技术领域technical field
本发明属于电力技术领域，具体涉及一种输电线路带电作业机器人的作业监控系统。The invention belongs to the field of electric power technology, and in particular relates to an operation monitoring system for a live-line operation robot of a power transmission line.
背景技术Background technique
目前，我国高压带电作业主要为人工作业。即便已经出现代替人工作业的机器人，其安全性也不能得到保障，仍然需要人工对其作业进行监控。由于输电线路机器人一般采用高空作业，操作人员在地面上通过目视无法及时有效地发现机器人作业过程中发生的故障。我国带电作业机器人起步较晚，目前没有针对输电线路带电作业机器人的监控方案，电网、机器人和操作人员的安全不能得到保障。为避免或减小机器人作业引发的安全事故，需要针对输电线路带电作业机器人设计专用的监控系统。At present, my country's high-voltage live work is mainly manual work. Even if robots that replace manual operations have appeared, their safety cannot be guaranteed, and humans still need to monitor their operations. Since transmission line robots generally work at high altitudes, operators cannot timely and effectively find faults that occur during robot operations through visual inspection on the ground. my country's live working robots started late, and currently there is no monitoring program for live working robots on transmission lines, and the safety of power grids, robots and operators cannot be guaranteed. In order to avoid or reduce safety accidents caused by robot operations, it is necessary to design a dedicated monitoring system for live-line working robots.
发明内容Contents of the invention
本发明解决的技术问题为，作业人员可通过监控系统远程监控机器人带电作业，保障了作业人员的安全。The technical problem solved by the invention is that the operator can remotely monitor the live working of the robot through the monitoring system, which ensures the safety of the operator.
为了解决上述技术问题，本发明提供一种带电作业机器人作业监控系统，包括带电作业机器人和监控系统；所述带电作业机器人包括绝缘斗臂车，搭载在绝缘斗臂车上的机器人平台，安装在机器人平台上的机械臂，数据采集系统以及数据处理和控制系统；所述机械臂包括第一机械臂、第二机械臂和辅助机械臂，所述摄像机包括双目摄像头、深度摄像头和全景摄像头，所述第一机械臂、第二机械臂和辅助机械臂上均搭载有双目摄像头；所述第一机械臂、第二机械臂和辅助机械臂均为多自由度机构，多自由度机构中各个关节均具有相应的正交旋转编码器和伺服驱动电机，正交旋转编码器用于采集各个关节的角度数据，伺服驱动电机用于控制各关节的运动；所述数据采集系统包括设置在机器人平台上的摄像机，摄像机用于采集机械臂作业场景图像，并将所述作业场景图像发送给数据处理和控制系统；所述数据处理和控制系统根据所述作业场景图像生成3D虚拟作业场景或者规划出机械臂空间路径，包括第一工控机、第二工控机；所述监控系统的监控对象为：第一机械臂、第二机械臂、辅助机械臂、蓄电池以及作业场景；所述监控系统中的监控设备为：温湿度传感器、压力传感器、电流采集器、电压采集器、数据采集卡、全景摄像头、双目摄像头、深度摄像头；温湿度传感器置于机器人平台上，用于采集作业环境温湿度；压力传感器安装在各机械臂末端，用于采集机械臂与环境的接触力；电压采集器与机械臂各关节的伺服驱动电机相连，用于采集伺服驱动电机的电流的大小；数据采集卡用于各项采集数据转换为数据处理和控制系统所识别的格式；全景摄像头、双目摄像头和深度摄像头拍摄的图像传递给显示器显示；所述监控系统中的人机交互设备为：第二工控机、显示器。In order to solve the above-mentioned technical problems, the present invention provides a live working robot operation monitoring system, including a live working robot and a monitoring system; A mechanical arm on a robot platform, a data acquisition system and a data processing and control system; the mechanical arm includes a first mechanical arm, a second mechanical arm and an auxiliary mechanical arm, and the camera includes a binocular camera, a depth camera and a panoramic camera, The first mechanical arm, the second mechanical arm and the auxiliary mechanical arm are all equipped with a binocular camera; the first mechanical arm, the second mechanical arm and the auxiliary mechanical arm are all multi-degree-of-freedom mechanisms. Each joint has a corresponding orthogonal rotary encoder and a servo drive motor, the orthogonal rotary encoder is used to collect the angle data of each joint, and the servo drive motor is used to control the motion of each joint; the data acquisition system includes The camera on the camera is used to collect the operation scene image of the manipulator, and send the operation scene image to the data processing and control system; the data processing and control system generates a 3D virtual operation scene or plans a The space path of the mechanical arm includes the first industrial computer and the second industrial computer; the monitoring objects of the monitoring system are: the first mechanical arm, the second mechanical arm, the auxiliary mechanical arm, the battery and the operation scene; the monitoring system in the The monitoring equipment is: temperature and humidity sensor, pressure sensor, current collector, voltage collector, data acquisition card, panoramic camera, binocular camera, depth camera; the temperature and humidity sensor is placed on the robot platform to collect the temperature and humidity of the working environment; The pressure sensor is installed at the end of each robot arm to collect the contact force between the robot arm and the environment; the voltage collector is connected to the servo drive motor of each joint of the robot arm to collect the current of the servo drive motor; the data acquisition card is used for Each collection data is converted into a format recognized by the data processing and control system; the images captured by the panoramic camera, the binocular camera and the depth camera are transmitted to the display for display; the human-computer interaction equipment in the monitoring system is: the second industrial computer, monitor.
进一步，所述第一工控机将温湿度传感器、压力传感器、电流采集器和电压采集器采集的数据与相应的安全范围值进行比较，如果当前采集的数据在相应的安全范围内，则认为带电机器人作业正常，如果当前采集的数据不在相应的安全范围内，则向第二工控机发送相应的告警信息；第二工控机将相应的告警信息显示在显示器上，操作人员根据显示器显示的告警信息，通过第二工控机做出机械臂动作指令，第二工控机向第一工控机发送机械臂动作指令，第一工控机根据机械臂动作指令控制机械臂动作。Further, the first industrial computer compares the data collected by the temperature and humidity sensor, the pressure sensor, the current collector and the voltage collector with the corresponding safe range value, and if the currently collected data is within the corresponding safe range, it is considered to be charged. The robot is working normally. If the currently collected data is not within the corresponding safety range, it will send corresponding alarm information to the second industrial computer; , the second industrial computer sends a mechanical arm movement instruction to the first industrial computer, and the first industrial computer controls the mechanical arm movement according to the mechanical arm movement instruction.
