Track inspection robot safe operation control method and system, track robot

Abstract

The present disclosure relates to the technical field of track robots, and proposes a track inspection robot safe operation control method and system and a track robot. The control method comprises the following steps: obtaining a motor position conversion value and a motor real-time speed of the inspection robot; sampling and integrating the obtained speed to obtain a position operation value; fusing and comparing the motor position conversion value, the operation value obtained by integrating the speed, and a calculation value obtained by a rotary encoder to determine that the robot position has jumped; and correcting the position of the robot when it is determined that the jump has occurred. The robot movement can be monitored in real time, the position of the robot can be accurately identified, and the transmission mechanism and special section of the robot can be protected.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of track robots, in particular, to a track inspection robot safe operation control method and system and a track robot. BACKGROUND

[0002] The statements in this section merely provide background information related to the present disclosure and do not necessarily constitute the prior art.

[0003] The track inspection robot all paths and business processes are planned based on its own real-time position on the track, so accurate position detection is the premise of smooth operation of various businesses, and is crucial to the safe operation of the track inspection robot.

[0004] The inventor found in the research that the existing position detection method mainly obtains the absolute position value of the motor from the servo motor through CAN communication, and then obtains the real-time position of the track robot on the track through conversion. In actual operation conditions, the robot position calculation may be wrong due to various external factors such as electromagnetic interference, circuit failure, servo system failure, etc., so that the position data of the track inspection robot is inaccurate, the navigation position of the track robot is inaccurate, and the track robot cannot correctly perform the inspection task. The existing robot does not have a protection method for hardware damage failure of itself. Due to inaccurate position positioning, problems such as collision with the detected equipment often occur. SUMMARY

[0005] In order to solve the above problems, the present disclosure provides a track inspection robot safe operation control method and system and a track robot, which can realize real-time monitoring of robot motion, accurately identify and correct the position of the robot, and protect the transmission mechanism and special interval of the robot.

[0006] In order to achieve the above purpose, the present disclosure adopts the following technical solutions:

[0007] One or more embodiments provide a track inspection robot safe operation control method, including the following steps:

[0008] Obtain the motor position conversion value and the real-time speed of the inspection robot;

[0009] Sample and integrate the obtained speed to obtain the operation value of the position;

[0010] Fuse and compare the motor position conversion value, the operation value obtained by integrating the speed, and the calculation value obtained by the rotary encoder to determine whether the position of the robot jumps;

[0011] When it is determined that the jump occurs, correct the position of the robot.

[0012] One or more embodiments provide a rail inspection robot safe operation control system, including:

[0013] An acquisition module is configured to obtain a motor position conversion value and a motor real-time speed of the inspection robot;

[0014] A calculation module is configured to sample and integrate the acquired velocity to obtain a calculated value of the position;

[0015] The jump judgment module is configured to fuse and compare the motor position conversion value, the operation value obtained by the speed integral, and the calculation value obtained by the set rotary encoder to determine whether the robot position has jumped;

[0016] The correction module is configured to correct the position of the robot when a jump is determined to have occurred.

[0017] An electronic device includes a memory and a processor, and computer instructions stored in the memory and executed on the processor. When the computer instructions are executed by the processor, the steps of the above method are completed.

[0018] A computer-readable storage medium is used to store computer instructions, and when the computer instructions are executed by a processor, the steps of the above method are completed.

[0019] A rail robot executes the steps of the above-mentioned rail inspection robot safe operation control method.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] In the present disclosure, the real-time speed of the motor is read at the same time as the motor position, and a set of rotary encoders are added to the motor shaft for backup and comparison. By integrating the data obtained by multiple acquisition mechanisms, the position of the robot is confirmed multiple times, so that it can be confirmed whether the motor position conversion value read through communication is accurate, thereby providing accurate position information for path planning and business execution.

[0022] The advantages of the present disclosure and additional advantages will be described in detail in the following specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings, which constitute a part of the present disclosure, are used to provide a further understanding of the present disclosure. The exemplary embodiments of the present disclosure and their descriptions are used to explain the present disclosure but do not constitute a limitation of the present disclosure.

[0024] Figure 1 is a flow chart of a real-time position detection method in the control method of embodiment 1 of the present disclosure;

[0025] Figure 2 is a flow chart of the transmission mechanism protection method in the control method of Example 1 of the present disclosure;

[0026] Figure 3 This is a flow chart of the interval protection method in the control method of Example 1 of the present disclosure. DETAILED DESCRIPTION

[0027] The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

[0028] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of the present disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present disclosure belongs.

[0029] It should be noted that the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit the exemplary embodiments according to the present disclosure. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof. It should be noted that, in the absence of conflict, the various embodiments in the present disclosure and the features in the embodiments can be combined with each other. The embodiments will be described in detail below with reference to the accompanying drawings.

