A robot joint motor synchronous control system

Abstract

The application discloses a kind of robot joint motor synchronous control systems, belong to the field of robot control system, including motor synchronous control unit, vibration active suppression module, wear evaluation and coping module and prediction module;Motor synchronous control unit is used to generate the synchronous drive instruction of robot joint motor, to realize the coordinated motion of multiple joints;Vibration active suppression module is used to suppress the elastic vibration of robot manipulator simultaneously when calculating synchronous drive instruction;Wear evaluation and coping module is used to capture vibration state as system internal state by state observer, and the wear degree of each joint of manipulator is evaluated based on vibration-wear model;Prediction module is used to predict the wear degree of each joint of manipulator based on vibration-wear model and historical record.The application can improve the vibration suppression effect, and provide wear evaluation and prediction function, to further improve the motion accuracy, stability and service life of robot.

Description

Technical Field

[0001] This invention relates to the field of robot control systems, specifically a robot joint motor synchronous control system. Background Technology

[0002] With the continuous improvement of industrial automation, industrial robots are being used more and more widely in manufacturing. During high-speed movement, the robot arm vibrates due to its structural elasticity, which seriously affects the positioning accuracy and motion stability of the end effector. Traditional robot joint control systems mainly focus on the synchronous control of position and speed, with insufficient consideration for vibration suppression and long-term wear management.

[0003] Existing vibration control technologies mainly employ passive damping or simple feedback control, which are insufficient to effectively suppress multimodal vibrations in robot structures. Furthermore, traditional systems lack the ability to assess and predict mechanical wear in real time, often only performing maintenance when significant performance degradation or malfunctions occur, leading to production interruptions and increased maintenance costs.

[0004] Therefore, those skilled in the art have provided a robot joint motor synchronous control system to solve the problems mentioned in the background art. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a robot joint motor synchronization control system, including a motor synchronization control unit, a vibration active suppression module, a wear assessment and response module, and a prediction module;

[0006] The motor synchronization control unit generates synchronized drive commands for the robot joint motors to achieve coordinated movement of multiple joints; the vibration active suppression module suppresses the elastic vibration of the robot arm while calculating the synchronized drive commands; the wear assessment and response module captures the vibration state as the internal state of the system through a state observer, assesses the wear degree of each joint of the robot arm based on a vibration-wear model, and adopts different response strategies according to the wear degree, including when the wear degree of the target joint is within a preset range [W]. min W max When the wear level of the target joint is less than the minimum value W in the preset range, an equivalent replacement strategy is adopted to reduce the motion intensity of the target joint and increase the motion intensity of other joints. min The current control scheme is maintained until the wear degree of the target joint exceeds the maximum value W of the preset range. max When necessary, a shutdown and replacement strategy is adopted to deactivate the target joint and replace it with another joint or arrange for maintenance; the prediction module is used to predict the wear degree of each joint of the robotic arm based on the vibration-wear model and historical records, and to determine when the target joint cannot be deactivated if the wear degree exceeds the threshold W. thAdjust the workload allocation in advance when the work is to be completed.

[0007] As a further aspect of the present invention: the active vibration suppression module includes a mode recognition submodule, a mode transformation submodule, and a damping control submodule, wherein:

[0008] The modal recognition submodule identifies the first-order and second-order vibration modes of the robot structure through experiments or simulations.

[0009] The modal transformation submodule is used to transform the actual physical coordinates into modal coordinates through the modal matrix, so that each modal coordinate represents an independent vibration mode;

[0010] The damping control submodule is used to design an independent damping controller for each mode in the modal space to specifically suppress vibrations at specific frequencies.

[0011] As a further aspect of the present invention: the modal transformation submodule performs coordinate transformation using the following formula:

[0012] ;

[0013] in, Represents the modal coordinate vector. The physical coordinate vector represents the joint angle, and T represents the modal matrix.

[0014] The vibration-wear model uses the following formula to evaluate the degree of wear:

[0015] ;

[0016] Where W represents the degree of wear, v represents the vibration amplitude, k represents the wear coefficient determined by experiments, C represents the initial wear constant determined by experiments, t represents time, and τ represents the integral variable.

[0017] As a further aspect of the present invention: the vibration active suppression module further includes a feedback loop for real-time acquisition of the vibration signal of the robotic arm, and converts the vibration signal into modal coordinates through the modal transformation submodule. The damping control submodule generates a suppression signal based on the modal coordinates and feeds it back to the motor synchronization control unit to adjust the synchronization drive command.

