Industrial robot actual energy consumption acquisition and control system based on power meter

Abstract

The invention discloses an industrial robot actual energy consumption acquisition and control system based on a power meter, and belongs to the technical field of robot data acquisition and control. The problem that the real-time energy consumption of the robot in the actual working state cannot be accurately obtained in an existing mode is solved. A power meter, a voltage clamp and a current clamp are used for collecting original voltage and current data in the operation process of the industrial robot and uploading the original voltage and current data to an upper computer; after a data processing module in the upper computer performs filtering processing, a power calculation module performs integration on a power signal vector to obtain actual operation average power of the industrial robot; the motion control module uses a control program to control the industrial robot to move freely in a working space range through the industrial robot controller; the upper computer sends a motion instruction to the industrial robot controller through the communication module, and the industrial robot controller returns industrial robot joint information to the upper computer in real time.

Description

Technical Field

[0001] This invention belongs to the field of robot data acquisition and control technology, specifically relating to an industrial robot actual energy consumption acquisition and control system. Background Technology

[0002] Industrial robots are widely used in various fields of industrial production because they can accurately complete various repetitive and regular tasks according to preset programs. They are a key element for my country's manufacturing industry to achieve high-quality automation and intelligence.

[0003] The energy consumption of industrial robots is receiving increasing attention. With the advancement of industrial intelligence, the number of industrial robots in use is growing rapidly year by year, and their power consumption is also increasing significantly. Accurately collecting the energy consumption data of industrial robots is crucial for optimizing energy utilization, reducing operating costs, and achieving intelligent energy management. Currently, the energy consumption of industrial robots is generally measured based on the energy consumption of the power system at the time of supply, or based on the overall energy consumption of all components of the industrial robot calibrated at the factory. However, both methods have certain problems:

[0004] The energy consumption measurement method based on the power system supply side is actually the energy consumption of the power system supply, which is not the actual energy consumption of the industrial robot, let alone the instantaneous energy consumption of the industrial robot. This seriously affects the accuracy of the estimation or research of the robot's working status and energy consumption. In addition, the energy consumption of the power system supply is actually the total energy consumption of multiple industrial robots. However, the energy consumption of industrial robots with different work tasks, different working states, and even different postures are different. Therefore, this method cannot accurately obtain the energy consumption of each industrial robot, let alone the instantaneous energy consumption of each industrial robot, which further exacerbates the aforementioned problems.

[0005] The overall calibration at the factory only determines the energy consumption corresponding to the action tasks of the industrial robot at the time of manufacture. It cannot represent the energy consumption of the industrial robot in actual application, let alone the real-time energy consumption for different tasks in actual application.

[0006] Therefore, there is a need to invent a data acquisition system that can monitor the actual energy consumption of industrial robots under different operating conditions in real time. Summary of the Invention

[0007] This invention aims to solve the problem that existing methods cannot accurately obtain the real-time energy consumption of a robot under actual working conditions.

[0008] An industrial robot actual energy consumption acquisition and control system based on a power meter includes a data acquisition module, a host computer, a communication module, and an industrial robot controller; the host computer is equipped with a data processing module, a power calculation module, and a motion control module.

[0009] Data acquisition module: Uses a power meter, voltage clamp, and current clamp to collect raw voltage and current data during the operation of the industrial robot, and uploads the collected raw voltage and current data to the host computer;

[0010] Data processing module: Reads the raw voltage and current data uploaded by the data acquisition module and performs filtering processing;

[0011] Power calculation module: Receives the data processed by the data processing module, multiplies the processed voltage signal vector and current signal vector by a dot to obtain the power signal vector, and integrates the power signal vector to obtain the average power of the industrial robot in actual operation.

