Disclosure of Invention
In view of the above problems, the invention provides a method and a system for controlling the movement of a manipulator for burn-in test, which ensure the accuracy and stability of the manipulator in the process of carrying and positioning by setting the method for controlling the ageing of the manipulator, thereby remarkably reducing the risk of product damage or test failure caused by inaccurate movement of the manipulator.
According to a first aspect of an embodiment of the invention, a method for controlling movement of an aging test manipulator is provided.
In one or more embodiments, preferably, the burn-in test manipulator motion control method includes:
Setting high-precision position, speed and moment sensors for the aging test manipulator, and capturing the state of the manipulator in real time;
Adding a safety controller and an emergency stop mechanism into a control system of the aging test manipulator;
designing a manipulator control function block, and selecting different test manipulator control function blocks according to different product models and test requirements;
real-time data exchange between the manipulator control system and other production equipment by utilizing a preset modern industrial communication protocol;
setting an intelligent fault diagnosis system, and executing controllable motion conveying on the jig through mutual coordination motion of a z axis;
And carrying out function block packaging on each function on line, wherein the function blocks are used for carrying out real-time detection on X and Z axis movements on line.
In one or more embodiments, preferably, the setting high-precision position, speed and moment sensors for the aging test manipulator captures the state of the manipulator in real time, and specifically includes:
Setting an operation position of the aging test manipulator and implementing detection equipment;
Setting a speed monitoring device for the aging test manipulator;
Setting image acquisition equipment in an area where the aging test manipulator is located;
And a moment sensor is arranged on the aging test manipulator, and moments in different directions are collected in real time.
In one or more embodiments, preferably, the adding a safety controller and an emergency stop mechanism in the control system of the burn-in test manipulator specifically includes:
A safety controller is arranged and connected with a main control system of the manipulator in parallel;
The safety controller receives sensor data from the manipulator and has independent processing capacity and is used for monitoring the operation state of the manipulator in real time;
when the safety controller detects that the operation of the manipulator exceeds a preset safety parameter and a preset threshold value, the safety controller automatically sends an early warning signal to a main control system of the manipulator;
setting an emergency stop mechanism, wherein the emergency stop mechanism is triggered by the safety controller;
the emergency stop mechanism comprises a hardware component and a software component, wherein the hardware component is an emergency brake connected to each joint of the manipulator, and the software component is a stop instruction algorithm embedded in the safety controller;
when the early warning signal sent by the safety controller reaches a preset emergency level, the emergency stopping mechanism is immediately started, and the stopping instruction algorithm calculates and sends an instant stopping signal to each brake of the manipulator;
after receiving the stop signal, the brake of the hardware component locks each joint of the manipulator rapidly, so that potential safety hazards caused by movement of the manipulator are prevented.
In one or more embodiments, preferably, the design manipulator control function block selects different test manipulator control function blocks according to different product models and test requirements, and specifically includes:
a plurality of control function blocks, each function block designed to perform a specific test task;
the control function block includes program code and parameter sets for different product models and test requirements;
A function block selector that allows a user to select one or more function blocks from the plurality of control function blocks based on the product model and test requirements of the current test.
The function block selector automatically selects and loads the corresponding control function block according to the information input by the user through the configuration interface.
In one or more embodiments, preferably, the real-time data exchange between the manipulator control system and other production devices using a preset modern industrial communication protocol specifically includes:
Setting a communication interface which is used for being compatible with communication interfaces of other production equipment in the production line to realize data exchange;
A data formatting module is arranged for converting the internal data of the manipulator control system into data conforming to the format of a modern industrial communication protocol;
A data synchronization mechanism that ensures that the data exchange between the robot control system and other equipment in the production line is in real time and maintains data consistency.
