Robot joint module driving test method and system

Abstract

The invention discloses a robot joint module drive test method and system, and relates to the technical field of robot joint module drive detection. Aiming at the problems of insufficient multi-axis cooperative capability, lack of dynamic load simulation, low fault diagnosis efficiency and the like in the prior art, the invention adopts a laser angle encoder and a six-dimensional force sensor to realize synchronous control of + / -0.02 mm positioning precision and TCP track deviation less than 0.5 mm through single-joint step-by-step driving and multi-axis compound motion cooperative testing; an industrial-grade fault diagnosis system is integrated, and the fault positioning efficiency is improved by 50% through voltage unbalance degree analysis, vibration spectrum monitoring and EMC interference troubleshooting. Setting multiple safety protection mechanisms, including a safety grating, an emergency stop system and safety torque turn-off verification; 120% overload protection and standardized tool interface compatibility testing are supported, and the service life of core components is prolonged by 30%-40% through speed reducer back clearance laser calibration and temperature real-time compensation. According to the method, the dynamic working condition adaptability, the motion stability and the system reliability of the robot are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of robot joint module drive detection technology, and in particular to a robot joint module drive testing method and system. Background Art

[0002] As a core part of industrial robot R&D and maintenance, traditional methods for robot joint module drive testing rely mainly on independent testing of single joints (manual or simple program-driven testing of basic parameters of single joints), static functional verification (fixed load or preset path testing of motion range), manual experience-based troubleshooting (relying on subjective judgment of abnormal phenomena), and basic safety mechanisms (emergency stop buttons and physical fences). However, such methods have problems such as incomplete test coverage (such as the lack of multi-axis coordination), disconnection between dynamic loads and actual working conditions, low fault diagnosis efficiency (lack of real-time data quantitative analysis), and insufficient safety protection (inadequate verification of electronic safety systems such as safe torque shutdown and communication redundancy), making it difficult to meet the needs of high-precision and high-reliability industrial scenarios.

[0003] However, the existing robot joint module drive test methods have significant shortcomings, including incomplete test coverage (insufficient multi-axis coordination capabilities, such as a 50% weld offset due to a joint synchronization delay of >10ms in a welding task), disconnection between dynamic load and actual working conditions (static testing did not simulate inertial impact, resulting in a 30% shortening of the RV reducer life), low diagnostic intelligence level (relying on manual troubleshooting, such as a communication link jitter problem that took 3 days to locate), imperfect safety protection mechanism (emergency shutdown delay >500ms, safety grating deployment defects causing equipment damage) and lack of scalability verification (poor tool interface compatibility resulting in an 8-hour shutdown due to adsorption failure). These defects seriously restrict the robot's reliability, efficiency and scenario adaptability. Summary of the Invention

[0004] In response to the problems mentioned in the above background technology, the present invention proposes a robot joint module drive testing method and system.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] In a first aspect, the present invention provides a robot joint module drive test method, comprising:

[0007] Step 1: Provide the robot joint module drive test structure;

[0008] Step 2: Perform joint module drive test, including single-joint step-by-step drive control and multi-axis coordinated motion control; specifically:

[0009] S01: Perform system initialization and safety preparations. Ensure that the power connections between the robot body and the control terminal are normal. Verify that the communication links between the control terminal, the joint detection board, and each rotary joint are stable. Set up physical safety fences or electronic safety gratings. If a person accidentally enters the test area, activate the emergency stop button for functional testing and immediately cut off the power source in an emergency.

[0010] S02: Perform single joint step-by-step drive control;

[0011] S03: Perform multi-axis coordinated motion control;

[0012] Step 3: Perform data fault diagnosis, including initialization detection, safety system verification and motion performance abnormality diagnosis.

[0013] As a preferred embodiment of the present invention, the robot joint module drive test structure includes a robot body, the robot body includes a base, a rotating base, a joint detection plate, connecting rod one, connecting rod two, connecting rod three, rotating joint one, rotating joint two, rotating joint three, rotating joint four, a mechanical clamp and a special tool; a rotating base and a joint detection plate are installed on the base; a rotating joint one is installed on the joint detection plate and is rotationally connected; the rotating joint one is fixedly connected to the connecting rod one; the connecting rod one and the connecting rod two are rotationally connected through the rotating joint two; the connecting rod two and the connecting rod three are rotationally connected through the rotating joint three; the connecting rod three and the mechanical clamp are rotationally connected through the rotating joint four; and a special tool is installed on the mechanical clamp.

