CN114734438A

CN114734438A - Fault diagnosis method and system for robot joint

Info

Publication number: CN114734438A
Application number: CN202210350847.7A
Authority: CN
Inventors: 岳克双; 杨跞; 许楠; 陈宏伟; 程小猛
Original assignee: Siasun Co Ltd
Current assignee: Siasun Co Ltd
Priority date: 2022-04-02
Filing date: 2022-04-02
Publication date: 2022-07-12

Abstract

The embodiment of the invention discloses a fault diagnosis method and a fault diagnosis system for a robot joint, wherein the robot joint is controlled by a driver to work, and the fault diagnosis method comprises the following steps: acquiring first parameter information of a robot joint and second parameter information of a driver; performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result; and carrying out fault early warning according to the first diagnosis result. The technical scheme provided by the embodiment of the invention aims to solve the technical problem that the fault diagnosis function of the existing robot joint is poor in reliability and safety.

Description

Fault diagnosis method and system for robot joint

Technical Field

The embodiment of the invention relates to the technical field of robot control, in particular to a method and a system for diagnosing faults of a robot joint.

Background

The robot has wider and wider application field, and the perfection of the fault diagnosis function of the robot joint is particularly important due to the perfect safety control function of the robot. Once a sensor, a motor or other control components in the robot joint have faults, if the faults cannot be found in time, great potential safety hazards exist, the robot joint cannot work normally, the production efficiency is reduced, and serious safety accidents can be caused.

Therefore, the reliability and the safety of the fault diagnosis function of the existing robot joint are poor, and the use experience of the robot is greatly reduced.

Disclosure of Invention

In view of this, embodiments of the present invention provide a method and a system for diagnosing a fault of a robot joint, so as to solve the technical problem that the reliability and the safety of a fault diagnosis function of an existing robot joint are poor.

In a first aspect, an embodiment of the present invention provides a method for diagnosing a fault of a robot joint, where the robot joint is controlled by a driver to operate, and the method includes:

acquiring first parameter information of the robot joint and second parameter information of a driver;

performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result;

and performing fault early warning according to the first diagnosis result.

In a second aspect, an embodiment of the present invention provides a system for diagnosing a fault of a robot joint, including a driver electrically connected to the robot joint, the driver being configured to perform the method for diagnosing a fault according to any one of the first aspect, the driver including:

the data acquisition module is used for acquiring first parameter information of the robot joint and second parameter information of the driver;

the first fault diagnosis module is used for carrying out online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information and determining a first diagnosis result;

and the fault warning module is used for carrying out fault warning according to the first diagnosis result.

In the embodiment of the invention, by acquiring the first parameter information of the robot joint and the second parameter information of the driver, closed-loop control can be performed according to the first parameter information and the second parameter information so as to drive the robot joint to work. And then performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information to detect whether the robot joint and the driver have faults in real time, determining a first diagnosis result when the faults are determined, and performing fault early warning according to the first diagnosis result to perform timely fault reminding. Therefore, safety accidents caused by faults of the robot joint and the driver in the working state can be avoided, the safety and the reliability of the robot joint and the driver are improved, good user experience is obtained, and the product competitiveness is improved.

Drawings

Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments made with reference to the following drawings:

fig. 1 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 2 is a schematic structural diagram of a robot joint according to an embodiment of the present invention;

fig. 3 is a flowchart of another method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 4 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 5 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 6 is a flowchart of a fault diagnosis method for a robot joint according to another embodiment of the present invention;

fig. 7 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 8 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 9 is a flowchart of a specific method for diagnosing a fault of a robot joint according to an embodiment of the present invention;

fig. 10 is a schematic structural diagram of a fault diagnosis system for a robot joint according to an embodiment of the present invention;

fig. 11 is a schematic structural diagram of another fault diagnosis system for a robot joint according to an embodiment of the present invention.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention clearer, the technical solutions of the present invention will be fully described by the detailed description with reference to the accompanying drawings in the embodiments of the present invention. It is obvious that the described embodiments are a part of the embodiments of the present invention, not all embodiments, and all other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without inventive efforts fall within the scope of the present invention.

Fig. 1 is a flowchart of a method for diagnosing a fault of a robot joint according to an embodiment of the present invention, where as shown in fig. 1, the robot joint is controlled by a driver to operate, and the method for diagnosing a fault includes:

s101, first parameter information of the robot joint and second parameter information of the driver are acquired.

It can be understood that fig. 2 is a schematic structural diagram of a robot joint according to an embodiment of the present invention, referring to fig. 2, a motor 11 is generally disposed in the robot joint 1, and a speed reducer 12, a connecting rod 13 and a load 14 are further disposed in the robot joint, and the motor 11 rotates to sequentially drive the speed reducer 12 and the connecting rod 13 to rotate, so as to drive the load 14 to work. The high-speed shaft incremental encoder (INC) is installed on one side of a high-speed shaft of the speed reducer 12, the INC is used for collecting the rotating angle of a motor shaft, the low-speed shaft absolute encoder (ABS) is installed on one side of a low-speed shaft of the speed reducer 12, the ABS is used for collecting the rotating angle of a connecting rod, and a band-type brake 15 is further arranged on a motor rotating shaft to control the work of the speed reducer. The driver 2 is electrically connected with the robot joint 1, the driver 2 controls the robot joint 1 to work, and usually, the driver 2 needs an external power supply to provide a power supply voltage (i.e. a driver bus voltage) to work.

