A single-arm complex robot

Abstract

The application provides a single-arm composite robot, and relates to the technical field of single-arm robots, which comprises an omnidirectional moving trolley, a storage arm, a folding mechanism, a joint module and a fixing mechanism; the top surface of the omnidirectional moving trolley is provided with a mounting base and a storage groove; the storage arm is internally provided with the folding mechanism; the joint module is connected with the folding mechanism and is provided with the fixing mechanism; the omnidirectional moving trolley is internally provided with a control mainboard; the mainboard is integrated with a posture detection module, a pressure sensing module, an environment sensing module, a storage state detection module and a power detection module. The control mainboard receives electrical signals of each module, calculates structural parameters such as joint posture deviation angle and average clamping force, and executes control logic, so as to solve the problems of low posture precision of a traditional single-arm robot, no feedback of clamping, no obstacle avoidance of movement, no detection of storage, no overload protection of an actuator and poor cooperation of multiple modules, and improve operation precision, clamping safety, movement reliability and actuator safety.

Description

Technical Field

[0001] This invention relates to the field of single-arm robot technology, and more particularly to a single-arm composite robot. Background Technology

[0002] As industrial automation upgrades towards flexibility and multi-station operations, single-arm robots need to possess composite functions such as omnidirectional movement, folding and storage, and stable clamping. Multi-station rotation in workshops requires robots to flexibly switch positions through omnidirectional movement; storage in confined spaces relies on storage arms and folding mechanisms to save floor space; and workpiece manipulation depends on fixed mechanisms for clamping. Traditional single-arm devices are mostly designed for a single function or only possess basic mechanical structures without integrated control, making it difficult to adapt to the continuous operational requirements of "movement-folding-clamping-storage." This drives the development of single-arm composite robots integrating multiple structures and control modules as the future direction of technological development.

[0003] Existing single-arm composite robots have significant drawbacks: the lack of a posture detection module makes it impossible to correct joint posture deviations, affecting operational accuracy; the absence of a pressure sensor module means there is no feedback on clamping force, easily causing workpiece damage or detachment; the lack of an environmental perception module makes it prone to collisions with obstacles during movement; the absence of a storage status detection module makes it difficult to confirm whether the storage arm is in place; the lack of a power detection module makes it prone to damage due to actuator overload; and the lack of a unified control board to coordinate the operation of various structures. These problems cannot be solved by the existing mechanical structure alone, and there is an urgent need for a solution that integrates corresponding detection modules and a control board to achieve precise control and safe operation. Summary of the Invention

[0004] This invention provides a single-arm composite robot that solves the problems of low posture adjustment accuracy, lack of feedback during clamping leading to workpiece damage, lack of obstacle avoidance during movement leading to collisions, lack of detection during storage leading to misalignment, lack of overload protection for actuators, and poor coordination among multiple modules in traditional single-arm robots.

[0005] To solve the above-mentioned technical problems, the present invention provides a single-arm composite robot, comprising:

[0006] The system includes an omnidirectional mobile trolley, a storage arm, a folding mechanism, a joint module, and a fixing mechanism. The top surface of the omnidirectional mobile trolley is equipped with a mounting base and a storage slot. A first motor is located on one side of the mounting base. The storage arm contains a folding mechanism, which includes a second motor, a worm gear, a worm wheel, and a flip base. Two electric push rods are located on the flip base, and the output ends of the electric push rods are connected to the joint module. The joint module is equipped with a fixing mechanism, which includes a positioning plate, a third motor, a lead screw, a clamping block, and a clamping plate.

[0007] The omnidirectional mobile vehicle is equipped with a control motherboard; the control motherboard also integrates an attitude detection module, a pressure sensing module, an environmental perception module, a storage status detection module, and a power detection module;

[0008] The attitude detection module includes a six-axis IMU sensor and a joint angle sensor. The six-axis IMU sensor is fixed to the end of the joint module, and the joint angle sensor is located at the joint axis. The pressure sensing module includes a pressure sensor, which is embedded in the inner side of the clamping plate and the clamping block.

[0009] The environmental perception module includes a lidar and an ultrasonic sensor. The lidar is fixed to the front of the omnidirectional mobile vehicle, and the ultrasonic sensors are symmetrically arranged on both sides of the omnidirectional mobile vehicle.

[0010] The storage status detection module includes a proximity sensor, which is embedded in the inner wall of the storage slot;

[0011] The power detection module is connected in series to the power supply circuit of each motor and electric actuator; the control board is configured to receive the electrical signals of each module and calculate the structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, retraction position, and actuator equivalent power, and execute the control logic with the structural parameters as input.

[0012] Preferably, the omnidirectional mobile vehicle is equipped with a drive wheel assembly and a positioning chip. The positioning chip is a GPS / BeiDou dual-mode chip, used to output the vehicle's position coordinates in real time. The proximity sensor of the storage status detection module is an infrared proximity sensor. When the storage arm is fully inserted into the storage slot, the proximity sensor outputs a position signal; otherwise, it outputs an abnormal signal.

