Multi-motor servo actuator fault hierarchical management method and system

Abstract

The invention discloses a hierarchical management method and system for faults of a multi-motor servo actuator, and belongs to the technical field of servo actuator control. The method comprises the following steps of: sequentially dividing the faults of the multi-motor servo actuator into three fault layers from a bottom layer to a top layer according to fault objects, and determining fault types contained in each fault layer; external sensor signals and hardware signal trigger information are collected, and after filtering, conditioning and data fusion, the feature state of the multi-motor servo actuator is extracted; and in combination with a preset fault category judgment rule and a fault response action strategy, analyzing the feature state based on a machine learning algorithm to determine a fault category and a fault mark, and obtaining a corresponding fault response action strategy. According to the multi-motor servo actuator fault hierarchical management method and the multi-motor servo actuator fault hierarchical management system, the fineness and the efficiency of fault management and the stability and the reliability of the system are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of servo actuators, and in particular relates to a multi-motor servo actuator fault hierarchical management method and system thereof. Background Art

[0002] In today's industrial automation and precision control fields, multi-motor servo actuators have become an indispensable component of various complex mechanical systems due to their excellent accuracy, fast response speed, strong load capacity and compact size. However, as the complexity of the system continues to increase, how to effectively diagnose and manage the failure of multi-motor servo actuators has become a challenge that needs to be solved urgently.

[0003] Traditional fault diagnosis methods mainly rely on simple threshold comparisons, which often fail to provide accurate diagnostic results in a changing industrial environment and are prone to false positives or false negatives. Existing fault management systems often lack effective hierarchical management strategies, and it is difficult to determine a reasonable processing sequence and strategy when faced with multiple faults. These systems usually use a single response measure to deal with different types of faults. A single fault response action cannot be applied to all situations and may even aggravate the problem. Many existing fault management systems also lack the ability to monitor in real time and perform predictive analysis, which limits their potential for early detection and prevention of faults.

[0004] Due to the lack of effective fault prediction and diagnosis tools, maintenance personnel need to invest a lot of time in troubleshooting and repair, which not only increases maintenance costs, but also prolongs downtime, and has a negative impact on production efficiency and economic benefits. Faced with the growing system complexity, traditional fault diagnosis and management methods can no longer meet the needs of modern industry, and there is an urgent need to introduce more advanced and intelligent technologies and methods to improve the efficiency and accuracy of fault handling. Summary of the invention

[0005] The purpose of the present invention is to overcome the deficiencies in the prior art and to provide a multi-motor servo actuator fault hierarchical management method and system.

[0006] To achieve the above object, the present invention is implemented by adopting the following technical solutions: In one aspect, the present invention provides a multi-motor servo actuator fault hierarchical management method, comprising the following steps: The faults of multi-motor servo actuators are divided into three fault layers from the bottom layer to the top layer according to the fault objects, and the fault categories contained in each fault layer are determined; Collect external sensor signals and hardware signal trigger information, and extract the characteristic state of the multi-motor servo actuator after filtering, conditioning, and data fusion; In combination with preset fault category determination rules and fault response action strategies, the characteristic state is analyzed based on a machine learning algorithm to determine the fault category, fault sign, and obtain the corresponding fault response action strategy.

[0007] Further, the fault layers are channel layer, drive system layer and servo actuator layer respectively; The channel layer fault includes n channel faults, the channel connected to the i-th motor is called channel i, and the fault category of each channel includes drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature and IGBT overheating; The fault categories of the drive system layer include hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage and communication failure; The fault categories of the servo actuator layer include limit fault, brake fault, brake release fault, speed error and redundant drive fault.

[0008] Further, the processing of external sensor signals and hardware signal trigger information includes limit sensor signals, brake current sensor signals, angle sensor position signals, angle sensor abnormality signals, drive system bus voltage signals, drive system bus current sensor signals, communication signals, drive module feedback signals, motor temperature signals and IGBT temperature signals; The characteristic states include limit state, hardware overvoltage trigger state, hardware overcurrent trigger state, reference current sampling state, bus voltage, bus current, communication data, and brake current of each channel motor, motor angle, motor speed, angle sensor abnormal state, angle sensor disconnection state, drive module state, motor temperature, and IGBT temperature.