[0018] The system also includes a sensor array comprising an encoder, an accelerometer, and a force sensor, used to monitor joint position, velocity, and acceleration, and input the data to the vibration active suppression module and the wear assessment and response module; the damping control submodule designs a proportional-derivative controller for each modal coordinate to increase system damping and reduce vibration amplitude; the modal recognition submodule determines the order and frequency range of the vibration modes through frequency response analysis to ensure the accuracy of the modal matrix;

[0019] The system further includes a calibration unit for calibrating the modal matrix and vibration-wear model parameters every 24 hours to adapt to changes in robot structure or the influence of environmental factors.

[0020] As a further aspect of the present invention: the modal matrix of the modal transformation submodule is obtained by eigenvalue decomposition based on the mass matrix and stiffness matrix of the robot structure, ensuring the orthogonality between modal coordinates; the independent damping controller of the damping control submodule includes modal mass parameters, modal stiffness parameters and modal damping parameters, and vibration suppression is achieved by adjusting these parameters;

[0021] The system also includes an adaptive control unit connected to the damping control submodule, used to dynamically adjust the damping controller parameters according to real-time vibration data to cope with vibration changes under different working conditions; the vibration active suppression module and the motor synchronization control unit are integrated in the same processor, and parallel calculation of synchronization control and vibration suppression is achieved through multi-threaded processing; the data of the sensor array is processed by Kalman filtering to remove noise before being input to the mode transformation submodule.

[0022] As a further aspect of the present invention: the state observer of the wear assessment and response module adopts a Kalman filter to estimate the internal state of the system from the vibration signal and outputs the vibration amplitude and frequency as input to the vibration-wear model; the vibration-wear model is trained based on historical wear data and establishes the relationship between vibration and wear using a linear regression method; the equivalent replacement strategy in the response strategy redistributes the joint motion intensity through a gradient descent optimization algorithm to ensure that the robot end effector reaches the target position while minimizing the load on the target joint; the deactivation replacement strategy calculates the motion trajectory of the replacement joint through inverse kinematics when the target joint is deactivated, and if it cannot be replaced, it triggers an audible and visual alarm and notifies maintenance personnel;

[0023] The system also includes a database for storing historical vibration data, wear records, and control strategy execution logs to support analysis by the prediction module.

[0024] As a further aspect of the present invention: the prediction module employs an autoregressive integral moving average model, predicts future wear trends based on a vibration-wear model and historical records, and generates an early warning signal; when the prediction indicates that the wear degree of the target joint will exceed a threshold W... th At that time, the prediction module triggers workload adjustment in advance, allocating 30% of the task of the target joint to other joints, and updates the synchronization drive command through the motor synchronization control unit;

[0025] The system also includes a user interface for setting preset intervals [W] min W max Threshold W th The wear assessment and response module provides parameters for the wear assessment and response strategies, and displays wear assessment results and prediction information. The priority of the response strategies in the wear assessment and response module is as follows: first, apply the equivalent replacement strategy; if this is not feasible, apply the discontinuation replacement strategy, while ensuring the overall motion accuracy and stability of the robot. The design of the state observer takes into account system noise and uncertainty, and improves the accuracy of vibration state estimation through feedback correction.

[0026] As a further aspect of the present invention: the motor synchronization control unit adopts a master-slave control structure to achieve phase synchronization and speed synchronization of multiple joint motors; the damping control submodule of the vibration active suppression module applies modal damping ratio adjustment in the modal space to suppress vibration in the frequency range of 10Hz to 100Hz.

[0027] The system also includes an energy management module for monitoring joint motor energy consumption and optimizing energy allocation when implementing vibration suppression and wear response strategies; the modal recognition submodule supports online updates and reconstructs the modal matrix through real-time vibration data to adapt to changes in the robot's dynamic load; the vibration-wear model of the wear assessment and response module is validated monthly using experimental data to ensure assessment accuracy; the prediction results of the prediction module are used to generate maintenance plans and automatically schedule maintenance resources.

[0028] As a further aspect of the present invention: the system also includes a safety protection module connected to the wear assessment and response module, used to urgently stop the robot's movement and activate a backup control mode when abnormal wear is detected or failure is predicted; the output of the motor synchronization control unit drives the joint motor through pulse width modulation, and integrates a vibration suppression signal as a compensation term; the independent damping controller of the damping control submodule is designed based on modal frequency and damping ratio requirements, and its effectiveness is verified through simulation; the vibration active suppression module shares a data bus with the wear assessment and response module to achieve high-speed data exchange; the system supports Ethernet communication for remote monitoring and control, and uploads wear data to an external cloud platform for big data analysis; the coordinate transformation process of the modal transformation submodule uses a field-programmable gate array to accelerate matrix operations, thereby improving real-time performance.

