CN106695793B - Active compliance control device and method for XYZR four-axis drilling robot - Google Patents
Active compliance control device and method for XYZR four-axis drilling robot Download PDFInfo
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Abstract
The invention belongs to the field of robot control, and particularly relates to an active compliance control device and method for an XYZR four-axis drilling robot. The device comprises a main control module, a servo drive control module and a human-computer interaction module; the main control module is connected with the servo drive control module, and the main control module is also connected with the man-machine interaction module. The invention has perfect function, clear structure, simple realization and low module coupling degree; meanwhile, the synchronism and the smoothness of the system motion are realized; the active compliance control decision module is designed independently, complex modeling of the propulsion process of the drilling machine and repeated splicing experiments of non-guiding rules are avoided when relevant data in the propulsion process of the drilling machine are obtained, expensive acceleration section sensors and force sensors are prevented from being used by each robot on line, cost is saved, unstable factors and system downtime processes introduced by on-line adjustment of control parameters are avoided, and the switching mechanism of kinematic position control and active compliance force control is reasonable.
Description
Technical Field
The invention belongs to the field of robot control, and particularly relates to an active compliance control device and method for an XYZR four-axis drilling robot.
Background
Present case package drilling robot mechanism design often adopts traditional robot mechanism, like planer-type robot, triaxial XYZ cartesian robot, four-axis XYZR drilling robot and six-axis joint type robot etc. robot control system often adopts the control scheme based on kinematics, uses the position of punching promptly to work as control objective, relatively is fit for being used for the drilling of non-deformable metal such as thick plate or cubic, plastic slab, inferior gram force board etc. material.
An active compliance control mechanism in the existing research depends on a six-dimensional force sensor to realize the detection of force and moment, a machine vision sensor to detect the current pose of a robot, and the position/force hybrid controller is designed by integrating the information. And a study is also made that an ETHERCAT master station is used for superposing motor periodic data acquired by a robot driver and a set expected value, performing impedance control and outputting a reference torque value to the robot driver, so that the method is suitable for contact operation application. Or a flexible grinding and polishing tool is arranged on the industrial robot, the computer is in bidirectional communication connection with the robot controller through a robot communication interface, the robot controller controls the industrial robot to act, the flexible grinding and polishing tool is used for grinding and polishing a workpiece fixed on a workbench, the force sensor is used for sending collected grinding and polishing force data to the computer for processing as a closed loop feedback signal, and the key technology is that the force sensor is suitable for sensing environmental acting force, the rope-driven robot is used for realizing impedance control, and the flexible pipe arm type environment operation is suitable.
When the drilling robot based on position control drills the easily deformable thin sheet metal, a control scheme based on kinematics is adopted, the drilling position is taken as a control target to work, the force and the acceleration of a drill bit are greatly fluctuated in the dynamic control process and cannot be kept on a reasonable specific time variable value, and therefore a drilling object is deformed, the hole shape is damaged, and burrs are too much and unqualified; the existing active compliance control scheme is mostly suitable for the working occasions with surface contact and specific pressure maintenance, and is not suitable for the working occasions with broken material surfaces such as drilling holes and the like; at present, an expensive force sensor is mostly adopted as a force detection device in an active compliance control scheme, and the cost is high.
Disclosure of Invention
In order to solve the problems, the invention provides an active compliance control device of an XYZR four-axis drilling robot, wherein the control objects of the active compliance control device are a four-way servo motor module and an electric drill module, and the device comprises a main control module, a servo drive control module and a human-computer interaction module; the main control module is connected with the servo drive control module, the servo drive control module is connected with the electric drill module, and the main control module is also connected with the man-machine interaction module;
the main control module is used for completing kinematic trajectory planning, active compliance control decision, expert experience learning, acceleration-force-current offline matching, acceleration-force-current online matching, communication management, IO management and drive data interaction;
the servo drive control module is used for controlling the four servo motor modules in real time;
the electric drill module belongs to basic components of an XYZR four-axis drilling robot, comprises a frequency converter controlled by a main control module and a main shaft electric drill and is used for controlling the main shaft electric drill to complete drilling;
the human-computer interaction module is used for an operator to edit tasks, send instructions, display the working state of the robot and complete communication with the main control module.
An XYZR four-axis drilling robot active compliance control device is disclosed, wherein a main control module comprises a kinematics trajectory planning sub-module, an active compliance control decision sub-module, an expert experience learning sub-module, an acceleration-force-current offline matching sub-module, an acceleration-force-current online matching sub-module, an RS485 communication sub-module, an IO control management sub-module, a power management sub-module, a safety control sub-module, a driving data interaction sub-module, a tool workpiece calibration sub-module, a PC debugging communication sub-module and an SD card reading and writing sub-module;
the tool workpiece calibration sub-module is a serial connection relation in sequence, the modules are defined as a first-class sub-module through data communication connection, and the first-class sub-module only needs to be operated once before the system is operated online to generate necessary control data for subsequent use; the kinematic trajectory planning submodule, the active compliance control decision submodule, the IO control management submodule and the driving data interaction submodule are sequentially connected in series, the submodules are defined as a second-class submodule through data communication connection, the second-class submodule is a module which must run when the system runs on line, the second-class submodule uses data generated by the first-class submodule, and the second-class submodule and the first-class submodule are connected through data communication; defining the RS485 communication sub-module and the PC debugging communication sub-module as a third sub-module, wherein the third sub-module is used for man-machine interaction operation, and the relation between the third sub-module and other sub-modules is a concurrent synchronization relation; and defining the power management sub-module, the safety control sub-module and the SD card read-write sub-module as a fourth sub-module, wherein the fourth sub-module and other sub-modules are in a concurrent synchronization relationship.
