Robot joint module driving test method and system

Abstract

The application discloses a robot joint module driving test method and system, and relates to the technical field of robot joint module driving detection; in view of the problems of insufficient multi-axis cooperation ability, missing dynamic load simulation, low fault diagnosis efficiency and the like in the prior art, the application realizes the synchronous control of positioning accuracy of + / -0.02mm and TCP trajectory deviation of <0.5mm through single-joint step-by-step driving and multi-axis compound motion cooperation test, adopts a laser angle encoder and a six-dimensional force sensor, integrates an industrial-grade fault diagnosis system, realizes the fault positioning efficiency improvement of 50% through voltage imbalance degree analysis, vibration spectrum monitoring and EMC interference investigation, sets multiple safety protection mechanisms including a safety grating, an emergency stop system and a safety torque shutdown verification, supports 120% overload protection and standardized tool interface compatibility test, prolongs the service life of core components by 30%-40% through reducer backlash laser calibration and real-time temperature compensation, and the method improves the dynamic working condition adaptability, motion stability and system reliability of the robot.

Description

Technical Field

[0001] This invention relates to the field of robot joint module drive testing technology, specifically to robot joint module drive testing methods and systems. Background Technology

[0002] Robot joint module drive testing is a core component of industrial robot R&D and maintenance. Traditional methods mainly rely on independent testing of single joints (manual or simple program-driven testing of basic parameters), static functional verification (fixed load or preset path testing of motion range), manual experience-based fault diagnosis (relying on subjective judgment of abnormal phenomena), and basic safety mechanisms (emergency stop buttons and physical fences). However, these methods suffer from incomplete test coverage (e.g., lack of multi-axis coordination), disconnect between dynamic loads and real-world 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 high-precision and high-reliability requirements of industrial scenarios.

[0003] However, existing testing methods for robot joint module drives have significant shortcomings, including incomplete test coverage (insufficient multi-axis coordination capability, such as weld seam offset exceeding the tolerance by 50% due to joint synchronization delay >10ms in welding tasks), disconnect between dynamic load and real working conditions (static tests do not simulate inertial impact, resulting in a 30% reduction in the lifespan of RV reducers), low level of diagnostic intelligence (relying on manual troubleshooting, such as communication link jitter issues taking 3 days to locate), imperfect safety protection mechanisms (emergency stop delay >500ms, equipment damage caused by defects in safety light curtain deployment), and lack of scalability verification (poor tool interface compatibility leads to adsorption failure and 8-hour downtime). These shortcomings severely restrict the reliability, efficiency, and scene adaptability of robots. Summary of the Invention

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

[0005] The objective of this invention can be achieved through the following technical solutions:

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

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

[0008] Step Two: Conduct joint module drive testing, including single-joint step-by-step drive control and multi-axis coordinated motion control; specifically:

[0009] S01: Perform system initialization and safety preparation, ensuring the power connection between the robot body and the control terminal is normal; verify the stability of the communication link between the control terminal and the joint detection board and each rotating joint; set up physical safety fences or electronic safety light curtains; if personnel accidentally enter the test area, activate the emergency stop button function test, and immediately cut off the power source in an emergency;

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

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

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

[0013] In a preferred embodiment of the present invention, the robot joint module drive test structure includes a robot body, which includes a base, a rotating base, a joint detection plate, a first link, a second link, a third link, a first rotating joint, a second rotating joint, a third rotating joint, a fourth rotating joint, a mechanical gripper, and a special tool. The rotating base and the joint detection plate are mounted on the base. The first rotating joint is mounted on the joint detection plate and is rotatably connected. The first rotating joint is fixedly connected to the first link. The first link and the second link are rotatably connected via the second rotating joint. The second link and the third link are rotatably connected via the third rotating joint. The third link and the mechanical gripper are rotatably connected via the fourth rotating joint. The special tool is mounted on the mechanical gripper.

[0014] As a preferred embodiment of the present invention, the specific process of performing single-joint step-by-step drive control 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 to drive the link to swing vertically; obtain the motion trajectory of the link.

[0017] S203: Drive rotary joint two and rotary joint three in sequence to verify multi-axis coordination capability;

[0018] Single-axis motion: Rotary joints two and three are controlled to swing independently;

[0019] Compound movement: synchronously driving rotational joints two and three to simulate the "arm raising-extension" movement;

[0020] S204: Drive rotary joint four 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 and function activation of the tools and grippers.