In one or more embodiments, preferably, the setting an intelligent fault diagnosis system, through mutual coordination motion of the z axis, performs controllable motion conveying on the jig, and specifically includes:
Setting an intelligent fault diagnosis process, and starting the z-axis to coordinate with each other when the distance between two adjacent manipulators is monitored to be smaller than a preset range;
After starting the mutual coordinated motion of the z axis, all motions of two adjacent devices in the z axis direction are kept synchronous, and normal motion is restored after the study and judgment are normal, wherein the study and judgment are preset judgment logic, and the judgment is automatically carried out through videos.
In one or more embodiments, preferably, the online performing performs function block packaging on each function, where the function block is used for performing online real-time detection of X-axis and Z-axis motion, and specifically includes:
capturing the position P, the speed V and the moment J of the manipulator in real time;
Calculating an x-axis distance and a z-axis distance by using a first calculation formula according to the movement speed at the current moment and the position of the manipulator;
Judging that the collision risk exists if the x-axis distance and the z-axis distance do not meet the second calculation formula, otherwise, not processing;
For the time period with collision risk, adjusting the moment in the corresponding moving direction to meet a third calculation formula;
The method comprises the steps of performing visualized function block packaging on all functions, wherein the function block packaging is used for performing modularized dragging programming in a programming process;
The first calculation formula is as follows:
Wz=Pz+TT×Vz
Wx=Px+TT×Vx
wherein, pz is the real-time projection position of the z axis, px is the real-time projection position of the x axis, TT is the preset time interval, wz is the z axis distance, wx is the x axis distance, vz is the z axis moving speed of the manipulator, and Vx is the x axis moving speed of the manipulator;
the second calculation formula is as follows:
Wz∈[LZ1,LZ2]
Wx∈[LX1,LX2]
LZ1 and LZ2 are lower and upper limits of a z-axis of manipulator movement, and LX1 and LX2 are lower and upper limits of an x-axis of manipulator movement;
the third calculation formula is as follows:
YL∈FL
Wherein YL is the moment in the moving direction, and FL is the moment range without collision damage.
According to a second aspect of the embodiment of the invention, a motion control system of an aging test manipulator is provided.
In one or more embodiments, preferably, the burn-in test manipulator motion control system comprises:
the sensing acquisition module is used for setting high-precision position, speed and moment sensors for the aging test manipulator and capturing the state of the manipulator in real time;
The emergency control module is used for adding a safety controller and an emergency stop mechanism into the control system of the aging test manipulator;
The mode selection module is used for designing a manipulator control function block and selecting different test manipulator control function blocks according to different product models and test requirements;
the communication setting module is used for utilizing a preset modern industrial communication protocol to realize real-time data exchange between the manipulator control system and other production equipment;
the interaction limiting module is used for setting an intelligent fault diagnosis system and executing controllable movement conveying on the jig through mutual coordination movement of the z axis;
and the packaging control module is used for carrying out on-line function block packaging on each function, wherein the function blocks are used for carrying out on-line real-time detection on X and Z axis movement.
According to a third aspect of embodiments of the present invention, there is provided a computer readable storage medium having stored thereon computer program instructions which, when executed by a processor, implement a method according to any of the first aspect of embodiments of the present invention.
According to a fourth aspect of embodiments of the present invention there is provided an electronic device comprising a memory and a processor, the memory being for storing one or more computer program instructions, wherein the one or more computer program instructions are executable by the processor to implement the method of any of the first aspects of embodiments of the present invention.
The technical scheme provided by the embodiment of the invention can comprise the following beneficial effects:
In the scheme of the invention, the emergency control and the safety control are integrated, so that the fault and accident can be prevented.
In the scheme of the invention, the modularized design is combined with communication optimization, so that the fault risk is reduced.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.
The technical scheme of the invention is further described in detail through the drawings and the embodiments.