The main control module is composed of a WINDOWS system architecture industrial personal computer based on an INTEL X86 hardware platform, a LINUX system architecture industrial personal computer based on an INTEL X86 hardware platform, a VXWORKS system architecture industrial personal computer based on an INTEL X86 hardware platform or an embedded control platform based on an ARM architecture.
The man-machine interaction module comprises a task editing submodule, a state monitoring submodule, an instruction receiving and sending submodule and a serial port communication submodule;
in the man-machine interaction module, a task editing sub-module and a state monitoring sub-module are in a concurrent and synchronous relation and are sequentially connected with an instruction receiving and transmitting sub-module and a serial communication sub-module in series through data lines;
the man-machine interaction module is composed of a teaching platform based on an independent operating system, or a teaching platform based on an operating system shared with a main control system, or an independent teaching platform based on a single chip microcomputer.
The servo drive control module comprises a main control data interaction module, a servo motor 1 drive control module, a servo motor 2 drive control module, a servo motor 3 drive control module and a servo motor 4 drive control module which are connected, wherein the servo motor 1 drive control module, the servo motor 2 drive control module, the servo motor 3 drive control module and the servo motor 4 drive control module are respectively connected with the servo motor 1 drive amplification module, the servo motor 2 drive amplification module, the servo motor 3 drive amplification module and the servo motor 4 drive amplification module, and then are respectively connected with four servo motor modules; the four-way servo motor module comprises a servo motor 1, a servo motor 2, a servo motor 3 and a servo motor 4, is a direct control object of the servo drive control module, and is also a basic driving component for forming the XYZR four-axis drilling robot;
the servo drive control module is composed of a plurality of paths of completely independent servo drivers with current control and position control, a relative integrated servo driver composed of a plurality of DSPs or FPGAs, an absolute integrated servo driver composed of a DSP or an absolute integrated servo driver composed of an FPGA.
An active compliance control method of a drilling robot based on four axes of XYZR comprises the following steps:
step 3, teaching the robot work task through a human-computer interaction module;
step 4, the main control module finishes kinematics trajectory planning according to the teaching task, generates driving data and sends the driving data to the servo driving control module for reference execution;
step 5, the main control module carries out active compliance control decision according to the robot state fed back by the servo drive control module, determines used position control parameters and compliance control parameters, and sends the position control parameters and the compliance control parameters to the servo drive control module for reference execution through the drive data interaction sub-module;
step 6, the master control module simultaneously completes the management and decision of the IO control management submodule;
step 7, the servo drive control module completes real-time control of the servo motors of all the axes according to the main control instruction;
and 8, starting and stopping the electric drill by the electric drill module according to the state of the IO control management submodule to drill.
The specific steps of the process of expert experience learning, namely the work of the expert experience learning submodule, are as follows:
step 101, connecting an acceleration sensor serial port data line in an electric drill module to a system PC debugging serial port, starting a drilling process expert experience learning submodule through a man-machine interaction module, and collecting drilling time of N groups of advanced technical workers in a drilling process and acceleration amplitude data in the time period, wherein N is more than 100;
102, calculating the average value and the variance of the drilling time of the acquired N groups of data and the 97.5% confidence interval of the data;
step 103, checking whether the drilling time of the N groups of data is within the confidence interval in the step 102, if so, rejecting the data, and assuming that the data left in the process is N1Group (d);
step 104, for N in step 1031Performing time normalization on the group data, performing data compression according to the average time when the drilling time is longer than the average time, and performing data expansion on the part with the drilling time shorter than the average time by taking the average time as a reference;
step 105, smoothing the data obtained in step 104, wherein the processing method adopts a moving average method, and then N is used1Averaging the group data according to sampling time points to obtain average drilling acceleration data after time normalization;
and 106, carrying out difference operation on the data obtained in the step 105, and dividing the data into acceleration adding data, acceleration homogenizing data and acceleration reducing data according to a difference result, wherein time periods corresponding to the three types of data are an acceleration adding time period, an acceleration homogenizing time period and an acceleration reducing time period respectively.