[0012] Motion control module: Used to manipulate the free movement of industrial robots within the workspace using a control program via an industrial robot controller;

[0013] Communication module: Used to enable real-time communication between the host computer, data acquisition module, and industrial robot controller;

[0014] Industrial robot controller: Used to control the movement of industrial robots within their workspace;

[0015] The host computer sends motion commands to the industrial robot controller via the communication module, and the industrial robot controller returns industrial robot joint information to the host computer in real time.

[0016] Furthermore, the CH_01 and CH_02 ports of the power meter are connected to the voltage clamp and the current clamp, respectively. The voltage clamp and the current clamp are then connected to the live wire and the neutral wire of the industrial robot's three-wire plug, respectively, to achieve the acquisition of raw voltage and current data during the operation of the industrial robot.

[0017] Furthermore, the process by which the data acquisition module uses a power meter, voltage clamp, and current clamp to collect raw voltage and current data during the operation of the industrial robot includes:

[0018] When the industrial robot starts moving, the power meter begins collecting voltage and current data; when the industrial robot stops moving, the power meter stops collecting data. The collected raw data is then uploaded to the host computer. The method for determining when the industrial robot starts moving is as follows: when the host computer determines that the industrial robot has started moving, it sends a start code to the data acquisition module, thus confirming that the industrial robot has started moving. The method for determining when the industrial robot stops moving is as follows: when the host computer determines that the industrial robot has stopped moving based on the joint information, it sends an end code to the data acquisition module, thus confirming that the industrial robot has stopped moving.

[0019] Furthermore, the filtering process performed by the data processing module includes:

[0020] The raw voltage or current data y1(n) is collected and filtered for the first time to obtain a forward filtered signal y2(n). The forward filtered signal y2(n) is then reversed to obtain y3(n). The reversed signal y3(n) is then input into the same filter as the one used in the first filtering for the second filtering. After filtering, the signal y4(n) is obtained. The signal is then reversed again and the zero-phase filtered signal is output.

[0021] Furthermore, during the filtering process using a filter, the normalized passband cutoff frequency ω of the voltage signal filter performance index... n The normalized stopband cutoff frequency ω is 0.00024. c The maximum passband attenuation R is 0.0040. p 0.40dB, maximum stopband attenuation A s 40dB; Normalized passband cutoff frequency ω of the current signal filter performance index n The normalized stopband cutoff frequency ω is 0.0032. c The maximum passband attenuation R is 0.0200. p 0.40dB, maximum stopband attenuation A s It is 40dB.

[0022] Furthermore, the motion control module uses the moveit_commander module as its control program. First, the moveit_commander module is initialized to create ROS nodes and a MoveGroupCommander object is created to control a planning group. The values ​​of goal_position_tolerance and goal_orientation_tolerance are set. The current position of the industrial robot is used as the starting position through the built-in function set_start_state_to_current_state(), and the target position is set through the built-in function set_pose_target(). The motion path of the industrial robot is planned using the built-in function ur5.plan(). Finally, the motion commands are packaged and sent to the industrial robot controller through the built-in functions ur5.execute() or ur5.go() to control the movement of the industrial robot.

[0023] Furthermore, the communication module enables real-time communication between the host computer, the data acquisition module, and the industrial robot controller by connecting the host computer, the data acquisition module, and the industrial robot controller through a switch, and connecting the power meters of the host computer, the industrial robot controller, and the data acquisition module to the switch through network ports, and establishing a local area network under the same network segment.

[0024] Furthermore, the communication between the host computer and the industrial robot controller adopts the TCP / IP protocol and is implemented using Socket programming.

[0025] Furthermore, the communication between the host computer and the data acquisition module is realized through the visual interface of the DL350 Assistant software. The data upload is realized through the visual interface of the DL350 Assistant software, and the power meter is connected to the host computer through the Connect function.

