Manipulator false impact control method and system based on vibration sensor

Abstract

The invention provides a manipulator false impact control method and system based on a vibration sensor, and relates to the technical field of intelligent control, and the method comprises the following steps: extracting real-time amplitude and frequency data corresponding to a manipulator according to a current state; calculating relative deviation between the real-time amplitude and frequency data and a preset reference value, wherein the relative deviation comprises amplitude relative deviation and frequency relative deviation; according to the relative deviation and a preset deviation threshold value, whether abnormal collision exists in the state of the mechanical arm or not is judged, and a judgment result is obtained; and according to the judgment result, a corresponding control instruction is sent to the manipulator, so that the manipulator moves according to the corresponding control instruction. By monitoring the amplitude and frequency data of the manipulator in real time, whether abnormal collision exists or not is accurately judged, the corresponding control instruction is sent to the manipulator according to the abnormal collision, and the operation safety and the intelligent level of the manipulator are effectively improved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent control technology, and in particular to a vibration sensor-based manipulator miscollision control method and system. Background Art

[0002] There are many possible risk factors in the process of transferring workpieces between the robot and peripheral equipment. Human operation error is a risk point. For example, the operator may enter the wrong coordinates when setting the robot's motion trajectory, or accidentally touch the control button, causing the robot to collide with surrounding equipment or workpieces.

[0003] Secondly, the failure of sensors or mechanical parts is also a cause of collisions. Take sensors as an example. If a photoelectric sensor used to detect the position of the robot fails due to dirt or damage, it cannot accurately sense the actual position of the robot, causing the control system to make wrong judgments. In terms of mechanical parts, if a bearing becomes loose due to long-term wear, the movement of the robot may become unstable, increasing the risk of collision with surrounding equipment.

[0004] In a highly automated production environment, the communication lines between the robot and the control system are tens or even hundreds of meters long. These lines may break during long-term use due to aging, rat bites, accidental pulling, etc. Once the communication line is broken, the robot may lose control and fail to move according to the predetermined trajectory, thus causing a collision accident. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a method and system for controlling manipulator miscollision based on a vibration sensor, which can timely prevent the damage caused by abnormal collision from further expanding, thereby reducing the time and property losses caused by equipment damage.

[0006] In order to solve the above technical problems, the technical solution of the present invention is as follows:

[0007] In a first aspect, a method for controlling a manipulator's accidental collision based on a vibration sensor comprises:

[0008] The current state of the manipulator is obtained in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds;

[0009] According to the current state, extract the real-time amplitude and frequency data corresponding to the robot;

[0010] Calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the relative amplitude deviation and the relative frequency deviation;

[0011] According to the relative deviation and the preset deviation threshold, it is judged whether there is abnormal collision in the state of the robot to obtain a judgment result;

[0012] According to the judgment result, a corresponding control instruction is issued to the robot so that the robot moves according to the corresponding control instruction.

[0013] Furthermore, the current state of the manipulator is obtained in real time through a vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds, including:

[0014] Acquire the running state of the manipulator in the state without the workpiece to obtain the amplitude and frequency data of the manipulator in the state without the workpiece;

[0015] Obtain the running state of the manipulator when carrying the workpiece to obtain the amplitude and frequency data of the manipulator when carrying the workpiece, specifically including:

[0016] According to the type and weight of each workpiece, the amplitude and frequency data of the manipulator at different movement speeds are obtained; according to the amplitude and frequency data of the manipulator at different movement speeds, the workpieces are classified according to different movement speeds.

[0017] Further, based on the relative deviation and the preset deviation threshold, it is judged whether there is an abnormal collision in the state of the manipulator to obtain a judgment result, including:

[0018] Calculate the relative deviation of the amplitude and frequency of the manipulator in real time, and obtain the preset amplitude relative deviation threshold and frequency relative deviation threshold from the controller of the manipulator;

[0019] Compare the amplitude relative deviation value and the frequency relative deviation value with a preset amplitude relative deviation threshold and a preset frequency relative deviation threshold;

[0020] If either the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that the robot has an abnormal collision; if the two relative deviations do not exceed the corresponding threshold, the controller determines that the robot is in a normal state;

[0021] The judgment of the robot is output to the controller to obtain the judgment result.

