Safety control system, safety control method, and robot

Abstract

The application discloses a safety control system, a safety control method and a robot. The safety control system comprises: a servo driver connected with a motor of the robot and configured to control the motor; and a motion controller connected with the servo driver through a safety bus and configured to monitor a motion state of the robot and send a safety control instruction to the servo driver in the case that the motion state of the robot is abnormal. The application seamlessly integrates the safety control system with the robot control system, realizes the function of the whole control system of the robot compatible with the safety control while performing a target task, is simple in system and compact in structure, adopts the safety bus technology, shortens the response time of collection, processing, analysis and evaluation of safety-related information, and improves the availability, real-time performance and reliability of the safety control system.

Description

Technical Field

[0001] This application relates to the field of robotics technology, specifically to a safety control system, safety control method, and robot. Background Technology

[0002] With the increasing demand and widespread application of mechanical automation in the new era, the focus on production safety is also constantly rising. Therefore, robot safety has become a hot topic. Investment and research in functional safety are gradually increasing to ensure the safe use of mechanical automation in production and daily life. Currently, most robots adopt an "independent safety prevention" control scheme, separating the safety system from the robot's operation control. The safety system requires many independent safety components, such as emergency braking, limit switches, and three-state enable signals, which necessitates setting up a large number of input / output (I / O) signals. The separation of the two systems makes the control system's logic complex, the wiring chaotic, and increases the delay between system signals, thus increasing the system's safety response time. Summary of the Invention

[0003] The purpose of this application is to provide a safety control system, safety control method, and robot for robots, in order to solve the problems of complex safety system logic and long response time in the prior art.

[0004] To achieve the above objectives, embodiments of this application provide a safety control system for a robot, the safety control system comprising:

[0005] Servo drivers, connected to the robot's motors, are configured to control the motors;

[0006] The motion controller, connected to the servo driver via a safety bus, is configured to monitor the robot's motion state and send safety control commands to the servo driver in the event of an abnormality in the robot's motion state.

[0007] In this embodiment of the application, the servo driver is further configured to:

[0008] The motor data sent by the motor is acquired according to a preset cycle and then sent to the motion controller.

[0009] In this embodiment of the application, the motion controller is further configured to:

[0010] Obtain motor data sent by the servo driver;

[0011] Compare the motor data with the set values;

[0012] If the motor data does not match the set value, it is determined that the robot's motion state is abnormal.

[0013] In this embodiment of the application, the motion controller is further configured to:

[0014] The first and second security control commands are acquired through dual channels.

[0015] Determine whether the first security control command and the second security control command match;

[0016] If the first and second safety control commands match, a safety control command is sent to the servo driver.

[0017] In this embodiment of the application, the motor data includes at least one of the following:

[0018] The motor's speed, position, torque, stationary state data, and acceleration.

[0019] In this embodiment, the safety bus is configured to interact with the motor data of the servo driver and the safety control commands of the motion controller.

[0020] In this embodiment of the application, the servo driver includes:

[0021] The safety torque cutoff module is configured to cut off the motor's torque output to stop the motor.

[0022] The first safety stop module is configured to control the motor to decelerate;

[0023] The safety brake module is configured to control the motor to perform brake operation.

[0024] In this embodiment of the application, the motion controller includes:

[0025] The second safety stop module is configured to keep the motion controller in a controlled stop state;

[0026] The safety speed limiting module is configured to send a command to the servo driver to trigger the first safety stop module if the motor speed exceeds the set speed.

[0027] The safety position limiting module is configured to send a command to the servo driver to trigger the first safety stop module to operate when the safety position exceeds the set safety position;

[0028] The safety torque limiting module is configured to send a command to the servo driver to trigger the safety torque cut-off module when the motor torque exceeds the set safety torque.

[0029] The safety operation stop module is configured to send a command to the servo driver to trigger the first safety stop module when the deviation between the robot's stationary state data and the set stationary state data is greater than a set threshold.

[0030] The safety acceleration limiting module is configured to send a trigger to the safety torque cutoff module to the servo driver when the motor acceleration exceeds a set acceleration.

[0031] A second aspect of this application provides a safety control method for a robot, applied to a motion controller, wherein the motion controller and a servo driver are connected via a safety bus, and the safety control method includes:

[0032] Monitor the robot's motion status;

[0033] In the event of an abnormal movement state of the robot, a safety control command is sent to the servo driver.

