CN111522329A - Industrial robot fault diagnosis method - Google Patents
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- CN111522329A CN111522329A CN202010382290.6A CN202010382290A CN111522329A CN 111522329 A CN111522329 A CN 111522329A CN 202010382290 A CN202010382290 A CN 202010382290A CN 111522329 A CN111522329 A CN 111522329A
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- 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
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0224—Process history based detection method, e.g. whereby history implies the availability of large amounts of data
- G05B23/0227—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
- G05B23/0229—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions knowledge based, e.g. expert systems; genetic algorithms
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Abstract
The invention discloses a fault diagnosis method for an industrial robot, which adopts a two-stage diagnosis method of on-line monitoring, simple diagnosis and off-line precise diagnosis, an on-line state monitoring and fault diagnosis integrated system is established, the grabbing robot carries out self-diagnosis through an internal controller of the equipment, and code is generated and uploaded to an on-line monitoring computer by utilizing an RS232 and a computer interface, the sensors are monitoring sensors arranged on the robot and comprise position feedback, speed feedback and other sensors, the sensors collect signals, and the signals are preprocessed and then subjected to primary fault identification by corresponding neural networks, then a fault comprehensive platform recognition expert system is used for fusing information to realize that once the fault confirmation, the primary diagnosis and the classification are confirmed, the alarm work is immediately carried out, and the main control computer is informed to take corresponding measures and automatically start an off-line precision diagnosis expert system for carrying out precision diagnosis on the fault needing precision diagnosis.
Description
Technical Field
The invention relates to the technical field of fault diagnosis, in particular to a fault diagnosis method for an industrial robot.
Background
With the increasing shortage of labor in China and the increasing cost of labor, a large number of labor-intensive production enterprises are faced with transformation and upgrading. The industrial robot has the advantages of strong universality, high efficiency, reliability, good repeatability precision and the like, plays an increasingly important role in transformation and upgrading of labor-intensive industries such as the traditional manufacturing industry and the like, and becomes a key for improving the production efficiency, improving the product quality and consistency and reducing the production and labor cost of enterprises. The demand of industrial robots by manufacturing enterprises has thus increased substantially.
According to the data of the international robot union, the sale amount of 2015 global industrial robots reaches nearly 240000, the sale amount is increased by 8%, and the innovation history in continuous H years is high. Where again china is the main driving force for sales growth. As the largest industrial robot sales market in the world at present, it is estimated that the number of industrial robots in China will exceed that in North America and Europe by 2017, and reach 400000; by 2018, the number of industrial robots in China is about H times of the total installation amount of the world.
Although industrial robots play an increasingly important role in the process of industrial production and industrial upgrading and are rapidly popularized in the global range, especially in China, because industrial robots are used as a mechatronic system with a precise and complex structure, the industrial robots integrate mechanical engineering technology, electronic engineering technology, information sensor technology W and computer science technology, the industrial robots are generally high in frequent maintenance and maintenance cost and have high technical requirements on daily maintenance personnel; especially when a fault occurs, it is often necessary for a professional technician of an industrial robot manufacturing enterprise to arrive at the site W for providing diagnosis and maintenance services. The losses caused by the downtime of the user enterprise due to the regular maintenance W of the industrial robot and the inevitable failure situations are enormous, and in particular the safety of the equipment and the king of staff may even be compromised in case of failure. In addition, when a technician of an industrial robot manufacturing enterprise provides maintenance service for the industrial robot, the technician cannot comprehensively and thoroughly acquire the daily operation state W of the failed industrial robot and the operation data information before and after a specific fault occurs before arriving at a fault site, so that the technician often cannot diagnose and process the fault rapidly in time, the time for production line rework is slowed down, and the loss of the shutdown enterprise is aggravated. For the above reasons, the industrial robot after-sales service based on daily operation state monitoring and fault diagnosis has been paid extensive attention by the king robot manufacturing enterprises, and becomes an important ring for improving enterprise competitiveness.
Therefore, research and development is a fault diagnosis system to industrial robot, through carrying out real-time monitoring to industrial robot operation data, from this to industrial robot's running state, for whether industrial robot needs to maintain the maintenance provide the basis, reduce unnecessary maintenance repair time, the latent trouble of early warning is probably to when the trouble takes place, provide the basis for industrial robot's fault diagnosis and processing, have important meaning.
Disclosure of Invention
In order to achieve the purpose, the invention provides a fault diagnosis method for an industrial robot, which can monitor a grabbing robot in real time, is convenient for observing the running state of the grabbing robot, provides a basis for maintenance of the grabbing robot, shortens the time required by maintenance, realizes early warning of potential faults through real-time monitoring, can quickly confirm the fault position after the faults occur, and processes the faults through a fault diagnosis expert system, thereby shortening the time required by fault processing.