[0022] Furthermore, the calculation formula of the amplitude relative deviation is:

[0023]

[0024] Among them, ΔA represents the relative deviation of amplitude; A m A represents the amplitude of the robot arm monitored by the vibration sensor in real time at the current moment; r(v,T,M) represents the amplitude reference value; v represents the operating speed of the robot; T represents the type of workpiece currently carried by the robot; M represents the weight of the workpiece currently carried by the robot.

[0025] Furthermore, the calculation formula of the relative frequency deviation is:

[0026]

[0027] Among them, Δf represents the relative frequency deviation; f m It indicates the frequency detected by the vibration sensor in real time when the robot is running; f r (v,T,M) represents the frequency reference value; ∈ represents a constant; δ represents an adjustment coefficient; v n Indicates the selected reference speed.

[0028] Further, according to the judgment result, a corresponding control instruction is issued to the manipulator so that the manipulator moves according to the corresponding control instruction, including:

[0029] According to the judgment result, a control instruction to be issued to the robot is determined, and the control instruction is sent to the robot;

[0030] The robot receives the control instruction and performs the corresponding action according to the instruction content. If the instruction is to continue to execute the current task, the robot maintains the normal motion state; if the instruction is to stop motion, the robot immediately stops the current motion; if the instruction is to stop motion and return to the specified position, the robot stops the current motion and returns to the specified position along the preset path.

[0031] In a second aspect, a robot arm accidental collision control system based on a vibration sensor comprises:

[0032] The acquisition module is used to obtain the current state of the manipulator in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds; according to the current state, the real-time amplitude and frequency data corresponding to the manipulator are extracted;

[0033] The processing module is used to calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the amplitude relative deviation and the frequency relative deviation; based on the relative deviation and the preset deviation threshold, determine whether there is an abnormal collision in the state of the manipulator to obtain a judgment result; based on the judgment result, issue a corresponding control instruction to the manipulator to make the manipulator move according to the corresponding control instruction.

[0034] According to a third aspect, a computing device includes:

[0035] one or more processors;

[0036] The storage device is used to store one or more programs. When the one or more programs are executed by the one or more processors, the one or more processors implement the method described.

[0037] In a fourth aspect, a computer-readable storage medium stores a program, and when the program is executed by a processor, the method described is implemented.

[0038] The above solution of the present invention includes at least the following beneficial effects:

[0039] The vibration sensor installed at the front end of the manipulator can obtain the current state of the manipulator in real time, including the amplitude and frequency data under different conditions. This real-time monitoring helps to detect potential collision risks in a timely manner, so that preventive measures can be taken before a collision occurs, improving the safety of manipulator operation. This method can accurately extract the amplitude and frequency data of the manipulator in different states, compare it with the preset reference value, and calculate the relative deviation. This precise data analysis provides a reliable basis for subsequent collision judgment.

[0040] By comparing the real-time amplitude and frequency data with the preset deviation threshold, it is possible to intelligently determine whether the robot has an abnormal collision. This intelligent judgment mechanism avoids errors caused by human intervention and improves the accuracy and efficiency of collision detection. Once an abnormal collision is detected, the corresponding control instructions can be quickly issued to the robot, so that the robot can adjust or stop moving according to the instructions. This rapid response mechanism helps to prevent the expansion of collision accidents in time and protect the robot and surrounding equipment from further damage. By reducing the occurrence of collision accidents, it helps to reduce the equipment damage rate and reduce maintenance and replacement costs. At the same time, avoiding production interruptions also improves production efficiency.

[0041] The robot's accidental collision control method based on vibration sensors enhances the stability and reliability of the entire production system. Through real-time monitoring and intelligent control, it ensures that the robot can operate safely and stably in complex working environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 It is a flow chart of a method for controlling a manipulator's miscollision based on a vibration sensor provided by an embodiment of the present invention.