[0034] In this embodiment of the application, monitoring the robot's motion state includes:

[0035] Obtain motor data sent by the servo driver;

[0036] Compare the motor data with the set values;

[0037] If the motor data does not match the set value, it is determined that the robot's motion state is abnormal.

[0038] In this embodiment, the servo driver includes a safety torque cutoff module, a first safety stop module, and a safety brake module. Determining an abnormal robot motion state when motor data does not match set values ​​includes:

[0039] If the motor speed exceeds the set speed, a command to trigger the first safety stop module is sent to the servo driver;

[0040] If the safe position exceeds the set safe position, a command to trigger the first safe stop module to run is sent to the servo driver;

[0041] If the motor torque exceeds the set safe torque, a command is sent to the servo driver to trigger the safe torque cutoff module.

[0042] If the deviation between the robot's stationary state data and the set stationary state data exceeds a set threshold, a command to trigger the first safe stop module is sent to the servo driver.

[0043] If the motor's acceleration exceeds the set acceleration, the safety torque cutoff module is triggered and sent to the servo driver.

[0044] In this embodiment of the application, sending a safety control command to the servo driver when the robot's motion state becomes abnormal includes:

[0045] In the event of an abnormal movement state of the robot, the first and second safety control commands are acquired through dual channels.

[0046] Determine whether the first security control command and the second security control command match;

[0047] If the first and second safety control commands match, a safety control command is sent to the servo driver.

[0048] A third aspect of this application provides a robot, including the aforementioned safety control system for the robot.

[0049] The above technical solution provides a safety control system for a robot, comprising: a servo driver connected to the robot's motor and configured to control the motor; and a motion controller connected to the servo driver via a safety bus and configured to monitor the robot's motion state and send safety control commands to the servo driver when the robot's motion state becomes abnormal. The motion controller monitors the robot's motion state and sends safety control commands to the servo driver when the robot's motion state becomes abnormal. This application seamlessly integrates the safety control system with the robot control system, enabling the entire robot control system to perform safety control functions while executing the target task. The system is simple and compact, and by employing safety bus technology, it shortens the response time for the acquisition, processing, analysis, and evaluation of safety-related information, thereby improving the availability, real-time performance, and reliability of the safety control system.

[0050] Other features and advantages of the embodiments of this application will be described in detail in the following detailed description section. Attached Figure Description

[0051] The accompanying drawings are provided to further illustrate the embodiments of this application and form part of the specification. They are used together with the following detailed description to explain the embodiments of this application, but do not constitute a limitation on the embodiments of this application. In the drawings:

[0052] Figure 1 This illustration schematically shows a structural diagram of a safety control system for a robot according to an embodiment of this application;

[0053] Figure 2 This illustration schematically shows a structural diagram of a safety control system for a robot according to another embodiment of this application;

[0054] Figure 3 The illustration shows a flowchart of a safety control method for a robot according to an embodiment of this application;

[0055] Figure 4 The illustration shows a flowchart of a safety control method for a robot according to another embodiment of this application.

[0056] Explanation of reference numerals in the attached figures

[0057] 100 Servo Drivers 200 Motion Controllers

[0058] 300 Safety Bus 110 Safety Torque Cut-off Module

[0059] 120 First safety stop module; 130 Safety brake module

[0060] 210 Second safety parking module; 220 Safety speed limit module

[0061] 230 Safe position limiting module; 240 Safe torque limiting module

[0062] 250 Safety Operation Stop Module 260 Safety Acceleration Limiting Module Detailed Implementation

[0063] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only for illustration and explanation of the embodiments of this application and are not intended to limit the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0064] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0065] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0066] Figure 1 The diagram illustrates the structure of a safety control system for a robot according to an embodiment of this application. Figure 1 As shown in one embodiment of this application, a safety control system for a robot is provided, which may include:

[0067] Servo driver 100, and the robot's motor (i.e. Figure 1 The M) connection is configured to control the motor;

[0068] The motion controller 200, connected to the servo driver 100 via a safety bus 300, is configured to monitor the motion state of the robot and send safety control commands to the servo driver 100 in the event of an abnormality in the robot's motion state.

[0069] Currently, most robots adopt an "independent safety prevention" control scheme, separating the safety system from the robot's operation control. The safety system requires many independent safety components, such as emergency braking, limit switches, and three-state enable signals, necessitating a large number of I / O signals. This separation of the two systems complicates the control system's logic, leads to messy wiring, increases signal delays, and extends the system's safety response time.

