WO2017113424A1 - 机器人控制系统及其驱动器故障判断方法 - Google Patents
机器人控制系统及其驱动器故障判断方法 Download PDFInfo
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- WO2017113424A1 WO2017113424A1 PCT/CN2015/100354 CN2015100354W WO2017113424A1 WO 2017113424 A1 WO2017113424 A1 WO 2017113424A1 CN 2015100354 W CN2015100354 W CN 2015100354W WO 2017113424 A1 WO2017113424 A1 WO 2017113424A1
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- Prior art keywords
- driver
- control system
- robot control
- drivers
- module
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Classifications
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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
- B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
Definitions
- the present invention relates to the field of robot technology, and in particular to a robot control system and a driver fault determination method thereof.
- the robot control system is widely used in various control fields. It is prone to drive failure during operation. Since the drive is connected in series to the link of the robot control system, any drive failure may lead to the operation of the robot control system. The machine does not function properly, so it is often necessary to check all drives.
- the technical problem mainly solved by the present invention is to provide a robot control system and a driver fault determination method thereof, which can shorten the debugging and maintenance time and improve the production efficiency of the production line.
- a technical solution adopted by the present invention is to provide a robot control system and a driver fault judging method thereof, the robot control system includes a host computer, a control cabinet and an operation machine, and the control cabinet is respectively connected with the host computer and the operation.
- the machine signal is connected, the control cabinet comprises at least two drivers and a motion control module, and the operating machine comprises at least two rotating shafts corresponding to at least two drivers one by one, the motion control module is connected with the driver signal through the bus, the motion control module and the upper computer Signal connection, at least 2 drivers are connected to at least 2 rotating shaft signals, and at least 2 drivers are used for driving at least 2 rotating shafts to perform specified actions, the method comprising: virtually configuring the robot control system, so that the upper computer is only for the robot One of at least two drivers on the control system transmits a control command; performs a line change on the robot control system, so that the robot control system only accesses the driver to be detected that receives the control command; and sends a control command to the driver to be detected; Drive driver to be tested and Corresponding to the rotation axis normal whether performing the specified actions; if not, the detector is determined to be failed drive.
- the method further includes: if yes, sequentially configuring the robot control system in a virtual manner, so that the upper computer only sends a control command to one of the remaining drivers on the robot control system; and continues to perform the circuit on the robot control system.
- the change is such that the robot control system only accesses the drive to be detected that receives the control command.
- the virtual configuration of the robot control system includes: performing station address configuration on one of the at least two drivers on the upper computer, and the remaining drivers are not configured with the station address or configuring the virtual station address, wherein the upper computer only configures the station address.
- the drive sends a control command.
- the circuit modification of the robot control system includes: connecting a driver configured with a station address in at least two drivers to the motion control module, and disconnecting the remaining drivers with the motion control module.
- the determining whether the driver driver to be detected and the corresponding rotation axis perform the specified action normally includes: acquiring the first driving data displayed on the upper computer, wherein the first driving data is at least two drivers driving at least two corresponding rotations thereof. Acquiring the fault data generated when the specified action is performed; acquiring second drive data displayed on the upper computer, wherein the second drive data is data generated when the drive to be detected drives the corresponding rotary axis to perform a specified action; Whether the driving data and the second driving data are the same; if yes, determining that the rotating axis corresponding to the driver to be detected does not perform the specified action abnormally; if not, determining that the rotating axis corresponding to the driver to be detected normally performs the specified action.
- the upper computer is a teach pendant.
- the bus is MIII bus or RTEX bus.
- At least two rotating shafts comprise six rotating shafts arranged in series.
- At least two rotating shafts further comprise six expandable rotating shafts.
- a robot control system which includes a host computer, a control cabinet, and an operation machine.
- the control cabinet is respectively connected with a signal of a host computer and an operation machine, and the control cabinet includes at least Two drivers and a motion control module, the operating machine includes at least two rotating shafts corresponding to at least two drivers, the motion control module is connected to the driver signal through a bus, the motion control module is connected with the upper computer signal, and at least two drivers are connected At least 2 rotating shaft signal connections, at least 2 drivers for driving at least 2 rotating shafts to perform specified actions, the upper computer includes a setting module, a transceiver module, a judging module and a decision module, the control cabinet includes a line changing module, and the setting module is used for Virtually configuring the robot control system, so that the host computer only sends a control command to one of the at least two drivers on the robot control system; the line change module is used to perform line change on the robot control system, so that the
- the setting module is configured to determine that the drive driver to be detected and the corresponding rotating shaft perform the specified action normally, and then virtually configure the robot control system so that the upper computer only acts on one of the remaining drives on the robot control system.
- a transmission control command is performed;
- the line change module is configured to continue to perform a line change to the robot control system, so that the robot control system only accesses the driver to be detected that receives the control command.
- the setting module is configured to perform station address configuration on one of the at least two drivers, and the remaining drivers do not configure the station address or configure the virtual station address, wherein the upper computer only sends a control command to the driver configured with the station address.
- the line change module is configured to connect the driver configured with the station address in at least two drivers to the motion control module, and the remaining drivers are disconnected from the motion control module.
- the upper computer includes a display module, and the determination module includes a first acquisition unit, a second acquisition unit, and a determination unit, where the display unit is configured to display the first driving data and the second driving data, wherein the first driving data is at least 2
- the driver drives the fault data generated when the corresponding at least two rotating shafts perform the specified action, and the second driving data is the data generated when the driver to be detected drives the corresponding rotating shaft to perform the specified action;
- the first acquiring unit uses Acquiring the first driving data;
- the second obtaining unit is configured to acquire the second driving data;
- the determining unit is configured to determine whether the first driving data and the second driving data are the same; if yes, the determining unit determines the rotation corresponding to the driver to be detected The axis does not normally perform the specified action; if not, the determining unit determines that the rotating axis corresponding to the driver to be detected normally performs the specified action.
