CN109324601B - Test platform of robot controller or control system based on hardware-in-the-loop - Google Patents
Test platform of robot controller or control system based on hardware-in-the-loop Download PDFInfo
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- CN109324601B CN109324601B CN201811336262.XA CN201811336262A CN109324601B CN 109324601 B CN109324601 B CN 109324601B CN 201811336262 A CN201811336262 A CN 201811336262A CN 109324601 B CN109324601 B CN 109324601B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
Abstract
The invention relates to a robot controller or control system test platform based on a hardware-in-loop, which is used for performing function and performance test, fault injection test and bus function test on the robot controller or control system, and is characterized in that the test system comprises: a control signal output module; a control signal input module; the main control module comprises a simulation object model generation unit, a test script generation unit, a signal acquisition unit, a man-machine interaction unit and a fault injection unit. Aiming at the characteristics that an industrial robot controller or a control system is more and more complex, a bus structure is various, safety requirements are higher and higher, and real-time requirements are strong, the invention designs a semi-physical simulation test platform based on the robot controller or the control system on the basis of the existing research. The platform supports simulation tests of various robot controllers or control systems by combining function and performance tests, fault injection tests and bus function tests, supports various bus interface extensions and can automatically execute the tests. The controller or the control system of the invention has good universality, high testing efficiency and good real-time effect.
Description
Technical Field
The invention relates to a hardware-in-loop simulation test platform for a robot controller or a control system, which is used for performing semi-physical simulation test on the controller or the control system of a robot (especially an industrial robot).
Background
Industrial robots have been developed to date, and have converged with various technologies such as automation, computer networking, sensor, electronic and electrical technology, artificial intelligence, mechanics and bionics, to a high degree of intelligence. Meanwhile, the number of industrial robots is also increasing continuously, and large-scale application is achieved. And the controller or the control system is used as a core component of the industrial robot and plays an important role in the safe operation of the robot. Therefore, the controller or the control system needs to be subjected to a rigorous test before it is shipped out of the factory.
Throughout the development of industrial robots, the complexity of the controller or control system is increasing. In order to verify the design scheme of the controller or the control system and reduce the potential hazards in the design, the function and performance test of the controller or the control system needs to be carried out, and whether the design meets the design requirements is verified.
In addition, controllers or control systems are evolving from single embedded systems to multi-bus, multi-node coordinated systems. The nodes adopt a composite network, such as CAN, serial port, Ethernet, EtherCAT and other bus types, as a carrier to collect, transmit and control information and data, the interaction relationship is complex, the types of bus interfaces are numerous, the quality assurance is a difficult problem, and the bus function test needs to be carried out on the bus.
Security of controllers or control systems is becoming more and more important, and security holes are increasing year by year for security reasons. In order to improve the security of the controller or the control system, the vulnerability needs to be detected and repaired, but the manual detection is too costly. The fault injection test can be used for detecting the controller or the control system and verifying the robustness and the safety of the controller or the control system.
Aiming at the problems of the industrial robot controller or the control system, the invention designs a semi-physical simulation platform based on the industrial robot controller or the control system. The semi-physical simulation test is used as an important means for quality assurance, and has been increasingly applied, such as high-speed train network control, industrial production and monitoring, satellite attitude control and the like, and a special semi-physical simulation test platform is established, but the semi-physical simulation test platform is special and has insufficient universality.
Disclosure of Invention
The invention aims to provide a hardware-in-loop-based semi-physical simulation test platform specially aiming at a robot controller or a control system.