[0070] Therefore, this application provides a robot safety control system that integrates the robot's operating system and safety system. It requires only a motion controller 200, a servo driver 100, and a safety bus 300, resulting in a compact integrated system. The implementation principle is as follows: the safety logic from a traditional control cabinet is integrated into the motion controller 200, while the safety bus 300 is used to control both the control and safety logic information. Relevant safety signals are transmitted through the safety bus 300 directly to the semiconductor devices of the servo driver 100, causing the servo driver 100 to enter a safe mode.

[0071] In the embodiments of this application, an electric motor refers to an electromagnetic device that converts or transmits electrical energy based on the law of electromagnetic induction. In the motor sub-circuit, it is generally represented by the letter M, and its main function is to generate driving torque, serving as a power source for electrical appliances or various machines.

[0072] In this embodiment, the servo drive 100, also known as a "servo controller" or "servo amplifier," is a controller used to control a motor. Its function is similar to that of a frequency converter for a regular AC motor, and it is part of a servo system, primarily used in high-precision positioning systems. Generally, it controls the servo motor through position, speed, and torque to achieve high-precision transmission system positioning, representing a high-end product in transmission technology. In one example, functions such as Safety Torque Off (STO), Safety Stop 1 (SS1), and Safety Brake Control (SBC) can be directly integrated into the servo drive 100, allowing the servo drive 100 to directly control the motor and implement safety functions.

[0073] Motion control typically refers to the transformation of predetermined control schemes and planning instructions into desired mechanical motion under complex conditions, achieving precise position control, speed control, acceleration control, torque or force control of the mechanical motion. In this embodiment, the motion controller 200 is connected to the servo driver 100 via a safety bus 300. The safety bus 300 includes both normal control information exchange and information transmission related to functional safety; therefore, it is used to exchange motor data from the servo driver 100 and safety control commands from the motion controller 200. The motion controller 200 can not only control the robot's motion but also send safety control commands to the servo driver 100 when abnormalities occur in the robot's motion state. This allows the servo driver 100 to promptly control the motor, thereby reducing the occurrence of safety accidents. In one example, functions such as Safety Stop 2 (SS2), Safety Limited Speed ​​(SLS), Safety Limited Position (SLP), Safety Limited Torque (SLT), Safety Limited Acceleration (SLA), and Safety Operation Stop (SOS) can be abstracted into logic and embedded into the motion controller. During motor operation, the robot's motion state is monitored, and function-related signals and data are periodically fed back, ultimately controlled via the STO, SS1, and SBC functions built into the servo driver 100.

[0074] The above technical solution provides a robot safety control system, which includes a servo driver 100 integrating multiple functions and a motion controller 200. The motion controller 200 is connected to the servo driver 100 via a safety bus 300. The servo driver 100 is configured to control motors; the motion controller 200 is configured to monitor the robot's motion state and send safety control commands to the servo driver 100 when the robot's motion state becomes abnormal. Thus, the motion controller 200 can monitor the robot's motion state and send safety control commands to the servo driver 100 when the robot's motion state becomes abnormal, enabling the servo driver 100 to adjust its motor control in a timely manner according to the safety situation. In summary, this application seamlessly integrates the safety control system with the robot control system, enabling the entire robot control system to perform target tasks while simultaneously incorporating safety control functions. The system is simple and compact, and the use of safety bus technology shortens the response time for the acquisition, processing, analysis, and evaluation of safety-related information, improving the availability, real-time performance, and reliability of the safety control system.

[0075] In this embodiment of the application, the servo driver 100 can also be configured to:

[0076] The motor data sent by the motor is acquired according to a preset cycle and then sent to the motion controller 200.

[0077] Specifically, the servo driver 100 is directly connected to the motor, enabling it to control the robot's motors and acquire motor data. This motor data may include, but is not limited to, motor speed, motor position, motor torque, motor stationary state data, and motor acceleration. For example, the robot may include multiple motors, each located at a corresponding joint, and each joint includes an encoder. After receiving a data acquisition command, the motors send the encoded data corresponding to each encoder to the servo driver 100. In this way, the servo driver 100 can obtain the motor's position to further determine whether the robot is in a dangerous state.