[0030] Example 1

[0031] In the technical solutions disclosed in one or more embodiments, Figure 1-Figure 3 As shown, the safe operation control method of the rail inspection robot includes a real-time position detection method, a transmission mechanism protection method and an interval protection method. The real-time position detection method includes the following steps:

[0032] Step 1: Obtain the motor position conversion value and real-time motor speed of the inspection robot;

[0033] Step 2: Sample and integrate the acquired velocity to obtain the calculated value of the position;

[0034] Step 3: The motor position conversion value, the speed integral calculation value, and the calculated value obtained by the set rotary encoder are integrated and compared to determine whether the robot position has jumped;

[0035] Step 4: When a jump occurs, the position of the robot is corrected.

[0036] In this embodiment, the real-time speed of the motor is read at the same time as the motor position, and a set of rotary encoders are added to the motor shaft for backup and comparison. By integrating the data obtained by multiple acquisition mechanisms, the position of the robot is confirmed multiple times, so that it can be confirmed whether the motor position conversion value read through communication is accurate, thereby providing accurate position information for path planning and business execution.

[0037] In step 3, the method for determining whether a jump occurs can be:

[0038] Step 31: Compare the position conversion value with the calculated value obtained by integrating the velocity. If the difference between the two exceeds a set first threshold, it is determined that there is a risk of a jump;

[0039] Step 32: Compare the read position conversion value with the position calculation value of the encoder set on the motor shaft. If the difference exceeds a set second threshold, it is determined that the robot position has jumped.

[0040] In this embodiment, the position conversion value read by communication is compared with the calculated value obtained by integrating the speed. If the difference between the two exceeds the set threshold, it is considered that the robot may be at risk of position jump. It is necessary to further compare the position conversion value read by communication with the position calculation value of the backup encoder to determine whether the position jumps or not, thereby improving the accuracy of position jump judgment.

[0041] In some embodiments, the calculation value obtained by speed integration can be obtained by sampling the motor speed at a set frequency, storing the sampled value in a corresponding memory, and then performing an integration operation on the speed sampled value a set number of times per second to obtain the calculation value of the position.

[0042] The speed sampling frequency can be set to 10 Hz, and the number of times per second can be set to 10.

[0043] In some embodiments, if the position of the track inspection robot jumps after the above logic judgment, the method for correcting the robot's position can optionally replace the motor position conversion value read by the robot communication with the encoder's position mileage, that is, the absolute position of the motor, which serves as the basis for program path planning and business execution;

[0044] In other embodiments, the position calibration can be performed by setting the RFID tag at intervals. The robot reads the information of the RFID tag, which stores the position information of the tag setting, and updates the motor position conversion value according to the position of the RFID tag.

[0045] Due to wear and aging during operation, there is a risk of belt tearing or motor shaft breaking during robot operation or climbing. If the belt breaks or the motor shaft breaks during the robot climbing, it will cause the robot to stall or slip, resulting in serious safety consequences. Therefore, the robot system needs to detect the transmission fault in time and apply the brakes immediately.

[0046] This embodiment proposes a transmission mechanism protection method. Specifically: based on the accurate position of the robot, the motor safety current value range corresponding to each position is determined, and the real-time current Ia of the robot motor is obtained. When the actual real-time current Ia exceeds the motor safety current value range, the transmission mechanism protection scheme is activated.

[0047] Optionally, the safe current value range of the motor is determined based on each position and robot parameters. The motor running current I can be calculated by obtaining the acceleration, the tilt angle and friction coefficient of the position, and the mass of the robot, and the safety factor Q is set. The safe current value range of the motor is the product of the motor running current I and the safety factor Q.

[0048] Specifically, the tilt angle of the position can be determined according to the position obtained by the real-time position detection method and the robot posture obtained by the robot equipment self-detection.

[0049] Specifically, taking the robot on a slope as an example, the calculation process is as follows:

[0050] The component of gravity when the robot is on the slope: mgsinθ;

[0051] The robot drive system provides the robot with acceleration: ma;

[0052] Robot transmission and motion friction loss f = μN = μmg;

[0053] Among them, μ is the comprehensive loss coefficient, m is the mass of the robot, θ is the slope, and a is the acceleration of the robot.

[0054] Driving force: F = mgsinθ + ma + μmg

[0055] θ can be used to obtain the robot's posture in real time through the ZYZ inertial navigation module equipped on the robot;

[0056] In this way, the driving force of the robot can be calculated. For example, the robot wheel radius is 35mm, the transmission ratio is 2.5, m is 40KG, and μ is 0.22. The torque of the drive motor can be calculated. The relationship between motor torque and motor current is as follows:

[0057] P=Tn / [(60 / 2π)*1000]=UI / 1000

[0058] Where P is the motor power (kW), T is the motor torque (Nm), U is the motor voltage (v), I is the motor current (A), and n is the motor speed (rpm).