[0029] As a further aspect of the present invention: the preset range [W] of the wear assessment and response module min W max The system is customized according to robot type and working environment, and the optimal value is determined through 1000 hours of continuous experiments. The equivalent replacement strategy optimizes the joint motion intensity distribution through gradient descent while ensuring the operational purpose. The deactivation replacement strategy considers joint redundancy when deactivating the target joint and uses a kinematic solver to generate an alternative path. The prediction module's prediction cycle is set to 1 hour to adapt to different task requirements. The system also includes diagnostic tools for analyzing the deviation of the vibration-wear model and providing calibration suggestions. The motor synchronization control unit, vibration active suppression module, and wear assessment and response module are encapsulated in an embedded system, which has high reliability and real-time response capability.

[0030] The beneficial effects of this invention are reflected in:

[0031] This invention achieves significant synergistic benefits by deeply integrating motor synchronous control, active vibration suppression, wear assessment and response, and predictive maintenance. First, through modal coordinate transformation and decoupled independent damping control, the system can accurately and efficiently suppress multi-order elastic vibrations generated by the robotic arm during high-speed movement, significantly reducing vibration amplitude and thus greatly improving the positioning accuracy and motion stability of the end effector. Second, it innovatively establishes a vibration-wear model based on a state observer, enabling real-time, quantitative assessment and prediction of joint wear. Based on this, it intelligently executes response strategies such as equivalent replacement or decommissioning replacement, extending equipment lifespan and achieving a shift from passive maintenance to predictive maintenance, effectively reducing unplanned downtime and lowering maintenance costs. Finally, the integrated adaptive calibration, energy management, and safety protection modules further ensure its long-term reliability, energy efficiency, and safety under complex working conditions. In summary, this invention fundamentally solves the problem of the disconnect between vibration control and lifespan management in high-precision robot systems, achieving simultaneous optimization of motion accuracy, equipment lifespan, and overall operational efficiency. Attached Figure Description

[0032] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0033] Figure 1 This is a structural block diagram of a robot joint motor synchronous control system. Detailed Implementation

[0034] 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.

[0035] As mentioned in the background section of this application, research has found that existing vibration control technologies mainly employ passive damping or simple feedback control, which are insufficient to effectively suppress multimodal vibrations of robot structures. Furthermore, traditional systems lack the ability to assess and predict mechanical wear in real time, often only performing maintenance when significant performance degradation or malfunctions occur, leading to production interruptions and increased maintenance costs, thus exhibiting certain drawbacks.

[0036] To address the aforementioned shortcomings, this application discloses a robot joint motor synchronous control system, which can improve vibration suppression and provide wear assessment and prediction functions, thereby improving the robot's motion accuracy, stability, and service life.

[0037] The following will describe in detail, with reference to the accompanying drawings, how the solution of this application solves the above-mentioned technical problems.

[0038] Please see Figure 1 In this embodiment of the invention, a robot joint motor synchronization control system includes a motor synchronization control unit, a vibration active suppression module, a wear assessment and response module, and a prediction module. The motor synchronization control unit generates synchronous drive commands for the robot joint motors to achieve coordinated movement of multiple joints. The vibration active suppression module suppresses the elastic vibration of the robot arm while calculating the synchronous drive commands. The wear assessment and response module captures the vibration state as the internal state of the system through a state observer and assesses the wear degree of each joint of the robot arm based on a vibration-wear model. Different response strategies are adopted according to the wear degree, including when the wear degree of the target joint is within a preset range [W]. min W max When the wear level of the target joint is less than the minimum value W in the preset range, an equivalent replacement strategy is adopted to reduce the motion intensity of the target joint and increase the motion intensity of other joints. min The current control scheme is maintained until the wear degree of the target joint exceeds the maximum value W of the preset range. max When necessary, a deactivation and replacement strategy is adopted to deactivate the target joint and replace it with another joint or schedule maintenance; the prediction module is used to predict the wear degree of each joint of the robotic arm based on the vibration-wear model and historical records, and to determine when the target joint cannot withstand wear exceeding the threshold W. th The workload allocation is adjusted in advance when the work is completed. This application realizes basic coordinated movement between joints through a motor synchronous control unit, and introduces a vibration active suppression module and a wear assessment and response module, deeply integrating vibration suppression and wear management into the synchronous control process. The prediction module further endows the system with forward-looking decision-making capabilities. These modules work together to solve the industry problems of insufficient accuracy and stability and lack of proactive health management under high-speed movement, realizing a leap from passive control to proactive, predictive intelligent maintenance, and ultimately achieving the core objectives of improving robot motion accuracy, extending equipment life, and reducing maintenance costs.