[0021] Multi-axis coordinated motion control: preset path motion to detect repeatability and synchronization error; additional standard load to simulate rated working conditions, and detect joint motor temperature rise and reducer vibration and noise.

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

[0023] The motion trajectory of the mechanical gripper is set as a "lifting arm - extending arm" compound motion, driving the synchronous movement of rotary joint two and rotary joint three;

[0024] Rotary joint 2 has a range of motion from 0° to 90°, and rotary joint 3 has a synchronous range of motion from 0° to 60°, using a fifth-order polynomial curve programming.

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

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

[0027] Z301: Initialization testing and security system verification;

[0028] Initialization testing includes input voltage detection, grounding resistance detection, and communication link verification;

[0029] The system detects the input voltage and generates a contact inspection command; based on the command, it checks for oxidation of the circuit breaker contacts in the distribution cabinet or the load distribution of the transformer.

[0030] The grounding resistance detection generates a line cross-section grinding command to check the cross-sectional area of ​​the grounding wire and grind the contact surface of the grounding terminal.

[0031] The communication link verification generates a communication link abnormality command, replaces the Cat6A shielded twisted pair cable, and re-crimps the RJ45 connector;

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

[0033] Z302: Detect SO2, specifically as follows:

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

[0035] Perform a vertical swing test on the linkage; obtain the preset test configuration, perform load simulation, obtain parameters and corresponding motion range: -90° to +90°, compare the speed curve with the S-shaped acceleration / deceleration and current limit, and if overload exists, perform overload protection;

[0036] Perform single-axis motion testing;

[0037] Perform compound motion tests;

[0038] End effector function verification: Mechanical gripper test:

[0039] Clamping force was tested using the Al 6061 standard test block:

[0040] The rotation accuracy of the rotary joint is ±180° rotation, and the repeatability 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 readjust the guide rod preload using a gripper calibrator.

[0041] In a preferred embodiment of the present invention, the input voltage detection specifically involves:

[0042] Using a Fluke 87V multimeter integrated within the industrial robot, the three-phase voltage at the input terminals of the robot body and control cabinet is measured. The measured voltage is compared with a preset allowable range to calculate the voltage imbalance. The negative sequence voltage component method is used, and the voltage imbalance is 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. It is compared with the corresponding preset range of voltage imbalance. If the preset allowable range and preset interval are not met, a test contact instruction is generated.

[0043] In a preferred embodiment of the present invention, the grounding resistance detection specifically involves:

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

[0045] If the measured value is greater than 4Ω, a grounding cross-section grinding command is generated, requiring the grounding wire cross-sectional area to be ≥16mm². 2 And grind the contact surface.

[0046] In a preferred embodiment of the present invention, the communication link verification specifically includes:

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

[0048] If the communication is interrupted and the redundant link is not switched within 50ms, a communication link error command will be generated, and the Cat6A shielded twisted pair cable will be replaced and the RJ45 connector will be re-crimped.

[0049] In a preferred embodiment of the present invention, the single-axis motion test and the composite motion test are performed as follows:

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

[0051] Perform compound movement tests:

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

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

[0054] If the phase delay of the sinusoidal trajectory is >5ms, adjust the velocity loop cutoff frequency: increase it from 50Hz to 80Hz; stiffness test: use a Kistler 9027C force 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 testing system, comprising: a test platform structure construction module, an initialization safety protection module, a single joint drive performance verification module, a multi-axis cooperative motion load testing module, and a data diagnosis and anomaly processing module;

[0056] The test platform structure construction module builds a robot body test platform, including a base, multi-level rotary joints, links and end effector grippers. The rotation angle and torque data are collected in real time through the joint detection plate to form a complete kinematic chain.

[0057] Initialize the safety protection module to verify power stability, grounding resistance and communication link, and deploy safety light curtains and emergency stop system;

[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 cooperative motion load test module uses a preset trajectory to drive multi-joint cooperative motion, testing repeatability and synchronization error; additional loads monitor temperature rise and vibration, and optimized control algorithms ensure motion stability.

[0060] The data diagnostic anomaly handling module collects joint data in real time, analyzes issues such as communication jitter and voltage anomalies, and automatically generates fault handling instructions.

