CN115042209A - Robot joint module servo controller with digital twin model - Google Patents
Robot joint module servo controller with digital twin model Download PDFInfo
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- CN115042209A CN115042209A CN202210542909.4A CN202210542909A CN115042209A CN 115042209 A CN115042209 A CN 115042209A CN 202210542909 A CN202210542909 A CN 202210542909A CN 115042209 A CN115042209 A CN 115042209A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J13/00—Controls for manipulators
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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
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Abstract
The invention belongs to the technical field of robot joint control systems, and particularly relates to a robot joint module servo controller with a digital twin model. The control and running state of the twin operation original joint module of the digital twin model in the second digital signal processor are utilized, the load size obtained by calculation of the load observer in the first digital signal processor is provided for the twin model to simulate the real-time running state of the motor, and the early warning information of the motor module is finally obtained.
Description
Technical Field
The invention belongs to the technical field of robot joint control systems, and particularly relates to a robot joint module servo controller with a digital twin model.
Background
The robot mechanical arm joint servo module consists of a servo motor, a speed reducer and a servo motor driver, and belongs to an electromechanical integrated system. In the operation process of the robot mechanical arm joint servo module, along with the increase of the operation age or the change of the operation environment, the servo module device is also aged, the performance is reduced, the operation precision of the mechanical arm is reduced, the vibration phenomenon occurs, and bad results such as the change of the response speed gradually occur. In the prior art, when the performance of the servo joint module is degraded due to aging along with the increase of the operation life, and the operation precision of the mechanical arm or the performance of the mechanical arm is degraded in other aspects, besides the necessary maintenance of physical components, the original performance is expected to be achieved by readjusting and optimizing the parameters of the servo joint module controller. Therefore, it is a challenge to let the servo module autonomously warn about such performance changes and prevent or take maintenance measures in advance.
Disclosure of Invention
In view of the above, the present invention provides a robot joint module servo controller with a digital twin model, which comprises a first digital signal processor and a second digital signal processor, wherein the second digital signal processor is provided with a digital twin model composed of a twin control ring and a motor module model. The control and running state of the original joint module is operated in a twinning mode by utilizing the digital twinning model in the second digital signal processor, the load size obtained by calculation of the load observer in the first digital signal processor is provided for the twinning model to simulate the real-time running state of the motor, and the early warning information of the motor module is finally obtained.
In order to achieve the technical purpose, the invention adopts the following specific technical scheme:
a robot joint module servo controller with a digital twin model, comprising:
the first digital signal processor receives an external instruction and controls a joint motor of the robot joint module based on an actual control ring;
a second digital signal processor, in communication with the first digital signal processor, running a digital twin model; the digital twin model is provided with a twin control ring and a motor module model;
the load observer runs in the first digital signal processor and calculates the load of the joint motor based on the actual speed, the motor current, the actual motor and the load inertia of the joint motor;
wherein: and the digital twin model is operated in a twin mode based on the external instruction, the given speed actual speed of the joint motor, the motor current, the motor inertia of the joint motor, the gear clearance effect of a speed reducer configured for the joint motor and the load size to obtain the operation current difference value and the operation speed difference value of the motor module model and the joint motor.
Furthermore, the actual control loop is based on a position controller, a speed controller, a current controller, a speed feedback processing unit and a position feedback processing unit to realize the control of the joint motor.
Furthermore, a twin control ring is arranged in the digital twin model; the twin control loop comprises a twin position controller, a twin speed controller and a twin current controller which are the same as the actual control loop; the twin control loop simulates the speed feedback processing unit based on a speed converter and simulates the position feedback processing unit based on a position converter; and data of the speed converter and the position converter are extracted from the motor module model.
Further, the expression of the joint motor mathematical model is as follows:
wherein Ud and Uq are d and q axis voltage components applied to the joint motor in a d-q coordinate system, respectively; rs and Ls are respectively the armature resistance and the inductance of the joint motor; w m The motor speed of the joint motor; λ pm is a permanent magnetic flux linkage of the joint motor;
the expression of the motor module model is as follows:
wherein: ks is the elastic coefficient of the coupling of the motor module model motor and the load; jm is the motor inertia of the motor module model; JL is the load inertia of the motor module model; te is the motor electromagnetic torque of the motor module model; ts is coulomb friction torque; omega m The motor rotating speed; omega L Is the load rotation speed.