Specifically, voltage and current sensors and the like are correspondingly arranged in the robot joint, the first parameter information comprises three-phase voltage and three-phase current of the motor, a rotation angle of the INC, a rotation angle of the ABS and the like, and the embodiment of the invention is not specially limited to this, and specific working information can be obtained according to actual motor control algorithm requirements. The second parameter information of the driver includes the bus voltage of the driver, and the like, which is not specially limited in the embodiment of the present invention, and can be adaptively set according to the requirement of the actual control model algorithm.

S102, performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result.

Specifically, the online fault diagnosis refers to real-time fault diagnosis performed when a robot joint and a driver are in a working state, and it can be understood that the online fault diagnosis does not affect the normal work of the robot joint, and includes, for example, hardware self-checking, ABS fault diagnosis, INC fault diagnosis, band-type brake signal fault diagnosis, communication fault diagnosis, external input signal fault diagnosis, driver output diagnosis, and the like. Therefore, the fault diagnosis can be carried out on the robot joint and the driver in real time in an all-round manner, so that the working state of the robot joint and the driver can be monitored in real time, the fault can be quickly and accurately positioned once the fault occurs, the robot joint and the driver are stopped, inspected and maintained in time, and safety accidents are avoided. Further, according to the specific situation of online fault diagnosis, a first diagnosis result is output, such as INC fault and the like.

It should be noted that the first diagnosis result may be one fault diagnosis result or may be multiple fault diagnosis results, which is not limited in the embodiment of the present invention. It is understood that if any one of the components, lines or signals of the robot joint and the driver is abnormal, the abnormality can be quickly and accurately presented through the first diagnosis result.

And S103, carrying out fault early warning according to the first diagnosis result.

The failure early warning mode may be an alarm lamp or an alarm sound, and the like, which is not limited in the embodiment of the present invention. The first diagnosis result is the abnormal diagnosis result of a certain element or signal, and the first diagnosis result can be timely reminded through an alarm lamp or alarm sound, so that the operator can stop the machine for inspection immediately, and safety accidents are avoided.

Specifically, in the working and running process of the robot joint, a driver acquires first parameter information of the robot joint and second parameter information of the driver in real time, then closed-loop control is performed according to the first parameter information and the second parameter information to generate a driving signal, namely a pulse modulation signal (PWM), for driving a motor in the robot joint to run, in the closed-loop control process, the driver performs online fault diagnosis in real time, including but not limited to hardware fault diagnosis such as a sensor, communication fault diagnosis and fault diagnosis of each signal in a closed-loop control loop, and when the robot joint or the driver is judged to have a fault, a first diagnosis result is output, fault early warning is performed according to the first diagnosis result, an operator is reminded in time, and safety accidents are avoided. It can be understood that, operating personnel can carry out timely inspection and maintenance according to the specific condition of the fault early warning and the specific fault reason of the first diagnosis result, so that the safety and reliability of the robot joint and the driver are ensured, good user experience is obtained, and the product competitiveness is improved.

Optionally, fig. 3 is a flowchart of another method for diagnosing a fault of a robot joint according to an embodiment of the present invention, which is shown in fig. 2 and fig. 3, where the robot joint includes a sensor component, and a control algorithm model is embedded in a driver; in fig. 1, step S102, performing online fault diagnosis on the robot joint and the driver itself according to the first parameter information and the second parameter information, includes: determining working parameters and working parameter estimated values of the robot joint according to the first parameter information and the second parameter information; comparing the working parameter with the working parameter estimated value by taking the working parameter estimated value as a reference, and carrying out fault diagnosis on the sensor assembly; and comparing the working parameter estimation value with the working parameter by taking the working parameter as reference, and carrying out fault diagnosis on the control algorithm model. Therefore, the fault diagnosis method specifically includes the steps of:

s301, first parameter information of the robot joint and second parameter information of the driver are acquired.

S302, determining working parameters and working parameter estimation values of the robot joint according to the first parameter information and the second parameter information.

The working parameters of the robot joint refer to parameters obtained by coordinate change or standard formula conversion of the first parameter information and the second parameter information, for example, the motor position parameters and the motor speed parameters can be obtained by directly converting the rotation angle information of the motor. It should be noted that the standard formula herein refers to a standard physical conversion formula, and one operating parameter may also be obtained from a plurality of operating information through the standard physical conversion formula.

