Synchronous control method and system for multiple robots based on PLC

Abstract

The invention discloses a synchronous control method and system for multiple robots based on a PLC. The control method comprises the steps that firstly, state information of each robot is monitored and collected in real time; 2, calculating the synchronization error of each robot according to the state information, then detecting the synchronization error, and if the synchronization error exceeds the range, executing the step 3; thirdly, a preliminary control instruction is generated according to the synchronization error of the robot, then the preliminary control instruction is adjusted from the three aspects of proportion, integration and differential parameters, and then the adjusted control instruction is sent to the corresponding robot; fourthly, the corresponding robots receive and execute the control instructions, and therefore the states of the robots are synchronized; the system comprises a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module. Therefore, efficient and high-precision synchronous control over the multiple robots can be achieved through the design.

Description

Technical Field

[0001] The present invention relates to a synchronous control method and system for multiple robots, belonging to the technical field of robot control, and in particular to a synchronous control method and system for multiple robots based on PLC. Background Art

[0002] With the rapid development of industrial automation technology, robots are increasingly used in the manufacturing industry. The advancement of robotics technology has not only improved production efficiency, but also enhanced the flexibility and precision of the production process. Since in many complex production tasks, multiple robots are required to work together to complete a specific production process, this requires accurate and efficient synchronization control between multiple robots. At present, programmable logic controllers (PLCs) are used in the field of synchronous control of robots because of their high reliability and convenient programming. However, in terms of synchronous control of multiple robots, the existing PLC-based control scheme cannot effectively solve the problem of accurate synchronization between multiple robots. Therefore, a synchronous control method and system for multiple robots based on PLC is needed to meet the needs of efficient and high-precision collaborative work of multiple robots in modern industrial production, thereby improving production efficiency and flexibility.

[0003] The Chinese patent application with application number 202210788664.3 and application date July 6, 2022 discloses a synchronous control system for multiple robots based on PLC, in which a programmable logic controller is respectively connected to multiple master control IO controllers, each master control IO controller is connected to a relay module, and each relay module is connected to the IO control modules of multiple robots; the programmable logic controller is used to obtain the operation instructions input by the key function module and the status information fed back by multiple robots through the master control IO controller and the relay module, generate synchronous control instructions for controlling multiple robots, and send the generated synchronous control instructions to the IO control module of each robot through the master control IO controller and the relay module, judge the execution result of the synchronous control instructions, and also propose a synchronous control method for multiple robots based on PLC. Although this patent effectively improves the efficiency and safety of the control of multiple robots, it still has the following defects:

[0004] This design cannot achieve efficient and high-precision synchronous control of multiple robots.

[0005] The information disclosed in this background technology section is only intended to increase the understanding of the overall background of this patent application, and should not be regarded as acknowledging or suggesting in any form that the information constitutes the prior art already known to ordinary technicians in this field. Summary of the invention

[0006] The purpose of the present invention is to overcome the defects and problems existing in the prior art that multiple robots cannot be efficiently and accurately controlled synchronously, and to provide a PLC-based synchronous control method and system for multiple robots that can realize efficient and accurate synchronous control of multiple robots.

[0007] To achieve the above objectives, the technical solution of the present invention is: a PLC-based synchronous control method and system for multiple robots, the PLC-based synchronous control method for multiple robots comprising the following steps:

[0008] Step 1: First, monitor and collect the status information of each robot in real time, and then perform data cleaning on the monitored and collected status information to obtain status information data;

[0009] Step 2: First, calculate the synchronization error of each robot based on the above status information data, and then detect whether the synchronization error of each robot exceeds the allowable range; if the synchronization error of a robot does not exceed the allowable range, continue to monitor and collect the status information of the robot; if the synchronization error of a robot exceeds the allowable range, execute the third step for the robot;

[0010] Step 3: First, generate a preliminary control instruction based on the synchronization error of the robot, then adjust the preliminary control instruction from three aspects of proportional, integral and differential parameters to generate a final control instruction, and then send the final control instruction to the robot;

[0011] Step 4: After receiving the above final control instruction, the robot executes the corresponding instruction action to adjust the state of the robot, thereby synchronizing the state of the robot.

[0012] In the third step, sending the final control instruction to the robot means: optimizing the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction, and finally sending the optimized control instruction to the robot;

[0013] In the fourth step, the robot receiving the final control instruction means that the robot receives the optimized control instruction.

[0014] The PLC-based synchronous control method for multiple robots also includes:

[0015] Step 5: Loop through steps 1 to 4 until a stop command is received or an unrecoverable fault occurs.

[0016] The PLC-based synchronous control system for multiple robots includes a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module;

[0017] The PLC control module is used to receive the status information data of each robot, and transmit the received status information data of each robot to the synchronous control algorithm module, and then issue control instructions according to the preset control logic;

[0018] The communication module is used to realize data communication between the PLC control module and each robot, transmit the status information data of each robot to the PLC control module, and at the same time, transmit the control instructions of the PLC control module and the synchronous control algorithm module to each robot;

[0019] The synchronous control algorithm module is embedded in the PLC control module and is used to process the synchronous control logic between multiple robots. After processing the state information data to generate control instructions, the control instructions are transmitted to the corresponding robots through the communication module.