Further, the servo controller obtains the early warning information of the motor module based on the running current difference value of the motor module model and the joint motor and the running speed difference value of the motor module model and the joint motor
Further, the method for acquiring the early warning information comprises the following steps:
respectively drawing a curve of the running current difference value and a curve of the running speed difference value on the basis of a time line, and extracting the most significant frequency in the two groups of curves;
and predicting the aging rule and fault information of the robot joint module based on the two groups of numerical curves with the most significant frequencies.
Furthermore, the servo controller also comprises an analysis and judgment module; the analysis and judgment module is used for comparing and analyzing the curve of the current difference value and the curve of the running speed difference value to judge whether the robot joint module is abnormal or not.
Further, the servo controller further comprises a feedback module; and the feedback module feeds back the abnormity to an upper computer of the servo controller.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a block diagram of an actual control loop in an embodiment of the present invention;
FIG. 2 is a block diagram of a digital twin model in an embodiment of the present invention;
FIG. 3 is a block diagram of the operation of a load observer in an embodiment of the present invention;
FIG. 4 is a block diagram illustrating interaction between a first DSP and a second DSP in an embodiment of the present invention;
FIG. 5 is a block diagram of the overall architecture of the digital control of the first DSP and the second DSP according to the embodiment of the present invention;
FIG. 6 is a block diagram of a load system model in accordance with an embodiment of the present invention;
FIG. 7 is a block diagram of a second DSP running data processing according to an embodiment of the present invention;
FIG. 8 is a diagram illustrating a calculation result of a digital twin model when a touch occurs on an exterior of a robot according to an embodiment of the present invention;
wherein: 1. a position controller; 2. a speed controller; 3. a current controller; 4. a joint motor; 5. a speed feedback processing unit; 6. a position feedback processing unit; 7. a twin position controller; 8. a twin speed controller; 9. a twin current controller; 10. a motor module model; 11. a speed converter; 12. a position transducer; 13. an analysis and judgment module; 14. and a load observer.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It is to be noted that the features in the following embodiments and examples may be combined with each other without conflict. 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.
It is noted that various aspects of the embodiments are described below within the scope of the appended claims. It should be apparent that the aspects described herein may be embodied in a wide variety of forms and that any specific structure and/or function described herein is merely illustrative. Based on the disclosure, one skilled in the art should appreciate that one aspect described herein may be implemented independently of any other aspects and that two or more of these aspects may be combined in various ways. For example, an apparatus may be implemented and/or a method practiced using any number of the aspects set forth herein. Additionally, such an apparatus may be implemented and/or such a method may be practiced using other structure and/or functionality in addition to one or more of the aspects set forth herein.
It should be further noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention, and the drawings only show the components related to the present invention rather than being drawn according to the number, shape and size of the components in actual implementation, and the type, quantity and proportion of each component in actual implementation can be changed freely, and the layout of the components may be more complicated.
In addition, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, it will be understood by those skilled in the art that the aspects may be practiced without these specific details.
In one embodiment of the present invention, a robot joint module servo controller with a digital twin model is provided, comprising:
the first digital signal processor receives an external instruction and controls a joint motor 4 of the robot joint module based on an actual control ring;
a second digital signal processor, in communication with the first digital signal processor, running a digital twin model; the digital twin model is provided with a twin control ring and a motor module model 10;
a load observer 14, running in the first digital signal processor, for calculating the load of the joint motor based on the actual speed, the motor current, the actual motor and the load inertia of the joint motor 4;
wherein: the digital twin model obtains an operation current difference value and an operation speed difference value of the motor module model 10 and the joint motor 4 based on an external instruction, an actual speed of the joint motor 4, a motor inertia of the joint motor 4, a gear clearance effect of a speed reducer configured for the joint motor 4 and a load size twin operation.
The joint motor 4 of the embodiment is a servo motor, and the first digital signal processor and the second digital signal processor are both conventional DSPs or two independent cores in the same DSP; the servo controller has the advantage of small size and convenience in integration, and the servo controller with the digital twin model is manufactured by utilizing two DSPs or two DSP cores, so that the servo controller is simpler, more convenient and lower in cost compared with a traditional digital twin mode.
As shown in fig. 1, the actual control loop of the present embodiment controls the joint motor 4 based on the position controller 1, the speed controller 2, the current controller 3, the speed feedback processing unit 5, and the position feedback processing unit 6.
