System and method for measuring energy consumption of single-phase power supply mechanical arm

Abstract

The invention discloses a single-phase power supply mechanical arm energy consumption measuring system and method, relates to the technical field of industrial mechanical arms, and aims to provide a single-phase power supply mechanical arm energy consumption measuring system and method which can accurately measure and visualize real-time energy consumption and accumulated energy consumption of a single-phase power supply mechanical arm under different working conditions. And reliable data support can be provided for energy consumption control and digital twinning of the mechanical arm. The single-phase power supply mechanical arm energy consumption measurement system comprises a power supply assembly, a to-be-measured mechanical arm body, a data acquisition assembly and a driving and data processing analysis assembly, and the core of the data acquisition assembly comprises an intelligent electric meter assembly and a 485 adapter; energy consumption parameters such as voltage, current, power and electric energy in the operation process of the mechanical arm are collected in real time, energy consumption data collected by the intelligent electric meter assembly are converted into information flow capable of being recognized by a computer through a 485 communication interface, and the information flow is merged into an energy consumption control and digital twin system.

Description

[0001] This invention relates to the field of single-phase powered robotic arm technology, and in particular to a single-phase powered robotic arm energy consumption measurement system and method. Background Technology

[0002] With the deep integration of global industrial automation and intelligent manufacturing, single-phase powered robotic arms, due to their core advantages such as low cost, simple wiring, and compatibility with small power distribution systems, have become core equipment in small and medium-sized production lines in fields such as electronics manufacturing, light industrial packaging, and medical devices. They are widely used in precision operations such as PCB mounting, precision sorting, and small component assembly. Their energy consumption control has a direct impact on robotic arm control research and digital twin applications. As robotic arm technology continues to advance and its application areas expand, the demand for accurate measurement of robotic arm energy consumption in the digital twin field is also gradually increasing. This necessitates higher requirements for the frequency of energy consumption data acquisition, transmission speed, and visualization accuracy of robotic arms.

[0003] Existing measurement systems often use general-purpose electrical parameter acquisition modules, which do not take into account the characteristics of frequent start-stop and large load fluctuations of robotic arms under single-phase power supply. This results in insufficient accuracy in capturing instantaneous voltage and current (sampling frequency is mostly below 500Hz), making it impossible to accurately calculate the instantaneous power during start-stop phases. This greatly limits the energy consumption control of single-phase powered robotic arms. With the ever-increasing demands for energy consumption management in industrial automation, energy consumption measurement technology has become a core supporting link for energy efficiency assessment and energy-saving retrofitting of single-phase powered robotic arms. The accuracy of its data directly determines the feasibility and effectiveness of energy optimization schemes. However, traditional measurement methods lack optimization algorithms for power calculation logic in single-phase circuits, relying solely on fixed power factors to estimate power. This results in measurement errors generally exceeding 10%, failing to meet the data accuracy requirements for energy efficiency assessment and energy-saving retrofitting of single-phase powered robotic arms. Therefore, in engineering applications, there is an urgent need for a system and method that can adapt to the dynamic operating characteristics of single-phase powered robotic arms and achieve high-precision energy consumption measurement, addressing the core problem of large measurement errors and the inability of existing technologies to meet the needs of energy efficiency assessment and energy-saving retrofitting. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a single-phase power supply robotic arm energy consumption measurement system and method. The system and method can measure and visualize the energy consumption of the robotic arm under different working conditions, providing data support for the energy consumption control of single-phase power supply robotic arms.

[0005] One of the technical solutions provided by this invention is a single-phase power supply robotic arm energy consumption measurement system, which includes a power supply component, a robotic arm under test, a data acquisition component, and a data processing and analysis component. The drive and data acquisition components are respectively connected to the power supply component, the robotic arm under test, and the data processing and analysis component. The data acquisition component includes several measurement modules that collect energy consumption parameters such as voltage, current, power, and electrical energy during the operation of the robotic arm in real time. The measured energy consumption data can be transmitted to the drive and data analysis and processing component.

[0006] The present invention provides a single-phase power supply robotic arm energy consumption measurement system, wherein the power supply components include a voltage regulator module and an overload protection unit.