[0020] The synchronous control algorithm module includes a PID control algorithm, which is used to accurately and synchronously control the movement of each robot from three aspects of proportional, integral and differential parameters;

[0021] The state monitoring module is connected to the PLC control module and is used to monitor and collect the working state data of each robot in real time, and transmit the data to the PLC control module through the communication module;

[0022] The fault diagnosis module is used to detect abnormal conditions in the system and provide fault handling solutions;

[0023] The user interface module is used for the operator to interact with the system, including system status display, control command input and system parameter configuration; the command is input through the control command input, and then the input command is passed to the PLC control module, and the PLC control module executes the corresponding control logic according to the input command, and feeds back the execution result to the user interface module; when the fault diagnosis module finds that the operating status is abnormal or faulty, it immediately notifies the operator, and the operator checks the system status, inputs control commands and configures system parameters through the user interface module;

[0024] In the first step, the state information of each robot is first monitored and collected in real time, and then the monitored and collected state information is cleaned. The state monitoring module first monitors and collects the state information of each robot in real time, and then cleans the monitored and collected state information;

[0025] In the second step, the synchronization error of each robot is calculated based on the above state information data, and then the synchronization error of each robot is detected. The synchronization error of each robot is calculated by the synchronization control algorithm module based on the above state information data, and then the synchronization error of each robot is detected; In the second step, the state information of the robot is continuously monitored and collected by the state monitoring module.

[0026] In the third step, the preliminary control instructions are generated according to the synchronization error of the robot by the synchronization control algorithm module; the preliminary control instructions are adjusted from three aspects of proportion, integration and differential parameters to generate the final control instructions by the PID control algorithm; the final control instructions are sent to the robot by the communication module.

[0027] The synchronous control algorithm module also includes a dynamic adjustment mechanism for dynamically adjusting control instructions according to the relative position and speed differences between the robots;

[0028] In the third step, the final control instruction is optimized again according to the relative position and speed difference between the robots to obtain the optimized control instruction. The dynamic adjustment mechanism optimizes the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction.

[0029] In the third step, the optimized control instruction is sent to the robot by the communication module.

[0030] The dynamic adjustment mechanism is implemented by the following algorithm formula:

[0031]

[0032] Among them, V adj is the adjusted speed command, P err is the position error between robots, K P and K d They are proportional gain and differential gain, which are used to adjust the response speed and stability of the system;

[0033] In the third step, the final control instruction is optimized again by an algorithm formula of a dynamic adjustment mechanism.

[0034] The state monitoring module includes a position sensor, a velocity sensor and an acceleration sensor, which are respectively used to monitor and collect the position, velocity and acceleration state information of each robot; the position sensor adopts laser ranging or encoder technology, and the velocity sensor uses the Doppler effect principle or speed measurement motor technology;

[0035] In the first step, the real-time monitoring and collection of the status information of each robot is performed by using a position sensor, a velocity sensor and an acceleration sensor to respectively monitor and collect the position, velocity and acceleration status information of each robot in real time;

[0036] In the second step, the state information of the robot is continuously monitored and collected by using a position sensor, a velocity sensor and an acceleration sensor to monitor and collect the position, velocity and acceleration state information of the robot respectively.

[0037] The communication module supports multiple communication protocols, including but not limited to industrial Ethernet, serial communication and wireless communication protocols.

[0038] The synchronous control algorithm module also includes: a prediction model based on time series analysis, which is used to predict the state changes of each robot in a future time period.

[0039] The user interface module also includes a simulation submodule for simulating the movement and operation process of the robot before actual operation. The user interface module remotely monitors the dynamics of the robot through the Internet.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] 1. A synchronous control method and system for multiple robots based on PLC, wherein the synchronous control system for multiple robots based on PLC includes a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module. A preliminary control instruction is first generated according to the synchronization error, and then the preliminary control instruction is adjusted from three aspects of proportion, integral and differential parameters to generate a final control instruction, and then the final control instruction is sent to the robot; when applied, the state monitoring module first detects and collects the state information of the robot in real time, and transmits it to the PLC control module through the communication module. The synchronous control algorithm module receives the state information data, calculates the synchronization error of each robot, and then detects the synchronization error. When the synchronization error exceeds the allowable range, the synchronous control algorithm module executes the synchronous control logic to generate a preliminary control instruction for the robot, and the PID control algorithm optimizes the preliminary control instruction from the proportion, integral and differential parameters to generate a final control instruction, and sends it to the corresponding robot through the communication module. After the robot receives and executes the instruction, each robot is synchronized. Due to the use of the PID control algorithm, the movement of the robot is precisely synchronized and controlled from three aspects of proportion, integral and differential parameters, thereby reducing the error and improving the synchronization accuracy. Therefore, the present invention can not only perform synchronous control on multiple robots, but also achieve efficient and high-precision synchronous control on multiple robots.

[0042] 2. A synchronous control method and system for multiple robots based on PLC, wherein the synchronous control algorithm module includes a PID control algorithm, and the synchronous control algorithm module also includes a dynamic adjustment mechanism. The synchronous control algorithm module also includes: a prediction model based on time series analysis, which is used to predict the state changes of each robot in the future time period; when applied, the PID control algorithm performs precise synchronous control on the movement of each robot from three aspects of proportional, integral and differential parameters, and the dynamic adjustment mechanism dynamically optimizes the control instructions according to the relative position and speed difference between the robots to achieve more precise and intelligent control of multiple robots. The prediction model based on time series analysis predicts the state changes of each robot in the future time period by analyzing historical data and trends, thereby adjusting the control instructions in advance and optimizing the synchronization performance of the robot. The combination of the three can improve the efficiency, accuracy and stability of the synchronous control of multiple robots. Therefore, the present invention can not only perform synchronous control on multiple robots, but also improve the efficiency, accuracy and stability of synchronous control.

[0043] 3. In a synchronous control method and system of multiple robots based on PLC, the state monitoring module includes a position sensor, a speed sensor and an acceleration sensor, which are respectively used to monitor and collect the position, speed and acceleration state information of each robot; when used, the position sensor, the speed sensor and the acceleration sensor monitor and collect the position, speed and acceleration motion state information of each robot in real time, and then transmit this information to the PLC control module through the communication module. Because the sensor has high accuracy, it provides accurate input information for the PLC control module, ensuring the accuracy and synchronization of the robot's movements, thereby improving the motion control accuracy and accuracy of each robot, and further improving the accuracy of synchronous control of multiple robots. Therefore, the present invention can not only improve the efficiency, accuracy and stability of synchronous control, but also improve the control accuracy and accuracy of robot movements. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a logical schematic diagram of the system in the present invention.