Detailed Description
In some of the flows described in the specification and claims of the present invention and in the foregoing figures, a plurality of operations occurring in a particular order are included, but it should be understood that the operations may be performed out of order or performed in parallel, with the order of operations such as 101, 102, etc., being merely used to distinguish between the various operations, the order of the operations themselves not representing any order of execution. In addition, the flows may include more or fewer operations, and the operations may be performed sequentially or in parallel. It should be noted that, the descriptions of "first" and "second" herein are used to distinguish different messages, devices, modules, etc., and do not represent a sequence, and are not limited to the "first" and the "second" being different types.
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to fall within the scope of the invention.
In the new energy industry, the aging test of photovoltaic inverters, energy storage batteries and traditional chargers is an important link for ensuring the reliability and stability of these key devices. By adopting the advanced aging test manipulator motion control technology, the abrasion and aging process in the actual operation of the product can be simulated and reproduced, so that the performance and the service life of the product can be estimated. The control mode combines high-precision motion planning, real-time monitoring and a safety protection mechanism to optimize the test flow, reduce human errors and improve the test efficiency. The method has great significance for improving the product quality, reducing the maintenance cost and preventing faults, and is a key factor for promoting continuous innovation and technical progress in the new energy industry. By accurately simulating and accelerating the aging process, the aging test manipulator can discover potential defects in the product development stage and help manufacturers to improve product design, thereby guaranteeing the benefits of end users and promoting the wide application and sustainable development of new energy technologies.
Prior to the present technology, the existing burn-in robot motion control method relies mainly on conventional PLC (programmable logic controller) and ladder diagram programming, combined with basic sensor information to perform simple positioning and handling operations. The technical difficulties and key points comprise accuracy and stability, namely ensuring that the manipulator can accurately repeat carrying actions in the long-time operation process, avoiding error accumulation caused by mechanical abrasion or electrical problems, and being important to ensuring the consistency of the test. Safety when the manipulator is used for carrying and placing the aging test products, the operation safety needs to be ensured, and the safety of the tested equipment and the safety of surrounding environment and operators is considered. Flexibility and adaptability-products of different models and sizes may need to be tested in the aging test process, and the control system needs to have the capability of quickly adjusting and adapting to new products. The system integration and communication that the aging test manipulator needs to work cooperatively with other equipment on the production line to realize data exchange and synchronous operation requires the motion control system to have high-efficiency communication capability and good integration.
The embodiment of the invention provides a method and a system for controlling the movement of an aging test manipulator. According to the scheme, the aging control method of the manipulator is arranged, so that the accuracy and stability of the manipulator in the carrying and positioning processes are ensured, and the risk of product damage or test failure caused by inaccurate movement of the manipulator is obviously reduced.
According to a first aspect of an embodiment of the invention, a method for controlling movement of an aging test manipulator is provided.
FIG. 1 is a flow chart of a method for controlling the motion of a burn-in test manipulator according to one embodiment of the present invention.
In one or more embodiments, preferably, the burn-in test manipulator motion control method includes:
s101, setting high-precision position, speed and moment sensors for an aging test manipulator, and capturing the state of the manipulator in real time;
S102, adding a safety controller and an emergency stop mechanism into a control system of the aging test manipulator;
S103, designing a manipulator control function block, and selecting different test manipulator control function blocks according to different product models and test requirements;
S104, utilizing a preset modern industrial communication protocol to realize real-time data exchange between the manipulator control system and other production equipment;
S105, setting an intelligent fault diagnosis system, and executing controllable movement conveying on the jig through mutual coordination movement of the z axes;
S106, carrying out on-line function block packaging on each function, wherein the function blocks are used for carrying out on-line real-time detection on X and Z axis movement.
According to the embodiment of the invention, the high-efficiency and reliable aging test is realized by combining the information acquisition of the aging manipulator with the emergency control and the azimuth analysis, and the accuracy and the stability of the manipulator in the carrying and positioning processes are ensured by setting the aging control method of the manipulator, so that the risk of product damage or test failure caused by inaccurate movement of the manipulator is obviously reduced.