[0007] The present invention discloses a single-phase powered robotic arm energy consumption measurement system, wherein the data acquisition component includes a smart meter component, a 485 communication interface, and a USB to 485 adapter.

[0008] The present invention discloses a single-phase power supply robotic arm energy consumption measurement system, wherein the smart meter component includes a voltage acquisition module, a current acquisition module, a power calculation module, and an energy metering module.

[0009] The present invention discloses a single-phase power supply robotic arm energy consumption measurement system, wherein the smart meter component has a local storage function, caches 72 hours of historical energy consumption data, and has a sampling frequency of not less than 1kHz.

[0010] The present invention discloses a single-phase power supply robotic arm energy consumption measurement system, wherein the 485 communication interface adopts the RS485 standard interface, supports half-duplex communication mode, and the communication baud rate can be adjusted within the range of 1200bps-115200bps.

[0011] The present invention provides a single-phase powered robotic arm energy consumption measurement system, wherein the USB to 485 adapter has a built-in level conversion circuit.

[0012] The present invention provides an energy consumption measurement system for a single-phase powered robotic arm, wherein the drive and data processing analysis components include a control cabinet, a driver, and a data processing analysis module.

[0013] The present invention provides a single-phase powered robotic arm energy consumption measurement system, wherein the system further includes a host computer, which is capable of communicating with the control cabinet and the driver respectively.

[0014] This invention discloses a single-phase powered robotic arm energy consumption measurement system, wherein the robotic arm energy consumption measurement system is characterized by comprising the following steps: S10, System assembly: Connect the data acquisition component to the power supply component, the robot arm under test, and the drive and data processing analysis component respectively. S20. Preparations before measurement: First, adjust the robot arm under test to the specified test posture. Adjust the wiring terminals of the smart meter component connected to the power supply circuit of the robot arm under test. Connect the 485 communication interface of the smart meter component to the USB to 485 adapter. Insert the USB end into the computer USB interface of the data processing and analysis component. At the same time, record the communication address of the 485 communication interface and the preset communication baud rate (the appropriate baud rate selected from the range of 1200bps-115200bps). Initialize the parameters of the smart meter component, configure the communication parameters of the data receiving module in the data processing and analysis component, and check and clean the storage space of the data storage module. After completion, perform a connectivity test on the entire data acquisition link. S30, Data Measurement: First, start the corresponding working condition test according to the preset test plan: control the robot arm under test to run according to the preset motion program, and the smart meter component collects energy consumption parameters such as voltage, current, instantaneous power and cumulative power during the operation of the robot arm in real time at a sampling frequency of not less than 1kHz; the smart meter component collects energy consumption data separately for each trajectory operation process, and each trajectory test is repeated 3 times to ensure data repeatability. S40, Data Processing: During data acquisition, the smart meter component captures electrical parameters in the power supply circuit in real time through its built-in voltage U(t) acquisition module and current I(t) acquisition module. The instantaneous power P is then calculated by the power calculation module, using the following formula: P=U(t)*I(t)*cosφ Where cosφ is the power factor of voltage and current, with a value range of 0~1, and is calculated in real time by the smart meter component through the phase detection function; Based on the instantaneous power P and the sampling time interval Δt (derived from the sampling frequency of the smart meter component; when the sampling frequency is 1kHz, Δt = 1ms), the cumulative energy consumption within a specified time period is calculated using an accumulation algorithm. The calculation formula is as follows: E=∑[P(t)*∆t] The collected energy consumption data is cached locally and transmitted via a USB-to-485 adapter through a 485 communication interface. The adapter converts the signal into a computer-readable format using a built-in level conversion circuit before transmitting it to the data processing and analysis component. The data receiving module receives energy consumption data in real time and transmits it to the data storage module for categorized storage. Simultaneously, the data analysis module performs preliminary processing on the received data in real time, removing obviously abnormal data. Throughout the data measurement process, the visualization module displays the energy consumption parameter change curve and the current cumulative energy in real time. If data transmission is interrupted or parameters are abnormal, the system automatically triggers a prompt signal, allowing testers to pause the measurement and troubleshoot the problem.