As shown in fig. 2, a twin control ring is arranged in the digital twin model; the twin control loop comprises a twin position controller 7, a twin speed controller 8 and a twin current controller 9 which are the same as those of the actual control loop; the twin control loop is based on a speed converter 11 simulation speed feedback processing unit 5 and a position converter 12 simulation position feedback processing unit 6; the data of the velocity converter 11 and the position converter 12 are extracted from the motor module model 10.
In the embodiment, the load observer 14 is arranged to calculate the load inertia, and can calculate the load magnitude value of the motor module as the load of the motor in the twin model.
The joint motor 4 of the present embodiment is provided with a speed reducer, the backlash effect of the speed reducer is also an important factor influencing the accuracy of the digital twin result, and the actual control loop receives a command (external command) from the robot controller to drive the joint motor 4 to perform a corresponding action. The block diagram of the basic control algorithm of the actual control loop is shown in fig. 1.
The actual control loop and the load observer 14 of the present embodiment run on a first DSP, and the motor module model 10 runs on a second DSP. In the second DSP, a digital twin model of the original joint motor 4 and an actual control loop is established according to actual control system control parameters and system parameters, the twin model is provided with a controller which is the same as that of the actual system, and a load equivalent model which is similar to that of the actual motor, a reducer and load characteristics, and receives the same control instruction as that of the actual system. As shown in fig. 2, the digital twin model includes: a position controller 1 identical to the position controller 1 in the first DSP; a speed controller 2 identical to the speed controller 2 in the first DSP; a current controller 3 identical to the current controller 3 in the first DSP; the load observation TL' is derived from the output value of the load observer 14 in the first DSP; the module model comprises a motor model and a load model.
As shown in fig. 2, the external command of this embodiment is a position command, that is, the joint motor 4 is controlled to operate to a corresponding position, and the position command in the digital twin model and the position command in the first DSP are the same command value.
In the digital twin model, an actual control loop and a motor module model 10 are respectively established, and a load equivalent model capable of reflecting the characteristic of the reducer is also established, and the models form a complete digital twin mathematical model. The second DSP operates the models independently from the first DSP, but simultaneously receives position instructions from the upper robot controller, a position actual control loop is formed by position feedback from the load model, a speed closed loop is formed by speed feedback from the load model, and current closed loop control is formed by current feedback from the joint motor 4 model.
In the first DSP, in addition to the actual control loop as the control algorithm of the joint motor 4, a load observer 14 is operated to estimate the load of the joint motor 4 in real time, and the real-time estimated load value is transmitted to the second DSP to be applied to the motor module model 10 as the load of the digital twin model, as shown in fig. 3, in fig. 3:
kt is the electromagnetic torque constant of the joint motor 4;
te': the joint motor 4 electromagnetic torque;
TL': an estimated load torque; (digital twin model inputted into the second DSP as a load of the motor module model 10)
ω m': estimated motor speed in a load observer
ω (t): actual rotation speed of the joint motor 4;
HPF: high Pass Filter, High Pass Filter;
jm: the motor inertia of the joint motor 4;
JL: the load inertia of the joint motor 4;
s: a Laplace operator;
i (t): the current of the joint motor 4;
θ (t): the rotor position angle of the joint motor 4;
the load observer 14 runs on a first DSP. The input of the motor is motor speed omega (t) and motor current i (t); the output is the estimated load torque TL', and the offset (of the output of the HPF into the actual motor speed loop).
In the load observer 14, a module HPF refers to a High Pass Filter (HPF), and a High frequency component in a difference between an actual speed of the joint motor 4 and a speed output by an observer theoretical load model (including motor inertia Jm and load inertia JL) is fed back to an actual motor control loop for compensation, so that the purpose that a dynamic component in the theoretical load model in the observer tracks a dynamic component in an actual system is achieved, the theoretical load model itself achieves theoretical speed closed-loop control through the controller a, and a torque output by the controller is input to the second DSP as a load torque of the digital twin model.
Thus, theoretically, the dynamic or static characteristics of the digital twin model, such as instantaneous speed, instantaneous torque, characteristic vibration frequency, etc., should be substantially close to or even equal to the actual system, so as to reflect the characteristics of the actual system, obtain the early warning information based on the characteristics of the actual system,
the method for acquiring the early warning information comprises the following steps:
respectively drawing a curve of the running current difference value and a curve of the running speed difference value on the basis of a time line, and extracting characteristic frequencies in the two groups of curves;
and (4) predicting the aging rule and fault information of the joint motor 4 based on the two groups of numerical curves of the characteristic frequency.