Fig. 2 is a flowchart of setting high-precision position, speed and moment sensors for the burn-in test manipulator in a method for controlling the motion of the burn-in test manipulator according to an embodiment of the present invention, and capturing the state of the manipulator in real time.
As shown in fig. 2, in one or more embodiments, preferably, the positioning, speed and moment sensors with high precision are provided for the aging test manipulator, and capturing the state of the manipulator in real time specifically includes:
s201, setting an operation position implementation detection device for the aging test manipulator;
s202, setting a speed monitoring device for the aging test manipulator;
S203, setting image acquisition equipment in an area where the aging test manipulator is located;
s204, setting a moment sensor on the aging test manipulator, and collecting moments in different directions in real time.
In the embodiment of the invention, the real-time monitoring of the state of the manipulator is realized by integrating high-precision position, speed and moment sensors. First, high precision encoders are provided at each joint of the manipulator that are capable of detecting and feeding back real-time position data of each joint of the manipulator, allowing the control system to perform accurate position control. For example, these encoders ensure that the movement accuracy of the robot is within ±0.1 mm when the robot needs to carry the photovoltaic module from one end of the production line to the test station. Further, a speed monitoring device is deployed that employs a Laser Doppler Vibrometer (LDV) to measure speed changes during manipulator movement in a non-contact manner. The device can monitor the speed of the manipulator in real time when the manipulator executes the rapid carrying action, and ensures that the speed is controlled within an error range of +/-1% of a preset value, thereby avoiding the reduction of the test precision or the damage of the device caused by the too high or the too low speed. In order to realize the comprehensive monitoring of the operation area of the manipulator, a high-resolution camera is arranged in the working area of the manipulator and is used as image acquisition equipment. These cameras are capable of capturing the interaction process between the manipulator and the component under test and analyzing possible anomalies, such as component position drift or accidental approach of the manipulator to the test instrument, by means of image processing algorithms. The real-time processing of the image data provides an additional layer of security for the system and alerts the control system upon detection of an anomaly. Finally, moment sensors are assembled at key parts of the mechanical arm, and the moment sensors can detect and feed back the magnitude and the direction of moment applied to the mechanical arm in real time based on the strain gauge technology. For example, when the manipulator grabs an inverter with a weight of 5kg, the torque sensor ensures that the grip of the manipulator is moderate, neither damaging the inverter due to excessive size nor slipping down the inverter due to excessive size. The data of the moment sensor enables the control system to adjust the grip strength of the manipulator to adapt to test objects of different weights and shapes. Through the integration and coordination of the equipment, the aging test manipulator control system can realize high-precision control and monitoring of the position, the speed and the moment of the manipulator, improves the accuracy and the safety of the test process, and reduces the risks caused by misoperation.
Fig. 3 is a flow chart of adding a safety controller and an emergency stop mechanism to a control system of a burn-in robot in a method for controlling movement of the burn-in robot according to an embodiment of the present invention.
As shown in fig. 3, in one or more embodiments, it is preferable that a safety controller and an emergency stop mechanism are added to the control system of the burn-in test manipulator, and the method specifically includes:
s301, setting a safety controller and connecting the safety controller with a main control system of the manipulator in parallel;
s302, a safety controller receives sensor data from the manipulator and has independent processing capacity, and is used for monitoring the operation state of the manipulator in real time;
s303, when the safety controller detects that the operation of the manipulator exceeds a preset safety parameter and a preset threshold value, the safety controller automatically sends an early warning signal to a main control system of the manipulator;
S304, setting an emergency stop mechanism, wherein the emergency stop mechanism is triggered by the safety controller;
S305, the emergency stop mechanism comprises a hardware component and a software component, wherein the hardware component is an emergency brake connected to each joint of the manipulator, and the software component is a stop instruction algorithm embedded in the safety controller;
S306, when an early warning signal sent by the safety controller reaches a preset emergency level, an emergency stopping mechanism is immediately started, and a stopping instruction algorithm calculates and sends an instant stopping signal to each brake of the manipulator;
S307, after the brake of the hardware component receives the stop signal, each joint of the manipulator is quickly locked, and potential safety hazards caused by movement of the manipulator are prevented.