进一步，所述第一工控机将温湿度传感器、压力传感器、电流采集器和电压采集器采集的数据与相应的安全范围值进行比较，如果当前采集的数据在相应的安全范围内，则认为带电机器人作业正常，如果当前采集的数据不在相应的安全范围内，则向第二工控机发送相应的告警信息；第二工控机将相应的告警信息显示在显示器上，同时，第一工控机根据告警信息类型控制机械臂动作。Further, the first industrial computer compares the data collected by the temperature and humidity sensor, the pressure sensor, the current collector and the voltage collector with the corresponding safe range value, and if the currently collected data is within the corresponding safe range, it is considered to be charged. The robot is working normally. If the currently collected data is not within the corresponding safety range, it will send corresponding alarm information to the second industrial computer; the second industrial computer will display the corresponding alarm information on the display. At the same time, the first industrial computer will The information type controls the movement of the robot arm.
进一步，全景摄像头、双目摄像头、深度摄像头将图像数据发送给第二工控机，第二工控机将图像数据显示在显示器上，操作人员根据显示器显示的图像监控机器人作业过程，当发现异常情况时，操作人员通过第二工控机做出机械臂动作指令，第二工控机向第一工控机发送机械臂动作指令，第一工控机根据机械臂动作指令控制机械臂动作。Further, the panoramic camera, the binocular camera, and the depth camera send the image data to the second industrial computer, and the second industrial computer displays the image data on the display, and the operator monitors the robot's working process according to the image displayed on the display. , the operator makes a mechanical arm movement command through the second industrial computer, the second industrial computer sends the mechanical arm movement command to the first industrial computer, and the first industrial computer controls the mechanical arm movement according to the mechanical arm movement command.
进一步，第二工控机内置图像处理器和带电作业动作序列库，所述带电作业动作序列库中预先存储有各项带电作业对应的动作序列数据；所述摄像机采集的作业场景图像发送给第二工控机，图像处理器对作业场景图像进行处理后获的机械臂与作业对象之间的相对位置关系，第二工控机所述相对位置关系以及具体带电作业所对应的动作序列规划机械臂的空间路径，并将所述机械臂的空间路径数据发送给第一工控机；第一工控机根据所述机械臂的空间路径控制机械臂动作。Further, the second industrial computer has a built-in image processor and a live work action sequence library, and the live work action sequence library pre-stores the action sequence data corresponding to each live work; the operation scene image collected by the camera is sent to the second The industrial computer, the image processor processes the image of the operation scene to obtain the relative positional relationship between the manipulator and the work object, the relative positional relationship described by the second industrial computer, and the action sequence corresponding to the specific live work to plan the space of the manipulator path, and send the spatial path data of the robotic arm to the first industrial computer; the first industrial computer controls the movement of the robotic arm according to the spatial path of the robotic arm.
进一步，所述绝缘斗臂车上设置有控制室，所述第一工控机、第二工控机和显示屏设置在控制室内，控制室内还设置有主操作手，主操作手与机械臂为主从操作关系，通过改变主操作手的姿态控制机械臂运动；所述摄像机采集的作业场景图像发送给第二工控机，图像处理器对作业场景图像进行处理后获的3D虚拟作业场景，并送显示器显示。Further, a control room is provided on the insulated bucket arm vehicle, the first industrial computer, the second industrial computer and the display screen are arranged in the control room, and the main operator is also arranged in the control room, and the main operator and the mechanical arm are mainly From the operational relationship, the movement of the mechanical arm is controlled by changing the posture of the main operator; the operation scene image collected by the camera is sent to the second industrial computer, and the 3D virtual operation scene obtained after the image processor processes the operation scene image is sent to The display shows.
进一步，所述机械臂或者主操作手为六自由度机构，包括基座，旋转轴方向与基座平面垂直的腰关节，与腰关节连接的肩关节，与肩关节连接的大臂，与大臂连接的肘关节，与肘关节连接的小臂，与小臂连接的腕关节，腕关节由三个旋转关节组成，分别为腕俯仰关节、腕摇摆关节和腕旋转关节；所述六自由度机构中各个关节均具有相应的正交旋转编码器和伺服驱动电机，正交旋转编码器用于采集各个关节的角度数据，伺服驱动电机用于控制各关节的运动；第一工控机根据机械臂各关节角度的期望值，通过控制伺服驱动电机控制按机械臂各关节运动。Further, the mechanical arm or the main manipulator is a six-degree-of-freedom mechanism, including a base, a waist joint whose rotation axis direction is perpendicular to the plane of the base, a shoulder joint connected to the waist joint, an arm connected to the shoulder joint, and a large arm connected to the shoulder joint. The elbow joint connected with the arm, the forearm connected with the elbow joint, and the wrist joint connected with the forearm, the wrist joint is composed of three rotation joints, which are respectively wrist pitch joint, wrist swing joint and wrist rotation joint; the six degrees of freedom Each joint in the mechanism has a corresponding orthogonal rotary encoder and servo drive motor, the orthogonal rotary encoder is used to collect the angle data of each joint, and the servo drive motor is used to control the movement of each joint; The expected value of the joint angle is controlled by the servo drive motor to control the movement of each joint of the mechanical arm.
