint matrix (2), the robot joint matrix (2) is connected with the robot connecting rod (3), and the encoder (4) is connected with the servo motor (1);
the device also comprises a grating ruler (5) and a reading head (6), wherein the grating ruler (5) adopts a linear grating, the grating ruler (5) is arranged on the side edge of the robot connecting rod (3), and coaxiality of the grating ruler (5) and the robot connecting rod (3) and roundness of the grating ruler (5) are ensured to be in a precision range; the reading head (6) is arranged at the side edge of the robot joint matrix (2); the distance between the grating ruler (5) and the reading head (6) can ensure that data reading is normal; the angle information of the joint is obtained through the relative movement between the grating ruler (5) and the reading head (6);
the method comprises the following steps:
step 1: embedding grating scales into 6 joints of the robot, and obtaining angle information of the joints through relative movement between the grating scales and a reading head;
step 2: the PLC reads the angle information of each reading head in real time through the multichannel network switch and stores the angle information in the PLC;
step 3: the PLC reads encoder information of each joint of the robot in real time, and simultaneously utilizes the PLC to control starting, suspending and emergency stopping of motors of each joint;
step 4: the angle values of the six joint grating rulers are respectively marked as Ai, the angle values of the 6 joint encoders are respectively marked as Bi, the angle difference value corresponding to the grating rulers and the encoders of each joint is Ci= |ai-Bi|, and the angle relative error is Di = Ci/Ai, wherein i is 1, 2, 3, 4, 5 and 6 respectively;
step 5: calibrating the angle information of the grating ruler and the angle information of the encoder to obtain a calibration result Di, wherein Di is less than or equal to 1/1000;
step 6: setting a relative error threshold E and an alarm duration threshold T, and setting a hierarchical alarm mechanism as follows:
A. when Di is less than or equal to E, E is a relative error threshold, the robot completely works normally, the alarm level is 4, and other operations are not needed by operators;
B. when a relative error Di of a joint angle is larger than E, the alarm level is 3, and an operator needs to be alerted without other operations; meanwhile, if the alarm time length exceeds T, the alarm level is increased to 2 levels, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention;
C. when the angle relative error Di of the two joints exceeds E, the alarm level is 2, and an operator can select to pause the operation of the robot or continue the operation according to the specific operation condition of the robot; if the temporary robot needs to operate, the robot can stop operating immediately through manual intervention; meanwhile, if the alarm time length of any joint exceeds T, the alarm level is automatically lifted to 1 level, the system intervention is automatically started, and the robot operation is automatically and immediately stopped;
D. when the relative errors Di of the angles of at least 3 joints exceed E, the alarm level is 1 level, the system intervention is automatically started, and the robot is automatically and immediately stopped.
2. The control method according to claim 1, characterized in that the calibration procedure of step 5 comprises the sub-steps of:
step 51, starting the robot, controlling each joint of the robot to rotate in a single joint, wherein the rotation angle is consistent with the travel of the unidirectional grating ruler of the joint, and acquiring the angle value of the joint motor encoder as reference data;
step 52, converting the angle value of the motor encoder and the grating number of the grating ruler read by the PLC to obtain an angle value corresponding to each grating, and completing preliminary calibration;
and step 53, controlling each joint of the robot to perform single joint movement again, taking the angle of each joint motor encoder as a theoretical value, taking the angle sampling resolution as the minimum resolution of the motor encoder as a standard, taking the angle of the grating ruler as an actual value, considering the joint error of the robot in the zero joint position as 0, generating an error table of the joint of the robot, and inputting the error table into a system variable, thereby finishing the precise calibration.
3. The control method according to claim 1, characterized in that six groups of robot joint motors and six groups of joint motor drivers are sequentially denoted as a first joint motor (101), a first joint motor driver (901), a second joint motor (102), a second joint motor driver (902), a third joint motor (103), a third joint motor driver (903), a fourth joint motor (104), a fourth joint motor driver (904), a fifth joint motor (105), a fifth joint motor driver (905), a sixth joint motor (106), a sixth joint motor driver (906); the net mouth of going up of first joint motor driver (901) connects the net mouth of going down of second joint motor driver (902), the net mouth of going up of second joint motor driver (902) connects the net mouth of going down of third joint motor driver (903), the net mouth of going up of third joint motor driver (903) is connected the net mouth of going down of fourth joint motor driver (904), the net mouth of going up of fourth joint motor driver (904) is connected the net mouth of going down of fifth joint motor driver (905), the net mouth of going up of fifth joint motor driver (905) is connected the net mouth of going down of sixth joint motor driver (906), the net mouth of going up of sixth joint motor driver (906) passes through switch board net mouth and connects network switch (10).
4. The control method according to claim 1, characterized in that the internet access of the joint 6 motor driver (906) is connected to the network switch (10) via the ethernet by means of a control cabinet internet access;
the network switch (10) is connected with the PLC (11) through the Ethernet.
5. The control method according to claim 1, further comprising a touch screen (12), wherein the PLC controller (11) is connected to the touch screen (12) through ethernet.
6. The control method according to claim 1, characterized in that the grating scale (5) is a Raney quick self-adhesive incremental grating scale with an accuracy of + -5 μm/m- + -15 μm/m and a maximum length of 10m.
7. The control method according to claim 1, characterized in that the grating ruler (5) is mounted at the side of the robot connecting rod (3), and the coaxiality of the grating ruler (5) and the robot connecting rod (3) and the roundness of the grating ruler (5) are ensured to be within the precision range; wherein the coaxiality of the grating ruler (5) and the robot connecting rod (3) is less than or equal to 0.001mm, and the roundness of the grating ruler (5) is less than or equal to 0.001mm.
8. The control method according to claim 1, further comprising a speed reducer (7), wherein the speed reducer (7) and the servo motor (1) are disposed in the robot joint base body (2), and the servo motor (1) is connected with the robot joint base body (2) through the speed reducer (7).
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