- the upper computer is a teach pendant.
- the bus is MIII bus or RTEX bus.
- At least two rotating shafts comprise six rotating shafts arranged in series.
- At least two rotating shafts further comprise six expandable rotating shafts.
- the utility model has the beneficial effects that the driver fault judging method of the robot control system of the present invention comprises: virtualizing the robot control system so that the host computer only has at least two drivers on the robot control system, different from the prior art. One of them performs a transmission control command; performs a line change on the robot control system, so that the robot control system only accesses the driver to be detected that receives the control command; sends a control command through the driver to be detected by the host computer; and determines the driver driver to be detected. Whether the corresponding rotating axis performs the specified action normally; if not, it determines that the drive to be detected has failed.
- the present invention also It can avoid the problem of poor contact caused by multiple plugging and unplugging of the drive and the connecting line, which greatly reduces the safety hazard of the robot control system.
- FIG. 1 is a schematic structural view of a first embodiment of a robot control system of the present invention
- FIG. 2 is a schematic structural view of a second embodiment of the robot control system of the present invention.
- Figure 3 is a schematic structural view of the upper computer of Figure 2;
- FIG. 4 is a schematic flow chart of a method for judging a driver failure of the robot control system of the present invention
- FIG. 5 is a schematic flow chart of the sub-steps of step S104 in FIG.
- the invention discloses a robot control system.
- the system is a robot control system using a bus type driver.
- the robot control system includes a host computer, a control cabinet 11, and an operating machine 12.
- the control cabinet 11 is separately coupled to the host computer 10 and the operating machine 12.
- the upper computer 10 is preferably a teaching device.
- the present invention does not limit the upper computer 10 as a teaching device. In other embodiments, the upper computer 10 may also be other devices having control functions.
- the host computer 10 includes a setting module 101, a transceiver module 102, a judging module 103, a decision module 104, and a display module 105.
- the setting module 101 is configured to virtually configure the robot control system, so that the host computer 10 only sends a control command to one of the at least two drivers 112 on the robot control system.
- the setting module 101 is configured to perform station address configuration on one of the at least two drivers 112, and the remaining drivers 112 do not configure the station address or configure the virtual station address, wherein the host computer 10 only performs the driver configured with the station address.
- each driver 112 is configured with a unique station address, and the host computer 10 transmits a control command only to the driver 112 configured with the station address.
- the station address is configured for the remaining drivers 112, but the stations configured for the remaining drivers 112 are configured.
- the address is a virtual station address, and the host computer 10 does not transmit a control command to the driver 112 configured with the virtual station address.
- the transceiver module 102 is configured to send a control command to the driver to be detected. That is, the control command is transmitted only to the driver to which the station address is connected and connected to the motion control module 111.
- the determining module 103 is configured to determine whether the drive driver to be detected and its corresponding rotating axis perform the specified action normally.
- the judging module 103 includes a first obtaining unit 1031, a second obtaining unit 1032, and a determining unit 1033.
- the display module 105 is configured to display the first driving data and the second driving data, wherein the first driving data is fault data generated when at least two drivers 112 drive the corresponding at least two rotating axes to perform a specified action, and the second driving The data is the data generated when the drive to be detected drives its corresponding rotary axis to perform a specified action.
- the first obtaining unit 1031 is configured to acquire first driving data; the second obtaining unit 1032 is configured to acquire second driving data; the determining unit 1033 is configured to determine whether the first driving data and the second driving data are the same; if yes, the determining unit 1033 determines that the rotation axis corresponding to the driver to be detected does not normally perform the specified action; if not, the determination unit 1033 determines that the rotation axis corresponding to the driver to be detected normally performs the specified action.
- the first driving data and the second driving data may allow a small range of errors to occur, such as when the degree of similarity between the first driving data and the second driving data reaches 90% or more, the determinable The first drive data and the second drive data are the same.
- the driver to be detected drives the corresponding rotating axis
- the fault prompt given on the display interface of the upper computer 10 and the fault prompt given on the display interface of the upper computer 10 when all the drives drive the corresponding rotating shaft it can be determined that the first drive data and the second drive data are the same.
- the decision module 104 is configured to determine, at the determining module 103, that the driver driver to be detected and its corresponding rotating axis do not perform the specified action abnormally, determine that the driver to be detected is faulty, and display the fault parameter through the display module 105 to remind the user that the fault has occurred.
- the display module 105 is configured to display parameters of the host computer 10, including normal operating parameters and fault parameters.
- the setting module 101 is configured to perform virtual configuration on the robot control system in sequence when the determining module 103 determines that the driver driver to be detected and the corresponding rotating axis perform the specified action normally, so that the host computer 10 only has the rest on the robot control system.
- One of the drives sends a control command.
- the control cabinet 11 includes a motion control module 111, at least two drivers 112, and a PLC (Programmable Logic Controller) module 113 and a line change module 115.
- the operation machine 12 includes at least two rotation axes that are in one-to-one correspondence with at least two drivers 112. 121.
- Motion control module 111 is coupled to driver 112, PLC module 113, and line modification module 115 via bus 114, respectively.
- the motion control module 111 is signally connected to the upper computer 10, at least two drivers 112 are signally connected to at least two rotating shafts 121, and at least two drivers 112 are used to drive at least two rotating shafts 121 to perform a designated operation.
- the drive 112 is a servo drive, and the rotary shaft 121 is a servo motor. Since the servo drive and the motion control module 111 are connected by a bus 114, the servo drive is equivalent to being connected in series in the link.