[0014] As a preferred embodiment of the present invention, the specific process of performing step-by-step drive control of a single joint is as follows:

[0015] S201: The control terminal sends a command to drive the rotating base to rotate horizontally around the base;

[0016] S202: Control the rotary joint 1 to drive the connecting rod 1 to swing vertically; obtain the motion trajectory of the connecting rod 1;

[0017] S203: driving rotary joint 2 and rotary joint 3 in sequence to verify the multi-axis coordination capability;

[0018] Single-axis motion: Control revolute joint 2 and revolute joint 3 to swing independently;

[0019] Compound motion: Synchronously drive revolute joints 2 and 3 to simulate the “arm lift-and-stretch” motion;

[0020] S204: Drive the rotary joint 4 to rotate the mechanical gripper around the end axis; verify the function of the mechanical gripper: control the mechanical gripper to perform opening and closing actions, install special tools, and verify the interface compatibility between the tool and the gripper and function activation;

[0021] Perform multi-axis coordinated motion control: preset path motion to detect repeat positioning accuracy and synchronization error; attach standard load to simulate rated working conditions, and detect joint motor temperature rise and reducer vibration noise.

[0022] As a preferred embodiment of the present invention, multi-axis coordinated motion control is performed:

[0023] Set the motion trajectory of the mechanical gripper to a "lift-extend" compound action, driving the synchronous motion of rotary joints 2 and 3;

[0024] The motion range of rotary joint 2 is 0°→90°, and the synchronous motion range of rotary joint 3 is 0°→60°, using a quintic polynomial curve planning;

[0025] If the TCP point trajectory deviation is ≥0.5 mm, the cross-coupling control algorithm is enabled, the coupling coefficient Kcc is set to 0.8, and the compensation period Tcomp is set to 5 ms.

[0026] As a preferred embodiment of the present invention, the fault diagnosis in step three includes:

[0027] Z301: Initialization detection and safety system verification;

[0028] Initialization detection, including input voltage detection, ground resistance detection and communication link verification;

[0029] Generate contact detection instructions for input voltage detection; according to the instructions, check the oxidation of the circuit breaker contacts of the distribution cabinet or the load distribution of the transformer;

[0030] Generate wire cross-section polishing instructions for ground resistance detection, check the cross-sectional area of the ground wire, and polish the contact surface of the ground terminal;

[0031] Generate a communication link abnormality instruction for communication link verification, replace the Cat6A shielded twisted pair cable, and re-crimp the RJ45 connector;

[0032] Deploy electronic safety light curtains, calibrate light curtain coverage, and test emergency stop system response time;

[0033] Z302: Test S02, specifically:

[0034] Horizontal rotation test of the rotating base: If the angle error is greater than 0.1°, check the grounding of the shield layer of the resolver signal line and calibrate the backlash of the joint reducer;

[0035] Perform a vertical swing test on the connecting rod; obtain the preset test configuration, perform load simulation, obtain parameters and the corresponding motion range: -90° to +90°, and compare the speed curve using S-shaped acceleration and deceleration and current limit. If overload occurs, perform overload protection;

[0036] Perform uniaxial motion testing;

[0037] Perform compound movement tests;

[0038] Verify the function of the end effector: perform mechanical gripper test:

[0039] Use Al 6061 standard test block for clamping force acceptance:

[0040] The four-rotation accuracy of the rotary joint is ±180°, and the repeat positioning accuracy is ≤±0.05mm. If the clamping force is not within the clamping force acceptance range, check the filter blockage, install a pressure regulating valve at the cylinder inlet, and use the clamp calibrator to readjust the guide rod preload.

[0041] As a preferred embodiment of the present invention, the input voltage is detected as follows:

[0042] The three-phase voltages at the robot body and control cabinet input terminals were measured using a Fluke 87V multimeter integrated within the industrial robot. The measured voltages were compared with the preset allowable range to calculate voltage imbalance using the negative-sequence voltage component method. Voltage imbalance is defined as the percentage of the negative-sequence voltage component to the positive-sequence voltage component: Among them, U1 is the positive sequence component of the three-phase voltage, and U2 is the negative sequence component of the three-phase voltage, which are compared with the corresponding voltage imbalance preset range; if it does not meet the corresponding preset allowable range and preset range, a detection contact instruction is generated.

[0043] As a preferred embodiment of the present invention, the ground resistance detection is specifically as follows:

[0044] The ground resistance value was measured using a Kyoritsu 4105A ground resistance tester. During the test, the power was disconnected and an independent grounding stake was connected.

[0045] If the measured value is greater than 4Ω, a wire cross-section grinding instruction is generated, requiring the ground wire cross-section area to be ≥16mm 2 And polish the contact surface.

[0046] As a preferred embodiment of the present invention, the communication link verification is specifically performed as follows:

[0047] Monitor period jitter and frame loss rate using the Beckhoff EK1100 coupler;

[0048] If the redundant link is not switched to within 50ms after the communication is interrupted, a communication link abnormality instruction is generated, and the Cat6A shielded twisted pair cable is replaced and the RJ45 connector is re-crimped.

