CN111469128B - Current coupling signal separation and extraction method for articulated robot - Google Patents
Current coupling signal separation and extraction method for articulated robot Download PDFInfo
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Abstract
The invention discloses a current coupling signal separation and extraction method for an articulated robot, which belongs to the field of state monitoring and fault diagnosis of industrial robots, and comprises the steps of firstly obtaining feedback pulse signals of a motor encoder of a joint to be researched of the robot in a single-joint motion state and a double-joint linkage state and calculating to obtain a real-time corner; then obtaining joint driving torque based on a dynamic simulation model; obtaining winding current through the relation between the driving torque and the current and judging whether a coupling effect exists or not according to the winding current; finally, acquiring a robot current signal, and extracting the envelope of the robot current signal after filtering processing to realize the coupling separation of the robot joint current signal; the method has no requirement on the noise of the robot joint current, and can filter the noise of the joint current signal in any operating environment through filtering processing to obtain a smooth current signal, so as to carry out envelope extraction and realize the separation of the coupling action part and the coupling irrelevant part of the joint robot current signal in any operating environment.
Description
Technical Field
The invention relates to a current coupling signal separation and extraction method for an articulated robot, and belongs to the technical field of state monitoring and fault diagnosis of industrial robots.
Background
The six-degree-of-freedom serial industrial robot is widely applied to industrial automatic production, and parts abrasion caused by long-time operation and the occurrence of some emergencies can cause the robot to stop operating suddenly, so that the operation of a production line is damaged, and loss is caused to enterprises. The main devices of the robot joint are a servo motor and a reducer, so that the monitoring of the robot and the traditional motor and reducer state monitoring method can be used for reference. Traditional motor state monitoring adopts its vibration signal or current signal, nevertheless to six degrees of freedom series connection robots, compares in current signal, and vibration signal has the problem that the collection degree of difficulty is big, with high costs, and current signal can follow the robot electricity cabinet the inside and directly acquire, gathers convenient, with low costs.
The current signals are used for carrying out fault diagnosis on mechanical devices such as gears, motors and the like, and the robot has a plurality of advantages when the current signals are used for monitoring the state of the robot, but joints of the serial robot are connected together, and coupling phenomena exist among the joints, namely except for a terminal motor, the current signals of other motors do not only express the state of a joint arm corresponding to the motor, but also include the running states of all joint arms connected behind the motor, so that the running state of each joint arm of the robot can be accurately monitored by using the robot current signals only by removing the coupling effect existing in the joint current signals; the coupling-related parts in the original motor current signals are separated and extracted, the extracted parts are utilized to perform subsequent robot current signal decoupling analysis, and joint robot current signal decoupling is achieved, namely the current signal of each joint only contains the state information of the current joint, and the method has great significance in performing state detection on the robot joints by using the current signals.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method for separating and extracting the current coupling signal of the articulated robot, which has no requirement on the noise of the current of the joint of the robot, can filter the noise of the current signal of the joint robot under any operating environment by filtering to obtain a smooth current signal, and can realize the separation of the current signal coupling action part and the coupling irrelevant part of the joint robot under any operating environment.
The method for separating and extracting the current coupling signal of the articulated robot comprises the following specific steps:
(1) When the robot moves by the angle theta in the single-joint motion state, the ith joint of the robot is acquiredFeeding back pulse signals by a motor encoder at different time points, and calculating real-time corner data of the ith joint of the robot at different time points by using the feedback pulse signals of the motor encoder; building a dynamic simulation model by using ADAMS software, substituting real-time corner data into the dynamic simulation model to obtain the driving torque F of the ith joint at different time points 1 ；
When the ith joint and the (i + 1) th joint move by a theta angle in a double-joint linkage state, collecting motor encoder feedback pulse signals of the ith joint and the (i + 1) th joint of the robot at different time points, and calculating real-time corner data of the ith joint and the (i + 1) th joint of the robot at different time points by using the feedback pulse signals of the motor encoder; building a dynamic simulation model by using ADAMS software, substituting the real-time corner data of the ith joint and the (i + 1) th joint into the dynamic simulation model to obtain the driving moment F of the ith joint at different time points 2 ；