[0015] The present invention, a single-phase powered robotic arm energy consumption measurement system and method, differs from existing technologies in that, during measurement, the smart meter component collects voltage and current parameters in real time at a sampling frequency of not less than 1kHz, and dynamically calculates the power factor through phase detection, replacing the traditional fixed power factor estimation method. This effectively eliminates measurement errors caused by voltage and current phase fluctuations during dynamic robotic arm operation, significantly improving measurement accuracy. Through the combination of a 485 communication interface and a USB-to-485 adapter, real-time transmission and computer-side processing of energy consumption data are achieved. Simultaneously, the smart meter component has a 72-hour local cache function to avoid information loss due to data transmission interruptions. Furthermore, the visualization module displays parameter curves and anomaly alerts in real time, eliminating the need for manual recording and post-processing, making operation simple and efficient. The system boasts high reliability and is adaptable to energy consumption measurement and digital twins of different models and operating conditions of single-phase powered robotic arms, exhibiting broad applicability.

[0016] The energy consumption measurement system and method for a single-phase powered robotic arm according to the present invention will be further described below with reference to the accompanying drawings. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the energy consumption measurement system for a single-phase powered robotic arm according to the present invention; Figure 2 This is a schematic diagram of the power supply component in a single-phase power supply robotic arm energy consumption measurement system of the present invention; Figure 3 This is a schematic diagram of the data acquisition component in a single-phase power supply robotic arm energy consumption measurement system of the present invention; Figure 4 This is a schematic diagram of the drive and data processing and analysis components in a single-phase power supply robotic arm energy consumption measurement system of the present invention; The markings in the diagram are as follows: 1-Power supply component; 11-Voltage regulator module; 12-Overload protection unit; 3-Data acquisition component; 31-Voltage acquisition module; 32-Current acquisition module; 33-Power calculation module; 34-Energy metering module; 35-485 adapter; 4-Drive and data processing analysis component; 41-Control cabinet; 42-Driver; 43-Data receiving and storage module; 44-Host computer. Detailed Implementation

[0018] The following examples are used to illustrate the present invention, but are not intended to limit the scope of the invention. Example

[0019] like Figure 1As shown, the single-phase power supply robotic arm energy consumption measurement system of the present invention includes a power supply component 1, a test body 2, a data acquisition component 3, and a drive and data processing analysis component 4. The power supply component 1 provides stable single-phase power support to the system and has circuit protection functions; the data acquisition component 3 is connected to the power supply circuit and is responsible for collecting and measuring electrical parameters during the power supply process, and converting data formats through a converter; the drive and data processing analysis component 4 communicates with the data acquisition component 3 via wired or wireless means. When the drive and data processing analysis component 4 drives the test body 2 to run according to the set program, the data acquisition component 3 simultaneously collects the electrical parameters of the test body 2 and transmits the measured data to the drive and data processing analysis component 4 using the established communication.

[0020] like Figure 2 As shown, the power supply components include a voltage regulator module 11 and an overload protection unit 12. The voltage regulator module 11 provides a stable single-phase voltage output for the entire system, ensuring the stability of power supply to the robotic arm and data acquisition components. The overload protection unit 12 is connected in series in the power supply circuit. When the current in the circuit exceeds a preset safety threshold, it can promptly cut off the power supply to prevent damage to system components due to overload, thus providing safety protection. The voltage regulator module 11 and the overload protection unit 12 work together to ensure a stable and safe power supply for the system.

[0021] The test body 2 is mainly a robotic arm whose energy consumption is to be measured. The test body 2 is connected to the drive and data processing analysis component 4 through a wiring harness. The drive and data processing analysis component 4 can control the robotic arm of the test body 2 to move according to different working conditions, thereby realizing the position and posture adjustment of the test body 2.

[0022] like Figure 3 As shown, the data acquisition component 3 includes a voltage acquisition module 31, a current acquisition module 32, a power calculation module 33, an energy metering module 34, and a 485 adapter 35. The voltage acquisition module 31 is connected to the power supply circuit and is used to acquire the power supply voltage signal in real time; the current acquisition module 32 is also connected to the power supply circuit and acquires the power supply current signal in real time. The power calculation module 33 receives the voltage and current signals transmitted from the voltage acquisition module 31 and the current acquisition module 32, performs calculations on them to obtain real-time power data; the energy metering module 34 calculates the cumulative energy consumption during the operation of the robotic arm based on the real-time power data from the power calculation module 33. These acquired and calculated energy consumption data are converted by the 485 adapter 35 and then transmitted to the drive and data processing analysis component 4 to provide data support for subsequent energy consumption analysis.

