CN109483547B - Robot control system, robot abnormal signal detection method and robot - Google Patents

Robot control system, robot abnormal signal detection method and robot Download PDF

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Publication number
CN109483547B
CN109483547B CN201811564601.XA CN201811564601A CN109483547B CN 109483547 B CN109483547 B CN 109483547B CN 201811564601 A CN201811564601 A CN 201811564601A CN 109483547 B CN109483547 B CN 109483547B
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slave station
robot
control system
signal detection
slave
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CN109483547A (en
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刘正勇
王毅
王松柏
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Hefei Sineva Intelligent Machine Co Ltd
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Hefei Sineva Intelligent Machine Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Programme-controlled manipulators
    • B25J9/16Programme controls
    • B25J9/1628Programme controls characterised by the control loop
    • B25J9/1643Programme controls characterised by the control loop redundant control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J19/00Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
    • B25J19/06Safety devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Programme-controlled manipulators
    • B25J9/16Programme controls
    • B25J9/1628Programme controls characterised by the control loop
    • B25J9/1653Programme controls characterised by the control loop parameters identification, estimation, stiffness, accuracy, error analysis

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  • Engineering & Computer Science (AREA)
  • Robotics (AREA)
  • Mechanical Engineering (AREA)
  • Manipulator (AREA)

Abstract

The invention discloses a robot control system, a robot abnormal signal detection method and a robot, relates to the technical field of robot control, and aims to solve the problem that a certain node on a wire harness of a physical connection between a master station and a slave station is abnormal and difficult to check and position. The robot control system includes: the master station is connected with the slave stations through communication buses and comprises a master controller and a level signal detection unit which are connected; each slave station is connected with an adjacent slave station through a serial circuit, the signal input end of the serial circuit is connected with a high-level signal source, and the signal output end of the serial circuit is connected with a level signal detection unit; each slave station also comprises a signal detection device and a microcontroller, wherein one end of the signal detection device is connected with the signal input end of the slave station, the other end of the signal detection device is connected with the microcontroller, and the microcontroller is used for receiving signals sent by the sensors to control the nodes in the slave stations to be disconnected. The invention is used for robot control.

