Intelligent charging system, method and robot for joint module encoder battery

Abstract

This invention relates to an intelligent charging system, method, and robot for an encoder battery in a joint module, comprising a control unit, an execution unit, and a detection unit. The control unit performs system data processing, determines the operating status, issues charging / power-off commands, and reports health information. The execution unit includes a joint module power-on / off management module, a voltage conversion module, and a charging module. The joint module power-on / off management module controls the power supply and disconnection of the joint module's input power. The voltage conversion module performs step-down conversion on the joint module's input power. The charging module charges the encoder battery, which provides continuous power to the encoder after the joint module is powered off. The detection unit collects real-time operating data from the charging module and the encoder battery, enabling fault diagnosis and data transmission. Based on the real-time detection data from the detection unit, the control unit comprehensively judges the system's operating status and selectively turns the charging module on or off. This invention can extend battery cycle life.

Description

Technical Field

[0001] This invention relates to the field of robot joint module technology, specifically to an intelligent charging system, method, and robot for a joint module encoder battery. Background Technology

[0002] Absolute encoders are widely used in robot joint modules, industrial automation equipment, and precision servo control systems to acquire real-time motor position, speed, and multi-turn information. To ensure that the encoder can maintain its position memory and avoid data loss after the main power supply to the system is interrupted, it is usually necessary to equip the encoder with a backup battery that can continue to supply power after power failure.

[0003] Existing solutions mainly fall into two categories:

[0004] Firstly, disposable lithium thionyl chloride batteries are used, which have low self-discharge rate and long storage life, but have problems such as high maintenance costs for regular replacement, inconvenience in replacement, and potential data loss during power outage replacement.

[0005] Secondly, a rechargeable battery (such as a lithium-ion battery or a lithium polymer battery) is used, and the voltage conversion circuit module inside the joint module (such as a DC-DC converter) is used to charge the battery when the main power supply is on, and the battery continues to supply power to the encoder after the main power supply is turned off.

[0006] However, the above-mentioned rechargeable solutions still have the following obvious shortcomings in practical applications:

[0007] First, most existing designs only implement basic charging on / off control and lack a real-time monitoring mechanism for parameters such as charging voltage, current, and temperature. This makes it difficult to adjust or cut off the charging circuit in time when the battery is close to full charge or when abnormalities occur, which can easily lead to battery overcharging, overheating, or even safety accidents.

[0008] Secondly, as the number of battery cycles increases, its health condition (such as increased internal resistance and capacity decay) will gradually deteriorate. However, existing solutions generally do not have battery health diagnosis functions and cannot provide early warnings or prompts for replacement. Once the battery fails at the moment of power failure, it will directly cause the encoder position memory to be lost.

[0009] Furthermore, when the joint module is under heavy load and high power output, the charging circuit may still operate at a fixed power, resulting in reduced efficiency at the power output end and affecting the overall output capability of the system.

[0010] Furthermore, although rechargeable batteries have the potential to be reused compared to disposable batteries, existing solutions often overlook the core objective of how to truly extend battery cycle life through reasonable charge and discharge management, thereby significantly reducing the frequency of manual replacement. As a result, batteries still need to be replaced frequently in actual use, failing to fully realize the advantages of rechargeable batteries. Summary of the Invention

[0011] The purpose of this invention is to provide an intelligent charging system, method, and robot for joint module encoder batteries, which can extend battery cycle life.

[0012] In a first aspect, the present invention provides an intelligent charging system for a joint module encoder battery, comprising a display unit, a control unit, an execution unit, and a detection unit;

[0013] The display unit is used to record system data and display detection data and prompt information according to preset parameters;

[0014] The control unit is used to perform system data processing, work status judgment, charging / power-off command issuance, and health information reporting.

[0015] The execution unit includes a joint module power-on / off management module, a voltage conversion module, and a charging module. The joint module power-on / off management module, voltage conversion module, charging module, and encoder battery are electrically connected in sequence. The joint module power-on / off management module is used to control the power supply and power-off of the joint module input power. The voltage conversion module is used to perform step-down conversion on the joint module input power. The charging module is used to charge the encoder battery. The encoder battery is used to continuously supply power to the encoder after the joint module is powered off.