[0061] Compared with the prior art, the beneficial effects of the present invention are:

[0062] 1. This invention covers the entire performance verification process from the rotating base to the end-effector by conducting collaborative testing of single-joint step-by-step drive and multi-axis compound motion. High-precision sensors (such as laser angle encoders and six-dimensional force sensors) and dynamic load simulation are employed, combined with cross-coupling control and thermal expansion compensation algorithms, to ensure the positioning accuracy (e.g., ±0.02mm) and synchronization error control (TCP trajectory deviation <0.5mm) of each joint in both independent and linked scenarios. This significantly improves the robot's motion stability and adaptability to complex tasks, and reduces 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 grounding resistance detection) with real-time data monitoring (vibration spectrum and motor temperature rise). Through automated threshold determination (such as voltage allowable range of 361-399V) and correction strategies (such as communication jitter and EMC interference troubleshooting), it achieves rapid fault location. Combined with safety light curtains, emergency stop systems (power cut-off delay ≤300ms), and safe torque shutdown (STO) verification according to EN ISO 13855 standards, it constructs a multi-layered protection mechanism, effectively preventing overload, misoperation, and environmental interference risks, and reducing downtime for maintenance 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 mechanical grippers and welding torches / suction cups) and load condition simulation (120% overload protection). It employs long-term compensation strategies (such as laser calibration of reducer backlash and real-time PT100 temperature compensation) and key component health monitoring (harmonic reducer vibration analysis and filter differential pressure early warning) to extend the lifespan of core components by 30%–40%. Simultaneously, it 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. Attached Figure Description

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

[0066] Figure 1 This is a diagram illustrating the method steps of the present invention;

[0067] Figure 2 This is a schematic diagram of the principle of the present invention;

[0068] Figure 3 This is a schematic diagram of robot detection according to the present invention. Figure 1 ;

[0069] Figure 4 This is a schematic diagram of robot detection according to the present invention. Figure 2 ;

[0070] Figure 5 This is a schematic diagram of robot detection according to the present invention. Figure 3 .

[0071] Figure descriptions: 1. Base; 2. Rotating base; 3. Joint detection plate; 4. Rotating joint one; 5. Link one; 6. Rotating joint two; 7. Link two; 8. Rotating joint three; 9. Link three; 10. Rotating joint four; 11. Mechanical gripper. Detailed Implementation

[0072] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0073] Please see Figure 1 As shown, this invention provides a robot joint module drive testing method, including:

[0074] Step 1: Construct the robot joint module drive test structure, including the robot body, which includes base 1, rotating base 2, joint detection plate 3, link 1 5, link 2 7, link 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, a rotating base 2 and a joint detection plate 3 are installed on the base rotating joint 1; a rotating joint 4 is installed on the joint detection plate 3, and the two are rotatably connected; the rotating joint 4 is connected to the connecting rod 5; the connecting rod 5 and the connecting rod 2 7 are rotatably connected through the rotating joint 2 6; the connecting rod 2 7 and the connecting rod 3 9 are rotatably connected through the rotating joint 3 8; the connecting rod 3 9 is rotatably connected to the mechanical gripper 11 through the rotating joint 4 10; a special tool is installed on the mechanical gripper 11.

[0076] Step 2: Perform joint module drive testing, with the control terminal controlling the industrial robot to reach the detection command 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 (e.g., EtherCAT, CAN bus); and set up physical safety fences or electronic safety light curtains to prevent personnel from accidentally entering the test area, activate the emergency stop button function test to ensure that the power source can be cut off immediately 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 acquires 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 plate 3 are consistent with the control command.

[0080] S202: Control the rotary joint 4 to drive the connecting rod 5 to swing vertically (e.g., ±90°); acquire the motion trajectory of the connecting rod 5, detect whether the motor current is within the rated range, and avoid overload.

[0081] S203: Drive rotary joint 26 (connecting link 15 and link 27) and rotary joint 38 (connecting link 27 and link 39) in sequence to verify multi-axis coordination capability;

[0082] Single-axis motion: Rotary joint 6 and rotary joint 8 are controlled to swing independently respectively;

[0083] Compound motion: synchronously drive rotational joint 2 (6) and rotational joint 3 (8) to simulate the "arm raising-extension" movement.

[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) to verify the interface compatibility and function activation (e.g., vacuum adsorption, current output) between the tool and the gripper.

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

[0086] Preset path motion control: Set typical motion trajectories (such as straight lines, arcs, and spirals) at the control terminal to drive all joints to move in coordination; repeatability positioning accuracy (verified by laser tracker or encoder data); synchronization error of each joint (feedback from joint detection board 3 of the deviation between the actual position and the commanded position of each axis).