The working parameter estimation value refers to an estimation value obtained by estimating the first parameter information and the second parameter information through a control algorithm model, and ideally, when the robot joint does not have a fault and runs stably, the working parameter representing the same physical quantity meaning is the same as the working parameter estimation value. In contrast, the estimated values of the working parameters are estimated through a control algorithm model, and the working parameters are obtained by converting the working information directly acquired by the sensors. It can be understood that the control algorithm model includes, but is not limited to, an existing non-inductive estimation algorithm, for example, the non-inductive estimation algorithm instaspininc of the company TI, and the estimation values of the operating parameters, such as the torque, the angular velocity, the angle, and the like of the motor can be obtained through estimation according to the three-phase voltage, the three-phase current, and the intrinsic parameters of the type of the motor and the parameter identification method.

And S303, comparing the working parameters with the working parameter estimated values by taking the working parameter estimated values as reference, and carrying out fault diagnosis on the sensor assembly.

Specifically, the sensor component includes, but is not limited to, INC or ABS, the INC collects the rotation angle of the motor shaft, the ABS collects the rotation angle information of the connecting rod, and in case of a fault of the INC or ABS, such as missing codes, singular points, hardware damage, and cable damage, the operation of the robot joint may be abnormal, and in case of serious condition, even a safety accident may be caused. Therefore, the estimated value of the working parameter obtained by controlling and processing according to the first parameter information and the second parameter information is taken as a reference, the working parameter acquired according to the sensor assembly is compared with the estimated value of the working parameter, real-time fault diagnosis can be performed on the sensor assembly, whether the first working parameter acquired by the sensor assembly is accurate or not is detected, a fault is discovered in time, safety accidents are avoided, and safety and reliability of products are improved.

S304, comparing the working parameter estimation value with the working parameter by taking the working parameter as a reference, carrying out fault diagnosis on the control algorithm model, and determining a first diagnosis result.

Specifically, the control algorithm model is a software control algorithm model embedded in the driver, and may be implemented by a control chip in the driver, and the like. Therefore, the working parameters are taken as reference, the estimated values of the working parameters are compared with the working parameters, fault diagnosis can be carried out on the control algorithm model, and optimization and adjustment of the control parameters or the control algorithm model are carried out when the control algorithm model is detected to be abnormal, so that safety accidents are avoided, and the safety and the reliability of products are improved.

And S305, carrying out fault early warning according to the first diagnosis result.

In this embodiment, after first parameter information of a robot joint and second parameter information of a driver are acquired, and a working parameter estimated value of the robot joint are determined according to the first parameter information and the second parameter information, the working parameter and the working parameter estimated value are compared with each other with reference to the working parameter estimated value, fault diagnosis is performed on a sensor assembly, and whether a working state of the sensor assembly is normal or not can be verified through the working parameter estimated value. And then, the working parameter estimation value is compared with the working parameter by taking the working parameter as a reference, the control algorithm model is subjected to fault diagnosis, whether the working parameter estimation value is correct or not is verified through the working parameter, and mutual verification of the same parameter quantity by the actual sensor component and the control algorithm model is realized, so that the fault diagnosis function is more comprehensive and complete. And after the first diagnosis result is determined, fault early warning is timely carried out to remind operators, so that the safety and the reliability of the whole product are further ensured, and safety accidents caused by faults are avoided.

Optionally, the sensor assembly includes a high speed shaft incremental encoder and a low speed shaft absolute encoder.

Specifically, referring to fig. 2, the high-speed shaft incremental encoder is installed on a side of the speed reducer close to the motor, and the low-speed shaft absolute encoder is installed on a side of the speed reducer far from the motor. Therefore, when fault diagnosis is carried out on the high-speed shaft incremental encoder, the rotating angle acquired by the high-speed shaft incremental encoder can be verified by acquiring the rotating angle acquired by the low-speed shaft absolute encoder, so that the safety of the robot joint is further ensured. In a similar way, when fault diagnosis is carried out on the low-speed shaft absolute encoder, the rotating angle acquired by the low-speed shaft absolute encoder can be checked by acquiring the rotating angle acquired by the high-speed shaft incremental encoder, so that the safety of the robot joint is further ensured.

In addition, the rotation angle acquired by the high-speed shaft incremental encoder and the rotation angle acquired by the low-speed shaft absolute encoder can be combined for further analysis so as to determine whether the speed reducer works normally. For example, the deceleration value of the speed reducer is obtained according to the rotation angle acquired by the high-speed shaft incremental encoder and the rotation angle acquired by the low-speed shaft absolute encoder, and the deceleration value is compared with a preset deceleration threshold value to determine whether the two values are consistent or not, so as to judge whether the speed reducer works normally or not. Therefore, the reliability and the safety of the robot joint are ensured, and safety accidents are avoided.

Optionally, fig. 4 is a flowchart of a fault diagnosis method for a robot joint according to another embodiment of the present invention, as shown in fig. 4, on the basis of fig. 1, the fault diagnosis method further includes: performing off-line fault diagnosis on the robot joint according to the first parameter information, and determining a second diagnosis result; and performing fault early warning according to the second diagnosis result. Therefore, the fault diagnosis method specifically includes the steps of:

s401, first parameter information of the robot joint and second parameter information of the driver are acquired.

