Aging test manipulator motion control method and system

Abstract

The present invention relates to the technical field of photovoltaic inverters, and more specifically, to a motion control method and system for an aging test manipulator. The scheme includes capturing the state of the manipulator in real time; adding a safety controller and an emergency stop mechanism to the control system of the aging test manipulator; designing a manipulator control function block; using a preset modern industrial communication protocol to exchange real-time data between the manipulator control system and other production equipment; setting up an intelligent fault diagnosis system to perform controllable motion transmission on the fixture through the coordinated motion of the z-axis; and encapsulating each function into a function block online, wherein the function block is used to perform real-time detection of online X and Z axis motion. The scheme ensures the accuracy and stability of the manipulator during the handling and positioning process by setting an aging control method for the manipulator, and significantly reduces the risk of product damage or test failure caused by inaccurate manipulator motion.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic inverters, and more specifically, to a motion control method and system for an aging test manipulator. Background Art

[0002] In the new energy industry, aging tests of photovoltaic inverters, energy storage inverters, energy storage batteries, and traditional chargers are important links to ensure the reliability and stability of these key devices. The use of advanced aging test manipulator motion control technology can simulate and reproduce the wear and aging process of the product in actual operation, so as to evaluate its performance and life. This control method combines high-precision motion planning, real-time monitoring and safety protection mechanisms to optimize the test process, reduce human errors and improve test efficiency. It is not only of great significance to improve product quality, reduce maintenance costs and prevent failures, but also a key factor in promoting continuous innovation and technological progress in the new energy industry. By accurately simulating and accelerating the aging process, the aging test manipulator can discover potential defects in the product development stage and help manufacturers improve product design, thereby protecting the interests of end users and promoting the widespread application and sustainable development of new energy technologies.

[0003] Prior to the present invention, the existing aging test manipulator motion control method mainly relied on traditional PLC (programmable logic controller) and ladder diagram programming, combined with basic sensor information to perform simple positioning and handling operations. The technical difficulties and key points include: ensuring that the manipulator can accurately repeat the handling action during long-term operation to avoid error accumulation caused by mechanical wear or electrical problems, which is crucial to ensure the consistency of the test. When the manipulator is carrying and placing aging test products, it is necessary to ensure the safety of the operation, not only to protect the equipment being tested, but also to consider the safety of the surrounding environment and operators. During the aging test process, it may be necessary to test products of different models and sizes, and the control system must have the ability to quickly adjust and adapt to new products. System integration and communication: The aging test manipulator needs to work with other equipment on the production line to achieve data exchange and synchronous operation, which requires the motion control system to have efficient communication capabilities and good integration. Summary of the invention

[0004] In view of the above problems, the present invention proposes an aging test robot motion control method and system. By setting the aging control method of the robot, the accuracy and stability of the robot during the handling and positioning process are ensured, and the risk of product damage or test failure caused by inaccurate movement of the robot is significantly reduced.

[0005] According to a first aspect of an embodiment of the present invention, a motion control method for a aging test manipulator is provided.

[0006] In one or more embodiments, preferably, the aging test manipulator motion control method includes:

[0007] Set high-precision position, speed and torque sensors on the aging test manipulator to capture the state of the manipulator in real time;

[0008] Add safety controller and emergency stop mechanism to the control system of the aging test manipulator;

[0009] Design the manipulator control function block and select different test manipulator control function blocks according to different product models and test requirements;

[0010] Real-time data exchange between robot control system and other production equipment using preset modern industrial communication protocols;

[0011] Set up an intelligent fault diagnosis system to perform controllable motion transportation on the fixture through the coordinated motion of the z-axis;

[0012] Each function is encapsulated into a function block online, wherein the function block is used to perform real-time detection of online X and Z axis motion.

[0013] In one or more embodiments, preferably, the aging test manipulator is provided with high-precision position, speed and torque sensors to capture the state of the manipulator in real time, specifically including:

[0014] Set the operating position of the aging test manipulator to implement the detection equipment;

[0015] Set up speed monitoring equipment for the aging test manipulator;

[0016] An image acquisition device is set up in the area where the aging test manipulator is located;

[0017] A torque sensor is set on the aging test manipulator to collect torques in different directions in real time.

[0018] In one or more embodiments, preferably, adding a safety controller and an emergency stop mechanism to the control system of the aging test manipulator specifically includes:

[0019] Set up a safety controller connected in parallel with the main control system of the manipulator;

[0020] The safety controller receives sensor data from the manipulator and has independent processing capabilities for real-time monitoring of the manipulator's operating status;

[0021] When the safety controller detects that the operation of the manipulator exceeds the preset safety parameters and thresholds, the safety controller automatically sends a warning signal to the main control system of the manipulator;

[0022] Set up an emergency stop mechanism, which is triggered by the safety controller;

[0023] The emergency stop mechanism includes hardware and software components. The hardware component is the emergency brake connected to each joint of the manipulator, and the software component is the stop command algorithm embedded in the safety controller.

[0024] When the warning signal from the safety controller reaches the predetermined emergency level, the emergency stop mechanism is immediately activated, stopping the command algorithm calculation and sending an immediate stop signal to each brake of the manipulator;

[0025] After receiving the stop signal, the brake of the hardware component quickly locks the joints of the robot to prevent safety hazards caused by the movement of the robot.