[0045] Figure 2 It is a flow chart of the control method in the present invention. DETAILED DESCRIPTION

[0046] The present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0047] See also Figure 1 — Figure 2 , a PLC-based synchronous control method and system for multiple robots, the PLC-based synchronous control method for multiple robots comprising the following steps:

[0048] Step 1: First, monitor and collect the status information of each robot in real time, and then perform data cleaning on the monitored and collected status information to obtain status information data;

[0049] Step 2: First, calculate the synchronization error of each robot based on the above status information data, and then detect whether the synchronization error of each robot exceeds the allowable range; if the synchronization error of a robot does not exceed the allowable range, continue to monitor and collect the status information of the robot; if the synchronization error of a robot exceeds the allowable range, execute the third step for the robot;

[0050] Step 3: First, generate a preliminary control instruction based on the synchronization error of the robot, then adjust the preliminary control instruction from three aspects of proportional, integral and differential parameters to generate a final control instruction, and then send the final control instruction to the robot;

[0051] Step 4: After receiving the above final control instruction, the robot executes the corresponding instruction action to adjust the state of the robot, thereby synchronizing the state of the robot.

[0052] In the third step, sending the final control instruction to the robot means: optimizing the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction, and finally sending the optimized control instruction to the robot;

[0053] In the fourth step, the robot receiving the final control instruction means that the robot receives the optimized control instruction.

[0054] The PLC-based synchronous control method for multiple robots also includes:

[0055] Step 5: Loop through steps 1 to 4 until a stop command is received or an unrecoverable fault occurs.

[0056] The PLC-based synchronous control system for multiple robots includes a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module;

[0057] The PLC control module is used to receive the status information data of each robot, and transmit the received status information data of each robot to the synchronous control algorithm module, and then issue control instructions according to the preset control logic;

[0058] The communication module is used to realize data communication between the PLC control module and each robot, transmit the status information data of each robot to the PLC control module, and at the same time, transmit the control instructions of the PLC control module and the synchronous control algorithm module to each robot;

[0059] The synchronous control algorithm module is embedded in the PLC control module and is used to process the synchronous control logic between multiple robots. After processing the state information data to generate control instructions, the control instructions are transmitted to the corresponding robots through the communication module.

[0060] The synchronous control algorithm module includes a PID control algorithm, which is used to accurately and synchronously control the movement of each robot from three aspects of proportional, integral and differential parameters;

[0061] The state monitoring module is connected to the PLC control module and is used to monitor and collect the working state data of each robot in real time, and transmit the data to the PLC control module through the communication module;

[0062] The fault diagnosis module is used to detect abnormal conditions in the system and provide fault handling solutions;

[0063] The user interface module is used for the operator to interact with the system, including system status display, control command input and system parameter configuration; the command is input through the control command input, and then the input command is passed to the PLC control module, and the PLC control module executes the corresponding control logic according to the input command, and feeds back the execution result to the user interface module; when the fault diagnosis module finds that the operating status is abnormal or faulty, it immediately notifies the operator, and the operator checks the system status, inputs control commands and configures system parameters through the user interface module;

[0064] In the first step, the state information of each robot is first monitored and collected in real time, and then the monitored and collected state information is cleaned. The state monitoring module first monitors and collects the state information of each robot in real time, and then cleans the monitored and collected state information;

[0065] In the second step, the synchronization error of each robot is calculated based on the above state information data, and then the synchronization error of each robot is detected. The synchronization error of each robot is calculated by the synchronization control algorithm module based on the above state information data, and then the synchronization error of each robot is detected; In the second step, the state information of the robot is continuously monitored and collected by the state monitoring module.

[0066] In the third step, the preliminary control instructions are generated according to the synchronization error of the robot by the synchronization control algorithm module; the preliminary control instructions are adjusted from three aspects of proportion, integration and differential parameters to generate the final control instructions by the PID control algorithm; the final control instructions are sent to the robot by the communication module.

[0067] The synchronous control algorithm module also includes a dynamic adjustment mechanism for dynamically adjusting control instructions according to the relative position and speed differences between the robots;

[0068] In the third step, the final control instruction is optimized again according to the relative position and speed difference between the robots to obtain the optimized control instruction. The dynamic adjustment mechanism optimizes the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction.

[0069] In the third step, the optimized control instruction is sent to the robot by the communication module.

[0070] The dynamic adjustment mechanism is implemented by the following algorithm formula:

[0071]

[0072] Among them, V adj is the adjusted speed command, P err is the position error between robots, K P and K d They are proportional gain and differential gain, which are used to adjust the response speed and stability of the system;

[0073] In the third step, the final control instruction is optimized again by an algorithm formula of a dynamic adjustment mechanism.

[0074] The state monitoring module includes a position sensor, a velocity sensor and an acceleration sensor, which are respectively used to monitor and collect the position, velocity and acceleration state information of each robot; the position sensor adopts laser ranging or encoder technology, and the velocity sensor uses the Doppler effect principle or speed measurement motor technology;

[0075] In the first step, the real-time monitoring and collection of the status information of each robot is performed by a position sensor, a velocity sensor and an acceleration sensor to respectively monitor and collect the position, velocity and acceleration status information of each robot in real time;

[0076] In the second step, the state information of the robot is continuously monitored and collected by using a position sensor, a velocity sensor and an acceleration sensor to monitor and collect the position, velocity and acceleration state information of the robot respectively.