[0009] Furthermore, the preset fault category determination rule and the fault response action strategy are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds with different data ranges according to different types of fault categories; and determine channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault. If a communication failure occurs in the drive system layer, the normal shutdown mode is adopted to stop working. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them are stopped by the enable priority shutdown mode; The servo drive layer failure adopts the brake priority shutdown working mode to stop working.

[0010] Furthermore, based on the machine learning algorithm, combined with the threshold set by the fault parameter, the extracted characteristic state is compared to determine whether it exceeds the preset fault threshold of the corresponding fault category; The identified fault category is matched with the predefined fault sign rule to generate a corresponding fault sign, each of which includes a fault type, a fault value, and a severity level.

[0011] Further, a fault response action strategy associated with the fault sign is adopted according to the fault sign, so as to respond to speed command adjustment, channel enable control, brake setting and execution of specific actions; the fault response action strategy includes normal shutdown, shutdown with enable priority, brake priority shutdown and channel enable disconnection; The normal shutdown is to set the speed command to zero speed, detect the speed value in real time, and when the feedback speed drops to zero, control the brakes of all channels to perform the closing action. After the brakes are closed, control all channels to disconnect and enable. The disconnection priority shutdown is to control all channels to disconnect and enable, and control all channels to perform the closing action. The brake priority shutdown and channel enable disconnection are to control all channel brakes to execute the closing action and set the speed command to zero speed; when the brake is closed, all channels are controlled to disconnect the enable.

[0012] On the other hand, the present invention provides a multi-motor servo actuator fault hierarchical management system, comprising the following modules: The fault layering template divides the multi-motor servo actuator faults into three layers from the bottom to the top according to the fault object, namely the channel layer, the drive system layer, and the servo actuator layer, and determines the fault categories contained in each fault layer; Fault parameter configuration module, which constructs fault parameters of multi-motor servo actuator fault management system, including time threshold configuration, data threshold configuration, channel redundancy configuration, fault type and response action configuration; The information processing module is responsible for receiving and optimizing the servo actuator and related sensor data for fault analysis, including external sensor signals and hardware signal trigger information; The fault analysis and sign generation module, based on the parameters and fault identification algorithm set by the fault parameter module, conducts in-depth analysis on the data obtained by the information processing module, determines the fault category and generates the associated fault sign; The fault response action module implements immediate fault management measures according to the analysis results of the fault category and fault sign, combined with the preset fault category judgment rules and the fault response action strategy, including normal shutdown, shutdown with priority to disconnection and enablement, shutdown with priority to braking, and channel disconnection and enablement; The fault output module issues an alarm and reports the fault information to the external monitoring system.

[0013] Furthermore, the channel layer fault includes n channel faults, the channel connected to the i-th motor is called channel i, and the fault category of each channel includes drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature and IGBT overheating; The fault categories of the drive system layer include hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage and communication failure; The fault categories of the servo actuator layer include limit fault, brake fault, brake release fault, speed error and redundant drive fault.

[0014] Furthermore, the time threshold configuration sets different time thresholds according to different types of fault categories to avoid frequent false alarms, and multiple levels of time thresholds can be set for the same fault to gradually respond to faults of different severity; The data threshold configuration configures the corresponding data threshold range according to different fault types; The channel redundancy configuration is used to determine channel layer faults and redundant fault determination to prevent system downtime caused by a single channel fault; The fault type and response action configuration are configured in association with each other according to the fault response actions specified for different fault categories.

[0015] Furthermore, the preset fault category determination rule and the fault response action strategy in the fault response action module are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds with different data ranges according to different types of fault categories; and determine channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault. If a communication failure occurs in the drive system layer, the normal shutdown mode is adopted to stop working. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them are stopped by the enable priority shutdown mode; The servo drive layer failure adopts the brake priority shutdown working mode to stop working.