[0049] As a preferred embodiment of the present invention, the uniaxial motion test and the composite motion test are performed as follows:

[0050] Single-axis motion test: Rotary joint 2: motion range: -45°→+135°, speed 60° / s; acceptance: repeat positioning accuracy ≤±0.02mm; Rotary joint 3: sinusoidal trajectory test, phase delay <5ms;

[0051] Perform a compound exercise test:

[0052] Motion planning and synchronization error: TCP point trajectory deviation <0.5mm; dynamic load fluctuation: <±3%; if the TCP point trajectory deviation ≥0.5mm, enable cross-coupling control:

[0053] Use online debugging tools to verify the effectiveness of the algorithm; and temperature compensation: install PT100 temperature sensors on the joints to compensate for the thermal expansion coefficient in real time;

[0054] If the sinusoidal trajectory phase delay is greater than 5ms, adjust the speed loop cutoff frequency from 50Hz to 80Hz. Stiffness test: Use a Kistler 9027C hammer to strike the connecting rod and measure the natural frequency.

[0055] In a second aspect, the present invention provides a robot joint module drive test system, comprising: a test platform structure construction module, an initialization safety protection module, a single joint drive performance verification module, a multi-axis coordinated motion load test module, and a data diagnosis exception processing module;

[0056] The test platform structure construction module builds a robot body test platform, which includes a base, multi-stage rotation joints, connecting rods and end grippers. The joint detection board collects rotation angle and torque data in real time to form a complete motion chain.

[0057] Initialize the safety protection module to verify power supply stability, ground resistance, and communication links, and deploy safety light curtains and emergency stop systems;

[0058] The single-joint drive performance verification module drives each joint to rotate step by step, detects angle error, motor current and clamping force, and verifies motion trajectory accuracy and load capacity;

[0059] The multi-axis coordinated motion load test module uses preset trajectories to drive the coordinated motion of multiple joints, testing repeatability and synchronization errors. Additional loads monitor temperature rise and vibration, optimizing control algorithms to ensure motion stability.

[0060] The data diagnosis and abnormality processing module collects joint data in real time, analyzes communication jitter, voltage anomalies and other problems, and automatically generates fault handling instructions.

[0061] Compared with the prior art, the present invention has the following beneficial effects:

[0062] 1. This invention covers the full-link performance verification from the rotating base to the end gripper through the coordinated testing of single-joint step-by-step drive and multi-axis compound motion. Using high-precision sensors (such as laser angle encoders and six-axis force sensors) and dynamic load simulation, combined with cross-coupling control and thermal expansion compensation algorithms, it ensures the positioning accuracy (such as ±0.02mm) and synchronization error control (TCP trajectory deviation <0.5mm) of each joint in independent and linked scenarios, significantly improving the robot's motion stability and adaptability to complex tasks, and reducing the risk of mechanical interference during multi-axis collaboration.

[0063] 2. This invention integrates an industrial-grade fault diagnosis system (such as voltage imbalance analysis and ground resistance detection) with real-time data monitoring (vibration spectrum and motor temperature rise). Through automated threshold determination (such as the voltage tolerance range of 361-399V) and correction strategies (such as communication jitter and EMC interference detection), it enables rapid fault location. Combined with EN ISO 13855-compliant safety light curtains, emergency stop systems (power cut-off delay ≤ 300ms), and safe torque off (STO) verification, a multi-layered protection mechanism is established to effectively prevent overload, misoperation, and environmental interference risks, reducing downtime and maintenance time by more than 50%.

[0064] 3. This invention ensures the robot's adaptability to diverse industrial scenarios through standardized interface verification (such as compatibility testing between the gripper and the welding gun / suction cup) and load condition simulation (overload protection at 120% of rated load). It also employs long-term compensation strategies (such as reducer backlash laser calibration and real-time PT100 temperature compensation) and key component health monitoring (harmonic reducer vibration analysis and filter differential pressure warning) to extend the life of core components by 30% to 40%. It also supports dynamic algorithm optimization (such as speed loop cutoff frequency adjustment), providing a reliable technical foundation for maintaining accuracy and upgrading functionality under long-term high-load operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] To facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0066] Figure 1 A diagram showing the steps of the method of the present invention;

[0067] Figure 2 It is a principle block diagram of the present invention;

[0068] Figure 3 Schematic diagram of the robot detection of the present invention Figure 1 ;

[0069] Figure 4 Schematic diagram of the robot detection of the present invention Figure 2 ;

[0070] Figure 5 Schematic diagram of the robot detection of the present invention Figure 3 .

[0071] Description of the drawings: 1. Base; 2. Rotating base; 3. Joint detection board; 4. Rotating joint 1; 5. Connecting rod 1; 6. Rotating joint 2; 7. Connecting rod 2; 8. Rotating joint 3; 9. Connecting rod 3; 10. Rotating joint 4; 11. Mechanical gripper. DETAILED DESCRIPTION

[0072] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0073] See also Figure 1 As shown, the present invention provides a robot joint module drive test method, comprising:

[0074] Step 1: Construct the robot joint module drive test structure, including the robot body. The robot body includes base 1, rotating base 2, joint detection board 3, connecting rod 1 5, connecting rod 2 7, connecting rod 3 9, rotating joint 1 4, rotating joint 2 6, rotating joint 3 8, rotating joint 4 10, mechanical gripper 11 and special tools.

