Robot safety control system and control method

Abstract

The invention discloses a robot safety control system and method. The system comprises a main control module and a demonstrator module. The demonstrator module is electrically connected to the main control module; the main control module is electrically connected with the first safety module, and the main control module is electrically connected with the servo module; the first safety module is electrically connected with the second safety module; a third safety module and a fourth safety module are configured in the demonstrator module; the third security module and the fourth security module receive the control instruction simultaneously; the third security module and the fourth security module check the control instruction to obtain a primary check result; the first security module and the second security module check the primary check result and the control instruction to obtain a secondary check result; the first safety module controls the servo module to act according to the secondary verification result; according to the invention, the safety of robot control is improved through two-stage cross validation, and electrical wiring among system modules is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of robot control, and in particular relates to a robot safety control system and a control method. Background Art

[0002] With the advancement of industrial automation, industrial robots are increasingly being used. While improving work efficiency, the safety function technology of industrial robots has become a top priority in research and development design. The realization of robot safety functions requires, on the one hand, the acquisition of safety input device signals to achieve emergency stop and protective stop, and on the other hand, the acquisition of dynamics and kinematics information of each moving joint of the robot to achieve safety monitoring functions in order to meet the functional safety standards of industrial robots.

[0003] However, the existing robot safety architecture is imperfect and can only perform a single verification based on the received control instructions. It does not consider whether the verification result is correct. When the verification result is wrong, the control instruction continues to be executed, which reduces the safety of robot control and increases the risk of accidents. Summary of the invention

[0004] The object of the present invention is to provide a robot safety control system and control method, which improve the safety of robot control through two-level cross-validation.

[0005] In order to achieve the above object, the technical solution adopted by the present invention is: In a first aspect, the present invention provides a robot safety control system, comprising a main control module and a teach pendant module; the teach pendant module is electrically connected to the main control module; the main control module is electrically connected to a first safety module, and the main control module is electrically connected to a servo module; the first safety module is electrically connected to a second safety module; The teach pendant module is configured with a third safety module and a fourth safety module; the third safety module and the fourth safety module are electrically connected and receive control instructions at the same time; the third safety module and the fourth safety module verify the control instructions to obtain primary verification results; the first safety module and the second safety module verify the primary verification results and the control instructions to obtain secondary verification results; the first safety module directly controls the servo module to stop according to the secondary verification results, or the main control module controls the servo module to move according to the secondary verification results.

[0006] Furthermore, the teach pendant module also includes a human-computer interaction module and a first communication integration module that are electrically connected to each other; the third safety module and the fourth safety module synchronize information with each other; the third safety module is electrically connected to the first communication integration module; the first communication integration module is electrically connected to the main control module; and the human-computer interaction module exchanges information with the main control module through the first communication integration module.

[0007] Further, the human-computer interaction module receives restriction range information, and the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range, and a servo voltage restriction range; The first safety module and the second safety module collect the working information of the servo module through the main control module; When there is a difference between the working information received by the first safety module and the second safety module from the servo module, the servo module is controlled to stop operating; When the first safety module and the second safety module both determine that the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, the servo module is controlled to act according to preset program instructions; otherwise, the servo module is controlled to stop acting.

[0008] Furthermore, the enabling switch, the emergency stop switch and the mode switching switch are electrically connected to the third safety module and the fourth safety module; the control instructions include the enabling control instructions input by the enabling switch, the emergency stop control instructions input by the emergency stop switch and the mode switching control instructions input by the mode switching switch.

[0009] Further, the main control module includes a second communication integration module and a motion control module electrically connected to each other; the teaching pendant module and the servo module are electrically connected to the second communication integration module; the first safety module is electrically connected to the second communication integration module and the motion control module; The motion control module generates a controlled stop command according to the secondary verification result, and sends the controlled stop command to the servo module through the second communication integration module; or the first safety module generates a controlled stop command according to the secondary verification result, and sends the stop command to the servo module through the second communication integration module.

[0010] Furthermore, the main control module also includes a timing module, and the timing module controls the second communication integration module to perform timed information exchange with the teaching pendant module, the first safety module and the servo module.