[0016] The detection unit is used to collect real-time operating data of the charging module and encoder battery, and to realize fault diagnosis and data transmission.

[0017] The control unit is connected to the detection unit, voltage conversion module, and display unit respectively. Based on the real-time detection data fed back by the detection unit, the control unit comprehensively judges the system operating status, selectively turns the charging module on or off, and pushes battery health information and fault information to the display unit for visual display.

[0018] Optionally, the control unit integrates a charging judgment module, a joint module operation status judgment module, a charging module status judgment module, a battery status judgment module, and a health diagnosis information reporting module;

[0019] The charging judgment module is configured to issue a charging command only when four conditions are met simultaneously: the charging module is fault-free, the joint module is in a non-high load power output state, the encoder battery remaining power is lower than a preset power value, and the encoder battery temperature is lower than a preset over-temperature threshold; if any one of the conditions is not met, a stop charging command is issued immediately.

[0020] Optionally, the joint module operation status determination module determines the high load power output status of the joint module by at least one of the following methods:

[0021] Power-current dual threshold determination method: preset the rated power and rated current of the joint module and the corresponding threshold coefficient, monitor the output power and output current in real time, and when either the output power or the output current meets the corresponding preset threshold and continues for the corresponding set duration, it is determined to be a high load state, and configure the de-jitter delay and hysteresis interval to avoid frequent state switching.

[0022] Torque-Power-Speed ​​Curve Lookup Table Evaluation Method: Pre-store three-dimensional lookup tables corresponding to the torque, speed, and power of the joint module, as well as three-dimensional lookup tables corresponding to the torque, speed, and current. Collect operating parameters in real time to obtain the limit output parameters by looking up the tables. Determine the high load state based on the ratio between the real-time output parameters and the limit output parameters.

[0023] Bus current change rate rapid detection method: Real-time monitoring of bus current change rate, and determination of high load operation status based on the current rise rate within a preset short period of time and the ratio of real-time current to rated current.

[0024] Optionally, the charging module status judgment module operates as follows: it pre-stores the ADC conversion data range corresponding to the charging module's overcurrent, overvoltage, open circuit, short circuit, and normal operating states; it reads the voltage and current ADC sampling data of the charging module in real time; it compares the data range with the preset data range to determine the module's operating state; and when a fault is detected, it synchronously reports a fault signal and terminates the charging request.

[0025] Optionally, the battery state determination module is configured with an internal resistance estimation method and a capacity decay estimation method to determine battery aging;

[0026] The internal resistance estimation method is as follows: the battery internal resistance is calculated by collecting the transient change data of the battery voltage and current at the moment of charging connection, and converting it into the equivalent internal resistance at the standard temperature of 20℃ by combining the preset temperature-internal resistance compensation table. When the equivalent internal resistance exceeds 1.5 times the initial internal resistance of the battery, the battery is judged to be aging.

[0027] The capacity decay estimation method is as follows: the actual charging capacity is calculated by coulomb integration, and the remaining battery capacity before and after charging is obtained by interpolation of the OCV-SOC curve. The battery health status SOH is calculated. When the battery health status SOH is lower than 70%, the battery is determined to be aging and a replacement reminder is pushed. The battery health status SOH calculation formula introduces a charging efficiency compensation coefficient, and the optimized formula is: SOH = actual charging capacity × charging efficiency compensation coefficient / standard charging capacity.

[0028] Optionally, the battery status judgment module uses a temperature-compensated OCV-SOC curve interpolation lookup table method and a coulomb integration monitoring method combining a sampling resistor and a current sensing chip to monitor the remaining battery power.

[0029] Optionally, the detection unit integrates a fault detection module, a temperature detection module, a battery internal resistance detection module, a battery power detection module, a voltage detection module, and a current detection module. Each module collects corresponding operating condition data in real time and uploads it to the control unit, providing data support for charging decisions, fault diagnosis, and battery health assessment.

[0030] Optionally, the system is configured with a wired and wireless dual-mode charging mechanism;

[0031] The wired charging mode is as follows: after the joint module is powered on, the voltage is stepped down by the voltage conversion module to supply power to the charging module, so as to realize the normal charging of the encoder battery;

[0032] The wireless charging mode is as follows: a backup wireless charging module is configured, and when the joint module is powered off and in standby mode for a long time, the encoder battery is charged through the wireless charging module.

