Tunnel robot instruction execution and fault self-recovery method

Abstract

The invention discloses a tunnel robot instruction execution and fault self-recovery method, and relates to the technical field of tunnel robot cooperative control and fault self-recovery, and the method comprises the steps: receiving a main control chip instruction packet, and carrying out the analysis of the instruction packet to obtain an instruction code and a data segment; driving an execution mechanism according to the instruction code and the data segment, and collecting operation parameters of a driving motor and transmitting the operation parameters back to the main control chip; continuously receiving the heartbeat data packet, resetting the timeout timer, and judging the fault type according to the state of the timeout timer and the operation information of the driving motor; and executing a differential recovery strategy according to the fault type, and waiting for the main control chip to re-issue an instruction after the fault is eliminated. According to the invention, automatic fault detection and recovery of the main control chip and the driving motor can be realized, manual intervention is not needed, the operation and maintenance cost is reduced, and continuous and stable operation of the tunnel robot in a severe environment is ensured.

Description

Technical Field

[0001] This invention relates to the field of collaborative control and fault self-recovery technology for tunnel robots, and in particular to a method for command execution and fault self-recovery of tunnel robots. Background Technology

[0002] In tunnel robot operations, the main control chip needs to handle complex computational functions such as path planning, data fusion, and task scheduling, while the execution layer requires rapid response and stable reliability. The tunnel environment presents harsh conditions such as electromagnetic interference, dust, and extreme temperatures, making the main control chip prone to malfunctions like jamming or unresponsiveness. Existing technologies suffer from two core problems: in master-slave chip collaborative architectures, the execution layer lacks an efficient and precise execution mechanism for responding to master chip commands, affecting the continuity of robot operation; and when critical hardware such as the main control chip or motors malfunction, there is a lack of autonomous recovery solutions without human intervention, requiring significant manpower and resources for on-site troubleshooting, and sometimes even road closures, leading to operational interruptions, soaring maintenance costs, and severely impacting the tunnel robot's continuous operation. Therefore, a technical solution is needed that can ensure efficient response of the execution layer to master control chip commands while also enabling autonomous fault recovery.

[0003] There are two typical implementation schemes in the existing technology. The first is a single-chip direct control scheme. This scheme uses a single master control chip to integrate all functions and connects directly to the robot actuator. The master control chip performs complex tasks such as path planning and data processing, and directly outputs control commands to drive the actuator, without the participation of an independent slave control chip. The second is a dual-chip scheme that relies on external circuit reset. This scheme adds an independent external reset module to the dual-chip architecture. The external reset module monitors parameters such as the voltage and clock signal of the master control chip through hardware circuitry. When an abnormality is detected, it triggers the master control chip to reset. The slave control chip only undertakes the execution function and does not participate in fault monitoring and reset control.

[0004] However, the aforementioned existing technologies have significant drawbacks. In the single-chip direct control scheme, the single chip is overloaded, and conflicts arise between complex calculations and real-time execution instructions, leading to control response delays and affecting the robot's operational accuracy. There is no independent fault monitoring unit; once the main control chip freezes, there is no autonomous recovery method, requiring manual power-off restart or on-site maintenance. Anti-interference capabilities are weak; a single chip failure directly causes the entire robot to stop, and there is no redundancy design. In the dual-chip scheme relying on external circuit reset, the external reset module can only monitor abnormal hardware parameters and cannot identify common faults such as "software freezes" in the main control chip, limiting reset trigger scenarios. The external module increases hardware complexity and has weak resistance to tunnel electromagnetic interference and dust, making it prone to self-failure leading to reset failure. The fixed reset logic cannot be linked with the execution status of the slave control chip, potentially causing malfunctions in the actuator during reset, posing a safety risk.

[0005] In summary, existing technologies cannot simultaneously meet the requirements of tunnel robots for efficient command execution and autonomous fault recovery, exhibiting serious shortcomings in response speed, fault coverage, autonomous recovery capability, operational safety, and adaptability to harsh environments. A new technical solution is urgently needed to identify abnormal states of devices such as the main control chip and motors in real time through a reliable fault detection mechanism, and to achieve efficient command execution through master-slave dual-chip collaborative control, enabling rapid restart and recovery without manual intervention, thus ensuring the safe, stable, and continuous operation of tunnel robots in harsh environments. Summary of the Invention

[0006] The technical problem this invention aims to solve is to address the shortcomings of existing technologies, specifically the low instruction execution efficiency in master-slave chip collaborative control of tunnel robots, the lack of autonomous recovery capability after failure of the master control chip and motor leading to high maintenance costs and operation interruptions. Specifically, this invention provides a method for instruction execution and fault self-recovery in tunnel robots, as detailed below: 1) In a first aspect, the present invention provides a method for instruction execution and fault self-recovery of a tunnel robot, the specific technical solution of which is as follows: S1, Receive instruction packets from the main control chip, and parse the instruction packets to obtain instruction codes and data segments; S2, according to the instruction code and the data segment, drive the actuator to perform corresponding operations, and after the execution is completed, collect the operating parameters of the drive motor in the actuator, package the operating parameters into a feedback data packet and send it back to the main control chip; S3, during the operation of the driven actuator, continuously receive heartbeat data packets from the main control chip; upon receiving the heartbeat data packet, reset the built-in timeout timer, and determine the fault type based on the state of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition; S4. Execute a differentiated recovery strategy according to the fault type, and wait for the main control chip to reissue instructions to resume operation after troubleshooting.