[0016] Furthermore, based on the machine learning algorithm, combined with the threshold set by the fault parameter, the extracted characteristic state is compared to determine whether it exceeds the preset fault threshold of the corresponding fault category; Matching the identified fault category with predefined fault sign rules to generate corresponding fault signs, each of which includes a fault type, a fault value, and a severity level; According to the fault sign, a fault response action strategy associated with the fault sign is adopted to respond to speed command adjustment, channel enable control, brake setting and execution of specific actions; the fault response action strategy includes normal shutdown, shutdown with enable priority, brake priority shutdown and channel enable disconnection.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] The multi-motor servo actuator fault hierarchical management method and system provided by the present invention adopts a hierarchical fault management mode of channel layer, drive system layer and servo actuator layer, and configures parameters such as channel redundancy, time threshold, data threshold, etc., and presets and associates multiple fault response action strategies according to fault hierarchy and fault category, thereby improving the precision and efficiency of fault management, realizing dynamic redundant fault tolerance, avoiding fault misjudgment, improving system stability and reliability, optimizing the system shutdown and recovery strategies, and ensuring stability and safety in the event of a fault. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A block diagram of a fault hierarchical structure of a multi-motor servo actuator provided according to an embodiment of the present invention.

[0020] Figure 2 The present invention provides a schematic diagram of the composition and principle of a multi-motor servo actuator fault management system according to an embodiment of the present invention.

[0021] Figure 3The present invention provides a block diagram of fault response strategies corresponding to different fault situations.

[0022] Figure 4 The present invention provides a normal shutdown mode control flow chart according to an embodiment of the present invention.

[0023] Figure 5 The present invention provides a flow chart of a shutdown mode control with priority enabled according to an embodiment of the present invention.

[0024] Figure 6 The present invention provides a control flow chart of a brake priority shutdown mode according to an embodiment of the present invention.

[0025] Figure 7 A block diagram of the structural relationship between a fault management system and motor control provided according to an embodiment of the present invention.

[0026] Figure 8 The present invention is a flowchart of a multi-motor servo actuator fault hierarchical management method provided according to an embodiment of the present invention. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and cannot be used to limit the protection scope of the present invention.

[0028] Example

[0029] The present invention provides a multi-motor servo actuator fault hierarchical management system, comprising the following modules: The fault layering template divides the multi-motor servo actuator faults into three layers from the bottom to the top according to the fault object, namely the channel layer, the drive system layer, and the servo actuator layer, and determines the fault categories contained in each fault layer; Fault parameter configuration module, which constructs fault parameters of multi-motor servo actuator fault management system, including time threshold configuration, data threshold configuration, channel redundancy configuration, fault type and response action configuration; The information processing module is responsible for receiving and optimizing the servo actuator and related sensor data for fault analysis, including external sensor signals and hardware signal trigger information; The fault analysis and sign generation module, based on the parameters and fault identification algorithm set by the fault parameter module, conducts in-depth analysis on the data obtained by the information processing module, determines the fault category and generates the associated fault sign; The fault response action module implements immediate fault management measures based on the analysis results of the fault category and fault sign, combined with the preset fault category judgment rules and fault response action strategies, including normal shutdown, shutdown with priority after disconnection of enable, shutdown with priority after braking, and channel disconnection of enable. The fault output module issues an alarm and reports the fault information to the external monitoring system.

[0030] like Figure 1 As shown in the figure, the multi-motor servo actuator fault is divided into three levels from bottom to top according to the fault object, namely channel level, drive system level and servo actuator level.

[0031] Among them, the channel layer fault includes the faults of n channels, where n is the number of motors required for the servo actuator to work at full motor drive, and each motor corresponds to a channel. The channel connected to the i-th motor is called channel i (i=1,2,3…n).

[0032] The fault types of each channel include: drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature, IGBT overheating. When channel i has at least one of the above faults, it can be called the i-th channel fault.

[0033] The types of drive system layer faults include: hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage, and communication failure; Servo actuator layer fault types include: limit fault, brake fault, brake release fault, speed deviation, and redundant drive fault.

[0034] like Figure 2 As shown, the entire system includes a fault parameter configuration module, an information processing module, a fault analysis and flag generation module, a fault response action module, and a fault output module.

[0035] The fault parameter module sets various fault detection parameters and fault levels. Fault detection parameters are used in the fault analysis process, and fault levels are used to configure fault response actions corresponding to different faults. The fault parameter configuration module includes time threshold configuration used for fault analysis, data threshold configuration, channel redundancy configuration, fault type and response action configuration.