[0033] Secondly, the intelligent charging method for a joint module encoder battery described in this invention, applied to the intelligent charging system described in this invention, includes the following steps:

[0034] After the joint module power-on / off management module detects that the joint module is powered on, it wakes up the control unit and collects real-time data on the charging module's operating status, the encoder battery's voltage, current, temperature, internal resistance, and remaining power through the detection unit.

[0035] Based on the collected data, the control unit detects the load status of the joint module and the aging of the battery, and at the same time determines the fault of the charging module, the battery temperature and the power status.

[0036] The control unit synchronously determines whether the preset charging conditions are met. If the charging module is fault-free, the joint module is in a non-high load working state, the encoder battery power is lower than the preset value and the battery temperature is normal, the charging process is triggered, the voltage conversion module is controlled to step down the power supply, and the charging module is activated to charge the encoder battery.

[0037] During the charging process, various operating parameters are dynamically monitored in real time. The real-time battery SOC is obtained by temperature compensation interpolation of the OCV-SOC curve. Once the battery SOC reaches the preset full charge threshold and the parameters are stable, it is determined to be fully charged, and the charging module is immediately disconnected to terminate charging.

[0038] If the joint module is powered off and in standby mode for an extended period, the wireless charging mode will be activated to recharge the encoder battery. The control unit will simultaneously push battery health data, fault information, and charging status information to the display unit to achieve data visualization and early warning.

[0039] Thirdly, the robot of the present invention includes a robot body, the robot body being equipped with a joint module, and the joint module being configured with an intelligent charging system for the joint module encoder battery of the present invention.

[0040] Compared with the prior art, the present invention has the following advantages and positive effects:

[0041] 1. This invention constructs a multi-dimensional real-time monitoring mechanism that dynamically collects key parameters such as voltage, current, and temperature of the encoder's backup battery. When anomalies (such as overvoltage, overcurrent, or overtemperature) are detected, the charging strategy is automatically adjusted or the charging circuit is disconnected. Compared to traditional solutions that only implement on / off control, this invention effectively avoids safety hazards such as battery overcharging and thermal runaway, significantly improving the safety and reliability of the charging process and ensuring the stable operation of the joint module and the entire device.

[0042] 2. This invention introduces a battery health diagnosis mechanism to periodically assess battery health indicators such as internal resistance and capacity decay, enabling timely warning signals when battery performance drops below a threshold. This function allows maintenance personnel to replace batteries that are about to fail in advance, avoiding the loss of encoder position memory due to battery failure during power outages, thereby improving the system's data retention and fault tolerance capabilities under power failure conditions.

[0043] 3. This invention utilizes an energy efficiency optimization mechanism to stop charging and prioritize driving the load when the joint module requires high power output. In low-power output states, it rationally utilizes idle low-voltage output to charge the encoder battery, thus not affecting the normal operation and power output of the joint module, while also improving the voltage utilization rate of the power supply.

[0044] 4. This invention effectively extends the actual cycle life of the encoder battery by implementing refined charge and discharge management of the rechargeable battery, including strategies such as controlling the depth of discharge and avoiding overcharging and over-discharging. Compared with existing solutions where batteries still need to be replaced frequently, this invention significantly reduces the number of battery replacements, lowers manual maintenance costs and downtime, and reduces the risk of data loss due to battery replacement, fully leveraging the reusability advantages of rechargeable batteries.

[0045] 5. This invention elevates charging management from simple power control to an intelligent management system integrating monitoring, diagnostics, and energy efficiency scheduling. Users or host computers can obtain battery status, health assessment results, and charging logs in real time, facilitating predictive maintenance and remote management. This design significantly improves the intelligence level of the joint module, enhancing the user experience and ease of operation and maintenance.