[0007] The beneficial effects of the tunnel robot command execution and fault self-recovery method provided by this invention are as follows: By receiving instruction packets from the main control chip, parsing instruction codes and data segments, and driving the actuator, while simultaneously collecting drive motor operating parameters after execution to form feedback data packets for transmission, a closed-loop control mechanism of instruction issuance, execution, and feedback is constructed, significantly improving instruction response efficiency and operational consistency. Utilizing a mechanism that continuously receives heartbeat data packets and triggers a timeout timer reset, combined with real-time acquisition of drive motor operating information, synchronous monitoring and accurate fault type determination of both the main control chip and drive motor are achieved, solving the problems of incomplete fault detection coverage and inability to identify software freezes in existing technologies. Differentiated recovery strategies are implemented based on fault type. When the main control chip fails, the intelligent power management module performs a power-off restart of the power supply branch for recovery. When the drive motor fails, the drive signal is first cut off, then power is cut off and restarted, and a clear command is output, achieving autonomous recovery for different fault sources without manual intervention, significantly reducing maintenance costs and the risk of operational interruption. After fault recovery, operation can only resume after the main control chip issues a new instruction, ensuring a safe and orderly restart after fault resolution, avoiding the risk of malfunction, and guaranteeing the tunnel robot's continuous and stable operation in harsh environments.

[0008] Based on the above solution, the present invention can be further improved as follows.

[0009] Furthermore, the step of determining the fault type based on the status of the built-in timeout timer and the operating information of the drive motor includes: When the timeout timer does not receive the heartbeat data packet within the set timeout threshold, it is determined that the main control chip has malfunctioned; When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold, it is determined that the drive motor has a first type of fault. When the fluctuation range of the rotation speed data exceeds the third preset threshold and the instruction code remains unchanged, it is determined that the drive motor has a second type of fault.

[0010] Furthermore, the step of executing a differentiated recovery strategy based on the fault type includes: When the main control chip malfunctions, the power supply branch of the main control chip is cut off. After a first delay, the power supply branch of the main control chip is restored, and the main control chip is allowed to restart and reissue instructions to resume operation.

[0011] Furthermore, the step of executing a differentiated recovery strategy based on the fault type includes: When the drive motor experiences a first-class or second-class fault, the drive signal of the drive motor is cut off, the power supply branch of the drive motor is cut off, and after a second delay time, the power supply branch of the motor is restored and a jog reverse command is output to clear the obstruction. When the re-collected operating information returns to normal, a recovery completion message is fed back.

[0012] Furthermore, it also includes: During fault diagnosis and recovery, the drive signal of the actuator is simultaneously cut off, the robot posture is locked to prevent the fault from spreading, and after recovery, the main control chip is waited for to reissue instructions to resume operation.

[0013] 2) In a second aspect, the present invention also provides a tunnel robot instruction execution and fault self-recovery system, the specific technical solution of which is as follows: including an instruction processing module, an execution feedback module, a status monitoring module and a fault recovery module; The instruction processing module is used to receive instruction packets from the main control chip and parse the instruction packets to obtain instruction codes and data segments. The execution feedback module is used to drive the actuator to perform corresponding operations according to the instruction code and the data segment. After the execution is completed, it collects the operating parameters of the drive motor in the actuator, packages the operating parameters into a feedback data packet and sends it back to the main control chip. The status monitoring module is used to continuously receive heartbeat data packets from the main control chip during the operation of the driven actuator; when the heartbeat data packet is received, the built-in timeout timer is reset, and the fault type is determined according to the status of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition. The fault recovery module is used to execute a differentiated recovery strategy according to the fault type, and wait for the main control chip to reissue instructions to resume operation after troubleshooting.

[0014] Based on the above solution, the present invention can be further improved as follows.

[0015] Furthermore, the step of determining the fault type based on the status of the built-in timeout timer and the operating information of the drive motor includes: When the timeout timer does not receive the heartbeat data packet within the set timeout threshold, it is determined that the main control chip has malfunctioned; When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold, it is determined that the drive motor has a first type of fault. When the fluctuation range of the rotation speed data exceeds the third preset threshold and the instruction code remains unchanged, it is determined that the drive motor has a second type of fault.

[0016] Furthermore, the step of executing a differentiated recovery strategy based on the fault type includes: When the main control chip malfunctions, the power supply branch of the main control chip is cut off. After a first delay, the power supply branch of the main control chip is restored, and the main control chip is allowed to restart and reissue instructions to resume operation.

[0017] Furthermore, the step of executing a differentiated recovery strategy based on the fault type includes: When the drive motor experiences a first-class or second-class fault, the drive signal of the drive motor is cut off, the power supply branch of the drive motor is cut off, and after a second delay time, the power supply branch of the motor is restored and a jog reverse command is output to clear the obstruction. When the re-collected operating information returns to normal, a recovery completion message is fed back.

[0018] Furthermore, it also includes: During fault diagnosis and recovery, the drive signal of the actuator is simultaneously cut off, the robot posture is locked to prevent the fault from spreading, and after recovery, the main control chip is waited for to reissue instructions to resume operation.

[0019] 3) In a third aspect, the present invention also provides a computer device, the computer device including a processor coupled to a memory, the memory storing at least one computer program, the at least one computer program being loaded and executed by the processor to enable the computer device to implement any of the above methods.

[0020] 4) In a fourth aspect, the present invention also provides a computer-readable storage medium storing at least one computer program, which is loaded and executed by a processor to enable a computer to implement any of the above methods.

[0021] It should be noted that the beneficial effects of the technical solutions of the second to fourth aspects of the present invention and their corresponding possible implementations can be found in the above description of the technical effects of the first aspect and its corresponding possible implementations, and will not be repeated here. Attached Figure Description

[0022] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a flowchart illustrating the steps of a tunnel robot instruction execution and fault self-recovery method according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structural relationships of a tunnel robot instruction execution and fault self-recovery method according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the intelligent power management module structure of a tunnel robot instruction execution and fault self-recovery method according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the master-slave chip instruction execution flow of a tunnel robot instruction execution and fault self-recovery method according to an embodiment of the present invention; Figure 5This is a schematic diagram of the fault self-recovery process of a tunnel robot instruction execution and fault self-recovery method according to an embodiment of the present invention; Figure 6 This is a structural block diagram of a computer device according to an embodiment of the present invention. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0024] like Figure 1 As shown in the figure, a method for command execution and fault self-recovery of a tunnel robot according to an embodiment of the present invention includes the following steps: S1 receives instruction packets from the main control chip, parses the instruction packets to obtain instruction codes and data segments; S2 drives the actuator to perform corresponding operations according to the instruction code and data segment. After the execution is completed, it collects the operating parameters of the drive motor in the actuator, packages the operating parameters into a feedback data packet and sends it back to the main control chip. S3 continuously receives heartbeat data packets from the main control chip during the operation of the driven actuator; upon receiving a heartbeat data packet, it resets the built-in timeout timer and determines the fault type based on the status of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition. S4 executes a differentiated recovery strategy based on the fault type, and waits for the main control chip to reissue instructions to resume operation after troubleshooting.