[0077] The communication module supports multiple communication protocols, including but not limited to industrial Ethernet, serial communication and wireless communication protocols.

[0078] The synchronous control algorithm module also includes: a prediction model based on time series analysis, which is used to predict the state changes of each robot in a future time period.

[0079] The user interface module also includes a simulation submodule for simulating the movement and operation process of the robot before actual operation. The user interface module remotely monitors the dynamics of the robot through the Internet.

[0080] The supplementary description of the present invention is as follows:

[0081] In the preferred first step of the present invention, the state information of the robot includes position, speed and acceleration information.

[0082] The present invention preferably uses the fault diagnosis module to detect and collect the operating status of the system and the robot in real time, and immediately notify the operator when an abnormality or failure is found in the operating status.

[0083] In the preferred second step of the present invention, the step of calculating the synchronization error of each robot based on the state information data refers to: the synchronization control algorithm module analyzes the state information data and calculates the synchronization error.

[0084] In the preferred second step of the present invention, if the synchronization error of a certain robot exceeds the allowable range, the synchronization control logic is executed.

[0085] In the preferred third step of the present invention, generating preliminary control instructions based on the synchronization error of the robot means that the robot executes the synchronization control logic, that is, the synchronization control algorithm module generates control instructions according to the synchronization error of the robot and the preset control logic.

[0086] The preferred PLC control module of the present invention can quickly parse and process a large amount of status information, and a special cache area is provided inside it for temporarily storing received information to ensure the efficiency and accuracy of data processing; at the same time, the PLC control module monitors its own operating status in real time, and can promptly issue an alarm to remind staff when an abnormality occurs.

[0087] The preferred communication module of the present invention has an automatic reconnection function. When the communication connection is interrupted, it can automatically attempt to reconnect, and can encrypt the transmitted data during the connection process to ensure the security of the data. In addition, the communication module also supports multi-channel transmission and can process data sent by multiple robots at the same time, thereby improving the overall communication efficiency of the system.

[0088] The preferred synchronous control algorithm module of the present invention is internally provided with a plurality of submodules, each of which is responsible for a different control function. These submodules cooperate with each other to jointly realize efficient and accurate synchronous control.

[0089] The preferred state monitoring module of the present invention adopts high-precision sensors and monitoring equipment, which can accurately obtain various working state information of the robot, including but not limited to position, speed, acceleration, temperature, pressure, etc.; the state monitoring module also has data filtering and preprocessing functions, which can screen and process the acquired raw data to remove noise and interference information, so as to ensure the accuracy and effectiveness of the data fed back to the PLC control module.

[0090] The preferred fault diagnosis module of the present invention performs a comprehensive analysis based on historical fault data and current system status, predicts possible faults, and takes corresponding measures in advance to prevent them; when a fault occurs, the fault diagnosis module can accurately locate the source of the fault and provide a detailed fault handling plan, including maintenance steps, required tools and materials, etc.

[0091] The preferred user interface module of the present invention has a multi-language support function, which can meet the needs of users in different countries and regions. At the same time, the user interface module also has a user authority management function, which can set different operation interfaces and functional permissions according to the roles and permissions of different users to ensure the security and confidentiality of the system.

[0092] The present invention prefers that the time series analysis in the prediction model based on time series analysis is based on a large amount of historical data and advanced algorithm models, which can accurately capture the periodicity and trend changes of the robot's motion state. In some complex assembly tasks, the robot's motion trajectory may show certain regularities over time. The prediction model based on time series analysis can predict the robot's position, speed, acceleration and other state parameters at a certain moment in the future based on past motion data, so that the synchronization control algorithm module can adjust the control instructions in advance to avoid synchronization errors between robots.

[0093] The prediction model preferably based on time series analysis of the present invention helps to identify and predict trends and periodic patterns in robot motion, so that the synchronization control algorithm can more effectively coordinate the actions of multiple robots and reduce synchronization errors; at the same time, the prediction model based on time series analysis discovers the common motion modes of robots in different working stages through deep learning and pattern recognition of historical data, such as acceleration and deceleration modes when grasping parts, fine-tuning modes during assembly, etc., so as to better adjust the control parameters and ensure that multiple robots can move accurately and synchronously.

[0094] The preferred state monitoring module of the present invention monitors the precise motion state of the robot in real time by using position sensors, velocity sensors and acceleration sensors, thereby obtaining key parameters such as the position, velocity and acceleration of the robot, and then uploads these parameter information to the PLC control module through the communication module, providing the PLC control module with precise input information, which helps to improve the control accuracy of the robot's motion and ensure the accuracy and synchronization of the robot's movements.

[0095] The preferred industrial Ethernet protocol of the present invention can provide high-speed and stable data transmission, which is suitable for large-scale data interaction between robots in large-scale industrial production environments. Its transmission rate can reach 100Mbps and above, which can meet the control instructions and status data transmission with high real-time requirements.

[0096] The preferred serial communication protocol of the present invention has the characteristics of being simple and reliable, and can provide a stable communication connection for some devices that do not require a high transmission rate but have a high requirement for stability, such as some small sensors or actuators.

[0097] The preferred wireless communication protocol of the present invention can not only reduce wiring, but also facilitate remote control and monitoring of the robot. In some dangerous environments or places where wiring is difficult, the working status of the robot can be remotely operated and monitored through Wi-Fi or Bluetooth technology, thereby improving the applicability and flexibility of the system.

[0098] The preferred PID control algorithm of the present invention performs precise synchronous control on the movements of each robot from three aspects of proportion, integration and differential parameters.