[0046] 6. The mechanisms proposed in this invention can be implemented on the basis of existing joint module hardware architecture by adding a small number of sensing and logic control circuits in conjunction with embedded software, resulting in low modification costs and high engineering feasibility. Furthermore, this technical solution does not rely on specific types of rechargeable batteries or encoders, possessing good versatility and portability, and can be widely applied to industrial robots, collaborative robots, servo drive systems, and other scenarios requiring absolute encoder backup power protection. Attached Figure Description

[0047] Figure 1 This is a block diagram of the intelligent charging system for the joint module encoder battery in the embodiments of this application. Figure 1 ;

[0048] Figure 2 This is a block diagram of the intelligent charging system for the joint module encoder battery in the embodiments of this application. Figure 2 ;

[0049] Figure 3 This is a flowchart of the intelligent charging method for the encoder battery of the joint module in this application embodiment;

[0050] Explanation of reference numerals in the attached figures:

[0051] 1. Display unit; 2. Control unit; 3. Execution unit; 4. Detection unit; 5. Encoder battery; 21. Charging judgment module; 22. Joint module operating status judgment module; 23. Charging module status judgment module; 24. Battery status judgment module; 25. Health diagnosis information reporting module; 31. Joint module power-on / off management module; 32. Voltage conversion module; 33. Charging module; 41. Fault detection module; 42. Temperature detection module; 43. Battery internal resistance detection module; 44. Battery power detection module; 45. Voltage detection module; 46. Current detection module. Detailed Implementation

[0052] The embodiments of the present invention will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be understood that the preferred embodiments are only for illustrating the present invention and not for limiting the scope of protection of the present invention.

[0053] like Figure 1 and Figure 2As shown in this embodiment, an intelligent charging system for a joint module encoder battery includes a display unit 1, a control unit 2, an execution unit 3, and a detection unit 4. The display unit 1 records system data and displays detection data and prompts according to preset parameters. The control unit 2 performs system data calculations, determines operating status, issues charging / power-off commands, and reports health information. The execution unit 3 includes a joint module power-on / off management module 31, a voltage conversion module 32, and a charging module 33, which are electrically connected sequentially to the encoder battery 5. The joint module power-on / off management module 31 controls the power supply and power-off of the joint module input power; the voltage conversion module 32 performs step-down conversion on the joint module input power; and the charging module 33 charges the encoder battery 5, which continuously supplies power to the encoder after the joint module is powered off. The detection unit 4 collects real-time operating data from the charging module 33 and the encoder battery 5, and performs fault diagnosis and data transmission. The control unit 2 is connected to the detection unit 4, the voltage conversion module 32, and the display unit 1 respectively. Based on the real-time detection data fed back by the detection unit 4, the control unit 2 comprehensively judges the system operating status, selectively turns the charging module 33 on or off, and pushes the battery health information and fault information to the display unit 1 for visual display.

[0054] This system can directly utilize the power supply of the joint module. After the power-on / off management module 31 of the joint module is powered on, it wakes up the control unit 2. The control unit 2 identifies and determines whether the current state is suitable for performing the charging action based on the monitoring data, and sends a command to the voltage conversion module 32 to activate the charging supply voltage to power the charging module 33, thereby completing the charging of the encoder battery 5. At the same time, it monitors the status of the encoder battery 5, calculates the time to stop charging, and sends a stop charging command to the voltage conversion module 32 to shut down the charging module 33. In addition, the control unit 2 sends the health information of the encoder battery 5 to the display unit 1, and presents the battery status in real time in a visual form through the display interface, which makes it convenient for users to judge when to replace the battery, thereby avoiding the loss of encoder position memory data due to insufficient power caused by battery aging or damage.

[0055] like Figure 2 As shown, in one possible embodiment, the control unit 2 includes, but is not limited to, functions such as determining battery status, determining charging circuit status, determining module operating status, determining whether charging has started, and reporting health diagnostic information. To achieve these functions, the control unit 2 integrates a charging determination module 21, a joint module operating status determination module 22, a charging module status determination module 23, a battery status determination module 24, and a health diagnostic information reporting module 25; detailed descriptions are as follows:

[0056] The charging determination module 21 is configured to issue a charging command when the following conditions are met simultaneously:

[0057] (1) The charging module 33 is in a fault-free state;

[0058] (2) The joint module is in a non-high load power output state (i.e., non-high output demand).

[0059] (3) The remaining power of the encoder battery 5 is lower than the preset power value;

[0060] (4) The current temperature of encoder battery 5 is lower than the over-temperature preset threshold.