When the error between the dynamic index of the actual system and the dynamic index output by the model changes obviously in a long time, which means that the physical component property of the actual system changes, the upper computer outputs relevant fault information or aging condition to prompt, so that the intelligent level of the module controller is higher and the module controller has the capability of self-diagnosis.
In this embodiment, the first DSP provides the position instruction, the real-time speed, the real-time current, and the load observation value to the second DSP. The second DSP provides early warning information for the first DSP; the first DSP and the upper robot control are communicated and exchange data.
The second DSP needs to process, analyze and judge the parameters from the first DSP besides running the digital twin model of the module, and synthesize the parameters into the final parameters which are output to the first DSP for the first DSP to upload to the upper robot controller.
Fig. 4 is a schematic block diagram of the interaction between two DSPs.
The first and second DSP digital control overall architecture is shown in fig. 5, where in fig. 5:
θ (t): the rotor position of the joint motor 4;
ω (t): the motor speed of the joint motor 4;
i (t): the current of the joint motor 4;
θ ref (t): setting a position value;
θ t (t): the motor rotor position of the motor module model 10;
ω t (t): the motor rotation speed of the motor module model 10;
it (t): motor current of the motor module model 10;
the first DSP runs the actual control system algorithms including the position loop, speed loop and current loop needed to control the joint motor 4. The first DSP runs an industrial communication bus and is responsible for communication with an upper robot controller, data exchange, alarm information transmission, instruction receiving and the like.
The second DSP runs the module digital twin model, the digital twin model receives the position command and the load observation value from the first DSP, and the three-loop control system is formed to run automatically, is similar to an actual control system with a load model, and has a servo performance close to the actual control of the first DSP.
An analysis and judgment module 13 is also operated in the second DSP and used for comparing and analyzing the result output by the digital twin model and the related parameters of the actual system to obtain the judgment whether the actual system is abnormal or not.
Fig. 6 shows a block diagram of a joint motor 4 model and a load system model in the motor module model 10, and a position feedback link in the load system model has a module for reflecting a backlash effect (backlash) of a reducer.
The expression of the joint motor mathematical model is as follows:
in the formula, Ud and Uq are d and q-axis voltage components applied to the joint motor 4 in a d-q coordinate system, respectively; rs and Ls are respectively armature resistance and inductance of the joint motor 4; wm is the motor speed of the joint motor 4; λ pm is the permanent magnetic flux linkage of the joint motor 4;
the expression of the motor module model is as follows:
wherein: ks is the elastic coefficient of the coupling of the motor and the load of the motor module model 10; jm is the motor inertia of the motor module model 10; JL is the load inertia of the motor module model 10; te is the motor electromagnetic torque of the motor module model 10; ts is coulomb friction torque; omega m is the rotating speed of the motor; ω L is the load speed.
In this embodiment, the servo controller obtains the early warning information of the motor module based on the running current difference between the motor module model and the joint motor and the running speed difference between the motor module model and the joint motor.
In one embodiment, the servo controller further comprises an analysis and judgment module 13; the analysis and judgment module 13 is used for comparing and analyzing the current difference curve and the running speed difference curve to judge whether the robot joint module is abnormal.
In one embodiment, the servo controller further comprises a feedback module; and the feedback module feeds back the abnormity to an upper computer of the servo controller.
In this embodiment, in the digital twin model, data received from the first DSP is compared and historical data of a certain length is recorded, and if a large deviation occurs in the data within a period of time, it means that an actual system has changed and an original control parameter has failed to achieve an expected performance, the feedback module sends a prompt to the upper controller to trigger attention, or a necessity of maintenance, so as to achieve an early warning purpose, and improve an intelligence level of the joint module and reliability of long-life high-performance operation.
Fig. 7 is a block flow diagram of the second DSP running data processing.
Fig. 7 is a block diagram illustrating a flow of real-time processing and determining of relevant data. After the data are calculated, the data are finally put in a frequency domain for analysis, and whether the actual system needs to be reminded of maintenance or has problems is judged.