[0099] The proportional control in the preferred PID control algorithm of the present invention is based on the size of the current error, that is, the error in the motion amplitude between the robots, which is the difference between the target value (set value) and the actual output value; the proportional control coefficient can be adjusted according to the actual situation. When the synchronization error between the robots is large, the proportional control coefficient can be appropriately increased so that the control instruction can correct the robot's motion more quickly and make it close to the target state; for example, in some tasks that require fast synchronization, such as when multiple robots are carrying a large object at the same time, if it is found that the motion amplitude of a certain robot is greatly different from that of other robots, the movement speed and direction of the robot can be quickly adjusted by increasing the proportional control coefficient to keep it synchronized with other robots.

[0100] The integral control in the preferred PID control algorithm of the present invention takes into account the accumulation of errors over time. It integrates past errors to eliminate long-standing steady-state errors between multiple robots. In some long-running tasks, even if the initial synchronization error between robots is small, over time, due to the influence of various factors, tiny errors may accumulate. Integral control can process these accumulated errors to ensure that the robots can still maintain precise synchronization during long-term operation.

[0101] The differential control in the preferred PID control algorithm of the present invention is based on the rate of change of the errors of multiple robot motions, that is, the speed at which the errors change over time. The differential predicts the future trend of the errors, allowing the system to make adjustments in advance, thereby reducing overshoot and oscillation. For example, in tasks where the robot performs high-speed movement or frequent speed changes, the differential control can adjust the control instructions in advance according to the rate of change of the errors, thereby avoiding oscillation of the robot due to excessive adjustment.

[0102] When the present invention preferably uses a dynamic adjustment mechanism, if a robot deviates from its original motion trajectory due to a collision, the dynamic adjustment mechanism can quickly adjust its control instructions based on the position and speed differences between it and other robots, so that it returns to the correct motion trajectory and keeps synchronization with other robots. At the same time, by adjusting the proportional gain and differential gain, the system can maintain good response speed and stability when facing different degrees of interference, ensuring that the robots can continue to move synchronously and stably.

[0103] The simulation submodule of the present invention is preferably capable of accepting control instructions input by the user and simulating the robot's response to these instructions, and the user interface module has network communication capabilities, allowing the user to remotely access and control; before actual deployment, the simulation submodule is fully tested to ensure its accuracy and reliability, so as to discover potential problems and errors in advance and reduce risks in actual operations.

[0104] Embodiment 1:

[0105] See also Figure 1 — Figure 2 , a PLC-based synchronous control method and system for multiple robots, the PLC-based synchronous control method for multiple robots comprising the following steps:

[0106] Step 1: First, monitor and collect the status information of each robot in real time, and then perform data cleaning on the monitored and collected status information to obtain status information data;

[0107] Step 2: First, calculate the synchronization error of each robot based on the above status information data, and then detect whether the synchronization error of each robot exceeds the allowable range; if the synchronization error of a robot does not exceed the allowable range, continue to monitor and collect the status information of the robot; if the synchronization error of a robot exceeds the allowable range, execute the third step for the robot;

[0108] Step 3: First, generate a preliminary control instruction based on the synchronization error of the robot, then adjust the preliminary control instruction from three aspects of proportional, integral and differential parameters to generate a final control instruction, and then send the final control instruction to the robot;

[0109] Step 4: After receiving the above final control instruction, the robot executes the corresponding instruction action to adjust the state of the robot, thereby synchronizing the state of the robot.

[0110] Embodiment 2:

[0111] The basic content is the same as Example 1, except that: in the third step, sending the final control instruction to the robot means: optimizing the final control instruction again based on the relative position and speed difference between the robots to obtain the optimized control instruction, and finally sending the optimized control instruction to the robot; in the fourth step, the robot receiving the above-mentioned final control instruction means: the robot receives the above-mentioned optimized control instruction.

[0112] When applied, the synchronous control algorithm module includes a PID control algorithm and a dynamic adjustment mechanism. When the dynamic adjustment mechanism is enabled, the synchronous control algorithm module first generates a preliminary control instruction according to the preset synchronous control logic, and then uses the PID control algorithm to adjust the proportional, integral and differential parameters of the preliminary control instruction to generate a final control instruction. At the same time, the dynamic adjustment mechanism optimizes the final control instruction again according to the relative position and speed differences between the robots to obtain the optimized control instruction, and then sends the optimized control instruction to the corresponding robot through the communication module. The joint cooperation of the PID control algorithm and the dynamic adjustment mechanism can improve the efficiency and stability of the synchronous control of multiple robots, and enhance the adaptability and flexibility of the system.

[0113] Embodiment 3:

[0114] The basic content is the same as that of Example 1, except that: the PLC-based synchronous control method for multiple robots also includes: Step 5: looping through Steps 1 to 4 until a stop command is received or an unrecoverable fault occurs.

[0115] When applied, the fifth step can continuously monitor the status of each robot by continuously looping through the first to fourth steps, and make adjustments based on real-time data to ensure the continuity and effectiveness of synchronous control.

[0116] Embodiment 4:

[0117] The basic content is the same as that of Example 1, except that: the PLC-based synchronous control system for multiple robots includes a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module; the PLC control module is used to receive the state information data of each robot, and pass the received state information data of each robot to the synchronous control algorithm module, and then issue a control instruction according to a preset control logic; the communication module is used to realize data communication between the PLC control module and each robot, pass the state information data of each robot to the PLC control module, and at the same time, pass the control instructions of the PLC control module and the synchronous control algorithm module to each robot The synchronous control algorithm module is embedded in the PLC control module and is used to process the synchronous control logic between multiple robots. After processing the state information data to generate control instructions, the control instructions are transmitted to the corresponding robots through the communication module. The synchronous control algorithm module includes a PID control algorithm, which is used to accurately and synchronously control the movement of each robot from three aspects: proportional, integral and differential parameters. The state monitoring module is connected to the PLC control module and is used to monitor and collect the working state data of each robot in real time, and transmit the data to the PLC control module through the communication module. The fault diagnosis module is used to detect abnormal conditions in the system and provide fault handling solutions. User interface module: used for operator to interact with the system, including system status display, control command input and system parameter configuration; input the command through the control command input, and then pass the input command to the PLC control module, the PLC control module executes the corresponding control logic according to the input command, and feeds back the execution result to the user interface module; when the fault diagnosis module finds that the running status is abnormal or faulty, it immediately notifies the operator, and the operator checks the system status, inputs control commands and configures system parameters through the user interface module; in the first step, the status information of each robot is first monitored and collected in real time, and then the monitored and collected status information is cleaned. The status monitoring module first cleans the status information of each robot The state information is monitored and collected in real time, and then the monitored and collected state information is cleaned; in the second step, the synchronization error of each robot is calculated based on the above state information data, and then the synchronization error of each robot is detected. The synchronization error of each robot is calculated by the synchronization control algorithm module based on the above state information data, and then the synchronization error of each robot is detected; in the second step, the state information of the robot is continued to be monitored and collected by the state monitoring module; in the third step, the preliminary control instruction is generated based on the synchronization error of the robot. The preliminary control instruction is generated by the synchronization control algorithm module based on the synchronization error of the robot;The preliminary control instruction is adjusted from the three aspects of proportion, integration and differential parameters to generate the final control instruction. The preliminary control instruction is adjusted from the three aspects of proportion, integration and differential parameters by the PID control algorithm to generate the final control instruction; the final control instruction is sent to the robot by the communication module. ;

[0118] When applied, start the PLC control module and initialize the communication module to ensure that the connection with all robots is normal; load the synchronous control algorithm module, including PID control and dynamic adjustment mechanism; activate the state monitoring module to prepare to receive the robot's state data; start the fault diagnosis module to prepare for abnormality detection; configure the user interface module to ensure that the system state display, control command input and system parameter configuration functions are available; first, the state monitoring module monitors and collects the state information of each robot in real time. Since the state monitoring module also has data filtering and preprocessing functions, it filters and processes the acquired raw state information data, and then transmits the processed state information data to the PLC control module through the communication module; the PLC control module transmits the received robot state information data to the synchronous control algorithm module, and the synchronous control algorithm module analyzes the data, calculates and Detect the synchronization error of each robot. When the synchronization error does not exceed the allowable range, continuously monitor the real-time status data of the robot. When the synchronization error exceeds the allowable range, execute the synchronization control logic, that is, the synchronization control algorithm module first generates a preliminary control instruction according to the preset synchronization control logic, and then uses the PID control algorithm to adjust the preliminary control instruction from three aspects: proportional, integral and differential parameters, so as to generate the final control instruction, and then send the final control instruction to the corresponding robot through the communication module. After the robot receives and executes the final control instruction, it synchronizes the status of each robot. Since the status monitoring module removes the noise and interference information in the original data, it ensures the accuracy and effectiveness of the data fed back to the PLC control module. Through the adjustment of the PID algorithm in the three parameters of proportional, integral and differential, it can achieve precise control of the robot motion and reduce the synchronization error.

[0119] Embodiment 5:

[0120] The basic content is the same as Example 4, except that: the synchronous control algorithm module also includes a dynamic adjustment mechanism for dynamically adjusting the control instructions according to the relative position and speed differences between the robots; in the third step, the final control instructions are optimized again based on the relative position and speed differences between the robots to obtain the optimized control instructions; the dynamic adjustment mechanism optimizes the final control instructions again based on the relative position and speed differences between the robots to obtain the optimized control instructions; in the third step, the optimized control instructions are sent to the robot by the communication module.

[0121] When applied, the motion state of each robot is monitored in real time through the state monitoring module. After being fed back to the PLC control module, the motion state of each robot is analyzed in real time through the synchronization control algorithm module, the actual difference between the robots and the error between the expected synchronization state are calculated, and the preliminary control instructions are generated. The PID control algorithm adjusts the preliminary control instructions from three aspects: proportional, integral and differential parameters to generate the final control instructions. Then the dynamic adjustment mechanism optimizes the final control instructions again according to the relative position and speed differences between the robots to obtain the optimized control instructions. Finally, the optimized control instructions are sent to the robot through the communication module. After the robot receives and executes the optimized control instructions, the state of the robot is synchronized. By adjusting the three parameters of proportional, integral and differential by the PID algorithm, the robot motion can be accurately controlled and the synchronization error can be reduced. The dynamic adjustment mechanism can optimize the response speed and stability of the system to ensure that the robot can move smoothly and accurately in synchronization.

[0122] Embodiment 6:

[0123] The basic content is the same as that of Example 5, except that the dynamic adjustment mechanism is implemented by the following algorithm formula:

[0124]

[0125] Among them, V adj is the adjusted speed command, P err is the position error between robots, K P and K d They are proportional gain and differential gain, respectively, which are used to adjust the response speed and stability of the system; in the third step, the final control instruction is optimized again by the algorithm formula of the dynamic adjustment mechanism.

[0126] When applied, the adjusted speed command is calculated according to the above formula. According to the calculated adjusted speed command, the control command sent to the robot is dynamically adjusted to reduce the position error and speed difference. After the adjusted control command is executed, the system continues to monitor the status of the robot and repeats the above process according to the new monitoring results to form a continuous feedback and adjustment cycle. By adjusting parameters such as proportional gain and differential gain, the response speed and stability of the system can be optimized to ensure that the robot can move smoothly and accurately in synchronization. At the same time, in actual applications, when the robot is subject to external interference during operation, such as collision, vibration or magnetic field interference, the position and speed of the robot will change. The dynamic adjustment mechanism can detect these changes in time and calculate the adjusted speed command according to the relative position and speed difference between the robots to ensure that the robot can continue to move in synchronization stably.