[0025] The beneficial effects of the tunnel robot command execution and fault self-recovery method provided by this invention are as follows: By receiving instruction packets from the main control chip, parsing instruction codes and data segments, and driving the actuator, while simultaneously collecting drive motor operating parameters after execution to form feedback data packets for transmission, a closed-loop control mechanism of instruction issuance, execution, and feedback is constructed, significantly improving instruction response efficiency and operational consistency. Utilizing a mechanism that continuously receives heartbeat data packets and triggers a timeout timer reset, combined with real-time acquisition of drive motor operating information, synchronous monitoring and accurate fault type determination of both the main control chip and drive motor are achieved, solving the problems of incomplete fault detection coverage and inability to identify software freezes in existing technologies. Differentiated recovery strategies are implemented based on fault type. When the main control chip fails, the intelligent power management module performs a power-off restart of the power supply branch for recovery. When the drive motor fails, the drive signal is first cut off, then power is cut off and restarted, and a clear command is output, achieving autonomous recovery for different fault sources without manual intervention, significantly reducing maintenance costs and the risk of operational interruption. After fault recovery, operation can only resume after the main control chip issues a new instruction, ensuring a safe and orderly restart after fault resolution, avoiding the risk of malfunction, and guaranteeing the tunnel robot's continuous and stable operation in harsh environments.

[0026] The tunnel robot command execution and fault self-recovery method proposed in this solution refers to a technical solution applied to robot control systems in tunnel operating environments. It achieves efficient command reception and parsing by using the control chip as an independent monitoring center between the main control and execution layers, enabling drive control of the actuators and autonomous fault detection and recovery for both the main control chip and the drive motor. By constructing a closed-loop control mechanism for command issuance, execution, and feedback, combined with heartbeat timeout detection and joint monitoring of motor operating parameters, fault determination is achieved. Differentiated power restart recovery strategies are implemented based on different fault types, ultimately ensuring the continuous and stable operation of the tunnel robot in harsh environments.

[0027] Figure 2 A schematic diagram of the structural relationships is shown below, such as Figure 2 As shown, the required structures to support the operation of this solution include: RK3568 master control module, STM32 slave control module, intelligent power management module, actuator module, and anti-interference communication module.

[0028] RK3568 main control module (main control chip): The core is a quad-core Cortex-A55 processor, which integrates a neural network acceleration unit. It is responsible for path planning, fusion of LiDAR and camera data, and complex calculations for task scheduling. It issues standardized instructions through the communication module and receives device status data fed back by STM32. It sends a heartbeat data packet containing its own operating status every 100ms.

[0029] STM32 Slave Control Module (Slave Control Chip): Utilizing an industrial-grade STM32F1 chip, it features high real-time performance. It is responsible for parsing the master control chip's instructions, driving the actuators, integrating a fault detection unit to monitor the master control chip's heartbeat signal in real time, and synchronously acquiring motor current and speed status parameters. It controls the switching of the intelligent power management module through general-purpose input / output (GPIO) pins.

[0030] Intelligent power management module: It includes two independent circuits: the main control chip power supply branch and the drive motor power supply branch. Figure 3 This is a schematic diagram of the intelligent power management module structure, such as... Figure 3 As shown, each power supply branch uses an N-channel metal-oxide-semiconductor field-effect transistor (MOSFET) connected in series as a controllable switch. The gate of the MOSFET is connected to the GPIO pin of the control chip. The control chip outputs high and low levels through the GPIO pin to control the conduction and cutoff of the MOSFET, thereby controlling the on / off state of the power supply branch. Each power supply branch is connected in parallel with a transient voltage suppressor (TVS) diode, model SMBJ5.0CA, to suppress surge interference in the power supply circuit. Each power supply branch is connected in parallel with a filter capacitor bank, consisting of a 100µF electrolytic capacitor and a 0.1µF ceramic capacitor, to filter out low-frequency and high-frequency noise. The drive motor power supply branch is connected in series with a 2-amp fuse to prevent overload and circuit burnout. The specific MOSFET used in this design is the IRF540N.

[0031] The actuator module consists of a drive motor (including an encoder), a sensor group (current sensor and speed sensor), and an actuator (pan-tilt unit). The drive motor is a brushless DC motor, and the sensor group collects the motor's operating parameters in real time and uploads them to the STM32 slave control module.

[0032] Anti-interference communication module: It adopts a combination structure of Universal Asynchronous Receiver / Transmitter (UART) interface and RS485 level conversion circuit (hereinafter referred to as RS485), with the communication baud rate set to 115200bps. The command packet adopts cyclic redundancy (CRC-16) check method to effectively resist command packet loss or bit error caused by tunnel electromagnetic interference.

[0033] It should be noted that, for ease of understanding, the technical terms used in this solution will be explained one by one, and will not be repeated hereafter: The main control chip refers to the central processing unit that undertakes core functions such as complex calculations and task scheduling for the tunnel robot. In this solution, the main control chip is the RK3568 main control module, specifically a quad-core Cortex-A55 processor chip with an integrated neural network acceleration unit. It is primarily responsible for complex calculations such as path planning, LiDAR and camera data fusion, and task scheduling. It also issues standardized commands to the slave control chips via a communication module and periodically sends heartbeat data packets containing its own operational status information. The main control chip achieves bidirectional data interaction with the slave control chips through an anti-interference communication module, forming the master control end in the master-slave dual-chip collaborative architecture.

[0034] Command packet: Refers to the control data unit packaged by the main control chip according to a custom standardized protocol. Its frame format is as follows: start byte 0xAA, instruction length 1 byte, instruction code 1 byte, data segment N bytes, CRC-16 checksum 2 bytes, and end byte 0x55. The command packet is used to carry the operation instructions issued by the main control chip and is transmitted to the slave control chip through the anti-interference communication module. After receiving it, the slave control chip needs to perform integrity verification and parsing to obtain the specific instruction code and data segment content.