[0023] In data acquisition component 3, voltage acquisition module 31 captures voltage parameters in the power supply circuit, and current acquisition module 32 captures current parameters; both provide the basic electrical signals for energy consumption data acquisition. Power calculation module 33 processes the signals from voltage acquisition module 31 and current acquisition module 32 to calculate the real-time power during robotic arm operation; energy metering module 34 accumulates the real-time power to obtain total energy consumption data. Finally, 485 adapter 35 converts the data into a suitable transmission format, thereby enabling the acquisition of electrical parameters of the tested body 2.

[0024] like Figure 4 As shown, the drive and data processing analysis component 4 includes a control cabinet 41, a driver 42, a data receiving and storage module 43, and a host computer 44. The control cabinet 41 is connected to the test body 2 via cables and communicates with the host computer 44 via wired or wireless connections. Based on the pose information of different operating conditions, the host computer 44 controls the rotation of each joint axis of the test body 2 by controlling the output signals of the control cabinet 41, thereby adjusting the operating conditions of the test body 2.

[0025] The driver 42 is connected to the test body 2 and the host computer 44 via a wiring harness. The host computer 44 controls the movement of each joint of the robotic arm through the driver 42, realizing precise control of the robotic arm's operating status, motion trajectory, and action sequence. Specifically, the host computer 44 sends preset control commands or motion programs to the driver 42. The driver 42 converts the commands into corresponding drive signals to drive the robotic arm's motors and other actuators. At the same time, the driver 42 also feeds back the robotic arm's real-time operating status (such as position, speed, current, etc.) to the host computer 44, forming a closed-loop control.

[0026] The data receiving and storage module 43 establishes a wired communication connection with the 485 adapter 35 in the data acquisition component 3, specifically to receive energy consumption data converted by the 485 adapter 35. This data includes real-time voltage values ​​collected by the voltage acquisition module 31, real-time current values ​​collected by the current acquisition module 32, real-time power data calculated by the power calculation module 33, and accumulated energy consumption data from the energy metering module 34. The data receiving and storage module 43 has a built-in high-speed storage unit, capable of real-time and orderly storage of massive amounts of received energy consumption data. It also supports data classification and archiving, allowing data to be tagged according to timestamps, robotic arm operating conditions, and other dimensions. The data is then transmitted in real-time to the host computer 44, which processes the data and visualizes the measured energy consumption data or transmits the energy consumption data to the digital twin.

[0027] The working principle of the single-phase power supply robotic arm energy consumption measurement system of the present invention is as follows.

[0028] 1) System assembly and debugging. First, install the body under test 2 on the fixed base. Connect the voltage regulator module 11 and the overload protection unit 12 in the power supply component 1 in series through the circuit to ensure that the stable single-phase power output of the voltage regulator module 11 passes through the overload protection unit 12 and is connected to the power supply terminal of the robotic arm body 2 under test and the power supply terminal of the data acquisition component 3 respectively. Connect the control cabinet 41 to the body under test 2 in a wired manner. The host computer 44 performs data communication tests with the control cabinet 41 through a wired or wireless connection and adjusts the movement mode of the body under test according to the working condition command of the control cabinet 41.

[0029] Assemble data acquisition component 3 by connecting voltage acquisition module 31 and current acquisition module 32 to the power supply circuit of the robotic arm under test, enabling voltage acquisition module 31 to acquire the power supply voltage signal and current acquisition module 32 to acquire the power supply current signal; then connect power calculation module 33 and energy metering module 34 to voltage acquisition module 31 and current acquisition module 32 via wiring. Connect 485 adapter 35 to energy metering module 34 to complete the assembly of data acquisition component 3.