[0013] Preferably, the six-axis IMU sensor of the attitude detection module is used to output the acceleration and angular velocity signals of the end effector of the joint module; the joint angle sensor is an absolute encoder used to output the real-time rotation angle of each joint; the control motherboard stores the reference attitude parameters of the joint module, including the joint reference angle and the end effector reference position. The reference parameters are fixed in non-volatile memory after factory calibration and support recalibration and update after maintenance.

[0014] Preferably, the pressure sensor of the pressure sensing module is used to collect the pressure signal between the clamping plate and the clamping block. At least two pressure sensors are embedded on the inner side of both the clamping plate and the clamping block, and they are symmetrically distributed. The control motherboard collects the pressure sensor signal at a frequency of not less than 10 Hz, calculates the average clamping force, and stores the safe clamping force threshold corresponding to different workpiece materials for later use.

[0015] Preferably, the LiDAR in the environmental perception module is used to output the distance and angle of obstacles on the moving path; the ultrasonic sensor is used to assist the LiDAR in detecting nearby obstacles; the control motherboard fuses the signals from the LiDAR and the ultrasonic sensor to calculate the obstacle avoidance safety distance, and triggers obstacle avoidance control when the obstacle distance is less than the safety distance.

[0016] Preferably, the power detection module is a shunt resistor sampling circuit connected in series in the power supply circuits of the first motor, the second motor, the third motor and the electric actuator, used to output the real-time operating current of each actuator; the control board calculates the equivalent power based on the operating current and the rated voltage, and stores the rated power threshold of each actuator. When the equivalent power exceeds the preset ratio of the rated power, overload protection is triggered.

[0017] This invention also proposes a multi-module collaborative control system for a single-arm composite robot, which includes a single-arm composite robot body, a processor, and a memory.

[0018] The single-arm composite robot body includes: an omnidirectional mobile vehicle, a storage arm, a folding mechanism, a joint module, a fixing mechanism, an environmental perception module, and a power detection module;

[0019] The processor and memory are integrated into the control motherboard and are electrically connected to the aforementioned motors, electric actuators, sensors, and modules;

[0020] The memory stores program instructions that run on the processor, which is configured to:

[0021] Electrical signals are acquired from various sensors and modules to calculate a set of structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position, and actuator equivalent power.

[0022] The memory stores program instructions that run on the processor. The processor is configured to: acquire electrical signals from various sensors and modules and calculate a set of structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position accuracy, and actuator equivalent power; and use the set of structural parameters as input to execute control logic, generate control signals according to preset thresholds and mapping relationships, and send them to each actuator, the configured display screen, and the alarm module to achieve posture accuracy compensation, adaptive clamping force adjustment, mobile obstacle avoidance navigation, storage status calibration, and overload fault indication.

[0023] As a preferred method, the processor calculates the joint attitude deviation angle as follows:

[0024] The processor acquires the real-time angles of each joint using joint angle sensors and compares them with the reference angles stored in the memory to obtain the single-joint deviation angle. Combined with the end-effector attitude signal output by the six-axis IMU sensor, the end-effector attitude deviation angle is calculated using forward kinematics. When the attitude deviation angle exceeds a preset threshold, the processor generates an attitude compensation signal to control the corresponding joint motors to fine-tune until the deviation angle is less than the threshold.

[0025] Preferably, the logic for the processor to perform adaptive clamping force adjustment is as follows:

[0026] During clamping operations, the pressure sensor collects the clamping force signal in real time, and the processor calculates the average clamping force. If the average clamping force is less than the lower limit of the safe clamping force for the corresponding workpiece, the third motor is controlled to rotate forward to increase the clamping force. If the average clamping force is greater than the upper limit of the safe clamping force, the third motor is controlled to rotate in reverse to decrease the clamping force. If the clamping force cannot reach the safe range for a preset time, a clamping abnormality prompt is issued through the display screen and alarm module.

[0027] Preferably, the processor executes the following logic for mobile obstacle avoidance navigation:

[0028] When the omnidirectional mobile vehicle moves, the lidar and ultrasonic sensors collect environmental signals in real time. The processor fuses the signals and calculates the distance to obstacles. If the distance to an obstacle is greater than the obstacle avoidance safety distance, the vehicle is controlled to move along a preset path. If the distance to an obstacle is less than the safety distance, the vehicle is controlled to stop moving and a detour path is planned. At the same time, the vehicle's position is calibrated through a positioning chip to avoid movement deviation.

[0029] Compared with related technologies, the single-arm composite robot provided by the present invention has the following beneficial effects:

[0030] This invention integrates an omnidirectional mobile vehicle, a storage arm, a folding mechanism, a joint module, and a fixing mechanism into a single-arm composite robot. A control motherboard coordinates the posture detection module, pressure sensing module, environmental perception module, storage status detection module, and power detection module. The control motherboard receives electrical signals from each module and calculates structural parameters such as joint posture deviation angles, average clamping force, and obstacle distance to execute control logic. This simultaneously solves the problems of traditional single-arm robots caused by the lack of integrated perception and control, including low posture adjustment accuracy, lack of clamping feedback leading to workpiece damage or detachment, lack of obstacle avoidance during movement resulting in collisions, difficulty in confirming the storage position without detection, and lack of overload protection for actuators leading to damage. This achieves a synergistic improvement in robot operation accuracy, clamping safety, movement reliability, storage accuracy, and actuator safety. Attached Figure Description

[0031] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0032] Figure 1 This is a schematic diagram of the overall appearance of the device proposed in this invention;

[0033] Figure 2 This is a rear view schematic diagram of the overall appearance of the device proposed in this invention;

[0034] Figure 3 This is a schematic diagram of the overall structure of the device proposed in this invention.