[0127] Embodiment 7:

[0128] The basic content is the same as Example 4, except that: the state monitoring module includes a position sensor, a velocity sensor and an acceleration sensor, which are respectively used to monitor and collect the position, velocity and acceleration state information of each robot; the position sensor adopts laser ranging or encoder technology, and the velocity sensor uses the Doppler effect principle or speed measurement motor technology; in the first step, the real-time monitoring and collection of the state information of each robot are respectively carried out by the position sensor, velocity sensor and acceleration sensor for real-time monitoring and collection of the position, velocity and acceleration state information of each robot; in the second step, the continued monitoring and collection of the state information of the robot are respectively carried out by the position sensor, velocity sensor and acceleration sensor for monitoring and collection of the position, velocity and acceleration state information of the robot.

[0129] When applied, position sensors, speed sensors and acceleration sensors are used to monitor the precise motion state of the robot in real time, so that the key parameters such as the position, speed and acceleration of the robot are uploaded to the PLC control module through the communication module, providing accurate input information for the PLC control module, which helps to improve the control accuracy of the robot's motion and ensure the accuracy and synchronization of the robot's movements; the position sensor uses laser ranging or encoder technology to accurately measure the position of the robot in three-dimensional space, and the position sensor can control the position accuracy of the robot within ±0.1mm; the speed sensor uses the Doppler effect principle or speed measurement motor technology to accurately obtain the robot's motion speed in real time, and can provide reliable speed data regardless of high-speed motion or low-speed fine-tuning; the acceleration sensor can sense the acceleration change of the robot's motion. For some tasks that require fast response and precise control, such as the robot's emergency stop and start operation, the acceleration sensor can timely feedback the robot's acceleration state, so that the PLC control module can adjust the control instructions more accurately according to these precise parameter information, ensure that the robot's motion meets expectations, and achieve high-precision synchronous motion between multiple robots.

[0130] Embodiment 8:

[0131] The basic content is the same as that of Example 4, except that the communication module supports multiple communication protocols, including but not limited to industrial Ethernet, serial communication and wireless communication protocols.

[0132] When applied, the communication module supports multiple communication protocols, allowing the system to communicate with different types of robots and equipment, thereby improving the compatibility and flexibility of the system, and when adding new robots or equipment, there is no need to worry about incompatibility of communication protocols; using multiple communication protocols can provide redundant communication methods. If one communication method fails, the system can automatically switch to other protocols, thereby improving the reliability of overall communication; at the same time, by using wireless communication protocols such as Bluetooth, Wi-Fi or ZigBee, it can reduce wiring requirements, reduce installation and maintenance costs, and reduce potential failure points caused by wiring.

[0133] Embodiment 9:

[0134] The basic content is the same as Example 4, except that: the synchronous control algorithm module also includes: a prediction model based on time series analysis, which is used to predict the state changes of each robot in the future time period.

[0135] When applied, the prediction model based on time series analysis discovers the common motion patterns of robots in different working stages through deep learning and pattern recognition of historical data, and accurately captures the periodic and trend changes in the robot's motion state; the prediction model based on time series analysis helps to identify and predict trends and periodic patterns in robot motion, so that the synchronous control algorithm can more effectively coordinate the actions of multiple robots and reduce synchronization errors, thereby better adjusting the control parameters to ensure that multiple robots can move accurately and synchronously.

[0136] Embodiment 10:

[0137] The basic content is the same as Example 4, except that: the user interface module also includes a simulation sub-module for simulating the movement and operation process of the robot before actual operation, and the user interface module remotely monitors the robot dynamics through the Internet.

[0138] When applied, the simulation submodule accepts the control instructions input by the user and simulates the robot's response to these instructions. The simulation submodule uses advanced computer graphics and physical engine technology to simulate the robot's movement and working environment. The user can observe the robot's movement trajectory, operation process and interaction with other objects in the simulation environment. For example, in some complex assembly tasks, the user can use the simulation submodule to understand in advance the problems that the robot may encounter in actual operation, such as whether the parts are grasped accurately, whether the assembly sequence is reasonable, etc., and can test the robot's response by inputting different control instructions, and optimize and adjust the simulation submodule; at the same time, the user interface module has network communication capabilities, allowing users to remotely access and control. The network communication capabilities of the user interface module enable users to remotely access and control the simulation submodule through the Internet at different locations, which facilitates user operation and management and improves work efficiency.

[0139] Embodiment 11:

[0140] The basic content is the same as that of Example 1, except that: the PLC-based synchronous control method for multiple robots further includes a fault diagnosis module that performs real-time analysis on the system operation status and detects abnormalities or faults;

[0141] If an anomaly or fault is detected, the operator is immediately notified, and the operator can view the system status, input control instructions and configure system parameters through the user interface module;

[0142] If no abnormality or failure is detected, the operation continues;

[0143] The fault diagnosis module continuously monitors, analyzes and detects the system operation status during system operation; through the continuous and real-time detection and analysis of faults by the fault diagnosis module, the timeliness of fault handling can be guaranteed, thereby improving the reliability of system operation.

[0144] The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiment. Any equivalent modifications or changes made by ordinary technicians in this field based on the contents disclosed by the present invention should be included in the protection scope recorded in the claims.

Claims

1. A synchronous control method for multiple robots based on PLC, characterized in that: The PLC-based synchronous control method for multiple robots comprises the following steps: Step 1: First, monitor and collect the status information of each robot in real time, and then perform data cleaning on the monitored and collected status information to obtain status information data; Step 2: First, calculate the synchronization error of each robot based on the above status information data, and then detect whether the synchronization error of each robot exceeds the allowable range; if the synchronization error of a robot does not exceed the allowable range, continue to monitor and collect the status information of the robot; if the synchronization error of a robot exceeds the allowable range, execute the third step for the robot; Step 3: First, generate a preliminary control instruction based on the synchronization error of the robot, then adjust the preliminary control instruction from three aspects of proportional, integral and differential parameters to generate a final control instruction, and then send the final control instruction to the robot; Step 4: After receiving the above final control instruction, the robot executes the corresponding instruction action to adjust the state of the robot, thereby synchronizing the state of the robot.