[0078] In this embodiment, the user can set a preset cycle for acquiring motor data according to actual needs. For example, a data acquisition command can be sent sequentially every 5 seconds. In this way, every 5 seconds, the servo driver 100 can acquire the motor data sent sequentially by the motors and send the motor data to the motion controller 200 so that the motion controller 200 can determine the safety status of the robot.

[0079] In this embodiment of the application, the motion controller 200 can also be configured to:

[0080] Acquire motor data sent by servo driver 100;

[0081] Compare the motor data with the set values;

[0082] If the motor data does not match the set value, it is determined that the robot's motion state is abnormal.

[0083] Specifically, the motion controller 200 can pre-store setting values ​​related to safety status determination. For example, these setting values ​​may include, but are not limited to: setting speed, setting safe position, setting safe torque, setting stationary state data, and setting acceleration. This allows for the limitation of safe speed, safe position, safe torque, safe operation stop, and safe acceleration of the robot.

[0084] In this embodiment, the motion controller 200 can acquire motor data sent by the servo driver 100 to determine the robot's safety status. Specifically, the motor data can be compared with corresponding set values. If the motor data matches the set values, the robot's motion state is determined to be safe; if the motor data does not match the set values, the robot's motion state is determined to be abnormal, and a safety control command is sent to the servo driver 100. The servo driver 100 controls the motors according to the safety control command to reduce the risk of the robot encountering danger.

[0085] In this embodiment of the application, the motion controller 200 can also be configured to:

[0086] The first and second security control commands are acquired through dual channels.

[0087] Determine whether the first security control command and the second security control command match;

[0088] If the first safety control command and the second safety control command match, a safety control command is sent to the servo driver 100.

[0089] Specifically, the motion controller 200 can verify the safety control commands before sending them. This embodiment uses a dual-channel monitoring mechanism to acquire two safety control commands: a first safety control command and a second safety control command. It determines whether the two commands match. If they match, the safety control command is sent to the servo driver. If they do not match, the safety control command is reacquired. This reduces the possibility of erroneous safety command transmission and improves the efficiency of robot safety control.

[0090] In this embodiment of the application, the motor data may include at least one of the following:

[0091] The motor's speed, position, torque, stationary state data, and acceleration.

[0092] Specifically, the motor data in this embodiment may include, but is not limited to, motor speed, motor position, motor torque, motor stationary state data, and motor acceleration. For example, a robot may include multiple motors, each of which may be installed at a corresponding joint of the robot, and each joint includes an encoder. After receiving a data acquisition command, the motor sends the encoded data corresponding to each encoder to the servo driver 100. In this way, the servo driver 100 can obtain the position of the motor to further determine whether the robot is in a dangerous state.

[0093] It should be noted that the motor data in this application embodiment is not limited to the above data, and corresponding motor data can also be obtained according to the user's actual needs.

[0094] In this embodiment, the safety bus 300 can be configured to interact with the motor data of the servo driver 100 and the safety control commands of the motion controller 200.

[0095] Specifically, the safety bus 300 includes both general control information exchange and information transmission related to functional safety. Therefore, the safety bus 300 is used to exchange motor data from the servo drive 100 and safety control commands from the motion controller 200. In one example, the safety bus 300 can be built on an existing fieldbus, adding safety information exchange and data verification functions to transmit motor data from the servo drive 100 to the motion controller 200, and to transmit safety control commands from the motion controller 200 to the servo drive. Compared to the prior art which requires multiple fieldbuses leading to messy wiring, this embodiment only requires data exchange through the safety bus, shortening the response time for the collection, processing, analysis, and evaluation of safety-related information.

[0096] Figure 2 A schematic diagram illustrating the structure of a safety control system for a robot according to another embodiment of this application is shown. Figure 2 As shown in this embodiment, the servo driver 100 may include:

[0097] The safety torque cutoff module 110 is configured to cut off the torque output of the motor to stop the motor;

[0098] The first safety stop module 120 is configured to control the motor to decelerate;

[0099] The safety brake module 130 is configured to control the motor to perform brake operation.

[0100] Specifically, the servo driver 100 typically controls the servo motor through three methods: position, speed, and torque, to achieve high-precision transmission system positioning. Functions such as STO, SS1, and SBC can be directly integrated into the servo driver 100, allowing the servo driver 100 to directly control the motor and implement safety functions.