In order to achieve the above object, a technical solution of the present invention is to provide a test platform for a robot controller or a control system based on a hardware-in-loop, which is used for performing a function and performance test, a fault injection test, and a bus function test on the robot controller or the control system, and is characterized in that the test system includes:
the control signal output module is used for injecting the test script into the controller or the control system through the virtual communication bus and the real bus interface, so that the controller or the control system runs according to the test script and generates a control signal for controlling the moving part;
the control signal input module is used for inputting a control signal generated by a controller or a control system to the main control module through the virtual communication bus;
the main control module comprises a simulation object model generation unit, a test script generation unit, a signal acquisition unit, a man-machine interaction unit and a fault injection unit, wherein:
the fault injection unit is used for generating fault information according to common fault types of a controller or a control system and fault types which cannot be automatically loaded in a semi-simulation test when a fault injection test is carried out, and injecting the fault information into the simulation object model generation unit; when a bus function test is carried out, generating a bus interference signal according to needs, and injecting the bus interference signal into a virtual communication bus;
a simulation object model generating unit for generating a normal simulation object model of the moving part according to the moving part controlled by the controller or the control system, or the fault simulation object model is used for generating the fault simulation object model of the moving component according to the moving component controlled by the controller or the control system and the fault information injected by the fault injection unit, when the function and performance test or the bus function test is performed, the normal simulation object model receives the control signal from the control signal input module, performs the simulation action according to the control information, when a fault injection test is carried out, a user utilizes a human-computer interaction unit to select and switch between a normal simulation object model and a fault simulation object model, the normal simulation object model or the fault simulation object model receives a control signal from a control signal input module, and a simulation action is carried out according to the control information;
the system comprises a test script generating unit, a human-computer interaction unit, a control unit and a control unit, wherein a user inputs basic parameters of a moving part controlled by a controller or a control system and key parameters of the controller or the control system into the test script generating unit by using the human-computer interaction unit, the test script generating unit independently stores the key parameters into an initial file, and the test script generating unit generates a test script according to the input basic parameters and key parameters and the moving part controlled by the controller or the control system;
and the signal acquisition unit is used for acquiring simulation output parameters of the normal simulation object model and/or the fault simulation object model after the simulation action, generating test conclusions of the function and performance test, the fault injection test or the bus function test according to the simulation output parameters, and checking the test conclusions by using the human-computer interaction unit.
Preferably, the main control module performs imaging editing through LEBVIEW software.
Preferably, the main control module uses the DAQ data acquisition unit and the XNET unit in the measurement I/O module of the LABVIEW, the DAQ data acquisition unit configures the controller or the control system using the key parameter, the XNET module checks whether the controller or the control system can execute the function and performance test, and if so, performs the corresponding test.
Preferably, the main control module is deployed on a plurality of PCs and controlled by a plurality of users, or is deployed on a single PC.
Aiming at the characteristics of complex interaction relation, various buses and strong real-time requirement of a robot system, the invention designs a semi-physical simulation test platform based on a robot controller or a control system on the basis of the existing research. The platform supports simulation tests of various robot controllers or control systems by combining function and performance tests, fault injection tests and bus function tests, supports various bus interface extensions and can automatically execute the tests. The controller or the control system of the invention has good universality, high testing efficiency and good real-time effect.
Drawings
FIG. 1 is a general system block diagram of the present invention;
FIG. 2 is an overall workflow diagram of the present invention;
FIG. 3 is a schematic diagram of the hardware components of the present invention;
FIG. 4 is a test flow diagram of the functional and performance test sub-platform;
FIG. 5 is a state diagram of the operation of the fault model;
fig. 6 is an operation state diagram of the bus function test.
Detailed Description
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention may be made by those skilled in the art after reading the teaching of the present invention, and such equivalents may fall within the scope of the present invention as defined in the appended claims.
On the basis of the existing research, the overall technical scheme of the robot controller or control system test platform based on the hardware-in-loop designed by the invention is shown in fig. 1. The invention can simulate the peripheral test environment of an industrial robot, take the received data as input and transmit the data into a tested piece (namely a controller or a control system for the robot) through the virtual communication bus.
The semi-physical simulation test system adopts the design concept of 'platform + multifunction', the platform comprises a main control module, a controller or a control system and a control signal input and output module, and the realized multifunction comprises the functions of realizing function and performance test, fault injection (fault injection) test system and bus function test. The main control module can be deployed on a plurality of PCs and controlled by a plurality of testers, and can also be deployed on a single PC and is responsible for test environment configuration, test script compiling and the like. The control signal input and output module is responsible for interacting the whole test environment, providing reliable data communication, and injecting test data into a controller or a control system through a specific bus interface to complete actual test.
The overall work flow of the semi-physical simulation test platform is shown in fig. 2, the main control module generates a test script according to a simulation model of an object controlled by a controller or a control system, namely a simulation model of a robot moving part and parameters input by a user from the outside, and the test script is injected into the controller or the control system through a virtual bus of a semi-physical simulation environment and a real bus interface. The controller or the control system operates according to the generated test control script, and the main control module acquires output data of the controller or the control system in real time and carries out corresponding processing.
As shown in FIG. 3, the hardware of the semi-physical simulation testing system includes a main control, a data acquisition card and a display screen. The main control module comprises a signal processing module and a model simulation module, graphical programming is carried out through LABVIEW software, a corresponding test port is configured, and a required control signal is output. The data acquisition card is responsible for acquiring current signals of the motor or signals such as voltage of a controller or a control system, analyzing current and rotating speed information of the motor in LABVIEW software, and drawing a needed curve. Finally, the control performance of the controller or control system is determined by analyzing the specific curve.