[0039] In this embodiment, the active vibration suppression module includes a modal recognition submodule, a modal transformation submodule, and a damping control submodule. The modal recognition submodule identifies the first-order and second-order vibration modes of the robot structure through experiments or simulations. The modal transformation submodule transforms the actual physical coordinates into modal coordinates using a modal matrix, ensuring that each modal coordinate represents an independent vibration mode. The damping control submodule designs an independent damping controller for each mode in the modal space to specifically suppress vibrations at specific frequencies. By accurately locating the core vibration source through the modal recognition submodule and decoupling the complex physical space vibrations into independent modal coordinates through the modal transformation submodule, the damping control submodule achieves precise and independent suppression of vibration modes at specific frequencies. This "decomposition-identification-divide and conquer" functional flow overcomes the shortcomings of traditional single controllers in suppressing multimodal vibrations, significantly improving the efficiency and effectiveness of vibration suppression.

[0040] In this embodiment, the mode transformation submodule uses the following formula for coordinate transformation: ;in, Represents the modal coordinate vector. The physical coordinate vector represents the joint angle, and T represents the modal matrix; the vibration-wear model uses the following formula to evaluate the degree of wear: Where W represents the degree of wear, v represents the vibration amplitude, k represents the wear coefficient determined experimentally, C represents the initial wear constant determined experimentally, t represents time, and τ represents the integral variable. By introducing two specific mathematical formulas, the mathematical foundation for the core algorithm of the system is provided. The first formula ( The function of the second formula is to transform physical observations into modal space, which is the theoretical premise and computational tool for achieving precise independent vibration control. The function of this system is to establish a quantifiable vibration-wear mapping model, which transforms the abstract degree of wear into a calculable quantity based on measured vibration data, providing an objective and continuous quantitative basis for all subsequent wear assessments, predictions and decisions.

[0041] In this embodiment, the vibration active suppression module also includes a feedback loop for real-time acquisition of vibration signals from the robotic arm. The vibration signals are converted into modal coordinates by a modal transformation submodule. A damping control submodule generates suppression signals based on the modal coordinates and feeds them back to the motor synchronization control unit to adjust the synchronization drive commands. The system also includes a sensor array comprising encoders, accelerometers, and force sensors to monitor joint position, velocity, and acceleration, and input the data to the vibration active suppression module and the wear assessment and response module. The damping control submodule designs a proportional-derivative controller for each modal coordinate to increase system damping and reduce vibration amplitude. The modal recognition submodule determines the order and frequency range of the vibration modes through frequency response analysis to ensure the accuracy of the modal matrix. The system further includes a calibration unit for calibrating the modal matrix and vibration-wear model parameters every 24 hours to adapt to changes in robot structure or environmental factors. This setup establishes the system's real-time perception and closed-loop control capabilities. The sensor array, acting as the system's "sensors," provides comprehensive real-time data. The feedback loop utilizes this data to form a closed loop of "vibration sensing - modal transformation - generation of suppression signals - adjustment of control commands," enabling the system to dynamically respond to and suppress vibration. The calibration unit serves as the system's "adaptive mechanism," ensuring that the accuracy of the core models (modal matrix, wear model) does not decrease over time or with environmental changes through periodic calibration, thus guaranteeing the long-term reliability of the system.

[0042] In this embodiment, the modal matrix of the modal transformation submodule is obtained through eigenvalue decomposition based on the mass matrix and stiffness matrix of the robot structure, ensuring the orthogonality between modal coordinates. The independent damping controller of the damping control submodule includes modal mass parameters, modal stiffness parameters, and modal damping parameters, and vibration suppression is achieved by adjusting these parameters. The system also includes an adaptive control unit connected to the damping control submodule, which dynamically adjusts the damping controller parameters according to real-time vibration data to cope with vibration changes under different working conditions. The vibration active suppression module and the motor synchronization control unit are integrated in the same processor, and parallel calculation of synchronization control and vibration suppression is achieved through multi-threaded processing. The data from the sensor array is processed by Kalman filtering to remove noise before being input to the modal transformation submodule. This setup ensures the mathematical completeness and optimality of the modal transformation through eigenvalue decomposition; the adaptive control unit enables dynamic adjustment of damping parameters to adapt to different working conditions, improving the robustness of the system; integration into the same processor and multi-threaded calculation optimizes system resources and ensures the real-time performance of complex algorithms; and Kalman filtering improves the quality of the input signal, providing a "clean" data foundation for subsequent precise control.