[0026] In one or more embodiments, preferably, the design of the manipulator control function block selects different test manipulator control function blocks according to different product models and test requirements, specifically including:

[0027] Multiple control function blocks, each designed to perform a specific test task;

[0028] The control function block includes program codes and parameter sets for different product models and test requirements;

[0029] A function block selector allows the user to select one or more function blocks from multiple control function blocks based on the product model currently being tested and the test requirements.

[0030] The function block selector automatically selects and loads the corresponding control function block according to the information input by the user through the configuration interface.

[0031] In one or more embodiments, preferably, the real-time data exchange between the robot control system and other production equipment using a preset modern industrial communication protocol specifically includes:

[0032] A communication interface is set up to be compatible with the communication interfaces of other production equipment in the production line to realize data exchange;

[0033] A data formatting module is provided to convert the internal data of the robot control system into data conforming to the format of modern industrial communication protocols;

[0034] A data synchronization mechanism that ensures that data exchange between the robot control system and other equipment in the production line is real-time and maintains data consistency.

[0035] In one or more embodiments, preferably, the intelligent fault diagnosis system is provided to perform controllable motion transmission on the fixture through the coordinated motion of the z-axis, specifically including:

[0036] Set up an intelligent fault diagnosis process. When it is detected that the distance between two adjacent manipulators is less than the preset range, the z-axis coordinated movement is started;

[0037] After starting the coordinated movement of the z-axis, all movements of the two adjacent devices in the z-axis direction remain synchronized, and after waiting to be judged to be normal, normal movement is resumed, wherein the judgment is a pre-set judgment logic and is automatically determined through video.

[0038] In one or more embodiments, preferably, the online encapsulation of each function into a function block, wherein the function block is used to perform real-time detection of online X-axis and Z-axis motion, specifically including:

[0039] Capture the position P, velocity V and torque J of the manipulator in real time;

[0040] Calculate the x-axis distance and the z-axis distance using the first calculation formula according to the current motion speed and the position of the manipulator;

[0041] If the x-axis distance and the z-axis distance do not satisfy the second calculation formula, it is considered that there is a collision risk, otherwise no processing is performed;

[0042] For the time period when there is a risk of collision, the torque in the corresponding moving direction is adjusted to satisfy the third calculation formula;

[0043] Visualize the functional block encapsulation of all functions for modular drag-and-drop programming during the programming process;

[0044] The first calculation formula is:

[0045] Wz=Pz+TT×Vz

[0046] Wx=Px+TT×Vx

[0047] Wherein, Pz is the real-time projection position of the z-axis, Px is the real-time projection position of the x-axis, TT is the preset time interval, Wz is the z-axis distance, Wx is the x-axis distance, Vz is the z-axis moving speed of the manipulator, and Vx is the x-axis moving speed of the manipulator;

[0048] The second calculation formula is:

[0049] Wz∈[LZ1,LZ2]

[0050] Wx∈[LX1,LX2]

[0051] Among them, LZ1 and LZ2 are the lower and upper limits of the manipulator's motion in the z-axis, and LX1 and LX2 are the lower and upper limits of the manipulator's motion in the x-axis;

[0052] The third calculation formula is:

[0053] YL∈FL

[0054] Among them, YL is the torque in the moving direction, and FL is the torque range without collision damage.

[0055] According to a second aspect of an embodiment of the present invention, a aging test manipulator motion control system is provided.

[0056] In one or more embodiments, preferably, the aging test manipulator motion control system includes:

[0057] The sensor acquisition module is used to set high-precision position, speed and torque sensors for the aging test manipulator to capture the state of the manipulator in real time;

[0058] Emergency control module, used to add safety controller and emergency stop mechanism to the control system of the aging test manipulator;

[0059] Mode selection module, used to design manipulator control function blocks and select different test manipulator control function blocks according to different product models and test requirements;

[0060] Communication setting module, used for real-time data exchange between robot control system and other production equipment using preset modern industrial communication protocols;

[0061] Interactive restriction module, used to set up intelligent fault diagnosis system, and perform controlled motion delivery of fixtures through coordinated motion of z-axis;

[0062] The encapsulation control module is used to encapsulate each function into a functional block online, wherein the functional block is used to perform real-time detection of online X and Z axis motion.

[0063] According to a third aspect of an embodiment of the present invention, there is provided a computer-readable storage medium on which computer program instructions are stored. When the computer program instructions are executed by a processor, the method as described in any one of the first aspect of the embodiment of the present invention is implemented.

[0064] According to a fourth aspect of an embodiment of the present invention, there is provided an electronic device, comprising a memory and a processor, wherein the memory is used to store one or more computer program instructions, wherein the one or more computer program instructions are executed by the processor to implement any one of the methods described in the first aspect of the embodiment of the present invention.

[0065] The technical solution provided by the embodiments of the present invention may have the following beneficial effects:

[0066] In the solution of the present invention, prevention of failures and accidents is achieved by integrating emergency control and safety control.

[0067] In the solution of the present invention, modular design is combined with communication optimization to reduce the risk of failure.

[0068] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description, claims, and drawings.