[0026] Furthermore, the host computer is also equipped with a human-computer interaction module;

[0027] Human-computer interaction module: This module is used to directly drag and drop the virtual model of the industrial robot on the host computer to control the industrial robot to move from one pose to another. The human-computer interaction module is implemented using the ROS Rviz module. The virtual model of the industrial robot is displayed in the Rviz visualization interface. The virtual industrial robot can be dragged to a specified position. The trajectory is planned using the RRT algorithm based on the plan function. After successful planning, the movement of the physical industrial robot is controlled through the execute function.

[0028] Beneficial effects:

[0029] This invention addresses the unique characteristics of industrial robots, whose energy consumption varies greatly depending on the task, state, and even posture. It provides a method for real-time robot control and instantaneous energy consumption data collection. This invention is an integrated system for actual energy consumption acquisition and control, effectively starting measurement immediately upon the robot's initiation of movement and ending the measurement the instant the movement ends. Therefore, it not only acquires instantaneous energy consumption data but also strictly relies on movement-based data, resulting in more timely and accurate energy consumption data. This invention can accurately acquire instantaneous energy consumption for robots under any task, state, and even posture. It not only reveals how much energy the robot consumes under different working conditions but also helps optimize industrial robots or working states based on the working conditions and corresponding energy consumption.

[0030] Furthermore, as an integrated system for actual energy consumption acquisition and control, this invention not only enables robot control but also achieves real-time and accurate energy consumption measurement, resulting in better integration and greater ease of use. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of an industrial robot energy consumption collection system.

[0032] Figure 2 This is a flowchart of the data acquisition module.

[0033] Figure 3 This is a wiring diagram for the data acquisition module.

[0034] Figure 4 This is a flowchart of the data processing module. Detailed Implementation

[0035] Specific implementation method one: Combining Figure 1 This implementation method is described below.

[0036] This embodiment is a power meter-based industrial robot actual energy consumption acquisition and control system. The system includes a data acquisition module, a host computer, a communication module, and an industrial robot controller. The host computer is equipped with a data processing module, a power calculation module, and a motion control module.

[0037] Data Acquisition Module: Using a power meter, voltage clamp, and current clamp, this module collects raw voltage and current data during the operation of the industrial robot. The power meter begins collecting data when the robot starts moving and stops collecting data when the robot stops moving. The data is saved to a .MAT file, and the raw data is uploaded to the host computer. The data acquisition module process is as follows: Figure 2As shown in the diagram. In this embodiment, a voltage clamp and a current clamp are connected to the CH_01 and CH_02 ports of the power meter, respectively. The voltage clamp and current clamp are then connected to the live and neutral wires of the industrial robot's three-prong plug, respectively, to establish the system's wiring. The voltage and current signals are transmitted to the power meter via the voltage clamp and current clamp, and the power meter saves the collected data to a .MAT file. In some embodiments, the voltage clamp is a Yokogawa series product with a frequency of 60MHz and a maximum range of 1000V; the current clamp is a Yokogawa series product with a maximum range of 30A and an accuracy of 10mV / A. In this embodiment, the industrial robot is a six-degree-of-freedom serial industrial robot, model UR5; the sampling frequency for the voltage and current signals is 500,000Hz. It should be noted that this invention can also be applied to other industrial robots.

[0038] Data Processing Module: This module is implemented via host computer programming. It reads raw voltage and current data uploaded by the data acquisition module from the .MAT file, performs filtering on the acquired raw voltage and current data to remove noise and abnormal data, extracts useful information from the data, and uploads the output signal to the power calculation module. In some embodiments, zero-phase filtering is used for data processing, such as... Figure 4 As shown, the specific implementation scheme is as follows: The acquired raw voltage or current data y1(n) is first filtered using a filter to obtain a forward filtered signal y2(n). The forward filtered signal y2(n) is then reverse-sorted to obtain y3(n). The reverse-sorted signal y3(n) is then input into the same filter used in the first filtering for a second filtering. After filtering, signal y4(n) is obtained. The signal is then reverse-sorted again, and finally, a zero-phase filtered signal is output. In some embodiments, the voltage signal filter performance index is the normalized passband cutoff frequency ω. n The normalized stopband cutoff frequency ω is 0.00024. c The maximum passband attenuation R is 0.0040. p 0.40dB, maximum stopband attenuation A s 40dB; Normalized passband cutoff frequency ω of the current signal filter performance index n The normalized stopband cutoff frequency ω is 0.0032. c The maximum passband attenuation R is 0.0200. p 0.40dB, maximum stopband attenuation A s The value is 40dB. In some embodiments, a Butterworth filter is used to implement the aforementioned filtering process.