S402, performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result.

And S403, performing fault early warning according to the first diagnosis result.

And S404, performing off-line fault diagnosis on the robot joint according to the first parameter information, and determining a second diagnosis result.

Specifically, the offline fault diagnosis refers to fault diagnosis performed in a robot joint non-operating state (i.e., during a no-task period), and includes, but is not limited to, fault diagnosis of robot joint hardware, such as whether a mounting, a wire harness, or a connector is normal. The off-line fault diagnosis of the robot joint comprises speed reducer function fault diagnosis, band-type brake function diagnosis and the like. In the off-line fault diagnosis of the robot joint, the robot joint may be operated according to a predetermined signal, the first parameter information of the robot joint may be acquired, and the first parameter information may be compared with the predetermined signal to perform the off-line fault diagnosis. Further comprehensively carry out fault diagnosis to the robot joint, in time inspect and maintain to the trouble before the robot joint starts working, avoid appearing the incident. Further, according to the specific situation of the offline fault diagnosis, a second diagnosis result, such as a brake fault and the like, is output.

It should be noted that the offline fault diagnosis may be a fault diagnosis operation performed periodically, or may be a fault diagnosis operation performed at any time when the robot joint is not in an operating state, which is not limited in the embodiment of the present invention.

And S405, performing fault early warning according to the second diagnosis result.

It can be understood that the manner of performing the fault pre-warning according to the second diagnosis result may be the same as the manner of performing the fault pre-warning according to the first diagnosis result, and the like, and details are not repeated herein.

In this embodiment, in a non-user task working state of the robot joint, the driver acquires the first parameter information of the robot joint in real time, and performs offline fault diagnosis on the robot joint according to the first parameter information, so that hardware inspection, such as installation, wiring harness, functions and the like, can be performed on devices and equipment in the robot joint with emphasis on the robot joint, and the robot joint can be ensured to work normally. And when the offline fault is determined, a second diagnosis result is output to carry out fault early warning prompt, so that the fault problem can be quickly positioned, an operator can conveniently carry out troubleshooting and maintenance, the safety and the reliability of the robot joint are ensured, the use experience of a product is improved, and the product competitiveness is improved.

Optionally, fig. 5 is a flowchart of a further method for diagnosing a fault of a robot joint according to an embodiment of the present invention, which is shown in fig. 2 and 4, where the robot joint includes a speed reducer assembly and a brake assembly, that is, the speed reducer and the brake in fig. 2; the first parameter information comprises a speed reducer rotation signal and a band-type brake switch signal; in step S404 in fig. 4, performing offline fault diagnosis on the robot joint according to the first parameter information, including: comparing the speed reducer rotation signal with a preset speed reducer rotation signal, and performing fault diagnosis on the speed reducer assembly; and comparing the band-type brake switch signal with a preset band-type brake switch signal, and performing fault diagnosis on the band-type brake assembly. Therefore, the fault diagnosis method specifically includes the steps of:

s501, first parameter information of the robot joint and second parameter information of the driver are obtained.

S502, performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result.

And S503, performing fault early warning according to the first diagnosis result.

S504, comparing the speed reducer rotation signal with a preset speed reducer rotation signal, and performing fault diagnosis on the speed reducer assembly.

The preset speed reducer rotation signal may be set inside the driver, or may be issued by an operator through an upper computer or other device in communication connection with the driver, which is not particularly limited in the embodiment of the present invention. The preset speed reducer rotation signal can reflect whether the output of the speed reducer is normal or not.

And S505, comparing the band-type brake switch signal with a preset band-type brake switch signal, performing fault diagnosis on the band-type brake assembly, and determining a second diagnosis result.

The preset brake switch signal may be set inside the driver, or may be issued by an operator through an upper computer or other device in communication connection with the driver, which is not particularly limited in the embodiment of the present invention. It can be understood that the preset band-type brake switch signal comprises two signals of band-type brake opening and band-type brake closing, and can be selectively set according to actual work.

And S506, performing fault early warning according to the second diagnosis result.

In this embodiment, when the robot joint is out of task, the function of the speed reducer assembly is detected according to the preset speed reducer rotation signal, for example, when the speed reducer is in a safe position, the normal output of the speed reducer can be detected, the rotation signal of the speed reducer at this time is obtained, and is compared with the preset speed reducer rotation signal to determine whether the speed reducer assembly is in fault, and a second diagnosis result is output when the speed reducer assembly is determined to be in fault. Similarly, the function of the brake component is detected according to the preset brake switch signal, for example, whether the brake force of the brake component meets the preset requirement or not, and the brake component can be normally opened or closed, the brake switch signal at the moment is obtained, and the brake switch signal is compared with the preset brake switch signal to judge whether the brake component is in fault or not, and a second diagnosis result is output when the brake component is judged to be in fault. Therefore, the function detection under the non-working state is carried out on the speed reducer assembly and the band-type brake assembly in the robot joint, so that the fault diagnosis function is more comprehensive and perfect. And after a second diagnosis result is determined, fault early warning is timely carried out to remind an operator, so that the safety and the reliability of the whole product are further ensured, and safety accidents caused by faults are avoided.