本发明与现有技术相比，其显著优点在于，本发明带电作业机器人的作业监控系统同时采集作业现场视频图像数据、机器人自身数据等监控数据，可从多个角度监控机器人作业；当机器人作业出现故障时，作业监控系统能够根据监控数据发现故障并根据故障采取相应的应急措施，作业人员也可以根据视频及机器人数据提前发现可能出现的故障。Compared with the prior art, the present invention has the remarkable advantage that the live working robot operation monitoring system of the present invention simultaneously collects monitoring data such as the video image data of the operation site and the data of the robot itself, and can monitor the operation of the robot from multiple angles; when the operation of the robot When a fault occurs, the operation monitoring system can find the fault based on the monitoring data and take corresponding emergency measures according to the fault. The operator can also find possible faults in advance based on the video and robot data.
附图说明Description of drawings
图1为本发明带电作业机器人一种实施例的整体结构示意图；Fig. 1 is the overall structure schematic diagram of an embodiment of the live working robot of the present invention;
图2为本发明中绝缘斗臂车的系统组成框图；Fig. 2 is a block diagram of the system composition of the insulating bucket arm car in the present invention;
图3为本发明中机器人平台的结构示意图；Fig. 3 is the structural representation of robot platform among the present invention;
图4为本发明中机械臂的结构示意图；Fig. 4 is the structural representation of mechanical arm among the present invention;
图5是带电作业机器人作业监控系统组成示意图。Fig. 5 is a schematic diagram of the composition of the live working robot operation monitoring system.
图中，1为绝缘斗臂车、2为控制室、3为伸缩臂、4为机器人平台，46为绝缘子、43为第一机械臂、44为第二机械臂、42为辅助机械臂、48为第一工控机、45为双目摄像头、41为全景摄像头、410为深度摄像头、49为蓄电池、47为专用工具箱，431为基座、432为腰关节、433为肩关节、434为大臂、435为肘关节、436为小臂、437为腕关节。In the figure, 1 is the insulated arm truck, 2 is the control room, 3 is the telescopic arm, 4 is the robot platform, 46 is the insulator, 43 is the first mechanical arm, 44 is the second mechanical arm, 42 is the auxiliary mechanical arm, 48 45 is a binocular camera, 41 is a panoramic camera, 410 is a depth camera, 49 is a storage battery, 47 is a special tool box, 431 is a base, 432 is a waist joint, 433 is a shoulder joint, 434 is a large Arm, 435 is the elbow joint, 436 is the forearm, 437 is the wrist joint.
具体实施方式detailed description
容易理解，依据本发明的技术方案，在不变更本发明的实质精神的情况下，本领域的一般技术人员可以想象出本发明带电作业机器人作业监控系统的多种实施方式。因此，以下具体实施方式和附图仅是对本发明的技术方案的示例性说明，而不应当视为本发明的全部或者视为对本发明技术方案的限制或限定。It is easy to understand that, according to the technical solution of the present invention, without changing the spirit of the present invention, those skilled in the art can imagine various implementations of the live working robot operation monitoring system of the present invention. Therefore, the following specific embodiments and drawings are only exemplary descriptions of the technical solution of the present invention, and should not be regarded as the entirety of the present invention or as a limitation or limitation on the technical solution of the present invention.
结合附图，监控系统所应用的带电作业机器人包括绝缘斗臂车1、控制室2、伸缩臂3、机器人平台4。其中，绝缘斗臂车1上架设控制室2和伸缩臂3，伸缩臂3末端连接机器人平台4，机器人平台4与控制室2之间采用光纤以太网通信或者无线网络通信。With reference to the accompanying drawings, the live working robot used in the monitoring system includes an insulated bucket truck 1 , a control room 2 , a telescopic arm 3 , and a robot platform 4 . Among them, the control room 2 and the telescopic arm 3 are erected on the insulated bucket truck 1, and the end of the telescopic arm 3 is connected to the robot platform 4, and the fiber optic Ethernet communication or wireless network communication is used between the robot platform 4 and the control room 2.
绝缘斗臂车1可供操作人员驾驶，从而将机器人平台4运输到作业现场。绝缘斗臂车1上装有支撑腿，支撑腿可以展开，从而将绝缘斗臂车1与地面稳固支撑。绝缘斗臂车1上装有发电机，从而给控制室2及伸缩臂3供电。The insulated arm truck 1 can be driven by an operator to transport the robot platform 4 to the job site. The insulating bucket truck 1 is equipped with supporting legs, and the supporting legs can be unfolded, so as to firmly support the insulating bucket truck 1 and the ground. A generator is installed on the insulated arm truck 1 to supply power to the control room 2 and the telescopic arm 3 .
伸缩臂3设有沿伸缩方向的驱动装置，操作人员可以通过控制驱动装置，从而将机器人平台4升降到作业高度。该伸缩臂3由绝缘材料制成，用于实现机器人平台4与控制室2的绝缘。在本发明中，伸缩臂3可有由剪叉式升降机构或其他机构代替。The telescopic arm 3 is provided with a driving device along the telescopic direction, and the operator can control the driving device to lift the robot platform 4 to the working height. The telescopic arm 3 is made of insulating material, and is used to realize the insulation between the robot platform 4 and the control room 2 . In the present invention, the telescopic arm 3 can be replaced by a scissor lift mechanism or other mechanisms.
控制室2中设置有第二工控机、显示屏、第一主操作手、第二主操作手、辅助主操作手以及通信模块等。The control room 2 is provided with a second industrial computer, a display screen, a first main operator, a second main operator, an auxiliary main operator, a communication module, and the like.
机器人平台4包括绝缘子46、第一机械臂43、第二机械臂44、辅助机械臂42、第一工控机48、双目摄像头45、全景摄像头41、深度摄像头410、蓄电池49、专用工具箱47、通信模块。The robot platform 4 comprises an insulator 46, a first mechanical arm 43, a second mechanical arm 44, an auxiliary mechanical arm 42, a first industrial computer 48, a binocular camera 45, a panoramic camera 41, a depth camera 410, a storage battery 49, and a special toolbox 47 , Communication module.
机器人平台4的绝缘子46用于支撑第一机械臂43、第二机械臂44、辅助机械臂42，将这三个机械臂的外壳与机器人平台4绝缘。The insulator 46 of the robot platform 4 is used to support the first robot arm 43 , the second robot arm 44 , and the auxiliary robot arm 42 , and insulate the shells of these three robot arms from the robot platform 4 .