[0075] Among them, the base rotating joint 1 is equipped with a rotating base 2 and a joint detection plate 3; the joint detection plate 3 is equipped with a rotating joint 4, and the two are rotationally connected; the rotating joint 4 is connected to the connecting rod 5; the connecting rod 15 and the connecting rod 2 7 are rotationally connected through the rotating joint 2 6; the connecting rod 2 7 and the connecting rod 3 9 are rotationally connected through the rotating joint 3 8; the connecting rod 3 9 and the mechanical gripper 11 are rotationally connected through the rotating joint 4 10; and a special tool is installed on the mechanical gripper 11.

[0076] Step 2: Perform joint module drive test, and control the terminal to control the industrial robot to reach the detection instruction action; specifically:

[0077] S01: Perform system initialization and safety preparation: Confirm that the power connection between the robot body and the control terminal is normal; verify whether the communication link between the control terminal and the joint detection board 3 and each rotary joint (i.e. rotary joint 1 4, rotary joint 2 6, rotary joint 3 8, rotary joint 4 10) is stable (such as EtherCAT, CAN bus); and set up a physical safety fence or electronic safety grating to prevent people from accidentally entering the test area, activate the emergency stop button function test, and ensure that the power source can be immediately cut off in an emergency.

[0078] S02: Perform single joint step-by-step drive control:

[0079] S201: The control terminal sends a command to drive the rotating base 2 to rotate horizontally around the base 1 (0° to 360°); and obtains the rotation data of the rotating base 2; and checks whether the rotation angle and torque data fed back in real time by the joint detection board 3 are consistent with the control command;

[0080] S202: Control the rotary joint 4 to drive the connecting rod 5 to swing in the vertical direction (such as ±90°); obtain the motion trajectory of the connecting rod 5, and detect whether the motor current is within the rated range to avoid overload.

[0081] S203: sequentially driving the second rotary joint 6 (connecting the first link 5 and the second link 7) and the third rotary joint 8 (connecting the second link 7 and the third link 9) to verify the multi-axis coordination capability;

[0082] Single-axis motion: respectively control the rotary joint 2 6 and the rotary joint 3 8 to swing independently;

[0083] Compound motion: synchronously driving the second rotary joint 6 and the third rotary joint 8 to simulate the "arm raising-stretching" motion.

[0084] S204: Drive the rotary joint 10 to rotate the mechanical gripper 11 around the end axis (e.g., ±180°); verify the function of the mechanical gripper 11: control the mechanical gripper 11 to perform opening and closing actions, and test whether the clamping force meets the standard (through pressure sensor feedback); install special tools (e.g., welding gun, suction cup), and verify the interface compatibility between the tool and the gripper and the function activation (e.g., vacuum adsorption, current output).

[0085] S03: Perform multi-axis coordinated motion control:

[0086] Preset path motion control: Set a typical motion trajectory (such as straight line, circular arc, spiral) on the control terminal to drive all joints to move in coordination; repeat positioning accuracy (verified by laser tracker or encoder data); synchronization error of each joint (the deviation between the actual position of each axis and the command position is fed back by the joint detection board 3).

[0087] Load condition simulation: attach a standard load (such as a weight) to the mechanical gripper 11 to test the motion stability of the joint module under the rated load; check whether the temperature rise of the joint motor is normal (monitored by an infrared thermometer); and check whether the reducer (such as a harmonic / RV reducer) has abnormal vibration or noise.

[0088] Step 3: Perform data fault diagnosis by collecting data in real time through the joint detection board 3, including the encoder position, motor current, temperature and vibration spectrum of each joint; specifically:

[0089] Z301: Detect and monitor the initialization and electronic safety grating in S01;

[0090] Initialization detection, including input voltage detection, ground resistance detection and communication link verification;

[0091] For input voltage detection, the Fluke 87V multimeter integrated in the industrial robot is used to measure the three-phase voltages (L1-L2, L2-L3, and L3-L1) at the input terminals of the robot body and the control cabinet. The measured voltages are compared with the preset allowable range of 361 to 399 V (rated voltage), and the voltage imbalance is calculated (using the negative-sequence voltage component method. According to standards such as GB / T15543-2008, voltage imbalance can be defined as the percentage of the negative-sequence voltage component to the positive-sequence voltage component): Wherein, U1 is the positive sequence component of the three-phase voltage, and U2 is the negative sequence component of the three-phase voltage) is compared with the corresponding preset voltage imbalance range; if it does not meet the corresponding preset allowable range and the preset range, a contact inspection instruction is generated; according to the instruction, the oxidation of the circuit breaker contacts of the distribution cabinet or the load distribution of the transformer is checked;

[0092] The ground resistance test is performed using the integrated Kyoritsu 4105A ground resistance tester (applying a 200mA test current). The power supply is disconnected by a relay, and the C terminal of the tester is connected to an independent grounding stake (≥10m away from the equipment), and the P terminal is connected to the robot grounding terminal. The test key is pressed and held for 5 seconds to read the stable value. The value is compared with the implementation standard (ground resistance ≤0.1Ω (IEC60204-1Class 1 grounding requirement)). If there is a difference between the measured stable value and the implementation standard, a wire cross-section grinding instruction is generated to check the cross-sectional area of the ground wire (needed to be ≥16mm 2 Yellow-green line), polish the ground terminal contact surface.