- the line change module 115 is configured to make a line change to the robot control system so that the robot control system only accesses the drive to be detected that receives the control command. Further, the line change module 115 is configured to connect the driver configured with the station address among the at least two drivers to the motion control module 111, and the remaining drivers are disconnected from the motion control module 111. Specifically, the line change module 115 connects the driver having the station address among the at least two drivers 112 to the motion control module 111, and the remaining drivers 112 are disconnected from the motion control module 111. In fact, in the entire robot control system, all the drivers are connected to the motion control module 111. Therefore, in order to satisfy the robot control system, only one driver is connected, and the driver that cannot receive the control command needs to be disconnected from the motion control module 111. .
- the user sends a control instruction corresponding to the specified action to be executed to the motion control module 111 through the transceiver module 102, and then sends the control command to the PLC module 113 or the driver 112 via the motion control module 111, thereby implementing the control operation machine. 12
- the requirement to perform the specified action includes an action execution control command and a logic control command
- the motion control module 111 sends the action execution control command to the driver 112
- the motion control module 111 sends the logic control command to the PLC module 113, and the PLC module 113 is used to operate the machine. 12 Perform action editing.
- the bus 114 is an MIII bus (a bus based on the field of digital control) or a RTEX bus (a bus based on the field of digital control).
- At least two rotating shafts 121 preferably include six rotating shafts arranged in series, that is, the operating machine 12 is a six-axis serial robot, and At least two drivers 112 preferably include six drivers that are signally coupled to the rotating shaft 121.
- the at least two rotating shafts 121 may further include six expandable rotating shafts, and at least two of the drivers 112 may further include six expandable drivers that are coupled to the expandable rotating shaft.
- the number of the rotating shaft 121 and the driver 112 is not limited to the above, and may be specially set according to actual scenes.
- FIG. 4 is a schematic flow chart of a method for judging a driver failure of the robot control system of the present invention. The method includes the following steps:
- Step S101 Virtually configuring the robot control system, so that the host computer 10 only applies a control command to one of the at least two drivers 112 on the robot control system.
- the station address is configured by one of the at least two drivers 112 on the host computer 10, and the remaining drivers 112 are not configured with the station address.
- each driver 112 is configured with a unique station address, and the host computer 10 transmits a control command only to the driver 112 configured with the station address.
- the station address is configured for the remaining drivers 112, but the stations configured for the remaining drivers 112 are configured.
- the address is the virtual station address.
- the upper computer 10 does not transmit a control command to the driver 112 in which the virtual station address is disposed.
- the actual number of servo drives of the robot control system is set to 1 on the host computer 10, that is, only one servo drive is configured with a station address, and the other five servos are configured.
- the drives are all set to virtual, ie the other 5 servo drives do not configure the station address or configure the virtual station address.
- at least two of the drives further include an expandable drive, in step S101, the station address is still configured for only one drive, and the remaining drives are not configured with the station address or the configured virtual station address.
- the user can perform virtual configuration on the display interface of the upper computer 10 itself, or virtualize the robot control system on the upper computer 10 through the peripheral device as a medium.
- Step S102 Perform line modification on the robot control system, so that the robot control system only accesses the driver to be detected that receives the control command.
- the line change may be manually performed on the robot control system, or the robot control system may automatically change its own line or make a line change to the robot control system through an additional robot.
- the present invention is not limited to the robot.
- the subject object in which the control system performs the line change is within the scope of the present invention as long as it can satisfy the line change of the robot control system.
- the modification of the line includes connecting the driver having the station address disposed in the at least two drivers 112 to the motion control module 111, and the remaining drivers 112 are disconnected from the motion control module 111. In fact, in the entire robot control system, all the drivers are connected to the motion control module 111. Therefore, in order to satisfy the robot control system, only one driver is connected, and the driver that cannot receive the control command needs to be disconnected from the motion control module 111. .
- the user changes the line at the job site including: connecting the servo driver configured with the station address to the motion control module 111, and the remaining five are not configured with the station address or configuration.
- the servo drive of the virtual station address disconnects from the motion control module 111.
- at least two of the drivers 112 further include an expandable drive, in step S102, only the servo drive configured with the station address is connected to the motion control module 111.
- Step S103 The control command is sent by the driver to be detected.
- step S103 a control command is transmitted only to the drive in which the station address is arranged and connected to the motion control module 111.
- Step S104 It is determined whether the driver drive to be detected and its corresponding rotation axis 121 perform the specified action normally.
- step S104 includes the following sub-steps:
- Step S1041 Acquire the first driving data displayed on the host computer 10.
- the first driving data is fault data generated when at least two drivers 112 drive the corresponding at least two rotating axes to perform a specified action, that is, the first driving data is when all the drivers simultaneously drive all the rotating axes to perform a specified action. Fault data generated by the robot control system.
- Step S1042 Acquire second driving data displayed on the host computer 10.
- the second driving data is data generated by the robot control system when the driver to be detected drives the corresponding rotating axis to perform a specified action.
- Step S1043 It is determined whether the first driving data and the second driving data are the same.
- the first driving data and the second driving data may allow a small range of errors to occur, for example, when the degree of similarity between the first driving data and the second driving data reaches 90% or more, It can be determined that the first drive data and the second drive data are the same. Or, when the driver to be detected drives the corresponding rotating axis, the fault prompt given on the display interface of the upper computer 10 and the fault prompt given on the display interface of the upper computer 10 when all the drives drive the corresponding rotating shaft When the same, it can be determined that the first drive data and the second drive data are the same.
- step S1044 is performed: determining that the rotating axis corresponding to the driver to be detected does not perform the specified action abnormally.
- step S1045 is performed: determining that the rotating axis corresponding to the driver to be detected normally performs the specified action.
- step S105 is performed to determine that the driver to be detected has failed.