[0069] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0071] Figure 1 The present invention is a flowchart of a motion control method for an aging test manipulator according to an embodiment of the present invention.

[0072] Figure 2 The present invention is a flowchart of a aging test manipulator motion control method in which high-precision position, speed and torque sensors are set for the aging test manipulator to capture the state of the manipulator in real time.

[0073] Figure 3 The present invention is a flowchart of adding a safety controller and an emergency stop mechanism to a control system of an aging test manipulator in a aging test manipulator motion control method according to an embodiment of the present invention.

[0074] Figure 4 The present invention discloses a flowchart of designing a manipulator control function block in a aging test manipulator motion control method according to an embodiment of the present invention, and selecting different test manipulator control function blocks according to different product models and test requirements.

[0075] Figure 5 The present invention is a flowchart of real-time data exchange between a robot control system and other production equipment using a preset modern industrial communication protocol in a aging test robot motion control method according to an embodiment of the present invention.

[0076] Figure 6 The present invention is a flowchart of an embodiment of an aging test robot motion control method in which an intelligent fault diagnosis system is set up to perform controllable motion transportation on a fixture through mutually coordinated motion of the z-axis.

[0077] Figure 7 The present invention is a flowchart of online encapsulation of each function in a aging test robot motion control method according to an embodiment of the present invention, wherein the function block is used to perform online real-time detection of X-axis and Z-axis motion.

[0078] Figure 8 It is a structural diagram of a motion control system of an aging test manipulator according to an embodiment of the present invention.

[0079] Fig. 9 It is a structural diagram of an electronic device in one embodiment of the present invention. DETAILED DESCRIPTION

[0080] In some of the processes described in the specification and claims of the present invention and the above-mentioned figures, multiple operations that appear in a specific order are included, but it should be clearly understood that these operations may not be executed in the order in which they appear in this article or executed in parallel. The serial numbers of the operations, such as 101, 102, etc., are only used to distinguish different operations, and the serial numbers themselves do not represent any execution order. In addition, these processes may include more or fewer operations, and these operations may be executed in sequence or in parallel. It should be noted that the descriptions of "first", "second", etc. in this article are used to distinguish different messages, devices, modules, etc., do not represent the order of precedence, and do not limit the "first" and "second" to be different types.

[0081] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0082] In the new energy industry, aging tests of photovoltaic inverters, energy storage inverters, energy storage batteries, and traditional chargers are important links to ensure the reliability and stability of these key devices. The use of advanced aging test manipulator motion control technology can simulate and reproduce the wear and aging process of the product in actual operation, so as to evaluate its performance and life. This control method combines high-precision motion planning, real-time monitoring and safety protection mechanisms to optimize the test process, reduce human errors and improve test efficiency. It is not only of great significance to improve product quality, reduce maintenance costs and prevent failures, but also a key factor in promoting continuous innovation and technological progress in the new energy industry. By accurately simulating and accelerating the aging process, the aging test manipulator can discover potential defects in the product development stage and help manufacturers improve product design, thereby protecting the interests of end users and promoting the widespread application and sustainable development of new energy technologies.

[0083] Prior to the present invention, the existing aging test manipulator motion control method mainly relied on traditional PLC (programmable logic controller) and ladder diagram programming, combined with basic sensor information to perform simple positioning and handling operations. The technical difficulties and key points include: Accuracy and stability: ensuring that the manipulator can accurately repeat the handling action during long-term operation to avoid error accumulation caused by mechanical wear or electrical problems, which is crucial to ensure the consistency of the test. Safety: When the manipulator is carrying and placing the aging test product, it is necessary to ensure the safety of the operation, not only to protect the equipment being tested, but also to consider the safety of the surrounding environment and the operator. Flexibility and adaptability: During the aging test, it may be necessary to test products of different models and sizes, and the control system must have the ability to quickly adjust and adapt to new products. System integration and communication: The aging test manipulator needs to work with other equipment on the production line to achieve data exchange and synchronous operation, which requires the motion control system to have efficient communication capabilities and good integration.

[0084] In an embodiment of the present invention, a motion control method and system for an aging test manipulator are provided. The solution ensures the accuracy and stability of the manipulator during handling and positioning by setting an aging control method for the manipulator, significantly reducing the risk of product damage or test failure caused by inaccurate manipulator movement.

[0085] According to a first aspect of an embodiment of the present invention, a motion control method for a aging test manipulator is provided.

[0086] Figure 1 The present invention is a flowchart of a motion control method for an aging test manipulator according to an embodiment of the present invention.

[0087] In one or more embodiments, preferably, the aging test manipulator motion control method includes:

[0088] S101, setting high-precision position, speed and torque sensors for the aging test manipulator to capture the state of the manipulator in real time;

[0089] S102. Add a safety controller and an emergency stop mechanism to the control system of the aging test manipulator;

[0090] S103, designing a manipulator control function block, and selecting different test manipulator control function blocks according to different product models and test requirements;

[0091] S104, using a preset modern industrial communication protocol to exchange real-time data between the robot control system and other production equipment;

[0092] S105, setting up an intelligent fault diagnosis system to perform controllable motion transport on the fixture through the coordinated motion of the z-axis;

[0093] S106 , encapsulating each function into a function block online, wherein the function block is used to perform real-time detection of online X-axis and Z-axis motion.

