A control method and system for preventing accidental impact of a manipulator based on a vibration sensor

Abstract

The present invention provides a method and system for controlling accidental impacts of a manipulator based on a vibration sensor, relating to the field of intelligent control technology. The method includes: extracting real-time amplitude and frequency data corresponding to the manipulator according to the current state; calculating the relative deviations between the real-time amplitude and frequency data and preset reference values, including amplitude relative deviation and frequency relative deviation; judging whether there is an abnormal collision in the state of the manipulator according to the relative deviations and preset deviation thresholds to obtain a judgment result; and sending corresponding control instructions to the manipulator according to the judgment result so that the manipulator moves according to the corresponding control instructions. By monitoring the amplitude and frequency data of the manipulator in real time, accurately judging whether there is an abnormal collision, and sending corresponding control instructions to the manipulator accordingly, the present invention effectively improves the operation safety and intelligent level of the manipulator.

Description

Technical Field

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

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

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

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

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

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

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

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

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

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

[0011] Based on the relative deviation and a preset deviation threshold, determine whether there is an abnormal collision in the state of the manipulator to obtain a judgment result;

[0012] According to the judgment result, send a corresponding control instruction to the manipulator so that the manipulator moves according to the corresponding control instruction.

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

[0014] Obtain the operating state of the manipulator in the state of no workpiece to obtain the amplitude and frequency data of the manipulator in the state of no workpiece;

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

[0016] According to the type and weight of each workpiece, obtain the amplitude and frequency data of the manipulator at different moving speeds; classify according to different moving speeds according to the amplitude and frequency data of the manipulator at different moving speeds.

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

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

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

[0020] If any one of the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that there is an abnormal collision in the manipulator; if the two relative deviations do not exceed the corresponding thresholds, it is determined that the state of the manipulator is normal;

[0021] Output the judgment on the manipulator to the controller to obtain a judgment result.

[0022] Further, the calculation formula for the amplitude relative deviation is:

[0023]

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

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

[0026]

[0027] Wherein, Δf represents the relative frequency deviation; f m represents the frequency real-time monitored by the vibration sensor during the operation of the robotic arm; f r (v, T, M) represents the frequency reference value; ∈ represents a constant; δ represents an adjustment coefficient; v n represents the selected reference speed.

[0028] Furthermore, according to the judgment result, a corresponding control instruction is sent to the robotic arm so that the robotic arm moves according to the corresponding control instruction, including:

[0029] According to the judgment result, determine the control instruction sent to the robotic arm and send the control instruction to the robotic arm;

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

[0031] In a second aspect, a mis-collision control system for a robotic arm based on a vibration sensor includes:

[0032] An acquisition module, configured to obtain the current state of the robotic arm in real time through a vibration sensor installed at the front end of the robotic arm. The current state includes the state of the robotic arm when there is a workpiece, when there is no workpiece, and at different operating speeds; according to the current state, extract the real-time amplitude and frequency data corresponding to the robotic arm;

[0033] A processing module, configured to calculate the relative deviation between the real-time amplitude and frequency data and the preset reference values, including the relative amplitude deviation and the relative frequency deviation; according to the relative deviation and the preset deviation threshold, judge whether there is an abnormal collision in the state of the robotic arm to obtain a judgment result; according to the judgment result, send a corresponding control instruction to the robotic arm so that the robotic arm moves according to the corresponding control instruction.

[0034] In a third aspect, a computing device includes:

[0035] One or more processors;

[0036] A storage device for storing one or more programs, which when executed by one or more processors cause the one or more processors to implement the method.

[0037] In a fourth aspect, a computer-readable storage medium stores a program which, when executed by a processor, implements the method.

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

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

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

[0041] The method for controlling mis-collision of a manipulator based on a vibration sensor enhances the stability and reliability of the entire production system. Through real-time monitoring and intelligent control, it ensures that the manipulator can operate safely and stably in a complex working environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 is a schematic flowchart of a method for controlling mis-collision of a manipulator based on a vibration sensor provided by an embodiment of the present invention.

[0043] Figure 2 is a schematic diagram of a system for controlling mis-collision of a manipulator based on a vibration sensor provided by an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

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

[0045] As Figure 1 shown, an embodiment of the present invention provides a method for controlling accidental impact of a manipulator based on a vibration sensor. The method includes the following steps:

[0046] Step 11: Real-time obtain the current state of the manipulator through a vibration sensor installed at the front end of the manipulator. The current state includes the states of the manipulator when there is a workpiece, when there is no workpiece, and at different moving speeds.

