CN111026037B - Industrial robot motion controller based on WINDOWS platform and control method - Google Patents
Industrial robot motion controller based on WINDOWS platform and control method Download PDFInfo
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- CN111026037B CN111026037B CN201911174959.6A CN201911174959A CN111026037B CN 111026037 B CN111026037 B CN 111026037B CN 201911174959 A CN201911174959 A CN 201911174959A CN 111026037 B CN111026037 B CN 111026037B
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/414—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
- G05B19/4142—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by the use of a microprocessor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
- B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
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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
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/34—Director, elements to supervisory
- G05B2219/34013—Servocontroller
Abstract
The invention discloses a motion controller of an industrial robot based on a WINDOWS platform and a control method. The WINDOWS system and the real-time system RTE are combined, so that the control precision of the motion controller is greatly improved. The motion controller comprises a PC board card, an EhterCAT bus, a WINDOWS system running on the PC board card and a real-time system RTE; the WINDOWS system is communicated with the real-time system RTE, and the WINDOWS system is connected with a servo control system of the controlled industrial robot through an EhtercAT bus.
Description
Technical Field
The invention relates to a motion controller, in particular to a motion controller of an industrial robot based on a WINDOWS platform and a control method.
Background
The motion controller receives a control scheme and a planning instruction of the terminal, decodes and calculates the instruction information to restore the instruction information into position information of the execution mechanism in space, responds to the control scheme to complete motion track planning, position control, speed control, acceleration control and the like, and sends the information to the motor through the servo driver, so that the motion control of the industrial robot is completed.
The traditional motion controller adopts a single chip microcomputer, a microcomputer processor or a special chip as a core processor, has the advantages of simple structure and low cost, but cannot ensure the high performance of the motion controller.
Specifically, the method comprises the following steps: the motion controller with the single chip or the microcomputer processor as the core has the defects of low control speed, low control precision and the like of the motion controller due to the memory, and is only suitable for control occasions with low performance requirements.
The motion controller using the special chip as the core processor cannot meet the requirements of multi-axis linkage and high-speed interpolation and cannot ensure high control precision of the motion controller because the form of the interactive information is a pulse signal, is in an open-loop control state and cannot provide a continuous interpolation function.
Disclosure of Invention
The invention provides an industrial robot motion controller based on a WINDOWS platform and a control method thereof, aiming at solving the problems of low control speed and low control precision caused by the industrial robot motion controller taking a single chip microcomputer or a microcomputer processor as a core and the problem of low control precision caused by the fact that a special chip is not capable of providing a continuous interpolation function.
The specific technical scheme of the invention is as follows:
the invention provides a motion controller based on a WINDOWS platform industrial robot, which comprises a PC board card, an EhterCAT bus, a WINDOWS system running on the PC board card and a real-time system RTE; the WINDOWS system is communicated with the real-time system RTE, and the WINDOWS system is connected with a servo control system of the controlled industrial robot through an EhtercAT bus.
