Joint module fatigue test method and system simulating wave force working condition

Abstract

The application provides a joint module fatigue test method and system for simulating wave force working conditions, and belongs to the technical field of motor performance testing. The method and system aim to solve the problems of existing test working condition simulation distortion and high energy consumption. The system includes wave energy absorption, power generation, energy storage, mechanical energy transmission, load adjustment and clutch, adaptive loading control and closed-loop testing modules. Wave energy is used in two ways, one for power generation to supply energy to the system, and the other for mechanical load conversion. The load adjustment and clutch module precisely adjusts the load and can cut off the load in abnormal conditions. The adaptive loading control module and the closed-loop testing module form a closed loop, dynamically adjust the load according to real-time data, and accurately reproduce random working conditions. The closed-loop testing module synchronously collects fatigue data and electrical, thermal and other performance parameters of the joint module, realizing collaborative testing.

Description

Technical Field

[0001] This invention relates to the field of motor performance testing technology, specifically to a fatigue testing method and system for joint modules under simulated wave force driving conditions. Background Technology

[0002] Humanoid joint modules are the core execution components of humanoid robots and humanoid bionic devices. Their operational stability and fatigue life directly determine the reliability of the entire machine. In actual movement (such as walking, crossing, and posture adjustment), the forces on humanoid joints have significant randomness and dynamic characteristics, which places extremely high demands on the realism of the working condition simulation in fatigue testing.

[0003] In existing technologies, fatigue testing of humanoid joint modules mostly adopts traditional electric drive loading methods, which involve setting constant loads and sinusoidal simulated loads for testing. This approach has the following core problems: First, the simulation of working conditions is severely distorted. The load form of traditional tests is preset manually, which cannot reproduce the complex and random stress state in the actual movement of humanoid joints. This leads to the test data being out of touch with the actual application conditions and making it difficult to accurately reflect the true fatigue life of the joint module. Some solutions attempt to simulate random loads through programs, but this is still a matter of manual fitting and deviates from the actual stress characteristics.

[0004] Secondly, the system has high energy consumption. The electric drive loading system relies on an external power grid or independent power source for continuous power supply. The energy loss during the operation of the drive loading mechanism is large, especially for long-term fatigue testing, resulting in high testing costs.

[0005] Third, there is insufficient adaptability to different scenarios. Existing tests are mostly limited to a single laboratory setting, lacking the ability to adapt to complex environments, and cannot meet the needs of both standardized laboratory testing and real-world field testing, resulting in limited applicability of the test results.

[0006] Fourth, the testing dimensions are limited. Existing systems only focus on the fatigue characteristics of the joint module itself, without taking into account the real-time performance changes of the motor that is paired with the joint module. They cannot capture the performance fluctuations of various parts of the motor, such as the stator, rotor, and windings, under different wave force loads. It is difficult to establish the correlation between the load and the fatigue life of the joint module, resulting in an inaccurate assessment of the impact on the operational stability of the joint module. The testing depth is insufficient, and it cannot provide reliable data support for the collaborative optimization of the joint module.

[0007] Fifth, the level of automation is insufficient and the test safety is inadequate. In the existing system, the load force transmitted from the wave energy transmission module to the joint module is prone to being too large or too small, making it impossible to achieve accurate load matching and affecting test accuracy. At the same time, when the joint module malfunctions (such as overload or excessive temperature rise) or the test duration expires, the load force transmission cannot be quickly cut off, requiring manual intervention to stop the test. This not only affects test efficiency but may also damage the joint module, making it impossible to achieve a fully automated test process.

[0008] Therefore, there is an urgent need in the market for a fatigue testing system that can accurately simulate the random stress characteristics of human joints, has low energy consumption, adapts to multiple scenarios, and can simultaneously perform real-time performance testing, with accurate load adaptation and automated clutch function, in order to solve the shortcomings of existing technologies and provide reliable support for optimizing the lifespan and improving the performance of human joint modules. Summary of the Invention

[0009] To address the shortcomings of existing technologies, the present invention aims to provide a fatigue testing method and system for joint modules under simulated wave force conditions, thereby overcoming the deficiencies of existing joint module fatigue testing technologies, such as distorted simulation of operating conditions, high energy consumption, insufficient scene adaptability, single testing dimension, low degree of automation, and poor safety.

[0010] The fatigue testing system for a joint module under simulated wave force conditions provided by the present invention includes: a wave energy absorption module, a power generation module, an electrical energy storage module, a mechanical energy transmission module, a load adjustment and clutch module, an adaptive loading control module, and a closed-loop testing module; After capturing wave energy, the wave energy absorption module outputs it in two ways: one way sends mechanical energy to the power generation module for power generation, and the other way sends mechanical energy to the mechanical energy transmission module as a mechanical loading source, forming a dual-path high-efficiency wave energy utilization structure. The power generation module is electrically connected to the energy storage module to realize power generation, energy storage and system self-powering; The load adjustment and clutch module is connected in series between the mechanical energy transmission module and the joint module under test, and is used to adjust the magnitude of the mechanical load output by the mechanical energy transmission module and realize the on / off control of the load force. The closed-loop test module and the adaptive loading control module establish a two-way signal interaction to form a fully closed-loop control mechanism, which is used to dynamically optimize test parameters to match test requirements. The closed-loop test module has a built-in joint module performance detection component, which synchronously collects the core performance parameters of the matching motor of the joint module under test under different wave force loads, thereby realizing the coordinated testing of the fatigue characteristics and performance of the joint module. The adaptive loading control module dynamically adjusts the load parameters by combining the real-time performance data of the joint module to ensure operational safety and testing accuracy.