[0047] Step 12: Extract the real-time amplitude and frequency data corresponding to the manipulator according to the current state.

[0048] Step 13: Calculate the relative deviations between the real-time amplitude and frequency data and a preset reference value, including the amplitude relative deviation and the frequency relative deviation.

[0049] Step 14: Determine whether there is an abnormal collision in the state of the manipulator according to the relative deviation and a preset deviation threshold to obtain a judgment result.

[0050] Step 15: Send a corresponding control instruction to the manipulator according to the judgment result so that the manipulator moves according to the corresponding control instruction.

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

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

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

[0054] Step 112, obtain the operating state of the manipulator in the state of no workpiece to obtain the amplitude and frequency data of the manipulator in the state of no workpiece;

[0055] Step 113, obtain the operating state of the manipulator in the state of carrying a workpiece to obtain the amplitude and frequency data of the manipulator in the state of carrying a workpiece, specifically including:

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

[0057] In the embodiment of the present invention, based on the vibration sensing technology, the operating state of the manipulator is evaluated by real-time monitoring and analyzing the vibration signal of the manipulator. Specifically, the system uses a high-precision vibration sensor installed at the front end of the manipulator to continuously capture the vibration data generated by the manipulator during the movement. These data are then transmitted to the processing unit for analysis to extract key information such as the amplitude and frequency of the manipulator. In the state of no workpiece, the system can understand its basic dynamic behavior by monitoring the natural vibration characteristics of the manipulator. In the state of carrying a workpiece, the system further analyzes the influence of the workpiece on the vibration characteristics of the manipulator, especially how factors such as the type, weight of the workpiece and the moving speed of the manipulator change its vibration mode. By classifying and storing these data, the system can establish a comprehensive database of the operating state of the manipulator. This not only helps to detect abnormal behaviors of the manipulator in time, such as collisions or faults, but also provides strong support for the optimization and maintenance of the manipulator.

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

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

[0060] By obtaining data in two states, namely without workpieces and carrying workpieces, a more comprehensive understanding of the operating state of the manipulator can be achieved. Classifying the data according to the type and weight of the workpiece and the movement speed of the manipulator makes the data analysis more refined and can more accurately identify the behavior characteristics of the manipulator under different conditions. By real-time monitoring and analyzing the vibration data of the manipulator in various states, abnormal situations such as workpiece detachment and manipulator failure can be discovered in time, thereby enhancing the safety of the operation process. By analyzing the vibration data of the manipulator at different speeds and loads, the motion trajectory and speed settings of the manipulator can be optimized, thereby improving production efficiency and reducing energy consumption. By real-time monitoring and timely adjusting the operating state of the manipulator, unnecessary mechanical wear and impact can be reduced, thereby extending the service life of the manipulator and its related equipment. The accumulated historical data can be used to predict the maintenance requirements of the manipulator, realize an intelligent maintenance plan, reduce unexpected downtime, and improve the overall efficiency of the production line.

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

[0062] The vibration sensor installed at the front end of the manipulator continuously monitors the vibration state of the manipulator. The sensor samples at a high frequency to ensure that every subtle vibration of the manipulator can be captured. The digital signals obtained by sampling are transmitted to the data processing unit in real time through data lines or wirelessly. The data processing unit first preprocesses the original data, including steps such as filtering and noise reduction, to improve the data quality. Specifically, let the original data be x(t), and the filtered data y(t) = LPF[x(t)]; where, LPF represents a low-pass filter used to remove high-frequency noise. For transient noise, wavelet transform can be used for denoising: y(t) = WT -1 [WT[x(t)]·M]; where, WT represents wavelet transform; WT -1 represents the inverse wavelet transform; M represents a mask used to retain or remove specific wavelet coefficients. The data is smoothed using the moving average method: where, N represents the size of the moving window; t represents time; i represents the summation index; x represents the original data point. The data is normalized to the range [0, 1]: where, min[x(t)], max[x(t)] represent the minimum and maximum values in the data respectively. Segment according to the motion period T of the manipulator: S k ={x(t)|kT≤t<(k + 1)T}; where, S k represents the k-th data segment; k represents an integer. Calculate the maximum amplitude within the data segment Sk where, max(x i ) represents the maximum data point; min(x i ) represents the minimum data point. The minimum amplitude where, N represents the number of data points; x i+1 represents the (i + 1)-th data point; x i represents the i-th data point. The average amplitude The standard deviation of the amplitude

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

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

[0065] Assign labels to each feature vector. For example: no workpiece state: 0; carrying a light workpiece: 1; carrying a heavy workpiece: 2.