Optionally, fig. 6 is a flowchart of a further method for diagnosing a fault of a robot joint according to an embodiment of the present invention, where on the basis of fig. 4, step S402 is performed to perform online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determine a first diagnosis result, where the method includes: performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information to generate a first fault code; performing fault analysis according to the first fault code, and determining a first diagnosis result; performing offline fault diagnosis on the robot joint according to the first parameter information, and determining a second diagnosis result, wherein the offline fault diagnosis comprises the following steps: performing off-line fault diagnosis on the robot joint according to the first parameter information to generate a second fault code; and performing fault analysis according to the second fault code, and determining a second diagnosis result. Therefore, the fault diagnosis method specifically includes the steps of:

s601, first parameter information of the robot joint and second parameter information of the driver are acquired.

And S602, performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and generating a first fault code.

The first fault code may be generated in the form of a binary code, and the specific number of bits may be 8 bits or 16 bits, which is not limited in this embodiment of the present invention.

And S603, performing fault analysis according to the first fault code, and determining a first diagnosis result.

For example, a preset fault analysis table may be arranged inside the driver, and it can be understood that the fault types corresponding to different first fault codes are different, so that the corresponding fault types can be obtained through analysis by comparing the first fault codes with the preset fault analysis table. The embodiment of the present invention is not limited to this.

And S604, performing fault early warning according to the first diagnosis result.

And S605, performing off-line fault diagnosis on the robot joint according to the first parameter information to generate a second fault code.

The second fault code may be generated in the form of a binary code, and the specific number of bits may be 8 bits or 16 bits, which is not limited in this embodiment of the present invention.

And S606, performing fault analysis according to the second fault code, and determining a second diagnosis result.

And S607, carrying out fault early warning according to the second diagnosis result.

In this embodiment, on-line fault diagnosis is performed on the robot joint and the driver according to the first parameter information and the second parameter information, a first fault code is generated, fault analysis is performed according to the first fault code, and a first diagnosis result is determined, which can be understood that different first fault codes correspond to different faults, for example, the first fault code corresponding to the INC fault is 0001, and the first fault code corresponding to the ABS fault is 0010. When the driver acquires that the first fault code is 0001, the corresponding fault can be determined to be INC through fault analysis, fault early warning is further conducted, and then an operator checks and maintains the INC according to the early-warning fault condition. Therefore, fault positioning and troubleshooting and maintenance can be performed quickly, and the fault detection efficiency is improved so as to ensure the safety of products. Similarly, off-line fault diagnosis is carried out on the robot joint according to the first parameter information, a second fault code is generated, fault analysis is carried out according to the second fault code, a second diagnosis result is determined, fault early warning is carried out according to the second diagnosis result, the fault detection efficiency is improved, the reliability and the safety of a product in working are guaranteed, safety accidents are avoided, and the product use experience is improved.

It should be noted that the first fault code and the second fault code may further include a fault clear code, and it can be understood that when the driver detects that no fault occurs in the robot joint and the driver itself, the fault clear code may be further generated to clear fault information cached before the driver, so as to avoid that the driver always performs fault early warning, which affects the misjudgment of an operator, and reduces the work efficiency of the product.

Optionally, fig. 7 is a flowchart of a further method for diagnosing a fault of a robot joint according to an embodiment of the present invention, and as shown in fig. 7, before the step S101 in fig. 1 acquires first parameter information of the robot joint and second parameter information of a driver, the method further includes: detecting whether the power supply voltage of the driver is normal or not, and performing hardware self-detection on the driver after judging that the power supply voltage of the driver is normal; when judging that the driver hardware has a fault, generating a third fault code, and performing fault analysis according to the third fault code to determine a third diagnosis result; when the driver hardware is determined to be fault-free, first parameter information of the robot joint and second parameter information of the driver are acquired. The method specifically comprises the following steps:

and S701, detecting whether the power supply voltage of the driver is normal.

The power supply voltage of the driver is the bus voltage of the driver, whether the power supply voltage of the driver is normal or not is judged by detecting the bus voltage of the driver and comparing the bus voltage with a preset threshold range, and it can be understood that if the power supply voltage exceeds the preset threshold range, the power supply voltage of the driver is abnormal, otherwise, the power supply voltage of the driver is normal. It should be noted that the preset threshold range may be selectively set according to actual situations or relevant standards, which is not limited in the embodiment of the present invention.

Illustratively, the power supply voltage of the driver is 48V, and the preset threshold range is a voltage range which is greater than 24V and less than 60V.

And S702, performing hardware self-check on the driver after judging that the power supply voltage of the driver is normal.

The driver hardware self-checking comprises the steps of judging whether driver bus connection is reversed or not, judging whether local short circuit occurs or not, judging whether the function of a driver fails or not, judging whether the connection of a driver to a robot joint is not firm, broken or not, judging whether an encoder is connected or not, and judging whether signals are abnormal or not. It can be understood that after the driver is powered on, the driver can acquire initial signals corresponding to each wire harness or device, and perform self-test on the driver according to comparison between each initial signal and a corresponding preset signal.