The technical scheme of the invention is as follows: a fault diagnosis method for an industrial robot comprises a real-time state monitoring and fault diagnosis system for a grabbing robot, a fault diagnosis expert system and hardware interfaces of an on-line diagnosis computer and an off-line diagnosis computer;
the real-time state monitoring and fault diagnosis system of the grabbing robot comprises a work station controller, a grabbing robot, a computer interface and a fault comprehensive expert identification system, wherein the work station controller is connected with the computer interface through RS232, a sensor for detection is installed on the grabbing robot, data collected by the sensor is accessed to the computer interface after signal collection and signal processing, a hardware alarm indicator lamp on the grabbing robot is accessed to the computer interface after I/O (input/output), a state change indicator lamp on the grabbing robot is also accessed to the computer interface after I/O (input/output), a fault code identification module, a detection module, a hardware alarm lamp identification module and a state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, and the fault code identification module, the fault alarm lamp identification module and the state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, The detection module, the hardware alarm lamp identification module and the state change identification module are respectively connected with the fault comprehensive expert identification system;
the detection module comprises signal anomaly detection and neural network fault identification;
the fault comprehensive expert identification system comprises a fault reporting FMS main controller, a sound alarm and a video monitor, wherein the video monitor is connected with the fault precision diagnosis expert system through a network.
As a preferred technical scheme of the invention, the fault precise diagnosis expert system comprises a fault diagnosis computer, a state monitoring computer and field equipment, wherein the field equipment mainly comprises a grabbing robot, a rail transport vehicle, a vertically placed part, a horizontally placed part, a placement center base and a three-coordinate measuring machine, the state transition monitoring computer mainly comprises a signal sampling module, an A/D, I/O processing module, a signal detection module, a simple diagnosis module and a communication module, and the fault diagnosis computer mainly comprises a control module, a state monitoring and alarming module, a precise diagnosis reasoning module, a database, an explanation mechanism module, a maintenance decision module, a knowledge base, a knowledge updating inspection and acquisition module, a statistical analysis maintenance recording module, a knowledge base management system, a maintenance record base, a statistical analysis maintenance record base module, a maintenance record base management system, a maintenance record base, a state monitoring and alarm module and a communication module, A man-machine interface and a machine interface.
As a preferred technical solution of the present invention, the connection between the field device and the status monitoring computer is: the data of the grabbing robot, the rail transport vehicle, the vertical part placing, the horizontal part placing, the central storage placing and the three-coordinate measuring machine are transmitted to the signal sampling module through a lead, and the connection between the fault diagnosis computer and the field equipment is as follows: the data of the grabbing robot, the rail transport vehicle, the vertical part, the horizontal part, the central storage and the three-coordinate measuring machine are transmitted to the knowledge base through wires, and the connection between the state monitoring calculation computer and the fault diagnosis computer is as follows: the communication module transmits data to the state monitoring and alarming module through a wire.
As a preferred embodiment of the present invention, the internal connection of the state monitoring computer is: the signal sampling module transmits the acquired signals to the A/D, I/O processing module, the data processed by the A/D, I/O processing module enter the signal detection module, the data processed by the signal detection module enter the simple diagnosis module, and the data processed by the signal detection module are transmitted through the communication module.
As a preferred technical scheme of the invention, the state monitoring and alarming module sends data to the control module through a lead, the control module processes the data through the precision diagnosis reasoning module, the precision diagnosis reasoning module calls the data from the knowledge base when processing the data, the precision diagnosis reasoning module stores the processed data in the maintenance record base, the maintenance record base realizes internal connection through a machine interface and then sends the data to the knowledge base management system, the knowledge base management system carries out bidirectional data communication with the knowledge updating checking and obtaining module, the knowledge updating checking and obtaining module sends the updated numerical control to the knowledge base for storage, the knowledge base management system realizes bidirectional data communication with the maintenance base management system through a human-machine interface, the maintenance management system and the statistical analysis maintenance recording module are also set to be in bidirectional data communication, the statistical analysis maintenance recording module respectively sends data to the maintenance record library and the maintenance decision module, the precise diagnosis reasoning module and the database are set to be in bidirectional data communication, and the database and the human-computer interface, the database and the explaining mechanism module and the human-computer interface are all set to be in bidirectional data communication.