[0011] Preferably, the wave energy absorption module adopts a floating capture structure, which can be adapted to wave scenarios with wavelengths of 0.5-2m and amplitudes of 0.1-0.8m, and can capture both simulated wave energy in the laboratory and actual sea wave energy. The wave energy absorption module is equipped with an angle adjustment component, which can adapt to different wave incident directions.

[0012] Preferably, the power generation module is a small electromagnetic induction wave generator with a built-in rectifier and filter unit, which can convert the mechanical energy of the undulating waves into stable direct current. The energy storage module includes a lithium battery pack, a charge and discharge management unit, and a voltage regulator circuit, which independently powers the system and the joint module under test, enabling self-powered operation without external power grid dependence.

[0013] Preferably, the mechanical energy transmission module adopts a combination structure of gear transmission box and flexible coupling, with a built-in load adjustment unit and a torque adjustment range of 0-500N. With a speed adjustment range of 0-300rpm, it can convert the wave energy transmitted by the wave energy absorption module into the initial dynamic mechanical load of the joint module and transmit it to the load adjustment and clutch module, providing a foundation for subsequent precise load adaptation.

[0014] Preferably, the load adjustment and clutch module adopts a combination structure of electromagnetic clutch and hydraulic adjustment unit, and has a built-in load detection sensor, force adjustment actuator and clutch control unit; The load detection sensor is used to collect the initial load force output by the mechanical energy transmission module in real time and feed the data back to the adaptive loading control module. The force adjustment actuator, based on the instructions issued by the adaptive loading control module, precisely adjusts the initial load force. Its adjustment range is 0-500 N·m, and the adjustment accuracy is ±0.1 N·m, to ensure that the load force finally output to the joint module under test meets the test conditions. Upon receiving the clutch command from the adaptive loading control module, the clutch control unit can quickly complete the clutch action, cut off the transmission of load force, and achieve zero load output.

[0015] Preferably, the adaptive loading control module is based on an industrial control computer, has a built-in database of various wave force driving conditions, adopts a PID control algorithm, dynamically adjusts load parameters based on multi-source feedback data, reproduces the wave force conditions of random fluctuations, and triggers emergency shutdown protection when the joint module parameters exceed the threshold.

[0016] Preferably, the closed-loop testing module includes a dynamic torque sensor, a laser displacement sensor, an ultrasonic fatigue monitoring sensor, and a data preprocessing unit, which collects the operating parameters and fatigue damage data of the joint module under test, and feeds them back to the adaptive loading control module after filtering and noise reduction.

[0017] Preferably, the joint module performance testing component includes a current sensor, a voltage sensor, a patch-type temperature sensor, a power sensor, and a speed sensor, which simultaneously collects stator current, supply voltage, winding temperature rise, operating efficiency, and speed parameters at a frequency of 100Hz.

[0018] Preferably, the testing system can be adapted to two application scenarios, as follows: In indoor laboratory settings, it can be integrated with wave simulation devices to achieve standardized and repeatable testing. Capture natural wave energy directly in real marine environments to achieve on-site self-sustaining testing.

[0019] A method for synergistic testing of fatigue and performance of a joint module based on the system provided by the present invention includes the following steps: Test preparation phase: Install the joint module to be tested and sensors, set wave conditions, safety thresholds and test duration, and start the system with self-powered operation; During the working condition simulation and data acquisition phase: Wave energy is utilized in two ways to be converted into test load. The adaptive loading control module regulates the load in a closed loop, and the closed-loop test module collects fatigue data and performance data simultaneously and stores them in real time. Anomaly Handling and Automation Termination Phase: When an abnormal performance of the joint module is detected or the test duration is reached, the load adjustment and clutch module quickly cuts off the load to achieve automatic shutdown and abnormal data recording. Test and analysis phase: Export test data, establish a correlation model between wave force load, joint module performance and fatigue life, and output a collaborative test evaluation report.

[0020] Compared with the prior art, the present invention has the following beneficial effects: 1. By utilizing the inherent randomness of wave energy and combining it with adaptive loading control, this invention can accurately reproduce the random load conditions of joint modules in actual service environments, thereby significantly improving the reliability of test results.

[0021] 2. This invention boasts excellent energy efficiency. By utilizing wave energy for both power generation and mechanical loading, it achieves system self-powering, balancing power supply stability and energy conservation. This aligns with green testing principles and reduces energy consumption and costs during extended testing. Furthermore, the system exhibits strong adaptability, catering to both standardized laboratory testing and real-world marine testing needs. By adjusting the parameters of the wave energy absorption module and the preset operating conditions of the adaptive loading control module, it can be adapted to test different models and specifications of wave force-driven joint modules, covering applications such as humanoid robots and industrial robots.

[0022] 3. This invention achieves precise load adaptation and automatic clutch function through load adjustment and clutch module, which can complete the test without manual intervention and effectively protect the module under test.