S703, judging whether the driver hardware is in failure, and executing step S704 when judging that the driver hardware is in failure; upon determining that the driver hardware is not malfunctioning, step 705 is performed.

S704, generating a third fault code, performing fault analysis according to the third fault code, determining a third diagnosis result, and performing fault early warning according to the third diagnosis result.

The third fault code may be generated in the form of a binary code, and the specific number of bits may be 8 bits or 16 bits, which is not limited in this embodiment of the present invention. The failure warning mode may be an alarm lamp or an alarm sound, and the like, which is not limited in the embodiment of the present invention.

S705, first parameter information of the robot joint and second parameter information of the driver are acquired.

And S706, performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, and determining a first diagnosis result.

And S707, carrying out fault early warning according to the first diagnosis result.

In this embodiment, the driver may detect the power supply voltage (i.e., the bus voltage), and determine whether the power supply voltage is normal, after determining that the power supply voltage of the driver is normal, the driver starts to perform driver hardware self-inspection, and compare the obtained initial signals of the first electrical parameter and the other signals with corresponding preset thresholds to determine whether the driver hardware has a fault such as damage, an installation error, or disconnection of a wire harness, and after determining that the driver hardware has a fault, generate a third fault code, and then perform fault analysis according to the third fault code to determine a third diagnosis result, and perform fault early warning according to the third diagnosis result, and prompt an operator to perform fault troubleshooting and maintenance. If the driver determines that the driver hardware is not faulty, the driver continues to execute steps S705 to S707. So, whether normal going on detecting and driver hardware self-checking through the supply voltage to the driver for the joint's of robot fault diagnosis function is more comprehensive and intelligent, guarantees the reliability and the security of robot joint work, avoids taking place the incident at any time, improves the work efficiency and the use experience of product, and then improves the competitiveness of product.

It should be noted that the third fault code also includes a fault clear code, and when the driver detects that no fault occurs in the robot joint or the driver itself, the driver generates the fault clear code to clear the fault information cached before the driver, thereby avoiding that the driver always performs fault early warning, which affects the misjudgment of the operator, and reduces the work efficiency of the product.

Optionally, fig. 8 is a flowchart of a further method for diagnosing a fault of a robot joint according to an embodiment of the present invention, and as shown in fig. 8, the online fault diagnosis further includes:

s801, communication fault diagnosis is carried out according to whether the time for establishing the communication connection exceeds a first preset time.

The time for establishing the communication connection may be measured from a time when the driver first sends a communication signal (e.g., a message signal) to a time when the driver first receives a feedback communication signal, and if the time difference exceeds a first preset time, a communication failure is indicated. Or the driver does not receive the feedback communication signal all the time, and the communication fault is also indicated. The embodiment of the present invention does not set any limit on the specific manner of how to establish the communication connection, and therefore, the specific manner of how to acquire the time for establishing the communication connection is not limited, and the above is only an example given for how to acquire the time for establishing the communication connection.

The specific time length of the first preset time is not limited in this embodiment of the present invention, and may be adaptively set according to an actual situation, for example, 3 s.

S802, performing driver signal receiving fault diagnosis according to whether the time for acquiring the external command signal exceeds second preset time.

It can be understood that the driver is also usually connected to the upper computer in a communication manner to obtain an external control command sent by the upper computer, including but not limited to a reference command of a control signal in the control algorithm model, and the like.

The specific time length of the second preset time is not limited in this embodiment of the present invention, and may be adaptively set according to an actual situation, for example, 100 ms.

And S803, detecting the output signal of the driver, and performing the output fault diagnosis of the driver signal according to whether the output signal of the driver exceeds a first preset range.

The first preset range value may be a hardware limit range of the driver, or a software limit range of a control algorithm model in the driver, which is not limited in the embodiment of the present invention. The driver output signal includes a drive signal (i.e., a PWM signal) that the driver outputs to the robot joint.

For example, the first preset range value may be a range of a driving signal for driving the robot joint to work normally, for example, a range from a minimum modulation degree to a modulation degree corresponding to a PWM modulation signal, or a range from a minimum limit value to a maximum limit value that the driver can output normally. The embodiment of the invention is not limited in any way, and can be selectively set according to the actual working condition.

Specifically, communication fault diagnosis is performed according to whether the time for establishing communication connection exceeds a first preset time, so that the driver and the communication between the driver and peripheral equipment can be ensured to be normal, and the driver can be ensured to be capable of driving the robot joint to work safely and reliably. And secondly, the driver performs signal receiving fault diagnosis on the driver according to whether the time for acquiring the external command signal exceeds a second preset time, so that the driver can accurately receive all signals without any delay, and the driver can further drive the robot joint to work safely and reliably. Then, the driver can also detect the output signal of the driver, and carry out signal output fault diagnosis of the driver according to whether the output signal of the driver exceeds a first preset range, so that the signal output by the driver cannot influence the normal work of the robot joint, and the reliability and the safety of a product are further improved. Therefore, the fault diagnosis function of the robot joint is more comprehensive through further communication fault diagnosis, driver signal receiving fault diagnosis and driver signal output fault diagnosis in the online fault diagnosis, safety accidents are avoided, and the use experience and the competitiveness of products are improved.