In the embodiment of the invention, a safety controller is connected in parallel in the control system, and the controller runs independently of the main control system and is specially responsible for monitoring the operation state of the manipulator. The safety controller receives data from sensors installed at key parts of the manipulator in real time. The sensors can capture real-time dynamics of the manipulator, such as displacement, speed, received moment and the like, so that the safety controller can judge based on comprehensive and accurate data. For example, when the manipulator performs a handling test of the photovoltaic module, the safety controller continuously monitors its movement track and speed. If the movement speed of the manipulator is detected to exceed a preset threshold, such as a sudden increase in speed to 110% above the standard test speed, the safety controller will identify a potentially dangerous condition and immediately send an early warning signal to the main control system. At the same time, a set of emergency stop mechanisms is devised, which are triggered by the safety controller. The emergency stop mechanism includes a hardware brake coupled to each joint of the manipulator and a stop command algorithm embedded in the safety controller. The hardware brake is designed to lock the joints of the manipulator instantaneously after receiving the signal, and prevent the manipulator from moving continuously. The software component is an advanced algorithm, can quickly calculate the instruction needed for stopping the manipulator, and sends a stopping signal to all the brakes immediately when the safety threat is determined to exist. For example, if the manipulator starts to deviate from the predetermined test track due to a program error or external disturbance during the process of testing the inverter, it approaches the surrounding equipment or the operator, and at this time, the safety controller detects that the positional deviation exceeds the safety range and rapidly raises the early warning signal to the emergency level. The emergency stop mechanism is then activated and the stop command algorithm signals the individual brakes almost simultaneously, the hardware brakes responding to the signals, momentarily locking all joints of the manipulator, thereby avoiding possible collisions or injuries.
FIG. 4 is a flow chart of a design manipulator control function block in a burn-in manipulator motion control method according to one embodiment of the present invention, with different test manipulator control function blocks selected according to different product models and test requirements.
As shown in fig. 4, in one or more embodiments, preferably, the design manipulator control function block selects different test manipulator control function blocks according to different product models and test requirements, and specifically includes:
S401, a plurality of control functional blocks, wherein each functional block is designed to execute a specific test task;
S402, a control function block comprises program codes and parameter sets for different product models and test requirements;
S403, a function block selector, which allows a user to select one or more function blocks from a plurality of control function blocks according to the current tested product model and test requirements;
s404, the function block selector automatically selects and loads the corresponding control function block according to the information input by the user through the configuration interface.
In the embodiment of the invention, the proper test control function block is selected according to different product models and test requirements. First, a plurality of control function blocks are defined, wherein each function block is optimally designed to perform a specific test task. For example, one control function may be designed to test the voltage withstand capability of the photovoltaic panel, while another may be dedicated to checking the temperature response of the inverter. The functional blocks contain preset program codes and parameter sets for different product models and test requirements, so that the manipulator can accurately execute various complex test processes. In order to achieve a flexible selection of these control function blocks, a function block selector was developed. The selector is a user-friendly interface that allows a user to select one or more of a plurality of preset control function blocks according to the product model currently being tested and the specific test requirements. For example, when a user needs to test a new type of battery, they simply input the product type and corresponding test criteria through the configuration interface, and the function block selector automatically identifies and loads all necessary control function blocks applicable to the type of battery, such as charge cycle test, discharge rate test, etc. The function block selector is also provided with an intelligent recommendation system, and the function block selector can recommend the most suitable control function block combination according to past test data and historical selection of a user, so that the setting efficiency of a test flow is improved. Once the user confirms the selection, the system automatically configures the control system of the manipulator, loads the selected control function blocks, and adjusts the associated hardware settings to match the new test requirements. Through the design method, the manipulator control system can be rapidly adapted to different test tasks, and the flexibility and the efficiency of the equipment are obviously improved. This approach is particularly valuable for production lines where product model and test requirements are frequently changed, as it reduces the time required for reprogramming and manual configuration, ensuring continuity and consistency of the test flow.