The invention relates to a test object of a test platform of a robot controller or a control system based on a hardware-in-loop, which is designed by the invention, is the controller or the control system of an industrial robot, the controller or the control system adopts a real controller or the control system to simulate the moving parts of the robot, and the established simulation model is established in a PC. The moving parts of the robot comprise important parts such as a motor, a driver and the like. The test platform uses LabVIEW software to design a set of controller or control system automatic test system, which can test various controllers or control systems. In this embodiment, the test platform uses a bus to communicate with the controller or the control system, so that data transmission can be stably and rapidly performed.
In the present invention, the controller or control system is the part to be tested, which is the core part of the industrial robot, which controls the working mode and status of the industrial robot. The signals of the controller or control system include a power signal, a motor signal, a vehicle speed signal, a sensor signal, and the like. The signal types include analog signals, PWM signals and digital signals, and cover most common signal types. In the control process of the industrial robot, in order to make a controller or a control system work normally, appropriate input signals and CAN signals must be provided, and the performance of the industrial robot CAN be evaluated by collecting output signals of the industrial robot. In the present invention, the object to be tested includes at least controllers or control systems of the type of cartesian robot, tripod robot, parallel robot, articulated robot, etc.
The main control module is described below with three different test functions implemented by the present invention:
1) function and performance testing sub-platform
The platform mainly performs function and performance tests of the controller or the control system. The function and performance test belongs to the last test of the controller or the control system leaving the factory, but the traditional manual test has the defects of long test period, multiple test items and the like, and the requirement of fast-rhythm test cannot be met.
In the function and performance testing sub-platform, a simulation model of the robot motion part is established, and the simulation model acquires control information in real time when the simulation model is in simulation operation under the control of a controller or a control system, so that the function and performance testing of the controller or the control system is completed. The simulation model established by LABVIEW can realize microsecond-level real-time simulation, and meets the requirements of the hardware-in-the-loop real-time simulation of a common controller or a control system. Besides high-efficiency real-time simulation, modules such as A/D conversion, PWM detection, a position sensor and the like are needed at the periphery of the main control to serve as a transfer station of control signals. In addition, the multi-path digital-to-analog conversion module on the controller or the control system peripheral is used for detecting the voltage, the current, the temperature and other information of the controller or the control system.
The main control module mainly comprises an embedded controller or a control system, and the embedded controller or the control system is mainly suitable for modular instruments and data acquisition application. Meanwhile, the main control module comprises a fault injection hard disk drive, a serial port and other peripheral I/O. The data acquisition module converts the current signal of the motor to be detected into a smaller current signal or a smaller voltage signal so as to facilitate the acquisition work of the data acquisition card.
In many programming jobs, the test platform chooses the LABVIEW programming software. The LABVIEW is different from other text programming languages, and is a graphical programming language, and only needs to add required controls or tools to a front panel or a program flow chart in a graphical programming mode. LABVIEW has a multi-threaded mode of operation, and can simultaneously complete multiple tasks. When the test is started, a tester only needs to click to start the test, and the main control can automatically complete the whole test process, including specific functions, performance curves, judgment of each evaluation index, storage of test data, test data under different working conditions and the like.
The testing process of the whole function and performance testing sub-platform is shown in fig. 4. Parameter configuration: the data acquisition card acquires voltage or current signals of the controller or the control system and transmits the signals to the master control. The DAQ configures a board card corresponding to the bus, so that the main controller can output a PWM signal, a digital signal, an analog voltage signal, and the like required by the controller or the control system. The XNET module is mainly used for outputting CAN signals. Checking whether the controller or the control system can execute the function and performance test, and if so, carrying out the corresponding test. The input module of the man-machine interaction module of the LABVIEW is used for inputting basic parameters corresponding to a control object of the controller or the control system, and key parameters of the controller or the control system are written into an initial file. When testing different controllers or control systems, only the key parameters of the control object need to be changed, and the complicated process of switching the human-computer interaction interface back and forth is avoided. And selecting a corresponding test type according to the test requirements, including the type of the controller or the control system. And when the test is finished, storing the curve obtained by the test and the curve of the key parameter.
2) Fault injection test sub-platform
The functional and performance test of the controller or the control system is indispensable in the industrial robot testing link, and can detect some functional problems which may occur in the running process of the robot to the maximum extent. Due to the fact that no real-scene test environment exists in the semi-physical simulation, many problems occurring in the actual operation process may not be exposed. The test platform comprises a fault injection test or a fault injection test of a controller or a control system.