Description

Robot control system, robot abnormal signal detection method and robot
Technical Field
The invention relates to the technical field of robot control, in particular to a robot control system, a robot abnormal signal detection method and a robot.
Background
With the development of society and the advancement of science and technology, robots are applied to more and more fields. Most of the current robot control systems adopt a master-slave bus type distributed structure, namely a master station and a plurality of slave stations, wherein the master station and each slave station are interconnected in a communication bus mode; the master station comprises a main controller, and the main controller is responsible for calculation, decision and motion control; the slave station comprises a microcontroller and sensors, the microcontroller is dispersedly installed on the robot body and is responsible for acquisition of sensor signals and control of actuator actions. In a robot control system, the sensor is usually a safety sensor for safety indication, and specifically the sensor acts to indicate that the robot has moved to an extreme position or that an operator has intervened in the working space of the robot. To ensure the safety of the operator and the integrity of the robot, it is important that the master controller responds in time according to the sensor actions. However, in the conventional bus-type distributed control system, all signals are transmitted through the communication bus, and delay is inevitable.
The prior art improves the problems, except that bus communication is adopted, sensor signals required by each shaft on the robot body are connected in series to the main controller through physical connection lines, and when the main controller detects level signal changes, all actuators are controlled to stop working, so that timely response to the sensor signals is realized. However, the control system has the following problems in the implementation process: if all the safety sensors work normally, and signals received or sent on the communication bus are normal, and a certain node on the wire harness of the physical connection line has a fault, such as wire harness fracture, poor contact, short circuit and the like, the main controller can detect that the level signal is abnormal, so that an alarm is given. For the alarm, the signal states fed back through the communication bus are normal, but fault points are difficult to locate, so that the problems of long troubleshooting time and high maintenance difficulty are caused.
Disclosure of Invention
The embodiment of the invention provides a robot control system, which solves the problem that a certain node on a wire harness of a physical connection between a master station and a slave station is abnormal but difficult to check and position on the premise of shortening the response time of a master controller to a sensor signal.
In one aspect, an embodiment of the present invention provides a robot control system, including: the master station is connected with the slave stations through communication buses and comprises a master controller and a level signal detection unit which are connected; each slave station is connected with the adjacent slave station through a serial circuit, the signal input end of the serial circuit is connected with a high-level signal source, and the signal output end of the serial circuit is connected with the level signal detection unit; each slave station further comprises a signal detection device and a microcontroller, one end of the signal detection device is connected with the signal input end of the slave station, the other end of the signal detection device is connected with the microcontroller, and the microcontroller is used for receiving signals sent by the sensors to control the nodes in the slave stations to be disconnected.
Optionally, the signal detection device is an optocoupler.
Optionally, each said secondary station further comprises a controllable switch connected to said microcontroller; the controllable switch of each slave is connected to the controllable switch of the adjacent slave through a serial circuit.
Optionally, each of the slave stations further comprises an input pin and an output pin, the controllable switch being located between the input pin and the output pin; and the input terminal pin of each slave station is connected with the output terminal pin of the adjacent slave station in series to form the serial circuit.
Optionally, the controllable switch is a thyristor switch.
Optionally, the sensor is a non-contact photoelectric sensor.
Optionally, the high-level signal source is a high-level direct-current voltage source.
Optionally, a terminal resistor is connected to an end of the communication bus close to the master station, and/or a terminal resistor is connected to an end of the communication bus far from the master station.
In another aspect, an embodiment of the present invention provides a method for detecting an abnormal signal of a robot, including: applying a sustained high signal to one of the secondary stations; enabling the high-level signals to sequentially pass through each slave station and be transmitted to a master station; collecting input level signals of each slave station; comparing the acquired input level signals with each other; and determining two adjacent slave stations with changed level signals.
In yet another aspect, an embodiment of the present invention provides a robot including the robot control system according to any one of the above aspects.
According to the robot control system provided by the embodiment of the invention, each slave station is connected with an adjacent slave station through a serial circuit, one end of the serial circuit is connected with a level signal detection unit, the other end of the serial circuit is connected with a high-level signal source, when a microcontroller receives a signal sent by a sensor, the nodes in the slave stations are controlled to be disconnected to cause the level signal change on the serial circuit, the level signal detection unit detects the level signal change and informs a main controller, and the main controller controls the robot to stop acting, so that the response time of the main controller to the sensor signal is shortened, the safety of the control system is improved, and the possibility of casualties and equipment damage is further reduced; by arranging the signal detection device on each slave station, the input level signal of the signal detection device is the same as the input level signal of the slave station, and the signal detection device transmits the input level signal to the microcontroller, so that the microcontroller can acquire the input level signal. When the level signal detection unit detects that the level signal changes, two conditions exist, namely a signal is possibly sent by a sensor, and a certain node on a wire harness of a serial circuit is possibly in fault, and then the main controller distinguishes the alarm reason in time by comparing the sensor state and the input level signal transmitted by each microcontroller through a communication bus; if a certain node on the wiring harness of the serial circuit breaks down, the main controller can quickly locate the fault point, so that the troubleshooting time is shortened, and the on-site maintenance work can be conveniently carried out as soon as possible.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a schematic structural diagram of a robot control system according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of another robot control system according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "central", "upper", "lower", and "upper" are used herein,