[0043] Figure 2 It is a schematic diagram of a manipulator miscollision control system based on a vibration sensor provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0044] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0045] like Figure 1 As shown, an embodiment of the present invention provides a manipulator miscollision control method based on a vibration sensor, the method comprising the following steps:

[0046] Step 11, obtaining the current state of the manipulator in real time through a vibration sensor installed at the front end of the manipulator, the current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds;

[0047] Step 12, extracting the real-time amplitude and frequency data corresponding to the manipulator according to the current state;

[0048] Step 13, calculating the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the amplitude relative deviation and the frequency relative deviation;

[0049] Step 14, judging whether there is an abnormal collision in the state of the manipulator according to the relative deviation and the preset deviation threshold, so as to obtain a judgment result;

[0050] Step 15: According to the judgment result, a corresponding control instruction is issued to the robot arm so that the robot arm moves according to the corresponding control instruction.

[0051] In an embodiment of the present invention, the vibration sensor can continuously and uninterruptedly monitor the real-time state of the manipulator to ensure a comprehensive grasp of the manipulator's behavior. Whether the manipulator is carrying a workpiece, without a workpiece, or moving at different speeds, its state information can be effectively obtained, showing a strong scene adaptability. Since the data is extracted in real time, it can reflect the instantaneous dynamics of the manipulator, making collision detection more timely and accurate. By calculating the relative deviation, the actual state of the manipulator is quantitatively compared with the ideal state, making the state evaluation more objective and accurate. Different reference values ​​can be set according to actual needs to adapt to the vibration characteristics of the manipulator in different working scenarios.

[0052] Through the preset deviation threshold, the system can intelligently identify whether the robot has an abnormal collision, reducing the need for manual monitoring. Identifying when a collision has just occurred or is about to occur helps to take timely preventive measures to avoid serious consequences caused by the collision. Once an abnormal collision is determined, the system can immediately issue a control command to the robot to ensure that it can respond in the shortest possible time. Through rapid control commands, the damage caused by the collision to the robot and surrounding equipment can be effectively reduced, and the service life of the equipment can be increased.

[0053] In a preferred embodiment of the present invention, in the above step 11, the current state of the manipulator is obtained in real time by a vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds, and may include:

[0054] Step 112, acquiring the operating state of the manipulator in a state without a workpiece, so as to obtain amplitude and frequency data of the manipulator in a state without a workpiece;

[0055] Step 113, obtaining the running state of the manipulator in the state of carrying the workpiece, so as to obtain the amplitude and frequency data of the manipulator in the state of carrying the workpiece, specifically includes:

[0056] Step 114, obtaining the amplitude and frequency data of the manipulator at different movement speeds according to the type and weight of each workpiece; and classifying the manipulator according to different movement speeds according to the amplitude and frequency data of the manipulator at different movement speeds.

[0057] In an embodiment of the present invention, based on vibration sensing technology, the operating status of the manipulator is evaluated by real-time monitoring and analysis of the vibration signal of the manipulator. Specifically, the system uses a high-precision vibration sensor installed at the front end of the manipulator to continuously capture the vibration data generated by the manipulator during movement. These data are then transmitted to the processing unit for analysis to extract key information such as the amplitude and frequency of the manipulator. In the state without a workpiece, the system can understand its basic dynamic behavior by monitoring the natural vibration characteristics of the manipulator. In the state of carrying a workpiece, the system further analyzes the impact of the workpiece on the vibration characteristics of the manipulator, especially how factors such as the type and weight of the workpiece and the movement speed of the manipulator change its vibration mode. By classifying and storing these data, the system can establish a comprehensive database of the operating status of the manipulator. This not only helps to detect abnormal behavior of the manipulator in a timely manner, such as collisions or failures, but also provides strong support for the optimization and maintenance of the manipulator.

[0058] Suppose a manufacturing company uses a vibration monitoring system based on the above robot. During a production process, the robot is set to perform a series of rapid movements without a workpiece. At this time, the vibration sensor continuously captures the vibration data of the robot and transmits it to the central processing unit. After analyzing this data, the processing unit finds that the amplitude of the robot is abnormally increased under a certain motion trajectory. This means that the robot has problems such as imbalance or wear on this trajectory. Based on this discovery, maintenance personnel can quickly check and adjust the robot to avoid potential safety hazards and improve production efficiency.