[0030] The control cabinet 41 and driver 42 are connected to the robot arm body 2 under test using a wiring harness to realize the drive control of the robot arm; the data receiving and storage module 43 is connected to the 485 adapter 35 via a wired connection so that the data receiving and storage module 43 can receive energy consumption data; then the host computer 44 establishes communication connections with the control cabinet 41, driver 42 and data receiving and storage module 43 respectively to complete the assembly of the entire system.

[0031] Start the voltage regulator module 11 of the power supply component 1, use a multimeter to detect the output voltage of the power supply circuit, and confirm that the voltage is stable at the preset value; simulate an overload situation, check whether the overload protection unit 12 can cut off the power supply in time, and verify its protection function.

[0032] With the robotic arm body 2 under test in standby mode, observe whether the voltage acquisition module 31 and current acquisition module 32 of the data acquisition component 3 can normally acquire the voltage and current signals in standby mode, whether the power calculation module 33 can correctly calculate the standby power, whether the cumulative power of the power metering module 34 can count normally, and at the same time check whether the 485 adapter 35 can stably transmit the data to the data receiving and storage module 43.

[0033] The host computer 44 sends control commands to the control cabinet 41 and the driver 42, observes whether the robot arm body 2 under test can complete the corresponding actions according to the commands, and verifies the drive control function; checks whether the energy consumption data received by the data receiving and storage module 43 can be accurately displayed on the host computer 44, and checks the real-time performance and accuracy of the data.

[0034] The robot arm under test 2 is set to run according to the preset working conditions. The power supply stability of the power supply component 1, the parameter acquisition accuracy of the data acquisition component 3, and the control and data processing effect of the drive and data processing analysis component 4 are monitored throughout the process to ensure that all components work together normally and the system can accurately measure the energy consumption of the robot arm.

[0035] 2) Preparatory work before measurement. The host computer 44 sends instructions to the control cabinet 41 to adjust the robot arm under test 2 to the specified test posture. After it is in position, adjust the wiring terminals of the smart meter component in the data acquisition component 3 to accurately connect it to the power supply circuit of the robot arm under test. At the same time, reliably connect the 485 communication interface of the smart meter component to the USB to 485 adapter. Insert the USB end of the adapter into the USB interface of the host computer 44 of the driver and data processing analysis component 4, and record the communication address of the 485 communication interface. Select an appropriate communication baud rate from the range of 1200bps-115200bps and record it. Initialize the parameters of the smart meter component, set the sampling frequency to 1kHz, and enable the local storage function. Configure the communication parameters of the data receiving and storage module 43 in the driver and data processing analysis component 4 to ensure that the communication parameters are consistent with those of the smart meter component. Check the storage space of the data storage module and clean up redundant data. After completing the above operations, conduct a connectivity test on the entire data acquisition circuit. Have the robot arm under test 2 perform a short simulated action and observe whether the host computer 44 can receive energy consumption data such as voltage, current, power, and electrical energy in real time. Confirm that the data transmission is normal and the acquisition is accurate. In this way, all the preparations before measurement have been completed.

[0036] 3) Data Measurement. At the start of measurement, the host computer 44 sends control commands to the driver 42 according to the corresponding working conditions, driving the robotic arm 2 under test to run according to the preset motion program. The smart meter component in the data acquisition module 3 starts real-time acquisition at a sampling frequency of 1kHz. The voltage acquisition module 31 captures the voltage signal U(t) of the power supply circuit in real time, and the current acquisition module 32 synchronously acquires the current signal I(t). After receiving the voltage and current signals, the power calculation module 33 calculates the power factor cosφ in real time through its built-in phase detection function to obtain the instantaneous power. The energy metering module 34 accumulates the energy consumption.

[0037] For each test trajectory, the smart meter component stores the energy consumption data for the corresponding time period separately, and each trajectory is tested three times: the first test records the energy consumption of the robotic arm running under no-load conditions, the second test records the energy consumption of running under 50% load, and the third test records the energy consumption of running under full load. During the data acquisition process, the smart meter component caches all data through its local storage function and transmits real-time data to a USB-to-485 adapter via the 485 communication interface. After being converted by the adapter's built-in level conversion circuit, the data is transmitted to the data receiving and storage module 43 of the drive and data processing analysis component 4, and the acquired data is then transmitted to the host computer 44.