[0066] Suppose there is a robotic arm on an assembly line that is responsible for grasping and placing parts. To ensure the precise operation of the robotic arm and avoid collisions, the above-mentioned vibration perception and data extraction system is applied. When the robotic arm performs a grasping action, the vibration sensor continuously monitors its vibration state. The sensor collects data at a frequency of thousands of times per second and transmits this data to the data processing unit in real time. When the robotic arm grasps a heavy part, the data processing unit extracts the amplitude and frequency features from the signal transmitted by the sensor. For example, it may be found that the amplitude increases significantly compared to when grasping a light part, while the frequency decreases. The system compares these features with the preset standard data to identify that the robotic arm is currently grasping a heavy part and its motion state is stable.

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

[0068] Step 144, calculate the relative deviation of the amplitude and frequency of the robotic arm in real time, and obtain the preset amplitude relative deviation threshold and frequency relative deviation threshold from the controller of the robotic arm;

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

[0070] Step 146, if any one of the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that there is an abnormal collision in the robotic arm; if both relative deviations do not exceed the corresponding thresholds, it is determined that the state of the robotic arm is normal;

[0071] Step 147, output the judgment on the robotic arm to the controller to obtain a judgment result.

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

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

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

[0075]

[0076] where ΔA represents the amplitude relative deviation; A m represents the amplitude of the manipulator real-time monitored by the vibration sensor at the current moment; Ar (v, T, M) represents the amplitude reference value; v represents the running speed of the manipulator; T represents the type of workpiece currently carried by the manipulator; M represents the weight of the workpiece currently carried by the manipulator.

[0077] In an embodiment of the present invention, a vibration sensor (such as an accelerometer) is installed on the manipulator. The sensor is configured to monitor the vibration of the manipulator in real time at a certain sampling frequency (such as hundreds of times per second). The amplitude data at the current moment is read from the sensor and denoted as A m . The current running speed v is obtained through the control system or sensors of the manipulator. The type of workpiece T currently carried by the manipulator is determined (by reading the output of the workpiece identification system). The weight M of the workpiece currently carried by the manipulator is obtained (a weight sensor is to be used). A series of tests are carried out on the manipulator, covering different running speeds, workpiece types and weights. The normal amplitude range of the manipulator under each condition is recorded. Based on the experimental data, a look-up table is established to predict the normal amplitude reference value A according to v, T and M r . According to the currently obtained values of v, T and M, the look-up table is used to calculate A r (v, T, M). The amplitude A m monitored in real time and the calculated reference value A r (v, T, M) are substituted into the formula. The relative amplitude deviation ΔA is calculated. The calculated value of ΔA is output to the interface of the control system. If ΔA exceeds a preset threshold, the alarm system is triggered to notify the operator. According to the magnitude of ΔA, it is judged whether there is an abnormal collision or other faults in the manipulator. If an abnormality is detected, appropriate measures are taken, such as decelerating, stopping for inspection or adjusting the operating parameters of the manipulator.

[0078] By using a vibration sensor to monitor the amplitude of the robotic arm in real time, the system can immediately obtain the operating status of the robotic arm. This allows for a quick response to any anomalies or deviations from the normal operating range. The calculation of the relative amplitude deviation helps identify potential abnormal collisions or malfunctions of the robotic arm. Once a deviation exceeding the preset threshold is detected, the system can quickly trigger an alarm, thereby preventing potential damage or dangerous situations and ensuring the safety of operators and equipment. By continuously monitoring and adjusting the operating status of the robotic arm, the stability and consistency during the production process can be ensured. This helps reduce production interruptions caused by robotic arm malfunctions or performance degradation, thereby improving production efficiency. At the same time, stable operating conditions also contribute to ensuring product quality. The relative amplitude deviation data can provide valuable reference for equipment maintenance. By analyzing the patterns and trends of the deviations, worn components or parameters that need adjustment in the robotic arm can be identified, enabling more precise preventive maintenance. Introducing the calculation of relative amplitude deviation is part of the intelligentization of the robotic arm control system. This ability enables the system to make decisions based on real-time data, rather than simply relying on preset programs or manual intervention. This improves the system's adaptability and flexibility. By reducing unexpected downtime and improving maintenance efficiency, the monitoring of relative amplitude deviation helps reduce the overall operating cost of the robotic arm. In addition, timely identification and handling of potential problems can also extend the service life of the equipment.