[0023] 4. This invention can simultaneously perform fatigue testing and real-time performance monitoring, capturing changes in the electrical, thermodynamic, and mechanical properties of the joint module under different loads, providing comprehensive data support for the comprehensive evaluation and optimization design of the joint module. Attached Figure Description

[0024] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a structural block diagram of a joint module fatigue testing system for wave force-driven simulated working conditions, provided in an embodiment of the present invention.

[0025] Explanation of reference numerals in the attached diagram: A - Wave energy absorption module; A1 - Power generation module; A2 - Mechanical energy transmission module; B - Electrical energy storage module; C - Load adjustment and clutch module; D1 - Adaptive loading control module; D2 - Multi-source sensor acquisition; D3 - Closed-loop testing module; E - Joint module under test. Detailed Implementation

[0026] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0027] This invention is applicable to the life fatigue detection and real-time performance testing of wave force driven joint modules in the fields of humanoid robots and industrial robots. It can accurately simulate actual working conditions and complete efficient testing.

[0028] Example 1 This embodiment provides a fatigue testing system for a joint module under simulated wave force conditions, and its structural block diagram is as follows. Figure 1 As shown, this system constructs a complete "energy capture-conversion-regulation-load adaptation-testing" chain, aiming to achieve collaborative testing of the fatigue life and real-time performance of wave force driven joint modules under simulated real-world working conditions through modular collaborative operation. Specifically, the system includes a wave energy absorption module A, a power generation module A1, an electrical energy storage module B, a mechanical energy transmission module A2, a load adjustment and clutch module C, an adaptive loading control module D1, and a closed-loop testing module D3.

[0029] The function of the wave energy absorption module A is to capture simulated or actual wave energy. In one embodiment of the invention, the wave energy absorption module A adopts a hemispherical floating capture structure with a float diameter of 1.2 meters to adapt to specific wave environments and effectively adapt to wave scenarios with wavelengths of 0.5–2 m and amplitudes of 0.1–0.8 m. It can capture both simulated wave energy in the laboratory and wave energy in actual sea areas. To improve energy capture efficiency, module A can also be equipped with an angle adjustment component and an energy capture efficiency enhancement component. The angle adjustment component allows the float to adapt to wave incidence from different directions to maintain the optimal wave-facing posture at all times. The captured wave energy is divided into two paths and output simultaneously through a force transmission component integrated inside the float: the first path of mechanical energy is transmitted to the power generation module A1 via a drive shaft for power generation; the second path of mechanical energy is transmitted to the mechanical energy transmission module A2 via a universal coupling as a direct mechanical loading source. This dual-path utilization design enables efficient utilization of wave energy.

[0030] The power generation module A1 is mechanically connected to the drive shaft of the wave energy absorption module A, and its function is to convert the received wave mechanical energy into electrical energy. As an optional implementation, the power generation module A1 can be a small electromagnetic induction wave generator with a rated power of 1500W. It should be noted that, due to the randomness of waves often leading to instability in the input mechanical energy, the power generation module A1 is specially equipped with a rectification and filtering unit. This unit can rectify and filter the raw AC power generated by the generator, outputting relatively stable DC power. For example, when the amplitude of the input wave fluctuates within ±0.3m, the processed output voltage fluctuation can be controlled within ±0.1V, which provides a foundation for the stable operation of the entire test system.

[0031] The energy storage module B is electrically connected to the power generation module A1 to store and manage the converted electrical energy. The core component of the energy storage module can be a 12V / 100Ah lithium battery pack, equipped with a charge / discharge management unit and a voltage regulator circuit. The charge / discharge management unit monitors the battery status and manages the charging and discharging process, achieving a charging efficiency of over 90% and efficiently storing redundant energy generated by the power generation module A1. When wave energy is sufficient, the system prioritizes using the real-time generated electrical energy, storing any excess in the battery pack. When wave energy is insufficient or interrupted, the lithium battery pack can seamlessly switch to independently provide a continuous and stable power supply to the entire system (including the test joint module E, load adjustment and clutch module C, adaptive loading control module D1, closed-loop test module D3, etc.), with a runtime of over 8 hours. This not only ensures the continuity of long-term fatigue testing but also allows the system to completely eliminate its dependence on the external power grid, achieving self-powering and significantly reducing operating costs. Furthermore, the voltage regulator circuit ensures that the power supply voltage to the joint module E under test is accurately controlled within ±0.1V. This is particularly important for testing the electrical performance of the joint module, effectively avoiding test data deviations caused by power fluctuations. It should be noted that the rated voltage of the lithium battery pack is selectable as 12V / 24V / 48V.

[0032] One end of the mechanical energy transmission module A2 is connected to the wave energy absorption module A via a universal coupling, and the other end is connected to the load adjustment and clutch module C. Its function is to convert the irregular raw wave mechanical energy transmitted from the wave energy absorption module A into an initial dynamic mechanical load suitable for the joint module E under test. In this embodiment, the mechanical energy transmission module can adopt a combination structure of a high-precision gear transmission box and a flexible coupling. The transmission ratio of the gear transmission box can be set to 1:5 for adjusting torque and speed. The module also includes a load adjustment unit driven by a stepper motor. This unit receives adjustment commands from the adaptive loading control module D1 and can initially adjust the magnitude, frequency of change, and fluctuation pattern of the initial load. Its torque adjustment range is 0-500 N·m, and its speed adjustment range is 0-300 rpm, with adjustment accuracies of ±0.1 N·m and ±1 r / min, respectively. After processing by this mechanical energy transmission module, the output initial mechanical load is transmitted to the load adjustment and clutch module C, providing a foundation for subsequent precise load adaptation.