[0038] 4) Data Processing. The host computer processes the collected data. First, the power calculation module 33 captures the electrical parameters in the power supply circuit in real time through its built-in voltage U(t) acquisition module and current I(t) acquisition module. The phase detection function calculates cosφ in real time. The instantaneous power P is then calculated by the power calculation module. The calculation formula is as follows: P=U(t)*I(t)*cosφ Based on the instantaneous power P and the sampling time interval Δt (derived from the sampling frequency of the smart meter component; when the sampling frequency is 1kHz, Δt = 1ms), the cumulative energy consumption within a specified time period is calculated using the accumulation algorithm of the energy metering module 34. The calculation formula is as follows: E=∑[P(t)*∆t] The host computer 44 processes the collected and calculated data and displays it in the form of multi-dimensional charts: Real-time energy consumption graph: Generates real-time change curves for voltage, current, and instantaneous power. The horizontal axis represents time (accurate to the second), and the vertical axis represents the corresponding parameter values. The curves are updated once per second. Cumulative Energy Consumption Statistics Chart: The current cumulative energy consumption (unit: kWh) is displayed in the form of a digital dashboard, and daily and monthly energy consumption bar charts are generated. The above data can provide data support for subsequent research on the energy consumption of robotic arms and digital twins. Example

[0039] This embodiment provides a method for measuring the energy consumption of a single-phase powered robotic arm, which is used to measure the digital twin energy consumption data of the robotic arm under test.

[0040] The present invention provides a method for measuring the energy consumption of a single-phase powered robotic arm, comprising the following steps: S10, System Assembly: Connect the data acquisition component 3 to the power supply component 1, the robot arm under test 2, and the drive and data processing analysis component 4 respectively. Specifically, connect the voltage regulator module 11 and the overload protection unit 12 in the power supply component 1 in series to ensure that the stable single-phase power output from the voltage regulator module 11 passes through the overload protection unit 12 and is then connected to the power supply terminals of the robot arm under test 2 and the data acquisition component 3 respectively. Connect the control cabinet 41 to the robot arm under test 2 via a wired connection. The host computer 44 performs data communication tests with the control cabinet 41 via a wired or wireless connection. Connect the voltage acquisition module 31 and the current acquisition module 32 to the power supply circuit of the robot arm under test. Then connect the power calculation module 33 and the energy metering module 34 to the voltage acquisition module 31 and the current acquisition module 32 via lines. Connect the 485 adapter 35 to the power metering module 34, connect the control cabinet 41 and the driver 42 to the robot arm body 2 under test; connect the data receiving and storage module 43 to the 485 adapter 35 via wired connection; then establish communication connections between the host computer 44 and the control cabinet 41, driver 42, and data receiving and storage module 43 respectively to complete the assembly of the entire system.

[0041] S20, Pre-measurement Preparation: The host computer 44 sends instructions to the control cabinet 41 to adjust the robot arm under test 2 to the specified test posture. After positioning, adjust the wiring terminals of the smart meter component in the data acquisition component 3 to accurately connect it to the power supply circuit of the robot arm under test. Simultaneously, reliably connect the 485 communication interface of the smart meter component to the USB-to-485 adapter. Insert the USB end of the adapter into the USB interface of the host computer 44 of the driver and data processing analysis component 4, and record the communication address of the 485 communication interface. Select and record the appropriate communication baud rate from the range of 1200bps-115200bps. Initialize the parameters of the smart meter component, set the sampling frequency to 1kHz, and enable the local storage function. Configure the communication parameters of the data receiving and storage module 43 in the driver and data processing analysis component 4 to ensure consistency with the communication parameters of the smart meter component. Check the storage space of the data storage module and clean up redundant data. After completing the above operations, conduct a connectivity test on the entire data acquisition circuit. Have the robot arm under test 2 perform a short simulated action and observe whether the host computer 44 can receive energy consumption data such as voltage, current, power, and electrical energy in real time. Confirm that the data transmission is normal and the acquisition is accurate. In this way, all the preparations before measurement have been completed.