The specific process of determining the proportional parameter of the driving current and the reference acceleration in the step 2 is
The acceleration-force-current offline matching sub-module and the acceleration-force-current online matching sub-module convert the acceleration required to be controlled in the punching process into control over the propulsion current through the force relationship; in a system prototype research and development stage, a serial port data line of an acceleration sensor in an electric drill module is connected to a system PC debugging serial port, an online acceleration-force-current matching function is started through a man-machine interaction module, then an acceleration-force-current offline matching submodule compares an actually acquired acceleration value with a reference acceleration to form negative feedback, and a proportional parameter of a driving current and the reference acceleration is adjusted to complete offline matching; before the first actual trial drilling, the acceleration-force-current online matching sub-module starts the proportional parameter of the driving current and the reference acceleration in the acceleration-force-current offline matching sub-module, controls the driving current to push the drilling machine to advance, detects the position of the drilling machine through the current pose state of the robot to perform second-order differential acquisition on the actual acceleration advanced by the drilling machine, then compares the actually acquired acceleration value with the reference acceleration to form negative feedback, updates the proportional parameter of the driving current and the reference acceleration, and completes online matching.
The specific process of the step 4 is as follows:
in order to realize the motion time synchronism and the motion process smoothness of the robot position motion process, namely the non-drilling process, a kinematics track planning submodule in the main control module unifies the current motion time of each axis motor and realizes the motor speed smooth motion through sectional control;
step 401, dividing the process of the motor to be moved into 7 sections, namely, adding acceleration, uniformly accelerating, subtracting acceleration, uniformly speed, adding acceleration and subtracting acceleration, uniformly decelerating and subtracting deceleration, setting the process as adding acceleration section time, uniformly accelerating section time, subtracting acceleration section time, uniformly speed section time, adding acceleration and subtracting acceleration section time, uniformly decelerating section time and subtracting deceleration section time, and representing the number of the motor shaft;
step 402, starting point speed v of the motion processsEnd point velocity veMaximum velocity vmMaximum acceleration amMaximum jerk jmAnd the total displacement S is used as a planning constraint condition;
step 403, planning the movement time of the first axis, i.e. the X-axis speed change section, and determining whether a uniform speed change section is included, wherein the acceleration process is as follows:
if it is
Then
t1-3＝t1-1；
If it is
Then
t1-2＝0,t1-3＝t1-1The actual maximum acceleration during acceleration does not reach the limit value am；
Integrating the acceleration of each time segment according to the obtained time to obtain the corresponding speed of each segment, and corresponding to each segmentIntegrating the speed to obtain the displacement S of the acceleration sectionacc；
Step 404, obtaining the displacement S of the deceleration section by using symmetry in the deceleration process in the gear section planningdec＝Sacc,t1-6＝t1-2,t1-5＝t1-7＝t1-3＝t1-1；
Step 405, judging whether a uniform speed segment exists in the motion process, wherein the judgment criterion is Sdec+Sacc<S contains the uniform velocity section, otherwise does not contain the uniform velocity section;
step 406, if there is a constant speed segment, the time of the constant speed segment is
If the constant speed section does not exist, the time t of the constant speed section1-4＝0；
Step 407, repeating step 103 and step 106 until the planning of the second, third and fourth axes is completed;
step 408, comparing the total running time of each shaft, and taking the maximum value as the total synchronous running time of each shaft;
according to a constraint equation
Find t2And t4；
Wherein, the sum is the time for accelerating, uniformly accelerating and uniformly speed-keeping each shaft motor after the four shaft motors synchronously move;
if the constraint equation is not solved or t2<0, the acceleration adding section and the deceleration reducing section are not present, and the constraint equation is converted into
Solving for t from this equation1And t4In addition from the symmetry t7＝t5＝t3＝t1,t6＝t20; and four-shaft motor synchronous motion deviceThe time of deceleration, acceleration, deceleration, uniform deceleration and deceleration of each motor after beam; and is the displacement of the motor in the corresponding acceleration and deceleration phases;
and step 409, transmitting the obtained time of each section and the position quantity and the speed quantity on the corresponding section as driving data to a servo driving control module for execution.
The active compliance control decision in the step 5 is to adjust the weight factors of the active compliance control and the kinematic position control according to the current robot task state and the current actual pose state of the robot, and the specific process is as follows:
when the human-computer interaction task is drilling and the current state of the robot is close to or already located in a drilling area, the active compliance control decision sub-module improves compliance control weight and reduces position control weight so as to generate a control parameter adjusting instruction: using a large compliance control parameter and a small position control parameter; when the human-computer interaction task is movement or the current state of the robot is far away from a drilling area, the active compliance control decision sub-module reduces the compliance control weight and improves the position control weight so as to generate a control parameter adjusting instruction: using a small compliance control parameter and a large position control parameter; the compliance control parameter and the position control parameter are parameters which are adjusted in advance and stored in the system; the compliance control parameters include a large compliance control parameter and a small compliance control parameter, and the position control parameters include a large position control parameter and a small position control parameter.