[0061] If any of the conditions (1) to (4) above are not met, the control unit 2 will issue a stop charging command.

[0062] Control unit 2 monitors the working status of the joint module and determines whether the joint module is in a high load and high power output state based on the output power and output current. If so, it stops requesting charging commands and prioritizes power output; otherwise, it keeps requesting charging commands.

[0063] Joint module operation status determination module 22: Determines the high load power output status of the joint module by at least one of the following methods:

[0064] Method 1, Power-Current Dual Threshold Determination: This method presets the rated power and current of the joint module, along with corresponding threshold coefficients. It monitors the output power and current in real time. When either the output power or output current meets the corresponding preset threshold and remains so for a set duration, it is determined to be a high-load state. A debouncing delay and hysteresis interval are configured to prevent frequent state switching. Specifically:

[0065] The rated power of the joint module is preset in control unit 2. and rated current And set a high load judgment threshold coefficient (e.g.) , Real-time monitoring of the joint module's output power. and output current When either of the following conditions (1) or (2) is met, the system is determined to be in a high-load state:

[0066] (1) And the duration exceeds ;

[0067] (2) And the duration exceeds .

[0068] If neither condition (1) nor (2) above is met, the high load flag is deactivated. To avoid frequent switching, a dejitter delay (e.g., 500ms) and a hysteresis interval (e.g., power drop-off) can be set. The following are considered to be in a non-high load state.

[0069] Method 2: Torque-Power-Speed ​​Curve Lookup Table Evaluation Method: A three-dimensional lookup table is pre-stored for the torque, speed, and power of the joint module, as well as a three-dimensional lookup table for torque, speed, and current. Operating parameters are collected in real-time, and the limiting output parameters are obtained by looking up the tables. The high-load condition is determined based on the ratio between the real-time output parameters and the limiting output parameters. Specifically:

[0070] The power MAP and output capability curve of the joint module are obtained in advance through experiments or motor parameters, and the torque is... Rotation speed ,power Current The corresponding relationship is stored as a three-dimensional lookup table (TnI, TnP) in control unit 2. Real-time acquisition of current torque and speed (or torque estimation based on current) is used to look up the table and obtain the maximum allowable continuous power under the current operating condition. and short-time peak power A state of high load is determined when either of the following conditions (1) or (2) is met:

[0071] (1) Current output power Exceed 90%, or more 80%;

[0072] (2) Current Exceeding 90% of the rated current.

[0073] If neither of the above conditions (1) nor (2) is met, the condition is determined to be a non-high load state.

[0074] Method 3: Rapid Detection of Bus Current Change Rate: Real-time monitoring of the bus current change rate; based on the current rise within a preset time period and the ratio of real-time current to rated current, the high-load operating status is determined; specifically:

[0075] For scenarios requiring rapid response, the rate of change of bus current can be monitored. When both of the following conditions (1) and (2) are met simultaneously, the system is considered to be in a high-load state.

[0076] (1) The current rises above the set threshold (e.g., 30% of the rated current) within a preset short time (e.g., 10ms).

[0077] (2) The current has exceeded 70% of the rated current.

[0078] If any of the above conditions are not met, the system is determined to be in a non-high load state.

[0079] In one possible embodiment, the charging module status judgment module 23 operates as follows: it pre-stores the ADC conversion data ranges corresponding to the overcurrent, overvoltage, open circuit, short circuit, and normal operation states of the charging module 33; it reads the voltage and current ADC sampling data of the charging module 33 in real time; it compares the data with the preset data range to determine the module's operating status; and when a fault is detected, it synchronously reports a fault signal and terminates the charging request. Specifically, it compares the ADC data to determine whether the detected parameter value is within the preset data range for normal operation. If it is, the charging circuit is determined to be normal; otherwise, a fault is determined, and a corresponding fault indication signal is sent, while the charging request command is stopped.

[0080] In one possible embodiment, the battery status judgment module 24 is configured with internal resistance estimation method and capacity decay estimation method to realize battery aging judgment; by monitoring the battery's charging and discharging capacity, internal resistance and other information, it can determine whether the battery is aging and prompt the user to pay attention to replacing the battery, and charge the battery on demand.