[0042] S30, Data Measurement: First, based on the corresponding working conditions, the host computer 44 sends control commands to the driver 42, driving the robot arm 2 under test to run according to the preset motion program. The smart meter component in the data acquisition component 3 starts real-time acquisition at a sampling frequency of 1kHz. Among them, the voltage acquisition module 31 captures the voltage signal U(t) of the power supply circuit in real time, and the current acquisition module 32 synchronously acquires the current signal I(t). After receiving the above voltage and current signals, the power calculation module 33 calculates the power factor cosφ in real time through the built-in phase detection function to calculate the instantaneous power. The energy metering module 34 accumulates the energy consumption.

[0043] For each test trajectory, the smart meter component stores the energy consumption data for the corresponding time period separately, and each trajectory is tested three times: the first test records the energy consumption of the robotic arm running under no-load conditions, the second test records the energy consumption of running under 50% load, and the third test records the energy consumption of running under full load. During the data acquisition process, the smart meter component caches all data through its local storage function and transmits real-time data to a USB-to-485 adapter via the 485 communication interface. After being converted by the adapter's built-in level conversion circuit, the data is transmitted to the data receiving and storage module 43 of the drive and data processing analysis component 4, and the collected data is then transmitted to the host computer 44.

[0044] S40, Data Processing: The host computer processes the collected data. First, the power calculation module 33 captures the electrical parameters in the power supply circuit in real time through the built-in voltage U(t) acquisition module and current I(t) acquisition module. The phase detection function calculates cosφ in real time. The instantaneous power P is then calculated by the power calculation module. The relevant calculation formula is shown below: P=U(t)*I(t)*cosφ Based on the instantaneous power P and the sampling time interval Δt (derived from the sampling frequency of the smart meter component; when the sampling frequency is 1kHz, Δt = 1ms), the cumulative energy consumption within a specified time period is calculated using the accumulation algorithm of the energy metering module 34. The relevant cumulative energy consumption calculation formula is as follows: E=∑[P(t)*∆t] The host computer 44 processes the collected and calculated data and displays it in the form of multi-dimensional charts: Real-time energy consumption graph: Generates real-time change curves for voltage, current, and instantaneous power. The horizontal axis represents time (accurate to the second), and the vertical axis represents the corresponding parameter values. The curves are updated once per second. Cumulative Energy Consumption Statistics Chart: The current cumulative energy consumption (unit: kWh) is displayed in the form of a digital dashboard, and daily and monthly energy consumption bar charts are generated. The above data can provide data support for subsequent research on the energy consumption of robotic arms and digital twins.

[0045] This invention discloses a single-phase powered robotic arm energy consumption measurement system and method. During measurement, the smart meter component collects voltage and current parameters in real time at a sampling frequency of no less than 1kHz. Furthermore, it dynamically calculates the power factor through phase detection, replacing the traditional fixed power factor estimation method. This effectively eliminates measurement errors caused by voltage and current phase fluctuations during dynamic robotic arm operation, significantly improving measurement accuracy. Through a 485 communication interface and a USB-to-485 adapter, real-time transmission and computer-side processing of energy consumption data are achieved. The smart meter component also features a 72-hour local cache function to prevent information loss due to data transmission interruptions. The visualization module displays parameter curves and anomaly alerts in real time, eliminating the need for manual recording and post-processing, making operation simple and efficient. The system boasts high reliability and is adaptable to energy consumption measurement and digital twins of different models and operating conditions of single-phase powered robotic arms, demonstrating broad applicability.

Claims

1. A single-phase power supply robot energy consumption measurement system, characterized by: The application relates to a mechanical arm energy consumption testing system, which comprises a power supply assembly, a to-be-tested mechanical arm body, a data acquisition assembly and a driving and data processing and analyzing assembly.

2. The single-phase power supply mechanical arm energy consumption measurement system according to claim 1, characterized in that: The power supply assembly comprises a voltage stabilizing power supply module and an overload protection unit.

3. The single-phase power supply mechanical arm energy consumption measurement system according to claim 1, characterized in that: The data acquisition assembly comprises an intelligent electric meter assembly, a 485 communication interface and a USB-485 adapter.

4. The single-phase power supply mechanical arm energy consumption measurement system according to claim 3, characterized in that: The intelligent electric meter assembly comprises a voltage acquisition module, a current acquisition module, a power calculation module and an electric energy metering module.