[0101] The servo driver 100 in this embodiment may include a safety torque cutoff module 110, a first safety stop module 120, and a safety brake module 130. The safety torque cutoff module 110 includes an STO (Safe Torque Off) function, used to cut off the motor's torque output to stop the motor, thereby preventing torque generation when the motor stops and making the machine part of a safety system. The first safety stop module 120 includes an SS1 (Safety Stop Initiation) function, where the axis is controlled to enter a stationary state, and then the motor power supply is safely interrupted, making the motor torque-free. This is used to control the motor to decelerate and stop, and automatically initiates STO or SBC (Safety Stop and Brake) after a certain delay. The safety brake module 130 includes an SBC function, providing a safety signal for controlling external and internal brakes. The servo driver 100 controls the motor according to the safety control commands sent by the motion controller 200 to put the robot into the corresponding safety mode.

[0102] In this embodiment of the application, the motion controller 200 may include:

[0103] The second safety stop module 210 is configured to keep the motion controller in a controlled stop state;

[0104] The safety speed limiting module 220 is configured to send a command to the servo driver to trigger the first safety stop module to operate when the speed of the motor exceeds the set speed.

[0105] The safety position limiting module 230 is configured to send a command to the servo driver to trigger the first safety stop module to run when the safety position exceeds the set safety position;

[0106] The safety torque limiting module 240 is configured to send a command to the servo driver to trigger the safety torque cut-off module when the motor torque exceeds the set safety torque.

[0107] The safety operation stop module 250 is configured to send a command to the servo driver to trigger the operation of the first safety stop module when the deviation between the robot's stationary state data and the set stationary state data is greater than a set threshold.

[0108] The safety acceleration limiting module 260 is configured to send a trigger to the safety torque cutoff module to the servo driver when the acceleration of the motor exceeds a set acceleration.

[0109] Specifically, the motion controller 200 is connected to the servo driver 100 via the safety bus 300. The motion controller 200 not only controls the robot's movement but also sends safety control commands to the servo driver 100 when the robot's movement becomes abnormal. This allows the servo driver 100 to control the motors promptly, reducing the occurrence of safety accidents. In this embodiment, functions such as SS2, SLS, SLP, SLT, SLA, and SOS can be abstracted into logic and embedded into the motion controller 200. During motor operation, the robot's movement state is monitored, and function-related signals and data are periodically fed back, ultimately controlled by the servo driver 100's built-in STO, SS1, and SBC functions.

[0110] The motion controller 200 in this application embodiment may include a second safe parking module 210, a safe speed limiting module 220, a safe position limiting module 230, a safe torque limiting module 240, a safe operation stop module 250, and a safe acceleration limiting module 260.

[0111] The second safety stop module 210 includes the SS2 function, in which the servo drive brakes to a stationary state and then remains in a controlled stop state. The servo drive 100 maintains the control function, keeping the motion controller 200 in a controlled stop state.

[0112] The safety speed limit module 220 includes an SLS function. The user can pre-determine a set speed; when the set speed is exceeded, a safety stop function is activated, thereby activating the servo drive 100. For example, a command to trigger the first safety stop module 120 to operate is sent to the servo drive 100.

[0113] The safety position limiting module 230 includes an SLP function. When the safe position exceeds a set safe position, it activates the response of the servo drive 100, for example, by sending a command to trigger the first safety stop module to operate to the servo drive 100. During robot operation, the safety position limiting module 230 monitors the absolute position of the robot to prevent it from exceeding the set limits and avoid mechanical collision accidents.

[0114] The safety torque limiting module 240 includes an SLT function. A motor can generally withstand a maximum torque of three times the set safety torque; otherwise, the motor may be damaged due to overheating, overcurrent, or other reasons. Therefore, when the motor torque exceeds the set safety torque, the servo driver 100 is activated. For example, a command to trigger the safety torque cutoff module is sent to the servo driver 100.

[0115] The safety operation stop module 250 includes an SOS function, which activates the servo driver 100 to respond when the deviation between the robot's stationary state data and the set stationary state data exceeds a set threshold. For example, it sends a command to the servo driver 100 to trigger the first safety stop module. The safety operation stop module 250 is used to monitor the stationary state of the motor to ensure that the motor is in a safe stop state.

[0116] The safety acceleration limiting module 260 includes an SLA function, which activates the response of the servo drive 100 when the motor acceleration exceeds a set acceleration. For example, it sends a trigger to the safety torque cutoff module 110 to the servo drive 100. The safety and speed limiting module 260 monitors the motor acceleration process to prevent exceeding the set acceleration value and avoid excessive current caused by mechanical collisions, which could damage the drive.