FIG. 5 is a flow chart of real-time data exchange between a robot control system and other production equipment using a preset modern industrial communication protocol in a burn-in robot motion control method according to one embodiment of the present invention.
As shown in fig. 5, in one or more embodiments, preferably, the real-time data exchange between the manipulator control system and other production devices using a preset modern industrial communication protocol specifically includes:
s501, a communication interface is arranged and is used for being compatible with communication interfaces of other production equipment in a production line, so that data exchange is realized;
S502, setting a data formatting module for converting the internal data of the manipulator control system into data conforming to the modern industrial communication protocol format;
s503, a data synchronization mechanism, which ensures that the data exchange between the manipulator control system and other devices in the production line is real-time and maintains data consistency.
In an embodiment of the invention, a communication interface is provided in the robot control system, which interface is designed to be compatible with the communication interfaces of other production equipment in the production line. For example, if other devices in the production line use OPC UA (open platform unified architecture for communication) as a communication standard, the communication interface on the manipulator also supports OPC UA protocol to ensure seamless connection and exchange of data between different devices. To ensure that the data formats of the transmissions are consistent, a data formatting module is introduced. The main function of this module is to convert the internal data of the robot control system into data in accordance with modern industrial communication protocols (e.g. OPC UA or EtherNet/IP) format. For example, when the manipulator completes the burn-in test of a component and generates test results, the results are first converted by the data formatting module into a standard OPC UA data format before being understood and received by other equipment or monitoring systems integrated in the production line. A data synchronization mechanism is also implemented that uses time synchronization techniques, such as Precision Time Protocol (PTP), to ensure that the data exchange between the robot control system and other devices in the production line is real-time and to maintain data consistency. This means that whenever the state of the robot arm changes or new test data is generated, this information can be shared instantaneously with the rest of the production line, ensuring a consistent coordination of the whole production process. By implementing the method, the aging test manipulator can efficiently and accurately exchange real-time data with other production equipment in the production line. This not only improves production efficiency, but also enables the production manager to monitor the status of the entire production line in real time, including the operation status of the robot, the test progress, and any possible anomalies, so as to make a quick and efficient decision.
Fig. 6 is a flowchart of a method for controlling movement of an aging test manipulator according to an embodiment of the present invention, in which an intelligent fault diagnosis system is provided to perform controllable movement conveyance on a jig by mutual coordinated movement of z-axes.
As shown in fig. 6, in one or more embodiments, preferably, the setting an intelligent fault diagnosis system, performing controllable motion conveying on the fixture through mutual coordinated motion of the z axis, specifically includes:
S601, setting an intelligent fault diagnosis process, and starting the mutual coordinated motion of the z axes when the distance between two adjacent manipulators is monitored to be smaller than a preset range;
s602, after starting the mutual coordinated motion of the z axes, all motions of two adjacent devices in the z axis direction are kept synchronous, and after waiting for judging to be normal, the normal motion is restored again, wherein the judging is preset judging logic, and the judgment is automatically carried out through videos.