The main control instruction in the step 7 is generated by a kinematics trajectory planning submodule and an active compliance control decision submodule, and the main control instruction comprises motor reference positions of all shafts, a drilling machine propulsion current and a control parameter adjusting instruction;
at least two sets of position rings, current ring parameters and a set of speed ring parameters which are debugged off line are arranged in the servo drive control module, wherein the parameters of the position ring 1 and the current ring 1 are suitable for precise kinematic position control, the parameters of the position ring 2 and the current ring 2 are suitable for active compliant force current control during drill propulsion, and the speed rings are the same in the two sets of control parameters; when the control parameter adjusting instruction in the main control instruction is to use a large compliance control parameter and a small position control parameter, the servo drive control module selects a control module consisting of a position ring 2, a speed ring and a current ring 2, the drill propulsion current in the main control instruction is a main control target, and the kinematic position control mainly plays a role in limiting and protecting at the moment, so that accidents such as collision in the drilling machine propulsion process are prevented; when the control parameter adjusting instruction in the main control instruction uses the small compliance control parameter and the large position control parameter, the servo drive control module selects a control module consisting of the position ring 1, the speed ring and the current ring 1, and the motor reference position in the main control instruction is controlled as a main control target, so that the rapid and accurate movement of the system is realized.
Advantageous effects
The invention adopts an active compliance control mechanism of a force/position hybrid control framework as a control scheme of the XYZR four-axis drilling robot, and in the point position motion control process of the robot, the position control is taken as a main part to ensure the speed and the smoothness of the motion process; in the drilling process, the force control taking the detection position information as a switching threshold value is mainly used to ensure that the acceleration of the drill bit pushed by the robot in the drilling process is strictly controlled within the deviation of an expected value; in order to avoid using expensive force sensors, an acceleration control index is converted into a force control index and then the force control index is converted into a current control index in the active compliance control process for design, current detection sensors carried by robot control systems are used as detection means for sensing, a current loop is used for controlling to obtain expected current, and the robot is driven to work to realize active compliance control; a set of flow and a device for automatically matching acceleration, force and current off-line/on-line are designed, so that time-consuming and tedious manual matching and calculating processes between acceleration, force and current are avoided; based on a drilling expert experience learning mechanism, a set of flow and device for self-learning expert drilling experience are designed, and complex drilling process modeling and data identification are not required to be additionally carried out. The invention has perfect function, clear structure, simple realization and low module coupling degree; meanwhile, the synchronism and the smoothness of the system motion are realized; the active compliance control decision sub-module is independently designed, and the part is not mixed in a control law any more, so that the method has the advantages of being clear, simple and easy to implement; when the related data in the drilling machine propelling process are obtained, complex drilling machine propelling process modeling and repeated splicing experiments of an instructive rule are avoided, the process is simple, the implementation is convenient, and the time is saved; expensive acceleration sensor and force sensor are avoided being used on line for each robot, so that cost is saved, and convenience is brought to users; the system control parameters are debugged off line, unstable factors and a system downtime process introduced by online adjustment of the control parameters are avoided, the switching mechanism of the kinematic position control and the active compliance force control is reasonable, the structure is simple to implement, the safety is high, and the universality is high.
Drawings
Fig. 1 is a schematic composition diagram of an active compliance control device of an XYZR four-axis drilling robot.
FIG. 2 is a schematic diagram of the operation of the active compliance control decision sub-module.
Fig. 3 is a control block diagram of the servo drive control module.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings. The invention provides an XYZR four-axis drilling robot active compliance control device, as shown in figure 1, the control objects of the device are a four-way servo motor module and an electric drill module, and the device comprises a main control module, a servo drive control module and a human-computer interaction module; the main control module is connected with the servo drive control module, the servo drive control module is connected with the electric drill module, and the main control module is also connected with the man-machine interaction module;
the main control module is used for completing kinematic trajectory planning, active compliance control decision, expert experience learning, acceleration-force-current offline matching, acceleration-force-current online matching, communication management, IO management and drive data interaction;
the servo drive control module is used for controlling the four servo motor modules in real time;
the electric drill module belongs to basic components of an XYZR four-axis drilling robot, comprises a frequency converter controlled by a main control module and a main shaft electric drill and is used for controlling the main shaft electric drill to complete drilling;
the human-computer interaction module is used for an operator to edit tasks, send instructions, display the working state of the robot and complete communication with the main control module.
The main control module comprises a kinematic trajectory planning sub-module, an active compliance control decision sub-module, an expert experience learning sub-module, an acceleration-force-current offline matching sub-module, an acceleration-force-current online matching sub-module, an RS485 communication sub-module, an IO control management sub-module, a power supply management sub-module, a safety control sub-module, a driving data interaction sub-module, a tool workpiece calibration sub-module, a PC debugging communication sub-module and an SD card read-write sub-module;
the main control module is composed of a WINDOWS system architecture industrial personal computer based on an INTEL X86 hardware platform, a LINUX system architecture industrial personal computer based on an INTEL X86 hardware platform, a VXWORKS system architecture industrial personal computer based on an INTEL X86 hardware platform or an embedded control platform based on an ARM architecture.
The human-computer interaction module comprises a task editing module, a state monitoring module, an instruction transceiving module and a serial port communication module;
the man-machine interaction module is composed of a teaching platform based on an independent operating system, or a teaching platform based on an operating system shared with a main control system, or an independent teaching platform based on a single chip microcomputer.