[0035] Instruction code: This refers to the 1-byte encoded information in the instruction packet that identifies the specific operation type. In this scheme, instruction code 0x01 represents motor forward rotation, instruction code 0x02 represents motor reverse rotation, instruction code 0x03 represents reading motor status, and instruction code 0x04 represents actuator start / stop. The control chip determines the specific operation type that needs to be driven by the actuator by parsing the instruction code in the instruction packet, and then executes the corresponding control action according to the corresponding data segment content.

[0036] Data segment: This refers to the N-byte variable-length area in the instruction packet located after the instruction code and before the CRC-16 checksum. It carries the specific operation parameters corresponding to the instruction code. For example, the data segment of a motor forward rotation instruction includes the speed value (2 bytes) and the duration (2 bytes). After parsing the data segment from the control chip, the specific parameter values ​​are extracted for precise control of the actuator's operating state.

[0037] Actuator: This refers to the component module in the tunnel robot that directly performs physical actions. It consists of a drive motor (including an encoder), a sensor group (current sensor, speed sensor), and an actuator (gimbal). After receiving the drive signal sent from the control chip, the actuator performs the corresponding operation. During its operation, the sensor group collects operating parameters in real time and uploads them to the control chip, forming a key link in closed-loop control.

[0038] Drive motor: refers to the brushless DC motor that provides power output in the actuator, with an integrated encoder for real-time speed feedback. As the core power component of the actuator, the drive motor's operating status is monitored by current data collected by a current sensor and speed data collected by a speed sensor, which are then used by the control chip for fault detection and operational parameter feedback. This solution mainly describes the fault detection and recovery of a single drive motor; in practical applications, multiple motors can independently employ the same mechanism.

[0039] Operating parameters: These refer to a dynamic data set reflecting the operating status of the actuator and drive motor, including drive motor speed, drive motor current, and actuator status. After execution, the control chip collects operating parameters, packages them into a feedback data packet, and sends it back to the main control chip. Simultaneously, during fault detection, operating parameters are collected in real time as operating information for fault determination. After recovery, the effectiveness of the recovery is judged by whether the operating parameters have returned to normal.

[0040] Feedback data packet: This refers to the data unit formed by the control chip after the actuator completes its operation, packaging the collected operating parameters according to the same protocol format as the instruction packet (start byte, instruction length, instruction code, data segment, CRC-16 checksum, and end byte). The feedback data packet is transmitted back to the main control chip through the anti-interference communication module, forming a closed-loop control process of instruction issuance, execution, and feedback, enabling the main control chip to monitor the operating status of the actuator in real time.

[0041] Heartbeat data packets: These are data packets sent by the main control chip to the slave control chip at fixed time intervals (100 milliseconds in this solution) to indicate its own operating status. The instruction code is 0x00, and the data segment contains the CPU utilization and memory usage of the main control chip. Heartbeat data packets are used by the slave control chip to monitor whether the main control chip is operating normally. Each time the slave control chip receives a heartbeat data packet, it resets its built-in timeout timer. If the timeout timer does not receive a heartbeat data packet within the set timeout threshold, it determines that the main control chip has malfunctioned.

[0042] Timeout timer: This refers to a timing device internal to the control chip used to monitor the interval between heartbeat data packet receptions. The timer is reset when a heartbeat data packet is received from the control chip, starting from 0 again. In this solution, the timeout threshold is set to 200 milliseconds. If no new heartbeat data packet is received after 200 milliseconds, the control chip determines that the main control chip has malfunctioned.

[0043] Operational information refers to the data set reflecting the operating status of the drive motor, obtained in real time from the control chip. This includes the drive motor's current data, speed data, and the command status corresponding to the command code. Operational information serves as a crucial basis for fault diagnosis, used to determine whether the main control chip is faulty (by receiving status data via heartbeat packets) and whether the drive motor has experienced a Type I or Type II fault.

[0044] Fault Type: This refers to the different fault categories identified for the core components of the tunnel robot in this solution, specifically including main control chip faults, first-type drive motor faults (stall faults), and second-type drive motor faults (abnormal faults). The fault type determination is based on the joint analysis results of the timeout timer status and drive motor operating information, and different fault types trigger corresponding differentiated recovery strategies.

[0045] Differentiated recovery strategies refer to different recovery processing schemes executed based on the determined fault type. Specifically, these include master control chip recovery strategies for main control chip faults (cutting off the main control chip power supply branch, restoring power supply after a delay, and waiting for restart) and motor recovery strategies for drive motor faults (cutting off the drive signal, cutting off the motor power supply branch, restoring power supply after a delay, and outputting a jog reverse command to clear the obstruction). Differentiated recovery strategies can take targeted recovery measures for different fault sources, improving recovery efficiency and success rate.

[0046] Current data: refers to the operating current value of the drive motor collected in real time by a current sensor, used to reflect the motor load status. In this scheme, a first preset threshold is set (1.5 times the rated current value). When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold (10% of the rated speed value), the drive motor is determined to have a first-type fault (stall fault).

[0047] Speed ​​data: refers to the rotational speed value of the drive motor collected in real time by a speed sensor or motor encoder, used to reflect the motor's operating speed. In this scheme, a second preset threshold (10% of the rated speed value) and a third preset threshold (fluctuation range of 20%) are set. Speed ​​data and current data are used together for the first type of fault determination, and the fluctuation range of speed data and command status are used together for the second type of fault determination.

[0048] First preset threshold: refers to the current critical value preset from the control chip to determine whether the drive motor is overloaded. In this scheme, it is set to 1.5 times the rated current value of the drive motor.

[0049] The second preset threshold: refers to the speed threshold preset in the control chip to determine whether the drive motor is stalling. In this scheme, it is set to 10% of the rated speed of the drive motor.