The theta angle change range of the joint motion does not exceed the maximum angle which can be rotated by the robot joint;
the dynamic simulation model is constructed by using ADAMS software as a conventional method, for example, the method is constructed by referring to the literature' Liupei Sen, long-nosed apricot and the like, [ J ] Industrial college of England Industrial science, 2018,21 (4): 10-13,59 ];
the real-time rotation angle is calculated by checking the total number m of pulses of each circle of a code disc of a motor encoder according to official information of a motor and a driver company used by the robot, and calculating the angle alpha =360 DEG/m corresponding to each pulse; calculating the real-time pulse number corresponding to the feedback pulse signal of the motor encoder at different time points by adopting Matlab software, wherein the real-time rotation angle = the real-time pulse number multiplied by alpha;
(2) Respectively calculating the winding current I in the single joint motion state and the double joint linkage state when the ith joint moves the angle theta by the following formula 1 And the winding current I 2 Obtaining a plurality of winding currents I 1 And the winding current I 2 Data;
formula (II)
Wherein K t As a torque constant, driving torque F 1 Or drive torque F 2 ＝T e X reduction ratio of the ith joint speed reducer;
(3) And (3) drawing the winding current I of the ith joint in the single-joint motion state and the double-joint linkage state by taking the time of the step (1) as an abscissa and the winding current as an ordinate 1 And the winding current I 2 Comparing whether the two curves are overlapped or not, wherein when the two curves are overlapped, the ith joint current does not have a coupling effect in a double-joint linkage state;
(4) When the two curves are not coincident, the ith joint current has a coupling effect in a double-joint linkage state; when the motion angle theta is formed in the single-joint motion state and the double-joint linkage state, the current sensor is respectively adopted to obtain the current signal data x of the ith joint in the single-joint motion state and the double-joint linkage state 1 (t) and x 2 (t), wherein t is the acquisition time;
(5) Filtering the current signal by adopting a zero-phase filtering and singular value denoising combined filtering method to obtain a filtered signal;
(6) Substituting the filtered signal into a formula z (t) = x (t) + jH [ x (t) ], so as to obtain an analytic signal of the current signal, wherein x (t) is a real part of the complex signal z (t), H [ x (t) ] is an imaginary part of the complex signal z (t), and j is an imaginary unit;
will H [ x (t)]Substituting x (t) into the formula
Obtaining the current envelope A of the filtered signal in the single joint motion state and the double joint linkage state 1 (t) and Current envelope A 2 And (t) separating the coupling action part from the coupling irrelevant part of the current signal of the joint robot.
The above-mentioned filtering method using the zero-phase filtering and the singular value denoising combined filtering method to filter the current signal is a conventional method, and the specific method is as follows:
(1) By zero-phase filters on the current signal x 1 (t) and x 2 (t) carrying out filtration, wherein,obtaining a filtering signal;
(2) Carrying out short-time Fourier transform on the filtered signals to obtain a time-frequency matrix A, wherein the time-frequency matrix is defined in such a way that each row represents a frequency point, each column represents a time point, and each value represents an amplitude value under a certain frequency at the acquisition moment;
(3) Substituting the time-frequency matrix A obtained in the step (2) into a formula A = U Sigma V to carry out singular value decomposition, and extracting a value of a diagonal matrix Sigma to obtain a singular value sequence d, wherein U and V are orthogonal arrays, and Sigma is the diagonal array;
(4) Sequentially subtracting the previous value from the next value by using the singular value sequence d obtained in the step (3) to obtain a new sequence, when the quotient of the first value and the next value in the new sequence reaches 20, selecting any value in a change interval corresponding to the difference value as a threshold value, and taking the singular value smaller than the threshold value as zero to form a new singular value sequence q;
(5) Constructing a new diagonal matrix sigma 'by using the new singular value sequence q, and substituting the sigma' into a formula A '= U sigma' V 'to obtain a new coefficient matrix A';
(6) And (4) carrying out short-time inverse Fourier transform on the coefficient matrix A' obtained in the step (5) to obtain a final filtering signal.
The invention has the beneficial effects that:
1. the invention essentially finds out the coupling mechanism of the current signal of the joint of the industrial robot, and combines a robot dynamics simulation model to obtain the essential embodiment of the coupling in the current signal of the joint of the robot;
2. the method has no requirement on the noise of the robot joint current, and can filter the noise of the joint robot current signal under any operating environment through filtering processing to obtain a smooth current signal, so as to carry out envelope extraction and realize the separation of the coupling action part and the coupling irrelevant part of the joint robot current signal under any operating environment.
3. The envelope extracted by separation can be used for decoupling analysis of robot current signals, and joint coupling effect in the robot current signals is removed, so that robot joint state detection is achieved by using the current signals.