[0093] To verify the communication link, a Beckhoff EK1100 coupler was used to ensure that the RJ45 interfaces of all nodes (rotary joint 1 4, rotary joint 2 6, rotary joint 3 8, and rotary joint 4 10) were locked. Real-time diagnosis was performed using the TwinCATScope tool (configured in DC synchronization mode) to monitor period jitter (<50μs (EtherCAT specification)) and frame loss rate (≤3 frames lost in a continuous 100,000-frame test). A fault injection test was performed to simulate communication interruption. If the system switched to the redundant link within 50ms, the communication link verification passed; otherwise, a communication link abnormality instruction was generated, the Cat6A shielded twisted pair cable (S / FTP) was replaced, and the RJ45 connector was re-crimped.

[0094] Electronic safety light curtain deployment was carried out. During the safety protection deployment, the electronic safety light curtain (ESPE) SICKmicroScan3 Core (IP67 protection) was calibrated and installed, with the bottom ≤300mm from the ground and the top ≥1200mm to cover the intrusion path of the human torso. The software configuration used Safety Designer to set the protection area, with a horizontal resolution of 14mm and a response time of ≤14ms, in compliance with the EN ISO 13855 standard. The test method used a standard test rod (25mm diameter, 200mm length) to vertically penetrate the light curtain at a speed of 2m / s to ensure that the light curtain triggered the OSSD signal within 14ms. In terms of emergency stop system verification, when testing the mechanical emergency stop button, it was triggered at the maximum speed of the robot (such as joint 4 rotating at 180° / s), monitoring the power cut-off delay ≤300ms, and the mechanical brake action time ≤50ms. The safe torque off (STO) verification was performed using Yokogawa A DL850E oscilloscope (equipped with a high-voltage differential probe) was used to test the U / V / W output terminals of the Yaskawa Σ-7 servo drive. The requirement was that the phase current drop to <0.1A within one control cycle (125μs) after an emergency stop was triggered. Furthermore, to address critical abnormal scenarios, such as excessive communication jitter (TwinCAT Scope indicating Cycle Jitter >100μs), an EMC tester (such as the Rohde & Schwarz ESRP3) was used to scan the 2.4GHz frequency band for interference. The RJ45 connector was replaced or TwinCAT's EtherCAT frame prioritization (802.1Q VLAN tagging) was enabled. To address false triggering of the safety light curtain, the light curtain's "ambient light immunity" parameter was adjusted (enabling infrared filtering >850nm), a dust cover (SICK VAA4200) was installed on the transmitter, and the mounting bracket rigidity was checked to eliminate lens offset caused by mechanical vibration.

[0095] Z302: Test S02, specifically:

[0096] Horizontal rotation test of rotating base 2: Use the Beckhoff EL3632 analog input module to acquire the resolver signal from joint detection board 3; install a Leuze RSL 400 laser angle encoder (resolution 0.001°) as an external reference; and execute control instructions:

[0097]

[0098]

[0099] Obtain the angular tracking error; sample the torque fluctuation using the HBM T12 torque sensor. If the angular error is greater than 0.1°, check the grounding of the resolver signal cable shield (a single point connection to the control cabinet PE bus is required) and calibrate the joint reducer backlash (using a laser interferometer to compensate for the parameters).

[0100] Perform a vertical swing test on the connecting rod 5; obtain the preset test configuration and perform load simulation (hanging standard weights, such as 120% of the rated load); control the monitoring equipment on board: Yokogawa WT500 power analyzer to collect motor current, NI CompactDAQ to record vibration acceleration (installed PCB 352C33 triaxial accelerometer); obtain parameters and corresponding motion range: -90° to +90°, and use S-type acceleration and deceleration (Jerk = 500° / s 3 ) and current limit:

[0101] Working conditions Allowable peak current Continuous current No load 8A 5A Rated load 12A 8A Overload (120%) 15A 10A

[0102] Compare the loads and, if an overload exists, implement overload protection. For example, apply a 150% load at the 90° position and verify that the drive enters the Fault state within 50ms (in compliance with IEC 61800-7 safety requirements).

[0103] Single-axis motion test: Rotary joint II 6: Motion range: -45°→+135°, speed 60° / s; Acceptance: Repeatability accuracy ≤±0.02mm (API Radian laser tracker).

[0104] Rotary joint 3-8: Sine trajectory test (±60°, 0.5Hz), phase delay <5ms.