[0050] The first type of fault refers to the drive motor stall fault defined in this solution. The judgment condition is that the current data exceeds the first preset threshold (1.5 times the rated current value) and the speed data is lower than the second preset threshold (10% of the rated speed value). The first type of fault is a type of fault in which the motor cannot rotate normally due to mechanical jamming. The recovery strategy includes cutting off the drive signal, cutting off the motor power supply, delaying restart, and outputting a jog reverse command to clear the jamming.

[0051] The third preset threshold: refers to the speed fluctuation threshold preset in the control chip to determine whether the drive motor is operating abnormally. In this scheme, the speed fluctuation amplitude is set to 20%.

[0052] The second type of fault refers to the abnormal fault of the drive motor defined in this solution. The judgment condition is that the fluctuation range of the speed data exceeds the third preset threshold (20%) and the command code remains unchanged. The second type of fault belongs to the fault type of unstable motor operation and abnormal speed fluctuation. The recovery strategy is the same as that of the first type of fault.

[0053] Power supply branches: These refer to the circuit loops in the intelligent power management module that independently supply power to different components, including two independent circuits: the main control chip power supply branch and the motor power supply branch. Each power supply branch uses a series MOSFET as a controllable switch. The control chip controls the conduction and cutoff of the MOSFET through GPIO pins to achieve on / off control of the corresponding power supply branch, thereby realizing the power-off restart operation during fault recovery.

[0054] The first delay time refers to the time interval during which the slave control chip waits for the circuit to discharge and reset after cutting off the power supply to the main control chip. This solution sets it to 500 milliseconds. The first delay time ensures that the main control chip is completely powered off and its internal capacitors have discharged completely, thereby ensuring the effectiveness of the restart and recovery.

[0055] Drive signals: These are the electrical signals sent from the control chip to the drive motor in the actuator to control its operation, including speed control signals and direction control signals. When a drive motor malfunctions, the control chip first cuts off the drive signals to stop the motor and prevent the fault from worsening. Then, it cuts off the motor's power supply branch to restart and restore operation.

[0056] The second delay time refers to the time interval between the control chip cutting off the motor power supply branch and waiting for the mechanical inertia to be eliminated and the circuit to reset. This solution sets it to 300 milliseconds. The second delay time is shorter than the first delay time, and its main purpose is to eliminate the motor's mechanical inertia and ensure normal startup after restarting.

[0057] Jog Reverse Command: This refers to a brief reverse rotation control command output by the control chip after restoring power to the motor power supply branch. It is used to clear any potential mechanical obstructions. The jog reverse command is a key step in the drive motor fault recovery strategy. By briefly reversing the rotation, it attempts to eliminate mechanical obstacles causing stalling or abnormalities, restoring normal operation.

[0058] Robot posture: refers to the position of the tunnel robot in space and the angular state of its joints and actuators. During fault detection and recovery, the drive signals of the actuators are synchronously cut off from the control chip to lock the robot posture, preventing unexpected actions caused by faults or recovery operations, avoiding the spread of faults or safety accidents, and ensuring safety.

[0059] Figure 4 The diagram illustrates the instruction execution flow of a master-slave chip, corresponding to steps S1-S2, combined with... Figure 4 In another embodiment of this solution, S1 is specifically implemented as follows: The anti-interference communication module adopts a combination of UART interface and RS485, with a communication baud rate set to 115200bps. The UART interface receiver is connected to the serial data input pin of the control chip, and the RS485 converts the differential signal into a single-ended signal for processing by the UART interface.

[0060] Data is received from the control chip using UART interrupt mode. When the UART interface detects the start byte 0xAA, a receive interrupt is triggered, and the control chip enters the interrupt service routine to receive instruction packets.

[0061] The instruction packet structure is represented as: start byte 0xAA, instruction length byte, instruction code byte, data segment byte sequence, CRC-16 check byte sequence, and end byte 0x55, and is formatted as [start byte 0xAA][instruction length 1 Byte][instruction code 1 Byte][data segment N Byte][CRC-16 check 2 Byte][end byte 0x55].

[0062] Let the instruction length byte value be L, the instruction code byte value be Cmd, the data segment byte sequence be Data[0] to Data[N-1], and the CRC-16 check byte sequence be CRC low and CRC high.

[0063] The control chip calculates the CRC-16 checksums of the instruction length byte, instruction code byte, and data segment byte sequence, and compares the results with the received CRC low and CRC high. If the comparison results match, the instruction packet passes the data integrity check, and the control chip parses the instruction code Cmd and the data segment byte sequence Data[0] to Data[N-1]. If the comparison results do not match, the instruction packet fails the data integrity check, and the control chip sends an instruction error feedback signal to the main control chip.

[0064] When parsing instruction code Cmd, the control chip determines the operation type based on a predefined instruction code table. Instruction code 0x01 indicates a forward rotation operation of the drive motor, instruction code 0x02 indicates a reverse rotation operation of the drive motor, instruction code 0x03 indicates a read drive motor status operation, and instruction code 0x04 indicates an actuator start / stop operation.

[0065] For example, when the instruction code Cmd is 0x01, the data segment byte sequence Data[0]Data[1] forms a 16-bit integer representing the target speed value, and the data segment byte sequence Data[2]Data[3] forms a 16-bit integer representing the duration value. The target speed value and duration value obtained from the control chip are stored in the register for subsequent driving of the actuator to perform corresponding operations.

[0066] In another embodiment of this solution, S2 is specifically implemented as follows: After parsing the instruction code and data segment from the control chip, the drive operation type is determined based on the instruction code value. When the instruction code is 0x01, the target speed value and duration value are extracted from the data segment by the control chip. The target speed value is converted into a pulse width modulation (PWM) signal duty cycle, and the duration value is converted into a timer count value. The PWM signal is then output to the drive motor (actuator) controller via a GPIO pin. The drive motor controller controls the drive motor speed according to the PWM signal duty cycle. The control chip starts a timer to count down; when the timer count reaches 0, the output of the PWM signal stops, and the drive motor stops running.

[0067] When the instruction code is 0x03, the current operating parameters of the drive motor are directly collected from the control chip, and no drive signal is output.