The directional or positional relationships "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are indicative of those directions or positional relationships illustrated in the drawings, merely to facilitate the description of the invention and to simplify the description, and are not intended to indicate or imply that the device or element so referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the invention.
The terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In one aspect, an embodiment of the present invention provides a robot control system, referring to fig. 1, including: the master station 10 comprises a master controller 11 and a level signal detection unit 12, wherein the master station 10 is connected with a plurality of slave stations 30 through a communication bus 20; each slave station 30 is connected with the adjacent slave station 30 through a serial circuit 40, the signal input end of the serial circuit 40 is connected with a high-level signal source 50, and the signal output end is connected with the level signal detection unit 12; each slave station 30 further comprises a signal detection means 33 and a microcontroller 31, the signal detection means 33 being connected at one end to a signal input of the slave station 30 and at the other end to the microcontroller 31, the microcontroller 31 being arranged to receive signals from the sensors to control the disconnection of the nodes in the slave station 30.
According to the robot control system provided by the embodiment of the invention, each slave station 30 is connected with the adjacent slave station 30 through the serial circuit 40, one end of the serial circuit 40 is connected with the level signal detection unit 12, the other end of the serial circuit 40 is connected with the high-level signal source 50, when the microcontroller 31 receives a signal sent by a sensor, the nodes in the slave stations 30 are controlled to be disconnected to cause the level signal change on the serial circuit 40, the level signal detection unit 12 detects the level signal change and informs the main controller 11, and the main controller 11 controls the robot to stop working, so that the response time of the main controller 11 to the sensor signal is shortened, the safety of the control system is improved, and the possibility of casualties and equipment damage is further reduced; by providing the signal detection device 33 at each slave station 30, the input level signal of the signal detection device 33 is the same as the input level signal of the slave station 30, and the signal detection device 33 transmits the input level signal to the microcontroller 31, so that the microcontroller 31 can also acquire the input level signal. When the level signal detecting unit 12 detects a level signal change, there are two situations, which may be a signal sent by a sensor, or a failure of a node on a wire harness of the serial circuit 40, at this time, the main controller 11 distinguishes an alarm reason in time by comparing the sensor state and the input level signal transmitted from each microcontroller 31 through the communication bus 20; if a certain node on the wiring harness of the serial circuit 40 breaks down, the main controller 11 can quickly locate the fault point, so that the troubleshooting time is shortened, and the on-site maintenance work can be performed as soon as possible. If a problem occurs in the communication bus 20, the communication bus 20 itself has a function of detecting a failure, so that the bus abnormality is not considered here.
The signal detection device 33 can be implemented in various ways as long as it can determine the level of the level signal. In one implementation, the signal detection device 33 may be an optical coupler, which has the main advantages of unidirectional signal transmission, electrical isolation between the input end and the output end, strong anti-interference capability, high transmission efficiency, stable operation, and long service life. The input of the optocoupler is connected to the input pin 34 of the slave 30 and the output of the optocoupler is connected to the microcontroller 31 of the slave 30. In practical situations, when the input signal of the optical coupler is a high-level signal, the optical coupler is turned on, and the output signal of the optical coupler is a low-level signal; when the input signal of the optical coupler is a low level signal, the optical coupler is cut off, and the output signal of the optical coupler is a high level signal. Adding a high-level signal source 50 to the last slave station 30, wherein if the serial circuit 40 between the slave stations 30 has no fault point and the sensors work normally, the input signals of the optical couplers are all high-level signals, the input signals of the microcontroller 31 are all low-level signals, and the low-level signals are fed back to the master station 10 through the communication bus 20; if there is a fault point in the serial circuit 40 between the nth slave station 30 and the nth slave station 30, the output signal of the nth slave station 30 is a high level signal, the input signal of the nth slave station 30 is a low level signal, and at this time, the input level signal of the microcontroller 31 in the nth slave station 30 is a high level signal, and the high level signal is fed back to the master station 10 through the communication bus 20, so that the master controller 11 can locate the fault point.
In order to make it more convenient for the microcontroller 31 to control the disconnection of the nodes in the slave stations 30, each slave station 30 further comprises a controllable switch 32 connected with the microcontroller 31; the controllable switch 32 of each slave station 30 is connected to the controllable switch 32 of the adjacent slave station 30 by a serial circuit 40. When the microcontroller 31 receives the signal from the sensor, the controllable switch 32 is turned off to cause a level signal change on the serial circuit 40, the level signal detection unit 12 detects the level signal change and informs the main controller 11, and the main controller 11 controls the robot to stop operating, thereby shortening the response time of the main controller 11 to the sensor signal.
Referring to fig. 2, each slave station 30 further comprises an input pin 34 and an output pin 35, the controllable switch 32 being located between the input pin 34 and the output pin 35; the input pin 34 of each slave station 30 is connected in series with the output pin 35 of an adjacent slave station 30 to form a serial circuit 40. A signal detection device 33 is arranged at an input terminal pin 34 of each slave station 30 receiving the adjacent slave station 30, an input level signal of the signal detection device 33 is the same as an input level signal of the slave station 30, the signal detection device 33 transmits the input level signal to the microcontroller 31, and meanwhile, the microcontroller 31 transmits a collected signal to the master controller through the communication bus 20. Therefore, when a fault point exists between two adjacent slave stations 30 so that the level signal changes, when the controllable switch 32 is not turned off, the input level signal and the output level signal in each slave station 30 are the same, at this time, the input level signal of some slave stations 30 is a high level signal, and the input level signal of some slave stations 30 is a low level signal, each microcontroller 31 transmits the acquired input level signal to the master station 10 through the communication bus 20, and the master station 10 can compare the input level signals transmitted by all the slave stations 30 with each other, so as to know the position of the fault point, so that a field worker can perform corresponding maintenance work.