[0039] Power calculation module: Receives the data processed by the data processing module, multiplies the processed voltage signal vector and current signal vector by a dot to obtain the power signal vector, integrates the power signal vector to calculate the average power of the industrial robot in actual operation, and stores the calculated energy consumption data in an array in double form.

[0040] Motion control module: Used to manipulate the free movement of industrial robots within the workspace using a control program via an industrial robot controller;

[0041] The control program is a ROS control program written in Python using Robotware Studio on an Ubuntu 18.04 system. It controls the industrial robot to move to any position within its working range. The control program uses the `moveit_commander` module. First, it initializes the `moveit_commander` module to create ROS nodes and creates a `MoveGroupCommander` object to control a planning group. The `goal_position_tolerance` value is set to 0.01, and the `goal_orientation_tolerance` value is set to 0.05. The current position of the industrial robot is used as the starting position through the built-in function `set_start_state_to_current_state()`, the target position is set through the built-in function `set_pose_target()`, and the motion path of the industrial robot is planned using the built-in function `ur5.plan()`. Finally, the motion commands are packaged and sent to the industrial robot controller through the built-in functions `ur5.execute()` or `ur5.go()` to control the movement of the industrial robot.

[0042] Communication Module: Enables real-time communication between the host computer, data acquisition module, and industrial robot controller. All components are connected via a switch. The host computer sends motion commands to the industrial robot controller through the communication module. The industrial robot controller returns joint information to the host computer in real time. When the host computer determines that the industrial robot has started moving, it sends a start code to the data acquisition module, which then begins data acquisition. When the host computer determines that the industrial robot has stopped moving based on the joint information, it sends an end code to the data acquisition module, which then stops acquiring data and saves the raw data to a .MAT file. This file is then saved to a folder named SD, and the SD folder is uploaded to the host computer. Figure 3As shown, in some embodiments, a switch connects the host computer, the data acquisition module, and the industrial robot controller. The host computer, the industrial robot controller, and the power meter of the data acquisition module are connected to the switch via Ethernet ports, and a local area network (LAN) is established on the same network segment. After the power meter acquires data, it saves it to a .MAT file, and then uploads the .MAT file to the host computer via the Ethernet port. The power meter model used in this embodiment is Yokogawa DL350.

[0043] The communication between the host computer and the industrial robot controller adopts the TCP / IP protocol and is implemented using Socket programming.

[0044] The communication between the host computer and the data acquisition module is realized through the visual interface of the DL350 Assistant software. The data upload is also realized through the visual interface of the DL350 Assistant software. By clicking Connect, the power meter is connected to the host computer. After the connection is successful, you can click Start to start the measurement. When you want to end the measurement, click Stop to end the measurement. Click Download to save the data to a .MAT file and save the file to the SD folder of the power meter's memory card. Finally, click Upload to upload the SD folder to the specified location on the host computer.

[0045] Industrial robot controller: Used to control the movement of the industrial robot within its workspace. The control data consists of the six-axis joint angles of the industrial robot. When it receives motion commands from the host computer via the communication module, the industrial robot controller parses the commands and controls the movement of the industrial robot according to the control data of the motion commands. In this embodiment, the industrial robot controller is a Universal Robots e-Series model. It should be noted that other models of industrial robot controllers can also be used in this invention.