[0059] In another scenario, when the robot is carrying workpieces of different types and weights, the vibration sensor is also constantly collecting data. By analyzing this data, the system can identify the impact of different workpieces on the vibration characteristics of the robot. For example, a heavy workpiece may cause the robot's vibration frequency to decrease, while a light workpiece may increase its frequency. With this information, production managers can arrange the robot's operation plan more reasonably to optimize production efficiency and extend the robot's service life. At the same time, this data can also provide valuable reference for the maintenance and upgrade of the robot.

[0060] By acquiring data in both the state of no workpiece and the state of carrying workpiece, the operating status of the robot can be more comprehensively understood. Classifying the data according to the type and weight of the workpiece and the movement speed of the robot makes the data analysis more refined and can more accurately identify the behavior characteristics of the robot under different conditions. By real-time monitoring and analysis of the vibration data of the robot in various states, abnormal situations such as workpiece shedding and robot failure can be discovered in time, thereby improving the safety of the operation process. By analyzing the vibration data of the robot at different speeds and loads, the movement trajectory and speed setting of the robot can be optimized, thereby improving production efficiency and reducing energy consumption. By real-time monitoring and timely adjustment of the operating status of the robot, unnecessary mechanical wear and impact can be reduced, thereby extending the service life of the robot and its related equipment. The accumulated historical data can be used to predict the maintenance needs of the robot, realize intelligent maintenance plans, reduce unexpected downtime, and improve the overall efficiency of the production line.

[0061] In a preferred embodiment of the present invention, the above step 12, extracting the real-time amplitude and frequency data corresponding to the manipulator according to the current state, may include:

[0062] The vibration sensor installed at the front end of the manipulator continuously monitors the vibration state of the manipulator. The sensor samples at a high frequency to ensure that every subtle vibration of the manipulator can be captured. The sampled digital signal is transmitted to the data processing unit in real time via a data line or wirelessly. The data processing unit first preprocesses the original data, including filtering, noise reduction and other steps to improve the data quality. Specifically, let the original data be x(t), and the filtered data y(t) = LPF[x(t)]; where LPF represents a low-pass filter, which is used to remove high-frequency noise. For transient noise, wavelet transform can be used for denoising: y(t) = WT -1 [WT[x(t)]·M]; where WT represents wavelet transform; WT -1 Represents the inverse wavelet transform; M represents the mask, which is used to retain or remove specific wavelet coefficients. Use the sliding average method to smooth the data: Where N is the size of the sliding window; t is the time; i is the sum index; x is the original data point. Normalize the data to the range [0,1]: Among them, min[x(t)] and max[x(t)] represent the minimum and maximum values ​​in the data respectively. Segment according to the motion cycle T of the manipulator: S k ={x(t)|kT≤t<(k+1)T}; where S k Represents the kth data segment; k represents an integer. Calculate the maximum amplitude in the data segment Sk Among them, max(x i ) represents the maximum data point; min(x i ) indicates the minimum data point. Minimum Amplitude Where N is the number of data points; x i+1 represents the i+1th data point; x i represents the i-th data point. The average amplitude Standard deviation of amplitude

[0063] Apply Fourier transform (FFT) to obtain the frequency spectrum: X(f) = FFT[x(t)]; where X(f) represents the complex amplitude at frequency f. Extract the dominant frequency f from the frequency spectrum d (frequency corresponding to the maximum amplitude), frequency peak A p (maximum amplitude) and frequency bandwidth B (the frequency range where the amplitude exceeds a certain threshold). The amplitude and frequency features are combined into a feature vector:

[0064] v k =[A max ,A min ,A m,A s ,f d ,A p ,B k ]{(v k , l k )}; where l k Indicates a label; v k represents a feature vector.

[0065] Assign a label to each feature vector, for example: no artifact state: 0; carrying light artifact: 1; carrying heavy artifact: 2.

[0066] Suppose there is a robot on an assembly line that is responsible for picking up and placing parts. To ensure the robot's precise operation and avoid collisions, the above-mentioned vibration sensing and data extraction system is applied. While the robot is performing the picking action, the vibration sensor continuously monitors its vibration state. The sensor collects data at a frequency of thousands of times per second and transmits this data to the data processing unit in real time. When the robot grabs a heavy part, the data processing unit extracts the amplitude and frequency characteristics from the signal transmitted by the sensor. For example, it may be found that the amplitude is significantly larger than when grabbing a light part, while the frequency is reduced. The system compares these characteristics with the preset standard data and recognizes that the robot is currently grabbing a heavy part and the motion state is stable.