In order to better verify the safety of a controller or a control system, a fault injection test sub-platform is built on the platform on the basis of a function and performance test sub-platform. The platform respectively designs an object model with a fault according to common fault types of a robot controller or a control system and fault types which cannot be automatically loaded in a semi-physical simulation test, and designs a human-computer interaction interface to switch a normal object model and a fault object model. During the simulation, the fault type can also be modified by changing the important coefficients in the fault object model. The operating state of the fault model is shown in fig. 5.
3) Bus function test sub-platform
The bus function test can verify whether the controller or the control system meets the design requirements of the bus from the aspects of physical characteristics, communication data and network behaviors of the bus. When the conformity of the real-time state of the controller or the control system and the user requirement is verified, the bus function test can also provide a basis for the later-stage modification of the controller or the control system.
The bus function test sub-platform needs test tools such as a power supply, a universal meter, an oscilloscope, a signal generator and the like. Firstly, in the process of testing the bus function, compiling a test program, setting a simulation node and configuring a test condition; monitoring the motion waveform of the bus in the test process, and analyzing the signal quality of the bus according to the motion waveform; under the condition of need, inputting relevant data of bus interference for simulating bus fault; and finally, recording data generated by the test and generating a test report. The operating state of the bus function test is shown in fig. 6.
Claims (4)
1. A robot controller or control system test platform based on hardware-in-the-loop is used for performing function and performance test, fault injection test and bus function test on the robot controller or control system, and is characterized in that the test platform comprises:
the control signal output module is used for injecting the test script into the controller or the control system through the virtual communication bus and the real bus interface, so that the controller or the control system runs according to the test script and generates a control signal for controlling the moving part;
the control signal input module is used for inputting a control signal generated by a controller or a control system to the main control module through the virtual communication bus;
the main control module comprises a simulation object model generation unit, a test script generation unit, a signal acquisition unit, a man-machine interaction unit and a fault injection unit, wherein:
the fault injection unit is used for generating fault information according to common fault types of a controller or a control system and fault types which cannot be automatically loaded in a semi-simulation test when a fault injection test is carried out, and injecting the fault information into the simulation object model generation unit; when a bus function test is carried out, generating a bus interference signal according to needs, and injecting the bus interference signal into a virtual communication bus;
a simulation object model generating unit for generating a normal simulation object model of the moving part according to the moving part controlled by the controller or the control system, or the fault simulation object model is used for generating the fault simulation object model of the moving component according to the moving component controlled by the controller or the control system and the fault information injected by the fault injection unit, when the function and performance test or the bus function test is performed, the normal simulation object model receives the control signal from the control signal input module, performs the simulation action according to the control information, when a fault injection test is carried out, a user utilizes a human-computer interaction unit to select and switch between a normal simulation object model and a fault simulation object model, the normal simulation object model or the fault simulation object model receives a control signal from a control signal input module, and a simulation action is carried out according to the control information;
the system comprises a test script generating unit, a human-computer interaction unit, a control unit and a control unit, wherein a user inputs basic parameters of a moving part controlled by a controller or a control system and key parameters of the controller or the control system into the test script generating unit by using the human-computer interaction unit, the test script generating unit independently stores the key parameters into an initial file, and the test script generating unit generates a test script according to the input basic parameters and key parameters and the moving part controlled by the controller or the control system;
and the signal acquisition unit is used for acquiring simulation output parameters of the normal simulation object model and/or the fault simulation object model after the simulation action, generating test conclusions of the function and performance test, the fault injection test or the bus function test according to the simulation output parameters, and checking the test conclusions by using the human-computer interaction unit.
2. The hardware-in-the-loop based robot controller or control system test platform of claim 1, wherein the master control module is graphically edited by LABVIEW software.
3. The hardware-in-the-loop based robot controller or control system testing platform of claim 2, wherein the main control module utilizes the DAQ data acquisition unit and XNET unit in the measurement I/O module of the LABVIEW, the DAQ data acquisition unit configures the controller or control system with the key parameters, the XNET unit checks whether the controller or control system can perform the function and performance tests, and if so, performs the corresponding tests.
4. A hardware-in-the-loop based robot controller or control system test platform as claimed in claim 1, wherein the master control module is deployed on multiple PCs controlled by multiple users or on a single PC.
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| CN109324601A (en) | 2019-02-12 |
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