[0033] The load adjustment and clutch module C is connected in series between the mechanical energy transmission module A2 and the joint module under test E, and has the core functions of accurate load adaptation, ensuring test safety, and realizing process automation. In this embodiment, the load adjustment and clutch module adopts a combination structure of electromagnetic clutch and hydraulic adjustment unit, which specifically includes a load detection sensor, a force adjustment actuator, and a clutch control unit. The load detection sensor can be a tension sensor with a measurement range of 0-500 N·m and an accuracy of ±0.05 N·m. This sensor is installed at the input end of the module and is used to collect the magnitude and fluctuation frequency of the initial load force output by the mechanical energy transmission module A2 in real time, and synchronously feed this real-time data back to the adaptive loading control module D1 via the CAN bus, providing accurate input for the closed-loop adjustment of the load. The force adjustment actuator, in this embodiment, can be a high-precision hydraulic actuator, which receives adjustment commands from the adaptive loading control module D1. Based on these commands, the hydraulic actuator performs rapid and precise fine-tuning of the initial load force, with an adjustment range of 0-500 N·m and an adjustment accuracy of ±0.1 N·m. This ensures that the final load force output to the test joint module E perfectly matches the preset test conditions (e.g., simulating random forces under specific sea conditions), effectively preventing the accuracy of the test from being affected by excessive or insufficient initial load. The clutch control unit is connected to an electromagnetic clutch and interacts with the adaptive loading control module D1. During normal testing, the clutch is engaged, transmitting the adjusted load force to the test joint module E. When the adaptive loading control module D1 issues a clutch command (e.g., detecting an abnormality in joint module E or the preset test duration has expired), the clutch control unit immediately drives the electromagnetic clutch to disengage within a preset time (e.g., within 50ms), thereby quickly cutting off the load force transmission and achieving zero load output. Upon test restart, engagement can be completed within 10ms, restoring load transmission; simultaneously, the clutch status (disengagement / engagement) is fed back to the closed-loop test module in real time for data recording and system status monitoring. This quick-clutch function helps improve the safety of testing, effectively protecting the test joint module E from damage in the event of an anomaly. It also enables the automatic termination and start of the test process without manual intervention.

[0034] The adaptive loading control module D1 serves as the core control of the entire testing system, responsible for formulating and executing all control strategies. In this embodiment, the adaptive loading control module uses an industrial control computer as its hardware core. Its internal software system stores a database of various typical wave force-driven operating conditions, such as nearshore random wave conditions, strong disturbance wave conditions, and low-frequency long surge wave conditions. Each operating condition corresponds to a set of detailed load parameters (such as average load, fluctuation range, frequency spectrum, etc.) and standard performance parameter thresholds for the tested joint module E (such as safe temperature, rated current, etc.). Module D1 communicates with other parts of the system at high speed via a CAN bus, with a data sampling and control command transmission frequency of up to 100Hz. The adaptive loading control module receives module operating parameters, fatigue damage data, and real-time performance data from the closed-loop testing module D3 in real time, and simultaneously receives real-time load detection data from the load adjustment and clutch module C, as well as load parameters from the dynamically adjusted mechanical energy transmission module and adjustment parameters from the load adjustment and clutch module. Based on this multi-source input information, the control algorithm built into module D1 performs real-time calculations, dynamically generating and sending adjustment commands to the load adjustment unit (for coarse adjustment) of mechanical energy transmission module A2 and the force adjustment actuator (for fine adjustment) of load adjustment and clutch module C. This allows the system to accurately reproduce extremely random and complex fluctuating load conditions, ensuring a high degree of consistency between the test scenario and the actual service environment of the joint module. Furthermore, when any performance parameter of joint module E exceeds a preset safety threshold (e.g., winding temperature rise exceeding 80°C, or stator current exceeding 1.2 times the rated current), module D1 immediately identifies it as an abnormal state and simultaneously sends an emergency clutch command to load adjustment and clutch module C to achieve rapid and safe shutdown, preventing motor overload damage. Simultaneously, it records the wave force load parameters, joint module performance data, load adjustment data, and clutch status under abnormal conditions, providing a basis for motor fault diagnosis and performance optimization.

[0035] The built-in control algorithms in module D1, such as the PID control algorithm, adopt an incremental PID architecture. For the random fluctuation characteristics of wave forces, the parameter ranges and engineering setpoints are tuned and limited: the proportional coefficient Kp ranges from 80 to 200, with a standard engineering setpoint of 120; the integral coefficient Ki ranges from 0.5 to 3, with a standard engineering setpoint of 1.5; and the derivative coefficient Kd ranges from 5 to 20, with a standard engineering setpoint of 10. The parameters and wave force conditions are matched using a graded matching rule: for stable, small-amplitude wave conditions (amplitude 0.1-0.3m), a low Kp and low Ki parameter combination is used to weaken the adjustment sensitivity; for random, large-amplitude wave conditions (amplitude 0.5-0.8m), a high Kp and high Kd parameter combination is used to improve the dynamic response speed; and for low-frequency, long-period wave conditions, the Ki coefficient is appropriately increased to eliminate steady-state load errors.