[0036] Among them, the time threshold configuration sets different time thresholds according to different types of fault categories to avoid frequent false alarms, and multiple levels of time thresholds can be set for the same fault to gradually respond to faults of different severity; Data threshold configuration: configure the corresponding data threshold range according to different fault types; Channel redundancy configuration is used to determine channel layer faults and redundant fault judgment to prevent system downtime caused by single channel failure; Fault type and response action configuration are associated and configured according to the fault response actions specified for different fault categories.

[0037] In one embodiment, different time thresholds and data thresholds are set according to different types of faults to avoid frequent false alarms, and the data threshold of each fault type has a data range definition. Multiple levels of time thresholds can be set for the same fault to gradually respond to faults of different severity. According to the temperature characteristics described in the IGBT manual, the data threshold of the IGBT overheating fault in the channel fault is configured to be 90°C, and the time threshold is 3s; the data threshold of the angle sensor abnormal fault in the channel fault is configured to be 3 times, and the time threshold is 50ms; the data threshold of the motor overtemperature fault in the channel fault is configured to be 160°C and 180°C. The data threshold of continuous overcurrent in the channel fault is configured to be 1.2 times the rated current amplitude; the data threshold of software overvoltage in the drive system layer fault is configured to be 600V; the data threshold of software undervoltage in the drive system layer fault is configured to be 350V; the data threshold of communication fault in the drive system layer fault is configured to be lost 3 times of data, and the time threshold is 500sms; Configure the brake fault data threshold of the servo actuator layer fault to 3.5A; configure the speed deviation data threshold of the servo actuator layer fault to 5500rpm, and the time threshold to 50ms; configure the channel redundancy to 1; configure the disconnection delay time to 500ms.

[0038] The monitoring system may be a host computer software, and the above configuration parameters are input into the interface, and the host computer sends them to the fault management system through the communication interface.

[0039] The fault response actions in the fault response action module include normal shutdown, disconnect enable priority shutdown, brake priority shutdown and channel enable disconnection. The fault types corresponding to these response modes are selected and associated, and the configuration information is sent to the fault management system through the communication interface.

[0040] The information processing module is responsible for receiving and optimizing the servo actuator and related sensor data, providing accurate and reliable information for fault analysis. The information processing module is used to collect and process equipment data, including processing external sensor signals and hardware signal trigger information to obtain multi-motor servo actuator system data.

[0041] The signals collected by the information processing module of the multi-motor servo actuator fault management system include: limit sensor signal, brake current sensor signal, angle sensor position signal, angle sensor abnormality signal, drive system bus voltage signal, drive system bus current sensor signal, communication signal, drive module feedback signal, motor temperature signal, and IGBT temperature signal.

[0042] In one embodiment, the limit sensor signal, drive module feedback signal, angle sensor abnormality signal, hardware overvoltage signal, hardware overcurrent signal, etc. are switch trigger signals; the brake current sensor signal, drive system bus voltage signal, drive system bus current sensor signal, motor temperature signal, reference current signal, IGBT temperature signal, etc. are analog acquisition signals, which need to be conditioned and calculated to obtain real physical values, and then filtered to eliminate abnormal values, and smoothed to reduce noise interference; the angle sensor position signal and communication signal are obtained through register query, and data shift calculation and other processing are required.

[0043] After the above information processing process, the characteristic status of the multi-motor servo actuator system can be obtained, including limit status, hardware overvoltage trigger status, hardware overcurrent trigger status, reference current sampling status, bus voltage, bus current, communication data, and brake current of each channel motor, motor angle, motor speed, angle sensor abnormal status, angle sensor disconnection status, drive module status, motor temperature, and IGBT temperature.

[0044] The fault analysis and sign generation module performs in-depth analysis on the data obtained by the information processing module according to the parameters and fault identification algorithm set by the fault parameter module, determines the fault type and generates a fault sign.

[0045] The fault analysis and sign generation module is the core component of the system. It is responsible for in-depth analysis of the data provided by the information processing module, identifying the fault type, and generating corresponding fault signs, including the fault analysis process and the sign generation process.