It should be noted that, in the embodiment of the present invention, no limitation is imposed on the specific execution sequence of steps S801, S802, and S803, and other offline fault diagnoses, and fig. 8 only shows an exemplary sequence of one of the online fault diagnoses.

To illustrate a specific example, fig. 9 is a flowchart of a specific method for diagnosing a fault of a robot joint according to an embodiment of the present invention, as shown in fig. 9,

and S901, detecting whether the power supply voltage of the driver is normal, if so, executing the step S902, and otherwise, finishing fault diagnosis.

And S902, carrying out driver hardware self-test.

S903, judging whether the driver hardware self-check is successful, and if so, executing the step S904, S9011 or S9012; if not, outputting a driver self-checking fault code, and executing step S9013.

S904, checking the INC signal, and if no fault exists, continuing to execute the step S905; otherwise, the INC fault code is output and step S9013 is executed.

S905, checking ABS signals, and if no fault exists, continuing to execute the step S906; otherwise, outputting the ABS fault code, and executing step S9013.

S906, carrying out non-inductive signal verification, and if no fault exists, continuing to execute the step S907; otherwise, outputting a non-inductive signal fault code and executing the step S9013.

S907, checking the brake signal, and if no fault exists, continuing to execute the step S908; otherwise, outputting a brake signal fault code and executing the step S9013.

S908, communication verification is carried out, and if no fault exists, the step S909 is continuously executed; otherwise, outputting the communication fault code and executing the step S9013.

S909, carrying out instruction checking, and if no fault exists, continuing to execute the step S9010; otherwise, outputting an instruction abnormal fault code, and executing the step S9013.

S9010, verifying the control output of the driver, and if no fault exists, returning to execute the step S901 again; otherwise, the driver controls to output the fault code, and performs step S9013.

And S9011, checking the functions of the speed reducer, if no fault exists, ending fault diagnosis, otherwise, outputting a speed reducer fault code, and executing the step S9013.

And S9012, checking the function of the band-type brake, if no fault exists, ending fault diagnosis, otherwise, outputting a band-type brake fault code, and executing the step S9013.

And S9013, fault code merging and fault code analysis are carried out.

And S9014, performing fault alarm.

Specifically, the steps S901 to S9010 belong to online fault diagnosis, and the steps S9011 to S9012 belong to offline fault diagnosis. It should be noted that, the specific steps of online fault diagnosis are not limited to the sequence in fig. 9, and especially, the sequence of steps S904 to S9010 may be arranged in any combination, and the embodiment of the present invention is not limited in any way. Similarly, the offline fault diagnosis may also include other fault diagnoses, such as a motor function check, a voltage sensor function check, or a current sensor function check. The embodiments of the present invention are not listed one by one, and those skilled in the art can selectively set them according to the actual situation. Through the online fault diagnosis and the offline fault diagnosis of the robot joint, the reliability and the safety of the robot joint work are ensured, the safety accident caused by the fault is avoided, the working efficiency of the robot joint is improved, and the robot joint has better use experience and product competitiveness.

Based on the same inventive concept, an embodiment of the present invention further provides a fault diagnosis system for a robot joint, fig. 10 is a schematic structural diagram of the fault diagnosis system for a robot joint provided in the embodiment of the present invention, and is shown in fig. 2 and fig. 10, the fault diagnosis system includes a driver electrically connected to the robot joint, the driver is configured to perform the fault diagnosis method in any of the embodiments, and the driver 2 includes: the data acquisition module 21 is used for acquiring first parameter information of the robot joint and second parameter information of the driver; the first fault diagnosis module 22 is used for performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information to determine a first diagnosis result; and the fault warning module 23 is used for performing fault warning according to the first diagnosis result.

In the embodiment of the present invention, the data obtaining module 21 obtains the first parameter information of the robot joint and the second parameter information of the driver, and closed-loop control may be performed according to the first parameter information and the second parameter information to drive the robot joint to work. Then, the first fault diagnosis module 22 performs online fault diagnosis on the robot joint and the driver itself according to the first parameter information and the second parameter information to detect whether the robot joint and the driver themselves are faulty in real time, and determines a first diagnosis result when it is determined that the fault is faulty. And the fault warning module 23 performs fault warning according to the first diagnosis result so as to prompt faults in time. Therefore, safety accidents caused by faults of the robot joint and the driver in the working state can be avoided, the safety and the reliability of the robot joint and the driver are improved, good user experience is obtained, and the product competitiveness is improved.