[0081] (1) To determine whether a battery is aging, the following methods can be used:

[0082] Method 1, the internal resistance estimation method, involves collecting transient voltage and current change data of the battery at the moment of charging connection to calculate the battery's internal resistance. This data is then converted to the equivalent internal resistance at a standard temperature of 20℃ using a preset temperature-internal resistance compensation table. When the equivalent internal resistance exceeds 1.5 times the battery's initial internal resistance, the battery is considered aged. Specifically:

[0083] The battery's internal resistance is the primary criterion. If the internal resistance is too high, the battery is considered aged, prompting the user to back up their data and replace the battery. At the instant the charging circuit is connected, after a certain period of stabilization before and after voltage and current changes, and when ΔI is greater than 0.25 times the rated capacity, the transient voltage and current changes at both ends of the backup battery are read. The internal resistance of the backup battery is then estimated by control unit 2. In control unit 2, a temperature-internal resistance compensation table is preset to uniformly convert the detected internal resistance to the equivalent value at a standard temperature of 20°C. If the estimated battery internal resistance R exceeds 1.5 times the initial battery internal resistance (the threshold for judging excessive internal resistance can be set according to the selected battery type), the battery is judged to be aging, and it is recommended to replace the battery. This method is stable and reliable and can be implemented without adding an additional monitoring chip.

[0084] Method 2, the capacity decay estimation method, calculates the actual charging capacity using coulomb integration, and obtains the remaining battery capacity before and after charging by interpolating the OCV-SOC curve. It then calculates the battery health status (SOH). When the SOH is below 70%, the battery is considered aged and a replacement reminder is sent. The SOH calculation formula incorporates a charging efficiency compensation coefficient, resulting in the optimized formula: SOH = Actual charging capacity × Charging efficiency compensation coefficient / Standard charging capacity. Specifically:

[0085] The primary criterion is full charge capacity. If the battery's full charge capacity is less than 70% of its initial capacity, it is considered aged, and battery replacement is recommended. A milliohm-level high-precision sampling resistor is connected in series at the negative terminal of the battery. After amplification by an operational amplifier, the signal is sent to the ADC pin of control unit 2 for sampling and integration calculation. The actual charge amount Q during the current charge is calculated using coulomb counting. In control unit 2, a battery terminal voltage-remaining capacity reference table (OCV-SOC curve) is preset. After the joint module is powered on and stabilized for 1 minute, the charging circuit is activated and the battery terminal voltage V1 before charging is obtained. After charging is completed and the voltage stabilizes for 1 minute, the battery terminal voltage V2 after charging is obtained. The corresponding remaining capacity is then determined using interpolation. and The difference between the two multiplied by the battery's nominal capacity That is, the amount of electricity required to charge. ,Right now ; Match the required charging power This allows you to calculate the battery capacity degradation data. If the State of Charge (SOH) is less than 70%, the battery is considered aged, and the user is advised to replace it. In practical applications, the charging efficiency compensation coefficient η can be pre-calibrated according to the battery type to further improve the accuracy of SOH calculation. The SOH calculation formula after introducing charging efficiency compensation can be optimized as follows:

[0086] .

[0087] In one possible embodiment, the battery status judgment module 24 uses a temperature-compensated OCV-SOC curve interpolation lookup table method and a coulomb integration monitoring method combining a sampling resistor and a current sensing chip to monitor the remaining battery power.

[0088] The system acquires the battery terminal voltage and temperature before charging, and performs temperature compensation on the OCV-SOC curve. Using the OCV-SOC curve data, it uses interpolation to look up the current remaining battery SOC. If the current battery level is lower than the preset charging trigger value, the control unit 2 determines that the battery level is insufficient and issues a charging request. Provided other charging conditions are met simultaneously, a charging command is triggered, and the charging circuit is activated to charge the backup battery. In addition to the OCV-SOC lookup method described above, online monitoring of battery level can also be achieved by combining a sampling resistor with a current sensing chip, along with a Coulomb integration algorithm, which can improve the online monitoring accuracy to ±3%.