The servo drive control module comprises a main control data interaction module, a servo motor 1 drive control module, a servo motor 2 drive control module, a servo motor 3 drive control module and a servo motor 4 drive control module which are connected, wherein the servo motor 1 drive control module, the servo motor 2 drive control module, the servo motor 3 drive control module and the servo motor 4 drive control module are respectively connected with the servo motor 1 drive amplification module, the servo motor 2 drive amplification module, the servo motor 3 drive amplification module and the servo motor 4 drive amplification module, and then are respectively connected with four servo motor modules; the four-way servo motor module comprises a servo motor 1, a servo motor 2, a servo motor 3 and a servo motor 4, is a direct control object of the servo driving module, and is also a basic driving component for forming the XYZR four-axis drilling robot;
the servo drive control module is composed of a plurality of paths of completely independent servo drivers with current control and position control, a relative integrated servo driver composed of a plurality of DSPs or FPGAs, an absolute integrated servo driver composed of a DSP or an absolute integrated servo driver composed of an FPGA.
The active compliance control method of the XYZR four-axis drilling robot based on the device comprises the following specific processes:
step 101, connecting an acceleration sensor serial port data line in an electric drill module to a system PC debugging serial port, starting a drilling process expert experience learning submodule through a man-machine interaction module, and collecting drilling time of N groups of advanced technical workers in a drilling process and acceleration amplitude data in the time period, wherein N is more than 100;
102, calculating the average value and the variance of the drilling time of the acquired N groups of data and the 97.5% confidence interval of the data;
step 103, checking whether the drilling time of the N groups of data is within the confidence interval in the step 102, if so, rejecting the data, and assuming that the data left in the process is N1Group (d);
step 104, for N in step 1031Performing time normalization on the group data, performing data compression according to the average time when the drilling time is longer than the average time, and performing data expansion on the part with the drilling time shorter than the average time by taking the average time as a reference;
step 105, smoothing the data obtained in step 104, wherein the processing method adopts a moving average method, and then N is used1Averaging the group data according to sampling time points to obtain average drilling acceleration data after time normalization;
and 106, carrying out difference operation on the data obtained in the step 105, and dividing the data into acceleration adding data, acceleration homogenizing data and acceleration reducing data according to a difference result, wherein time periods corresponding to the three types of data are an acceleration adding time period, an acceleration homogenizing time period and an acceleration reducing time period respectively.
the acceleration-force-current offline matching sub-module and the acceleration-force-current online matching sub-module convert the acceleration required to be controlled in the punching process into control over the propulsion current through the force relationship; in a system prototype research and development stage, a serial port data line of an acceleration sensor in an electric drill module is connected to a system PC debugging serial port, an online acceleration-force-current matching function is started through a man-machine interaction module, then an acceleration-force-current offline matching submodule compares an actually acquired acceleration value with a reference acceleration to form negative feedback, and a proportional parameter of a driving current and the reference acceleration is adjusted to complete offline matching; before the first actual trial drilling, the acceleration-force-current online matching sub-module starts the proportional parameter of the driving current and the reference acceleration in the acceleration-force-current offline matching sub-module, controls the driving current to push the drilling machine to advance, detects the position of the drilling machine through the current pose state of the robot to perform second-order differential acquisition on the actual acceleration advanced by the drilling machine, then compares the actually acquired acceleration value with the reference acceleration to form negative feedback, updates the proportional parameter of the driving current and the reference acceleration, and completes online matching.
Step 3, teaching the robot work task through a human-computer interaction module;
step 4, the main control module finishes kinematics trajectory planning according to the teaching task, generates driving data and sends the driving data to the servo driving control module for reference execution;
the specific process of the step 4 is as follows:
in order to realize the motion time synchronism and the motion process smoothness of the robot position motion process, namely the non-drilling process, a kinematics track planning submodule in the main control module unifies the current motion time of each axis motor and realizes the motor speed smooth motion through sectional control;
step 401, dividing the process of the motor to be moved into 7 sections, namely, adding acceleration, uniformly accelerating, subtracting acceleration, uniformly speed, adding acceleration and subtracting acceleration, uniformly decelerating and subtracting deceleration, setting the process as adding acceleration section time, uniformly accelerating section time, subtracting acceleration section time, uniformly speed section time, adding acceleration and subtracting acceleration section time, uniformly decelerating section time and subtracting deceleration section time, and representing the number of the motor shaft;
step 402, starting point speed v of the motion processsEnd point velocity veMaximum velocity vmMaximum acceleration amMaximum jerk jmAnd the total displacement S is used as a planning constraint condition;
step 403, planning the movement time of the first axis, i.e. the X-axis speed change section, and determining whether a uniform speed change section is included, wherein the acceleration process is as follows:
if it is
Then
t1-3＝t1-1；
If it is
Then
t1-2＝0,t1-3＝t1-1The actual maximum acceleration during acceleration does not reach the limit value am；
Integrating the acceleration of each time segment according to the obtained time to obtain the corresponding speed of each segment, and integrating the corresponding speed of each segment to obtain the displacement S of the acceleration segmentacc；
Step 404, obtaining the displacement S of the deceleration section by using symmetry in the deceleration process in the gear section planningdec＝Sacc,t1-6＝t1-2,t1-5＝t1-7＝t1-3＝t1-1；
Step 405, judging whether a uniform speed segment exists in the motion process, wherein the judgment criterion is Sdec+Sacc<S contains the uniform velocity section, otherwise does not contain the uniform velocity section;
step 406, if there is a constant speed segment, the time of the constant speed segment is
If the constant speed section does not exist, the time t of the constant speed section1-4＝0；
Step 407, repeating step 103 and step 106 until the planning of the second, third and fourth axes is completed;
step 408, comparing the total running time of each shaft, and taking the maximum value as the total synchronous running time of each shaft;
according to a constraint equation
Find t2And t4；
Wherein, the sum is the time for accelerating, uniformly accelerating and uniformly speed-keeping each shaft motor after the four shaft motors synchronously move;
if the constraint equation is not solved or t2<0, the acceleration adding section and the deceleration reducing section are not present, and the constraint equation is converted into
Solving for t from this equation1And t4In addition from the symmetry t7＝t5＝t3＝t1,t6＝t20; and the time of deceleration, acceleration, deceleration, uniform deceleration and deceleration of each shaft motor after the synchronous motion of the four shaft motors is restrained respectively; and is the displacement of the motor in the corresponding acceleration and deceleration phases;
and step 409, transmitting the obtained time of each section and the position quantity and the speed quantity on the corresponding section as driving data to a servo driving control module for execution.