The method for controlling the industrial robot based on the motion controller comprises the following specific steps:
step 1: the kernel layer of the WINDOWS system receives pulse data sent by a servo control system of the controlled industrial robot in the previous period through an EhterCAT bus and sends the pulse data to the application layer of the WINDOWS system; the pulse data is the actual pulse number;
step 2: the WINDOWS system application layer processes the pulse data to obtain previous period angle data of all joint shafts of the controlled industrial robot; the angle data is an actual angle;
and step 3: the method comprises the following steps that a WINDOWS system application layer finishes formulation of a first input parameter structure body, the first input parameter structure body is used as input of a real-time system RTE and is sent to the real-time system RTE to start kinematics forward solution operation;
the first input parameter structure body is formed by packaging an actual angle, a DH model parameter of a controlled industrial robot, a user coordinate system calibration parameter and a tool coordinate system calibration parameter;
and 4, step 4: the real-time system RTE is subjected to forward solution operation through kinematics and the operation result is packaged into a first output parameter structure body which is used as the output of the RTE system and is sent to a WINDOWS system application layer;
the kinematic positive solution operation process comprises the following steps: determining a relative coordinate system of each connecting rod through DH model parameters of the industrial robot, establishing a transformation matrix of each connecting rod, and multiplying the known angle parameters of each joint by the transformation matrix to obtain the actual pose of the tail end of the controlled industrial robot;
the first output parameter structure body is formed by packaging a kinematics forward solution operation completion state, an error state, a running state and an actual pose of the tail end of the controlled industrial robot;
and 5: the WINDOWS system application layer receives the actual pose of the end of the controlled industrial robot obtained by forward kinematics, completes the formulation of a second input parameter structural body, and sends the second input parameter structural body as input to the real-time system RTE again to start the trajectory planning;
when the track is planned to be a linear track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught linear end point pose, a dynamic parameter percentage, a DH model parameter of the controlled industrial robot and a joint axis limiting parameter of the controlled industrial robot; the actual pose is a starting pose of a linear track;
when the track is planned to be an arc track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught arc middle point pose, a taught arc end point pose, dynamic parameters, dynamic parameter percentages, industrial robot DH model parameters and industrial robot joint axis limiting parameters; the actual pose is a starting point pose of the circular arc track; the dynamic parameters are speed, acceleration, deceleration and jerk;
step 6: a result obtained by the real-time system RTE through trajectory planning is used as a second output parameter structure body and is sent to a WINDOWS system application layer;
the second output parameter structure body is formed by packaging a track planning completion state, an error state, an operation state and a current period target angle;
and 7: the WINDOWS system application layer receives the target angle in the current period and calculates the final target angle, and the specific calculation formula is as follows:
the final target angle is (the target angle in the current period-the actual angle in the previous period) + the actual angle in the previous period + the zero point of the motor/the scale factor;
wherein, the scale factor is the gear ratio, the resolution of the encoder, the motor direction and 360
And 8: the application layer of the WINDOWS system converts the target angle of the controlled industrial robot into a final target pulse, and the final target pulse is sent to the motor through the servo control system of the controlled industrial robot in a transmission mode of an EtherCAT bus, so that the control of the industrial robot is realized.
Further, in order to further improve the requirement on the motion control precision, the pulse data further comprises a tracking error; the specific calculation formula of the final target angle in step 7 is as follows:
and the final target angle is (the target angle in the current period-the actual angle in the last period) + the actual angle in the last period + the tracking error + the zero point of the motor/the scale factor.
Compared with the prior art, the invention has the beneficial effects that:
the invention provides a motion controller with a brand-new control system architecture. The motion controller is bus type equipment based on a WINDOWS platform industrial robot, and meanwhile, the real-time performance of a control system is improved by utilizing a real-time system RTE, and the control precision of the motion controller is greatly improved.
The motion controller organically combines the information processing capability and the open type characteristic of the PC board card with the motion track control capability of the motion controller, and has the characteristics of strong information processing capability, high open degree, accurate motion track control and good universality. The motion controller supports multi-axis coordinated motion control and complex motion trajectory planning, interpolation operation, error compensation and servo filtering algorithm in real time and can realize closed-loop control.
Drawings
FIG. 1 is an architecture diagram of a motion controller;
FIG. 2 is a flow chart of a motion control method;
FIG. 3 is an architectural diagram of a motion control platform;
the reference numbers are as follows:
the system comprises a motion controller 1, a TCP/IP bus 2, an EtherCAT bus 3, an upper computer 4, a demonstrator 5, a servo drive system 6, a motor 7, an IO device 8 and an external device 9.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
As shown in fig. 1, a motion controller based on a WINDOWS platform industrial robot comprises a PC board card, an EhterCAT bus, a WINDOWS system running on the PC board card, and a real-time system RTE; the WINDOWS system is communicated with the real-time system RTE, and the WINDOWS system is connected with a servo control system of the controlled industrial robot through an EhtercAT bus.