[0089] In one possible embodiment, the detection unit 4 includes, but is not limited to, fault detection of the charging circuit and health detection of the encoder battery 5 (such as temperature monitoring, internal resistance monitoring, power monitoring, voltage / current monitoring, etc.). Through a fault detection mechanism, it determines whether a fault exists in the charging circuit, and if a fault is found, it feeds back to the control unit 2. The detection unit 4 integrates a fault detection module 41, a temperature detection module 42, a battery internal resistance detection module 43, a battery power detection module 44, a voltage detection module 45, and a current detection module 46. Each module collects corresponding operating condition data in real time and uploads it to the control unit 2, providing data support for charging decisions, fault diagnosis, and battery health assessment. If an abnormality is detected in the detection unit 4, the control unit 2 reports fault information and displays it to the user through the display unit 1, indicating the fault, battery power status, and that the battery is aging and needs replacement. The displayed content can be preset or adjusted according to the user's actual needs.

[0090] In one possible embodiment, the system is configured with a wired and wireless dual-mode charging mechanism.

[0091] The wired charging mode is as follows: after the joint module is powered on, the voltage is stepped down by the voltage conversion module 32 to power the charging module 33, so as to realize the normal charging of the encoder battery 5.

[0092] The wireless charging mode is as follows: a backup wireless charging module is configured so that when the joint module is powered off and in standby mode for a long time, the encoder battery 5 is charged through the wireless charging module.

[0093] To prevent the encoder battery from continuously draining due to the joint module being powered off for extended periods, this application includes a backup wireless charging module. Even if the joint module is not powered on, the encoder battery 5 can be temporarily charged via wireless charging.

[0094] In this embodiment of the application, a smart charging method for a joint module encoder battery is applied to the smart charging system of this application. The method includes the following steps:

[0095] After the joint module power-on / off management module 31 detects that the joint module is powered on, it wakes up the control unit 2 and collects the operating data of the charging module 33, the voltage, current, temperature, internal resistance and remaining power data of the encoder battery 5 in real time through the detection unit 4.

[0096] Based on the collected data, the control unit 2 detects the load status of the joint module and the aging of the battery, and at the same time determines the fault of the charging module (33), the battery temperature and the power status.

[0097] Control unit 2 synchronously determines whether the preset charging conditions are met. If the charging module 33 is fault-free, the joint module is in a non-high load working state, the encoder battery 5 has a power level lower than the preset value and the battery temperature is normal, the charging process is triggered, the voltage conversion module 32 is controlled to step down the power supply, and the charging module 33 is activated to charge the encoder battery 5.

[0098] During the charging process, various operating parameters are dynamically monitored in real time. The real-time battery SOC is obtained by temperature compensation interpolation method of OCV-SOC curve. Once the battery SOC reaches the preset full charge threshold and the parameters are stable, it is determined to be fully charged, and the charging module 33 is immediately disconnected to terminate charging.

[0099] If the joint module is powered off and in standby mode for a long time, the wireless charging mode will be activated to recharge the encoder battery 5; the control unit 2 will push the battery health data, fault information and charging status information to the display unit 1 simultaneously to realize data visualization and early warning.

[0100] like Figure 3 As shown below, the process of intelligent charging method for joint module encoder battery is explained in detail:

[0101] S0: Joint module powered on: Start control process.

[0102] S1: Detect the status of encoder battery 5: Read data such as voltage, current, and temperature of encoder battery 5;

[0103] S2: Display battery health data: After reading the data, it is converted by the control unit 2, and the data is recorded and displayed on the display interface;

[0104] S3: Determine if encoder battery 5 is aged: Aging can be determined by internal resistance method or full charge capacity SOH estimation method. If encoder battery 5 is determined to be aged, execute S4 and then S5; otherwise, only S5 needs to be executed.

[0105] S4: Prompt to replace encoder battery.

[0106] S5: Determine if the charging module is faulty: Check if the charging module has faults such as overcurrent, overvoltage, short circuit, open circuit, or overtemperature. If a fault is found, execute S6, then execute S13; otherwise, execute S7.

[0107] S6: Record and report fault information: Upon detecting a fault, record the fault data and display relevant fault information to the user through the display interface. The content of the prompts can be selectively set as needed.

[0108] S7: Determine if it is under high load: The joint module can be determined to be under high load power output by using the power-current dual threshold judgment method, the torque-power-speed curve lookup table method, or the bus current change rate detection method. If yes, execute S13 directly; otherwise, continue to execute S8.