Step 5, the main control module carries out active compliance control decision according to the robot state fed back by the servo drive control module, determines used position control parameters and compliance control parameters, and sends the position control parameters and the compliance control parameters to the servo drive module for reference execution through the drive data interaction sub-module;
the active compliance control decision-making is to adjust the weight factors of the active compliance control and the kinematic position control according to the current robot task state and the current actual pose state of the robot, and the specific process is as shown in fig. 2:
when the human-computer interaction task is drilling and the current state of the robot is close to or already located in a drilling area, the active compliance control decision sub-module improves compliance control weight and reduces position control weight so as to generate a control parameter adjusting instruction: using a large compliance control parameter and a small position control parameter; when the human-computer interaction task is movement or the current state of the robot is far away from a drilling area, the active compliance control decision sub-module reduces the compliance control weight and improves the position control weight so as to generate a control parameter adjusting instruction: using a small compliance control parameter and a large position control parameter; the compliance control parameter and the position control parameter are parameters which are adjusted in advance and stored in the system; the compliance control parameters include a large compliance control parameter and a small compliance control parameter, and the position control parameters include a large position control parameter and a small position control parameter.
Step 6, the master control module simultaneously completes the management and decision of the IO control management submodule;
step 7, the servo driving module completes real-time control of the servo motors of all the shafts according to the main control instruction; the main control instruction is generated by a kinematics trajectory planning submodule and an active compliance control decision submodule, and comprises motor reference positions of all axes, drilling machine propulsion current and control parameter adjusting instructions; as shown in fig. 3, at least two sets of position loop, current loop parameters and a set of speed loop parameters which are debugged off-line are arranged in the servo drive control module, wherein the parameters of the position loop 1 and the current loop 1 are suitable for precise kinematic position control, the parameters of the position loop 2 and the current loop 2 are suitable for active compliant force current control during drill propulsion, and the speed loops are the same in the two sets of control parameters; when the control parameter adjusting instruction in the main control instruction is to use a large compliance control parameter and a small position control parameter, the servo drive control module selects a control module consisting of a position ring 2, a speed ring and a current ring 2, the drill propulsion current in the main control instruction is a main control target, and the kinematic position control mainly plays a role in limiting and protecting at the moment, so that accidents such as collision in the drilling machine propulsion process are prevented; when the control parameter adjusting instruction in the main control instruction uses the small compliance control parameter and the large position control parameter, the servo drive control module selects a control module consisting of the position ring 1, the speed ring and the current ring 1, and the motor reference position in the main control instruction is controlled as a main control target, so that the rapid and accurate movement of the system is realized.
And 8, starting and stopping the electric drill by the electric drill module according to the state of the IO control management submodule to drill.
Claims (9)
1. An active compliance control device of an XYZR four-axis drilling robot is characterized by comprising a main control module, a servo drive control module and a human-computer interaction module, wherein control objects of the active compliance control device are four servo motor modules and an electric drill module; the main control module is connected with the servo drive control module, the servo drive control module is connected with the electric drill module, and the main control module is also connected with the man-machine interaction module;
the main control module is used for completing kinematic trajectory planning, active compliance control decision, expert experience learning, acceleration-force-current offline matching, acceleration-force-current online matching, communication management, IO management and drive data interaction;
the servo drive control module is used for controlling the four servo motor modules in real time;
the electric drill module belongs to basic components of an XYZR four-axis drilling robot, comprises a frequency converter controlled by a main control module and a main shaft electric drill and is used for controlling the main shaft electric drill to complete drilling;
the human-computer interaction module is used for an operator to edit tasks, send instructions, display the working state of the robot and complete communication with the main control module;
the main control module comprises an acceleration-force-current offline matching submodule and an acceleration-force-current online matching submodule, wherein the acceleration-force-current offline matching submodule compares an actually acquired acceleration value with a reference acceleration to form negative feedback, and adjusts a proportional parameter of a driving current and the reference acceleration to complete offline matching; before the first actual trial drilling, the acceleration-force-current online matching sub-module starts the proportional parameters of the driving current and the reference acceleration in the acceleration-force-current offline matching sub-module, controls the driving current to push the drilling machine to advance, detects the position of the drilling machine through the current pose state of the robot to perform second-order differential acquisition on the actual acceleration advanced by the drilling machine, then compares the actually acquired acceleration value with the reference acceleration to form negative feedback, updates the proportional parameters of the driving current and the reference acceleration, and completes online matching.