[0067] In a preferred embodiment of the present invention, the above step 14, judging whether there is an abnormal collision in the state of the manipulator according to the relative deviation and the preset deviation threshold value to obtain the judgment result, may include:

[0068] Step 144, calculating the relative deviation of the amplitude and frequency of the manipulator in real time, and obtaining a preset amplitude relative deviation threshold and a frequency relative deviation threshold from the controller of the manipulator;

[0069] Step 145, comparing the amplitude relative deviation value and the frequency relative deviation value with a preset amplitude relative deviation threshold and a preset frequency relative deviation threshold;

[0070] Step 146, if either the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that the manipulator has an abnormal collision; if the two relative deviations do not exceed the corresponding threshold, the controller determines that the manipulator is in a normal state;

[0071] Step 147, outputting the judgment of the robot to the controller to obtain the judgment result.

[0072] In an embodiment of the present invention, the system collects the motion data of the manipulator in real time through sensors, including position, speed, acceleration, etc. Using these data, the system can calculate the amplitude (i.e., the maximum deviation degree of the manipulator during the motion process) and frequency (i.e., the speed at which the manipulator completes a complete motion cycle) of the manipulator in real time. Furthermore, the system will calculate the relative deviations of the amplitude and frequency, which reflect the difference between the current motion state of the manipulator and the ideal state. Before the manipulator is put into operation, the amplitude relative deviation threshold and the frequency relative deviation threshold have been preset in the controller according to the design specifications, historical operation data and safety operation standards of the manipulator. For example, the amplitude relative deviation threshold may be set to 5%, and the frequency relative deviation threshold may be set to 3%. Assume that at a certain moment, the amplitude relative deviation calculated by the system is 4% and the frequency relative deviation is 2%. Both values ​​do not exceed the preset thresholds (5% and 3%), so the system determines that the current state of the manipulator is normal and no abnormal collision occurs. However, if at another moment, the system detects that the amplitude relative deviation suddenly increases to 6%, exceeding the preset 5% threshold, although the frequency relative deviation is still within the normal range, the system will still determine that the manipulator has the risk of abnormal collision. Once the system determines that the robot has an abnormal collision, it will immediately display a warning message through the controller interface, such as "The robot amplitude is abnormal, there may be a risk of collision." At the same time, this information will also be transmitted to the robot management system, triggering the alarm device to alert the operator in the form of sound or light. After receiving the alarm, the operator can quickly take measures, such as pausing the movement of the robot, checking whether there are obstacles in the surrounding environment, or making necessary adjustments and maintenance to the robot.

[0073] The system can monitor the operation status of the robot in real time and detect potential collision risks in time. By comparing with preset thresholds, an early warning can be issued before or at the early stage of a collision, improving safety. Once an abnormal collision is detected, the system can automatically trigger protective measures, such as stopping the robot movement or adjusting its trajectory to prevent further damage or accidents. By reducing unexpected collisions, the maintenance frequency and downtime of the robot can be reduced, thereby improving production efficiency. The system can be integrated with a larger production management system to achieve intelligent and automated production monitoring and management. Through data analysis, the operation status of the robot can also be optimized to improve overall production efficiency and safety.

[0074] In a preferred embodiment of the present invention, the calculation formula of the amplitude relative deviation is:

[0075]

[0076] Among them, ΔA represents the relative deviation of amplitude; A m A represents the amplitude of the robot arm monitored by the vibration sensor in real time at the current moment;r (v,T,M) represents the amplitude reference value; v represents the operating speed of the robot; T represents the type of workpiece currently carried by the robot; M represents the weight of the workpiece currently carried by the robot.