[0035] Figure 4 This is a schematic diagram of the folding mechanism structure proposed in this invention;

[0036] Figure 5 This is a schematic diagram of the fixing mechanism structure proposed in this invention;

[0037] Figure 6 The figure is provided by the present invention.

[0038] The following components are labeled in the diagram: 1. Omnidirectional moving trolley; 2. Storage arm; 3. Joint module; 4. Mounting base; 5. First motor; 6. Second motor; 7. Flipping base; 8. Worm gear; 9. Worm wheel; 10. Electric actuator; 11. Positioning plate; 12. Third motor; 13. Lead screw; 14. Clamping block; 15. Clamping plate; 16. Rotating base; 17. Environmental sensing module; 18. Fourth motor. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The terminology used in this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. The singular forms “group,” “class,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0041] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0042] Please refer to the following: Figures 1-5 A single-arm composite robot includes an omnidirectional mobile vehicle 1, a storage arm 2, a folding mechanism, a joint module 3, and a fixing mechanism;

[0043] Specifically, the omnidirectional mobile vehicle 1, model R5-MEC, has a mounting base 4 and a storage slot bolted to its top surface. The storage slot matches the shape of the storage arm 2. A first motor 5 is located on one side of the mounting base 4. The output end of the first motor 5 is rigidly connected to the rotating shaft of the storage arm 2 through a flexible coupling to ensure backlash-free transmission and realize the lifting and storage of the storage arm 2. A positioning chip is embedded in the center of the vehicle and connected to the control motherboard through an SPI bus to output the vehicle's coordinates in real time to prevent movement deviation. A laser radar is fixed to the center of the front face of the vehicle through a bracket for long-distance obstacle detection. An ultrasonic sensor is fixed to the middle of each of the left and right sides of the vehicle and connected to the GPIO port of the control motherboard through DuPont wires to assist the laser radar in detecting nearby obstacles.

[0044] Two proximity sensors, model GP2Y0A21YK, are symmetrically embedded in the inner wall of the storage slot. The detection distance is 10-80cm. The probes face the storage arm 2. The output signal is converted by ADC and then transmitted to the control motherboard to determine whether the storage arm 2 is in position.

[0045] The storage arm 2 is made of aluminum alloy with a U-shaped cross-section and its opening faces upward. Its inner diameter is adapted to the flip base 7, and one end is hinged to the mounting base 4. The outer wall of one side of the storage arm 2 is fixed with a second motor 6 through a motor bracket. The output end of the second motor 6 is connected to a worm gear 8 through a coupling. The worm gear 8 meshes with a worm wheel 9. The center hole of the worm wheel 9 is fixed to the hinge shaft of the flip base 7 through a key to ensure transmission accuracy. Two electric push rods 10 are fixed on the flip base 7 with bolts. The output end of the electric push rods 10 is fixedly connected to the rear end of the joint module 3 through a flange.

[0046] A power detection module is connected in series in the power supply circuit of the electric actuator 10. It consists of a 1Ω / 2W shunt resistor and an INA219 current detection chip. The output is connected to the control motherboard through an I2C bus to collect the working current in real time and calculate the equivalent power P=UI to avoid overload. The joint angle sensor is fixed with set screws at the connection between the flip base 7 and the joint module 3, and at the joint shaft of each joint of the joint module 3. This sensor is used to detect the real-time rotation angle of each joint.

[0047] The joint module 3 consists of three micro joint modules connected in series. Adjacent joints are rigidly connected by flanges to ensure flexibility in posture adjustment. The front end of the joint module 3 is fixedly connected to the positioning plate 11 of the fixing mechanism by bolts.

[0048] The end of the joint module 3, near the fixed mechanism, is fitted with a six-axis IMU sensor via a bracket. It is connected to the control motherboard via an I2C bus to collect end-effector acceleration and angular velocity signals in real time to assist in attitude calibration.

[0049] The joint module 3 is equipped with a fixing mechanism, which includes a positioning plate 11, a third motor 12, a lead screw 13, a clamping block 14, and a clamping plate 15. The positioning plate 11 is a rectangular steel plate with a lead screw 13 mounting groove inside. The rear end of the positioning plate 11 is fixed to the front end of the joint module 3 by bolts, and the third motor 12 is fixed inside by a motor bracket. The output end of the third motor 12 is connected to the lead screw 13 through a coupling. The two ends of the lead screw 13 are rotatably installed inside the positioning plate 11 through bearing seats. The clamping block 14 is threaded onto the lead screw 13. The clamping block 14 is made of nylon and has an anti-slip pad on the inside. The clamping plate 15 is fixed to one side of the front end face of the positioning plate 11 by bolts. The clamping plate 15 is symmetrical to the clamping block 14 and has multiple rubber protrusions fixed to its inside. The positioning plate 11 has a sliding groove that matches the clamping block 14 to ensure that the clamping block 14 moves smoothly.