[0011] Furthermore, the second communication integration module collects the execution information of the servo module and sends it to the first safety module; the first safety module records the execution time of the servo module; the first safety module calculates the actual position difference of the servo according to the execution information, and when the execution time of the servo module reaches the set time, or the actual position difference of the servo is greater than the error threshold, the first safety module sends an emergency stop command to the servo module through the second communication integration module.

[0012] Further, the first security module includes a first security control module; the first security control module is electrically connected to a first security communication module, a first security storage module, a first security synchronization module and a second security communication module; the first security communication module is connected to a main control module via a communication link; the first security storage module stores interaction information in the first security control module; The second security module includes a second security control module; the second security control module is electrically connected to the second security storage module, the second security synchronization module and the third security communication module; the second security storage module stores the interaction information in the second security control module; The first safety synchronization module is connected to the second safety synchronization module via a communication link; the second safety communication module is connected to the third safety communication module via a communication link.

[0013] Further, the third safety module includes a third safety control module; the third safety control module is electrically connected to the fourth safety communication module, the third safety synchronization module and the fifth safety communication module; the fourth safety communication module is connected to the main control module via a communication link; The fourth safety module includes a fourth safety control module; the fourth safety control module is electrically connected to the fourth safety synchronization module and the sixth safety communication module; The third safety synchronization module is connected to the fourth safety synchronization module via a communication link; the fifth safety communication module is connected to the sixth safety communication module via a communication link.

[0014] In a second aspect, the present invention provides a control method for a robot safety control system, comprising: Inputting the control instruction into the third safety module and the fourth safety module at the same time; verifying the control instruction through the third safety module and the fourth safety module to obtain a primary verification result; The primary verification result and the control instruction are verified by the first safety module and the second safety module to obtain the secondary verification result; the servo module action is controlled according to the secondary verification result; wherein, controlling the servo module action includes but is not limited to controlling the servo module to move and controlling the servo module to stop.

[0015] Further, the control instruction is verified by the third safety module and the fourth safety module to obtain a primary verification result, and the process includes: The control instruction is identified by the third security module and the fourth security module to obtain a confirmation result; the confirmation result synchronization of the third security module and the fourth security module is initiated regularly, and when the confirmation results of the third security module and the fourth security module are the same, the primary verification result is normal; when the confirmation result synchronization of the third security module and the fourth security module times out or the confirmation results of the third security module and the fourth security module are opposite, the primary verification result is abnormal.

[0016] Further, the primary verification result and the control instruction are verified by the first safety module and the second safety module to obtain a secondary verification result, and the servo module action is controlled according to the secondary verification result, specifically including: The control instruction is identified by the first safety module and the second safety module to obtain a confirmation result; when the confirmation results of the third safety module and the fourth safety module are the same, and the confirmation results of the first safety module and the second safety module are the same, the secondary verification result is normal, and the servo module is controlled to execute the control instruction; otherwise, the secondary verification result is abnormal, and the servo module is controlled to stop moving.

[0017] Further, it also includes: accepting restriction range information, wherein the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range, and a servo voltage restriction range; The main control module collects the working information of the servo module; when there is a difference between the working information of the servo module received by the first safety module and the second safety module, the servo module is controlled to stop the action; When the first safety module and the second safety module both determine that the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, the servo module is controlled to act according to preset program instructions; otherwise, the servo module is controlled to stop acting.

[0018] Compared with the prior art, the present invention has the following beneficial effects: In the present invention, the third safety module and the fourth safety module receive control instructions at the same time; the third safety module and the fourth safety module verify the control instructions to obtain primary verification results; the first safety module and the second safety module verify the primary verification results and the control instructions to obtain secondary verification results; the main control module controls the action of the servo module according to the secondary verification results; and the safety of robot control is improved through two-level cross-validation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a structural diagram of a robot safety control system provided in this embodiment 1; Figure 2is a structural diagram of the teaching pendant module provided in this embodiment 1; Figure 3 is a structural diagram of the main control module provided in this embodiment 1; Figure 4 is a structural diagram of a first security module and a second security module provided in Embodiment 1; Figure 5 It is a structural diagram of the third security module and the fourth security module provided in this embodiment 1. DETAILED DESCRIPTION

[0020] 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.