- step S106 the robot control system is sequentially configured in a virtual manner, so that the host computer 10 transmits only one of the remaining drivers on the robot control system. Control instruction. After step S106 is performed, the process returns to step S102 to perform line change on the remaining drivers in the robot control system.
- the commissioning and maintenance personnel do not need to remove the drive from the control cabinet, and then take it to the laboratory for testing using special equipment and software. Only the user needs to set the actual drive number of the drive of the robot control system to 1 in the upper computer, and set the correct station address, and the other drives are set to be virtual, and the station address is not set for it. Then replace the connection order of the lines and only access one drive to be tested. Finally, the power is turned on, the operating machine starts to run, and the fault prompt given on the display interface of the upper computer is observed to determine whether the drive has a fault. If the operating machine can run normally, it indicates that the drive is normal. According to the above methods and judgment criteria, the other drives are sequentially connected, that is, the faults can be located and checked for all the drives.
- the method for judging the driver failure of the robot control system of the present invention comprises: virtually configuring the robot control system, so that the upper computer only sends a control command to one of at least two drivers on the robot control system; The system performs line change, so that the robot control system only accesses the driver to be detected that receives the control command; the driver to be detected sends a control command; determines whether the driver driver to be detected and its corresponding rotating axis perform the specified action normally; if not, determine The drive to be tested has failed.
- the robot control system fails, it is not necessary to remove all the drives to perform inspection by using special equipment and software, and only need to access only one driver at a time on the job site to perform one-by-one troubleshooting and locate faults.
- the drive can greatly shorten the debugging and maintenance time and effectively improve the production efficiency of the production line.
- the invention can also avoid the contact failure problem caused by multiple insertion and removal of the driver and the connecting line, thereby greatly reducing the safety of the robot control system. Hidden dangers.
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Abstract
一种机器人控制系统的驱动器（112）故障判断方法，包括：对机器人控制系统进行虚拟配置，使上位机（10）只对机器人控制系统上的至少2个驱动器（112）中的一者进行发送控制指令（S101）；对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器（112）（S102）；对待检测的驱动器（112）发送控制指令（S103）；判断待检测的驱动器（112）驱动与其对应的转动轴（121）是否正常执行指定动作（S104）；如果否，确定待检测的驱动器（112）发生故障（S105）。通过上述方式能够在机器人控制系统发生故障时，不必拆除所有驱动器（112）进行检测，可以在作业现场就进行故障定位，大大缩短调试维护时间。