As shown in fig. 7, Sign _ maintennce represents a category that raises an early warning:
sign _ maintenance is 1, which indicates that a sudden external force may be applied to the mechanical arm component during the actual system operation, and an early warning needs to be initiated;
sign _ maintenance is 2, which indicates that the high-frequency characteristic of the actual system has obvious change, which means that the system has obvious vibration phenomenon, which may cause the increase of positioning error and needs to trigger early warning.
Sign _ maintenance is 3, which indicates that the low-frequency characteristics of the actual system have significant changes, meaning that potential faults and even looseness of mechanical parts of the system may occur, and an early warning needs to be triggered.
As shown in fig. 8, when the robot arm touches an external object during the operation, the value of the fer _ vel data curve calculated by the digital twin model exceeds the threshold value at time t0, and then Sign _ maintennce is set to 1 and sent to the first DSP, so as to trigger the early warning process.
The above description is only for the specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (8)
1. A servo controller for a robot joint module having a digital twin model, comprising:
the first digital signal processor receives an external instruction and controls a joint motor of the robot joint module based on an actual control ring;
a second digital signal processor, in communication with the first digital signal processor, running a digital twin model; the digital twin model is provided with a twin control ring and a motor module model;
the load observer runs in the first digital signal processor and calculates the load of the joint motor based on the actual speed, the motor current, the actual motor and the load inertia of the joint motor;
wherein: and the digital twin model is operated based on the external instruction, the actual speed of the joint motor, the motor current, the motor inertia of the joint motor, the gear clearance effect of a speed reducer configured for the joint motor and the load size twin to obtain the operation current difference and the operation speed difference between the motor module model and the joint motor.
2. The servo controller of claim 1, wherein: the actual control loop is based on a position controller, a speed controller, a current controller, a speed feedback processing unit and a position feedback processing unit to realize the control of the joint motor.
3. The servo controller of claim 2, wherein: a twin control ring is arranged in the digital twin model; the twin control loop comprises a twin position controller, a twin speed controller and a twin current controller which are the same as the actual control loop; the twin control loop simulates the speed feedback processing unit based on a speed converter and simulates the position feedback processing unit based on a position converter; and extracting the data of the speed converter and the position converter from the motor module model.
4. The servo controller of claim 1, wherein: the expression of the joint motor mathematical model is as follows:
wherein Ud and Uq are d and q axis voltage components applied to the joint motor in a d-q coordinate system, respectively; rs and Ls are respectively the armature resistance and the inductance of the joint motor; w m The motor speed of the joint motor; λ pm is a permanent magnetic flux linkage of the joint motor;
the expression of the motor module model is as follows:
wherein: ks is the elastic coefficient of the coupling of the motor module model motor and the load; jm is the motor inertia of the motor module model; JL is the load inertia of the motor module model; te is the motor of the motor module modelAn electromagnetic torque; ts is coulomb friction torque; omega m The motor rotating speed; omega L Is the load rotation speed.
5. The servo controller of claim 1, wherein: the servo controller obtains early warning information of the motor module based on the running current difference value of the motor module model and the joint motor and the running speed difference value of the motor module model and the joint motor.
6. The servo controller of claim 5, wherein: the method for acquiring the early warning information comprises the following steps:
respectively drawing a curve of the running current difference value and a curve of the running speed difference value on the basis of a time line, and extracting the most significant frequency in the two groups of curves;
and predicting the aging rule and fault information of the robot joint module based on the two groups of numerical curves with the most significant frequencies.
7. The servo controller of claim 6, wherein: the servo controller also comprises an analysis and judgment module; the analysis and judgment module is used for comparing and analyzing the curve of the current difference value and the curve of the running speed difference value to judge whether the robot joint module is abnormal or not.
8. The servo controller of claim 7, wherein: the servo controller further comprises a feedback module; and the feedback module feeds back the abnormity to an upper computer of the servo controller.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117182930A (en) * | 2023-11-07 | 2023-12-08 | 山东捷瑞数字科技股份有限公司 | Four-axis mechanical arm binding method, system, equipment and medium based on digital twin |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117182930A (en) * | 2023-11-07 | 2023-12-08 | 山东捷瑞数字科技股份有限公司 | Four-axis mechanical arm binding method, system, equipment and medium based on digital twin |
| CN117182930B (en) * | 2023-11-07 | 2024-02-13 | 山东捷瑞数字科技股份有限公司 | Four-axis mechanical arm binding method, system, equipment and medium based on digital twin |
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