The PC board card is used as a hardware part of the motion controller, receives an external signal and completes analysis and processing of the signal;
the WINDOWS system runs on the PC board card and is used as a platform for controlling the system to run so as to complete data interaction;
a real-Time system RTE (real Time environment) runs on an operating system of a PC board card, is used as a hard real-Time running system of a Windows system, is positioned at an equipment layer in a development framework, and ensures real-Time performance during data interaction;
the EtherCAT bus is used as a carrier of interactive data, and defines a data transmission format for transmitting data, data addresses and control signals.
The core of the invention is to realize the control of the industrial robot based on a WINDOWS system and an RTE system, and the specific control process is as follows: the motor reads actual pulses of the controlled industrial robot through the encoder, the actual pulse number is sent to the servo driving system, the servo driving system sends the actual pulses and tracking errors (the tracking errors can be not considered in occasions with low precision requirements) to the PC board card, the circulating tasks of the PC board card read the actual pulses and the tracking errors through periodic scanning, and the actual pose tracking errors of the controlled industrial robot are obtained through resolving. The actual pose and the tracking error of an EtherCAT data frame structure are obtained through encapsulation of an EtherCAT protocol and are sent to a control system of a PC board card, the control system obtains a structural body containing information such as actual pose data, the tracking error and dynamic parameters through processing and sends the structural body to an operation module, a target angle in a track point row form is obtained through kinematics forward solution operation and track planning, a final target angle is calculated through the PC board card, and final target pulses are fed back to a motor through a servo driving system in a communication mode of an EtherCAT bus through a circulating task of the PC board card and encapsulation of the EtherCAT protocol, so that closed-loop control is achieved.
In the data transmission process, the WINDOWS system application layer is responsible for receiving and converting actual pulses and tracking errors sent by the EtherCAT servo drive system to obtain an actual pose under a robot coordinate system, and parameter information in a structure form is obtained through processing data by the WINDOWS system kernel layer and the application layer. The parameter structure body is an interface of a WINDOWS system and a real-time system RTE; the WINDOWS system sends an input parameter structural body containing actual pose information to a real-time system RTE as an input interface of the real-time system RTE, an output parameter structural body containing a target angle is generated after the real-time system RTE completes kinematics forward solution operation and trajectory planning with high requirements on real-time performance, the output parameter structural body is sent to the WINDOWS system as an output interface of the real-time system RTE, an application layer of the WINDOWS system completes final calculation and data conversion and sends final target pulses to a motor through a servo driving system in an EtherCAT bus transmission mode.
As shown in fig. 2, a specific method for controlling an industrial robot based on the motion controller includes the following steps:
step 1: the kernel layer of the WINDOWS system receives pulse data sent by a servo control system of the controlled industrial robot in the previous period through an EhterCAT bus and sends the pulse data to the application layer of the WINDOWS system; the pulse data is the actual pulse number and the tracking error;
step 2: the WINDOWS system application layer processes the pulse data to obtain previous period angle data of all joint shafts of the controlled industrial robot; the angle data are actual angles and tracking errors;
and step 3: the method comprises the following steps that a WINDOWS system application layer finishes formulation of a first input parameter structure body, the first input parameter structure body is used as input of a real-time system RTE and is sent to the real-time system RTE to start kinematics forward solution operation;
the first input parameter structure body is formed by packaging an actual angle, a DH model parameter of a controlled industrial robot, a user coordinate system calibration parameter and a tool coordinate system calibration parameter;
and 4, step 4: the real-time system RTE is subjected to forward solution operation through kinematics and the operation result is packaged into a first output parameter structure body which is used as the output of the RTE system and is sent to a WINDOWS system application layer;
the kinematic positive solution operation process comprises the following steps: determining a relative coordinate system of each connecting rod through DH model parameters of the industrial robot, establishing a transformation matrix of each connecting rod, and multiplying the known angle parameters of each joint by the transformation matrix to obtain the actual pose of the tail end of the controlled industrial robot;
the first output parameter structure body is formed by packaging a kinematics forward solution operation completion state, an error state, a running state and an actual pose of the tail end of the controlled industrial robot;
and 5: the WINDOWS system application layer receives the actual pose of the end of the controlled industrial robot obtained by forward kinematics, completes the formulation of a second input parameter structural body, and sends the second input parameter structural body as input to the real-time system RTE again to start the trajectory planning;
planning a track, namely planning an expected motion path, speed and acceleration for the joint or the tail end of the industrial robot according to a task instruction of a terminal;
taking the planning of the circular arc track as an example, the track planning is divided into four steps, wherein in the first step, physical parameters such as circle center coordinates, radius and the like of the circular arc track are obtained according to plane theorem and matrix operation; secondly, calculating motion parameters such as path total length, running time, speed, acceleration and the like of the arc track according to the arc physical parameters; thirdly, carrying out real-time interpolation operation according to a specific algorithm to obtain the coordinates of the path intermediate point; and fourthly, obtaining a target angle according to inverse solution operation of kinematics.