[0046] In this embodiment, the host computer control program directly controls the movement of the industrial robot through the robot controller. Data is collected when the industrial robot starts moving and ends when the industrial robot finishes moving. The raw data file .MAT is uploaded to the host computer through the DL350 Assistant software. The host computer reads the data in the file, performs filtering processing using the data processing module program, and finally inputs the processed data into the power calculation module to calculate the actual power of the industrial robot during this operation.

[0047] This invention addresses the unique characteristics of industrial robots, whose energy consumption varies greatly depending on the task, state, and even posture. It provides a method for real-time robot control and instantaneous energy consumption data collection. This invention is an integrated system for actual energy consumption acquisition and control, effectively starting measurement immediately upon the robot's initiation of movement and ending the measurement the instant the movement ends. Therefore, it not only acquires instantaneous energy consumption data but also strictly relies on movement-based data, resulting in more timely and accurate energy consumption data. This invention can accurately acquire instantaneous energy consumption for robots under any task, state, and even posture. It not only reveals how much energy the robot consumes under different working conditions but also helps optimize industrial robots or working states based on the working conditions and corresponding energy consumption.

[0048] Because of its integrated design for actual energy consumption acquisition and control, this invention can also apply measured energy consumption to the control system, thereby achieving energy consumption control. Furthermore, it can optimize the working state of industrial robots based on data, and even optimize and adjust the robot's structure, such as arm length. Therefore, as an integrated system for actual energy consumption acquisition and control, this invention not only enables robot control but also achieves real-time and accurate energy consumption measurement, resulting in better integration and ease of use. Specific Implementation Method Two:

[0050] The present embodiment describes an industrial robot actual energy consumption acquisition and control system based on a power meter, the system further including a human-machine interaction module.

[0051] Human-computer interaction module: This module is used to directly drag and drop the virtual model of the industrial robot on the host computer to control the industrial robot to move from one pose to another. The human-computer interaction module is implemented using the ROS Rviz module. The virtual model of the industrial robot is displayed in the Rviz visualization interface. The virtual industrial robot is dragged to a specified position. Clicking "plan" uses the RRT algorithm to plan the trajectory. After successful planning, clicking "execute" controls the movement of the physical industrial robot.

[0052] In this embodiment, the industrial robot is controlled by directly dragging the model of the industrial robot onto the host computer, making the control method more flexible and intuitive.

[0053] The other modules and steps are the same as in Specific Implementation Method 1. This implementation method, based on Specific Implementation Method 1, further incorporates a human-computer interaction module, improving operational convenience and ease of use, making the system of this invention even more convenient to use.

[0054] The above examples of the present invention are merely illustrative of the computational model and process of the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is impossible to exhaustively list all possible implementations here. Any obvious variations or modifications derived from the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A power meter-based system for collecting and controlling the actual energy consumption of an industrial robot, characterized in that, It includes a data acquisition module, a host computer, a communication module, and an industrial robot controller; the host computer is equipped with a data processing module, a power calculation module, and a motion control module. Data acquisition module: Uses a power meter, voltage clamp, and current clamp to collect raw voltage and current data during the operation of the industrial robot, and uploads the collected raw voltage and current data to the host computer; Data processing module: Reads the raw voltage and current data uploaded by the data acquisition module and performs filtering processing; Power calculation module: Receives the data processed by the data processing module, multiplies the processed voltage signal vector and current signal vector by a dot to obtain the power signal vector, and integrates the power signal vector to obtain the average power of the industrial robot in actual operation. Motion control module: Used to manipulate the free movement of industrial robots within the workspace using a control program via an industrial robot controller; Communication module: Used to enable real-time communication between the host computer, data acquisition module, and industrial robot controller; Industrial robot controller: Used to control the movement of industrial robots within their workspace; The host computer sends motion commands to the industrial robot controller via the communication module, and the industrial robot controller returns industrial robot joint information to the host computer in real time.

2. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The CH_01 and CH_02 ports of the power meter are connected to the voltage clamp and the current clamp, respectively. The voltage clamp and the current clamp are then connected to the live wire and the neutral wire of the three-wire plug of the industrial robot, respectively, to realize the acquisition of raw voltage and current data during the operation of the industrial robot.

3. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 2, characterized in that, The data acquisition module uses a power meter, voltage clamp, and current clamp to collect raw voltage and current data during the operation of the industrial robot. The process includes: When the industrial robot starts moving, the power meter begins collecting voltage and current data; when the industrial robot stops moving, the power meter stops collecting data. The collected raw data is then uploaded to the host computer. The method for determining when the industrial robot starts moving is as follows: when the host computer determines that the industrial robot has started moving, it sends a start code to the data acquisition module, thus confirming that the industrial robot has started moving. The method for determining when the industrial robot stops moving is as follows: when the host computer determines that the industrial robot has stopped moving based on the joint information, it sends an end code to the data acquisition module, thus confirming that the industrial robot has stopped moving.

4. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The filtering process performed by the data processing module includes: The raw voltage or current data y1(n) is collected and filtered for the first time to obtain a forward filtered signal y2(n). The forward filtered signal y2(n) is then reversed to obtain y3(n). The reversed signal y3(n) is then input into the same filter as the one used in the first filtering for the second filtering. After filtering, the signal y4(n) is obtained. The signal is then reversed again and the zero-phase filtered signal is output.

5. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 4, characterized in that, In the process of filtering using a filter, the normalized passband cutoff frequency ω of the voltage signal filter performance index is... n The normalized stopband cutoff frequency ω is 0.00024. c The maximum passband attenuation R is 0.0040. p 0.40dB, maximum stopband attenuation A s 40dB; Normalized passband cutoff frequency ω of the current signal filter performance index n The normalized stopband cutoff frequency ω is 0.0032. c The maximum passband attenuation R is 0.0200. p 0.40dB, maximum stopband attenuation A s It is 40dB.

6. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The motion control module uses the moveit_commander module. First, the moveit_commander module is initialized to create ROS nodes and a MoveGroupCommander object to control a planning group. The values ​​of goal_position_tolerance and goal_orientation_tolerance are set. The current position of the industrial robot is used as the starting position via the built-in function set_start_state_to_current_state(), and the target position is set via the built-in function set_pose_target(). The built-in function ur5.plan() is used to plan the industrial robot's motion path. Finally, the motion commands are packaged and sent to the industrial robot controller via the built-in functions ur5.execute() or ur5.go() to control the industrial robot's movement.

7. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The communication module enables real-time communication between the host computer, data acquisition module, and industrial robot controller as follows: the host computer, data acquisition module, and industrial robot controller are connected through a switch, and the power meters of the host computer, industrial robot controller, and data acquisition module are connected to the switch through network ports, and a local area network is established under the same network segment.

8. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The communication between the host computer and the industrial robot controller adopts the TCP / IP protocol and is implemented using Socket programming.

9. The industrial robot actual energy consumption acquisition and control system based on a power meter according to claim 1, characterized in that, The communication between the host computer and the data acquisition module is realized through the visual interface of the DL350 Assistant software. The data upload is realized through the visual interface of the DL350 Assistant software, and the power meter is connected to the host computer through the Connect function.

10. A power meter-based industrial robot actual energy consumption acquisition and control system according to any one of claims 1 to 9, characterized in that, The host computer is also equipped with a human-computer interaction module; Human-computer interaction module: This module is used to directly drag and drop the virtual model of the industrial robot on the host computer to control the industrial robot to move from one pose to another. The human-computer interaction module is implemented using the ROS Rviz module. The virtual model of the industrial robot is displayed in the Rviz visualization interface. The virtual industrial robot can be dragged to a specified position. The trajectory is planned using the RRT algorithm based on the plan function. After successful planning, the movement of the physical industrial robot is controlled through the execute function.

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