蓄电池49为第一工控机48、第一机械臂43、第二机械臂44、辅助机械臂42、全景摄像头41、双目摄像头45、深度摄像头410、通信模块供电。The battery 49 supplies power for the first industrial computer 48, the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, the panoramic camera 41, the binocular camera 45, the depth camera 410, and the communication module.
作为一种实施方式，双目摄像头45一共有三个，分别安装在第一机械臂43、第二机械臂44和辅助机械臂42的腕关节437上，负责采集作业场景的图像数据，并将图像数据发送给第二工控机。双目摄像头45由两个光轴平行的工业相机组成，平行光轴之间的距离固定。As an implementation, there are three binocular cameras 45, which are respectively installed on the wrist joints 437 of the first mechanical arm 43, the second mechanical arm 44, and the auxiliary mechanical arm 42, responsible for collecting image data of the operation scene, and The image data is sent to the second industrial computer. The binocular camera 45 is made up of two industrial cameras whose optical axes are parallel, and the distance between the parallel optical axes is fixed.
深度摄像头410安装在机器人平台4正对作业场景的侧面，负责采集作业场景的景深数据，将景深数据发送给第二工控机。The depth camera 410 is installed on the side of the robot platform 4 facing the operation scene, and is responsible for collecting the depth of field data of the operation scene, and sending the depth of field data to the second industrial computer.
全景摄像头41通过支架安装在机器人平台4的上方，负责采集作业场景的全景图像数据，将图像数据发送给第二工控机，并显示在显示器上，作业人员可以通过全景图像监控作业场景。The panoramic camera 41 is installed on the top of the robot platform 4 through a bracket, and is responsible for collecting the panoramic image data of the operation scene, sending the image data to the second industrial computer, and displaying it on the display, so that the operator can monitor the operation scene through the panoramic image.
专用工具箱47是放置抓具、扳手等作业工具的场所。机械臂末端安装有工具快换装置。机械臂根据作业任务的类型到专用工具箱47中使用工具快换装置获取作业工具。The special tool box 47 is a place where working tools such as grippers and wrenches are placed. A tool quick change device is installed at the end of the robotic arm. The mechanical arm goes to the special tool box 47 according to the type of the job task and uses the tool quick change device to obtain the job tool.
控制室2中第一主操作手、第二主操作手以及辅助主操作手是一种用于人工远程操作机械臂的操作装置，他们与第一机械臂43、第二机械臂44和辅助机械臂42构成主从操作关系。机械臂和主操作手具有相同的结构，只是主操作手尺寸规格比机械臂小，以便于操作人员操作。机械臂和主操作手拥有六个关节，每个关节都有光电编码器采集角度数据，各主操作手的微型控制器通过串口将六个关节的角度数据发送给第二工控机。The first main operator, the second main operator and the auxiliary main operator in the control room 2 are operating devices for manual remote operation of the mechanical arm, and they are connected with the first mechanical arm 43, the second mechanical arm 44 and the auxiliary mechanical The arm 42 constitutes a master-slave operating relationship. The mechanical arm and the main operator have the same structure, but the size of the main operator is smaller than that of the mechanical arm to facilitate the operation of the operator. The mechanical arm and the main operator have six joints, and each joint has a photoelectric encoder to collect angle data, and the micro-controller of each main operator sends the angle data of the six joints to the second industrial computer through the serial port.
作为一种实施方式，所述机械臂为六自由度机构，包括基座431，旋转轴方向与基座平面垂直的腰关节432，与腰关节432连接的肩关节433，与肩关节433连接的大臂434，与大臂434连接的肘关节435，与肘关节435连接的小臂436，与小臂436连接的腕关节437，腕关节437由三个旋转关节组成，分别为腕俯仰关节、腕摇摆关节和腕旋转关节；所述六自由度机构中各个关节均具有相应的正交旋转编码器31和伺服驱动电机，正交旋转编码器31用于采集各个关节的角度数据，伺服驱动电机用于控制各关节的运动；第一工控机根据所述机械臂的空间路径解算出各关节的运动角度，控制伺服驱动电机按照所述运动角度控制机械臂各关节运动。As an implementation, the mechanical arm is a six-degree-of-freedom mechanism, including a base 431, a waist joint 432 whose rotation axis direction is perpendicular to the plane of the base, a shoulder joint 433 connected to the waist joint 432, and a shoulder joint 433 connected to the shoulder joint 433. The big arm 434, the elbow joint 435 connected with the big arm 434, the small arm 436 connected with the elbow joint 435, and the wrist joint 437 connected with the small arm 436, the wrist joint 437 is composed of three rotation joints, which are wrist pitch joint, Wrist swing joints and wrist rotation joints; each joint in the six-degree-of-freedom mechanism has a corresponding orthogonal rotary encoder 31 and a servo drive motor, the orthogonal rotary encoder 31 is used to collect the angle data of each joint, and the servo drive motor It is used to control the movement of each joint; the first industrial computer calculates the movement angle of each joint according to the space path of the manipulator, and controls the servo drive motor to control the movement of each joint of the manipulator according to the movement angle.
作为一种实施方式，机器人平台4与控制室2之间的数据传输通过光纤有线传输，或者使用无线网络传输。机器人平台4上的通信模块是光纤收发器，光纤收发器用于实现光纤中的光信号与双绞线中的电信号的相互转换，从而在通信上实现机器人平台4与控制室2的电气隔离。控制室2中的通信模块是光纤收发器，光纤收发器用于实现光纤中的光信号与双绞线中的电信号的相互转换，从而在通信上实现机器人平台4与控制室2的电气隔离。As an implementation manner, the data transmission between the robot platform 4 and the control room 2 is transmitted through optical fiber cable, or through wireless network transmission. The communication module on the robot platform 4 is a fiber optic transceiver. The fiber optic transceiver is used to realize the mutual conversion between the optical signal in the fiber and the electrical signal in the twisted pair, so as to realize the electrical isolation between the robot platform 4 and the control room 2 in communication. The communication module in the control room 2 is a fiber optic transceiver. The fiber optic transceiver is used to realize the mutual conversion between the optical signal in the fiber and the electrical signal in the twisted pair, so as to realize the electrical isolation between the robot platform 4 and the control room 2 in terms of communication.