As a preferred technical scheme of the invention, the hardware interfaces of the online and offline diagnosis computers comprise an online diagnosis computer, an RS-232 serial interface, a zero modem, an RS-232 serial interface and an offline diagnosis computer, and bidirectional data communication is carried out between the offline diagnosis computer and the zero modem and between the online diagnosis computer and the zero modem through the RS-232 serial interfaces.
As a preferred technical scheme of the invention, the knowledge base comprises a concept base, a rule base and a graph base.
The invention has the beneficial effects that: after the fault occurs, the code is sent to a communication end of an off-line diagnosis computer, the off-line diagnosis computer receives the code, translates the code into fault information, displays the fault information and gives an alarm; then carrying out precision diagnosis on the fault, starting a fault diagnosis expert system and carrying out precision diagnosis on the fault; after the fault is removed, the off-line diagnosis computer redisplays the normal operation of the grabbing robot: and the off-line diagnosis computer stops working to close the communication port and finish the running of the program.
Drawings
Fig. 1 is a general structure diagram of a real-time status monitoring and fault diagnosis system of a grabbing robot according to the present invention.
Fig. 2 is a general block diagram of a fault diagnosis precision diagnosis expert system according to the present invention.
FIG. 3 is a diagram of a hardware interface of an off-line diagnostic computer according to 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.
Referring to fig. 1-3, the present invention provides a technical solution: a fault diagnosis method for an industrial robot is characterized by comprising the following steps: the system comprises a real-time state monitoring and fault diagnosis system of the grabbing robot, a fault diagnosis expert system and hardware interfaces of an on-line diagnosis computer and an off-line diagnosis computer;
the real-time state monitoring and fault diagnosis system of the grabbing robot comprises a work station controller, a grabbing robot, a computer interface and a fault comprehensive expert identification system, wherein the work station controller is connected with the computer interface through RS232, a sensor for detection is installed on the grabbing robot, data collected by the sensor is accessed to the computer interface after signal collection and signal processing, a hardware alarm indicator lamp on the grabbing robot is accessed to the computer interface after I/O (input/output), a state change indicator lamp on the grabbing robot is also accessed to the computer interface after I/O (input/output), a fault code identification module, a detection module, a hardware alarm lamp identification module and a state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, and the fault code identification module, the fault alarm lamp identification module and the state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, The detection module, the hardware alarm lamp identification module and the state change identification module are respectively connected with the fault comprehensive expert identification system;
the detection module comprises signal anomaly detection and neural network fault identification;
the fault comprehensive expert identification system comprises a fault reporting FMS main controller, a sound alarm and a video monitor, wherein the video monitor is connected with the fault precision diagnosis expert system through a network.
Preferably: the fault precision diagnosis expert system comprises a fault diagnosis computer, a state monitoring computer and field equipment, wherein the field equipment mainly comprises a grabbing robot, a rail transport vehicle, a vertically placed part, a horizontally placed part, a placement center base and a three-coordinate measuring machine, the state transition monitoring computer mainly comprises a signal sampling module, an A/D, I/O processing module, a signal detection module, a simple diagnosis module and a communication module, the fault diagnosis computer mainly comprises a control module, a state monitoring and alarming module, a precision diagnosis reasoning module, a database, an interpretation mechanism module, a maintenance decision module, a knowledge base, a knowledge updating, checking and obtaining module, a statistical analysis maintenance recording module, a knowledge base management system, a maintenance recording base, a human-machine interface and a machine interface, and the grabbing robot common faults include robot out-of-control, robot out-of-control, state monitoring and alarming, a placement center base and a, The robot does not move, and the like, so that if the robot is not found and eliminated in time after the fault occurs, mechanical accidents or damage to workers can be caused, and great loss is caused. Adopts a two-stage diagnosis method of on-line monitoring, simple diagnosis and off-line precise diagnosis, establishes an on-line and off-line state monitoring and fault diagnosis integrated system, carries out self-diagnosis by a grabbing robot through an internal controller of the equipment, and code is generated and uploaded to an on-line monitoring computer by utilizing an RS232 and a computer interface, the sensors are monitoring sensors arranged on the robot and comprise position feedback, speed feedback and other sensors, the sensors collect signals, and the signals are preprocessed and then subjected to primary fault identification by corresponding neural networks, then a fault comprehensive platform recognition expert system is used for fusing information to realize that once the fault confirmation, the primary diagnosis and the classification are confirmed, the alarm work is immediately carried out, and the main control computer is informed to take corresponding measures and automatically start an off-line precision diagnosis expert system for carrying out precision diagnosis on the fault needing precision diagnosis.