[0117] It should be noted that the servo driver 100 and motion controller 200 of this application are not limited to the modules mentioned above. The servo driver 100 and motion controller 200 can also be configured according to actual needs to more efficiently control the robot safely.

[0118] Figure 3 The illustration shows a schematic flowchart of a robot safety control method according to an embodiment of this application. Figure 3 As shown in one embodiment of this application, a safety control method for a robot is provided, applied to a motion controller. The motion controller can be connected to a servo driver via a safety bus. The safety control method may include the following steps:

[0119] Step 301: Monitor the robot's motion status;

[0120] Step 302: In the event of an abnormal movement state of the robot, send a safety control command to the servo driver.

[0121] This application provides a robot safety control system that integrates the robot's operating system and safety system. It requires only a motion controller, a set of servo drivers, and a safety bus, resulting in a compact integrated system. The implementation principle is as follows: the safety logic from a traditional control cabinet is integrated into the motion controller, while the safety bus is used to control both the control and safety logic information. Relevant safety signals are transmitted via the safety bus directly to the semiconductor devices of the servo driver, causing the servo driver to enter a safe mode.

[0122] In this embodiment, the servo drive is a controller used to control a motor, similar in function to a frequency converter for a regular AC motor. It is part of a servo system and primarily used in high-precision positioning systems. Generally, it controls the servo motor through position, speed, and torque to achieve high-precision transmission system positioning, representing a high-end product in transmission technology. In one example, functions such as Safety Torque Off (STO), Safety Stop 1 (SS1), and Safety Brake Control (SBC) can be directly integrated into the servo drive, allowing the servo drive to directly control the motor and implement safety functions.

[0123] In this embodiment, the motion controller is connected to the servo driver via a safety bus. The safety bus includes both general control information exchange and information transmission related to functional safety. Therefore, the safety bus is used to exchange motor data from the servo driver and safety control commands from the motion controller. The motion controller can not only control the robot's motion but also send safety control commands to the servo driver when the robot's motion state becomes abnormal. This allows the servo driver to control the motor in a timely manner, thereby reducing the occurrence of safety accidents. In one example, functions such as Safety Stop 2 (SS2), Safety Limited Speed ​​(SLS), Safety Limited Position (SLP), Safety Limited Torque (SLT), Safety Limited Acceleration (SLA), and Safety Operation Stop (SOS) can be abstracted into logic and embedded into the motion controller. During motor operation, the robot's motion state is monitored, and function-related signals and data are periodically fed back, ultimately controlled through the servo driver's built-in STO, SS1, and SBC.

[0124] The above technical solution provides a robot safety control system, which includes a servo driver and a motion controller integrating multiple functions. The motion controller is connected to the servo driver via a safety bus. The motion controller can monitor the robot's motion state and, in the event of an abnormality in the robot's motion state, send safety control commands to the servo driver, enabling the servo driver to adjust its motor control in a timely manner according to the safety situation. In summary, this application seamlessly integrates the safety control system with the robot control system, enabling the entire robot control system to perform target tasks while simultaneously incorporating safety control functions. The system is simple, compact, and employs safety bus technology, shortening the response time for the acquisition, processing, analysis, and evaluation of safety-related information, and improving the availability, real-time performance, and reliability of the safety control system.

[0125] Figure 4 A schematic flowchart illustrating a safety control method for a robot according to another embodiment of this application is shown. Figure 4 As shown in the embodiment of this application, step 301, monitoring the robot's motion state, may include:

[0126] Step 401: Obtain motor data sent by the servo driver;

[0127] Step 402: Compare the motor data with the set values;

[0128] Step 403: If the motor data does not match the set value, determine that the robot's motion state is abnormal.

[0129] In this embodiment, the motion controller can pre-store setting values ​​related to safety status determination. For example, these setting values ​​may include, but are not limited to: setting speed, setting safe position, setting safe torque, setting stationary state data, and setting acceleration. This allows for the limitation of safe speed, safe position, safe torque, safe operation stop, and safe acceleration of the robot.

[0130] In this embodiment, the motion controller can acquire motor data sent by the servo driver to determine the robot's safety status. Specifically, the motor data can be compared with corresponding set values. If the motor data matches the set values, the robot's motion state is determined to be safe; if the motor data does not match the set values, the robot's motion state is determined to be abnormal, and a safety control command is sent to the servo driver. The servo driver controls the motors according to the safety control command to reduce the risk of the robot encountering danger.