[0021] It should be noted that in the description of the present invention, the directions or positional relationships indicated by the terms "front", "rear", "left", "right", "up", "down", "inside", "outside", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention rather than requiring the present invention to be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. The terms "front", "rear", "left", "right", "up", and "down" used in the description of the present invention refer to the directions in the accompanying drawings, and the terms "inside" and "outside" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0022] Example 1

[0023] like Figures 1 to 5 As shown, a robot safety control system includes a main control module and a teach pendant module; the teach pendant module is electrically connected to the main control module; the main control module is electrically connected to the first safety module, and the main control module is electrically connected to the servo module; the servo module has the following safety functions: the main control module accepts STO (safe torque off) and SBC (safe brake control) control through the communication port and uploads servo module information including actual position, actual speed, actual torque, actual current, actual voltage, STO status word, and SBC status word.

[0024] The first security module is electrically connected to the second security module. The first security module includes a first security control module; the first security control module is electrically connected to a first security communication module, a first security storage module, a first security synchronization module and a second security communication module; the first security communication module is connected to a main control module via a communication link; the first security storage module stores interactive information in the first security control module; the second security module includes a second security control module; the second security control module is electrically connected to a second security storage module, a second security synchronization module and a third security communication module; the second security storage module stores interactive information in the second security control module; the first security synchronization module is connected to the second security synchronization module via a communication link; the second security communication module and the third security communication module are connected via a communication link.

[0025] The teaching pendant module includes a third safety module, a fourth safety module, a human-computer interaction module and a first communication integration module which are electrically connected to each other; The third safety module and the fourth safety module synchronize information with each other; the third safety module is electrically connected to the first communication integration module; the first communication integration module is electrically connected to the main control module; the human-computer interaction module exchanges information with the main control module through the first communication integration module.

[0026] Among them, the third safety module includes a third safety control module; the third safety control module is electrically connected to the fourth safety communication module, the third safety synchronization module and the fifth safety communication module; the fourth safety communication module is connected to the main control module through a communication link; the fourth safety module includes a fourth safety control module; the fourth safety control module is electrically connected to the fourth safety synchronization module and the sixth safety communication module; the third safety synchronization module is connected to the fourth safety synchronization module through a communication link; the fifth safety communication module and the sixth safety communication module are connected through a communication link.

[0027] The third safety module and the fourth safety module receive control instructions at the same time; the enabling switch, the emergency stop switch and the mode switching switch in this embodiment electrically connect the third safety module and the fourth safety module; the control instructions include the enabling control instructions input by the enabling switch, the emergency stop control instructions input by the emergency stop switch and the mode switching control instructions input by the mode switching switch. The third safety module and the fourth safety module verify the control instructions to obtain primary verification results; the first safety module and the second safety module verify the primary verification results and the control instructions to obtain secondary verification results, and the main control module controls the servo module action according to the secondary verification results; wherein, controlling the servo module action includes but is not limited to controlling the servo module to move and controlling the servo module to stop.

[0028] The motion control module generates a controlled stop command according to the secondary verification result, and sends the controlled stop command to the servo module through the second communication integration module; or the first safety module generates a controlled stop command according to the secondary verification result, and sends the stop command to the servo module through the second communication integration module.

[0029] The human-computer interaction module receives the restriction range information, wherein the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range and a servo voltage restriction range; The main control module includes a second communication integration module and a motion control module that are electrically connected to each other; the teach pendant module and the servo module are electrically connected to the second communication integration module; the first safety module is electrically connected to the second communication integration module and the motion control module; the main control module also includes a timing module, and the timing module controls the second communication integration module to exchange information with the teach pendant module, the first safety module and the servo module at a timed basis.

[0030] The first safety module and the second safety module collect the working information of the servo module through the second communication integration module; when there is a difference between the working information of the servo module received by the first safety module and the second safety module, the servo module is controlled to stop the action.

[0031] When the first safety module and the second safety module both determine that the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, the servo module is controlled to act according to preset program instructions; otherwise, the servo module is controlled to stop acting.

[0032] For the control word STO and SBC communication path of the servo module: the first safety communication module of the first safety module, the second communication integration module and the servo module; the upload path of the servo module status information (actual position, etc.): the servo module, the second communication integration module and the first safety communication module of the first safety module.