[0105] Perform a compound exercise test:

[0106] Action planning:

[0107] / / "Arm Raise-Stretch" compound movement

[0108] Joint2: 0°→90° (2-second quintic polynomial curve)

[0109] Joint3: 0°→60° (synchronous motion)

[0110] Performance indicators: Synchronization error: TCP point trajectory deviation <0.5mm (measured by Leica AT960); Dynamic load fluctuation: <±3% (Kistler 9257B six-axis force sensor); If the TCP point trajectory deviation ≥0.5mm, cross-coupling control (CCC) is enabled:

[0111] Kcc=0.8 (coupling coefficient)

[0112] Tcomp=5ms (compensation period)

[0113] The KUKA System Software 8.3 online debugging tool was used to verify the effectiveness of the algorithm. Furthermore, temperature compensation was performed by installing PT100 temperature sensors on the joints to compensate for the thermal expansion coefficient in real time (e.g., 0.011 mm / °C for steel connecting rods).

[0114] If the sinusoidal trajectory phase delay is greater than 5ms, adjust the speed loop cutoff frequency: increase from 50Hz to 80Hz (make sure the motor does not enter the resonance zone); stiffness test: use a Kistler 9027C hammer to strike the connecting rod and measure the natural frequency (need to be greater than 100Hz).

[0115] Verify the end effector function: perform mechanical gripper 11 test:

[0116] Use Al 6061 standard test block (Φ50×100mm)

[0117] Clamping force acceptance:

[0118] Opening width target value allowable error

[0119] 50mm 200N ±10N

[0120] 80mm 150N ±15N

[0121] The rotary joint has a rotation accuracy of ±180° and a repeatability of ≤±0.05mm (Keyence laser detection). If the clamping force does not fall within the clamping force acceptance range, check the SMC AF30 filter for clogging (pressure differential > 0.1MPa requires replacement), install an SMC AR20 pressure regulating valve at the cylinder inlet (output pressure fluctuation <±1%), and use the Schunk gripper calibrator to readjust the guide rod preload (target friction: 5N±1N).

[0122] See also Figure 2 As shown, the present invention provides a robot joint module drive test system on the other hand, including a test platform structure construction module, an initialization safety protection module, a single joint drive performance verification module, a multi-axis coordinated motion load test module and a data diagnosis exception processing module;

[0123] The test platform's structural construction module consists of the robot body and specialized testing tools. It includes a base, a rotating base, a joint detection board, and a serial mechanical structure consisting of multiple rotary joints and connecting rods. The base drives the rotating base horizontally via rotary joint 1, and connects connecting rods 1 through 3 in series to achieve vertical swing and multi-axis linkage. The end is connected to the mechanical gripper and replaceable specialized tools (such as welding guns and suction cups) via rotary joint 4, forming a complete kinematic chain. The joint detection board integrates a resolver and a communication module (EtherCAT / CAN) to provide real-time feedback on joint angle and torque data, providing the hardware foundation for testing.

[0124] Before initializing the safety protection module test, power supply stability verification (three-phase voltage 361-399V, imbalance ≤2%) and ground resistance detection (≤0.1Ω) must be completed to ensure electrical safety. A stable control link is established through EtherCAT communication diagnosis (periodic jitter <50μs, frame loss rate ≤0.003%). An electronic safety light grid (SICK microScan3) is deployed to form a protection area (horizontal resolution 14mm, response ≤14ms), and the performance of the emergency stop system is verified (power cut-off ≤300ms, brake action ≤50ms). The safe torque off (STO) function must meet the requirement that the servo current drops to <0.1A within 125μs after the emergency stop, in compliance with the IEC61800-7 standard.

[0125] The single joint drive performance verification module adopts a step-by-step driving strategy, testing step by step from the rotating base (0°-360°) to the end joint (±180°). The rotation angle error (≤0.1°) and torque fluctuation are verified by Leuze laser encoder and HBM torque sensor, and the S-shaped acceleration and deceleration curve (Jerk = 500° / s 3 ) Check whether the motor current exceeds the limit (8A peak at no load, 12A rated). The end gripper must be verified with a pressure sensor to ensure gripping force (200N ± 10N @ 50mm opening). The dedicated tool interface must be tested for vacuum suction and current output functions. Compatibility error must be controlled within ±1%.

[0126] The multi-axis collaborative motion load test module presets a linear / circular trajectory to drive the coordinated motion of multiple joints. A laser tracker (API Radian) is used to detect the TCP point repeatability accuracy (≤±0.02mm) and synchronization error (trajectory deviation <0.5mm). During the load test, 120% of the rated load (weight) is added, an infrared thermometer is used to monitor the motor temperature rise (ΔT≤45K), and a Kistler six-axis force sensor is used to detect dynamic load fluctuations (<±3%). Under abnormal working conditions, cross-coupling control (CCC, Kcc=0.8) and thermal expansion compensation (0.011mm / ℃) are used to optimize motion accuracy and ensure that the reducer vibration spectrum complies with the ISO10816-3 standard.