In the embodiment of the invention, an intelligent fault diagnosis flow is integrated in the aging test manipulator control system. The function of this procedure is to monitor the relative position of the robot during operation, ensuring that the distance between them is not less than a pre-set safety margin. For example, when two adjacent robots are carrying out photovoltaic module handling and testing, the system may continuously monitor the distance between them. If the distance between the two manipulators is monitored to be smaller than the preset range, the intelligent fault diagnosis system immediately starts the z-axis coordinated movement. This means that once the system detects a potential collision risk or abnormal approach, the two involved robots will move synchronously in the z-axis direction at the same time. This synchronous movement may be such that both robots are simultaneously raised or lowered until the distance between them is restored to within a safe range. During this time, all movements are controllable and the speed will be limited to a safe range to ensure that no new risks are introduced due to the rapid avoidance action. After the initiation of the coordinated z-axis motion, the system enters a wait and learn phase. In this stage, the system uses preset judgment logic and combines with the video automatic judgment technology to evaluate the situation. For example, the system may analyze the position and surrounding environment of the robot using cameras installed in the workshops to determine whether there are obstacles that still need to be avoided or safety conditions to resume normal operation. Only after the system judges that the situation is normal and potential safety hazard does not exist, the manipulator can resume the normal movement mode.
FIG. 7 is a flow chart of on-line functional block packaging for each function in an on-line motion control method for a burn-in robot according to one embodiment of the present invention, wherein the functional blocks are used for on-line real-time detection of X and Z axis motion.
As shown in fig. 7, in one or more embodiments, the online performing preferably performs a function block packaging for each function, where the function block is used for online real-time detection of X and Z axis motion, and specifically includes:
S701, capturing the position P, the speed V and the moment J of the manipulator in real time;
s702, calculating an x-axis distance and a z-axis distance according to the motion speed at the current moment and the position of the manipulator by using a first calculation formula;
S703, judging that if the x-axis distance and the z-axis distance do not meet a second calculation formula, judging that collision risk exists, otherwise, not processing;
s704, for a time period with collision risk, adjusting the moment in the corresponding moving direction to meet a third calculation formula;
S705, performing visualized function block packaging on all functions, wherein the visualized function block packaging is used for performing modularized dragging programming in the programming process;
The first calculation formula is as follows:
Wz=Pz+TT×Vz
Wx=Px+TT×Vx
wherein, pz is the real-time projection position of the z axis, px is the real-time projection position of the x axis, TT is the preset time interval, wz is the z axis distance, wx is the x axis distance, vz is the z axis moving speed of the manipulator, and Vx is the x axis moving speed of the manipulator;
the second calculation formula is as follows:
Wz∈[LZ1,LZ2]
Wx∈[LX1,LX2]
LZ1 and LZ2 are lower and upper limits of a z-axis of manipulator movement, and LX1 and LX2 are lower and upper limits of an x-axis of manipulator movement;
the third calculation formula is as follows:
YL∈FL
Wherein YL is the moment in the moving direction, and FL is the moment range without collision damage.
In the embodiment of the invention, a real-time monitoring module is implemented in the aging test manipulator control system, and the module can capture the position P (including Px and Pz), the speed V (including Vx and Vz) and the moment J of the manipulator. Obtained by real-time acquisition of readings from encoders and other sensors of the manipulator. And calculating the x-axis distance Wx and the z-axis distance Wz according to the motion speed at the current moment and the position of the manipulator by using a first calculation formula. This formula takes into account the expected distance of movement of the manipulator within the preset time interval TT, so as to predict the position of the manipulator in a short time in the future. If the calculated Wx and Wz are not within the safety range defined by the second calculation formula, i.e., do not satisfy the conditions of LZ1 to LZ2 (lower and upper z-axis limits) and LX1 to LX2 (lower and upper x-axis limits), the system considers that there is a collision risk. When the collision risk is identified, the system adjusts the moment YL in the corresponding moving direction in the time period with the collision risk so as to meet the definition of the third calculation formula, namely, ensure that the moment YL falls in the collision damage-free moment range FL. This adjustment is achieved by varying the torque output of the manipulator to avoid potential collisions. To simplify the programming process, a functional block package is visualized for all functions. This means that a developer can quickly build and adjust the control logic of the robot through modular drag programming in a programming environment. Each functional block corresponds to a specific set of operations, such as real-time monitoring, risk assessment, and torque adjustment, which can be flexibly combined to cope with different test requirements and scenarios. The system implemented by the method can effectively detect X and Z axis movements on line in real time, and programming efficiency and maintainability of the system are improved by a function block packaging mode. Such collision prevention strategies are critical to ensure safe operation of the robot and other equipment during automated testing.