5. The single-phase power supply mechanical arm energy consumption measurement system according to claim 3, characterized in that: The intelligent electric meter assembly has a local storage function, can cache 72-hour historical energy consumption data and has a sampling frequency of 1 kHz, so that the instantaneous change of the energy consumption parameters in the dynamic operation process of the to-be-tested mechanical arm can be captured.

6. The single-phase power supply mechanical arm energy consumption measurement system according to claim 3, characterized in that: The 485 communication interface adopts an RS485 standard interface, supports a half-duplex communication mode and can adjust the communication baud rate in the range of 1200bps-115200bps.

7. The single-phase power supply mechanical arm energy consumption measurement system according to claim 3, characterized in that: The USB-485 adapter is internally provided with a level conversion circuit.

8. The single-phase power supply mechanical arm energy consumption measurement system according to claim 1, characterized in that: The driving and data processing and analyzing assembly comprises a data receiving module, a data storage module, a data analyzing module and a visualizing module.

9. The single-phase power supply mechanical arm energy consumption measurement system according to claim 8, characterized in that: The application further comprises an upper computer which can communicate with the control cabinet and the driver.

10. A single-phase power supply mechanical arm energy consumption measurement method, using the mechanical arm energy consumption measurement system of any one of claims 1-9, characterized in that: The application comprises the following steps: S10, system assembly, connecting the data acquisition assembly with the power supply assembly, the to-be-tested mechanical arm body and the driving and data processing and analyzing assembly; S20, preparation before measurement, first adjusting the to-be-tested mechanical arm body to run to a specified test posture, adjusting the wiring terminal of the intelligent electric meter assembly connected to the power supply loop of the to-be-tested mechanical arm, connecting the 485 communication interface of the intelligent electric meter assembly with the USB-485 adapter, inserting the USB end into the computer USB interface of the data processing and analyzing assembly, recording the communication address of the 485 communication interface, the preset communication baud rate (an adaptive baud rate selected from the range of 1200bps-115200bps), initializing the parameters of the intelligent electric meter assembly, configuring the communication parameters of the data receiving module in the data processing and analyzing assembly, checking and cleaning the storage space of the data storage module and testing the connectivity of the whole data acquisition link after completion; S30, data measurement, first starting the corresponding working condition test according to the preset test scheme: controlling the to-be-tested mechanical arm body to run according to the preset motion program, the intelligent electric meter assembly collecting the voltage, current, instantaneous power and cumulative electric energy and other energy consumption parameters in the running process of the mechanical arm at a sampling frequency of not less than 1 kHz; the intelligent electric meter assembly separately collects energy consumption data for each track running process, and each track test is repeated for 3 times to ensure data repeatability. S40, data processing, in the data acquisition process, the smart meter component captures the electrical parameters in the power supply circuit in real time through the built-in voltage U(t) acquisition module and current I(t) acquisition module, and calculates the instantaneous power P through the power calculation module. The calculation formula is as follows: P=U(t)*I(t)*cosφ Where cosφ is the power factor of voltage and current, the value range is 0~1, calculated by the smart meter component in real time through the phase detection function; Based on the instantaneous power P and the sampling time interval Δt (derived from the sampling frequency of the smart meter component, when the sampling frequency is 1kHz, Δt=1ms), the cumulative energy consumption in a specified time period is calculated by the accumulation algorithm, the formula is: E=∑[P(t)*∆t] The collected energy consumption data is cached through the local storage function on the one hand, and transmitted to the USB to 485 adapter through the 485 communication interface on the other hand. The adapter converts the signal into a format that can be recognized by the computer through the built-in level conversion circuit, and then transmits it to the data processing and analysis component. The data receiving module receives the energy consumption data in real time and transmits it to the data storage module for classified storage. At the same time, the data analysis module processes the received data in real time and eliminates obvious abnormal data. During the entire data measurement process, the visualization module displays the energy consumption parameter change curve and the current cumulative electric energy in real time. If the data transmission is interrupted or the parameter is abnormal, the system will automatically trigger a prompt signal, and the tester can pause the measurement and troubleshoot the problem.

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