作为一种实施方式，第二工控机可以完成以下任务：As an implementation manner, the second industrial computer can complete the following tasks:
建立动作序列库。预先将各项带电作业任务分解为作用序列，组成动作序列库，存储在第二工控机中，用于机械臂路径规划。Build an action sequence library. Each live work task is decomposed into action sequences in advance to form an action sequence library, which is stored in the second industrial computer and used for path planning of the manipulator.
建立作业对象模型库。预先制作各项带电作业任务所涉及的作业对象的三维模型和目标识别模型，例如，根据电力塔杆、电线、耐张绝缘子、隔离刀闸、避雷器等器件实物，制作三维模型和目标识别模型，用于带电作业机器人自动识别作业对象，构建作业场景三维虚拟场景。Build a job object model library. Prepare in advance the 3D model and target recognition model of the work objects involved in various live work tasks, for example, make the 3D model and target recognition model based on the actual devices such as power towers, wires, tension insulators, isolation switches, and lightning arresters. It is used for live working robots to automatically identify work objects and construct a three-dimensional virtual scene of the work scene.
建立机械臂和专用工具模型库。预先制作机械臂和专用工具的三维模型和目标识别模型，例如，扳手等，用于带电作业机器人自动构建作业场景三维虚拟场景，规划机械臂空间路径。Build libraries of robotic arms and specialized tooling models. Prefabricate the 3D model and target recognition model of the manipulator and special tools, such as wrench, etc., for the live working robot to automatically construct the 3D virtual scene of the work scene, and plan the space path of the manipulator.
获取图像数据。获取全景图像、深度图像和双目图像的数据信息。Get image data. Obtain the data information of panoramic image, depth image and binocular image.
根据图像数据识别和跟踪作业目标。Identify and track job targets based on image data.
获取主操作手的角度、角速度和角加速度数据，获取机械臂的角度、角速度和角加速度数据。Obtain the angle, angular velocity and angular acceleration data of the main operator, and obtain the angle, angular velocity and angular acceleration data of the mechanical arm.
对相关图像数据进行处理和计算，获取机械臂位置，获取作业对象的位置，获取机械臂与作业对象之间的相对位置，并根据相对位置和作业任务规划机械臂的空间路径。Process and calculate the relevant image data, obtain the position of the manipulator, obtain the position of the work object, obtain the relative position between the manipulator and the work object, and plan the space path of the manipulator according to the relative position and the work task.
根据图像数据构建作业对象三维场景，根据机械臂角度信息和作业对象三维场景获得机械臂与作业对象的相对位置，并根据相对位置和作业任务规划机械臂的空间路径。The three-dimensional scene of the work object is constructed according to the image data, the relative position of the manipulator and the work object is obtained according to the angle information of the manipulator and the three-dimensional scene of the work object, and the spatial path of the manipulator is planned according to the relative position and the work task.
对相关图像数据进行处理和计算，构建3D虚拟作业场景，送显示器显示，操作人员根据3D虚拟作业场景监控作业过程。与全景图像相比，3D虚拟作业场景综合和深度图像信息和双目图像信息，对机器臂与作业对象之间、机械臂之间、作业对象与作业环境之间的相对位置的判断更精确，且不会存在视觉死角。因此，操作人员通过3D虚拟作业场景进行作业监控，操作精度更高，可以防止碰撞发生，提高了安全性。同时，3D虚拟作业场景显示在控制室2中的显示器上，远离机械臂作业现场，提高了人作业人员的人身安全。Process and calculate the relevant image data, build a 3D virtual operation scene, send it to the monitor for display, and the operator monitors the operation process according to the 3D virtual operation scene. Compared with the panoramic image, the 3D virtual operation scene integrates the depth image information and the binocular image information, and the judgment of the relative position between the robot arm and the operation object, between the robot arms, and between the operation object and the operation environment is more accurate. And there will be no visual dead ends. Therefore, the operator monitors the operation through the 3D virtual operation scene, the operation accuracy is higher, the collision can be prevented, and the safety is improved. At the same time, the 3D virtual operation scene is displayed on the monitor in the control room 2, away from the operation site of the mechanical arm, which improves the personal safety of human operators.
作为一种实施方式，第一工控机可以完成以下任务：As an implementation, the first industrial computer can complete the following tasks:
根据第二工控机发送的主操作手各关节的角度信息，控制机械臂各关节的运动。According to the angle information of each joint of the main manipulator sent by the second industrial computer, the movement of each joint of the mechanical arm is controlled.
获取第二工控机发送的机械臂的空间路径数据，根据作业任务的动作序列，解算出机械臂各关节的角度数据运动量，并控制机械臂各关节运动。Obtain the spatial path data of the robotic arm sent by the second industrial computer, and calculate the angular data motion of each joint of the robotic arm according to the action sequence of the job task, and control the movement of each joint of the robotic arm.
本发明中，第一机械臂和第二机械臂相互配合，可以模仿人的两个手的作业顺序完成带电作业。考虑到灵活性，可以再增加一个强壮的辅助机械臂，此时，辅助机械臂专司器件夹持等力道大的动作，第一机械臂和第二机械臂则进行相关业务操作。In the present invention, the first mechanical arm and the second mechanical arm cooperate with each other to complete live work by imitating the operation sequence of two hands of a person. Considering the flexibility, a strong auxiliary manipulator can be added. At this time, the auxiliary manipulator is responsible for powerful actions such as device clamping, while the first manipulator and the second manipulator perform related business operations.