When the track is planned to be a linear track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught linear end point pose, a dynamic parameter percentage, a DH model parameter of the controlled industrial robot and a joint axis limiting parameter of the controlled industrial robot; the actual pose is a starting pose of a linear track;
when the track is planned to be an arc track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught arc middle point pose, a taught arc end point pose, dynamic parameters, dynamic parameter percentages, industrial robot DH model parameters and industrial robot joint axis limiting parameters; the actual pose is a starting point pose of the circular arc track; the dynamic parameters are speed, acceleration, deceleration and jerk;
step 6: a result obtained by the real-time system RTE through trajectory planning is used as a second output parameter structure body and is sent to a WINDOWS system application layer;
the second output parameter structure body is formed by packaging a track planning completion state, an error state, an operation state and a current period target angle;
and 7: the WINDOWS system application layer receives the target angle in the current period and calculates the final target angle, and the specific calculation formula is as follows:
the final target angle is (the target angle in the current period-the actual angle in the last period) + the actual angle in the last period + the tracking error + the zero point of the motor/the scale factor;
wherein, the scale factor is the gear ratio, the resolution of the encoder and the motor direction/360; the gear ratio here is the gear ratio of the motor on the industrial robot to be controlled.
And 8: the application layer of the WINDOWS system converts the target angle of the controlled industrial robot into a final target pulse, and the final target pulse is sent to the motor through the servo control system of the controlled industrial robot in a transmission mode of an EtherCAT bus, so that the control of the industrial robot is realized.
As shown in fig. 3, based on the motion controller of the present invention, a control platform using the motion controller as a core is introduced, the motion controller 1 completes data interaction through a TCP/IP bus 2 and an EtherCAT bus 3, and is connected to external devices 9 such as a keyboard and a mouse through reserved interfaces such as RS232 and USB. The teaching device 5, the upper computer 4 and other devices can be hung on the TCP/IP protocol network, the EtherCAT protocol network is hung on the servo drive system 6, the IO device 8 and other EtherCAT slave station devices, the motor 7 can be hung on the lower stage of the servo drive system 6, and the welding gun and other tools can be hung on the lower stage of the IO device 8.
With reference to fig. 2 and 3, the basic control method principle of the motion control platform is as follows:
the control software core of the motion controller is a multi-task scheduling mechanism based on priority. The control tasks are of two types, one is an event task which issues functions such as system login, parameter editing, coordinate system setting, teaching programs and the like through a control of a human-computer interaction interface and an external key, and the other is a cyclic task which scans information such as the space pose of the industrial robot fed back by a servo driving system. The control system periodically scans cyclic tasks, simultaneously needs to process tasks triggered by external events, selects a universal and strong-compatibility WINDOWS system to ensure simultaneous operation of various tasks, thereby ensuring stable operation of the control system, and the application of the RTE real-time system can improve the precision of the whole control system on the basis of the WINDOWS system, realize more accurate planning and interpolation of track point sequences, thereby improving the precision of the whole industrial robot.
The motion controller receives the command, firstly completes the analysis work of the command, analyzes the command into a character string containing information such as motion, position or variable and the like, contains the motion, and outputs coordinate information in the motion space of the execution mechanism by combining the character string of the position information with current point location information of periodic scanning through a planning algorithm and forward and backward solution operation of kinematics so as to complete the planning and interpolation operation of the track point sequence. The information is transmitted to a servo system through an EtherCAT protocol network, so that the position of the motor is indirectly controlled, and the complete machine control of the industrial robot is completed.