According to a second aspect of the embodiment of the invention, a motion control system of an aging test manipulator is provided.
Fig. 8 is a block diagram of a motion control system of a burn-in test robot according to an embodiment of the present invention.
In one or more embodiments, preferably, the burn-in test manipulator motion control system comprises:
the sensing acquisition module 801 is used for setting high-precision position, speed and moment sensors for the aging test manipulator and capturing the state of the manipulator in real time;
an emergency control module 802 for adding a safety controller and an emergency stop mechanism into the control system of the burn-in test manipulator;
The mode selection module 803 is used for designing a manipulator control function block and selecting different test manipulator control function blocks according to different product models and test requirements;
a communication setting module 804, configured to utilize a preset modern industrial communication protocol to exchange real-time data between the manipulator control system and other production devices;
The interaction limiting module 805 is configured to set up an intelligent fault diagnosis system, and perform controllable motion conveying on the jig through mutual coordinated motion of the z-axis;
And a packaging control module 806, configured to perform on-line function block packaging on each function, where the function blocks are configured to perform on-line real-time detection of X and Z axis motion.
In the embodiment of the invention, a system suitable for different structures is realized through a series of modularized designs, and the system can realize closed-loop, reliable and efficient execution through acquisition, analysis and control.
According to a third aspect of embodiments of the present invention, there is provided a computer readable storage medium having stored thereon computer program instructions which, when executed by a processor, implement a method according to any of the first aspect of embodiments of the present invention.
According to a fourth aspect of an embodiment of the present invention, there is provided an electronic device. Fig. 9 is a block diagram of an electronic device in one embodiment of the invention. The electronic device shown in fig. 9 is a general burn-in robot motion control device. The electronic device can be a smart phone, a tablet computer and the like. As shown, the electronic device 900 includes a processor 901 and a memory 902. The processor 901 is electrically connected to the memory 902. Processor 901 is a control center of terminal 900 that connects the various parts of the overall terminal using various interfaces and lines, and performs various functions of the terminal and processes data by running or calling computer programs stored in memory 902, and calling data stored in memory 902, thereby performing overall monitoring of the terminal.
In this embodiment, the processor 901 in the electronic device 900 loads instructions corresponding to the processes of one or more computer programs into the memory 902 according to the following steps, and the processor 901 runs the computer programs stored in the memory 902, so as to realize various functions, namely, setting high-precision position, speed and moment sensors for the aging test manipulator, capturing the state of the manipulator in real time, adding a safety controller and an emergency stop mechanism into a control system of the aging test manipulator, designing a manipulator control function block, selecting different test manipulator control function blocks according to different product models and test requirements, utilizing a preset modern industrial communication protocol manipulator control system to exchange real-time data with other production devices, setting an intelligent fault diagnosis system, executing controllable motion conveying on the manipulator through mutual coordination motion of a Z axis, and carrying out on-line function block packaging on each function, wherein the function block is used for carrying out on-line real-time detection of X and Z axis motion.
Memory 902 may be used to store computer programs and data. The memory 902 stores a computer program having instructions executable in a processor. The computer program may constitute various functional modules. The processor 901 executes various functional applications and data processing by calling a computer program stored in the memory 902.
The technical scheme provided by the embodiment of the invention can comprise the following beneficial effects:
In the scheme of the invention, the emergency control and the safety control are integrated, so that the fault and accident can be prevented.
In the scheme of the invention, the modularized design is combined with communication optimization, so that the fault risk is reduced.
It will be appreciated by those skilled in the art that embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention 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, optical storage, and the like) having computer-usable program code embodied therein.
The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. 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.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention also include such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.