根据第二工控机和第一工控机完成的不同任务的组合，本发明带电作业机器人既可以由作业人员进行远程摇操作以完成带电作业，又可以进行自主带电作业。在进行带电作业之前，作业人员先通过观察全景图像，将机器人平台4移动至作业对象附近。According to the combination of different tasks completed by the second industrial computer and the first industrial computer, the live working robot of the present invention can not only be operated remotely by operators to complete live work, but also can perform live work autonomously. Before carrying out live work, the operator first moves the robot platform 4 to the vicinity of the work object by observing the panoramic image.
如果选择人工远程摇操作，则由第二工控机根据数目图像和深度图像构建3D虚拟作业场景并送显示器显示，作业人员通过3D虚拟作业场景监控操作过程，通过主操作手控制机械臂的动作，以完成带电作业。在此过程中，作业人员改变主操作手姿态后，主操作手中各关节的光电编码器采集各关节角度，各主操作手的微型控制器通过串口将各关节的角度数据发送给第二工控机。第二工控机将主操作手各关节的角度数据作为机械臂各关节角度的期望值发送给第一工控机，第一工控机根据角度期望值通过伺服电机控制机械臂各关节的运动，已完成带电作业。If manual remote operation is selected, the second industrial computer constructs a 3D virtual operation scene based on the number image and depth image and sends it to the monitor for display. The operator monitors the operation process through the 3D virtual operation scene, and controls the movement of the mechanical arm through the main operator. To complete live work. In this process, after the operator changes the posture of the main operator, the photoelectric encoders of each joint in the main operator collect the angles of each joint, and the micro-controllers of each main operator send the angle data of each joint to the second industrial computer through the serial port . The second industrial computer sends the angle data of each joint of the main operator as the expected value of each joint angle of the mechanical arm to the first industrial computer, and the first industrial computer controls the movement of each joint of the mechanical arm through a servo motor according to the expected angle value, and the live work has been completed .
如果选择自主作业，则由第二工控机根据数目图像和深度图像计算获取作业对象和机械臂之间的相对位置关系，然后依据作业任务所对应的动作序列进行机械臂空间路径规划，并将空间路径发送给第一工控机，第一工控机解算出机械臂各关节需要转动的角度数据作为机械臂各关节角度的期望值，通过伺服电机控制机械臂各关节的运动，已完成带电作业。If you choose to work autonomously, the second industrial computer calculates and obtains the relative positional relationship between the work object and the manipulator based on the number image and the depth image, and then plans the space path of the manipulator according to the action sequence corresponding to the work task, and divides the space The path is sent to the first industrial computer, and the first industrial computer calculates the angle data that each joint of the mechanical arm needs to rotate as the expected value of the angle of each joint of the mechanical arm. The movement of each joint of the mechanical arm is controlled by a servo motor, and the live work has been completed.
在本发明中，被监控对象包括：第一机械臂43、第二机械臂44、辅助机械臂42、和蓄电池；In the present invention, the monitored objects include: the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, and the storage battery;
在本发明中，监控数据获取设备包括：温湿度传感器、压力传感器、电流采集器、电压采集器、全景摄像头41、双目摄像头45、深度摄像头410、数据采集卡；In the present invention, the monitoring data acquisition device includes: a temperature and humidity sensor, a pressure sensor, a current collector, a voltage collector, a panoramic camera 41, a binocular camera 45, a depth camera 410, and a data acquisition card;
在本发明中，监控数据收集设备包括：第一工控机；In the present invention, the monitoring data collection equipment includes: a first industrial computer;
人机交互设备包括：第二工控机、显示器。Human-computer interaction equipment includes: a second industrial computer and a display.
温湿度传感器安装在机器人平台4上，用于采集作业环境的温度和湿度。The temperature and humidity sensor is installed on the robot platform 4 and is used to collect the temperature and humidity of the working environment.
压力传感器安装在第一机械臂43、第二机械臂44和辅助机械臂42的腕关节437末端，用于采集机械臂与环境的接触力。The pressure sensors are installed at the ends of the wrist joints 437 of the first robotic arm 43 , the second robotic arm 44 and the auxiliary robotic arm 42 for collecting contact forces between the robotic arms and the environment.
电流采集器与第一机械臂43、第二机械臂44和辅助机械臂42的每个关节的伺服驱动电机相连，用于采集驱动电机的电流的大小。The current collector is connected to the servo drive motors of each joint of the first mechanical arm 43 , the second mechanical arm 44 and the auxiliary mechanical arm 42 , and is used to collect the current of the drive motors.
电压采集器与蓄电池的正负极连接，用于采集蓄电池的电压的大小。The voltage collector is connected with the positive and negative poles of the storage battery, and is used for collecting the voltage of the storage battery.
数据采集卡安装在第一工控机48上，用于获取温湿度传感器、压力传感器、电流采集器以及电压采集器采集的采集数据，并将这些数据转换成计算机容易处理的数据格式。The data acquisition card is installed on the first industrial computer 48, and is used to obtain the collected data collected by the temperature and humidity sensors, pressure sensors, current collectors and voltage collectors, and convert these data into a data format that can be easily processed by a computer.
第一工控机将各个传感器的数据与其安全范围的数据相比较，如果当前采集到某一传感器的数据在安全范围内，则不处理，如果当前采集到某一传感器的数据在安全范围外，则将对应数据的错误指令发送到第二工控机。The first industrial computer compares the data of each sensor with the data in the safe range. If the data currently collected by a certain sensor is within the safe range, it will not process it. If the data currently collected by a certain sensor is outside the safe range, then Send the error command corresponding to the data to the second industrial computer.