Preferably: the data of the grabbing robot, the rail transport vehicle, the vertical part placing, the horizontal part placing, the central storage placing and the three-coordinate measuring machine are transmitted to the signal sampling module through a lead, and the connection between the fault diagnosis computer and the field equipment is as follows: the data of the grabbing robot, the rail transport vehicle, the vertical part, the horizontal part, the central storage and the three-coordinate measuring machine are transmitted to the knowledge base through wires, and the connection between the state monitoring calculation computer and the fault diagnosis computer is as follows: the communication module transmits data to the state monitoring and alarming module through a wire, and the online diagnosis computer is composed of a signal acquisition part, a processing I/O interface, an on-state identification part and a primary diagnosis part, and the monitoring and the diagnosis are carried out in the online diagnosis computer. At silk ribbon for holding a jade seal through its nose the diagnostic computer has 3 inputs: namely running state information, hardware alarm information and controller instruction information detected from the robot control system. The 3 kinds of information are analyzed and processed by different modules respectively. The running state information is processed by a neural network fault diagnosis module with a self-learning function, and real-time monitoring is carried out in an inquiry mode. The hardware alarm lamp information is processed by a fault inquiry positioning module to process the instruction information of a controller, and is processed by a fault code identification module, once a monitoring module finds abnormality, the latter two modules work in a hardware interruption mode, a fault comprehensive identification expert system of primary diagnosis is started to perform data fusion and primary fault positioning, and then the processing result is reported to a main control computer and an off-line precision diagnosis expert system.
Preferably: the internal connections of the state monitoring computer are: the signal sampling module transmits collected signals to the A/D, I/O processing module, data processed by the A/D, I/O processing module enter the signal detection module, data processed by the signal detection module enter the simple diagnosis module, the data processed by the signal detection module are sent through the communication module, the signals are collected through the sensor, then the signals are processed through the state monitoring computer, and the processed signals are sent to the inside of the fault diagnosis computer through the communication module.
Preferably: the state monitoring and alarming module sends data to the control module through a lead, the control module processes the data through the precision diagnosis reasoning module, the precision diagnosis reasoning module retrieves the data from the knowledge base when processing the data, the precision diagnosis reasoning module stores the processed data in the maintenance record base, the maintenance record base realizes internal connection through a machine interface and then sends the data to the knowledge base management system, the knowledge base management system carries out bidirectional data communication with the knowledge updating checking and obtaining module, the knowledge updating checking and obtaining module sends the updated numerical control to the knowledge base for storage, the knowledge base management system realizes bidirectional data communication with the maintenance base management system through the man-machine interface, and the maintenance base management system and the statistical analysis maintenance record module are also set to be bidirectional data communication, the statistical analysis maintenance record module sends data to the maintenance record base and the maintenance decision module respectively, the precise diagnosis reasoning module and the database are in bidirectional data communication, the database and the man-machine interface, the database and the explaining mechanism module are in bidirectional data communication, equipment information used on site is recorded and stored through the knowledge base, the real-time collected data and the original data are compared and analyzed, the state of the equipment is monitored, faults are found in time, and the fault information can be quickly sent and uploaded, so that workers can quickly respond, the faults can be found and processed early, the fault information can be stored, and similar faults can be detected, and a certain reference is provided for the next maintenance.
Preferably: the hardware interfaces of the online and offline diagnosis computers comprise an online diagnosis computer, an RS-232 serial interface, a zero modem, an RS-232 serial interface and an offline diagnosis computer, and bidirectional data communication is carried out between the offline diagnosis computer and the zero modem and between the online diagnosis computer and the zero modem through the RS-232 serial interface, so that information transmission and communication in online and offline are realized, and a user can conveniently carry out operations such as inquiry, recording, uploading and the like.
Preferably: the knowledge base consists of a concept base, a rule base and a graph base, and can perform real-time updating operation on internal storage trust of the knowledge base through a knowledge updating inspection and acquisition module, so that the knowledge base corresponds to field information in real time, and the accuracy of fault judgment is ensured.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. A fault diagnosis method for an industrial robot is characterized by comprising the following steps: the system comprises a real-time state monitoring and fault diagnosis system of the grabbing robot, a fault diagnosis expert system and hardware interfaces of an on-line diagnosis computer and an off-line diagnosis computer;
the real-time state monitoring and fault diagnosis system of the grabbing robot comprises a work station controller, a grabbing robot, a computer interface and a fault comprehensive expert identification system, wherein the work station controller is connected with the computer interface through RS232, a sensor for detection is installed on the grabbing robot, data collected by the sensor is accessed to the computer interface after signal collection and signal processing, a hardware alarm indicator lamp on the grabbing robot is accessed to the computer interface after I/O (input/output), a state change indicator lamp on the grabbing robot is also accessed to the computer interface after I/O (input/output), a fault code identification module, a detection module, a hardware alarm lamp identification module and a state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, and the fault code identification module, the fault alarm lamp identification module and the state change identification module are arranged between the computer interface and the fault comprehensive expert identification system, The detection module, the hardware alarm lamp identification module and the state change identification module are respectively connected with the fault comprehensive expert identification system;
the detection module comprises signal anomaly detection and neural network fault identification;
the fault comprehensive expert identification system comprises a fault reporting FMS main controller, a sound alarm and a video monitor, wherein the video monitor is connected with the fault precision diagnosis expert system through a network.