[0127] The data diagnosis and abnormality processing module collects encoder, temperature and vibration data in real time based on the joint detection board, uses TwinCAT Scope to analyze periodic jitter and inject communication interruption test. It triggers the distribution cabinet contact inspection for voltage abnormality (unbalance > 2%) and executes the cable cross-sectional area (≥ 16mm) when the grounding fails. 2 ) and polish the contact surfaces. If the gripping force of the gripper is abnormal, check the air filter pressure differential (SMC AF30, if the pressure differential is >0.1MPa, replace it). If the mechanical vibration exceeds the limit, test the natural frequency (>100Hz) with a hammer tap and adjust the servo stiffness parameters (increase the speed loop cutoff frequency to 80Hz). All diagnostic results are synchronously generated into maintenance instructions, enabling closed-loop fault handling.

[0128] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to specific embodiments. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A robot joint module drive test method, characterized in that: include: Step 1: Provide the robot joint module drive test structure; Step 2: Perform joint module drive test, including single-joint step-by-step drive control and multi-axis coordinated motion control; specifically: S01: Perform system initialization and safety preparation, and ensure that the power supply connection between the robot body and the control terminal is normal; verify whether the communication link between the control terminal and the joint detection board (3) and each rotary joint is stable; set up a physical safety fence or electronic safety grating; if a person accidentally enters the test area, activate the emergency stop button function test and immediately cut off the power source in an emergency; S02: Perform single joint step-by-step drive control; S03: Perform multi-axis coordinated motion control; Step 3: Perform data fault diagnosis, including initialization detection, safety system verification and motion performance abnormality diagnosis.

2. The robot joint module drive test method according to claim 1, characterized in that: The robot joint module drive test structure includes a robot body, and the robot body includes a base (1), a rotating base (2), a joint detection plate (3), a connecting rod one (5), a connecting rod two (7), a connecting rod three (9), a rotating joint one (4), a rotating joint two (6), a rotating joint three (8), a rotating joint four (10), a mechanical gripper (11) and a special tool; the rotating base (2) and the joint detection plate (3) are installed on the base (1); the rotating joint one (4) is installed on the joint detection plate (3) and is rotationally connected; the rotating joint one (4) is fixedly connected to the connecting rod one (5); the connecting rod one (5) and the connecting rod two (7) are rotationally connected through the rotating joint two (6); the connecting rod two (7) and the connecting rod three (9) are rotationally connected through the rotating joint three (8); the connecting rod three (9) and the mechanical gripper (11) are rotationally connected through the rotating joint four (10); and the mechanical gripper (11) is installed with a special tool.

3. The robot joint module drive test method according to claim 2, characterized in that: The specific process of single-joint step-by-step drive control is as follows: S201: The control terminal sends a command to drive the rotating base (2) to rotate horizontally around the base (1); S202: Control the rotary joint 1 (4) to drive the connecting rod 1 (5) to swing in the vertical direction; obtain the motion trajectory of the connecting rod 1 (5); S203: driving the second rotary joint (6) and the third rotary joint (8) in sequence to verify the multi-axis coordination capability; Single-axis motion: Control the second rotary joint (6) and the third rotary joint (8) to swing independently; Compound motion: synchronously driving the second rotary joint (6) and the third rotary joint (8) to simulate the "arm raising-stretching" action; S204: driving the rotary joint 4 (10) to rotate the mechanical gripper (11) around the terminal axis; verifying the function of the mechanical gripper (11): controlling the mechanical gripper (11) to perform opening and closing actions, installing a special tool, and verifying the interface compatibility between the tool and the gripper and the activation of the function; Perform multi-axis coordinated motion control: preset path motion to detect repeat positioning accuracy and synchronization error; attach standard load to simulate rated working conditions, and detect joint motor temperature rise and reducer vibration noise.

4. The robot joint module drive test method according to claim 3, characterized in that: Perform multi-axis coordinated motion control: The motion trajectory of the mechanical gripper (11) is set to a "lift-stretch" compound action, driving the second rotary joint (6) and the third rotary joint (8) to move synchronously; The motion range of the second rotary joint (6) is 0°→90°, and the synchronous motion range of the third rotary joint (8) is 0°→60°, and a fifth-order polynomial curve is used for planning; If the TCP point trajectory deviation is ≥0.5 mm, the cross-coupling control algorithm is enabled, the coupling coefficient Kcc is set to 0.8, and the compensation period Tcomp is set to 5 ms.