具体故障分类及措施：Specific fault classification and measures:
环境温度过低：第一工控机48获取温湿度传感器采集的温度数据，将该温度数据的值与存储在第一工控机48内的温度数据的安全范围的值的大小进行比较，若该温度数据的值小于安全范围的值，则发生环境温度过低故障。第一工控机48将环境温度过低的故障指令发送给第二工控机，第二工控机将环境温度过低的故障信息显示在显示屏上。操作人员输入全平台停止工作指令，第二工控机将该指令发送给第一工控机48，第一工控机48依次控制第一机械臂43、第二机械臂44、辅助机械臂42、全景摄像头41、双目摄像头45、深度摄像头410关闭。The ambient temperature is too low: the first industrial computer 48 obtains the temperature data collected by the temperature and humidity sensor, compares the value of the temperature data with the value of the safe range of the temperature data stored in the first industrial computer 48, if the temperature If the value of the data is less than the value in the safe range, a low ambient temperature fault occurs. The first industrial computer 48 sends the failure command of too low ambient temperature to the second industrial computer, and the second industrial computer displays the failure information of too low ambient temperature on the display screen. The operator inputs an instruction to stop working on the entire platform, and the second industrial computer sends the instruction to the first industrial computer 48, and the first industrial computer 48 sequentially controls the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, and the panoramic camera. 41. The binocular camera 45 and the depth camera 410 are turned off.
环境温度过高：第一工控机48获取温湿度传感器采集的温度数据，将该温度数据的值与存储在第一工控机48内的温度数据的安全范围的值的大小进行比较，若该温度数据的值大于安全范围的值，则发生环境温度过高故障。第一工控机48将环境温度过高的故障指令发送给第二工控机，第二工控机将环境温度过高的故障信息显示在显示屏上。操作人员输入全平台停止工作指令，第二工控机将该指令发送给第一工控机48，第一工控机48依次控制第一机械臂43、第二机械臂44、辅助机械臂42、全景摄像头41、双目摄像头45、深度摄像头410关闭。The ambient temperature is too high: the first industrial computer 48 obtains the temperature data collected by the temperature and humidity sensor, compares the value of the temperature data with the value of the safe range of the temperature data stored in the first industrial computer 48, if the temperature If the value of the data is greater than the value in the safe range, the ambient temperature is too high fault occurs. The first industrial computer 48 sends the fault command of high ambient temperature to the second industrial computer, and the second industrial computer displays the fault information of high ambient temperature on the display screen. The operator inputs an instruction to stop working on the entire platform, and the second industrial computer sends the instruction to the first industrial computer 48, and the first industrial computer 48 sequentially controls the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, and the panoramic camera. 41. The binocular camera 45 and the depth camera 410 are turned off.
环境湿度过高：第一工控机48获取温湿度传感器采集的湿度数据，将该湿度数据的值与存储在第一工控机48内的湿度数据的安全范围的值的大小进行比较，若该湿度数据的值大于安全范围的值，则发生环境湿度过高故障。第一工控机48将环境湿度过高的故障指令发送给第二工控机，第二工控机将环境湿度过高的故障信息显示在显示屏上。操作人员输入全平台停止工作指令，第二工控机将该指令发送给第一工控机48，第一工控机48依次控制第一机械臂43、第二机械臂44、辅助机械臂42、全景摄像头41、双目摄像头45、深度摄像头410关闭。The ambient humidity is too high: the first industrial computer 48 obtains the humidity data collected by the temperature and humidity sensor, compares the value of the humidity data with the value of the safe range of the humidity data stored in the first industrial computer 48, if the humidity If the value of the data is greater than the value in the safe range, the fault of high ambient humidity will occur. The first industrial computer 48 sends the fault instruction of high ambient humidity to the second industrial computer, and the second industrial computer displays the fault information of high ambient humidity on the display screen. The operator inputs an instruction to stop working on the entire platform, and the second industrial computer sends the instruction to the first industrial computer 48, and the first industrial computer 48 sequentially controls the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, and the panoramic camera. 41. The binocular camera 45 and the depth camera 410 are turned off.
机械臂接触压力过大：第一工控机48获取压力传感器采集的压力数据，将该压力数据的值与存储在第一工控机48内的压力数据的安全范围的值的大小进行比较，若该压力数据的值大于安全范围的值，则发生机械臂接触压力过大故障。第一工控机48将机械臂接触压力过大的故障指令发送给第二工控机，第二工控机将机械臂接触压力过大的故障信息显示在显示屏上。操作人员输入机械臂停止工作指令，若第二工控机处于自主工作模式，第二工控机将退出自主工作模式并将机械臂停止工作指令发送给第一工控机48，第一工控机48控制第一机械臂43、第二机械臂44、辅助机械臂42停止工作。The contact pressure of the mechanical arm is too large: the first industrial computer 48 obtains the pressure data collected by the pressure sensor, compares the value of the pressure data with the value of the safe range of the pressure data stored in the first industrial computer 48, if the If the value of the pressure data is greater than the value in the safe range, the fault of excessive contact pressure of the mechanical arm will occur. The first industrial computer 48 sends the fault instruction of excessive contact pressure of the mechanical arm to the second industrial computer, and the second industrial computer displays the fault information of excessive contact pressure of the mechanical arm on the display screen. The operator inputs the command to stop the mechanical arm. If the second industrial computer is in the autonomous operation mode, the second industrial computer will exit the autonomous operation mode and send the instruction to stop the mechanical arm to the first industrial computer 48, and the first industrial computer 48 controls the first industrial computer 48. A mechanical arm 43, a second mechanical arm 44, and an auxiliary mechanical arm 42 stop working.
机械臂负载过大：第一工控机48获取电流采集器采集的电流数据，将该电流数据的值与存储在第一工控机48内的电流数据的安全范围的值的大小进行比较，若该电流数据的值大于安全范围的值，则发生机械臂负载过大故障。第一工控机48将机械臂负载过大的故障指令发送给第二工控机，第二工控机将机械臂负载过大的故障信息显示在显示屏上。操作人员输入机械臂停止工作指令，若第二工控机处于自主工作模式，第二工控机将退出自主工作模式并将机械臂停止工作指令发送给第一工控机48，第一工控机48控制第一机械臂43、第二机械臂44、辅助机械臂42停止工作。The load of the mechanical arm is too large: the first industrial computer 48 obtains the current data collected by the current collector, and compares the value of the current data with the value of the safe range of the current data stored in the first industrial computer 48, if the If the value of the current data is greater than the value in the safe range, the fault of excessive loading of the mechanical arm will occur. The first industrial computer 48 sends a fault instruction indicating that the load of the mechanical arm is too large to the second industrial computer, and the second industrial computer displays the fault information that the load of the mechanical arm is too large on the display screen. The operator inputs the command to stop the mechanical arm. If the second industrial computer is in the autonomous operation mode, the second industrial computer will exit the autonomous operation mode and send the instruction to stop the mechanical arm to the first industrial computer 48, and the first industrial computer 48 controls the first industrial computer 48. A mechanical arm 43, a second mechanical arm 44, and an auxiliary mechanical arm 42 stop working.