[0050] The side of the storage arm 2 is equipped with a display screen and an alarm module. The alarm module consists of a buzzer and a red LED. The display screen is connected to the control motherboard via the SPI bus and the alarm module is connected via the GPIO port to display parameters and fault prompts.

[0051] The omnidirectional mobile vehicle 1 has a control motherboard installed in a waterproof box inside. The control motherboard is connected to the drivers of each motor and electric push rod 10 via a CAN bus, and to a six-axis IMU sensor, joint angle sensor, pressure sensor, power detection module, and positioning chip via an I2C bus. It is also connected to a lidar, ultrasonic sensor, proximity sensor, display screen, and alarm module via GPIO ports. The control motherboard has an external 16MB Flash memory for storing reference parameters (joint reference angle, end effector reference attitude), safety thresholds (clamping force, obstacle avoidance distance, power) and control programs.

[0052] Please refer to Figure 6 The core of this invention lies in its integrated configuration of the control motherboard and its multi-module collaborative sensing control. The control motherboard integrates the following sensors and functional modules:

[0053] The attitude detection module includes a six-axis IMU sensor and a joint angle sensor. The six-axis IMU sensor is fixed to the end of the joint module 3, and the joint angle sensor is located at the joint axis. The pressure sensing module includes a pressure sensor, which is embedded in the inner side of the clamping plate 15 and the clamping block 14.

[0054] The environmental perception module 17 includes a lidar and an ultrasonic sensor. The lidar is fixed to the front end of the omnidirectional mobile vehicle 1, and the ultrasonic sensor is symmetrically arranged on both sides of the omnidirectional mobile vehicle 1.

[0055] The top of the storage arm 2 is fixed to a rotating base 16, and an environmental sensing module 17 is hinged to the inside of the rotating base 16. A fourth motor 18 is installed on one side of the rotating base 16, and the output end of the fourth motor 18 is connected to the hinge shaft of the environmental sensing module 17 through a coupling.

[0056] The storage status detection module includes a proximity sensor, which is embedded in the inner wall of the storage slot;

[0057] The power detection module is connected in series to the power supply circuit of each motor and electric push rod 10; the control board is configured to receive the electrical signals of each module and calculate the structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position, and actuator equivalent power, and execute the control logic with the structural parameters as input.

[0058] In some embodiments, the omnidirectional mobile vehicle 1 is equipped with a drive wheel assembly and a positioning chip. The positioning chip is a GPS / BeiDou dual-mode chip, which is used to output the vehicle's position coordinates in real time.

[0059] The proximity sensor of the storage status detection module is an infrared proximity sensor with a detection distance range of 0-50mm. It outputs the detection distance d at a frequency of not less than 5 Hz and determines whether the storage wall is completely placed in the storage slot based on the storage positioning judgment logic. The expression is: ;in The maximum distance threshold when storage arm 2 is fully inserted into the storage slot, such as .

[0060] In some embodiments, the six-axis IMU sensor of the attitude detection module is an MPU6050, used to output acceleration and angular velocity signals at the end of the joint module 3, and the acceleration signals in the three-dimensional directions are denoted as follows: The angular velocity signals in the three-dimensional directions are denoted as The joint angle sensors are absolute encoders, model AS5600, located at each joint axis, outputting real-time rotation angles at a frequency of 50 Hz. The number of sensors matches the number of joints, used to output the real-time rotation angles of each joint. The control motherboard stores the reference attitude parameters of joint module 3, including the joint reference angles. End reference position Where i = 1, 2, ..., n, n is the joint number. The reference parameters are fixed in non-volatile memory after factory calibration and can be recalibrated and updated after maintenance.

[0061] In some embodiments, the pressure sensor of the pressure sensing module is an FSR402 with a detection range of 0-100N. It is used to collect the pressure signal between the clamping plate 15 and the clamping block 14. At least two pressure sensors are embedded on the inner surfaces of both the clamping plate 15 and the clamping block 14 and are symmetrically distributed. The control motherboard collects the pressure sensor signal at a frequency of not less than 10 Hz, calculates the average clamping force, and stores the safe clamping force thresholds corresponding to different workpiece materials (such as 5-10N for plastic parts and 15-25N for metal parts) for later retrieval.

[0062] In some embodiments, the environmental perception module 17 uses a LiDAR model of RPLIDAR1 with a scanning angle of 360° and a detection distance of 0.15-12m, which is used to output the distance and angle of obstacles on the moving path; and an ultrasonic sensor model of HC-SR04 with a detection distance of 2-400cm, which is used to assist the LiDAR in detecting nearby obstacles; the control motherboard fuses the signals from the LiDAR and the ultrasonic sensor to calculate the obstacle avoidance safety distance (default 50cm, which can be customized), and triggers obstacle avoidance control when the obstacle distance is less than the safety distance.