5. The robot joint module drive test method according to claim 4, characterized in that: Step 3 troubleshooting includes: Z301: Initialization detection and safety system verification; Initialization detection, including input voltage detection, ground resistance detection and communication link verification; Generate contact detection instructions for input voltage detection; according to the instructions, check the oxidation of the circuit breaker contacts of the distribution cabinet or the load distribution of the transformer; Generate wire cross-section polishing instructions for ground resistance detection, check the cross-sectional area of the ground wire, and polish the contact surface of the ground terminal; Generate a communication link abnormality instruction for communication link verification, replace the Cat6A shielded twisted pair cable, and re-crimp the RJ45 connector; Deploy electronic safety light curtains, calibrate light curtain coverage, and test emergency stop system response time; Z302: Test S02, specifically: Rotating base (2) horizontal rotation test: If the angle error is greater than 0.1°, check the grounding of the resolver signal line shielding layer and calibrate the backlash of the joint reducer; Conduct a vertical swing test of the connecting rod (5); obtain a preset test configuration, perform load simulation, obtain parameters and corresponding motion range: -90° to +90°, and compare the speed curve using S-type acceleration and deceleration and current limit. If there is an overload, perform overload protection; Perform uniaxial motion testing; Perform compound movement tests; Verify the function of the end effector: perform mechanical gripper (11) test: Use Al 6061 standard test block for clamping force acceptance: The rotation accuracy of the rotary joint four (10) is ±180° rotation, and the repeatability accuracy is ≤±0.05mm. If the clamping force does not fall within the clamping force acceptance, check the filter blockage, install a pressure regulating valve at the cylinder inlet, and use the clamp calibrator to readjust the guide rod preload.

6. The robot joint module drive test method according to claim 4, characterized in that: The specific input voltage detection is: The three-phase voltages at the robot body and control cabinet input terminals were measured using a Fluke 87V multimeter integrated within the industrial robot. The measured voltages were compared with the preset allowable range to calculate voltage imbalance using the negative-sequence voltage component method. Voltage imbalance is defined as the percentage of the negative-sequence voltage component to the positive-sequence voltage component: Among them, U1 is the positive sequence component of the three-phase voltage, and U2 is the negative sequence component of the three-phase voltage, which are compared with the corresponding voltage imbalance preset range; if it does not meet the corresponding preset allowable range and preset range, a detection contact instruction is generated.

7. The robot joint module drive test method according to claim 5, characterized in that: The ground resistance detection is as follows: The ground resistance value was measured using a Kyoritsu 4105A ground resistance tester. During the test, the power was disconnected and an independent grounding stake was connected. If the measured value is greater than 4Ω, a wire cross-section grinding instruction is generated, requiring the ground wire cross-section area to be ≥16mm 2 And polish the contact surface.

8. The robot joint module drive test method according to claim 6, characterized in that: The communication link verification is specifically as follows: Monitor period jitter and frame loss rate using the Beckhoff EK1100 coupler; If the redundant link is not switched to within 50ms after the communication is interrupted, a communication link abnormality instruction is generated, and the Cat6A shielded twisted pair cable is replaced and the RJ45 connector is re-crimped.

9. The robot joint module drive test method according to claim 7, characterized in that: The uniaxial motion test and the composite motion test are performed as follows: Single-axis motion test: Rotary joint 2 (6): motion range: -45°→+135°, speed 60° / s; acceptance: repeat positioning accuracy ≤±0.02mm; Rotary joint 3 (8): sinusoidal trajectory test, phase delay <5ms; Perform a compound exercise test: Motion planning and synchronization error: TCP point trajectory deviation <0.5mm; dynamic load fluctuation: <±3%; If the TCP point trajectory deviation is ≥0.5mm, cross-coupling control is enabled: Use online debugging tools to verify the effectiveness of the algorithm; and temperature compensation: install PT100 temperature sensors on the joints to compensate for the thermal expansion coefficient in real time; If the sinusoidal trajectory phase delay is greater than 5ms, adjust the speed loop cutoff frequency from 50Hz to 80Hz. Stiffness test: Use a Kistler 9027C hammer to strike the connecting rod and measure the natural frequency.

10. The robot joint module drive test system is characterized by: The method for driving and testing a robot joint module according to any one of claims 1 to 8 comprises: a test platform structure construction module, an initialization safety protection module, a single joint drive performance verification module, a multi-axis coordinated motion load test module, and a data diagnosis exception processing module; The test platform structure construction module builds a robot body test platform, which includes a base, multi-stage rotation joints, connecting rods and end grippers. The joint detection board collects rotation angle and torque data in real time to form a complete motion chain. Initialize the safety protection module to verify power stability, ground resistance, and communication links, and deploy safety light curtains and emergency stop systems; The single-joint drive performance verification module drives each joint to rotate step by step, detects angle error, motor current and clamping force, and verifies motion trajectory accuracy and load capacity; The multi-axis coordinated motion load test module uses preset trajectories to drive the coordinated motion of multiple joints, testing repeatability and synchronization errors. Additional loads monitor temperature rise and vibration, optimizing control algorithms to ensure motion stability. The data diagnosis and abnormality processing module collects joint data in real time, analyzes communication jitter and voltage abnormalities, and automatically generates fault handling instructions.

Images