[0046] Specifically, based on the machine learning algorithm and in combination with the threshold set by the fault parameter, the extracted characteristic state is compared to determine whether it exceeds the preset fault threshold of the corresponding fault category; Match the identified fault category with the predefined fault flag rules to generate corresponding fault flags, each of which contains the fault type, fault value, and severity level; According to the fault sign, the fault response action strategy associated with the fault sign is adopted to respond to speed command adjustment, channel enable control, brake setting and execution of specific actions; the fault response action strategies include normal shutdown, shutdown with enable disconnection priority, brake priority shutdown and channel enable disconnection.

[0047] In one example, fault analysis uses a rule-based approach to monitor the parameter status in the information processing module in real time, combines the threshold input set by the fault parameter configuration module, processes the input data through predefined rules, uses the inference engine to perform logical reasoning, analyzes and determines the cause of the fault, and generates valve fault signs corresponding to different fault types. The fault sign should contain information such as the fault type, fault value, and severity.

[0048] For example, in a rule-based fault analysis module, the abnormal fault analysis process of the angle sensor at the channel layer includes data acquisition, time window, value jump detection, threshold comparison, fault judgment logic, fault type output, fault value recording, and fault flag generation. The fault analysis module obtains the angle sensor feedback value through the information processing module, and the time window is determined according to the time threshold of 50ms set by the fault parameter module. The number of value jumps is detected within the time window. If the number of jumps exceeds the preset threshold 3 times, the fault judgment logic is triggered, and the fault type is output as "angle sensor abnormality". The specific value and number of jumps when the fault occurs are recorded, and the fault flag is generated; the analysis process of communication faults involves real-time monitoring of the communication link to record the receiving status of the data packet, and the time window is determined according to the time threshold of 500ms set by the fault parameter module. The data loss in the time window is recorded and compared with the preset 3-time data loss threshold. Once the number of data loss exceeds the threshold, the fault judgment logic is triggered, it is determined that a communication fault has occurred, and the fault type is output as "communication data loss". Subsequently, the system records the specific number of data losses and time window when the fault occurs, and the generated fault flag contains the fault type.

[0049] The fault response action module implements immediate response measures according to the fault analysis results, including normal shutdown, shutdown with priority after disconnection, brake priority shutdown, and channel disconnection, so as to achieve rapid response and reduce the impact of faults on system operation.

[0050] In this embodiment, a fault response action is formulated according to the fault stratification and fault category of the servo actuator. The channel layer fault is a low-level fault. According to step 1, there are n channels in total. If multiple channels fail at the same time, but the number of channel failures does not exceed the channel redundancy, the fault response action is to only enable the channel with the failure. Since the motor of the servo actuator is redundant, the system can still operate, which is conducive to enhancing the stability and reliability of the system.

[0051] If multiple channels fail simultaneously and the failure exceeds the channel redundancy, the failure is a redundant drive failure, and the level to which it belongs is the servo actuator level.

[0052] If there is a communication failure at the drive system level, the normal shutdown method is used to stop working. If there are other drive system level failures such as hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, the enable priority shutdown method is used to stop working.

[0053] If a servo drive fault occurs, such as limit fault, brake fault, brake release fault, speed error, redundant drive fault, the system will stop working by using the brake priority shutdown mode.

[0054] Specifically, the fault category determination rules and fault response action strategies preset in the fault response action module are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds with different data ranges according to different types of fault categories; and determine channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault; If a communication failure occurs at the drive system layer, the system will stop working in a normal shutdown mode. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them will stop working in a shutdown mode with priority to disconnecting the enable function. When the servo drive fails, the driver stops working by using the brake priority shutdown mode.

[0055] In this embodiment, the fault response action module adopts the response strategy associated with the fault sign according to the result of the fault analysis, including but not limited to speed command adjustment, channel enable control, brake setting and execution of specific actions. The fault response action module performs the following four fault response actions: normal shutdown, shutdown with enable priority, shutdown with brake priority and channel enable disconnection.