Drawings
FIG. 1 is a schematic view of a robot configuration;
FIG. 2 shows winding current I of the 2 nd joint in a single joint motion state and a double joint linkage state 1 And the winding current I 2 A graph is shown schematically;
FIG. 3 shows a current signal x of the 2 nd joint in a single joint motion state 1 (t) a schematic diagram of the original waveform;
FIG. 4 shows a current signal x of the 2 nd and 3 rd joints in a double-joint linkage state 2 (t) a schematic diagram of the original waveform;
FIG. 5 is a schematic waveform diagram of a current signal after filtering of a2 nd joint in a single joint motion state;
FIG. 6 is a schematic waveform diagram of a2 nd joint current signal after filtering in a double-joint linkage state;
FIG. 7 is a schematic envelope diagram of a current signal of the 2 nd joint in a single joint motion state;
FIG. 8 is an envelope diagram of the current signal of the 2 nd joint in a two-joint linkage state;
in FIG. 1: the device comprises a 1-1 st joint, a2 nd joint, a 3 rd connecting arm I, a 4 rd-3 rd joint, a 5 th-4 th joint, a 6 th-connecting arm II, a 7 th-5 th joint, an 8 th-6 th joint, a 9-electric cabinet and a 10-current sensor.
Detailed Description
The present invention is further illustrated by the following examples, but the scope of the invention is not limited to the above-described examples.
Example 1: the current coupling signal separation and extraction method of the articulated robot comprises the following steps:
adopting a Qianjiang QJR6-1 welding robot, establishing a SolidWorks three-dimensional model according to official data of Qianjiang robot company, and importing the three-dimensional model into ADAMS software to establish a dynamic simulation model according to dynamic simulation analysis steps in documents of Liu Paison, long-nosed apricot and the like, 10-13,59. The dynamic simulation analysis steps in the ADAMS-based industrial robot modeling and dynamic simulation college academy of industry, 2018,21 (4) and the robot structure schematic diagram in figure 1 is a robot structure schematic diagram and comprises a1 st joint 1, a2 nd joint 2, a connecting arm I3, a 3 rd joint 4, a 4 th joint 5, a connecting arm II 6, a 5 th joint 7, a 6 th joint 8, an electric cabinet 9 and a current sensor 10; the implementation objects are a2 nd joint and a 3 rd joint, the motion angle theta is rotated by 90 degrees, and the specific operation flow is as follows:
1. acquiring motor encoder feedback pulse signals of continuous time points when the 2 nd joint of the robot rotates by 90 degrees in a2 nd joint single-joint motion state, searching the total number m =1500 of pulses of each circle of a code disc of a motor encoder according to official information of a motor and a driver company used by the robot, and calculating an angle alpha =360 degrees/m =0.24 degrees corresponding to each pulse; calculating the real-time pulse number corresponding to the feedback pulse signal of the motor encoder at the continuous time point when the 2 nd joint rotates by 90 degrees by adopting Matlab software, wherein the real-time rotation angle = the real-time pulse number multiplied by alpha; substituting the real-time corner data into a dynamic simulation model to obtain the driving torque F of the 2 nd joint at a continuous time point when the 2 nd joint rotates by 90 DEG 1 As shown in the following table:
TABLE 1
2. Acquiring motor encoder feedback pulse signals of continuous time points when the 2 nd joint and the 3 rd joint of the robot rotate by 90 degrees under the double-joint linkage state of the 2 nd joint and the 3 rd joint, checking the total number m =1500 of pulses of each circle of a code disc of a motor encoder according to official information of a motor and a driver company used by the robot, and calculating an angle alpha =360 DEG/m =0.24 DEG corresponding to each pulse; calculating the real-time pulse number corresponding to the feedback pulse signal of the motor encoder at the continuous time point when the 2 nd joint and the 3 rd joint rotate by 90 degrees by adopting Matlab software, wherein the real-time rotation angle = the real-time pulse number multiplied by alpha; substituting the real-time corner data of the ith joint and the (i + 1) th joint into a dynamic simulation model to obtain the driving moment F of the continuous time point of the 2 nd joint when the joint rotates 90 DEG 2 As shown in the following table:
TABLE 2
3. The winding current I in the single joint motion state and the double joint linkage state when the 2 nd joint rotates 90 degrees is respectively calculated by the following formula 1 And the winding current I 2 Obtaining a plurality of winding currents I 1 And the winding current I 2 Data, see Table 3, where current _ m2 is I 1 Current _ m2m3 is I 2 And the time point corresponding to the current;