[0077] In the embodiment of the present invention, a vibration sensor (such as an accelerometer) is installed on the manipulator. The sensor is configured to monitor the vibration of the manipulator in real time at a certain sampling frequency (such as hundreds of times per second). The amplitude data at the current moment is read from the sensor, which is recorded as A m . Obtain the current operating speed v through the robot's control system or sensor. Determine the type of workpiece T currently carried by the robot (by reading the output of the workpiece identification system). Obtain the weight M of the workpiece currently carried by the robot (using a weight sensor). Perform a series of tests on the robot covering different operating speeds, workpiece types, and weights. Record the normal amplitude range of the robot under each condition. Based on the experimental data, establish a lookup table to predict the normal amplitude reference value A based on v, T, and M. r . Based on the currently acquired v, T, and M values, use the lookup table to calculate A r (v,T,M). The amplitude A monitored in real time m and the calculated reference value A r Substitute (v, T, M) into the formula. Calculate the relative amplitude deviation ΔA. Output the calculated ΔA value to the control system interface. If ΔA exceeds the preset threshold, trigger the alarm system to notify the operator. According to the size of ΔA, determine whether the robot has an abnormal collision or other faults. If an abnormality is detected, take appropriate measures, such as deceleration, shutdown inspection, or adjustment of the robot's operating parameters.

[0078] By monitoring the amplitude of the manipulator in real time through the vibration sensor, the system can instantly obtain the operating status of the manipulator. This allows a quick response to any abnormalities or deviations from the normal operating range. The calculation of the relative deviation of the amplitude helps to identify abnormal collisions or failures that may occur in the manipulator. Once the deviation is detected to exceed the preset threshold, the system can quickly trigger an alarm to prevent potential damage or dangerous situations and ensure the safety of operators and equipment. By continuously monitoring and adjusting the operating status of the manipulator, stability and consistency in the production process can be ensured. This helps to reduce production interruptions caused by manipulator failure or performance degradation, thereby improving production efficiency. At the same time, stable operating conditions also help to ensure product quality. The relative deviation data of the amplitude can provide a valuable reference for equipment maintenance. By analyzing the patterns and trends of the deviations, possible worn parts or parameters that need to be adjusted in the manipulator can be identified, thereby achieving more accurate preventive maintenance. The introduction of the calculation of the relative deviation of the amplitude is part of the intelligence of the manipulator control system. This capability enables the system to make decisions based on real-time data, rather than relying solely on preset programs or manual intervention. This improves the adaptability and flexibility of the system. Monitoring relative amplitude deviation helps reduce the overall operating costs of a robot by reducing unplanned downtime and improving maintenance efficiency. In addition, timely identification and treatment of potential problems can extend the service life of the equipment.

[0079] In a preferred embodiment of the present invention, the calculation formula of the relative frequency deviation is:

[0080]

[0081] Among them, Δf represents the relative frequency deviation; f m It indicates the frequency detected by the vibration sensor in real time when the robot is running; f r (v,T,M) represents the frequency reference value; ∈ represents a constant; δ represents an adjustment coefficient; v n Indicates the selected reference speed.

[0082] In the embodiment of the present invention, the vibration frequency f of the manipulator is captured in real time by a vibration sensor installed on the manipulator. m . Get the current running speed v from the relevant sensors of the robot. Determine the type T and weight M of the workpiece currently carried by the robot. Get or set the selected reference speed v n . Set the constant ∈ to avoid zero denominators and increase numerical stability. Set the adjustment factor δ to adjust the sensitivity of the deviation calculation based on speed changes. Test the robot at different operating speeds, workpiece types, and weights. Record the normal vibration frequency range of the robot under various conditions. Use this data to create a lookup table to predict the normal frequency reference value f based on v, T, and M r(v, T, M). When the robot is running, it uses the established lookup table to calculate f based on the current v, T, and M values. r (v,T,M).

[0083] The frequency f monitored in real time m , the calculated reference value f r Substitute (v,T,M), constant ∈ and speed adjustment term into the calculation formula of frequency relative deviation to obtain frequency relative deviation Δf. Output the calculated Δf value to the user interface of the control system. If Δf exceeds the preset threshold, trigger an alarm to perform automatic countermeasures. Based on the value of Δf, evaluate whether the operating status of the robot is normal. If an abnormal frequency deviation is detected, it is necessary to adjust the operating parameters of the robot, check the workpiece loading condition or perform maintenance operations.