2. The XYZR four-axis drilling robot active compliance control device according to claim 1, wherein the main control module further comprises a kinematics trajectory planning sub-module, an active compliance control decision sub-module, an expert experience learning sub-module, an RS485 communication sub-module, an IO control management sub-module, a power management sub-module, a safety control sub-module, a driving data interaction sub-module, a tool workpiece calibration sub-module, a PC debugging communication sub-module, and an SD card read-write sub-module;
the tool workpiece calibration sub-module is a serial connection relation in sequence, the modules are defined as a first-class sub-module through data communication connection, and the first-class sub-module only needs to be operated once before the system is operated online to generate necessary control data for subsequent use; the kinematic trajectory planning submodule, the active compliance control decision submodule, the IO control management submodule and the driving data interaction submodule are sequentially connected in series, the submodules are defined as a second-class submodule through data communication connection, the second-class submodule is a module which must run when the system runs on line, the second-class submodule uses data generated by the first-class submodule, and the second-class submodule and the first-class submodule are connected through data communication; defining the RS485 communication sub-module and the PC debugging communication sub-module as a third sub-module, wherein the third sub-module is used for man-machine interaction operation, and the relation between the third sub-module and other sub-modules is a concurrent synchronization relation; defining a power management sub-module, a safety control sub-module and an SD card read-write sub-module as a fourth sub-module, wherein the fourth sub-module and other sub-modules are in a concurrent synchronization relationship;
the main control module is composed of a WINDOWS system architecture industrial personal computer based on an INTEL X86 hardware platform, a LINUX system architecture industrial personal computer based on an INTEL X86 hardware platform, a VXWORKS system architecture industrial personal computer based on an INTEL X86 hardware platform or an embedded control platform based on an ARM architecture.
3. The active compliance control device of the XYZR four-axis drilling robot of claim 1, wherein the human-computer interaction module comprises a task editing sub-module, a state monitoring sub-module, an instruction transceiving sub-module and a serial communication sub-module;
in the man-machine interaction module, a task editing sub-module and a state monitoring sub-module are in a concurrent and synchronous relation and are sequentially connected with an instruction receiving and transmitting sub-module and a serial communication sub-module in series through data lines;
the man-machine interaction module is composed of a teaching platform based on an independent operating system, or a teaching platform based on an operating system shared with a main control system, or an independent teaching platform based on a single chip microcomputer.
4. The XYZR four-axis drilling robot active compliance control device according to claim 1, wherein the servo drive control module comprises a master control data interaction module connected with a servo motor 1 drive control module, a servo motor 2 drive control module, a servo motor 3 drive control module, and a servo motor 4 drive control module, the servo motor 1 drive control module, the servo motor 2 drive control module, the servo motor 3 drive control module, and the servo motor 4 drive control module are respectively connected with a servo motor 1 drive amplification module, a servo motor 2 drive amplification module, a servo motor 3 drive amplification module, and a servo motor 4 drive amplification module, and then respectively connected with four servo motor modules; the four-way servo motor module comprises a servo motor 1, a servo motor 2, a servo motor 3 and a servo motor 4, is a direct control object of the servo drive control module, and is also a basic driving component for forming the XYZR four-axis drilling robot;
the servo drive control module is composed of a plurality of paths of completely independent servo drivers with current control and position control, a relative integrated servo driver composed of a plurality of DSPs or FPGAs, an absolute integrated servo driver composed of a DSP or an absolute integrated servo driver composed of an FPGA.
5. An XYZR four-axis drilling robot active compliance control method based on the device of claim 1, which is specifically characterized in that:
step 1, an operator interacts with a main control module through a man-machine interaction module to control a robot to complete expert experience learning in a drilling process;
step 2, commanding a system to complete acceleration-force-current off-line and on-line matching through a human-computer interaction module, determining a proportional parameter of the driving current and the reference acceleration, and sending the proportional parameter to a servo driving control module for use through a driving data interaction sub-module;
step 3, teaching the robot work task through a human-computer interaction module;
step 4, the main control module finishes kinematics trajectory planning according to the teaching task, generates driving data and sends the driving data to the servo driving control module for reference execution;
step 5, the main control module carries out active compliance control decision according to the robot state fed back by the servo drive control module, determines used position control parameters and compliance control parameters, and sends the position control parameters and the compliance control parameters to the servo drive control module for reference execution through the drive data interaction sub-module;
step 6, the master control module simultaneously completes the management and decision of the IO control management submodule;
step 7, the servo drive control module completes real-time control of the servo motors of all the axes according to the main control instruction;
and 8, starting and stopping the electric drill by the electric drill module according to the state of the IO control management submodule to drill.