[0063] In some embodiments, the power detection module is a shunt resistor sampling circuit connected in series in the power supply circuits of the first motor 5, the second motor 6, the third motor 12, and the electric actuator 10, outputting the real-time operating current I of each actuator at a frequency of not less than 20 Hz; the control main board calculates the equivalent power based on the operating current and rated voltage, using the formula P=U×I, and stores the rated power threshold of each actuator. When the equivalent power P exceeds the rated power The default ratio is 120%, which triggers overload protection.

[0064] The present invention also proposes a multi-module collaborative control system for a single-arm composite robot, which is applied to the single-arm composite robot mentioned above. The system includes a single-arm composite robot body, a processor, and a memory.

[0065] The single-arm composite robot body includes: an omnidirectional mobile vehicle 1 (including drive wheel set and positioning chip), a storage arm 2 (including first motor 5, storage slot and proximity sensor), a folding mechanism (including second motor 6, worm gear 8, worm wheel 9, flip base 7 and electric push rod 10), a joint module 3 (including six-axis IMU sensor and joint angle sensor), a fixing mechanism (including positioning plate 11, third motor 12, lead screw 13, clamping block 14, clamping plate 15 and pressure sensor), an environmental perception module 17 (including lidar and ultrasonic sensor) and a power detection module;

[0066] The processor is electrically connected to the memory and the aforementioned motors, electric actuators 10, sensors, and modules.

[0067] The memory stores program instructions that run on the processor. The processor is configured to: acquire electrical signals from various sensors and modules and calculate a set of structural parameters (including joint posture deviation angle, average clamping force, obstacle distance, storage position accuracy, and actuator equivalent power); and use the set of structural parameters as input to execute the control board. The control board is configured to generate control signals for posture accuracy compensation, adaptive clamping force adjustment, mobile obstacle avoidance navigation, storage status calibration, and overload fault indication based on preset thresholds and mapping relationships, and send the control signals to each actuator, display screen, and alarm module respectively.

[0068] In some embodiments, the processor calculates the joint attitude deviation angle as follows:

[0069] The real-time angles of each joint are acquired by joint angle sensors and compared with the reference angles stored in the memory to obtain the single joint deviation angle. The formula is ;in Let be the real-time rotation angle of the i-th joint. Let be the reference angle of the i-th joint;

[0070] By combining the end-effector attitude signal output from the six-axis IMU sensor, the end-effector attitude deviation angle is calculated using forward kinematics, including:

[0071] Calculate the end pitch angle from the acceleration signal The formula is ;

[0072] The difference between the real-time pitch angle at the terminal and the reference pitch angle is the terminal attitude deviation angle. The formula is ;in This is the real-time pitch angle at the end point. The reference pitch angle at the end;

[0073] When the attitude deviation angle exceeds a preset threshold (e.g., 0.5° by default, which can be customized), i.e. The processor generates attitude compensation signals and controls the corresponding joint motors to fine-tune until the deviation angle is ≤0.5°.

[0074] In some embodiments, the logic for the processor to perform adaptive clamping force adjustment is as follows:

[0075] During clamping operations, pressure sensors collect clamping force signals in real time, and the processor calculates the average clamping force. The average clamping force is calculated using the arithmetic mean method to eliminate errors caused by uneven local pressure. The formula is as follows: ,in For the real-time reading of the j-th pressure sensor; Control logic:

[0076] If the average clamping force Less than the lower limit of the safe clamping force for the corresponding workpiece Control the third motor 12 to rotate forward, increasing the clamping force;

[0077] If the average clamping force Greater than the upper limit of safety clamping force The third motor 12 is controlled to reverse, reducing the clamping force;

[0078] If the clamping force cannot reach the safe clamping force range within the preset time (e.g., 10 seconds), It issues a clamping abnormality warning via the display screen and alarm module.

[0079] In some embodiments, the logic for the processor to perform mobile obstacle avoidance navigation is as follows:

[0080] As the omnidirectional mobile vehicle 1 moves, the lidar and ultrasonic sensors collect environmental signals in real time, including:

[0081] LiDAR sensors are used to output the distance to obstacles on the moving path. With angle;

[0082] Ultrasonic sensors are used to assist lidar in detecting nearby obstacles. .

[0083] Control the motherboard's preset obstacle avoidance safety distance, such as It supports customization and modification through the control panel.

[0084] The processor calculates the distance to obstacles after fusing the signals. The scalar weighted fusion method is used for calculation, and the formula is as follows: Among them (due to the higher accuracy of lidar, the distance to this obstacle is...); The corresponding weight is greater than that of nearby obstacles. (Specific settings will be determined based on the actual situation and the specific personnel in the field).

[0085] If the distance to the obstacle Greater than the obstacle avoidance safe distance Control the car to move along a preset path; if the obstacle is within a certain distance... Less than or equal to the safe distance The obstacle avoidance control is triggered, the vehicle stops moving, and a detour path is planned, such as prioritizing detour to the left or right. If there is no detour space, the vehicle moves back 30cm and re-detects. At the same time, the vehicle's position is calibrated through the positioning chip to avoid movement deviation.