[0084] By capturing the vibration frequency f of the robot in real time m and with the reference value f r (v, T, M) can be compared to monitor the frequency change with high precision. Multiple influencing factors such as the robot's operating speed v, workpiece type T, and workpiece weight M are included to make the frequency reference value f r The calculation of (v, T, M) is more comprehensive and accurate. The introduction of the constant ∈ ensures that the denominator of the formula will not be zero, thus avoiding numerical instability and errors in the calculation process. When the monitored frequency relative deviation Δf exceeds the preset threshold, the early warning system can be triggered to promptly notify the operator to take appropriate measures. This helps prevent potential failures and damages and improve the safety and reliability of the equipment.

[0085] In a preferred embodiment of the present invention, the above step 15, according to the judgment result, sends a corresponding control instruction to the manipulator so that the manipulator moves according to the corresponding control instruction, which may include:

[0086] Step 155, determining a control instruction to be issued to the manipulator according to the judgment result, and sending the control instruction to the manipulator;

[0087] Step 156, the robot receives the control instruction and performs the corresponding action according to the instruction content. If the instruction is to continue to execute the current task, the robot maintains a normal motion state; if the instruction is to stop moving and return to the specified position, the robot stops the current motion and returns to the specified position along the preset path.

[0088] In an embodiment of the present invention, based on the comparison result, the system determines the control instructions that need to be issued to the manipulator. For example, if the relative frequency deviation exceeds the safety threshold, the system may generate an instruction to "stop moving and return to the specified position". After determining the instruction, the system sends the instruction to the manipulator through wireless data transmission technology. After receiving the control instruction, the manipulator will parse it to confirm the specific content and requirements of the instruction. According to the parsed instruction, the manipulator will perform the corresponding action. If the instruction is "continue to execute the current task", the manipulator will maintain a normal motion state; if the instruction is "stop moving and return to the specified position", the manipulator will immediately interrupt the current task and return safely along the preset path. After executing the instruction, the manipulator will feed back its current state to the system so that the system can perform further monitoring and adjustment. Based on the feedback status information, the system can adjust the monitoring parameters, safety thresholds or control strategies in real time to optimize the performance and safety of the manipulator.

[0089] Through real-time monitoring and quick judgment, the system can detect potential problems or abnormal situations at the first time and immediately issue corresponding control instructions to the manipulator. This real-time response capability significantly improves the safety and reliability of the manipulator's operation. Stopping the movement of the manipulator in time when an abnormality is detected can effectively prevent possible failures or damage, thereby reducing maintenance costs and production losses. At the same time, returning the manipulator to the specified position through instructions is also convenient for subsequent inspection and maintenance work. The manipulator can make judgments and action responses autonomously according to the instructions received, reducing dependence on manual operation and improving production efficiency and consistency of operation. Since the system can issue different control instructions based on different judgment results, this enables the manipulator to respond flexibly in a variety of work scenarios, showing greater adaptability and versatility. Whether it is normal operation or encountering abnormal situations, the manipulator can respond appropriately.

[0090] like Figure 2 As shown, an embodiment of the present invention further provides a manipulator mis-collision control system 20 based on a vibration sensor, comprising:

[0091] The acquisition module 21 is used to obtain the current state of the manipulator in real time through a vibration sensor installed at the front end of the manipulator, the current state includes the state of the manipulator when there is a workpiece, when there is no workpiece and at different movement speeds; according to the current state, extract the real-time amplitude and frequency data corresponding to the manipulator;

[0092] The processing module 22 is used to calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the amplitude relative deviation and the frequency relative deviation; based on the relative deviation and the preset deviation threshold, determine whether there is an abnormal collision in the state of the manipulator to obtain a judgment result; based on the judgment result, issue a corresponding control instruction to the manipulator to make the manipulator move according to the corresponding control instruction.

[0093] It should be noted that the system is a system corresponding to the above method, and all implementation methods in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0094] The embodiment of the present invention further provides a computing device, comprising: a processor, a memory storing a computer program, wherein when the computer program is executed by the processor, the method described above is executed. All implementations in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0095] The embodiment of the present invention also provides a computer-readable storage medium storing instructions, which, when executed on a computer, enable the computer to execute the method described above. All implementations in the above method embodiment are applicable to this embodiment and can achieve the same technical effect.