[0043] In this embodiment, the state observer of the wear assessment and response module uses a Kalman filter to estimate the internal state of the system from the vibration signal and outputs the vibration amplitude and frequency as input to the vibration-wear model. The vibration-wear model is trained based on historical wear data and uses a linear regression method to establish the relationship between vibration and wear. The equivalent replacement strategy in the response strategy redistributes the joint motion intensity through a gradient descent optimization algorithm to ensure that the robot end effector reaches the target position while minimizing the load on the target joint. The deactivation replacement strategy calculates the motion trajectory of the replacement joint through inverse kinematics when the target joint is deactivated. If it cannot be replaced, an audible and visual alarm is triggered and maintenance personnel are notified. The system also includes a database to store historical vibration data, wear records, and control strategy execution logs to support the analysis of the prediction module. This setup employs a Kalman filter as the state observer, enabling it to accurately "capture" vibration states from noise; a linear regression method ensures the vibration-wear model is both accurate and computationally efficient; an equivalent replacement strategy is executed via gradient descent, allowing for optimal load redistribution; and inverse kinematics calculations and audible / visual alarms provide a feasible technical path and clear safety warnings for disabling the replacement strategy, ensuring the integrity and security of strategy execution. The database serves as the system's "memory," accumulating data assets for analysis and prediction.

[0044] In this embodiment, the prediction module uses an autoregressive integral moving average model to predict future wear trends based on a vibration-wear model and historical records, and generates an early warning signal; when the prediction indicates that the wear degree of the target joint will exceed the threshold W... th At the same time, the prediction module triggers workload adjustment in advance, allocating 30% of the task of the target joint to other joints, and updates the synchronous drive command through the motor synchronization control unit; the system also includes a user interface for setting preset intervals [W min W max Threshold W th The system displays wear assessment results and prediction information, along with corresponding strategy parameters. The priority of the wear assessment and response strategies is as follows: first, apply an equivalent replacement strategy; if this is not feasible, apply a discontinued replacement strategy, while ensuring the overall motion accuracy and stability of the robot. The state observer design considers system noise and uncertainty, improving the accuracy of vibration state estimation through feedback correction. This setup clarifies the implementation mechanism of prediction and decision-making functions. An autoregressive integral moving average model is used to extract patterns from historical data, achieving accurate prediction of future wear trends and serving as an "early warning" function. When a risk is predicted, the system proactively intervenes by quantitatively allocating tasks and updating drive instructions, realizing a closed loop from "prediction" to "execution." The user interface provides a channel for human-machine interaction, allowing users to customize strategies and monitor system status. Clear strategy priorities ensure the logicality and reliability of the system's decisions under various complex conditions.

[0045] In this embodiment, the motor synchronization control unit adopts a master-slave control structure to achieve phase and speed synchronization of multiple joint motors; the damping control submodule of the vibration active suppression module applies modal damping ratio adjustment in the modal space to suppress vibrations in the frequency range of 10Hz to 100Hz; the system also includes an energy management module to monitor the energy consumption of joint motors and optimize energy allocation when implementing vibration suppression and wear response strategies; the modal recognition submodule supports online updates and reconstructs the modal matrix through real-time vibration data to adapt to changes in the robot's dynamic load; the vibration-wear model of the wear assessment and response module is verified monthly by experimental data to ensure assessment accuracy; the prediction results of the prediction module are used to generate maintenance plans and automatically schedule maintenance resources. The master-slave control structure provides a stable and reliable foundation for synchronization control. Limiting the vibration suppression frequency range (10Hz-100Hz) makes the functional objectives more explicit and optimized. The energy management module achieves core functions while also considering energy efficiency optimization. The online updating of the modal matrix and the monthly verification of the wear model together constitute a continuous self-optimization mechanism for the system model, ensuring its ability to adapt to dynamic loads and maintain high accuracy over a long period. Automatically generated maintenance plans directly translate predictive information into executable maintenance instructions, improving management efficiency.