2. Method for fault diagnosis of an industrial robot according to claim 1, characterized in that: the fault precision diagnosis expert system comprises a fault diagnosis computer, a state monitoring computer and field equipment, the field device mainly comprises a grabbing robot, a rail transport vehicle, a vertical placing part, a horizontal placing part, a placing center warehouse and a three-coordinate measuring machine, the state-changing monitoring computer mainly comprises a signal sampling module, an A/D, I/O processing module, a signal detection module, a simple diagnosis module and a communication module, the computer for fault diagnosis mainly comprises a control module, a state monitoring and alarming module, a precise diagnosis reasoning module, a database, an interpretation mechanism module, a maintenance decision module, a knowledge base, a knowledge updating, checking and obtaining module, a statistic analysis maintenance record module, a knowledge base management system, a maintenance record base, a man-machine interface and a machine interface.
3. Method for fault diagnosis of an industrial robot according to claim 2, characterized in that: the connection between the field device and the condition monitoring computer is: the data of the grabbing robot, the rail transport vehicle, the vertical part placing, the horizontal part placing, the central storage placing and the three-coordinate measuring machine are transmitted to the signal sampling module through a lead, and the connection between the fault diagnosis computer and the field equipment is as follows: the data of the grabbing robot, the rail transport vehicle, the vertical part, the horizontal part, the central storage and the three-coordinate measuring machine are transmitted to the knowledge base through wires, and the connection between the state monitoring calculation computer and the fault diagnosis computer is as follows: the communication module transmits data to the state monitoring and alarming module through a wire.
4. Method for fault diagnosis of an industrial robot according to claim 2, characterized in that: the internal connections of the state monitoring computer are: the signal sampling module transmits the acquired signals to the A/D, I/O processing module, the data processed by the A/D, I/O processing module enter the signal detection module, the data processed by the signal detection module enter the simple diagnosis module, and the data processed by the signal detection module are transmitted through the communication module.
5. Method for fault diagnosis of an industrial robot according to claim 2, characterized in that: the state monitoring and alarming module sends data to the control module through a lead, the control module processes the data through the precision diagnosis reasoning module, the precision diagnosis reasoning module retrieves the data from the knowledge base when processing the data, the precision diagnosis reasoning module stores the processed data in the maintenance record base, the maintenance record base realizes internal connection through a machine interface and then sends the data to the knowledge base management system, the knowledge base management system carries out bidirectional data communication with the knowledge updating checking and obtaining module, the knowledge updating checking and obtaining module sends the updated numerical control to the knowledge base for storage, the knowledge base management system realizes bidirectional data communication with the maintenance base management system through the man-machine interface, and the maintenance base management system and the statistical analysis maintenance record module are also set to be bidirectional data communication, the system comprises a precision diagnosis reasoning module, a maintenance record database, an interpretation mechanism module, a statistic analysis maintenance record module, a maintenance decision module, a precision diagnosis reasoning module and a human-computer interface, wherein the statistic analysis maintenance record module sends data to the maintenance record database and the maintenance decision module respectively, the precision diagnosis reasoning module and the database are in bidirectional data communication, and the database and the human-computer interface, the database and the interpretation mechanism module and the human-computer interface are in bidirectional data communication.
6. Method for fault diagnosis of an industrial robot according to claim 1, characterized in that: the hardware interfaces of the online and offline diagnosis computers comprise an online diagnosis computer, an RS-232 serial interface, a zero modem, an RS-232 serial interface and the offline diagnosis computer, and bidirectional data communication is carried out between the offline diagnosis computer and the zero modem and between the online diagnosis computer and the zero modem through the RS-232 serial interface.
7. Method for fault diagnosis of an industrial robot according to claim 2, characterized in that: the knowledge base consists of a concept base, a rule base and a graph base.
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Application publication date: 20200811 |