蓄电池欠压：第一工控机48获取电压采集器采集的电压数据，将该电压数据的值与存储在第一工控机48内的电压数据的安全范围的值的大小进行比较，若该电压数据的值小于安全范围的值，则发生蓄电池欠压故障。第一工控机48将蓄电池欠压的故障指令发送给第二工控机，第二工控机将蓄电池欠压的故障信息显示在显示屏上。操作人员输入全平台停止工作指令，第二工控机将该指令发送给第一工控机48，第一工控机48依次控制第一机械臂43、第二机械臂44、辅助机械臂42、全景摄像头41、双目摄像头45、深度摄像头410关闭。操作人员为蓄电池充电。该监控系统的工作过程分为自动检测监控和人工远程监控两个部分。Battery undervoltage: the first industrial computer 48 obtains the voltage data collected by the voltage collector, compares the value of the voltage data with the value of the safe range of the voltage data stored in the first industrial computer 48, if the voltage data If the value is less than the value in the safe range, the battery undervoltage fault occurs. The first industrial computer 48 sends the battery undervoltage fault command to the second industrial computer, and the second industrial computer displays the battery undervoltage fault information on the display screen. The operator inputs an instruction to stop working on the entire platform, and the second industrial computer sends the instruction to the first industrial computer 48, and the first industrial computer 48 sequentially controls the first mechanical arm 43, the second mechanical arm 44, the auxiliary mechanical arm 42, and the panoramic camera. 41. The binocular camera 45 and the depth camera 410 are turned off. The operator charges the battery. The working process of the monitoring system is divided into two parts: automatic detection monitoring and manual remote monitoring.
自动检测监控按照以下步骤进行：Auto-detection monitoring proceeds in the following steps:
步骤1，数据采集卡采集温湿度传感器、压力传感器、电流采集器、电压采集器测量得到的数据；Step 1, the data acquisition card collects the data measured by the temperature and humidity sensors, pressure sensors, current collectors, and voltage collectors;
步骤2，根据湿度传感器、压力传感器、电流采集器、电压采集器各自的标定数据表，第一工控机48将步骤1采集得到的数据转换成便于人类识别的数据；Step 2, according to the respective calibration data tables of the humidity sensor, pressure sensor, current collector, and voltage collector, the first industrial computer 48 converts the data collected in step 1 into data that is easy for human identification;
步骤3，第一工控机48将步骤2得到的数据与安全范围数据表对比，如果步骤2得到的数据超出安全数据表范围，第一工控机48将超出安全数据表范围的数据的错误指令发送给第二工控机；Step 3, the first industrial computer 48 compares the data obtained in step 2 with the safety range data table, if the data obtained in step 2 exceeds the range of the safety data table, the first industrial computer 48 sends an error instruction for data exceeding the range of the safety data table to the second industrial computer;
步骤4，第二工控机接收错误指令，将错误指令显示在显示屏上；Step 4, the second industrial computer receives the error command and displays the error command on the display screen;
步骤5，操作人员根据错误指令决定是否需要输入紧急停止指令。Step 5, the operator decides whether to input an emergency stop command according to the wrong command.
人工远程监控按照以下步骤进行：Manual remote monitoring is carried out according to the following steps:
步骤1，全景摄像头41、双目摄像头45、深度摄像头410将图像数据发送给第二工控机；Step 1, the panoramic camera 41, the binocular camera 45, and the depth camera 410 send the image data to the second industrial computer;
步骤2，第二工控机将步骤1中的图像数据显示在显示屏上。Step 2, the second industrial computer displays the image data in step 1 on the display screen.
步骤3，操作人员根据显示的图像监控机器人作业过程，发现其中可能出现的故障，决定是否需要输入紧急停止指令。Step 3, the operator monitors the robot's working process according to the displayed image, finds possible faults, and decides whether to input an emergency stop command.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201621355728.7UCN206623081U (en) | 2016-12-09 | 2016-12-09 | A kind of hot line robot operation monitoring system |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201621355728.7UCN206623081U (en) | 2016-12-09 | 2016-12-09 | A kind of hot line robot operation monitoring system |
| Publication Number | Publication Date |
|---|---|
| CN206623081Utrue CN206623081U (en) | 2017-11-10 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201621355728.7UActiveCN206623081U (en) | 2016-12-09 | 2016-12-09 | A kind of hot line robot operation monitoring system |
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| CN (1) | CN206623081U (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106737548A (en)* | 2016-12-09 | 2017-05-31 | 南京理工大学 | A kind of hot line robot operation monitoring system |
| CN110554650A (en)* | 2019-09-18 | 2019-12-10 | 创泽智能机器人股份有限公司 | Remote online monitoring robot system |
| CN111452029A (en)* | 2020-04-14 | 2020-07-28 | 山东乐普韦尔自动化技术有限公司 | Live working robot control system and live working robot |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106737548A (en)* | 2016-12-09 | 2017-05-31 | 南京理工大学 | A kind of hot line robot operation monitoring system |
| CN110554650A (en)* | 2019-09-18 | 2019-12-10 | 创泽智能机器人股份有限公司 | Remote online monitoring robot system |
| CN111452029A (en)* | 2020-04-14 | 2020-07-28 | 山东乐普韦尔自动化技术有限公司 | Live working robot control system and live working robot |
| CN111452029B (en)* | 2020-04-14 | 2023-12-29 | 山东乐普韦尔自动化技术有限公司 | Live working robot control system and live working robot |
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