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

[0080]

[0081] where, Δf represents the relative frequency deviation; f m represents the frequency real-time monitored by the vibration sensor during the operation of the robotic arm; f r (v, T, M) represents the frequency reference value; ∈ represents a constant; δ represents an adjustment coefficient; v n represents the selected reference speed.

[0082] In an embodiment of the present invention, through the vibration sensor installed on the robotic arm, the vibration frequency f of the robotic arm is captured in real time m . The current operating speed v is obtained from the relevant sensors of the robotic arm. The current workpiece type T and weight M carried by the robotic arm are determined. The selected reference speed v n is obtained or set. A constant ∈ is set to avoid the denominator being zero and increase numerical stability. An adjustment coefficient δ is set to adjust the sensitivity of the deviation calculation according to speed changes. The robotic arm is tested under different operating speeds, workpiece types, and weight conditions. The normal vibration frequency range of the robotic arm under various conditions is recorded. Using this data, a look-up table is established to predict the normal frequency reference value f according to v, T, and M r(v, T, M). When the manipulator is running, according to the current values of v, T, and M, use the established look-up table to calculate f r (v, T, M).

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

[0084] By capturing the vibration frequency f of the manipulator in real time m and comparing it with the reference value f r (v, T, M), the change of the frequency can be monitored with high precision. Incorporating multiple influencing factors such as the operating speed v of the manipulator, the workpiece type T, and the workpiece weight M makes the calculation of the frequency reference value f r (v, T, M) more comprehensive and accurate. Introducing the constant ∈ ensures that the denominator of the formula will not be zero, thus avoiding numerical instability and errors in the calculation process. When the monitored relative frequency deviation Δf exceeds the preset threshold, the early warning system can be triggered to notify the operator to take corresponding measures in time. This helps to prevent potential failures and damages and improve the safety and reliability of the equipment.

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

[0086] Step 155, according to the judgment result, determine the control instruction to be sent to the manipulator and send the control instruction to the manipulator;

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

[0088] In the embodiments of the present invention, according to the comparison result, the system determines the control instruction to be sent to the manipulator. For example, if the relative frequency deviation exceeds the safety threshold, the system may generate an instruction of "stop moving and return to the specified position". After determining the instruction, the system sends the instruction to the manipulator through wireless data transmission technology. After receiving the control instruction, the manipulator parses it to confirm the specific content and requirements of the instruction. According to the parsed instruction, the manipulator performs corresponding actions. If the instruction is "continue to execute the current task", the manipulator will maintain the normal motion state; if the instruction is "stop moving and return to the specified position", the manipulator will immediately interrupt the current task and safely return according to the preset path. After executing the instruction, the manipulator feeds back its current state to the system for further monitoring and adjustment. According to the feedback status information, the system can adjust the monitoring parameters, safety threshold or control strategy in real time to optimize the performance and safety of the manipulator.

[0089] Through real-time monitoring and quick judgment, the system can discover potential problems or abnormal situations in the first time and immediately send corresponding control instructions to the manipulator. This real-time response ability significantly improves the safety and reliability of the manipulator operation. Stopping the movement of the manipulator in time when detecting an abnormality can effectively prevent possible failures or damages, thus reducing the maintenance cost and production losses. At the same time, by instructing the manipulator to return to the specified position, it is also convenient for subsequent inspection and maintenance work. The manipulator can make independent judgments and action responses according to the received instructions, reducing the dependence on manual operation, improving the production efficiency and operation consistency. Since the system can send different control instructions according to different judgment results, the manipulator can flexibly respond in a variety of working scenarios, showing stronger adaptability and versatility. Whether in normal operation or in case of abnormality, the manipulator can make appropriate responses.