[0131] In this embodiment, the servo driver may include a safety torque cutoff module, a first safety stop module, and a safety brake module. Step 403, determining that the robot's motion state is abnormal when the motor data does not match the set value, may include:

[0132] If the motor speed exceeds the set speed, a command to trigger the first safety stop module is sent to the servo driver;

[0133] If the safe position exceeds the set safe position, a command to trigger the first safe stop module to run is sent to the servo driver;

[0134] If the motor torque exceeds the set safe torque, a command is sent to the servo driver to trigger the safe torque cutoff module.

[0135] If the deviation between the robot's stationary state data and the set stationary state data exceeds a set threshold, a command to trigger the first safe stop module is sent to the servo driver.

[0136] If the motor's acceleration exceeds the set acceleration, the safety torque cutoff module is triggered and sent to the servo driver.

[0137] Specifically, servo drives typically control servo motors through position, speed, and torque to achieve high-precision positioning of the transmission system. Functions such as STO, SS1, and SBC can be directly integrated into the servo drive, allowing the servo drive to directly control the motor and implement safety functions.

[0138] The servo driver in this embodiment may include a safety torque cutoff module, a first safety stop module, and a safety brake module. The safety torque cutoff module includes an STO (Safe Torque Off) function, used to cut off the motor's torque output to stop the motor, thereby preventing torque generation when the motor stops and making the machine part of a safety system. The first safety stop module includes an SS1 (Safety Stop Initiation) function, where the axis is controlled to enter a stationary state, and then the motor power supply is safely interrupted, causing the motor to become torque-free. This is used to control the motor to decelerate and stop, and automatically initiates STO or SBC (Safety Stop and Brake) after a certain delay. The safety brake module includes an SBC function, providing a safety signal for controlling external and internal brakes. The servo driver controls the motor according to safety control commands sent by the motion controller to put the robot into the corresponding safety mode.

[0139] The motion controller is connected to the servo driver via a safety bus. The motion controller not only controls the robot's movement but also sends safety control commands to the servo driver in case of abnormal robot movement. This allows the servo driver to control the motors promptly, reducing the occurrence of safety accidents. In this embodiment, functions such as SS2, SLS, SLP, SLT, SLA, and SOS are abstracted into logic and embedded into the motion controller. During motor operation, the robot's movement state is monitored, and function-related signals and data are periodically fed back, ultimately controlled through the servo driver's built-in STO, SS1, and SBC functions.

[0140] The motion controller in this application embodiment may include a second safe stop module, a safe speed limit module, a safe position limit module, a safe torque limit module, a safe operation stop module, and a safe acceleration limit module.

[0141] The second safety stop module includes the SS2 function, in which the servo drive brakes to a stationary state and then remains in a controlled stop state. The servo drive maintains the control function, keeping the motion controller in a controlled stop state.

[0142] The safety speed limit module includes an SLS function. The user can pre-determine a set speed; if this speed is exceeded, a safety stop function is triggered, thereby activating the servo drive. For example, it can send a command to the servo drive to trigger the first safety stop module.

[0143] The safety position limiting module includes an SLP (Safe Position Limiting) function. If the safe position exceeds a set safe position, it activates the servo drive, for example, by sending a command to the servo drive to trigger the first safety stop module. During robot operation, the safety position limiting module monitors the robot's absolute position to prevent exceeding the set limits and avoid mechanical collisions.

[0144] The safety torque limiting module includes an SLT (Safe Torque Limiting) function. Motors typically can only withstand a maximum torque of three times the set safety torque; otherwise, they may be damaged due to overheating or overcurrent. Therefore, if the motor torque exceeds the set safety torque, the servo drive's response is activated. For example, a command to trigger the safety torque cutoff module is sent to the servo drive.

[0145] The safe operation stop module includes an SOS function, which activates the servo drive's response when the deviation between the robot's stationary state data and the set stationary state data exceeds a set threshold. For example, it sends a command to the servo drive to trigger the first safe stop module. The safe operation stop module monitors the motor's stationary state to ensure the motor is in a safe stop condition.

[0146] The safety acceleration limiting module includes an SLA function, which activates the servo drive's response when the motor's acceleration exceeds a set acceleration. For example, it sends a trigger to the safety torque cutoff module to the servo drive. The safety and speed limiting module monitors the motor's acceleration process to prevent exceeding the set acceleration value and avoids excessive current caused by mechanical collisions, which could damage the drive.