[0068] When the instruction code is 0x04, the slave control chip controls the actuator to start and stop based on the actuator status value in the data segment. When the actuator status value is 1, the slave control chip outputs a high level to the actuator drive circuit through the GPIO pin, and the actuator starts; when the actuator status value is 0, it outputs a low level, and the actuator stops.

[0069] The actuator's sensor array includes a current sensor and a speed sensor. The current sensor is connected in series in the drive motor's power supply circuit, outputting an analog voltage signal in real time to the input pin of the analog-to-digital converter on the control chip. The speed sensor uses an encoder, and the encoder's signal output is connected to the counter input pin on the control chip. The actuator's status is determined by the GPIO pin levels.

[0070] After execution, the control chip converts the analog voltage signal output by the current sensor into a digital value via an analog-to-digital converter. The digital value is then multiplied by the current sensor's conversion factor to obtain the current value I. A timer / counter counts the number of pulses generated by the encoder within a fixed time interval. This pulse count is divided by the product of the number of pulses per encoder revolution and the time interval, and then multiplied by 60 to obtain the rotational speed R.

[0071] The actuator status is acquired from the control chip by reading the GPIO pin level of the actuator. A high level indicates that the actuator is in the start state, and a low level indicates that the actuator is in the stop state.

[0072] The control chip collects current value I, speed value R, and actuator status value, which are then packaged into a feedback data packet format. The feedback data packet structure is as follows: start byte 0xAA, instruction length byte Lfeedback, instruction code byte Cmd, data segment byte sequence, CRC-16 check byte sequence CRC low and CRC high, and end byte 0x55.

[0073] Let the current value I occupy 2 bytes, denoted as Ihigh and Ilow; the rotational speed value R occupy 2 bytes, denoted as Rhigh and Rlow; and the actuator status value occupy 1 byte, denoted as Sactuator. The data segment byte sequence is Ihigh, Ilow, Rhigh, Rlow, Sactuator. Calculate the CRC-16 checksum of the instruction length byte Lfeedback, the instruction code byte Cmd, and the data segment byte sequence from the control chip, and assign the results to CRC low and CRC high.

[0074] The control chip sends the packaged feedback data packet to the RS485 via the UART interface. The RS485 converts the single-ended signal into a differential signal and transmits it to the main control chip, completing the feedback of operating parameters.

[0075] Figure 5 This is a schematic diagram of the fault self-recovery process, corresponding to steps S3 and S4, combined with... Figure 5 In another embodiment of this solution, S3 is specifically implemented as follows: The main control chip sends heartbeat data packets through the anti-interference communication module at fixed time intervals of 100ms. The heartbeat data packet structure is represented as follows: start byte 0xAA, instruction length byte, instruction code 0x00, data segment byte sequence, CRC-16 checksum byte sequence, and end byte 0x55. The data segment byte sequence includes the main control chip's CPU utilization rate byte and memory usage rate byte.

[0076] After receiving a heartbeat data packet from the UART interface of the control chip, the interrupt service routine reads the data from the receive buffer and completes the heartbeat data packet reception processing. After processing, the slave control chip resets the built-in timeout timer count to zero, and the timeout timer restarts from 0. The slave control chip continuously monitors the timeout timer count. When the timeout timer count is greater than or equal to Tout (a set timeout threshold, set to 200ms in this scheme), it is determined that the master control chip has failed.

[0077] The control chip collects real-time drive motor operating information, including current and speed data. The analog voltage signal output from the current sensor is converted to a digital value using an analog-to-digital converter. This digital value is then multiplied by the current sensor's conversion factor to obtain the current data I. A timer / counter counts the number of pulses generated by the encoder within a fixed time interval. This pulse count is divided by the product of the encoder's pulses per revolution and the time interval, then multiplied by 60 to obtain the speed data R.

[0078] The control chip determines the type of drive motor fault based on current data I and speed data R. Let the rated current of the drive motor be Irated and the rated speed be Rrated. When the current data I is greater than 1.5 times Irated (Type 1 fault) and the speed data R is less than 0.1 times Rrated (Second preset threshold), the drive motor is determined to have experienced a Type 1 fault.

[0079] The control chip calculates the absolute value of the difference between the current speed data R and the previous speed data Rprev, divides it by the time interval to obtain the speed change rate, and multiplies the speed change rate by 100 to obtain the speed fluctuation percentage. When the speed fluctuation percentage is greater than 20% (the third preset threshold) and the command code remains unchanged, the drive motor is determined to have experienced a second type of fault.

[0080] In another embodiment of this solution, S4 is specifically implemented as follows: The control chip executes a differentiated recovery strategy based on the determined fault type. Fault types include main control chip faults, type 1 drive motor faults, and type 2 drive motor faults.

[0081] When a fault is detected in the main control chip, the slave control chip sends a first control signal to the intelligent power management module via a GPIO pin. The intelligent power management module then cuts off the MOSFET, disconnecting the power supply to the main control chip. After a 500ms delay (the first delay time), the slave control chip sends a recovery signal via a GPIO pin. The intelligent power management module then turns on the MOSFET, restoring power to the main control chip. The main control chip restarts upon power-up, and the slave control chip resumes command interaction after successfully receiving the heartbeat data packet.

[0082] When a Class I or Class II fault is detected in the drive motor, the control chip stops outputting pulse width modulation (PWM) signals, cutting off the drive motor's drive signal. The control chip sends a second control signal to the intelligent power management module via a GPIO pin. The intelligent power management module controls the MOSFET to turn off, cutting off the drive motor's power supply branch. After a 300ms delay (the second delay time), the control chip sends a recovery signal. The intelligent power management module controls the MOSFET to turn on, restoring power to the drive motor's power supply branch. After power restoration, the control chip outputs a 100ms reverse PWM signal to the drive motor controller, causing the drive motor to briefly reverse and clear any mechanical obstruction. The control chip re-acquires the drive motor's operating information, calculating the current data I and speed data R. When the current data I is less than 1.5 times the rated current and the speed data R is greater than 0.1 times the rated speed, the drive motor is considered to have returned to normal. The control chip sends a recovery completion message to the main control chip via an anti-interference communication module.