Description
【技术领域】
本发明涉及机器人技术领域，特别是涉及一种机器人控制系统及其驱动器故障判断方法。
【背景技术】
机器人控制系统大量应用在各个控制领域中，在操作过程中容易出现驱动器故障，由于驱动器是串联在机器人控制系统的链路中的，因此任何一个驱动器出现故障，都有可能导致机器人控制系统的操作机无法正常运行，因此往往需要对所有驱动器进行检查。
对驱动器进行故障定位检查时，往往需要调试维护人员拆下所有的驱动器，并利用专用设备和软件检查所有驱动器，从而定位出哪个驱动器出现故障。该检测方法存在的问题是：必须拆除所有驱动器并利用专用设备和软件进行检测，再更换出现故障的驱动器；且不能在作业现场就进行故障的定位，要对全部驱动器进行检测，需要花费大量的时间，调试维护的时间成本很高，严重影响产线的生产效率。
综上所述，有必要提供一种机器人控制系统及其驱动器故障判断方法以解决上述问题。
【发明内容】
本发明主要解决的技术问题是提供一种机器人控制系统及其驱动器故障判断方法，能够缩短调试维护时间，提高产线的生产效率。
为解决上述技术问题，本发明采用的一个技术方案是：提供一种机器人控制系统及其驱动器故障判断方法，该机器人控制系统包括上位机、控制柜以及操作机，控制柜分别与上位机和操作机信号连接，控制柜包括至少2个驱动器以及运动控制模块，操作机包括与至少2个驱动器一一对应的至少2个转动轴，运动控制模块通过总线与驱动器信号连接，运动控制模块与上位机信号连接，至少2个驱动器与至少2个转动轴信号连接，至少2个驱动器用于驱动至少2个转动轴执行指定动作，该方法包括：对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的至少2个驱动器中的一者进行发送控制指令；对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器；对待检测的驱动器发送控制指令；判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作；如果否，确定待检测的驱动器发生故障。
其中，该方法还包括：如果是，则依次对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的其余驱动器中的一者进行发送控制指令；并继续执行对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器的步骤。
其中，对机器人控制系统进行虚拟配置包括：在上位机上对至少2个驱动器中的一者进行站地址配置，其余的驱动器不配置站地址或配置虚拟站地址，其中上位机只对配置有站地址的驱动器进行发送控制指令。
其中，对机器人控制系统进行线路更改包括：将至少2个驱动器中配置有站地址的驱动器与运动控制模块连接，其余的驱动器断开与运动控制模块连接。
其中，判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作包括：获取在上位机上所显示的第一驱动数据，其中第一驱动数据为至少2个驱动器驱动其对应的至少2个转动轴执行指定动作时所产生的故障数据；获取在上位机上所显示的第二驱动数据，其中第二驱动数据为待检测的驱动器驱动其对应的转动轴执行指定动作时所产生的数据；判断第一驱动数据与第二驱动数据是否相同；如果是，则确定待检测的驱动器对应的转动轴不正常执行指定动作；如果否，则确定待检测的驱动器对应的转动轴正常执行指定动作。
其中，上位机为示教器。
其中，总线为MIII总线或RTEX总线。
其中，至少2个转动轴包括6个通过串联方式设置的转动轴。
其中，至少2个转动轴还包括6个可扩展转动轴。
为解决上述技术问题，本发明采用的另一个技术方案是：提供一种机器人控制系统，其包括上位机、控制柜以及操作机，控制柜分别与上位机和操作机信号连接，控制柜包括至少2个驱动器以及运动控制模块，操作机包括与至少2个驱动器一一对应的至少2个转动轴，运动控制模块通过总线与驱动器信号连接，运动控制模块与上位机信号连接，至少2个驱动器与至少2个转动轴信号连接，至少2个驱动器用于驱动至少2个转动轴执行指定动作，上位机包括设置模块、收发模块、判断模块和决策模块，控制柜包括线路更改模块，设置模块用于对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的至少2个驱动器中的一者进行发送控制指令；线路更改模块用于对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器；收发模块用于对待检测的驱动器发送控制指令；判断模块用于判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作；决策模块用于在判断模块确定待检测的驱动器驱动与其对应的转动轴不正常执行指定动作，确定待检测的驱动器发生故障。
其中，设置模块用于确定待检测的驱动器驱动与其对应的转动轴正常执行指定动作时，依次对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的其余所述驱动器中的一者进行发送控制指令；线路更改模块用于继续执行对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器的步骤。
其中，设置模块用于对至少2个驱动器中的一者进行站地址配置，其余的驱动器不配置站地址或配置虚拟站地址，其中上位机只对配置有站地址的驱动器进行发送控制指令。
其中，线路更改模块用于将至少2个驱动器中配置有站地址的驱动器与运动控制模块连接，其余的驱动器断开与运动控制模块连接。
其中，上位机包括显示模块，所述判断模块包括第一获取单元、第二获取单元和判定单元，显示单元用于显示第一驱动数据和第二驱动数据，其中，第一驱动数据为至少2个驱动器驱动其对应的至少2个转动轴执行指定动作时所产生的故障数据，第二驱动数据为待检测的驱动器驱动其对应的转动轴执行指定动作时所产生的数据；第一获取单元用于获取第一驱动数据；第二获取单元用于获取第二驱动数据；判定单元用于判断第一驱动数据与第二驱动数据是否相同；如果是，则判定单元确定待检测的驱动器对应的转动轴不正常执行指定动作；如果否，则判定单元确定待检测的驱动器对应的转动轴正常执行指定动作。
其中，上位机为示教器。