[0094] In an embodiment of the present invention, efficient and reliable aging testing is achieved through information collection of the aging manipulator combined with emergency control and orientation analysis. By setting an aging control method for the manipulator, the accuracy and stability of the manipulator during the handling and positioning process are ensured, thereby significantly reducing the risk of product damage or test failure due to inaccurate movement of the manipulator.

[0095] Figure 2 The present invention is a flowchart of a aging test manipulator motion control method in which high-precision position, speed and torque sensors are set for the aging test manipulator to capture the state of the manipulator in real time.

[0096] like Figure 2 As shown, in one or more embodiments, preferably, the aging test manipulator is provided with high-precision position, speed and torque sensors to capture the state of the manipulator in real time, specifically including:

[0097] S201, setting the operating position of the aging test manipulator to implement the detection equipment;

[0098] S202, setting a speed monitoring device for the aging test manipulator;

[0099] S203, setting an image acquisition device in the area where the aging test manipulator is located;

[0100] S204, setting a torque sensor on the aging test manipulator to collect torques in different directions in real time.

[0101] In an embodiment of the present invention, real-time monitoring of the state of the manipulator is achieved by integrating high-precision position, speed and torque sensors. First, high-precision encoders are equipped at each joint of the manipulator, which can detect and feedback the real-time position data of each joint of the manipulator, allowing the control system to perform precise position control. For example, when the manipulator needs to move the photovoltaic module from one end of the production line to the test station, these encoders ensure that the movement accuracy of the manipulator is within ±0.1 mm. Further, a speed monitoring device is deployed, which uses a laser Doppler vibrometer (LDV) to measure the speed change during the movement of the manipulator in a non-contact manner. This device can monitor the speed of the manipulator in real time when it performs a fast handling action, ensuring that the speed is controlled within the ±1% error range of the preset value, thereby avoiding the reduction of test accuracy or equipment damage caused by too fast or too slow speed. In order to achieve comprehensive monitoring of the manipulator operation area, high-resolution cameras are installed in the working area of ​​the manipulator as image acquisition devices. These cameras can capture the interaction process between the manipulator and the tested component, and analyze possible abnormal situations such as component position offset or accidental approach of the manipulator to the test instrument through image processing algorithms. Real-time processing of image data provides an additional layer of safety protection for the system and instantly alerts the control system when anomalies are detected. Finally, torque sensors are installed at key parts of the manipulator. These sensors are based on strain gauge technology and can detect and feedback the magnitude and direction of the torque applied to the manipulator in real time. For example, when the manipulator grabs a 5kg inverter, the torque sensor ensures that the manipulator's grip is moderate, neither too much to damage the inverter nor too little to cause the inverter to slip. The data from the torque sensor enables the control system to adjust the manipulator's grip to adapt to test objects of different weights and shapes. Through the integration and coordination of the above equipment, the aging test manipulator control system can achieve high-precision control and monitoring of the manipulator's position, speed and torque, improving the accuracy and safety of the test process while reducing the risk of operational errors.

[0102] Figure 3 The present invention is a flowchart of adding a safety controller and an emergency stop mechanism to a control system of an aging test manipulator in a aging test manipulator motion control method according to an embodiment of the present invention.

[0103] like Figure 3 As shown, in one or more embodiments, preferably, adding a safety controller and an emergency stop mechanism to the control system of the aging test manipulator specifically includes:

[0104] S301, setting a safety controller to be connected in parallel with the main control system of the manipulator;

[0105] S302, the safety controller receives sensor data from the manipulator and has independent processing capabilities for real-time monitoring of the operating status of the manipulator;

[0106] S303, when the safety controller detects that the operation of the manipulator exceeds the preset safety parameters and thresholds, the safety controller automatically sends a warning signal to the main control system of the manipulator;

[0107] S304, setting an emergency stop mechanism, which is triggered by the safety controller;

[0108] S305, the emergency stop mechanism includes hardware and software components, the hardware component is the emergency brake connected to each joint of the manipulator, and the software component is the stop command algorithm embedded in the safety controller;

[0109] S306, when the warning signal sent by the safety controller reaches a predetermined emergency level, the emergency stop mechanism is immediately activated, the command algorithm calculation is stopped and an immediate stop signal is sent to each brake of the manipulator;

[0110] S307. After receiving the stop signal, the brake of the hardware component quickly locks the joints of the manipulator to prevent safety hazards caused by the movement of the manipulator.