Claims (2)
1. A motion control method of an industrial robot based on a WINDOWS platform is characterized in that an adopted motion controller comprises a PC board card, an EhterCAT bus, a WINDOWS system running on the PC board card and a real-time system RTE; the WINDOWS system is communicated with the real-time system RTE, and the WINDOWS system is connected with a servo control system of the controlled industrial robot through an EhtercAT bus;
the specific steps of the motion controller for control are as follows:
step 1: the kernel layer of the WINDOWS system receives pulse data sent by a servo control system of the controlled industrial robot in the previous period through an EhterCAT bus and sends the pulse data to the application layer of the WINDOWS system; the pulse data is the actual pulse number;
step 2: the WINDOWS system application layer processes the pulse data to obtain previous period angle data of all joint shafts of the controlled industrial robot; the angle data is an actual angle;
and step 3: the method comprises the following steps that a WINDOWS system application layer finishes formulation of a first input parameter structure body, the first input parameter structure body is used as input of a real-time system RTE and is sent to the real-time system RTE to start kinematics forward solution operation;
the first input parameter structure body is formed by packaging an actual angle, a DH model parameter of a controlled industrial robot, a user coordinate system calibration parameter and a tool coordinate system calibration parameter;
and 4, step 4: the real-time system RTE is subjected to forward solution operation through kinematics and the operation result is packaged into a first output parameter structure body which is used as the output of the RTE system and is sent to a WINDOWS system application layer;
the kinematic positive solution operation process comprises the following steps: determining a relative coordinate system of each connecting rod through DH model parameters of the industrial robot, establishing a transformation matrix of each connecting rod, and multiplying the known angle parameters of each joint by the transformation matrix to obtain the actual pose of the tail end of the controlled industrial robot;
the first output parameter structure body is formed by packaging a kinematics forward solution operation completion state, an error state, a running state and an actual pose of the tail end of the controlled industrial robot;
and 5: the WINDOWS system application layer receives the actual pose of the end of the controlled industrial robot obtained by forward kinematics, completes the formulation of a second input parameter structural body, and sends the second input parameter structural body as input to the real-time system RTE again to start the trajectory planning;
when the track is planned to be a linear track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught linear end point pose, a dynamic parameter percentage, a DH model parameter of the controlled industrial robot and a joint axis limiting parameter of the controlled industrial robot; the actual pose is a starting pose of a linear track;
when the track is planned to be an arc track, the second input parameter structure body is formed by packaging a cycle period, an actual pose, a taught arc middle point pose, a taught arc end point pose, dynamic parameters, dynamic parameter percentages, industrial robot DH model parameters and industrial robot joint axis limiting parameters; the actual pose is a starting point pose of the circular arc track; the dynamic parameters are speed, acceleration, deceleration and jerk;
step 6: a result obtained by the real-time system RTE through trajectory planning is used as a second output parameter structure body and is sent to a WINDOWS system application layer;
the second output parameter structure body is formed by packaging a track planning completion state, an error state, an operation state and a current period target angle;
and 7: the WINDOWS system application layer receives the target angle in the current period and calculates the final target angle, and the specific calculation formula is as follows:
the final target angle is (the target angle in the current period-the actual angle in the previous period) + the actual angle in the previous period + the zero point of the motor/the scale factor;
wherein, the scale factor is the gear ratio, the resolution of the encoder, the motor direction and 360
And 8: the application layer of the WINDOWS system converts the target angle of the controlled industrial robot into a final target pulse, and the final target pulse is sent to the motor through the servo control system of the controlled industrial robot in a transmission mode of an EtherCAT bus, so that the control of the industrial robot is realized.
2. The WINDOWS platform-based industrial robot motion control method according to claim 1, characterized in that: the pulse data further includes a tracking error; the specific calculation formula of the final target angle in step 7 is as follows:
and the final target angle is (the target angle in the current period-the actual angle in the last period) + the actual angle in the last period + the tracking error + the zero point of the motor/the scale factor.
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