其中，总线为MIII总线或RTEX总线。
其中，至少2个转动轴包括6个通过串联方式设置的转动轴。
其中，至少2个转动轴还包括6个可扩展转动轴。
本发明的有益效果是：区别于现有技术的情况，本发明的机器人控制系统的驱动器故障判断方法包括：对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的至少2个驱动器中的一者进行发送控制指令；对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器；通过上位机对待检测的驱动器发送控制指令；判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作；如果否，确定待检测的驱动器发生故障。通过上述方式，本发明在机器人控制系统发生故障时，不必拆除所有驱动器进行检测，可以直接在作业现场就进行故障定位，大大缩短调试维护时间，有效提高产线的生产效率；同时，本发明还可以避免因多次插拔驱动器和连接线而造成的接触不良问题，大大降低了机器人控制系统的安全隐患。
【附图说明】
图1是本发明机器人控制系统的第一实施例的结构示意图；
图2是本发明机器人控制系统的第二实施例的结构示意图；
图3是图2中上位机的结构示意图；
图4是本发明机器人控制系统的驱动器故障判断方法的流程示意图；
图5是图3中步骤S104的子步骤流程示意图。
【具体实施方式】
下面结合附图和实施方式对本发明进行详细说明。
本发明公开一种机器人控制系统，优选地，该系统为采用总线型驱动器的机器人控制系统。如图1-图3所示，机器人控制系统包括上位机、控制柜11和操作机12。控制柜11分别与上位机10和操作机12信号连接。在本实施例中，上位机10优选为示教器，当然，本发明并不限定上位机10为示教器，在其他实施例中，上位机10还可以是其他具有控制功能的器件。
上位机10包括设置模块101、收发模块102、判断模块103、决策模块104和显示模块105。
设置模块101用于对机器人控制系统进行虚拟配置，使上位机10只对机器人控制系统上的至少2个驱动器112中的一者进行发送控制指令。具体地，设置模块101用于对至少2个驱动器112中的一者进行站地址配置，其余的驱动器112不配置站地址或配置虚拟站地址，其中上位机10只对配置有站地址的驱动器进行发送控制指令。在本实施例中，每一驱动器112配置有唯一的站地址，上位机10只对配置有站地址的驱动器112进行发送控制指令。应理解，在一些实施例中，除了在上位机10上对至少2个驱动器112中的一者进行站地址配置外，还对其余的驱动器112配置站地址，但对其余的驱动器112配置的站地址是虚拟站地址，其中上位机10对配置有虚拟站地址的驱动器112不进行发送控制指令。
收发模块102用于对待检测的驱动器发送控制指令。即，只对配置有站地址且与运动控制模块111连接的驱动器发送控制指令。
判断模块103用于判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作。具体地，判断模块103包括第一获取单元1031、第二获取单元1032和判定单元1033。显示模块105用于显示第一驱动数据和第二驱动数据，其中，第一驱动数据为至少2个驱动器112驱动其对应的至少2个转动轴执行指定动作时所产生的故障数据，第二驱动数据为待检测的驱动器驱动其对应的转动轴执行指定动作时所产生的数据。第一获取单元1031用于获取第一驱动数据；第二获取单元1032用于获取第二驱动数据；判定单元1033用于判断第一驱动数据与第二驱动数据是否相同；如果是，则判定单元1033确定待检测的驱动器对应的转动轴不正常执行指定动作；如果否，则判定单元1033确定待检测的驱动器对应的转动轴正常执行指定动作。
在本实施例中，考虑到误差的出现，第一驱动数据与第二驱动数据可以允许出现小范围的误差，如第一驱动数据与第二驱动数据的相似程度达到90%以上时，可判定第一驱动数据和第二驱动数据相同。又或者，待检测的驱动器驱动其对应的转动轴时，在上位机10的显示界面给出的故障提示与全部驱动器驱动其对应的转动轴时在上位机10的显示界面上给出的故障提示相同时，可判定第一驱动数据和第二驱动数据相同。
决策模块104用于在判断模块103确定待检测的驱动器驱动与其对应的转动轴不正常执行指定动作，确定待检测的驱动器发生故障，并通过显示模块105显示故障参数以提醒用户发生故障。
显示模块105用于显示上位机10的参数，该参数包括正常工作参数和故障参数等。
进一步地，设置模块101用于在判断模块103确定待检测的驱动器驱动与其对应的转动轴正常执行指定动作时，依次对机器人控制系统进行虚拟配置，使上位机10只对机器人控制系统上的其余驱动器中的一者进行发送控制指令。
控制柜11包括运动控制模块111、至少2个驱动器112和PLC（可编程逻辑控制器）模块113和线路更改模块115，操作机12包括与至少2个驱动器112一一对应的至少2个转动轴121。运动控制模块111通过总线114分别与驱动器112、PLC模块113和线路更改模块115信号连接。运动控制模块111与上位机10信号连接，至少2个驱动器112与至少2个转动轴121信号连接，至少2个驱动器112用于驱动至少2个转动轴121执行指定动作。驱动器112为伺服驱动器，转动轴121为伺服电机，由于伺服驱动器和运动控制模块111之间通过总线114连接，因此伺服驱动器相当于串联在链路中。
线路更改模块115用于对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器。进一步地，线路更改模块115用于将至少2个驱动器中配置有站地址的驱动器与运动控制模块111连接，其余的驱动器断开与运动控制模块111连接。具体地，线路更改模块115将至少2个驱动器112中配置有站地址的驱动器与运动控制模块111连接，其余的驱动器112断开与运动控制模块111连接。实际上，在整个机器人控制系统中，所有的驱动器是与运动控制模块111连接的，因此为了满足机器人控制系统只接入一个驱动器，需要将不能接收控制指令的驱动器断开与运动控制模块111连接。
在本实施例中，用户通过收发模块102将要执行的指定动作对应的控制指令发送给运动控制模块111，再经由运动控制模块111将控制指令发送给PLC模块113或驱动器112，从而实现控制操作机12执行指定动作的需求。应理解，控制指令包括动作执行控制指令和逻辑控制指令，运动控制模块111将动作执行控制指令发送给驱动器112，运动控制模块111将逻辑控制指令发送PLC模块113，PLC模块113用于对操作机12进行动作编辑。