[0111] In an embodiment of the present invention, a safety controller is connected in parallel to the control system, which runs independently of the main control system and is specifically responsible for monitoring the operating status of the manipulator. The safety controller receives data from sensors installed at key parts of the manipulator in real time. These sensors can capture the real-time dynamics of the manipulator, such as displacement, speed, and torque, to ensure that the safety controller can make judgments based on comprehensive and accurate data. For example, when the manipulator performs a handling test of a photovoltaic module, the safety controller continuously monitors its motion trajectory and speed. If it is detected that the movement speed of the manipulator exceeds a preset threshold, such as a sudden increase in speed to more than 110% of the standard test speed, the safety controller will identify it as a potential dangerous state and immediately send an early warning signal to the main control system. At the same time, an emergency stop mechanism is designed, which is triggered by the safety controller. The emergency stop mechanism includes a hardware brake connected to each joint of the manipulator and a stop command algorithm embedded in the safety controller. This hardware brake is designed to instantly lock the joints of the manipulator after receiving a signal to prevent it from continuing to move. The software component is an advanced algorithm that can quickly calculate the instructions required to stop the manipulator and immediately send a stop signal to all brakes when a safety threat is determined. For example, if during the inverter test, the robot begins to deviate from the predetermined test trajectory due to program errors or external interference and approaches surrounding equipment or operators, the safety controller will detect that the position deviation exceeds the safety range and quickly raise the warning signal to the emergency level. The emergency stop mechanism is then activated, and the stop command algorithm sends signals to each brake almost simultaneously. The hardware brake responds to the signal and instantly locks all joints of the robot to avoid possible collision or injury.

[0112] Figure 4 The present invention discloses a flowchart of designing a manipulator control function block in a aging test manipulator motion control method according to an embodiment of the present invention, and selecting different test manipulator control function blocks according to different product models and test requirements.

[0113] like Figure 4 As shown, in one or more embodiments, preferably, the design of the manipulator control function block selects different test manipulator control function blocks according to different product models and test requirements, specifically including:

[0114] S401, multiple control function blocks, each function block is designed to perform a specific test task;

[0115] S402, the control function block includes program codes and parameter sets for different product models and test requirements;

[0116] S403, a function block selector, which allows the user to select one or more function blocks from a plurality of control function blocks according to the product model currently being tested and the test requirements;

[0117] S404: The function block selector automatically selects and loads a corresponding control function block according to information input by the user through the configuration interface.

[0118] In an embodiment of the present invention, appropriate test control function blocks are selected according to different product models and test requirements. First, multiple control function blocks are defined, each of which is optimized to perform specific test tasks. For example, one control function block may be designed to test the voltage resistance of a photovoltaic panel, while another may be specifically used to check the temperature response of an inverter. These function blocks contain preset program codes and parameter sets for different product models and test requirements, enabling the manipulator to accurately perform various complex test processes. In order to achieve flexible selection of these control function blocks, a function block selector is developed. The selector is a user-friendly interface that allows users to select one or more from multiple preset control function blocks based on the product model currently to be tested and the specific test requirements. For example, when users need to test a new model of battery, they only need to enter the product model and the corresponding test standard through the configuration interface, and the function block selector will automatically identify and load all necessary control function blocks applicable to the battery model, such as charging cycle test, discharge rate test, etc. The function block selector also has an intelligent recommendation system that can recommend the most suitable control function block combination based on past test data and user's historical selections, thereby improving the setting efficiency of the test process. Once the user confirms the selection, the system automatically configures the robot's control system, loads the selected control function block, and adjusts the relevant hardware settings to match the new test requirements. Through the above design method, the robot control system can quickly adapt to different test tasks, significantly improving the flexibility and efficiency of the equipment. This approach is particularly valuable for production lines that frequently change product models and test requirements, because it reduces the time required for reprogramming and manual configuration, ensuring the continuity and consistency of the test process.

[0119] Figure 5 The present invention is a flowchart of real-time data exchange between a robot control system and other production equipment using a preset modern industrial communication protocol in a aging test robot motion control method according to an embodiment of the present invention.

[0120] like Figure 5 As shown, in one or more embodiments, preferably, the real-time data exchange between the robot control system and other production equipment using a preset modern industrial communication protocol specifically includes:

[0121] S501, setting a communication interface for compatibility with the communication interfaces of other production equipment in the production line to achieve data exchange;

[0122] S502, setting a data formatting module for converting the internal data of the robot control system into data in a format that conforms to a modern industrial communication protocol;

[0123] S503. A data synchronization mechanism, which ensures that the data exchange between the robot control system and other equipment in the production line is real-time and maintains data consistency.

[0124] In an embodiment of the present invention, a communication interface is set in the manipulator control system, and this interface is designed to be compatible with the communication interface of other production equipment in the production line. For example, if other equipment in the production line uses OPC UA (Open Platform Communication Unified Architecture) as the communication standard, the communication interface on the manipulator also supports the OPC UA protocol to ensure that different devices can be seamlessly connected and exchange data. In order to ensure that the transmitted data format is consistent, a data formatting module is introduced. The main function of this module is to convert the internal data of the manipulator control system into data in the format of modern industrial communication protocols (such as OPC UA or EtherNet / IP). For example, when the manipulator completes the aging test of a component and generates test results, these results will first be converted into a standard OPC UA data format by the data formatting module before they can be understood and received by other devices or monitoring systems integrated in the production line. A data synchronization mechanism is also implemented, which uses time synchronization technology, such as the Precision Time Protocol (PTP), to ensure that the data exchange between the manipulator control system and other equipment in the production line is real-time and maintains data consistency. This means that whenever the state of the robot changes or new test data is generated, this information can be instantly shared with the rest of the production line, ensuring the coordination of the entire production process. Through the implementation of the above method, the aging test robot can efficiently and accurately exchange real-time data with other production equipment in the production line. This not only improves production efficiency, but also enables production managers to monitor the status of the entire production line in real time, including the operating status of the robot, test progress, and any abnormal situations that may occur, so as to make quick and effective decisions.