[0036] The closed-loop test module D3 (which contains multi-source sensor acquisition) is used for data acquisition and feedback. It is tightly integrated with the joint module E under test and connected to the adaptive loading control module D1, thus forming a complete acquisition-feedback-adjustment closed loop. This closed-loop test module consists of a series of high-precision sensors and data processing units. On one hand, it includes sensors for fatigue characteristic monitoring, such as dynamic torque sensors, laser displacement sensors, and ultrasonic fatigue monitoring sensors. These sensors are used to acquire in real-time operating parameters of the joint module E under test, such as output torque, rotational speed, and angular displacement, as well as fatigue damage data such as the propagation of microcracks on the module housing surface and minor deformations of internal parts. On the other hand, module D3 also includes a dedicated joint module performance detection component. This component consists of a set of sensors specifically designed to synchronously monitor the real-time performance changes of the joint module under different wave force loads. Specifically, the component may include: 1. A current sensor: connected in series with the voltage bus circuit of the joint module, with a measurement range of 0-100A and an accuracy of ±0.01A, used to collect changes in the stator current of the joint module under different wave force loads in real time, capturing the pattern of low current under light load, stable current under rated load, and sudden current increase under overload. 2. A voltage sensor: connected in parallel with the DC bus of the joint module, with a measurement range of 0-60V and an accuracy of ±0.01V, used to collect the supply voltage of the joint module in real time, monitoring voltage stability and the impact of load changes on voltage. 3. Surface Mount Temperature Sensors: Multiple sensors are attached to key components of the joint module, including the stator, rotor, windings, and housing. The measurement range is -20℃ to 150℃, with an accuracy of ±0.5℃. These sensors are used to monitor the temperature rise rate and steady-state temperature of various parts of the joint module under different wave force loads in real time, analyze the correlation between load intensity and joint module temperature rise, and evaluate the heat dissipation performance of the joint module. 4. Power Sensor: Connected in series in the joint module's power supply circuit, this sensor collects the input power of the joint module in real time. Simultaneously, a dynamic torque tester measures the output power, allowing for real-time calculation of the joint module's operating efficiency and analysis of changes in the energy conversion efficiency under different wave force loads. 5. Speed ​​Sensor: Installed on the joint module's output shaft, the measurement range is 0-300 r / min, with an accuracy of ±1 r / min. This sensor collects the joint module's rotational speed and speed fluctuations in real time, evaluating the joint module's operational stability and response speed under different loads. It is understood that the data acquisition frequency of all sensors can be set to 100Hz to ensure the capture of instantaneous dynamic changes in load and performance parameters. The collected raw data is first sent to the data preprocessing unit built into module D3. This unit filters, reduces noise, and normalizes the data to eliminate the impact of environmental interference and sensor noise on test accuracy.The processed data is divided into two paths: one path is fed back to the adaptive load control module D1 in real time via the CAN bus for dynamic optimization of load adjustment strategies and clutch control; the other path is stored in the background data server, where a correlation model is established between wave force load (amplitude, frequency) and joint module performance parameters (current, voltage, temperature rise, efficiency, speed), joint module fatigue damage data, and load adjustment parameters through built-in data analysis algorithms. The correlation model is a multivariate nonlinear regression fitting model, which is adapted to the nonlinear characteristics of random wave force fluctuations and joint module performance-fatigue coupling. It takes into account both laboratory standardized fitting and field measurement iteration requirements, and adopts an architecture that combines piecewise nonlinear fitting and weighted fusion. For stable wave conditions, a multinomial regression model is selected, and for random large disturbance wave conditions, a BP neural network fitting model is selected, which balances fitting accuracy and computational efficiency, and meets the dual requirements of real-time control and offline analysis. This model is built upon massive amounts of real-world measured data. First, preprocessed time-series data undergoes segmentation, outlier removal, and normalization scaling. Then, it advances fitting and modeling according to different operating conditions. Cross-validation is used to optimize parameters and eliminate redundant variables to reduce overfitting risk. Finally, a general fitting formula and condition-specific sub-models are formed. Input variables include wave force load characteristics, load adjustment parameters, and test environment parameters. Output variables include joint module performance characteristics, fatigue characteristics, and safety warning thresholds. The training fitting employs a phased fitting and weighted iteration rule. Standardized laboratory test data serves as the basic training set with 60% weight, while real-world sea-area measured data serves as the optimization set with 40% weight. Minimizing the mean square error is the fitting objective, and the iterative optimization coefficients are considered complete when the error value is less than ±2%. The model supports online incremental updates, automatically supplementing measured data after every 100 hours of testing to complete iterative optimization, further improving the adaptability accuracy for different scenarios.

[0037] It can intuitively present the performance change patterns of various parts of the motor under different wave forces, as well as the impact of abnormal joint module performance on the joint module's operational stability and fatigue life, providing accurate data support for the optimized design of the joint module.