在本实施例中，总线114为MIII总线（一种基于数字控制领域的总线）或RTEX总线（一种基于数字控制领域的总线）。
驱动器112和转动轴121是一一对应的，因此，在本发明中，至少2个转动轴121优选包括6个通过串联方式设置的转动轴，即相当于操作机12为6轴串联机器人，同时，至少2个驱动器112优选包括6个与转动轴121信号连接的驱动器。当然，在另一实施例中，至少2个转动轴121还可以包括6个可扩展转动轴，同时，至少2个驱动器112还可以包括6个与可扩展转动轴信号连接的可扩展驱动器。应理解，转动轴121和驱动器112的数量并不限定于上述所述，可以根据实际场景特别设置。
如图4所示，图4是本发明机器人控制系统的驱动器故障判断方法的流程示意图。该方法包括以下步骤：
步骤S101：对机器人控制系统进行虚拟配置，使上位机10只对机器人控制系统上的至少2个驱动器112中的一者进行施加控制指令。
在步骤S101中，通过在上位机10上对至少2个驱动器112中的一者进行站地址配置，其余的驱动器112不配置站地址。在本实施例中，每一驱动器112配置有唯一的站地址，上位机10只对配置有站地址的驱动器112进行发送控制指令。应理解，在一些实施例中，除了在上位机10上对至少2个驱动器112中的一者进行站地址配置外，还对其余的驱动器112配置站地址，但对其余的驱动器112配置的站地址是虚拟站地址。其中上位机10对配置有虚拟站地址的驱动器112不进行发送控制指令。
具体地，如至少2个驱动器112包括6个伺服驱动器，在上位机10上将机器人控制系统的伺服驱动器的实际驱动数设置成1，即只为1个伺服驱动器配置站地址，其他5个伺服驱动器都设置成虚拟，即其他5个伺服驱动器不配置站地址或配置虚拟站地址。当然，倘若至少2个驱动器还包括可扩展驱动器，在步骤S101中依然是对只对1个驱动器配置站地址，其余驱动器不配置站地址或配置虚拟站地址。
在本实施例中，用户可以在上位机10本身的显示界面上对机器人控制系统进行虚拟配置，也可以通过外设设备作为介质在上位机10上对机器人控制系统进行虚拟配置。
步骤S102：对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器。
在步骤S102中，可以是人为对机器人控制系统进行线路更改，也可以是机器人控制系统自动对其本身的线路进行更改或者通过额外的机器人对机器人控制系统进行线路更改，本发明并不限定对机器人控制系统进行线路更改的主体对象，只要满足能够对机器人控制系统进行线路更改都处于本发明的保护范围。具体地，对线路进行更改包括：将至少2个驱动器112中配置有站地址的驱动器与运动控制模块111连接，其余的驱动器112断开与运动控制模块111连接。实际上，在整个机器人控制系统中，所有的驱动器是与运动控制模块111连接的，因此为了满足机器人控制系统只接入一个驱动器，需要将不能接收控制指令的驱动器断开与运动控制模块111连接。
举例而言，如至少2个驱动器112包括6个伺服驱动器，用户在作业现场对线路更改包括：将配置有站地址的伺服驱动器与运动控制模块111连接，其余5个不配置有站地址或配置虚拟站地址的伺服驱动器断开与运动控制模块111的连接。当然，倘若至少2个驱动器112还包括可扩展驱动器，在步骤S102中依然是对只将配置有站地址的伺服驱动器与运动控制模块111连接。
步骤S103：对待检测的驱动器发送控制指令。
在步骤S103中，只对配置有站地址且与运动控制模块111连接的驱动器发送控制指令。
步骤S104：判断待检测的驱动器驱动与其对应的转动轴121是否正常执行指定动作。
如图5所示，步骤S104包括以下子步骤：
步骤S1041：获取在上位机10上所显示的第一驱动数据。
其中，第一驱动数据为至少2个驱动器112驱动其对应的至少2个转动轴执行指定动作时所产生的故障数据，即，第一驱动数据为全部驱动器同时驱动所有的转动轴执行指定动作时机器人控制系统所产生的故障数据。
步骤S1042：获取在上位机10上所显示的第二驱动数据。
其中，第二驱动数据为待检测的驱动器驱动其对应的转动轴执行指定动作时机器人控制系统所产生的数据。
步骤S1043：判断第一驱动数据与第二驱动数据是否相同。
应理解，在步骤S1043中，考虑到误差的出现，第一驱动数据与第二驱动数据可以允许出现小范围的误差，如第一驱动数据与第二驱动数据的相似程度达到90%以上时，可判定第一驱动数据和第二驱动数据相同。又或者，待检测的驱动器驱动其对应的转动轴时，在上位机10的显示界面给出的故障提示与全部驱动器驱动其对应的转动轴时在上位机10的显示界面上给出的故障提示相同时，可判定第一驱动数据和第二驱动数据相同。
如果确定第一驱动数据与第二驱动数据相同，则执行步骤S1044：确定待检测的驱动器对应的转动轴不正常执行指定动作。
如果确定第一驱动数据与第二驱动数据不相同，则执行步骤S1045：确定待检测的驱动器对应的转动轴正常执行指定动作。
如果确定待检测的驱动器驱动与其对应的转动轴不正常执行指定动作，则执行步骤S105：确定待检测的驱动器发生故障。
如果确定待检测的驱动器驱动与其对应的转动轴正常执行指定动作，则执行步骤S106：依次对机器人控制系统进行虚拟配置，使上位机10只对机器人控制系统上的其余驱动器中的一者进行发送控制指令。执行完步骤S106后，返回继续执行步骤S102，以对机器人控制系统中的其余驱动器进行线路更改。
本发明中，在驱动器发生故障时，调试维护人员不用将驱动器从控制柜中拆除，再拿到实验室利用专用设备和软件进行检测。而只需要用户在上位机将机器人控制系统的驱动器的实际驱动数设置成1，并设置正确的站地址，其他的驱动器都设置成虚拟，不为其设置站地址。然后更换线路的连接顺序，只接入1个待检测的驱动器。最后接通电源，操作机开始运行，观察上位机的显示界面上给出的故障提示，从而判断该驱动器是否出现故障。若操作机能够正常运行，说明该驱动器正常，按照上述方法和判断准则，依次接入其他驱动器，即可以对所有驱动器都进行故障的定位和排查。
综上，本发明的机器人控制系统的驱动器故障判断方法包括：对机器人控制系统进行虚拟配置，使上位机只对机器人控制系统上的至少2个驱动器中的一者进行发送控制指令；对机器人控制系统进行线路更改，使机器人控制系统只接入接收控制指令的待检测的驱动器；对待检测的驱动器发送控制指令；判断待检测的驱动器驱动与其对应的转动轴是否正常执行指定动作；如果否，确定待检测的驱动器发生故障。通过上述方式，本发明在机器人控制系统发生故障时，不需要拆下所有的驱动器利用专用设备和软件进行检查，只需要在作业现场，每次只接入一个驱动器，来进行逐一排查，定位故障的驱动器，这样能够大大缩短调试维护时间，有效提高产线的生产效率；同时，本发明还可以避免因多次插拔驱动器和连接线而造成的接触不良问题，大大降低了机器人控制系统的安全隐患。