[0056] like Figure 3 As shown in the figure, when a fault occurs in the channel layer, the response is to disconnect the control channel. When a communication fault occurs in the drive system layer, the fault response action is normal shutdown. When the drive system layer fault occurs: hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage, the fault response action is to disconnect the enable priority shutdown. When a fault occurs in the servo actuator layer, the fault response action is to brake the priority shutdown.

[0057] like Figure 4 The figure shows the normal shutdown process. When executing the normal shutdown process, first set the speed command to zero speed, detect the speed value in real time and make a judgment. When the feedback speed drops to zero, control the brakes of all channels to execute the closing action. When the brakes are closed, control all channels to cut off the enable.

[0058] like Figure 5The figure shows the off-enable priority shutdown process. When the off-enable priority shutdown process is executed, n on-off enables are controlled, and then all channel brakes are controlled to perform closing actions.

[0059] like Figure 6 The brake priority shutdown process shown in the figure, when executing the brake priority shutdown process, control all channel brakes to perform closing action, then set the speed command to zero speed, and then when the brake is closed, control all channels to cut off the enable.

[0060] The fault output module is responsible for issuing alarm prompts and reporting fault information to the external monitoring system for data sharing and further analysis.

[0061] In this embodiment, the fault output module can report the fault information to the external host computer software through the communication interface for prompting, and can also output and control the sound and light alarm to give a sound and light alarm warning.

[0062] The relationship between the multi-motor servo actuator fault management system software and the motor control structure in the servo actuator, such as Figure 7 As shown, the motor closed-loop control part mainly includes speed controller, current controller, Park inverse transform, SVPWM algorithm, sensor feedback, Clark transform and Park transform.

[0063] The information processing module in the fault management system software of the multi-motor servo actuator obtains the status data according to the sensor feedback, generates the fault flag through the fault analysis and flag generation module, and matches the fault response type through the fault response action module. After the speed is set to zero speed and acts on the speed command, if the channel is disconnected, the speed controller and current controller will no longer perform closed-loop operation and cut off the three-phase inverter output.

[0064] like Figure 8 As shown, an embodiment of the present invention provides a multi-motor servo actuator fault hierarchical management method, comprising the following steps: The faults of multi-motor servo actuators are divided into three fault layers from the bottom layer to the top layer according to the fault objects, and the fault categories contained in each fault layer are determined; Collect external sensor signals and hardware signal trigger information, and extract the characteristic state of the multi-motor servo actuator after filtering, conditioning, and data fusion; Combined with the preset fault category determination rules and fault response action strategies, the characteristic state is analyzed based on the machine learning algorithm to determine the fault category, fault sign and obtain the corresponding fault response action strategy.

[0065] In this embodiment, the fault layers are the channel layer, the drive system layer, and the servo actuator layer; Channel-level faults include n channel faults. The channel connected to the i-th motor is called channel i. The fault categories of each channel include drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature and IGBT overheating. The fault categories at the drive system layer include hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage, and communication failure; Servo actuator layer fault categories include limit fault, brake fault, brake release fault, speed error and redundant drive fault.

[0066] In this embodiment, external sensor signals and hardware signal trigger information are processed, including limit sensor signals, brake current sensor signals, angle sensor position signals, angle sensor abnormality signals, drive system bus voltage signals, drive system bus current sensor signals, communication signals, drive module feedback signals, motor temperature signals, and IGBT temperature signals; Feature status, including limit status, hardware overvoltage trigger status, hardware overcurrent trigger status, reference current sampling status, bus voltage, bus current, communication data, and brake current of each channel motor, motor angle, motor speed, angle sensor abnormal status, angle sensor disconnection status, drive module status, motor temperature, and IGBT temperature.

[0067] In this embodiment, the preset fault category determination rules and fault response action strategies are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds with different data ranges according to different types of fault categories; and determine channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault; If a communication failure occurs at the drive system layer, the system will stop working in a normal shutdown mode. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them will stop working in a shutdown mode with priority to disconnecting the enable function. When the servo drive fails, the driver stops working by using the brake priority shutdown mode.

[0068] In this embodiment, based on the machine learning algorithm, combined with the threshold set by the fault parameter, the extracted characteristic state is compared to determine whether it exceeds the preset fault threshold of the corresponding fault category; The identified fault category is matched with the predefined fault flag rules to generate the corresponding fault flag, each of which contains the fault type, fault value, and severity level.