6. The method of claim 5, wherein the expert experience learning process, namely the work of the expert experience learning submodule, comprises the following specific steps:
step 101, connecting an acceleration sensor serial port data line in an electric drill module to a system PC debugging serial port, starting a drilling process expert experience learning submodule through a man-machine interaction module, and collecting drilling time of N groups of advanced technical workers in a drilling process and acceleration amplitude data in the time period, wherein N is more than 100;
102, calculating the average value and the variance of the drilling time of the acquired N groups of data and the 97.5% confidence interval of the data;
step 103, checking whether the drilling time of the N groups of data is within the confidence interval in the step 102, if so, rejecting the data, and assuming that the data left in the process is N1Group (d);
step 104, for N in step 1031Performing time normalization on the group data, performing data compression according to the average time when the drilling time is longer than the average time, and performing data expansion on the part with the drilling time shorter than the average time by taking the average time as a reference;
step 105, smoothing the data obtained in step 104, wherein the processing method adopts a moving average method, and then N is used1Averaging the group data according to sampling time points to obtain average drilling acceleration data after time normalization;
and 106, carrying out difference operation on the data obtained in the step 105, and dividing the data into acceleration adding data, acceleration homogenizing data and acceleration reducing data according to a difference result, wherein time periods corresponding to the three types of data are an acceleration adding time period, an acceleration homogenizing time period and an acceleration reducing time period respectively.
7. The method according to claim 5, wherein the specific process of determining the proportional parameter of the driving current and the reference acceleration in step 2 is
The acceleration-force-current offline matching sub-module and the acceleration-force-current online matching sub-module convert the acceleration required to be controlled in the punching process into control over the propulsion current through the force relationship; in a system prototype research and development stage, a serial port data line of an acceleration sensor in an electric drill module is connected to a system PC debugging serial port, an online acceleration-force-current matching function is started through a man-machine interaction module, then an acceleration-force-current offline matching submodule compares an actually acquired acceleration value with a reference acceleration to form negative feedback, and a proportional parameter of a driving current and the reference acceleration is adjusted to complete offline matching; before the first actual trial drilling, the acceleration-force-current online matching sub-module starts the proportional parameter of the driving current and the reference acceleration in the acceleration-force-current offline matching sub-module, controls the driving current to push the drilling machine to advance, detects the position of the drilling machine through the current pose state of the robot to perform second-order differential acquisition on the actual acceleration advanced by the drilling machine, then compares the actually acquired acceleration value with the reference acceleration to form negative feedback, updates the proportional parameter of the driving current and the reference acceleration, and completes online matching.
8. The method according to claim 5, wherein the active compliance control decision in step 5 is to adjust the weight factors of the active compliance control and the kinematic position control according to the current robot task state and the current actual pose state of the robot by:
when the human-computer interaction task is drilling and the current state of the robot is close to or already located in a drilling area, the active compliance control decision sub-module improves compliance control weight and reduces position control weight so as to generate a control parameter adjusting instruction: using a large compliance control parameter and a small position control parameter; when the human-computer interaction task is movement or the current state of the robot is far away from a drilling area, the active compliance control decision sub-module reduces the compliance control weight and improves the position control weight so as to generate a control parameter adjusting instruction: using a small compliance control parameter and a large position control parameter; the compliance control parameter and the position control parameter are parameters which are adjusted in advance and stored in the system; the compliance control parameters include a large compliance control parameter and a small compliance control parameter, and the position control parameters include a large position control parameter and a small position control parameter.
9. The method according to claim 5, wherein the main control instruction in the step 7 is generated by a kinematics trajectory planning sub-module and an active compliance control decision sub-module, and the main control instruction comprises a motor reference position of each shaft, a drilling machine propulsion current and a control parameter adjusting instruction;
at least two sets of position rings, current ring parameters and a set of speed ring parameters which are debugged off line are arranged in the servo drive control module, wherein the parameters of the position ring 1 and the current ring 1 are suitable for precise kinematic position control, the parameters of the position ring 2 and the current ring 2 are suitable for active compliant force current control during drill propulsion, and the speed rings are the same in the two sets of control parameters; when the control parameter adjusting instruction in the main control instruction is to use a large compliance control parameter and a small position control parameter, the servo drive control module selects a control module consisting of a position ring 2, a speed ring and a current ring 2, the drill propulsion current in the main control instruction is a main control target, and the kinematic position control mainly plays a role in limiting and protecting at the moment, so that accidents such as collision in the drilling machine propulsion process are prevented; when the control parameter adjusting instruction in the main control instruction uses the small compliance control parameter and the large position control parameter, the servo drive control module selects a control module consisting of the position ring 1, the speed ring and the current ring 1, and the motor reference position in the main control instruction is controlled as a main control target, so that the rapid and accurate movement of the system is realized.
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