[0090] As Figure 2 shown, the embodiments of the present invention also provide a manipulator mis-impact control system 20 based on a vibration sensor, including:

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

[0092] A processing module 22 is configured to calculate the relative deviations between the real-time amplitude and frequency data and the preset reference values, including the amplitude relative deviation and the frequency relative deviation; determine whether there is an abnormal collision in the state of the manipulator according to the relative deviations and the preset deviation thresholds to obtain a judgment result; and send corresponding control instructions to the manipulator according to the judgment result, so that the manipulator moves according to the corresponding control instructions.

[0093] It should be noted that this system corresponds to the above method. All implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0094] An embodiment of the present invention further provides a computing device, including: a processor and a memory storing a computer program. When the computer program is run by the processor, it executes the method as described above. All implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0095] An embodiment of the present invention further provides a computer-readable storage medium storing instructions. When the instructions are run on a computer, the computer is caused to execute the method as described above. All implementation manners in the above method embodiments are applicable to this embodiment and can achieve the same technical effects.

[0096] The above are the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. A method for controlling manipulator accidental collision based on a vibration sensor, characterized in that: The method comprises: The current state of the manipulator is obtained in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds; According to the current state, extract the real-time amplitude and frequency data corresponding to the robot; Calculate the relative deviation between the real-time amplitude and frequency data and the preset reference value, including the relative amplitude deviation and the relative frequency deviation; According to the relative deviation and the preset deviation threshold, it is judged whether there is abnormal collision in the state of the robot to obtain a judgment result; According to the judgment result, a corresponding control instruction is issued to the manipulator so that the manipulator moves according to the corresponding control instruction; the current state of the manipulator is obtained in real time through the vibration sensor installed at the front end of the manipulator. The current state includes the state of the manipulator when there is a workpiece, when there is no workpiece, and at different movement speeds, including: Acquire the running state of the manipulator in the state without the workpiece to obtain the amplitude and frequency data of the manipulator in the state without the workpiece; The operation state of the manipulator in the state of carrying the workpiece is obtained to obtain the amplitude and frequency data of the manipulator in the state of carrying the workpiece, specifically including: obtaining the amplitude and frequency data of the manipulator at different movement speeds according to the type and weight of each workpiece; classifying the manipulator according to different movement speeds according to the amplitude and frequency data of the manipulator at different movement speeds; judging whether there is an abnormal collision in the state of the manipulator according to the relative deviation and the preset deviation threshold, so as to obtain the judgment result, including: Calculate the relative deviation of the amplitude and frequency of the manipulator in real time, and obtain the preset amplitude relative deviation threshold and frequency relative deviation threshold from the controller of the manipulator; Compare the amplitude relative deviation value and the frequency relative deviation value with a preset amplitude relative deviation threshold and a preset frequency relative deviation threshold; If either the amplitude relative deviation or the frequency relative deviation exceeds the corresponding threshold, the controller determines that the robot has an abnormal collision; if the two relative deviations do not exceed the corresponding threshold, the controller determines that the robot is in a normal state; The judgment of the manipulator is output to the controller to obtain the judgment result; the calculation formula of the relative deviation of the amplitude is: in, Indicates the relative deviation of amplitude; It indicates the amplitude of the robot arm monitored by the vibration sensor in real time at the current moment; Indicates the amplitude reference value; Indicates the operating speed of the robot; Indicates the type of workpiece currently carried by the robot; Indicates the weight of the workpiece currently carried by the robot; the calculation formula for the relative frequency deviation is: in, Indicates the relative frequency deviation; It indicates the frequency monitored in real time by the vibration sensor when the robot is running; Indicates the frequency reference value; represents a constant; represents the adjustment factor; Indicates the selected reference speed.

2. The method for controlling manipulator accidental collision based on vibration sensor according to claim 1, characterized in that: According to the judgment result, a corresponding control instruction is issued to the manipulator so that the manipulator moves according to the corresponding control instruction, including: According to the judgment result, a control instruction to be issued to the robot is determined, and the control instruction is sent to the robot; The robot receives the control instruction and performs the corresponding action according to the instruction content. If the instruction is to continue to execute the current task, the robot maintains the normal motion state; if the instruction is to stop moving and return to the specified position, the robot stops the current motion and returns to the specified position according to the preset path.

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

4. A computing device, characterized in that include: one or more processors; A storage device for storing one or more programs, when the one or more programs are executed by the one or more processors, the one or more processors implement the method as claimed in any one of claims 1 to 2.

5. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a program, which implements the method according to any one of claims 1 to 2 when executed by a processor.

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