[0087] Load condition simulation: Apply a standard load (such as a weight) to the mechanical gripper 11 to test the motion stability of the joint module under rated load; check whether the temperature rise of the joint motor is normal (monitored by an infrared thermometer); 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 encoder position, motor current, temperature, and vibration spectrum of each joint; specifically:

[0089] Z301: Detects and monitors the initialization and electronic safety light curtain in S01;

[0090] Initialization testing includes input voltage detection, grounding resistance detection, and communication link verification;

[0091] For input voltage detection, the three-phase voltages (L1-L2, L2-L3, L3-L1) at the input terminals of the robot body and control cabinet are measured using a Fluke 87V multimeter integrated within the industrial robot. The measured voltages are compared with the preset allowable range of 361 to 399V (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). Where U1 is the positive sequence component of the three-phase voltage and U2 is the negative sequence component of the three-phase voltage, it is compared with the corresponding preset range of voltage imbalance; if the preset allowable range and preset range are not met, a test contact instruction is generated; according to the instruction, the oxidation of the circuit breaker contacts in the distribution cabinet or the transformer load distribution are checked.

[0092] Grounding resistance is tested using an integrated Kyoritsu 4105A grounding resistance tester (applying a 200mA test current). The power is disconnected via a relay. Connect the tester's C terminal to an independent grounding stake (≥10m from the equipment), and the P terminal to the robot's grounding terminal. Press the test button and hold for 5 seconds to read the stable value. Compare this value with the applicable standard (grounding resistance ≤0.1Ω (IEC60204-1 Class 1 grounding requirements)). If the measured stable value differs from the applicable standard, a wire cross-section grinding command is generated to check the grounding wire cross-sectional area (≥16mm²). 2 (Yellow-green wire), grind the contact surface of the grounding terminal.

[0093] For communication link verification, Beckhoff EK1100 couplers were 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 diagnostics were performed using the TwinCATScope tool (configured in DC synchronization mode) to monitor periodic jitter (<50μs (EtherCAT specification)) and frame loss rate (≤3 frames lost in 100,000 consecutive frame tests). Faults were injected into the test to simulate communication interruption. If the system switched to the redundant link within 50ms, the communication link verification passed; otherwise, a communication link abnormality command was generated, the Cat6A shielded twisted pair cable (S / FTP) was replaced, and the RJ45 connectors were re-crimped.

[0094] The deployment of the electronic safety light curtain (ESPE) involved calibrating and installing the SICKmicroScan3 Core (IP67 protection) with the bottom ≤300mm from the ground and the top ≥1200mm to cover the human torso intrusion path. The software configuration used Safety Designer to set the protected area, with a horizontal resolution of 14mm and a response time ≤14ms, conforming to EN ISO 13855 standards. The testing method involved vertically penetrating the light curtain with a standard test bar (25mm diameter, 200mm length) at a speed of 2m / s, ensuring the light curtain triggered the OSSD signal within 14ms. For the emergency stop system verification, the mechanical emergency stop button was tested under the robot's maximum speed (e.g., joint 4 rotating at 180° / s), with a power cut-off delay ≤300ms and a mechanical brake action time ≤50ms. Safety Torque Off (STO) verification was performed using Yokogawa. A DL850E oscilloscope (with a high-voltage differential probe) was used to test the U / V / W output terminals of the Yaskawa Σ-7 servo driver, requiring the phase current to drop to <0.1A within one control cycle (125μs) after an emergency stop trigger. Furthermore, for handling critical abnormal scenarios, such as communication jitter exceeding limits (TwinCAT Scope showing Cycle Jitter >100μs), an EMC tester (such as a Rohde & Schwarz ESRP3) was used to scan the 2.4GHz band to troubleshoot interference. This included replacing the RJ45 connector or enabling EtherCAT frame priority (802.1Q VLAN tagging) for TwinCAT. For the issue of safety light curtain mis-triggered signals, the "ambient light immunity" parameter of the light curtain was adjusted (enabling >850nm infrared filtering), a dust cover (SICK VAA4200) was added to the transmitter, and the rigidity of the mounting bracket was checked to eliminate lens shift caused by mechanical vibration.