formula (la)
Wherein K t Torque constant =0.91, driving torque F 1 Or drive torque F 2 ＝T e The reduction ratio of × 2 nd joint reducer, the reduction ratio of 2 nd joint reducer =81;
TABLE 3 winding current I 1 And the winding current I 2 Data of
4. And (2) taking the continuous time points in the step (1) as an abscissa, namely time _ m2 and time _ m2m3 in the table 3 as abscissas, and winding current as an ordinate, and drawing winding current I of the 2 nd joint in a single-joint motion state and a double-joint linkage state 1 And the winding current I 2 The curve is shown in fig. 2, and the two curves are not overlapped, which shows that the 2 nd joint current has a coupling effect in a double-joint linkage state;
5. adopting a current sensor to respectively obtain current signals x of the 2 nd joint in a single joint motion state and a double-joint linkage state 1 (t) and x 2 (t), as shown in fig. 3 and 4, t is the acquisition time, the acquisition card adopted is NI9215, the acquisition software is SignalExpress, and the sampling frequency is 8192Hz;
6. filtering the current signal by adopting a zero-phase filtering and singular value denoising combined filtering method to obtain a filtered signal, which comprises the following steps:
(1) By zero-phase filters on the current signal x 1 (t) and x 2 (t) filtering to obtain a filtered signal;
(2) Carrying out short-time Fourier transform on the filtered signals to obtain time-frequency matrixes A1 and A2, wherein the time-frequency matrixes are defined in such a way that each row represents a frequency point, each column represents a time point, and each value represents an amplitude value under a certain frequency at the acquisition moment;
(3) Substituting the time-frequency matrixes A1 and A2 obtained in the step (2) into a formula A = U sigma V to carry out singular value decomposition, and extracting the diagonal matrixes sigma 1 Sum Σ 2 The singular value sequences d1 and d2 are obtained, as shown in table 4, wherein U and V are both orthogonal arrays, and Σ is a diagonal array;
TABLE 4 singular value sequence for single joint motion and double joint linkage
| d_m2 | d_m2m3 |
| 2432.421 | 2270.41 |
| 906.9608 | 773.4315 |
| 561.6425 | 462.6762 |
| 302.3551 | 242.9642 |
| 177.0268 | 142.4626 |
| 103.7739 | 77.7333 |
| 51.65359 | 41.4323 |
| 19.79018 | 19.01606 |
| 17.71604 | 17.49756 |
| 16.84157 | 16.9581 |
| 15.78628 | 16.32425 |
| 14.80652 | 15.48301 |
| 12.72295 | 13.58477 |
| 12.12206 | 12.01732 |
| 11.04193 | 11.14144 |
| 10.51087 | 10.57703 |
| 10.20449 | 9.98004 |
| ... | ... |
(4) Sequentially subtracting the previous value from the next value by using the singular value sequences d1 and d2 obtained in the step (3) to obtain a new sequence, wherein the quotient of the first value and the next 5 th value in the 2 nd joint single joint motion state in the new sequence reaches 20, and selecting a value 150 of a change interval [100, 174] corresponding to the difference value as a threshold value; the interval obtained by the double joint linkage of the 2 nd joint and the 3 rd joint is [70, 128], the selected value is 100, the selected value is used as a threshold value, singular values smaller than the threshold value are taken as zero, and new singular value sequences q1 and q2 are formed;
(5) Constructing a new diagonal matrix sigma 'by using new singular value sequences q1 and q 2' 1 And' 2 Will be ∑' 1 And' 2 Substituting formula A '= U sigma' V 'to obtain a new coefficient matrix A' 1 And A' 2 ；
(6) To the coefficient matrix A 'obtained in the step (5)' 1 And A' 2 Performing short-time inverse fourier transform to obtain a final filtered signal, as shown in fig. 5 and 6;
7. substituting the filtered signal into a formula z (t) = x (t) + jH [ x (t) ], so as to obtain an analytic signal of the current signal, wherein x (t) is a real part of the complex signal z (t), H [ x (t) ] is an imaginary part of the complex signal z (t), and j is an imaginary unit;
will H [ x (t)]Substituting x (t) into the formula
Obtaining the current envelope A of the filtered signal in the single joint motion state and the double joint linkage state 1 (t) and Current envelope A 2 (t), as shown in fig. 7 and 8, realizing the separation of the current signal coupling action part and the coupling irrelevant part of the joint robot; the extracted part is utilized to perform subsequent robot current signal decoupling analysis, the running state of each joint arm of the robot is further accurately monitored, the early characteristics of the robot fault are found in time, corresponding measures are taken, and the robot is prevented from suddenly stopping running and damaging a production line due to part abrasion and the occurrence of some emergencies.