[0086] This invention provides a collaborative control method for a single-arm composite robot based on a device structure, applied to the single-arm composite robot described in the above embodiments. The method includes the following steps:

[0087] Step 1: System Initialization and Reference Calibration

[0088] After the motherboard powers on, it automatically starts the initialization process, performing three steps: parameter loading, module self-test, and benchmark calibration.

[0089] Read preset parameters from non-volatile memory, including reference angles for each joint. End reference pitch angle Clamping force thresholds for workpieces of different materials Obstacle avoidance safe distance and actuator rated power ;

[0090] Communication link detection is performed on the attitude detection module, pressure sensing module, environmental perception module 17, storage status detection module and power detection module. If any module times out of communication for a set number of consecutive times, the LED on the alarm module will flash and the buzzer will sound, and the faulty module will be marked on the display screen.

[0091] Triggering attitude baseline and clamping force baseline calibration: Controlling joint module 3 to return to the mechanical zero point and recording the initial value update of the joint angle sensor. The control clamp 15 is closed under no-load conditions, and the pressure sensor signal is acquired at a frequency of not less than 10 Hz. The initial zero drift value is calculated and the calibration parameters are stored.

[0092] Step 2: Mode Selection and Job Parameter Matching

[0093] Select the target working mode (movement / clamping / storage) using the mode switch key on the control panel. The mainboard will automatically match the sensor working parameters and execution logic according to the mode.

[0094] If the mobile mode is selected: activate the lidar, ultrasonic sensor and GPS / BeiDou dual-mode positioning chip, and load the obstacle avoidance safety distance threshold and path planning algorithm;

[0095] If the clamping mode is selected: confirm the workpiece material (such as plastic / metal) through the parameter setting key, call the corresponding clamping force threshold range, activate the pressure sensing module and attitude detection module, and set the pressure signal acquisition frequency to ≥10Hz;

[0096] If the storage mode is selected: activate the infrared proximity sensor in the storage slot and the drive circuit of the electric push rod 10, and load the storage positioning distance threshold.

[0097] Step 3: Multi-sensor collaborative sensing and parameter calculation

[0098] Each module acquires raw signals at a preset frequency and controls the mainboard to perform fusion calculations and status analysis:

[0099] Attitude parameter calculation: based on real-time angles output by AS5600 Through formula Calculate the single-joint deviation angle; using the acceleration signal from the MPU6050. According to the formula Calculate the terminal pitch angle to obtain the terminal attitude deviation. ;

[0100] Clamping force calculation: Real-time pressure values ​​from four FSR402 sensors were collected. By arithmetic mean Eliminate local errors to obtain the average clamping force ;

[0101] Obstacle distance fusion: A weighted fusion algorithm is used to process the distance of the LiDAR-detected obstacle Dultra collected by the ultrasonic sensor at close range, and the obstacle distance D is calculated using the formula: D=α⋅Dlidar+(1−α)⋅Dultra, which is used to improve the accuracy of close range obstacle detection.

[0102] Power and storage status monitoring: The real-time current I of the actuator is collected through the shunt resistor circuit, and the equivalent power P is calculated according to P=U×I; the storage status is determined by reading the distance d of the proximity sensor.

[0103] Step 4: Closed-loop control command execution. The mainboard compares the calculated parameters with the preset threshold every 50ms and sends adjustment commands to the actuator.

[0104] Movement control: If the distance to obstacles after merging Immediately control the drive wheel group to brake, and at the same time plan a detour path based on the obstacle angle information of the lidar, drive the omnidirectional mobile car 1 to travel along the new path, and the display screen updates the positioning coordinates in sync.

[0105] Clamping control: If Control the third motor 12 to rotate forward to increase the clamping force; if Control the motor to reverse and reduce the clamping force; if the attitude deviation angle The corresponding joint motor is driven to perform a compensation action until the deviation angle is ≤0.5°;

[0106] Storage control: Control electric actuator 10 to push storage arm 2 to retract, when proximity sensor detects... When the device is in place, a storage completion signal is output, and the electric actuator 10 stops moving; if no completion signal is detected within 10 seconds, a storage abnormality alarm is triggered.

[0107] Step 5: Anomaly Monitoring and Emergency Response

[0108] The processing system monitors the status of each module in real time and triggers a tiered processing mechanism:

[0109] Mild abnormality: When the clamping force fluctuation exceeds the threshold range but the duration is <2s and the attitude deviation angle is 0.5°~1°, the control motherboard will automatically adjust the actuator action, and the display screen will flash to indicate "parameter fluctuation". No shutdown is required.

[0110] Severe anomaly: When the equivalent power P exceeds the rated power. If any of the following conditions are triggered, such as when the preset ratio is 120%, overload protection is activated, clamping force exceeds the limit for 10 seconds (clamping abnormality), or storage timeout (storage abnormality), the power supply to the corresponding actuator will be immediately cut off, the red LED on the alarm module will remain lit and a buzzer will sound, and the display screen will indicate the fault type.

[0111] Emergency Stop: Press the red emergency stop button on the control panel for 2 seconds to cut off the power to all actuators. The system will lock all actions and retain only the fault reset function. The fault reset button must be pressed after troubleshooting before restarting.