[0095] Z302: Detect SO2, specifically as follows:

[0096] Horizontal rotation test of rotating base 2: Beckhoff EL3632 analog input module was used to acquire the refractive signal of joint detection plate 3; Leuze RSL 400 laser angle encoder was installed as an external reference (resolution 0.001°); control commands were executed:

[0097]

[0098]

[0099] Obtain the angle following error; sample torque fluctuations using the HBM T12 torque sensor; if the angle error is >0.1°, check the grounding of the resolver signal line shield (single-point connection to the PE busbar of the control cabinet is required), and calibrate the backlash of the joint reducer (using a laser interferometer to compensate for parameters).

[0100] Perform a vertical swing test on link 5; obtain the preset test configuration and simulate the load (suspending standard weights, such as 120% of the rated load); control the onboard monitoring equipment: Yokogawa WT500 power analyzer to collect motor current, and NI CompactDAQ to record vibration acceleration (installing a PCB 352C33 triaxial accelerometer); obtain parameters and corresponding motion range: -90° to +90°, with the velocity curve using an S-shaped acceleration / deceleration pattern (Jerk = 500° / s). 3 and current limits:

[0101] Operating conditions Allowable peak current continuous current Unloaded 8A 5A Rated load 12A 8A Overload (120%) 15A 10A

[0102] The comparison is performed, and if an overload is found, overload protection is implemented; for example, a 150% load is applied at a 90° position, and the driver is verified to enter the Fault state within 50ms (compliant with IEC 61800-7 safety requirements).

[0103] Perform single-axis motion test: Rotary joint 26: range of motion: -45°→+135°, speed 60° / s; acceptance: repeatability accuracy ≤±0.02mm (API Radial laser tracker).

[0104] Rotary joint 3.8: Sine trajectory test (±60°, 0.5Hz), phase delay <5ms.

[0105] Perform compound movement tests:

[0106] Motion planning:

[0107] / / "Arm Raise-Extend" Compound Movement

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

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

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

[0111] Kcc = 0.8 (coupling coefficient)

[0112] Tcomp = 5ms (compensation period)

[0113] The effectiveness of the algorithm was verified using the KUKA System Software 8.3 online debugging tool; and temperature compensation was performed: PT100 temperature sensors were installed on the joints to compensate for the coefficient of thermal expansion in real time (e.g., 0.011 mm / ℃ compensation for steel connecting rods).

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

[0115] End effector function verification: Mechanical gripper 11 test:

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

[0117] Clamping force acceptance:

[0118] Allowable error of target opening width

[0119] 50mm 200N ±10N

[0120] 80mm 150N ±15N

[0121] Rotary joint 410 rotation accuracy ±180° rotation, repeatability ≤±0.05mm (KEYENCE line laser detection). If the clamping force is not within the clamping force acceptance range, check the SMC AF30 filter for blockage (pressure difference > 0.1MPa requires replacement). Install an SMC AR20 pressure regulating valve at the cylinder inlet (output pressure fluctuation < ±1%). Use a Schunk gripper calibrator to readjust the guide rod preload (target friction force: 5N ± 1N).

[0122] Please see Figure 2 As shown, another aspect of the present invention provides a robot joint module drive testing system, including a test platform structure construction module, an initialization safety protection module, a single joint drive performance verification module, a multi-axis cooperative motion load testing module, and a data diagnosis anomaly processing module;

[0123] The test platform consists of a robot body and specialized testing tools, comprising a base, a rotating base, a joint detection plate, and a series of rotating joints and links forming a sequential mechanical structure. The base is driven to rotate horizontally via rotating joint one, and connected to links one through three to achieve vertical swinging and multi-axis linkage. The end effector connects to a mechanical gripper and replaceable specialized tools (such as a welding torch or suction cup) via rotating joint four, forming a complete kinematic chain. The joint detection plate integrates a rotary transformer and a communication module (EtherCAT / CAN) to provide real-time feedback of 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 grounding resistance detection (≤0.1Ω) must be completed to ensure electrical safety. A stable control link is established through EtherCAT communication diagnostics (periodic jitter <50μs, frame loss rate ≤0.003%). An electronic safety light curtain (SICK microScan3) is deployed to form a protected area (horizontal resolution 14mm, response ≤14ms), and the emergency stop system performance is verified (power cut-off ≤300ms, brake action ≤50ms). The Safety Torque Off (STO) function must ensure that the servo current drops to <0.1A within 125μs after an emergency stop, conforming to IEC61800-7 standard.