[0125] Figure 6 The present invention is a flowchart of an embodiment of an aging test robot motion control method in which an intelligent fault diagnosis system is set up to perform controllable motion transportation on a fixture through mutually coordinated motion of the z-axis.

[0126] like Figure 6As shown, in one or more embodiments, preferably, the intelligent fault diagnosis system is set to perform controllable motion transmission on the fixture through the coordinated motion of the z-axis, specifically including:

[0127] S601, setting an intelligent fault diagnosis process, when it is detected that the distance between two adjacent manipulators is less than a preset range, the z-axis mutual coordinated movement is started;

[0128] S602. After starting the coordinated movement of the z-axis, all the movements of the two adjacent devices in the z-axis direction are kept synchronized, and after being judged to be normal, normal movement is resumed, wherein the judgment is a pre-set judgment logic and is automatically judged through video.

[0129] In an embodiment of the present invention, an intelligent fault diagnosis process is integrated in the aging test manipulator control system. The function of this process is to monitor the relative position of the manipulator during operation to ensure that the distance between them is not less than the preset safety range. For example, when two adjacent manipulators are carrying and testing photovoltaic modules, the system will continue to monitor the distance between them. If it is detected that the distance between the two manipulators is less than the preset range, the intelligent fault diagnosis system will immediately start the z-axis coordinated movement. This means that once the system detects a potential collision risk or abnormal approach, the two manipulators involved will move synchronously along the z-axis direction at the same time. This synchronous movement can be that the two manipulators rise or fall at the same time until the distance between them returns to a safe range. During this period, all movements are controllable and the speed will be limited to a safe range to ensure that no new risks are introduced due to rapid avoidance actions. After the z-axis coordinated movement is started, the system will enter a waiting and judgment stage. In this stage, the system will use the preset judgment logic combined with the video automatic discrimination technology to evaluate the situation. For example, the system may use cameras installed on the shop floor to analyze the robot's position and surroundings to determine if there are still obstacles that need to be avoided or if it is safe to resume normal operation. Only after the system determines that the situation is normal and there are no safety hazards will the robot resume its normal movement mode.

[0130] Figure 7 The present invention is a flowchart of online encapsulation of each function in a aging test robot motion control method according to an embodiment of the present invention, wherein the function block is used to perform online real-time detection of X-axis and Z-axis motion.

[0131] like Figure 7 As shown, in one or more embodiments, preferably, the online encapsulation of each function into a functional block, wherein the functional block is used to perform real-time detection of online X and Z axis motion, specifically including:

[0132] S701, capturing the position P, velocity V and torque J of the manipulator in real time;

[0133] S702, calculating the x-axis distance and the z-axis distance using the first calculation formula according to the current movement speed and the position of the manipulator;

[0134] S703: If the x-axis distance and the z-axis distance do not satisfy the second calculation formula, it is considered that there is a collision risk, otherwise no processing is performed;

[0135] S704. For a time period in which there is a risk of collision, adjust the torque in the corresponding moving direction to satisfy a third calculation formula;

[0136] S705, visually encapsulate all functions into functional blocks for modular drag-and-drop programming during programming;

[0137] The first calculation formula is:

[0138] Wz=Pz+TT×Vz

[0139] Wx=Px+TT×Vx

[0140] Wherein, Pz is the real-time projection position of the z-axis, Px is the real-time projection position of the x-axis, TT is the preset time interval, Wz is the z-axis distance, Wx is the x-axis distance, Vz is the z-axis moving speed of the manipulator, and Vx is the x-axis moving speed of the manipulator;

[0141] The second calculation formula is:

[0142] Wz∈[LZ1,LZ2]

[0143] Wx∈[LX1,LX2]

[0144] Among them, LZ1 and LZ2 are the lower and upper limits of the manipulator's motion in the z-axis, and LX1 and LX2 are the lower and upper limits of the manipulator's motion in the x-axis;

[0145] The third calculation formula is:

[0146] YL∈FL

[0147] Among them, YL is the torque in the moving direction, and FL is the torque range without collision damage.

[0148] In an embodiment of the present invention, a real-time monitoring module is implemented in the aging test manipulator control system, which can capture the position P (including Px and Pz), speed V (including Vx and Vz) and torque J of the manipulator. It is obtained by real-time acquisition of the readings of the encoder and other sensors of the manipulator. Using the first calculation formula, the x-axis distance Wx and the z-axis distance Wz are calculated according to the current movement speed and the position of the manipulator. This formula takes into account the expected movement distance of the manipulator within the preset time interval TT, thereby predicting the position of the manipulator in a short time in the future. If the calculated Wx and Wz are not within the safety range defined by the second calculation formula, that is, they do not meet the conditions of LZ1 to LZ2 (z-axis lower and upper limits) and LX1 to LX2 (x-axis lower and upper limits), the system considers that there is a collision risk. When the collision risk is identified, the system adjusts the torque YL in the corresponding moving direction during the time period where there is a collision risk so that it meets the definition of the third calculation formula, that is, ensures that the torque YL falls within the collision-free damage torque range FL. This adjustment is achieved by changing the torque output of the manipulator to avoid potential collisions. In order to simplify the programming process, all functions are visually encapsulated in function blocks. This means that developers can quickly build and adjust the control logic of the robot through modular drag-and-drop programming in the programming environment. Each function block corresponds to a specific set of operations, such as real-time monitoring, risk assessment, and torque adjustment, which can be flexibly combined to meet different test requirements and scenarios. The system implemented by the above method can effectively perform real-time detection of X and Z axis motion online, and improves programming efficiency and system maintainability through function block encapsulation. This collision prevention strategy is essential to ensure the safe operation of robots and other equipment during automated testing.