[0069] In this embodiment, a fault response action strategy associated with the fault flag is adopted according to the fault flag, so as to respond to the speed command adjustment, channel enable control, brake setting and execution of specific actions; the fault response action strategy includes normal shutdown, shutdown with enable priority, brake priority shutdown and channel enable disconnection; Normal shutdown is to set the speed command to zero speed, detect the speed value in real time, and when the feedback speed drops to zero, control the brakes of all channels to execute the closing action. When the brakes are closed, control all channels to cut off the enable; The enable is disconnected and the shutdown is prioritized, which is to control the enable of all channels and control the brakes of all channels to execute the closing action; Braking priority shutdown and channel enable disconnection are used to control all channel brakes to execute closing action and set the speed command to zero speed; when the brake is closed, all channels are controlled to disconnect enable.

[0070] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A multi-motor servo actuator fault hierarchical management method, characterized in that: The steps include: The faults of multi-motor servo actuators are divided into three fault layers from the bottom layer to the top layer according to the fault objects, and the fault categories contained in each fault layer are determined; Collect external sensor signals and hardware signal trigger information, and extract the characteristic state of the multi-motor servo actuator after filtering, conditioning, and data fusion; In combination with preset fault category determination rules and fault response action strategies, the characteristic state is analyzed based on a machine learning algorithm to determine the fault category, fault sign, and obtain the corresponding fault response action strategy.

2. The multi-motor servo actuator fault hierarchical management method according to claim 1, characterized in that: The fault layers are respectively the channel layer, the drive system layer and the servo actuator layer; The channel layer fault includes n channel faults, the channel connected to the i-th motor is called channel i, and the fault category of each channel includes drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature and IGBT overheating; The fault categories of the drive system layer include hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage and communication failure; The fault categories of the servo actuator layer include limit fault, brake fault, brake release fault, speed error and redundant drive fault.

3. The multi-motor servo actuator fault hierarchical management method according to claim 2, characterized in that: The processing of external sensor signals and hardware signal trigger information includes limit sensor signals, brake current sensor signals, angle sensor position signals, angle sensor abnormality signals, drive system bus voltage signals, drive system bus current sensor signals, communication signals, drive module feedback signals, motor temperature signals and IGBT temperature signals; The characteristic states include limit state, hardware overvoltage trigger state, hardware overcurrent trigger state, reference current sampling state, bus voltage, bus current, communication data, and brake current of each channel motor, motor angle, motor speed, angle sensor abnormal state, angle sensor disconnection state, drive module state, motor temperature, and IGBT temperature.

4. The multi-motor servo actuator fault hierarchical management method according to claim 1, characterized in that: The preset fault category determination rule and the fault response action strategy are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds for different data ranges according to different types of fault categories; and judging channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault. If a communication failure occurs in the drive system layer, the normal shutdown mode is adopted to stop working. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them are stopped by the enable priority shutdown mode; The servo drive layer failure adopts the brake priority shutdown working mode to stop working.

5. The multi-motor servo actuator fault hierarchical management method according to claim 4, characterized in that: Based on the machine learning algorithm and the threshold set by the fault parameters, the extracted feature states are compared to determine whether they exceed the preset fault threshold of the corresponding fault category; Matching the identified fault category with predefined fault sign rules to generate corresponding fault signs, each of which includes a fault type, a fault value, and a severity level; Adopting a fault response action strategy associated with the fault flag according to the fault flag, so as to respond to speed command adjustment, channel enable control, brake setting and execution of specific actions; The fault response action strategies include normal shutdown, shutdown with priority to enable disconnection, shutdown with priority to brake, and channel enable disconnection; The normal shutdown is to set the speed command to zero speed, detect the speed value in real time, and when the feedback speed drops to zero, control the brakes of all channels to perform the closing action. After the brakes are closed, control all channels to disconnect and enable. The disconnection priority shutdown is to control all channels to disconnect and enable, and control all channels to perform the closing action. The brake priority shutdown and channel enable disconnection are to control all channel brakes to perform closing actions and set the speed command to zero speed; When the brake is closed, all channels are controlled to be disconnected.