[0125] The single-joint drive performance verification module adopts a step-by-step drive strategy, testing progressively from the rotating base (0°-360°) to the end joint (±180°). Rotation angle error (≤0.1°) and torque fluctuation are verified using a Leuze laser encoder and an HBM torque sensor, employing an S-shaped acceleration / deceleration curve (Jerk = 500° / s). 3 Check if the motor current exceeds the limit (no-load peak 8A, rated 12A). The end gripper needs to have its clamping force verified by a pressure sensor (200N±10N@50mm opening). The special tool interface needs to be tested for vacuum adsorption / current output function, and the compatibility error should be controlled within ±1%.

[0126] The multi-axis coordinated motion load test module uses preset linear / circular trajectories to drive multi-joint coordinated motion. A laser tracker (API Radial) is used to detect the TCP point repeatability (≤±0.02mm) and synchronization error (trajectory deviation <0.5mm). During load testing, a 120% rated load (weights) is applied, and an infrared thermometer monitors the motor temperature rise (ΔT≤45K). A Kistler six-dimensional force sensor detects dynamic load fluctuations (<±3%). Under abnormal operating conditions, motion accuracy is optimized through cross-coupling control (CCC, Kcc=0.8) and thermal expansion compensation (0.011mm / ℃) to ensure the reducer vibration spectrum complies with ISO10816-3 standards.

[0127] The data diagnostic anomaly handling module collects encoder, temperature, and vibration data in real time based on the joint detection board. It uses TwinCAT Scope to analyze periodic jitter and injects communication interruption tests. Voltage anomalies (imbalance > 2%) trigger a check of the distribution cabinet contacts; in case of grounding failure, it performs checks on cables with a cross-sectional area ≥ 16mm². 2 The contact surfaces are polished. If the gripper clamping force is abnormal, check the air filter pressure difference (replace SMC AF30 if pressure difference > 0.1MPa). If the mechanical vibration exceeds the limit, test the natural frequency (>100Hz) by tapping with a force hammer and adjust the servo stiffness parameters (increase the speed loop cutoff frequency to 80Hz). All diagnostic results are used to generate maintenance instructions simultaneously to achieve closed-loop fault handling.

[0128] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A method of driving test for a robot joint module, characterized by, Comprise: Step one: provide a robot joint module drive test structure including a robot body; 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 clamp jaw (11) and a special tool; Step two: joint module drive test, including single joint step-by-step drive control and multi-axis coordinated motion control; specifically: S01: system initialization and safety preparation, the power supply connection of the robot body and the control terminal is normal; verify whether the communication link of the control terminal and the joint detection plate (3) and each rotating joint is stable; set up physical safety fence or electronic safety grating; personnel misentry test area, activate emergency stop button function test, immediately cut off power source in emergency; S02: single joint step-by-step drive control; S03: multi-axis coordinated motion control; Step three: data fault diagnosis: Z301: initialization detection and safety system verification; Initialization detection, including input voltage detection, ground resistance detection and communication link verification; Input voltage detection: measure the three-phase voltage of the robot body and the control cabinet input through the Fluke 87V multimeter integrated inside the industrial robot; compare the measured voltage with the preset allowed range, calculate the voltage imbalance, use the negative sequence voltage component method, and the voltage imbalance is 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, U2 is the negative sequence component of the three-phase voltage, and the corresponding voltage imbalance preset interval is compared; if it does not satisfy the corresponding preset allowed range and preset interval, a detection contact instruction is generated; according to the instruction, check the oxidation of the distribution cabinet circuit breaker contact or the transformer load distribution; Ground resistance detection: measure the ground resistance value by Kyoritsu 4105A ground resistance tester, disconnect the power supply during testing, and connect the independent grounding pile; if the measured value is > 4Ω, generate a line cross section polishing instruction, requiring the cross sectional area of the grounding wire to be ≥16mm² and polishing the contact surface; Communication link verification: monitor the period jitter and frame loss rate through Beifu EK1100 coupler; if the communication is interrupted and the redundant link is not switched within 50ms, generate a communication link exception instruction, replace the Cat6A shielded twisted pair and repress the RJ45 connector; Deploy the electronic safety grating, calibrate the light curtain coverage range, and test the emergency stop system response time; Z302: detect S02, specifically: Rotating base (2) horizontal rotation test: if the angle error is > 0.1°, check the shielded layer ground of the rotating variable signal line and calibrate the joint reducer backlash; Perform connecting rod one (5) vertical swing test; get the preset test configuration, perform load simulation, get the parameters and corresponding motion range: -90° to +90°, compare the speed curve with S-type acceleration and deceleration and current limit value, if there is overload, perform overload protection; Single-axis motion test: rotating joint two (6): motion range: -45°→+135°, speed 60° / s; acceptance: repeat positioning accuracy ≤±0.02mm; rotating joint three (8): sine trajectory test, phase delay <5ms; Composite motion test: motion planning, synchronization error: TCP point trajectory deviation <0.5mm; make dynamic load fluctuation: <±3%; if TCP point trajectory deviation >=0.5mm, enable cross-coupling control: use online debugging tools to verify algorithm effectiveness; and temperature compensation: install PT100 temperature sensor on joint, real-time compensate thermal expansion coefficient; if sinusoidal trajectory phase delay >5ms, adjust speed loop cutoff frequency: from 50Hz to 80Hz; stiffness detection: use Kistler 9027C force hammer to knock the connecting rod, measure natural frequency; End effector function verification: perform mechanical test gripper (11) test.