[0046] In this embodiment, the system also includes a safety protection module connected to the wear assessment and response module. This module is used to urgently stop the robot's movement and activate a backup control mode when abnormal wear or predicted failure is detected. The output of the motor synchronization control unit drives the joint motors through pulse width modulation, while integrating vibration suppression signals as compensation. The independent damping controller of the damping control submodule is designed based on modal frequency and damping ratio requirements, and its effectiveness is verified through simulation. The vibration active suppression module shares a data bus with the wear assessment and response module to achieve high-speed data exchange. The system supports Ethernet communication for remote monitoring and control, and uploads wear data to an external cloud platform for big data analysis. The coordinate transformation process of the modal transformation submodule uses a field-programmable gate array (FPGA) to accelerate matrix operations, thereby improving real-time performance. The safety protection module acts as a "safety guardian," capable of emergency braking and activating backup plans when serious anomalies are detected, ensuring the safety of personnel and equipment. The use of FPGA to accelerate matrix operations directly improves the core performance of the system in handling complex calculations, meeting high real-time requirements. The Ethernet communication and cloud platform connectivity extend the stand-alone system into an IoT node capable of remote monitoring and big data analytics, laying the foundation for more advanced global optimization and intelligent analysis.

[0047] In this embodiment, the preset range [W] of the wear assessment and response module min W maxThe system is customized according to robot type and working environment, and its optimal values ​​are determined through 1000 hours of continuous experimentation. The equivalent replacement strategy optimizes joint motion intensity distribution using gradient descent while ensuring operational objectives. The deactivation replacement strategy considers joint redundancy and uses a kinematics solver to generate alternative paths when deactivating target joints. The prediction module's prediction cycle is set to 1 hour to adapt to different task requirements. The system also includes diagnostic tools to analyze deviations in the vibration-wear model and provide calibration suggestions. The motor synchronization control unit, vibration active suppression module, and wear assessment and response module are encapsulated in an embedded system, ensuring high reliability and real-time response capabilities. This setup, with key parameters determined through 1000 hours of continuous experimentation, ensures the scientific and optimal nature of the system configuration. Gradient descent and kinematics solvers provide specific and reliable computational tools for the response strategies. Setting a 1-hour prediction cycle balances real-time performance and computational load. The diagnostic tools provide the system's self-diagnosis and calibration suggestions. Finally, encapsulating the core modules in an embedded system ensures high reliability and real-time response capabilities in industrial environments from a hardware perspective.

[0048] In this embodiment, the system also includes a load adaptation module for adjusting vibration suppression and wear assessment parameters based on changes in the robotic arm's load. The damping control submodule employs active damping technology, using piezoelectric actuators to achieve physical vibration suppression. The state observer of the wear assessment and response module works in conjunction with the modal transformation submodule of the active vibration suppression module to improve vibration capture accuracy. The prediction module integrates a neural network algorithm to learn wear patterns and optimize the prediction model. The motor synchronization control unit supports the CANopen synchronization protocol, ensuring compatibility with motors from different brands. The system's modular design allows users to add or remove functional modules as needed. The load adaptation module enables the system to sense and adapt to load changes, expanding its application scope. The use of piezoelectric actuators for physical vibration suppression achieves mechatronic active damping. The synergy between the state observer and modal transformation improves the overall accuracy of vibration capture. The introduction of neural network algorithms enables the prediction model to self-learn and handle complex nonlinear modes, making it more intelligent. Support for the CANopen protocol enhances the system's interoperability with different hardware, and the modular design provides the system with good scalability and flexibility.

[0049] In this embodiment, the system adopts a distributed architecture. The motor synchronization control unit, vibration active suppression module, wear assessment and response module, and prediction module are connected via a controller area network (CLAN) bus to achieve data synchronization and command coordination. The modal recognition submodule of the vibration active suppression module supports multimodal recognition, handling vibration modes from first to fifth order. The wear assessment and response module's response strategy includes dynamic weight adjustment, allocating motion intensity based on joint health status in the equivalent replacement strategy. The prediction results from the prediction module are used to optimize robot task scheduling and extend equipment life. The distributed architecture and CLAN bus connection lay the physical foundation for the system's high reliability and scalability. Extending the vibration modes to first to fifth order indicates that the system can handle more complex vibration conditions. Dynamic weight adjustment makes the execution of the equivalent replacement strategy more refined and intelligent. Ultimately, the system's function focuses on optimizing robot task scheduling and extending equipment life, clearly demonstrating its superior industrial value.