[0112] Step 6: Finishing the job and putting the system on standby

[0113] After the task is completed, manually switch to storage mode. After confirming that storage arm 2 is in place, control the main board to shut down all sensor acquisition channels, leaving only the positioning chip and system status monitoring module running.

[0114] Automatically store the data for this operation, including the maximum attitude deviation, average clamping force, number of obstacle avoidance attempts, and fault records, and update it to non-volatile memory;

[0115] The system switches to standby mode, and the display screen only shows the current location coordinates and the system normal status indicator to reduce the overall power consumption and wait for the next operation command.

[0116] The present invention also provides a single-arm composite robot system, including a processor, a memory, and the single-arm composite robot body described in the above embodiments.

[0117] The processor is integrated into the control motherboard (core chip such as STM32H743), and can be a microcontroller or embedded processing unit to meet the requirements of multi-sensor data collaborative processing and real-time control.

[0118] The memory includes 16MB of Flash non-volatile memory (stores reference parameters, threshold table, and control program), ROM (solidified underlying driver), and RAM (temporary cache for real-time data), supporting long-term storage and fast read / write.

[0119] The program instructions stored in the memory enable the processor to execute the above-mentioned collaborative control method for a single-arm composite robot, including system initialization and benchmark calibration, mode selection and operation parameter matching, multi-sensor perception and parameter calculation, closed-loop control execution and anomaly monitoring and handling.

[0120] The present invention also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the above-described single-arm composite robot cooperative control method, including:

[0121] System initialization (parameter loading, module self-test, attitude and clamping force baseline calibration).

[0122] Working mode matching (sensor and logic adaptation for moving / clamping / storage modes);

[0123] Multi-sensor perception (signal acquisition of attitude, clamping force, obstacles, and storage status);

[0124] Closed-loop control (movement obstacle avoidance, attitude compensation, clamping force adjustment, storage control);

[0125] Abnormal handling (overload protection, clamping abnormality alarm, emergency stop).

[0126] Storage media can include USB flash drives, flash memory (such as EEPROM), portable hard drives, optical discs, ROM, RAM, etc. Program instructions can be transmitted via wired (USB, CAN bus) or wireless (Bluetooth, Wi-Fi).

[0127] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them; modifications or substitutions of some features in the technical solutions of the foregoing embodiments do not depart from the essence of the solutions.

[0128] The embodiments of the present invention can be implemented by software, hardware, firmware or a combination thereof: when implemented in software, it is manifested as a computer program product, and the robot collaborative control process is generated after the instructions are loaded; when implemented in hardware, the core logic can be completed by ASIC or FPGA.

[0129] The system units are divided by logical functions and can be integrated or deployed in a distributed manner. The modules communicate with each other through electrical interfaces. When the software functional units are sold independently, they can be stored in the aforementioned readable media. The instructions can drive the equipment to perform core steps such as data fusion, dynamic threshold calculation, and hierarchical early warning.

[0130] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the following claims.

[0131] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A single-arm composite robot, characterized in that, The system includes an omnidirectional mobile trolley, a storage arm, a folding mechanism, a joint module, and a fixing mechanism. The top surface of the omnidirectional mobile trolley is equipped with a mounting base and a storage slot. A first motor is located on one side of the mounting base, and the output end of the first motor is rigidly connected to the rotating shaft of the storage arm through a flexible coupling. The storage arm is equipped with a folding mechanism, which includes a second motor, a worm gear, a worm wheel, and a flip base. Two electric push rods are located on the flip base, and the output ends of the electric push rods are connected to the joint module. The joint module is equipped with a fixing mechanism, which includes a positioning plate, a third motor, a lead screw, a clamping block, and a clamping plate. The omnidirectional mobile vehicle is equipped with a control motherboard; the control motherboard also integrates an attitude detection module, a pressure sensing module, an environmental perception module, a storage status detection module, and a power detection module; The attitude detection module includes a six-axis IMU sensor and a joint angle sensor. The six-axis IMU sensor is fixed to the end of the joint module, and the joint angle sensor is located at the joint axis. The pressure sensing module includes a pressure sensor, which is embedded in the inner side of the clamping plate and the clamping block. The environmental perception module includes a lidar and an ultrasonic sensor. The lidar is fixed to the front end of the omnidirectional mobile vehicle, and the ultrasonic sensors are symmetrically arranged on both sides of the omnidirectional mobile vehicle. The storage status detection module includes a proximity sensor, which is embedded in the inner wall of the storage slot. The power detection module is connected in series to the power supply circuit of each motor and electric actuator; the control board is configured to receive the electrical signals of each module and calculate the structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position, and actuator equivalent power, and execute the control logic with the structural parameters as input. The single-arm composite robot supports moving, gripping, and storage modes. In storage mode, the proximity sensor and the drive circuit of the electric push rod in the storage slot are activated, and the storage positioning distance threshold is applied to completely place the storage arm into the storage slot.