[0149] According to a second aspect of an embodiment of the present invention, a aging test manipulator motion control system is provided.

[0150] Figure 8 It is a structural diagram of a motion control system of an aging test manipulator according to an embodiment of the present invention.

[0151] In one or more embodiments, preferably, the aging test manipulator motion control system includes:

[0152] The sensor acquisition module 801 is used to set high-precision position, speed and torque sensors for the aging test manipulator to capture the state of the manipulator in real time;

[0153] Emergency control module 802, used to add a safety controller and an emergency stop mechanism to the control system of the aging test manipulator;

[0154] Mode selection module 803, used to design manipulator control function blocks and select different test manipulator control function blocks according to different product models and test requirements;

[0155] The communication setting module 804 is used for real-time data exchange between the robot control system and other production equipment using a preset modern industrial communication protocol;

[0156] Interaction restriction module 805, used to set up an intelligent fault diagnosis system, and perform controllable motion delivery on the fixture through mutually coordinated motion of the z-axis;

[0157] The packaging control module 806 is used to perform online functional block packaging of each function, wherein the functional block is used to perform online real-time detection of X-axis and Z-axis motion.

[0158] In the embodiment of the present invention, a system suitable for different structures is realized through a series of modular designs. The system can achieve closed-loop, reliable and efficient execution through collection, analysis and control.

[0159] According to a third aspect of an embodiment of the present invention, there is provided a computer-readable storage medium on which computer program instructions are stored. When the computer program instructions are executed by a processor, the method as described in any one of the first aspect of the embodiment of the present invention is implemented.

[0160] According to a fourth aspect of an embodiment of the present invention, an electronic device is provided. Fig. 9 It is a structural diagram of an electronic device in one embodiment of the present invention. Fig. 9 The electronic device shown is a universal aging test manipulator motion control device. The electronic device can be a smart phone, a tablet computer, or other device. As shown, the electronic device 900 includes a processor 901 and a memory 902. The processor 901 is electrically connected to the memory 902. The processor 901 is the control center of the terminal 900, and uses various interfaces and lines to connect various parts of the entire terminal. By running or calling a computer program stored in the memory 902, and calling the data stored in the memory 902, the various functions of the terminal are executed and the data is processed, thereby monitoring the terminal as a whole.

[0161] In this embodiment, the processor 901 in the electronic device 900 will load the instructions corresponding to the processes of one or more computer programs into the memory 902 according to the following steps, and the processor 901 will run the computer program stored in the memory 902 to realize various functions: set high-precision position, speed and torque sensors for the aging test manipulator to capture the state of the manipulator in real time; add a safety controller and an emergency stop mechanism to the control system of the aging test manipulator; design the manipulator control function block, and select different test manipulator control function blocks according to different product models and test requirements; use the preset modern industrial communication protocol to exchange real-time data between the manipulator control system and other production equipment; set up an intelligent fault diagnosis system to perform controllable motion transmission on the fixture through the coordinated motion of the z-axis; and perform function block encapsulation for each function online, wherein the function block is used to perform real-time detection of online X and Z axis motion.

[0162] The memory 902 may be used to store computer programs and data. The computer programs stored in the memory 902 include instructions that can be executed in the processor. The computer programs may constitute various functional modules. The processor 901 executes various functional applications and data processing by calling the computer programs stored in the memory 902.

[0163] The technical solution provided by the embodiments of the present invention may have the following beneficial effects:

[0164] In the solution of the present invention, prevention of failures and accidents is achieved by integrating emergency control and safety control.

[0165] In the solution of the present invention, modular design is combined with communication optimization to reduce the risk of failure.

[0166] It should be understood by those skilled in the art that the embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage and optical storage, etc.) containing computer-usable program codes.

[0167] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0168] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0169] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0170] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A motion control method for an aging test manipulator, characterized in that: The method includes: Set high-precision position, speed and torque sensors on the aging test manipulator to capture the state of the manipulator in real time; Add safety controller and emergency stop mechanism to the control system of the aging test manipulator; Design the manipulator control function block and select different test manipulator control function blocks according to different product models and test requirements; Real-time data exchange between robot control system and other production equipment using preset modern industrial communication protocols; Set up an intelligent fault diagnosis system to perform controllable motion transportation on the fixture through the coordinated motion of the z-axis; Each function is encapsulated into a function block online, where the function block is used to perform real-time detection of online X and Z axis motion; The online process of encapsulating each function into a functional block, wherein the functional block is used to perform real-time detection of online X-axis and Z-axis motion, specifically including: Capture the position P, velocity V and torque J of the manipulator in real time; Calculate the x-axis distance and the z-axis distance using the first calculation formula according to the current motion speed and the position of the manipulator; If the x-axis distance and the z-axis distance do not satisfy the second calculation formula, it is considered that there is a collision risk, otherwise no processing is performed; For the time period when there is a risk of collision, the torque in the corresponding moving direction is adjusted to satisfy the third calculation formula; Visualize the functional block encapsulation of all functions for modular drag-and-drop programming during the programming process; The first calculation formula is: ； Wherein, Pz is the real-time projection position of the z-axis, Px is the real-time projection position of the x-axis, TT is the preset time interval, Wz is the z-axis distance, Wx is the x-axis distance, Vz is the z-axis moving speed of the manipulator, and Vx is the x-axis moving speed of the manipulator; The second calculation formula is: ； Among them, LZ1 and LZ2 are the lower and upper limits of the manipulator's motion in the z-axis, and LX1 and LX2 are the lower and upper limits of the manipulator's motion in the x-axis; The third calculation formula is: YL∈FL Among them, YL is the torque in the moving direction, and FL is the torque range without collision damage.