[0033] The second communication integration module collects the execution information of the servo module and sends it to the first safety module; the first safety module records the execution time of the servo module; the first safety module calculates the actual position difference of the servo according to the execution information, and when the execution time of the servo module reaches the set time, or the actual position difference of the servo is greater than the error threshold, the first safety module sends an emergency stop command to the servo module through the second communication integration module.

[0034] Example 2

[0035] This embodiment provides a robot safety control method, which is applied to the safety control system described in Example 1, and includes: Input the control instruction to the third safety module and the fourth safety module at the same time; verify the control instruction by the third safety module and the fourth safety module to obtain a primary verification result, the process includes: The control instruction is identified by the third security module and the fourth security module to obtain a confirmation result; the confirmation result synchronization of the third security module and the fourth security module is initiated regularly, and when the confirmation results of the third security module and the fourth security module are the same, the primary verification result is normal; when the confirmation result synchronization of the third security module and the fourth security module times out or the confirmation results of the third security module and the fourth security module are opposite, the primary verification result is abnormal.

[0036] Using the first safety module and the second safety module to verify the primary verification result and the control instruction to obtain a secondary verification result, and controlling the servo module action according to the secondary verification result, specifically includes: The control instruction is identified by the first safety module and the second safety module to obtain a confirmation result; when the confirmation results of the third safety module and the fourth safety module are the same, and the confirmation results of the first safety module and the second safety module are the same, the secondary verification result is normal, and the servo module is controlled to execute the control instruction; otherwise, the secondary verification result is abnormal, and the servo module is controlled to stop moving.

[0037] Accepting restriction range information, wherein the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range, and a servo voltage restriction range; The main control module collects the working information of the servo module; when there is a difference between the working information of the servo module received by the first safety module and the second safety module, the servo module is controlled to stop the action; When the first safety module and the second safety module both determine that the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, the servo module is controlled to act according to preset program instructions; otherwise, the servo module is controlled to stop acting.

[0038] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, etc.) containing computer-usable program code. M , optical storage, etc.).

[0039] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0040] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0041] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0042] 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 robot safety control system, characterized in that: It includes a main control module and a teaching pendant module; the teaching pendant module is electrically connected to the main control module; the main control module is electrically connected to the first safety module, and the main control module is electrically connected to the servo module; the first safety module is electrically connected to the second safety module; The teaching pendant module is provided with a third safety module and a fourth safety module; the third safety module and the fourth safety module are electrically connected and receive control instructions at the same time; the third safety module and the fourth safety module verify the control instructions to obtain a primary verification result; the first safety module and the second safety module verify the primary verification result and the control instructions to obtain a secondary verification result; The first safety module directly controls the servo module to stop according to the secondary verification result, or the main control module controls the servo module to move according to the secondary verification result.

2. The robot safety control system according to claim 1, characterized in that: The teach pendant module also includes a human-computer interaction module and a first communication integration module that are electrically connected to each other; the third safety module and the fourth safety module synchronize information with each other; the third safety module is electrically connected to the first communication integration module; the first communication integration module is electrically connected to the main control module; the human-computer interaction module exchanges information with the main control module through the first communication integration module.

3. The robot safety control system according to claim 2, characterized in that: The human-computer interaction module receives the restriction range information, wherein the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range and a servo voltage restriction range; The first safety module and the second safety module collect the working information of the servo module through the main control module; When there is a difference between the working information received by the first safety module and the second safety module from the servo module, the servo module is controlled to stop operating; The first safety module and the second safety module both determine whether the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, and control the servo module to act according to preset program instructions; otherwise, control the servo module to stop acting.

4. The robot safety control system according to claim 1, characterized in that: The enabling switch, the emergency stop switch and the mode switching switch are electrically connected to the third safety module and the fourth safety module; the control instructions include the enabling control instructions input by the enabling switch, the emergency stop control instructions input by the emergency stop switch and the mode switching control instructions input by the mode switching switch.

5. The robot safety control system according to claim 1, characterized in that: The main control module includes a second communication integration module and a motion control module electrically connected to each other; the teaching pendant module and the servo module are electrically connected to the second communication integration module; the first safety module is electrically connected to the second communication integration module and the motion control module; The motion control module generates a controlled stop command according to the secondary verification result, and sends the controlled stop command to the servo module through the second communication integration module; Alternatively, the first safety module generates a control stop command according to the secondary verification result, and sends the stop command to the servo module through the second communication integration module.