[0096] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A method for controlling manipulator accidental collision based on a vibration sensor, characterized in that: The method comprises: The current state of the manipulator is obtained in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds; According to the current state, extract the real-time amplitude and frequency data corresponding to the robot; Calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the relative amplitude deviation and the relative frequency deviation; According to the relative deviation and the preset deviation threshold, it is judged whether there is abnormal collision in the state of the robot to obtain a judgment result; According to the judgment result, a corresponding control instruction is issued to the robot so that the robot moves according to the corresponding control instruction.

2. The method for controlling manipulator accidental collision based on vibration sensor according to claim 1, characterized in that: The current state of the robot is obtained in real time through the vibration sensor installed at the front end of the robot. The current state includes the state of the robot with workpiece, without workpiece and at different movement speeds, including: Acquire the running state of the manipulator in the state without the workpiece to obtain the amplitude and frequency data of the manipulator in the state without the workpiece; The operating status of the manipulator when carrying a workpiece is obtained to obtain the amplitude and frequency data of the manipulator when carrying the workpiece, specifically including: obtaining the amplitude and frequency data of the manipulator at different movement speeds according to the type and weight of each workpiece; and classifying the manipulator according to different movement speeds based on the amplitude and frequency data of the manipulator at different movement speeds.

3. The method for controlling manipulator accidental collision based on vibration sensor according to claim 2, characterized in that: According to the relative deviation and the preset deviation threshold, it is judged whether there is abnormal collision in the state of the robot to obtain the judgment result, including: Calculate the relative deviation of the amplitude and frequency of the manipulator in real time, and obtain the preset amplitude relative deviation threshold and frequency relative deviation threshold from the controller of the manipulator; Compare the amplitude relative deviation value and the frequency relative deviation value with a preset amplitude relative deviation threshold and a preset frequency relative deviation threshold; If either the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that the robot has an abnormal collision; if the two relative deviations do not exceed the corresponding threshold, the controller determines that the robot is in a normal state; The judgment of the robot is output to the controller to obtain the judgment result.

4. The method for controlling manipulator accidental collision based on vibration sensor according to claim 3 is characterized in that: The calculation formula of the amplitude relative deviation is: Among them, ΔA represents the relative deviation of amplitude; A m A represents the amplitude of the robot arm monitored by the vibration sensor in real time at the current moment; r (v,T,M) represents the amplitude reference value; v represents the operating speed of the robot; T represents the type of workpiece currently carried by the robot; M represents the weight of the workpiece currently carried by the robot.

5. The method for controlling manipulator accidental collision based on vibration sensor according to claim 4 is characterized in that: The calculation formula for relative frequency deviation is: Among them, Δf represents the relative frequency deviation; f m It indicates the frequency detected by the vibration sensor in real time when the robot is running; f r (v,T,M) represents the frequency reference value; ∈ represents a constant; δ represents an adjustment coefficient; v n Indicates the selected reference speed.

6. The method for controlling manipulator accidental collision based on vibration sensor according to claim 5, characterized in that: According to the judgment result, a corresponding control instruction is issued to the manipulator so that the manipulator moves according to the corresponding control instruction, including: According to the judgment result, a control instruction to be issued to the robot is determined, and the control instruction is sent to the robot; The robot receives the control instruction and performs the corresponding action according to the instruction content. If the instruction is to continue to execute the current task, the robot maintains the normal motion state; if the instruction is to stop motion, the robot immediately stops the current motion; if the instruction is to stop motion and return to the specified position, the robot stops the current motion and returns to the specified position along the preset path.

7. A robot arm accidental collision control system based on a vibration sensor, characterized in that: include: The acquisition module is used to obtain the current state of the manipulator in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds; according to the current state, the real-time amplitude and frequency data corresponding to the manipulator are extracted; A processing module, used to calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the amplitude relative deviation and the frequency relative deviation; Based on the relative deviation and the preset deviation threshold, it is judged whether there is an abnormal collision in the state of the robot to obtain a judgment result; based on the judgment result, a corresponding control instruction is issued to the robot to make the robot move according to the corresponding control instruction.

8. A computing device, characterized in that include: one or more processors; A storage device for storing one or more programs, when the one or more programs are executed by the one or more processors, the one or more processors implement the method as claimed in any one of claims 1 to 6.

9. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a program, which, when executed by a processor, implements the method according to any one of claims 1 to 6.

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