2. A aging test manipulator motion control method as claimed in claim 1, characterized in that: The aging test manipulator is provided with high-precision position, speed and torque sensors to capture the state of the manipulator in real time, specifically including: Set the operating position of the aging test manipulator to implement the detection equipment; Set up speed monitoring equipment for the aging test manipulator; An image acquisition device is set up in the area where the aging test manipulator is located; A torque sensor is set on the aging test manipulator to collect torques in different directions in real time.

3. The aging test manipulator motion control method according to claim 1, characterized in that: The step of adding a safety controller and an emergency stop mechanism to the control system of the aging test manipulator specifically includes: Set up a safety controller connected in parallel with the main control system of the manipulator; The safety controller receives sensor data from the manipulator and has independent processing capabilities for real-time monitoring of the manipulator's operating status; When the safety controller detects that the operation of the manipulator exceeds the preset safety parameters and thresholds, the safety controller automatically sends a warning signal to the main control system of the manipulator; Set up an emergency stop mechanism, which is triggered by the safety controller; The emergency stop mechanism includes hardware and software components. The hardware component is the emergency brake connected to each joint of the manipulator, and the software component is the stop command algorithm embedded in the safety controller. When the warning signal from the safety controller reaches the predetermined emergency level, the emergency stop mechanism is immediately activated, stopping the command algorithm calculation and sending an immediate stop signal to each brake of the manipulator; After receiving the stop signal, the brake of the hardware component quickly locks the joints of the robot to prevent safety hazards caused by the movement of the robot.

4. The aging test manipulator motion control method according to claim 1, characterized in that: The design of the manipulator control function block selects different test manipulator control function blocks according to different product models and test requirements, specifically including: Multiple control function blocks, each designed to perform a specific test task; The control function block includes program codes and parameter sets for different product models and test requirements; A function block selector, which allows the user to select one or more function blocks from multiple control function blocks according to the product model and test requirements currently being tested; The function block selector automatically selects and loads the corresponding control function block according to the information input by the user through the configuration interface.

5. The aging test manipulator motion control method according to claim 1, characterized in that: The real-time data exchange between the robot control system and other production equipment using the preset modern industrial communication protocol specifically includes: A communication interface is set up to be compatible with the communication interfaces of other production equipment in the production line to realize data exchange; A data formatting module is provided to convert the internal data of the robot control system into data conforming to the format of modern industrial communication protocols; A data synchronization mechanism that ensures that data exchange between the robot control system and other equipment in the production line is real-time and maintains data consistency.

6. The aging test manipulator motion control method according to claim 1, characterized in that: The intelligent fault diagnosis system is provided to perform controllable motion transmission on the fixture through the coordinated motion of the z-axis, specifically including: Set up an intelligent fault diagnosis process. When it is detected that the distance between two adjacent manipulators is less than the preset range, the z-axis coordinated movement is started; After starting the coordinated movement of the z-axis, all movements of the two adjacent devices in the z-axis direction remain synchronized, and after waiting to be judged to be normal, normal movement is resumed, wherein the judgment is a pre-set judgment logic and is automatically determined through video.

7. A aging test manipulator motion control system, characterized in that: The system is used to implement the method according to any one of claims 1 to 6, and the system comprises: The sensor acquisition module is used to set high-precision position, speed and torque sensors for the aging test manipulator to capture the state of the manipulator in real time; Emergency control module, used to add safety controller and emergency stop mechanism to the control system of the aging test manipulator; Mode selection module, used to design manipulator control function blocks and select different test manipulator control function blocks according to different product models and test requirements; Communication setting module, used for real-time data exchange between robot control system and other production equipment using preset modern industrial communication protocols; Interactive restriction module, used to set up intelligent fault diagnosis system, and perform controlled motion delivery of fixtures through coordinated motion of z-axis; The encapsulation control module is used to encapsulate each function into a functional block online, wherein the functional block is used to perform real-time detection of online X and Z axis motion.

8. A computer-readable storage medium storing computer program instructions, characterized in that: The computer program instructions implement the method according to any one of claims 1 to 6 when executed by a processor.

9. An electronic device, comprising a memory and a processor, characterized in that: The memory is used to store one or more computer program instructions, wherein the one or more computer program instructions are executed by the processor to implement the method according to any one of claims 1-6.

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