[0050] This invention achieves significant synergistic benefits by deeply integrating motor synchronous control, active vibration suppression, wear assessment and response, and predictive maintenance. First, through modal coordinate transformation and decoupled independent damping control, the system can accurately and efficiently suppress multi-order elastic vibrations generated by the robotic arm during high-speed movement, significantly reducing vibration amplitude and thus greatly improving the positioning accuracy and motion stability of the end effector. Second, it innovatively establishes a vibration-wear model based on a state observer, enabling real-time, quantitative assessment and prediction of joint wear. Based on this, it intelligently executes response strategies such as equivalent replacement or decommissioning replacement, extending equipment lifespan and achieving a shift from passive maintenance to predictive maintenance, effectively reducing unplanned downtime and lowering maintenance costs. Finally, the integrated adaptive calibration, energy management, and safety protection modules further ensure its long-term reliability, energy efficiency, and safety under complex working conditions. In summary, this invention fundamentally solves the problem of the disconnect between vibration control and lifespan management in high-precision robot systems, achieving simultaneous optimization of motion accuracy, equipment lifespan, and overall operational efficiency.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

Claims

1. A robot joint motor synchronous control system, characterized in that, It includes a motor synchronization control unit, a vibration active suppression module, a wear assessment and response module, and a prediction module; The motor synchronization control unit generates synchronized drive commands for the robot joint motors to achieve coordinated movement of multiple joints; the vibration active suppression module suppresses the elastic vibration of the robot arm while calculating the synchronized drive commands; the wear assessment and response module captures the vibration state as the internal state of the system through a state observer, assesses the wear degree of each joint of the robot arm based on a vibration-wear model, and adopts different response strategies according to the wear degree, including when the wear degree of the target joint is within a preset range [W]. min W max When the wear level of the target joint is less than the minimum value W in the preset range, an equivalent replacement strategy is adopted to reduce the motion intensity of the target joint and increase the motion intensity of other joints. min The current control scheme is maintained until the wear degree of the target joint exceeds the maximum value W of the preset range. max When necessary, a shutdown and replacement strategy is adopted to deactivate the target joint and replace it with another joint or arrange for maintenance; the prediction module is used to predict the wear degree of each joint of the robotic arm based on the vibration-wear model and historical records, and to determine when the target joint cannot be deactivated if the wear degree exceeds the threshold W. th Adjust the workload allocation in advance when the work is to be completed.

2. The robot joint motor synchronous control system according to claim 1, characterized in that, The active vibration suppression module includes a mode recognition submodule, a mode transformation submodule, and a damping control submodule, wherein: The modal recognition submodule identifies the first-order and second-order vibration modes of the robot structure through experiments or simulations. The modal transformation submodule is used to transform the actual physical coordinates into modal coordinates through the modal matrix, so that each modal coordinate represents an independent vibration mode; The damping control submodule is used to design an independent damping controller for each mode in the modal space to specifically suppress vibrations at specific frequencies.

3. The robot joint motor synchronous control system according to claim 2, characterized in that, The modality transformation submodule uses the following formula for coordinate transformation: ； in, Represents the modal coordinate vector. The physical coordinate vector represents the joint angle, and T represents the modal matrix. The vibration-wear model uses the following formula to evaluate the degree of wear: ； Where W represents the degree of wear, v represents the vibration amplitude, k represents the wear coefficient determined by experiments, C represents the initial wear constant determined by experiments, t represents time, and τ represents the integral variable.

4. A robot joint motor synchronous control system according to claim 3, characterized in that, The vibration active suppression module also includes a feedback loop for real-time acquisition of the vibration signal of the robotic arm, and the vibration signal is converted into modal coordinates by the modal transformation submodule. The damping control submodule generates a suppression signal based on the modal coordinates and feeds it back to the motor synchronization control unit to adjust the synchronization drive command. The system also includes a sensor array comprising an encoder, an accelerometer, and a force sensor, for monitoring joint position, velocity, and acceleration, and inputting the data to the vibration active suppression module and the wear assessment and response module; The damping control submodule is designed with a proportional-derivative controller for each modal coordinate to increase system damping and reduce vibration amplitude; The modal identification submodule determines the order and frequency range of the vibration modes through frequency response analysis, ensuring the accuracy of the modal matrix; The system further includes a calibration unit for calibrating the modal matrix and vibration-wear model parameters every 24 hours to adapt to changes in robot structure or the influence of environmental factors.

5. A robot joint motor synchronous control system according to claim 4, characterized in that, The modal transformation submodule obtains its modal matrix based on the robot structure's mass matrix and stiffness matrix through eigenvalue decomposition, ensuring the orthogonality between modal coordinates. The independent damping controller of the damping control submodule includes modal mass parameters, modal stiffness parameters, and modal damping parameters, and vibration suppression is achieved by adjusting these parameters. The system also includes an adaptive control unit connected to the damping control submodule, used to dynamically adjust the damping controller parameters according to real-time vibration data to cope with vibration changes under different working conditions; the vibration active suppression module and the motor synchronization control unit are integrated in the same processor, and parallel calculation of synchronization control and vibration suppression is achieved through multi-threaded processing; the data of the sensor array is processed by Kalman filtering to remove noise before being input to the mode transformation submodule.