[0083] During fault diagnosis and recovery, the slave control chip outputs a low level to all actuator drive circuits, cutting off the drive signals to the actuators, stopping their movement, and locking the robot's posture. After the recovery process is complete, the slave control chip waits for the master control chip to send new instructions. Upon receiving the new instruction packet from the master control chip, the slave control chip parses the instruction code and data segments, and drives the actuators to resume operation based on the parsing results.

[0084] Furthermore, the fault type is determined based on the status of the built-in timeout timer and the operating information of the drive motor, including: If the timeout timer does not receive a heartbeat data packet within the set timeout threshold, it is determined that the main control chip has malfunctioned. When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold, it is determined that the drive motor has a first type of fault. When the fluctuation range of the speed data exceeds the third preset threshold and the command code remains unchanged, the drive motor is determined to have a second type of fault.

[0085] Furthermore, differentiated recovery strategies are implemented based on the fault type, including: When the main control chip fails, the power supply to the main control chip is cut off. After the first delay time, the power supply to the main control chip is restored, and the main control chip is allowed to restart and reissue instructions to resume operation.

[0086] Furthermore, differentiated recovery strategies are implemented based on the fault type, including: When the drive motor experiences a first-class or second-class fault, the drive signal of the drive motor is cut off, the power supply branch of the drive motor is cut off, and after a second delay time, the power supply branch of the motor is restored and a jog reverse command is output to clear the obstruction. When the re-collected operating information returns to normal, a recovery completion message is fed back.

[0087] Furthermore, it also includes: During fault diagnosis and recovery, the drive signal of the actuator is simultaneously cut off, the robot posture is locked to prevent the fault from spreading, and after recovery, the robot waits for the main control chip to reissue instructions to resume operation.

[0088] The beneficial effects are as follows: The system receives instruction packets, parses instruction codes and data segments, drives the actuator, and collects drive motor operating parameters after execution, transmitting them back to the RK3568 to construct a closed-loop control system, improving response efficiency and operational accuracy. It continuously receives heartbeat data packets and resets the timeout timer, collects current and speed data in real time, and determines the fault type based on the timeout timer status and operating information. This enables synchronous monitoring of RK3568 software freezes, drive motor stalls, and abnormal fluctuations, overcoming the limitation of existing technologies that cannot identify software freezes. Differentiated recovery strategies are executed based on the fault type: when the RK3568 fails, the power supply branch is cut off and then restored; when the drive motor fails, the power supply branch is cut off and then restored, and a jog reversal command is output to clear the obstruction. This enables autonomous recovery of RK3568 and drive motor faults, reducing maintenance costs and eliminating the need for manual power-off restarts. During fault determination and recovery, the actuator drive signal is simultaneously cut off, and the robot posture is locked. The STM32 outputs a lock level to the actuator drive circuit to prevent fault propagation or malfunction, resolving the issue of actuator malfunction during reset. The anti-interference communication module adopts a combination of UART interface and RS485 level conversion circuit, the command packet adopts CRC-16 check, and the power supply branch is equipped with TVS diodes and filter capacitors to reduce the command transmission bit error rate and power module failure rate, reduce hardware cost and module size, and has an IP65 protection level. It is suitable for tunnel environments with strong electromagnetic interference, high dust, and high and low temperatures, ensuring the continuous and stable operation of the tunnel robot.

[0089] In the above embodiments, although the steps are numbered S1, S2, etc., they are only specific embodiments given by the present invention. Those skilled in the art can adjust the execution order of S1, S2, etc. according to the actual situation, and these situations are also within the protection scope of the present invention. It can be understood that in some embodiments, some or all of the above embodiments may be included.

[0090] The present invention also provides a tunnel robot instruction execution and fault self-recovery system, the specific technical solution of which is as follows: including an instruction processing module, an execution feedback module, a status monitoring module and a fault recovery module; The instruction processing module is used to receive instruction packets from the main control chip, parse the instruction packets to obtain instruction codes and data segments; The execution feedback module is used to drive the actuator to perform corresponding operations according to the instruction code and data segment. After the execution is completed, it collects the operating parameters of the drive motor in the actuator, packages the operating parameters into a feedback data packet and sends it back to the main control chip. The status monitoring module is used to continuously receive heartbeat data packets from the main control chip during the operation of the driven actuator; when a heartbeat data packet is received, the built-in timeout timer is reset, and the fault type is determined based on the status of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition. The fault recovery module is used to execute differentiated recovery strategies according to the fault type, and waits for the main control chip to reissue instructions to resume operation after troubleshooting.

[0091] It should be noted that the beneficial effects of the tunnel robot instruction execution and fault self-recovery system provided in the above embodiments are the same as those of the tunnel robot instruction execution and fault self-recovery method described above, and will not be repeated here. Furthermore, the system provided in the above embodiments is only illustrated by the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the system can be divided into different functional modules according to the actual situation to complete all or part of the functions described above. In addition, the system and method embodiments provided in the above embodiments belong to the same concept, and their specific implementation process is detailed in the method embodiments, and will not be repeated here.

[0092] like Figure 6 As shown, an embodiment of the present invention provides a computer device 300, which includes a processor 320 coupled to a memory 310. The memory 310 stores at least one computer program 330, which is loaded and executed by the processor 320 to enable the computer device 300 to implement any of the above-described methods. Specifically: The computer device 300 can vary considerably due to differences in configuration or performance. It may include one or more processors 320 (Central Processing Units, CPUs) and one or more memories 310. The one or more memories 310 store at least one computer program 330, which is loaded and executed by the one or more processors 320 to enable the computer device 300 to implement the tunnel robot instruction execution and fault self-recovery method provided in the above embodiments. Of course, the computer device 300 may also have wired or wireless network interfaces, a keyboard, and input / output interfaces for input and output. The computer device 300 may also include other components for implementing device functions, which will not be elaborated here.

[0093] An embodiment of the present invention provides a computer-readable storage medium storing at least one computer program, which is loaded and executed by a processor to enable a computer to implement any of the above-described methods.