When the robot moves to the limit position or an operator intervenes in the working space of the robot, the microcontroller 31 receives signals sent by the sensor, and in order to realize the rapid on-off of the serial circuit 40, the controllable switch 32 can select a silicon controlled rectifier as a contactless switch, so as to realize the rapid change of level signals, thereby realizing the rapid response of the main controller 11 to the sensor signals. The controllable silicon also has the advantages of small volume, high efficiency, good stability, reliable work and the like, and is convenient for the integration of a control system.
The sensors are of various types, and for reliable use in safety indication, the sensors may be non-contact photoelectric sensors. The non-contact photoelectric sensor has high reaction speed, can realize non-contact measurement, and has high precision, good reliability and high resolution, so whether an operator intervenes in the working space of the robot or timely and quickly indicates the movement limit position of the robot, thereby ensuring the personal safety of the operator and the intact equipment; in addition, the photosensitive device has the advantages of small volume, light weight, low power consumption, convenience in integration and the like, so that the space for arranging the device by the robot can be saved.
In addition, the high-level signal source 50 may be a high-level dc voltage source. When the robot control system works normally, the level signal detection unit 12 detects a definite high level signal; when the controllable switch 32 is turned off or a fault point occurs on the serial circuit 40, the level signal detecting unit 12 detects a high-to-low level change signal.
To improve the signal quality and increase the matching degree, referring to fig. 2, the termination resistor 60 may be connected to the end of the communication bus 20 close to the master station 10, or the termination resistor 60 may be connected to the end of the communication bus 20 far from the master station 10, or both termination resistors 60 may be connected. This is because, in the case of high-frequency signal transmission, the signal wavelength is short relative to the transmission line, and the signal forms a reflected wave at the transmission line terminal, which interferes with the original signal, and therefore, in the actual arrangement, it is necessary to access the termination resistor 60 at the end of the communication bus 20 (i.e., the last slave station 30) so that the signal does not reflect after reaching the transmission line terminal. In long-line signal transmission, it is also necessary to access the terminating resistor 60 at the beginning of the communication bus 20 (i.e. at the central station) in order to avoid signal reflection and echo, while the communication bus 20 in the middle part does not need to access the terminating resistor 60, which otherwise is prone to communication errors. The value of the terminating resistor 60 here depends on the impedance characteristics of the wire harness, and is generally between 100 and 140 Ω regardless of the length of the wire harness.
In another aspect, an embodiment of the present invention provides a method for detecting an abnormal signal of a robot, including: applying a sustained high signal to one of the secondary stations 30; transmitting the high level signal to the master station 10 through each slave station 30 in sequence; collecting input level signals of the slave stations 30; comparing the acquired input level signals with each other; two adjacent ones of the secondary stations 30 having a changed level signal are determined. In the robot control system, a master station 10 and a plurality of slave stations 30 are connected through a communication bus 20, in order to shorten the response time of the master station 10 to a sensor signal, a controllable switch 32 of each slave station 30 is physically connected in series to a level signal detection unit 12 of the master station 10 to form a serial circuit 40, a high level signal source 50 is applied to one end of the serial circuit 40, when a sensor sends a signal, a microcontroller 31 controls the controllable switch 32 to be disconnected, the level signal detection unit 12 detects the change of the level signal and further informs a master controller 11, and the master controller 11 controls an actuator to stop working, so that the personal safety of an operator and the integrity of robot equipment are ensured. In the case where all the controllable switches 32 are turned on, if there is no fault point on the serial circuit 40, the level signal detecting unit 12 receives a high level signal; the level signal detecting unit 12 receives a low level signal if there is a fault point on the serial circuit 40. When the level signal detecting unit 12 detects a level signal change on the serial circuit 40, the signal detecting device 33 of each slave station 30 transmits the acquired input level signal to the microcontroller 31, the microcontroller 31 transmits the input level signal to the master controller 11 of the master station 10 through the communication bus 20, and the master controller 11 compares the input level signals with each other to find out two adjacent slave stations 30 with changed level signals, that is, a fault point exists between the two slave stations 30. Therefore, the fault point can be quickly and accurately positioned, the troubleshooting time of the fault point is shortened, and the on-site worker can timely perform maintenance work. However, in the prior art, a jig provided with an indicator light and a switch button is used, when the above-mentioned abnormal alarm occurs, the serial circuit 40 between two adjacent slave stations 30 is disconnected in sequence from the last slave station 30, the jig is connected between the two slave stations 30, whether the previous slave station 30 outputs normally is judged by observing the indicator light, and whether the next slave station 30 inputs normally is judged by shifting the switch button. The method has strong universality, but the difficulty of troubleshooting and fault solving of maintenance personnel on site is increased due to the responsibility of assembling, installing and arranging the robot body.
In yet another aspect, an embodiment of the present invention provides a robot including the robot control system according to any one of the above aspects.
The robot provided by the embodiment of the invention comprises the robot control system, so that the robot can also distinguish the alarm reason in time, quickly locate the fault point and further shorten the troubleshooting time, thereby being beneficial to developing maintenance work on site as soon as possible.
In the description herein, particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of the changes or substitutions within the technical scope of the present invention, and all the changes or substitutions should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.