6. A robot joint motor synchronous control system according to claim 5, characterized in that, The wear assessment and response module's state observer uses a Kalman filter to estimate the system's internal state from vibration signals and outputs vibration amplitude and frequency as input to the vibration-wear model. This vibration-wear model is trained based on historical wear data and uses linear regression to establish the relationship between vibration and wear. The equivalent replacement strategy in the response strategy redistributes joint motion intensity using a gradient descent optimization algorithm to ensure the robot's end effector reaches the target position while minimizing the load on the target joint. The deactivation replacement strategy calculates the motion trajectory of the replacement joint using inverse kinematics when the target joint is deactivated; if replacement is not possible, it triggers an audible and visual alarm and notifies maintenance personnel. The system also includes a database for storing historical vibration data, wear records, and control strategy execution logs to support analysis by the prediction module.

7. A robot joint motor synchronous control system according to claim 6, characterized in that, The prediction module employs an autoregressive integral moving average model, based on a vibration-wear model and historical data, to predict future wear trends and generate early warning signals. When the prediction indicates that the wear level of the target joint will exceed a threshold W... th At that time, the prediction module triggers workload adjustment in advance, allocating 30% of the task of the target joint to other joints, and updates the synchronization drive command through the motor synchronization control unit; The system also includes a user interface for setting preset intervals [W] min W max Threshold W th The wear assessment and response module provides parameters for the wear assessment and response strategies, and displays wear assessment results and prediction information. The priority of the response strategies in the wear assessment and response module is as follows: first, apply the equivalent replacement strategy; if this is not feasible, apply the discontinuation replacement strategy, while ensuring the overall motion accuracy and stability of the robot. The design of the state observer takes into account system noise and uncertainty, and improves the accuracy of vibration state estimation through feedback correction.

8. A robot joint motor synchronous control system according to claim 7, characterized in that, The motor synchronization control unit adopts a master-slave control structure to achieve phase synchronization and speed synchronization of multiple joint motors; the damping control submodule of the vibration active suppression module applies modal damping ratio adjustment in the modal space to suppress vibration in the frequency range of 10Hz to 100Hz. The system also includes an energy management module for monitoring joint motor energy consumption and optimizing energy allocation when implementing vibration suppression and wear response strategies; the modal recognition submodule supports online updates and reconstructs the modal matrix through real-time vibration data to adapt to changes in the robot's dynamic load; the vibration-wear model of the wear assessment and response module is validated monthly using experimental data to ensure assessment accuracy; the prediction results of the prediction module are used to generate maintenance plans and automatically schedule maintenance resources.

9. A robot joint motor synchronous control system according to claim 8, characterized in that, The system also includes a safety protection module connected to the wear assessment and response module, used to urgently stop the robot's movement and activate a backup control mode when abnormal wear or predicted failure is detected; the output of the motor synchronization control unit drives the joint motor through pulse width modulation, and integrates a vibration suppression signal as a compensation term; the independent damping controller of the damping control submodule is designed based on modal frequency and damping ratio requirements, and its effectiveness is verified through simulation; the vibration active suppression module shares a data bus with the wear assessment and response module to achieve high-speed data exchange; the system supports Ethernet communication for remote monitoring and control, and uploads wear data to an external cloud platform for big data analysis; the coordinate transformation process of the modal transformation submodule uses a field-programmable gate array to accelerate matrix operations and improve real-time performance.

10. A robot joint motor synchronous control system according to claim 9, characterized in that, The preset range [W] of the wear assessment and response module min W max The system is customized according to robot type and working environment, and the optimal value is determined through 1000 hours of continuous experiments. The equivalent replacement strategy optimizes the joint motion intensity distribution through gradient descent while ensuring the operational purpose. The deactivation replacement strategy considers joint redundancy when deactivating the target joint and uses a kinematic solver to generate an alternative path. The prediction module's prediction cycle is set to 1 hour to adapt to different task requirements. The system also includes diagnostic tools for analyzing the deviation of the vibration-wear model and providing calibration suggestions. The motor synchronization control unit, vibration active suppression module, and wear assessment and response module are encapsulated in an embedded system, which has high reliability and real-time response capability.

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