[0094] Alternatively, the computer-readable storage medium may be a read-only memory (ROM), a random access memory (RAM), a compact disc read-only memory (CD-ROM), magnetic tape, a floppy disk, and an optical data storage device, etc.

[0095] In an exemplary embodiment, a computer program product or computer program is also provided, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform any of the tunnel robot instruction execution and fault self-recovery methods described above.

[0096] It should be noted that the terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and represent a limitation on a specific order or sequence. Where appropriate, the order of use for similar objects can be interchanged so that the embodiments of this application described herein can be implemented in an order other than that shown or described.

[0097] Those skilled in the art will recognize that this invention can be implemented as a system, method, or computer program product. Therefore, this disclosure can be specifically implemented in the following forms: it can be entirely hardware, entirely software (including firmware, resident software, microcode, etc.), or a combination of hardware and software, generally referred to herein as a "circuit," "module," or "system." Furthermore, in some embodiments, the invention can also be implemented as a computer program product contained in one or more computer-readable media, which includes computer-readable program code.

[0098] Any combination of one or more computer-readable media may be used. A computer-readable medium can be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium can be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination thereof. More specific examples (a non-exhaustive list) of computer-readable storage media include: an electrical connection having one or more wires, a portable computer disk, a hard disk, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), optical fiber, portable compact disk read-only memory (CD-ROM), optical storage device, magnetic storage device, or any suitable combination thereof. In this document, a computer-readable storage medium can be any tangible medium that contains or stores a program that can be used by or in connection with an instruction execution system, apparatus, or device.

[0099] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for instruction execution and fault self-recovery in a tunnel robot, characterized in that, include: S1, Receive instruction packets from the main control chip, and parse the instruction packets to obtain instruction codes and data segments; S2, according to the instruction code and the data segment, drive the actuator to perform corresponding operations, and after the execution is completed, collect the operating parameters of the drive motor in the actuator, package the operating parameters into a feedback data packet and send it back to the main control chip; S3, during the operation of the driven actuator, continuously receive heartbeat data packets from the main control chip; upon receiving the heartbeat data packet, reset the built-in timeout timer, and determine the fault type based on the state of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition; S4. Execute a differentiated recovery strategy according to the fault type, and wait for the main control chip to reissue instructions to resume operation after troubleshooting.

2. The method for instruction execution and fault self-recovery of a tunnel robot according to claim 1, characterized in that, The step of determining the fault type based on the status of the built-in timeout timer and the operating information of the drive motor includes: When the timeout timer does not receive the heartbeat data packet within the set timeout threshold, it is determined that the main control chip has malfunctioned; When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold, it is determined that the drive motor has a first type of fault. When the fluctuation range of the rotation speed data exceeds the third preset threshold and the instruction code remains unchanged, it is determined that the drive motor has a second type of fault.

3. The method for instruction execution and fault self-recovery of a tunnel robot according to claim 2, characterized in that, The step of executing a differentiated recovery strategy based on the fault type includes: When the main control chip malfunctions, the power supply branch of the main control chip is cut off. After a first delay, the power supply branch of the main control chip is restored, and the main control chip is allowed to restart and reissue instructions to resume operation.

4. The method for instruction execution and fault self-recovery of a tunnel robot according to claim 2, characterized in that, The step of executing a differentiated recovery strategy based on the fault type includes: When the drive motor experiences a first-class or second-class fault, the drive signal of the drive motor is cut off, the power supply branch of the drive motor is cut off, and after a second delay time, the power supply branch of the motor is restored and a jog reverse command is output to clear the obstruction. When the re-collected operating information returns to normal, a recovery completion message is fed back.

5. The method for instruction execution and fault self-recovery of a tunnel robot according to claim 1, characterized in that, Also includes: During fault diagnosis and recovery, the drive signal of the actuator is simultaneously cut off, the robot posture is locked to prevent the fault from spreading, and after recovery, the main control chip is waited for to reissue instructions to resume operation.

6. A tunnel robot instruction execution and fault self-recovery system, characterized in that, include: The module includes an instruction processing module, an execution feedback module, a status monitoring module, and a fault recovery module. The instruction processing module is used to receive instruction packets from the main control chip and parse the instruction packets to obtain instruction codes and data segments. The execution feedback module is used to drive the actuator to perform corresponding operations according to the instruction code and the data segment. After the execution is completed, it collects the operating parameters of the drive motor in the actuator, packages the operating parameters into a feedback data packet and sends it back to the main control chip. The status monitoring module is used to continuously receive heartbeat data packets from the main control chip during the operation of the driven actuator; when the heartbeat data packet is received, the built-in timeout timer is reset, and the fault type is determined according to the status of the built-in timeout timer and the operating information of the drive motor; the operating information is obtained through real-time acquisition. The fault recovery module is used to execute a differentiated recovery strategy according to the fault type, and wait for the main control chip to reissue instructions to resume operation after troubleshooting.

7. The tunnel robot instruction execution and fault self-recovery system according to claim 6, characterized in that, The step of determining the fault type based on the status of the built-in timeout timer and the operating information of the drive motor includes: When the timeout timer does not receive the heartbeat data packet within the set timeout threshold, it is determined that the main control chip has malfunctioned; When the current data exceeds the first preset threshold and the speed data is lower than the second preset threshold, it is determined that the drive motor has a first type of fault. When the fluctuation range of the rotation speed data exceeds the third preset threshold and the instruction code remains unchanged, it is determined that the drive motor has a second type of fault.

8. The tunnel robot instruction execution and fault self-recovery system according to claim 6, characterized in that, Also includes: During fault diagnosis and recovery, the drive signal of the actuator is simultaneously cut off, the robot posture is locked to prevent the fault from spreading, and operation can only resume after the main control chip reissues instructions after recovery is completed.

9. A computer device, characterized in that, The computer device includes a processor coupled to a memory storing at least one computer program, which is loaded and executed by the processor to enable the computer device to implement a tunnel robot instruction execution and fault self-recovery method as described in any one of claims 1 to 5.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores at least one computer program, which is loaded and executed by a processor to enable the computer to implement a tunnel robot instruction execution and fault self-recovery method as described in any one of claims 1 to 5.

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