Claims (10)

1. A robotic control system, comprising: the master station is connected with the slave stations through communication buses and is characterized by comprising a master controller and a level signal detection unit which are connected; each slave station is connected with the adjacent slave station through a serial circuit, the signal input end of the serial circuit is connected with a high-level signal source, and the signal output end of the serial circuit is connected with the level signal detection unit; each slave station further comprises a signal detection device and a microcontroller, one end of the signal detection device is connected with the signal input end of the slave station, the other end of the signal detection device is connected with the microcontroller, and the microcontroller is used for receiving signals sent by the sensor to control the disconnection of nodes in the slave station and collecting input level signals of the slave station and transmitting the input level signals to the master station through the communication bus; the master controller is configured to compare the sensor state with an input level signal of the slave station.
2. The robot control system of claim 1, wherein the signal detection device is an optocoupler.
3. A robot control system according to claim 1 or 2, characterized in that each of the slave stations further comprises a controllable switch connected to the microcontroller; the controllable switch of each slave is connected to the controllable switch of the adjacent slave through a serial circuit.
4. The robot control system of claim 3, wherein each of the slave stations further comprises an input pin and an output pin, the controllable switch being located between the input pin and the output pin; and the input terminal pin of each slave station is connected with the output terminal pin of the adjacent slave station in series to form the serial circuit.
5. The robot control system of claim 4, wherein the controllable switch is a thyristor switch.
6. The robot control system of claim 5, wherein the sensor is a non-contact photoelectric sensor.
7. The robot control system of claim 6, wherein the high level signal source is a high level DC voltage source.
8. A robot control system according to claim 7, characterized in that a terminating resistor is connected to the end of the communication bus close to the master station and/or a terminating resistor is connected to the end of the communication bus remote from the master station.
9. A robot abnormal signal detection method is characterized by comprising the following steps: applying a sustained high signal to one of the secondary stations; enabling the high-level signals to sequentially pass through each slave station and be transmitted to a master station; collecting input level signals of each slave station; comparing the acquired input level signals with each other; and determining two adjacent slave stations with changed level signals.
10. A robot characterized by comprising a robot control system according to any of claims 1 to 8.
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