[0038] Example 2 This embodiment describes in detail a method for performing a complete joint module fatigue and performance co-test using the system described in Embodiment 1. The method process reflects the system's high degree of automation, high precision, and comprehensive testing capabilities.

[0039] (1) Test preparation stage. First, the joint module E to be tested is firmly installed on the fixed fixture of the test platform, and its output flange is connected to the output end of the load adjustment and clutch module C to ensure mechanical alignment. Next, the various sensors in the closed-loop test module D3 (including torque sensor, laser displacement sensor, ultrasonic fatigue monitoring sensor, and current, voltage, temperature, power, and speed sensors in the performance testing component) are installed on the joint module E to be tested according to the predetermined positions, and all signal cable connections are checked to ensure they are secure and communication is normal. Subsequently, in the control interface of the adaptive loading control module D1, the operator sets the working conditions of this test according to the test requirements. For example, a test simulating medium sea state can be set, with the preset wave parameters being amplitude 0.3-0.6m, and the standard performance parameters safety thresholds of this type of joint module (such as maximum allowable temperature 85℃, maximum allowable current 50A) and total test duration (such as 1000h) are input. This test included a control group, employing a mainstream electric-driven joint module fatigue testing system. Parallel tests were conducted under the same joint module, rated load parameters, 1000-hour test duration, and ambient temperature and humidity conditions, providing a precise data comparison between this invention and traditional electric-driven testing methods. The test subjects were the same model of humanoid robot joint modules, with a test duration of 1000 hours and a uniform peak torque of 300 N·m. The core test data comparison is as follows: 1. Energy consumption: This invention relies on wave energy for self-powered operation, with no external power grid connection during the entire test. It only consumes redundant power from the energy storage module, resulting in an energy consumption of only 0.8 kW·h per hour. In contrast, the existing mainstream electric-driven testing system relies on continuous external mains power, consuming up to 6.2 kW·h per hour. This invention reduces energy consumption by more than 87%. 2. Accuracy of Working Condition Fitting: This invention is based on the simulation of random loads from real wave forces, with a 96% fit between load fluctuations and actual sea conditions. The fatigue damage trajectory of the joint module deviates from the field measurement by ≤2.1%. The electric drive system uses a preset sinusoidal / constant load, resulting in high distortion of the working condition simulation and a fatigue life test deviation of 11.3%. 3. Completeness of Performance Monitoring: This invention simultaneously collects multi-dimensional data on fatigue, electrical, and thermodynamics, fully capturing the correlation between load fluctuations and module performance degradation. The electric drive system only monitors fatigue and basic torque data, lacking key performance parameters such as temperature rise, efficiency, and current fluctuations, resulting in a missing testing dimension of over 40%. 4. Test Safety: This invention features real-time abnormal clutch protection, rapidly cutting off the load within 50ms, and exhibiting no module overload damage during 1000 hours of testing. The electric drive system has a delayed overload response, and two winding over-temperature warnings occurred during testing, posing a risk of module damage. 5. Data reusability: The test data of this invention can be directly used for life prediction under real marine conditions, with a data reuse rate of 89%; the test data of electric drive is only suitable for laboratory scenarios, with an on-site working condition adaptability rate of only 32%.Finally, the main power supply of the system is turned on, the wave energy absorption module A starts to work, and the power generation module A1 and the energy storage module B then supply power to the entire system and the joint module E under test, and wait for the power supply voltage to stabilize.

[0040] (2) Working Condition Simulation and Data Acquisition Stage. After the operator starts the test on the control interface, the system immediately enters the fully automatic test mode. The wave energy captured by the wave energy absorption module A is converted into an initial dynamic mechanical load through the mechanical energy transmission module A2. The load detection sensor in the load adjustment and clutch module C immediately collects the real-time data of the initial load and reports it to the adaptive loading control module D1. Accordingly, the adaptive loading control module D1, based on the currently set medium sea state working condition requirements, compares the real-time load data with the target load range, calculates the adjustment command through its built-in control algorithm, and sends it to the force adjustment actuator of the load adjustment and clutch module C. The force adjustment actuator performs precise fine-tuning of the initial load to ensure that the load force finally applied to the test joint module E is precisely within the preset random fluctuation range. At the same time, the clutch control unit controls the electromagnetic clutch to be engaged, and the load begins to drive the test joint module E to run. Throughout the test process, the adaptive loading control module D1 and the closed-loop test module D3 form a tight closed loop. The closed-loop test module D3 synchronously collects all fatigue data (such as torque, displacement, and crack signals) and performance data (such as stator current, winding temperature rise, operating efficiency, and output speed) of joint module E at a frequency of 100Hz. This data, after preprocessing, is fed back to the adaptive load control module D1 in real time. D1 then continuously and dynamically fine-tunes the load parameters based on this feedback data to ensure the continuous realism of the operating condition simulation. For example, if the speed of joint module E deviates from the target range due to load fluctuations, D1 will immediately adjust the load to bring it back to the normal range. All collected data, including load data, fatigue data, performance data, and the status information of each module, is recorded in detail and stored in the data server every 10ms to ensure data continuity and integrity.