6. A multi-motor servo actuator fault hierarchical management system, characterized in that: Includes the following modules: The fault layering template divides the multi-motor servo actuator faults into three layers from the bottom to the top according to the fault object, namely the channel layer, the drive system layer, and the servo actuator layer, and determines the fault categories contained in each fault layer; Fault parameter configuration module, which constructs fault parameters of multi-motor servo actuator fault management system, including time threshold configuration, data threshold configuration, channel redundancy configuration, fault type and response action configuration; The information processing module is responsible for receiving and optimizing the servo actuator and related sensor data for fault analysis, including external sensor signals and hardware signal trigger information; The fault analysis and sign generation module, based on the parameters and fault identification algorithm set by the fault parameter module, conducts in-depth analysis on the data obtained by the information processing module, determines the fault category and generates the associated fault sign; The fault response action module implements immediate fault management measures according to the analysis results of the fault category and fault sign, combined with the preset fault category judgment rules and the fault response action strategy, including normal shutdown, shutdown with priority to disconnection and enablement, shutdown with priority to braking, and channel disconnection and enablement; The fault output module issues an alarm and reports the fault information to the external monitoring system.

7. The multi-motor servo actuator fault hierarchical management system according to claim 6, characterized in that: The channel layer fault includes n channel faults, the channel connected to the i-th motor is called channel i, and the fault category of each channel includes drive module fault, angle sensor abnormality, angle sensor disconnection, continuous overcurrent, motor overtemperature and IGBT overheating; The fault categories of the drive system layer include hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, software undervoltage and communication failure; The fault categories of the servo actuator layer include limit fault, brake fault, brake release fault, speed error and redundant drive fault.

8. The multi-motor servo actuator fault hierarchical management system according to claim 7, characterized in that: The time threshold configuration sets different time thresholds according to different types of fault categories to avoid frequent false alarms, and multiple levels of time thresholds can be set for the same fault to gradually respond to faults of different severity; The data threshold configuration configures the corresponding data threshold range according to different fault types; The channel redundancy configuration is used to determine channel layer faults and redundant fault determination to prevent system downtime caused by a single channel fault; The fault type and response action configuration are configured in association with the fault response actions specified for different fault categories.

9. The multi-motor servo actuator fault hierarchical management system according to claim 8, characterized in that: The preset fault category determination rule and the fault response action strategy in the fault response action module are: Construct fault parameters for multi-motor servo actuator faults, set different time thresholds according to different types of fault categories to avoid frequent false alarms, and set multiple levels of time thresholds for the same type of faults to gradually respond to faults of different severity; Configure data thresholds for different data ranges according to different types of fault categories; and judging channel-level faults and redundancy faults through channel redundancy to prevent system downtime caused by single channel faults; The channel layer fault is regarded as a low-level fault. If multiple channels fail and the number of channels with channel failures does not exceed the channel redundancy, only the channels with failures will be disabled and the servo actuator can still work. Otherwise, if the number of channels with channel failures exceeds the channel redundancy, the fault is a redundant drive fault and belongs to the servo actuator layer fault. If a communication failure occurs in the drive system layer, the normal shutdown mode is adopted to stop working. For other drive system layer failures, including hardware overvoltage, hardware overcurrent, current sampling abnormality, software overvoltage, and software undervoltage, all of them are stopped by the enable priority shutdown mode; The servo drive layer failure adopts the braking priority shutdown working mode to stop working.

10. The multi-motor servo actuator fault hierarchical management system according to claim 7, characterized in that: Based on the machine learning algorithm and the threshold set by the fault parameters, the extracted characteristic states are compared to determine whether they exceed the preset fault threshold of the corresponding fault category; Matching the identified fault category with predefined fault sign rules to generate corresponding fault signs, each of which includes a fault type, a fault value, and a severity level; According to the fault sign, a fault response action strategy associated with the fault sign is adopted to respond to speed command adjustment, channel enable control, brake setting and execution of specific actions; the fault response action strategy includes normal shutdown, shutdown with enable priority, brake priority shutdown and channel enable disconnection.

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