2. The method of claim 1, wherein, The robot body, in particular: The base (1) is provided with a rotating base (2) and a joint detection plate (3); the joint detection plate (3) is provided with a rotating joint one (4) and is rotatably connected; the rotating joint one (4) is fixedly connected with a connecting rod one (5); the connecting rod one (5) and a connecting rod two (7) are rotatably connected through a rotating joint two (6); the connecting rod two (7) and a connecting rod three (9) are rotatably connected through a rotating joint three (8); the connecting rod three (9) and a mechanical gripper (11) are rotatably connected through a rotating joint four (10); the mechanical gripper (11) is provided with a special tool.

3. The method of claim 2, wherein, The specific process of single-joint step-by-step driving control is as follows: S201: the control terminal sends instructions to drive the rotating base (2) to rotate horizontally around the base (1); S202: control the rotating joint one (4) to drive the connecting rod one (5) to swing in the vertical direction; obtain the motion trajectory of the connecting rod one (5); S203: sequentially drive the rotating joint two (6) and the rotating joint three (8) to verify the multi-axis coordination capability; Single-axis motion: control the rotating joint two (6) and the rotating joint three (8) to swing independently; Composite motion: synchronously drive the rotating joint two (6) and the rotating joint three (8) to simulate the "arm lifting-stretching" action; S204: drive the rotating joint four (10) to make the mechanical gripper (11) rotate around the end axis; function verification of the mechanical gripper (11): control the mechanical gripper (11) to perform opening and closing actions, install a special tool, and verify the interface compatibility and function activation of the tool and the gripper; Multi-axis coordinated motion control: preset path motion to detect repeatability and synchronization error; additional standard load simulation of rated working condition to detect joint motor temperature rise and reducer vibration noise.

4. The method of claim 3, wherein, Multi-axis coordinated motion control: Set the motion trajectory of the mechanical gripper (11) as "arm lifting-stretching" composite action, and drive the rotating joint two (6) and the rotating joint three (8) to move synchronously; The motion range of the rotating joint two (6) is 0°→90°, and the synchronous motion range of the rotating joint three (8) is 0°→60°, adopting a quintic polynomial curve planning; If the TCP point trajectory deviation >=0.5mm, enable the cross-coupling control algorithm, set the coupling coefficient Kcc=0.8, and the compensation period Tcomp=5ms.

5. A robot joint module drive test system, characterized by, The application is applied to the robot joint module driving test method of any one of claims 1-4, comprising: a test platform structure construction module, an initialization safety protection module, a single joint driving performance verification module, a multi-axis collaborative motion load test module and a data diagnosis exception processing module; The test platform structure construction module builds a robot body test platform, which contains a base, multi-stage rotary joints, connecting rods and end grippers. The rotary angle and torque data are collected in real time through the joint detection plate to form a complete kinematic chain. The initialization safety protection module verifies the power stability, ground resistance and communication link, and deploys a safety grating and an emergency stop system. The single joint driving performance verification module drives each joint rotation step by step, detects the angle error, motor current and clamping force, and verifies the motion trajectory accuracy and load capacity. The multi-axis collaborative motion load test module drives multi-joint collaborative motion with a preset trajectory, tests the repeat positioning accuracy and synchronization error, and monitors the temperature rise and vibration of the additional load to optimize the control algorithm and ensure the motion stability. The data diagnosis exception processing module collects joint data in real time, analyzes the communication jitter and voltage abnormality problems, and automatically generates fault processing instructions.

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