[0041] (3) Abnormal Handling and Automated Termination Stage. This system provides an intelligent safety protection mechanism. During the testing process, which lasts for thousands of hours, if any performance abnormality occurs in the joint module E under test, for example, if the closed-loop test module D3 detects that the temperature sensor reading of its internal winding exceeds the preset threshold of 85°C, or if the current sensor detects a sudden change in current, these abnormal signals will be immediately reported to the adaptive load control module D1. Upon receiving the abnormal signal, the control program of D1 will immediately execute the highest priority safety protection program and immediately send an emergency separation command to the clutch control unit of the load adjustment and clutch module C. Within 50ms, the clutch control unit drives the electromagnetic clutch to separate, instantly cutting off the transmission of load force, so that the joint module E under test enters an unloaded state, thereby avoiding permanent damage due to overheating or overcurrent. While executing the clutch action, the system will automatically record all relevant data in the short period of time before the abnormality occurs, including the wave force load parameters at that time, various performance data of the joint module, load adjustment data, and clutch status, providing data support for subsequent fault analysis and cause investigation. In addition, when the test run time reaches the preset 1000h, the adaptive load control module D1 will also automatically send a clutch command to the load adjustment and clutch module C to disconnect the load and indicate that the test is complete. The entire test process will then terminate automatically and safely.

[0042] (4) Test Completion and Data Analysis Phase. After the test is terminated, the operator can export all the data from the data server. The accompanying data analysis software can process and visualize the massive amounts of data. For example, it can generate curves showing the performance parameters of the joint module over time under different wave force load levels (light load, medium load, heavy load), such as current-time curves, temperature rise-time curves, and efficiency-load curves. Simultaneously, it can also generate curves showing the change in fatigue damage (such as crack length) of the joint module with the number of loading cycles. Furthermore, through multivariate statistical analysis or machine learning algorithms, a correlation model can be established between wave force load (characterized by amplitude, frequency, etc.), joint module performance parameters (such as efficiency and temperature rise rate), load adjustment parameters, and the fatigue life of the joint module. Based on this model, the performance degradation law of the joint module and the impact of abnormal changes in certain performance parameters (such as a sudden drop in efficiency) on its operational stability and final fatigue life can be clearly analyzed. Ultimately, the system can output a comprehensive test report, completing a collaborative evaluation of the fatigue characteristics and real-time performance of the joint module, providing data support for the subsequent optimization design, material selection, or control strategy improvement of the module.

[0043] Example 3 This embodiment aims to illustrate the deployment and operation of the system described in Embodiment 1 in different application scenarios, so as to demonstrate its scenario adaptability.

[0044] The first scenario is standardized laboratory testing. In this scenario, the testing system is deployed in an indoor laboratory. Due to the lack of real ocean waves, the wave energy absorption module A will interface with a wave simulation device. This wave simulation device can be a large water tank equipped with a programmable wave generator. Operators can precisely set the wave type to be simulated on the interface of the adaptive loading control module D1. For example, generating regular waves with constant period and amplitude to test the response characteristics of the joint module at a specific frequency; or generating random waves following a specific spectral function (such as the JONSWAP spectrum) for more realistic fatigue testing. Understandably, in this controlled environment, interference from other environmental factors such as wind and currents in real ocean areas can be eliminated, resulting in good repeatability of test results. This is highly advantageous for comparing the performance of joint modules with different designs or for standardized life certification testing of the same module. The operation of other parts of the system, such as the power generation, energy storage, loading, control, and testing modules, is basically the same as described in Examples 1 and 2.

[0045] The second scenario is on-site testing in real-world marine environments. In this scenario, the entire testing system is deployed in a real marine environment, for example, anchored in shallow near-shore waters at a depth of 2 to 5 meters. Wave energy absorption module A directly captures the energy of natural ocean waves, and its angle adjustment component automatically adjusts the float's attitude based on the real-time incident direction of the waves to maximize energy capture efficiency. In this scenario, the self-powered nature of power generation module A1 and energy storage module B allows the system to operate independently for extended periods without the need for laying submarine cables from the shore. This on-site testing allows the tested joint module E to withstand real, completely random, multi-dimensional mechanical environments, and the test results better reflect the joint module's actual performance and fatigue life in real-world service environments. For example, in addition to the direct effects of waves, factors such as ocean currents and gusts are indirectly transmitted to the loading system through the float, creating an extremely complex composite loading condition. The collaborative work of adaptive loading control module D1 and closed-loop testing module D3 accurately records every subtle performance change and fatigue damage accumulation process of the joint module under these real and complex conditions. The data obtained through this testing method is of great significance for verifying and optimizing the reliability and durability of the joint module in extreme marine environments.

[0046] As can be seen from the descriptions of the two scenarios above, the system provided by this invention can meet the requirements for precise control and standardization of test conditions in a laboratory environment, as well as the requirements for the authenticity of working conditions and the self-sufficiency of the system in real application scenarios. It has good application flexibility and a wide range of applicability.

[0047] Those skilled in the art will understand that, besides implementing the system and its various devices, modules, and units provided by this invention in the form of purely computer-readable program code, the same functions can be achieved entirely through logical programming of the method steps, making the system and its various devices, modules, and units of this invention function in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers. Therefore, the system and its various devices, modules, and units provided by this invention can be considered as a hardware component, and the devices, modules, and units included therein for implementing various functions can also be considered as structures within the hardware component; alternatively, the devices, modules, and units for implementing various functions can be considered as both software modules implementing the method and structures within the hardware component.