2. A single-arm composite robot according to claim 1, characterized in that, The omnidirectional mobile vehicle is equipped with a drive wheel assembly and a positioning chip. The positioning chip is a GPS / BeiDou dual-mode chip, which is used to output the vehicle's position coordinates in real time. The proximity sensor of the storage status detection module is an infrared proximity sensor. When the storage arm is fully inserted into the storage slot, the proximity sensor outputs a position signal; otherwise, it outputs an abnormal signal.

3. A single-arm composite robot according to claim 1, characterized in that, The six-axis IMU sensor of the attitude detection module is used to output the acceleration and angular velocity signals of the end of the joint module; the joint angle sensor is an absolute encoder used to output the real-time rotation angle of each joint. The motherboard stores the reference attitude parameters of the joint module, including the joint reference angle and the end-effector reference position. The reference parameters are fixed in non-volatile memory after factory calibration and can be recalibrated and updated after maintenance.

4. A single-arm composite robot according to claim 1, characterized in that, The pressure sensor of the pressure sensing module is used to collect the pressure signal between the clamping plate and the clamping block. At least two pressure sensors are embedded on the inner side of both the clamping plate and the clamping block and are symmetrically distributed. The control motherboard collects the pressure sensor signal at a frequency of not less than 10 Hz, calculates the average clamping force, and stores the safe clamping force threshold corresponding to different workpiece materials for later use.

5. A single-arm composite robot according to claim 1, characterized in that, The environmental perception module's lidar is used to output the distance and angle of obstacles on the movement path; the ultrasonic sensor is used to assist the lidar in detecting nearby obstacles; the control motherboard fuses the signals from the lidar and the ultrasonic sensor to calculate the obstacle avoidance safety distance, and triggers obstacle avoidance control when the obstacle distance is less than the safety distance.

6. A single-arm composite robot according to claim 1, characterized in that, The power detection module is a shunt resistor sampling circuit connected in series in the power supply circuits of the first motor, the second motor, the third motor and the electric actuator, used to output the real-time operating current of each actuator; the control board calculates the equivalent power based on the operating current and the rated voltage, and stores the rated power threshold of each actuator. When the equivalent power exceeds the preset ratio of the rated power, overload protection is triggered.

7. A multi-module collaborative control system for a single-arm composite robot, characterized in that, The system is applied to the single-arm composite robot of any one of claims 1-6, and includes a single-arm composite robot body, a processor, and a memory. The single-arm composite robot body includes: an omnidirectional mobile vehicle, a storage arm, a folding mechanism, a joint module, a fixing mechanism, an environmental perception module, and a power detection module; The processor and memory are integrated into the control motherboard and are electrically connected to the aforementioned motors, electric actuators, sensors, and modules; The memory stores program instructions that run on the processor, which is configured to: Electrical signals are acquired from various sensors and modules to calculate a set of structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position, and actuator equivalent power. The memory stores program instructions that run on the processor. The processor is configured to: acquire electrical signals from various sensors and modules and calculate a set of structural parameters, including joint posture deviation angle, average clamping force, obstacle distance, storage position accuracy, and actuator equivalent power; and use the set of structural parameters as input to execute control logic, generate control signals according to preset thresholds and mapping relationships, and send them to each actuator, the configured display screen, and the alarm module to achieve posture accuracy compensation, adaptive clamping force adjustment, mobile obstacle avoidance navigation, storage status calibration, and overload fault indication.

8. The multi-module collaborative control system according to claim 7, characterized in that, The processor calculates the joint attitude deviation angle in the following way: The processor acquires the real-time angles of each joint using joint angle sensors and compares them with the reference angles stored in the memory to obtain the single-joint deviation angle. Combined with the end-effector attitude signal output by the six-axis IMU sensor, the end-effector attitude deviation angle is calculated using forward kinematics. When the attitude deviation angle exceeds a preset threshold, the processor generates an attitude compensation signal to control the corresponding joint motors to fine-tune until the deviation angle is less than the threshold.

9. The multi-module collaborative control system according to claim 7, characterized in that, The logic for the processor to perform adaptive clamping force adjustment is as follows: During clamping operations, the pressure sensor collects the clamping force signal in real time, and the processor calculates the average clamping force. If the average clamping force is less than the lower limit of the safe clamping force for the corresponding workpiece, the third motor is controlled to rotate forward to increase the clamping force. If the average clamping force is greater than the upper limit of the safe clamping force, the third motor is controlled to rotate in reverse to decrease the clamping force. If the clamping force cannot reach the safe range for a preset time, a clamping abnormality prompt is issued through the display screen and alarm module.

10. The multi-module collaborative control system according to claim 7, characterized in that, The logic for the processor to execute mobile obstacle avoidance navigation is as follows: When the omnidirectional mobile vehicle moves, the lidar and ultrasonic sensors collect environmental signals in real time. The processor fuses the signals and calculates the distance to obstacles. If the distance to an obstacle is greater than the obstacle avoidance safety distance, the vehicle is controlled to move along a preset path. If the distance to an obstacle is less than the safety distance, the vehicle is controlled to stop moving and a detour path is planned. At the same time, the vehicle's position is calibrated through a positioning chip to avoid movement deviation.

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