以上所述仅为本发明的实施方式，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。
Claims (18)
- 一种机器人控制系统的驱动器故障判断方法，所述机器人控制系统包括上位机、控制柜以及操作机，所述控制柜分别与所述上位机和所述操作机信号连接，所述控制柜包括至少2个驱动器以及运动控制模块，所述操作机包括与所述至少2个驱动器一一对应的至少2个转动轴，所述运动控制模块通过总线与所述驱动器信号连接，所述运动控制模块与所述上位机信号连接，所述至少2个驱动器与所述至少2个转动轴信号连接，所述至少2个驱动器用于驱动所述至少2个转动轴执行指定动作，其特征在于，所述方法包括：对所述机器人控制系统进行虚拟配置，使所述上位机只对所述机器人控制系统上的所述至少2个驱动器中的一者进行发送控制指令；对所述机器人控制系统进行线路更改，使所述机器人控制系统只接入接收所述控制指令的待检测的驱动器；对所述待检测的驱动器发送所述控制指令；判断所述待检测的驱动器驱动与其对应的所述转动轴是否正常执行指定动作；如果否，确定所述待检测的驱动器发生故障。
- 根据权利要求1所述的方法，其特征在于，所述方法还包括：如果是，则依次对所述机器人控制系统进行虚拟配置，使所述上位机只对所述机器人控制系统上的其余所述驱动器中的一者进行发送所述控制指令；并继续执行对所述机器人控制系统进行线路更改，使所述机器人控制系统只接入接收所述控制指令的待检测的驱动器的步骤。
- 根据权利要求2所述的方法，其特征在于，所述对所述机器人控制系统进行虚拟配置包括：对所述至少2个驱动器中的一者进行站地址配置，其余的所述驱动器不配置所述站地址或配置虚拟站地址，其中所述上位机只对配置有所述站地址的所述驱动器进行发送所述控制指令。
- 根据权利要求3所述的方法，其特征在于，所述对所述机器人控制系统进行线路更改包括：将所述至少2个驱动器中配置有所述站地址的所述驱动器与所述运动控制模块连接，其余的所述驱动器断开与所述运动控制模块连接。
- 根据权利要求4所述的方法，其特征在于，所述判断所述待检测的驱动器驱动与其对应的所述转动轴是否正常执行指定动作包括：获取在所述上位机上所显示的第一驱动数据，其中所述第一驱动数据为所述至少2个驱动器驱动其对应的所述至少2个转动轴执行指定动作时所产生的故障数据；获取在所述上位机上所显示的第二驱动数据，其中所述第二驱动数据为所述待检测的驱动器驱动其对应的所述转动轴执行指定动作时所产生的数据；判断所述第一驱动数据与所述第二驱动数据是否相同；如果是，则确定所述待检测的驱动器对应的所述转动轴不正常执行指定动作；如果否，则确定所述待检测的驱动器对应的所述转动轴正常执行指定动作。
- 根据权利要求1所述的方法，其特征在于，所述上位机为示教器。
- 根据权利要求1所述的方法，其特征在于，所述总线为MIII总线或RTEX总线。
- 根据权利要求1所述的方法，其特征在于，所述至少2个转动轴包括6个通过串联方式设置的转动轴。
- 根据权利要求8所述的方法，其特征在于，所述至少2个转动轴还包括6个可扩展转动轴。
- 一种机器人控制系统，其包括上位机、控制柜以及操作机，所述控制柜分别与所述上位机和所述操作机信号连接，所述控制柜包括至少2个驱动器以及运动控制模块，所述操作机包括与所述至少2个驱动器一一对应的至少2个转动轴，所述运动控制模块通过总线与所述驱动器信号连接，所述运动控制模块与所述上位机信号连接，所述至少2个驱动器与所述至少2个转动轴信号连接，所述至少2个驱动器用于驱动所述至少2个转动轴执行指定动作，其特征在于，所述上位机包括设置模块、收发模块、判断模块和决策模块，所述控制柜包括线路更改模块，所述设置模块用于对所述机器人控制系统进行虚拟配置，使所述上位机只对所述机器人控制系统上的所述至少2个驱动器中的一者进行发送控制指令；所述线路更改模块用于对所述机器人控制系统进行线路更改，使所述机器人控制系统只接入接收所述控制指令的待检测的驱动器；所述收发模块用于对所述待检测的驱动器发送所述控制指令；所述判断模块用于判断所述待检测的驱动器驱动与其对应的所述转动轴是否正常执行指定动作；所述决策模块用于在所述判断模块确定所述待检测的驱动器驱动与其对应的所述转动轴不正常执行指定动作，确定所述待检测的驱动器发生故障。
- 根据权利要求10所述的机器人控制系统，其特征在于，所述设置模块用于在所述判断模块确定所述待检测的驱动器驱动与其对应的所述转动轴正常执行指定动作时，依次对所述机器人控制系统进行虚拟配置，使所述上位机只对所述机器人控制系统上的其余所述驱动器中的一者进行发送所述控制指令；所述线路更改模块用于继续执行对所述机器人控制系统进行线路更改，使所述机器人控制系统只接入接收所述控制指令的待检测的驱动器的步骤。
- 根据权利要求11所述的机器人控制系统，其特征在于，所述设置模块用于对所述至少2个驱动器中的一者进行站地址配置，其余的所述驱动器不配置所述站地址或配置虚拟站地址，其中所述上位机只对配置有所述站地址的所述驱动器进行发送所述控制指令。
- 根据权利要求12所述的机器人控制系统，其特征在于，所述线路更改模块用于将所述至少2个驱动器中配置有所述站地址的所述驱动器与所述运动控制模块连接，其余的所述驱动器断开与所述运动控制模块连接。
- 根据权利要求13所述的机器人控制系统，其特征在于，所述上位机包括显示模块，所述判断模块包括第一获取单元、第二获取单元和判定单元，所述显示模块用于显示第一驱动数据和第二驱动数据，其中，所述第一驱动数据为所述至少2个驱动器驱动其对应的所述至少2个转动轴执行指定动作时所产生的故障数据，所述第二驱动数据为所述待检测的驱动器驱动其对应的所述转动轴执行指定动作时所产生的数据；所述第一获取单元用于获取第一驱动数据；所述第二获取单元用于获取第二驱动数据；所述判定单元用于判断所述第一驱动数据与所述第二驱动数据是否相同；如果是，则所述判定单元确定所述待检测的驱动器对应的所述转动轴不正常执行指定动作；如果否，则所述判定单元确定所述待检测的驱动器对应的所述转动轴正常执行指定动作。
- 根据权利要求1所述的机器人控制系统，其特征在于，所述上位机为示教器。
- 根据权利要求1所述的机器人控制系统，其特征在于，所述总线为MIII总线或RTEX总线。
- 根据权利要求1所述的机器人控制系统，其特征在于，所述至少2个转动轴包括6个通过串联方式设置的转动轴。
- 根据权利要求17所述的机器人控制系统，其特征在于，所述至少2个转动轴还包括6个可扩展转动轴。
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