[0059] Through the above calculations, the relationship between the current I and torque of the motor can be obtained.

[0060] Optionally, the empirical safety factor Q can be set to: (*0.7 <Q<1.25*)。

[0061] In some embodiments, the transmission mechanism protection scheme can immediately control the brake and report the fault to the robot background.

[0062] Furthermore, the interval protection method is as follows:

[0063] According to the identified position of the robot, multiple partition intervals are set in sequence from far to near according to the distance from the inspected equipment or on-site equipment; in each interval from far to near, the robot sequentially performs the steps of parking confirmation, low-speed passing, communication data collection, detection of the status of the inspected equipment, and troubleshooting of the inspected equipment.

[0064] Specifically, the inspected equipment or on-site equipment corresponding to the interval protection method includes fire doors, track changes, and smart charging stations.

[0065] In a specific embodiment, a parking confirmation interval, a low-speed passing interval, and a real-time confirmation and control interval can be set.

[0066] Specifically, in the parking confirmation section, the robot stops moving, establishes communication with the inspected equipment, and determines the status of the inspected equipment.

[0067] When the robot moves toward the equipment, if it reaches the edge of the stop confirmation zone, the robot automatically stops and communicates with the on-site equipment through a redundant network. For example, the redundant network can include a dual-channel redundant network of WiFi and Zigbee. After confirming that the on-site equipment is in a normal state and allows passage, the robot is started at the set speed and enters the low-speed passing zone.

[0068] Specifically, in the low-speed passing section, the robot is controlled to travel at a low speed lower than the set speed, so that the robot can reduce the risk of colliding with the inspected equipment and the degree of damage after the collision;

[0069] In this embodiment, a low-speed passing section is set. Within the low-speed passing section, the robot runs at a set speed. This can prevent network delays and other failures from causing state misjudgment, and minimize the risk of collision and the degree of damage after the collision while taking into account timeliness.

[0070] Specifically, in the real-time confirmation and control section, the robot is controlled to obtain the status of the inspected equipment and diagnose the network link.

[0071] Furthermore, in the real-time confirmation and control section, it also includes identifying communication anomalies between the robot and the inspected equipment, and identifying status anomalies of the inspected equipment.

[0072] Furthermore, in the real-time confirmation and control section, when communication anomalies and abnormal status of the inspected equipment are identified, the robot repairs the network connection and controls the corresponding equipment to return to normal status.

[0073] For example, when passing through a fire door, if the collected information about the fire door is closed, the robot will stop and issue an opening command to the fire door, controlling the fire door to open until the robot safely passes through the protection zone and then controls it to close.

[0074] Optionally, the setting data for the safety interval can be as follows:

[0075] Fire doors of on-site equipment:

[0076] Parking confirmation area: 2.2 meters before and after the door;

[0077] Low-speed passing area: 1.8 meters before and after the door. In this area, the robot turns off the ultrasonic radars on both sides of the image below and only turns on the two in the middle to prevent false detection. The detection width is greater than the width of the robot body.

[0078] Real-time confirmation and control range: 1.5 meters before and after the door;

[0079] Track changing device for on-site equipment:

[0080] Stop confirmation zone: 2.0 meters before and after the track change point;

[0081] Low-speed passing section: 1.5 meters before and after the track change point;

[0082] Real-time confirmation and control area: 1.0m before and after the track change point;

[0083] The data settings of the intelligent charging station of the on-site equipment can be the same as those of the track changing device. The settings of the above interval positions can be set and adjusted according to the actual working conditions on site.

[0084] Example 2

[0085] Based on Example 1, this embodiment provides a rail inspection robot safe operation control system, including:

[0086] An acquisition module is configured to obtain a motor position conversion value and a motor real-time speed of the inspection robot;

[0087] The computing module is configured to sample and integrate the obtained speed to obtain a calculated value of position.

[0088] The jump judging module is configured to fuse and compare the motor position conversion value, the calculated value obtained by integrating the speed, and the calculated value obtained by the rotary encoder to determine whether the robot position jumps.

[0089] The correction module is configured to correct the position of the robot when it is determined that the jump occurs.

[0090] It should be noted that each module in the embodiment corresponds to each step in Embodiment 1 one by one, and the specific implementation process is the same, which will not be repeated here.

[0091] Embodiment 3

[0092] The embodiment provides an electronic device, which comprises a memory and a processor, and computer instructions stored in the memory and running on the processor, when the computer instructions are run by the processor, the steps of the method of Embodiment 1 are completed.

[0093] Embodiment 4

[0094] The embodiment provides a computer readable storage medium for storing computer instructions, when the computer instructions are executed by the processor, the steps of the method of Embodiment 1 are completed.