Claims (2)
1. A method for separating and extracting a current coupling signal of an articulated robot is characterized by comprising the following specific steps:
(1) When the robot moves by an angle theta in a single joint movement state, collecting feedback pulse signals of a motor encoder of the ith joint of the robot at different time points, and calculating real-time rotation angles of the ith joint of the robot at different time points by using the feedback pulse signals of the motor encoder; building a dynamic simulation model by using ADAMS software, substituting real-time corner data into the dynamic simulation model to obtain the driving torque F of the ith joint at different time points 1 ；
When the robot moves by a theta angle under the double-joint linkage state of the ith joint and the (i + 1) th joint, collecting feedback pulse signals of motor encoders of the ith joint and the (i + 1) th joint of the robot at different time points, and calculating real-time corner data of the ith joint and the (i + 1) th joint of the robot at different time points by using the feedback pulse signals of the motor encoders; building a dynamic simulation model by using ADAMS software, substituting real-time corner data of the ith joint and the (i + 1) th joint into the dynamic simulation model to obtain the driving moment F of the ith joint at different time points 2 ；
(2) Respectively calculating the winding current I in the single joint motion state and the double joint linkage state when the ith joint moves the angle theta by the following formula 1 And the winding current I 2 Obtaining a plurality of winding currents I 1 And the winding current I 2 Data;
formula (la)
Wherein K t Is a torque constant, T e Is torque, I is winding current, drive torque F 1 Or drive torque F 2 ＝T e X the reduction ratio of the i-th joint reducer,
(3) And (3) drawing the winding current I of the ith joint in the single-joint motion state and the double-joint linkage state by taking the time of the step (1) as an abscissa and the winding current as an ordinate 1 And the winding current I 2 Comparing whether the two curves are coincident or not when the two curves are coincidentWhen the two curves are superposed, the ith joint current does not have a coupling effect in a double-joint linkage state;
(4) When the two curves are not coincident, the ith joint current has a coupling effect in a double-joint linkage state; when the motion angle theta is formed in the single-joint motion state and the double-joint linkage state, the current sensor is respectively adopted to obtain the current signal data x of the ith joint in the single-joint motion state and the double-joint linkage state 1 (t) and x 2 (t), wherein t is the acquisition time;
(5) Filtering the current signal by adopting a zero-phase filtering and singular value denoising combined filtering method to obtain a filtered signal;
(6) Substituting the filtered signal into a formula z (t) = x (t) + jH [ x (t) ], so as to obtain an analytic signal of the current signal, wherein x (t) is a real part of the complex signal z (t), H [ x (t) ] is an imaginary part of the complex signal z (t), and j is an imaginary unit;
h [ x (t)]Substituting x (t) into the formula
Obtaining the current envelope A of the filtered signal in the single joint motion state and the double joint linkage state 1 (t) and Current envelope A 2 And (t) realizing the separation of the current signal coupling action part and the coupling irrelevant part of the joint robot.
2. The method for separating and extracting the current-coupled signal of the articulated robot according to claim 1, wherein the combined filtering method comprises:
A. by zero-phase filter on current signal x 1 (t) and x 2 (t) filtering to obtain a filtered signal;
B. carrying out short-time Fourier transform on the filtered signals to obtain a time-frequency matrix A, wherein the time-frequency matrix is defined in such a way that each row represents a frequency point, each column represents a time point, and each value represents an amplitude value under a certain frequency at the acquisition moment;
C. substituting the time-frequency matrix A obtained in the step B into a formula A = U Sigma V to carry out singular value decomposition, and extracting a value of a diagonal matrix Sigma to obtain a singular value sequence d, wherein U and V are both orthogonal arrays, and Sigma is the diagonal array;
D. c, subtracting the previous value from the next value in sequence by using the singular value sequence d obtained in the step C to obtain a new sequence, when the quotient of the first value and the next value in the new sequence reaches 20, selecting any value in a change interval corresponding to the next value as a threshold value, and taking a singular value smaller than the threshold value as zero to form a new singular value sequence q;
E. constructing a new diagonal matrix sigma 'by using the new singular value sequence q, and substituting the sigma' into a formula A '= U sigma' V 'to obtain a new coefficient matrix A';
F. and E, performing short-time inverse Fourier transform on the coefficient matrix A' obtained in the step E to obtain a final filtering signal.
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