[0048] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A wave force driven simulated operating condition joint module fatigue test system, characterized by, include: Wave energy absorption module, power generation module, electrical energy storage module, mechanical energy transmission module, load adjustment and clutch module, adaptive loading control module, and closed-loop testing module; After capturing wave energy, the wave energy absorption module outputs it in two ways: one way sends mechanical energy to the power generation module for power generation, and the other way sends mechanical energy to the mechanical energy transmission module as a mechanical loading source, forming a dual-path high-efficiency wave energy utilization structure. The power generation module is electrically connected to the energy storage module to realize power generation, energy storage and system self-powering; The load adjustment and clutch module is connected in series between the mechanical energy transmission module and the joint module under test, and is used to adjust the magnitude of the mechanical load output by the mechanical energy transmission module and realize the on / off control of the load force. The closed-loop test module and the adaptive loading control module establish a two-way signal interaction to form a full closed-loop control mechanism, which is used to dynamically optimize test parameters to match test requirements. The closed-loop test module has a built-in joint module performance detection component, which synchronously collects the core performance parameters of the matching motor of the joint module under test under different wave force loads, thereby realizing the joint module fatigue characteristics and performance testing. The adaptive loading control module dynamically adjusts the load parameters by combining the real-time performance data of the joint module to ensure operational safety and testing accuracy.

2. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The wave energy absorption module adopts a floating capture structure, which can be adapted to wave scenarios with wavelengths of 0.5-2m and amplitudes of 0.1-0.8m. It can capture both simulated wave energy in the laboratory and actual sea wave energy. The wave energy absorption module is equipped with an angle adjustment component, which can adapt to different wave incident directions.

3. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The power generation module is a small electromagnetic induction wave generator with a built-in rectifier and filter unit, which can convert the mechanical energy of the wave into stable DC power. The energy storage module includes a lithium battery pack, a charge and discharge management unit, and a voltage regulator circuit, which independently powers the system and the joint module under test, enabling self-powered operation without external power grid dependence.

4. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The mechanical energy transmission module adopts a combination structure of gear transmission box and flexible coupling, and has a built-in load adjustment unit with a torque adjustment range of 0-500N. With a speed adjustment range of 0-300rpm, it can convert the wave energy transmitted by the wave energy absorption module into the initial dynamic mechanical load of the joint module and transmit it to the load adjustment and clutch module, providing a foundation for subsequent precise load adaptation.

5. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The load adjustment and clutch module adopts a combination structure of electromagnetic clutch and hydraulic adjustment unit, and has a built-in load detection sensor, force adjustment actuator and clutch control unit. The load detection sensor is used to collect the initial load force output by the mechanical energy transmission module in real time and feed the data back to the adaptive loading control module. The force adjustment actuator, based on the instructions issued by the adaptive loading control module, precisely adjusts the initial load force. Its adjustment range is 0-500 N·m, and the adjustment accuracy is ±0.1 N·m, to ensure that the load force finally output to the joint module under test meets the test conditions. Upon receiving the clutch command from the adaptive loading control module, the clutch control unit can quickly complete the clutch action, cut off the transmission of load force, and achieve zero load output.

6. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The adaptive loading control module is based on an industrial control computer, has a built-in database of various wave force driving conditions, adopts a PID control algorithm, dynamically adjusts load parameters based on multi-source feedback data, reproduces the random fluctuation of wave force conditions, and triggers emergency shutdown protection when the joint module parameters exceed the threshold.

7. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The closed-loop testing module includes a dynamic torque sensor, a laser displacement sensor, an ultrasonic fatigue monitoring sensor, and a data preprocessing unit. It collects the operating parameters and fatigue damage data of the joint module under test, and feeds them back to the adaptive loading control module after filtering and noise reduction.

8. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 7, characterized in that, The joint module performance testing component includes a current sensor, a voltage sensor, a patch temperature sensor, a power sensor, and a speed sensor, which simultaneously collects stator current, supply voltage, winding temperature rise, operating efficiency, and speed parameters at a frequency of 100Hz.

9. The joint module fatigue testing system for wave force-driven simulated working conditions according to claim 1, characterized in that, The testing system can be adapted to two application scenarios, as follows: In indoor laboratory settings, it can be integrated with wave simulation devices to achieve standardized and repeatable testing. Capture natural wave energy directly in real marine environments to achieve on-site self-sustaining testing.

10. A fatigue testing method for a joint module based on simulated wave force conditions of the system according to any one of claims 1-9, characterized in that, Includes the following steps: Test preparation phase: Install the joint module to be tested and sensors, set wave conditions, safety thresholds and test duration, and start the system with self-powered operation; During the working condition simulation and data acquisition phase: Wave energy is utilized in two ways to be converted into test load. The adaptive loading control module regulates the load in a closed loop, and the closed-loop test module collects fatigue data and performance data simultaneously and stores them in real time. Anomaly Handling and Automation Termination Phase: When an abnormal performance of the joint module is detected or the test duration is reached, the load adjustment and clutch module quickly cuts off the load to achieve automatic shutdown and abnormal data recording. Test and analysis phase: Export test data, establish a correlation model between wave force load, joint module performance and fatigue life, and output a collaborative test evaluation report.

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