6. The robot safety control system according to claim 5, characterized in that: The main control module further includes a timing module, which controls the second communication integration module to perform timed information exchange with the teaching pendant module, the first safety module and the servo module.

7. The robot safety control system according to claim 5, characterized in that: The second communication integration module collects the execution information of the servo module and sends it to the first safety module; the first safety module records the execution time of the servo module; the first safety module calculates the actual position difference of the servo according to the execution information, and when the execution time of the servo module reaches the set time, or the actual position difference of the servo is greater than the error threshold, the first safety module sends an emergency stop command to the servo module through the second communication integration module.

8. The robot safety control system according to claim 1, characterized in that: The first security module includes a first security control module; the first security control module is electrically connected to a first security communication module, a first security storage module, a first security synchronization module and a second security communication module; The first safety communication module is connected to the main control module via a communication link; The first security storage module stores the interaction information in the first security control module; The second safety module includes a second safety control module; The second safety control module is electrically connected to the second safety storage module, the second safety synchronization module and the third safety communication module; The second security storage module stores the interaction information in the second security control module; The first safety synchronization module is connected to the second safety synchronization module via a communication link; the second safety communication module is connected to the third safety communication module via a communication link.

9. The robot safety control system according to claim 1, characterized in that: The third safety module includes a third safety control module; the third safety control module is electrically connected to the fourth safety communication module, the third safety synchronization module and the fifth safety communication module; the fourth safety communication module is connected to the main control module via a communication link; The fourth safety module includes a fourth safety control module; the fourth safety control module is electrically connected to the fourth safety synchronization module and the sixth safety communication module; The third safety synchronization module is connected to the fourth safety synchronization module via a communication link; the fifth safety communication module is connected to the sixth safety communication module via a communication link.

10. The control method of the robot safety control system according to any one of claims 1 to 9, characterized in that: include: inputting the control instruction to the third safety module and the fourth safety module simultaneously; Verifying the control instruction by the third safety module and the fourth safety module to obtain a primary verification result; Using the first safety module and the second safety module to verify the primary verification result and the control instruction to obtain a secondary verification result; The first safety module directly controls the servo module to stop according to the secondary verification result, or the main control module controls the servo module to move according to the secondary verification result.

11. The control method according to claim 10, characterized in that: The control instruction is verified by the third safety module and the fourth safety module to obtain a primary verification result, and the process includes: The control instruction is identified by the third security module and the fourth security module to obtain a confirmation result; the confirmation result synchronization of the third security module and the fourth security module is initiated regularly, and when the confirmation results of the third security module and the fourth security module are the same, the primary verification result is normal; when the confirmation result synchronization of the third security module and the fourth security module times out or the confirmation results of the third security module and the fourth security module are opposite, the primary verification result is abnormal.

12. The control method according to claim 10, characterized in that: Using the first safety module and the second safety module to verify the primary verification result and the control instruction to obtain a secondary verification result, and controlling the servo module action according to the secondary verification result, specifically includes: The control instruction is identified by the first safety module and the second safety module to obtain a confirmation result; when the confirmation results of the third safety module and the fourth safety module are the same, and the confirmation results of the first safety module and the second safety module are the same, the secondary verification result is normal, and the servo module is controlled to execute the control instruction; otherwise, the secondary verification result is abnormal, and the servo module is controlled to stop moving.

13. The control method according to claim 10, characterized in that: Also includes: Accepting restriction range information, wherein the restriction range information includes a servo position restriction range, a servo speed restriction range, a servo torque restriction range, a servo current restriction range, and a servo voltage restriction range; Collecting the working information of the servo module; when there is a difference between the working information of the servo module received by the first safety module and the second safety module, controlling the servo module to stop operating; When the first safety module and the second safety module both determine that the working information of the servo module is respectively within the servo position limit range, the servo speed limit range, the servo torque limit range, the servo current limit range and the servo voltage limit range, the servo module is controlled to act according to preset program instructions; otherwise, the servo module is controlled to stop acting.

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