2. The method for synchronous control of multiple robots based on PLC according to claim 1, characterized in that: In the third step, sending the final control instruction to the robot means: optimizing the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction, and finally sending the optimized control instruction to the robot; In the fourth step, the robot receiving the final control instruction means that the robot receives the optimized control instruction.

3. A PLC-based synchronous control method for multiple robots according to claim 1 or 2, characterized in that: The PLC-based synchronous control method for multiple robots also includes: Step 5: Loop through steps 1 to 4 until a stop command is received or an unrecoverable fault occurs.

4. A system in which the PLC-based synchronous control method for multiple robots according to claim 2 is located, characterized in that: The PLC-based synchronous control system for multiple robots includes a PLC control module, a communication module, a synchronous control algorithm module, a state monitoring module, a fault diagnosis module and a user interface module; The PLC control module is used to receive the status information data of each robot, and transmit the received status information data of each robot to the synchronous control algorithm module, and then issue control instructions according to the preset control logic; The communication module is used to realize data communication between the PLC control module and each robot, transmit the status information data of each robot to the PLC control module, and at the same time, transmit the control instructions of the PLC control module and the synchronous control algorithm module to each robot; The synchronous control algorithm module is embedded in the PLC control module and is used to process the synchronous control logic between multiple robots. After processing the state information data to generate control instructions, the control instructions are transmitted to the corresponding robots through the communication module. The synchronous control algorithm module includes a PID control algorithm, which is used to accurately and synchronously control the movement of each robot from three aspects of proportional, integral and differential parameters; The state monitoring module is connected to the PLC control module and is used to monitor and collect the working state data of each robot in real time, and transmit the data to the PLC control module through the communication module; The fault diagnosis module is used to detect abnormal conditions in the system and provide fault handling solutions; The user interface module is used for the operator to interact with the system, including system status display, control command input and system parameter configuration; the command is input through the control command input, and then the input command is passed to the PLC control module, and the PLC control module executes the corresponding control logic according to the input command, and feeds back the execution result to the user interface module; when the fault diagnosis module finds that the operating status is abnormal or faulty, it immediately notifies the operator, and the operator checks the system status, inputs control commands and configures system parameters through the user interface module; In the first step, the state information of each robot is first monitored and collected in real time, and then the monitored and collected state information is cleaned. The state monitoring module first monitors and collects the state information of each robot in real time, and then cleans the monitored and collected state information; In the second step, the synchronization error of each robot is calculated based on the above state information data, and then the synchronization error of each robot is detected. The synchronization error of each robot is calculated by the synchronization control algorithm module based on the above state information data, and then the synchronization error of each robot is detected; In the second step, the state information of the robot is continuously monitored and collected by the state monitoring module. In the third step, the preliminary control instructions are generated according to the synchronization error of the robot by the synchronization control algorithm module; the preliminary control instructions are adjusted from three aspects of proportion, integration and differential parameters to generate the final control instructions by the PID control algorithm; the final control instructions are sent to the robot by the communication module.

5. A PLC-based synchronous control system for multiple robots according to claim 4, characterized in that: The synchronous control algorithm module also includes a dynamic adjustment mechanism for dynamically adjusting control instructions according to the relative position and speed differences between the robots; In the third step, the final control instruction is optimized again according to the relative position and speed difference between the robots to obtain the optimized control instruction. The dynamic adjustment mechanism optimizes the final control instruction again according to the relative position and speed difference between the robots to obtain the optimized control instruction. In the third step, the optimized control instruction is sent to the robot by the communication module.

6. A PLC-based synchronous control system for multiple robots according to claim 5, characterized in that: The dynamic adjustment mechanism is implemented by the following algorithm formula: Among them, V adj is the adjusted speed command, P err is the position error between robots, K P and K d They are proportional gain and differential gain, which are used to adjust the response speed and stability of the system; In the third step, the final control instruction is optimized again by an algorithm formula of a dynamic adjustment mechanism.

7. A PLC-based synchronous control system for multiple robots according to any one of claims 4 to 6, characterized in that: The state monitoring module includes a position sensor, a velocity sensor and an acceleration sensor, which are respectively used to monitor and collect the position, velocity and acceleration state information of each robot; the position sensor adopts laser ranging or encoder technology, and the velocity sensor uses the Doppler effect principle or speed measurement motor technology; In the first step, the real-time monitoring and collection of the status information of each robot is performed by using a position sensor, a velocity sensor and an acceleration sensor to respectively monitor and collect the position, velocity and acceleration status information of each robot in real time; In the second step, the state information of the robot is continuously monitored and collected by using a position sensor, a velocity sensor and an acceleration sensor to monitor and collect the position, velocity and acceleration state information of the robot respectively.

8. A PLC-based synchronous control system for multiple robots according to any one of claims 4 to 6, characterized in that: The communication module supports multiple communication protocols, including but not limited to industrial Ethernet, serial communication and wireless communication protocols.

9. A PLC-based synchronous control system for multiple robots according to any one of claims 4 to 6, characterized in that: The synchronous control algorithm module also includes: a prediction model based on time series analysis, which is used to predict the state changes of each robot in a future time period.

10. A PLC-based synchronous control system for multiple robots according to any one of claims 4 to 6, characterized in that: The user interface module also includes a simulation submodule for simulating the movement and operation process of the robot before actual operation. The user interface module remotely monitors the dynamics of the robot through the Internet.

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