[0147] It should be noted that the servo driver and motion controller in this application embodiment are not limited to the modules described above. The servo driver and motion controller can be set according to actual needs. Furthermore, the method of sending safety commands in this application embodiment is not limited to the above scheme. Other safety control methods that can more efficiently control the robot can also be used.

[0148] In this embodiment of the application, step 302, sending a safety control command to the servo driver when the robot's motion state becomes abnormal, may include:

[0149] In the event of an abnormal movement state of the robot, the first and second safety control commands are acquired through dual channels.

[0150] Determine whether the first security control command and the second security control command match;

[0151] If the first and second safety control commands match, a safety control command is sent to the servo driver.

[0152] Specifically, the motion controller can verify the safety control commands before sending them. This embodiment uses a dual-channel monitoring mechanism to acquire two safety control commands: a first safety control command and a second safety control command. It determines whether the two commands match. If they match, the safety control command is sent to the servo driver. If they do not match, the safety control command is reacquired. This reduces the possibility of erroneous safety command transmission and improves the efficiency of robot safety control.

[0153] This application also provides a robot, including the safety control system described above.

[0154] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0155] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0156] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0157] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0158] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0159] Memory may include non-persistent memory in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0160] Computer-readable media includes both permanent and non-permanent, removable and non-removable media that can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient computer-readable media, such as modulated data signals and carrier waves.

[0161] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0162] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A safety control system for a robot, characterized in that, The safety control system includes: A servo driver, connected to the robot's motor, is configured to control the motor. The servo driver is also configured to acquire motor data sent by the motor at a preset period and send the motor data to a motion controller. A motion controller, connected to the servo driver via a safety bus, is configured to monitor the robot's motion state and send safety control commands to the servo driver when the robot's motion state becomes abnormal. The motion controller is also configured to: acquire motor data sent by the servo driver; compare the motor data with a set value; and determine that the robot's motion state is abnormal if the motor data does not match the set value. The motion controller is further configured to control the robot's motion. The servo driver includes: A safety torque cutoff module is configured to cut off the torque output of the motor to stop the motor; The first safety stop module is configured to control the motor to decelerate; The safety brake module is configured to control the motor to perform a braking action; The motion controller includes: The second safety parking module is configured to keep the motion controller in a controlled stop state; A safety speed limiting module is configured to send a command to the servo driver to trigger the first safety stop module to operate when the speed of the motor exceeds a set speed; The safe position limiting module is configured to send a command to the servo driver to trigger the first safe stop module to operate when the safe position exceeds a set safe position; A safety torque limiting module is configured to send a command to the servo driver to trigger the operation of the safety torque cut-off module when the torque of the motor exceeds a set safety torque. The safety operation stop module is configured to send a command to the servo driver to trigger the first safety stop module to run when the deviation between the robot's stationary state data and the set stationary state data is greater than a set threshold. The safety acceleration limiting module is configured to trigger the safety torque cutoff module to operate the servo drive when the acceleration of the motor exceeds a set acceleration.

2. The safety control system according to claim 1, characterized in that, The motion controller is also configured to: The first and second security control commands are acquired through dual channels. Determine whether the first security control command and the second security control command match; If the first security control command and the second security control command match, a security control command is sent to the servo driver.

3. The safety control system according to claim 1, characterized in that, The motor data includes at least one of the following: The speed of the motor, the position of the motor, the torque of the motor, the stationary state data of the motor, and the acceleration of the motor.

4. The safety control system according to claim 1, characterized in that, The safety bus is configured to interact with the motor data of the servo driver and the safety control commands of the motion controller.

5. A safety control method for a robot, characterized in that, A safety control system for a robot according to any one of claims 1 to 4, wherein the motion controller and the servo driver are connected via a safety bus, and the safety control method includes: To monitor the robot's motion status and control its motion; In the event of an abnormal movement state of the robot, a safety control command is sent to the servo driver.

6. The safety control method according to claim 5, characterized in that, The step of sending a safety control command to the servo driver when the robot's motion state becomes abnormal includes: In the event of an abnormal movement state of the robot, a first safety control command and a second safety control command are acquired through dual channels. Determine whether the first security control command and the second security control command match; If the first security control command and the second security control command match, a security control command is sent to the servo driver.

7. A robot, characterized in that, The safety control system for the robot includes any one of claims 1 to 4.

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