[0095] Embodiment 5

[0096] The embodiment provides a track robot, which executes the steps of the method of Embodiment 1.

[0097] The above only describes the preferred embodiments of the present disclosure and is not intended to limit the present disclosure. Those skilled in the art can make various modifications and changes to the present disclosure. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present disclosure shall be included in the protection scope of the present disclosure.

[0098] The above describes the specific embodiments of the present disclosure in conjunction with the accompanying drawings, but is not a limitation on the protection scope of the present disclosure. Those skilled in the art should understand that various modifications or changes made on the basis of the technical solutions of the present disclosure without creative labor are still within the protection scope of the present disclosure.

Claims

1. A method for controlling safe operation of a track inspection robot, characterized in that: The steps include: Obtain the motor position conversion value and real-time motor speed of the inspection robot; The acquired velocity is sampled and integrated to obtain the calculated value of the position; The robot position jump is determined by integrating and comparing the motor position conversion value, the calculated value obtained by speed integration, and the calculated value obtained by the set rotary encoder; When a jump occurs, the robot's position is corrected; Methods for determining when a jump occurs include the following: Compare the position conversion value with the calculated value obtained by integrating the velocity. If the difference between the two exceeds a set first threshold, it is determined that there is a risk of a jump; The read position conversion value is compared with the position calculation value of the encoder set on the motor shaft. If the difference exceeds a set second threshold, it is determined that the robot position has jumped.

2. The rail inspection robot safe operation control method according to claim 1, characterized in that: The calculated value obtained by integrating the speed: the motor speed is sampled at a set frequency, and the speed sampling value is integrated for the set number of times per second to obtain the calculated value of the position; Alternatively, a correction method may be performed by replacing the motor position conversion value read by the robot communication with the encoder position mileage; Alternatively, the correction method is to set the RFID tag at intervals for position calibration, the robot reads the information of the RFID tag, the RFID tag stores the position information of the tag setting, and updates the motor position conversion value according to the position of the RFID tag.

3. The method for controlling safe operation of a rail inspection robot according to claim 1, wherein: Based on the accurate position of the robot, the safe current value range of the motor at each position is determined, and the real-time current of the robot motor is obtained. When the actual real-time current exceeds the safe current value range of the motor, the transmission mechanism protection scheme is activated.

4. The rail inspection robot safe operation control method according to claim 1, characterized in that: It also includes a method for setting interval protection: according to the identified position of the robot, multiple partition intervals are set in sequence from far to near according to the distance from the inspected equipment or on-site equipment; in each interval from far to near, the robot sequentially performs the steps of parking confirmation, low-speed passing, communication data collection, detection of the status of the inspected equipment, and troubleshooting of the inspected equipment.

5. The rail inspection robot safe operation control method according to claim 4, characterized in that: Set parking confirmation interval, low-speed passing interval, real-time confirmation and control interval; In the parking confirmation section, the robot stops moving, establishes communication with the inspected equipment, and determines the status of the inspected equipment; In the low-speed passing section, the robot is controlled to travel at a speed lower than the set speed; In the real-time confirmation and control interval, the robot is controlled to obtain the status of the inspected equipment and diagnose the network link; or / and, the robot is identified to have communication anomalies with the inspected equipment, and to have status anomalies of the inspected equipment; or / and, the robot repairs the network connection and controls the corresponding equipment to return to normal status.

6. The track inspection robot safe operation control system is characterized by: include: An acquisition module is configured to obtain a motor position conversion value and a motor real-time speed of the inspection robot; A calculation module is configured to sample and integrate the acquired velocity to obtain a calculated value of the position; The jump judgment module is configured to fuse and compare the motor position conversion value, the operation value obtained by the speed integral, and the calculation value obtained by the set rotary encoder to determine whether the robot position has jumped; A correction module is configured to correct the position of the robot when a jump is determined; Methods for determining when a jump occurs include the following: Compare the position conversion value with the calculated value obtained by integrating the velocity. If the difference between the two exceeds a set first threshold, it is determined that there is a risk of a jump; The read position conversion value is compared with the position calculation value of the encoder set on the motor shaft. If the difference exceeds a set second threshold, it is determined that the robot position has jumped.

7. An electronic device, characterized in that: The method comprises a memory and a processor, and computer instructions stored in the memory and executed on the processor, wherein when the computer instructions are executed by the processor, the steps of any one of the methods of claims 1 to 5 are completed.

8. A computer-readable storage medium, characterized in that Used to store computer instructions, which, when executed by a processor, complete the steps of any one of the methods of claims 1 to 5.

9. A rail robot, characterized in that: The rail robot executes the steps of the rail inspection robot safe operation control method according to any one of claims 1 to 5.

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