Optionally, fig. 11 is a schematic structural diagram of another fault diagnosis system for a robot joint according to an embodiment of the present invention, and as shown in fig. 11, the driver 2 further includes: the second fault diagnosis module 24 is used for performing offline fault diagnosis on the robot joint according to the first parameter information and determining a second diagnosis result; and the fault warning module 23 is used for performing fault warning according to the second diagnosis result.

Specifically, in the non-working state of the robot joint, the second fault diagnosis module 24 performs offline fault diagnosis on the robot joint according to the first parameter information, so as to focus on hardware inspection on devices and equipment in the robot joint, such as installation, wiring harness, and functions, and ensure that the robot joint can work normally. And when the offline fault is determined, a second diagnosis result is output, and the fault warning module 23 carries out fault warning prompt, so that the fault problem can be quickly positioned, operators can conveniently carry out troubleshooting and maintenance, the safety and the reliability of the robot joint are ensured, the use experience of a product is improved, and the product competitiveness is improved.

It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. Those skilled in the art will appreciate that the present invention is not limited to the specific embodiments described herein, and that the features of the various embodiments of the invention may be partially or fully coupled or combined with each other and may be coordinated with each other and technically driven in various ways. Numerous variations, rearrangements, combinations, and substitutions will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A method for diagnosing a failure in a robot joint, the robot joint being controlled by a driver, the method comprising:

performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information to determine a first diagnosis result;

and performing fault early warning according to the first diagnosis result.

2. The method for diagnosing a malfunction of a robot joint according to claim 1, wherein the robot joint includes a sensor assembly, and the driver has a control algorithm model embedded therein;

performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information, including:

determining working parameters and working parameter estimated values of the robot joint according to the first parameter information and the second parameter information;

comparing the working parameter with the working parameter estimated value by taking the working parameter estimated value as a reference, and carrying out fault diagnosis on the sensor assembly;

and comparing the working parameter estimation value with the working parameter by taking the working parameter as reference, and carrying out fault diagnosis on the control algorithm model.

3. The method of diagnosing a malfunction of a robot joint according to claim 2, wherein the sensor assembly includes a high-speed shaft incremental encoder and a low-speed shaft absolute encoder.

4. The method of diagnosing a malfunction of a robot joint according to claim 1, further comprising:

performing off-line fault diagnosis on the robot joint according to the first parameter information, and determining a second diagnosis result;

and carrying out fault early warning according to the second diagnosis result.

5. The method according to claim 4, wherein the robot joint includes a speed reducer component and a brake component; the first parameter information comprises a speed reducer rotation signal and a band-type brake switch signal;

performing offline fault diagnosis on the robot joint according to the first parameter information, wherein the offline fault diagnosis comprises the following steps:

comparing the speed reducer rotation signal with a preset speed reducer rotation signal, and performing fault diagnosis on the speed reducer assembly;

and comparing the band-type brake switch signal with a preset band-type brake switch signal, and carrying out fault diagnosis on the band-type brake assembly.

6. The method according to claim 4, wherein performing online fault diagnosis on the robot joint and the driver itself based on the first parameter information and the second parameter information to determine a first diagnosis result includes:

performing online fault diagnosis on the robot joint and the driver according to the first parameter information and the second parameter information to generate a first fault code;

performing fault analysis according to the first fault code, and determining a first diagnosis result;

performing offline fault diagnosis on the robot joint according to the first parameter information, and determining a second diagnosis result, wherein the offline fault diagnosis comprises the following steps:

performing off-line fault diagnosis on the robot joint according to the first parameter information to generate a second fault code;

and performing fault analysis according to the second fault code, and determining a second diagnosis result.

7. The method of diagnosing a malfunction of a robot joint according to claim 1, further comprising, before acquiring the first parameter information of the robot joint and the second parameter information of the driver:

detecting whether the power supply voltage of the driver is normal or not, and performing hardware self-detection on the driver after judging that the power supply voltage of the driver is normal;

when the hardware fault of the driver is judged, generating a third fault code, performing fault analysis according to the third fault code, determining a third diagnosis result, and performing fault early warning according to the third diagnosis result;

and when the driver hardware is determined to be fault-free, acquiring first parameter information of the robot joint and second parameter information of the driver.

8. The method of diagnosing a malfunction of a robot joint according to claim 1, wherein the online fault diagnosis further includes:

performing communication fault diagnosis according to whether the time for establishing the communication connection exceeds a first preset time;

performing driver signal receiving fault diagnosis according to whether the time for acquiring the external command signal exceeds second preset time;

and detecting the output signal of the driver, and performing the output fault diagnosis of the driver signal according to whether the output signal of the driver exceeds a first preset range.

9. A system for diagnosing a malfunction of a robot joint, comprising a driver electrically connected to the robot joint, the driver being configured to perform the method for diagnosing a malfunction according to any one of claims 1 to 8, the driver comprising:

10. The system for diagnosing a malfunction of a robot joint according to claim 9, wherein the driver further includes:

the second fault diagnosis module is used for performing off-line fault diagnosis on the robot joint according to the first parameter information and determining a second diagnosis result;

and the fault warning module is used for carrying out fault warning according to the second diagnosis result.