[0109] S8: Determine if the remaining battery power is too low: Estimate the remaining power using the OCV-SOC curve lookup table method or the online monitoring method of the sampling resistor, combined with temperature compensation. Determine if the remaining battery power is lower than the preset power value. If yes, it is determined that the power is insufficient (i.e., the encoder battery needs to be charged), and continue to S9; otherwise, proceed to S13.

[0110] S9: Determine if the battery temperature is too high: Determine if the detected temperature is lower than the preset temperature value. If yes, execute S10; otherwise, execute S13.

[0111] S10: Connect the charging module to charge the encoder battery 5.

[0112] S11: Determine if the battery is fully charged: Continuously monitor the battery level and determine if it is fully charged. If not fully charged, proceed to S10 to continue charging; if fully charged, proceed to S12 and then S13.

[0113] S12: Fully charged notification: If the battery is detected to be fully charged, a notification will be displayed on the screen indicating that the battery is fully charged.

[0114] S13: Disconnect the charging module, process ends.

[0115] This application proposes a real-time monitoring mechanism, which collects the status data (including voltage, current, temperature, internal resistance, power, etc.) of the charging module and encoder battery 5 in real time through the monitoring unit (i.e., the detection module) and feeds it back to the control unit 2, providing dynamic basis for charging decisions and health diagnosis.

[0116] This application proposes a health diagnosis mechanism. The control unit 2 combines methods such as internal resistance estimation, coulomb integration and OCV-SOC curve comparison to determine the degree of battery aging (such as internal resistance exceeding 1.5 times the initial value or battery capacity decay data being less than 70%), and reports information such as circuit faults, power status and replacement reminders through a visual interface to realize battery health trend monitoring and maintenance early warning.

[0117] This application proposes an energy efficiency optimization mechanism for the joint module. The control unit 2 determines whether the joint module is under high load and high power output based on its output power and current. If so, the charging request is stopped to prioritize the module's power output; if not, the charging request is maintained to avoid affecting the joint module's operating efficiency, thereby optimizing energy utilization. On the other hand, by assessing the battery charge level to achieve precise on-demand charging, the charging efficiency of the encoder battery 5 can be improved.

[0118] This application proposes a dual-mode charging prevention mechanism. In addition to directly charging the encoder battery 5 using the voltage conversion module 32 inside the joint module, a wireless charging module can be added as a backup solution. When the joint module is powered off for an extended period, the encoder battery 5 can be recharged wirelessly to prevent data loss due to continuous power consumption of the encoder battery 5.

[0119] In this embodiment of the application, a robot includes a robot body, the robot body is equipped with a joint module, and the joint module is configured with the intelligent charging system of the joint module encoder battery of this application.

[0120] However, the implementation of the present invention is not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. An intelligent charging system for joint module encoder batteries, characterized in that, It includes a display unit (1), a control unit (2), an execution unit (3), and a detection unit (4); The display unit (1) is used to record system data and display detection data and prompt information according to preset parameters; The control unit (2) is used to perform system data calculation, work status judgment, power-off command issuance and health information reporting; The execution unit (3) includes a joint module power-on / off management module (31), a voltage conversion module (32), and a charging module (33). The joint module power-on / off management module (31), voltage conversion module (32), charging module (33), and encoder battery (5) are electrically connected in sequence. The joint module power-on / off management module (31) is used to control the power supply and power-off of the joint module input power. The voltage conversion module (32) is used to perform step-down conversion on the joint module input power. The charging module (33) is used to charge the encoder battery (5). The encoder battery (5) is used to continuously supply power to the encoder after the joint module is powered off. The detection unit (4) is used to collect the operating data of the charging module (33) and encoder battery (5) in real time, and to realize fault diagnosis and data transmission; The control unit (2) is connected to the detection unit (4), voltage conversion module (32) and display unit (1) respectively. The control unit (2) judges the system operating status based on the real-time detection data fed back by the detection unit (4), selectively turns on or off the charging module (33), and pushes the battery health information and fault information to the display unit (1) for visual display.

2. The intelligent charging system for joint module encoder battery of claim 1, wherein, The control unit (2) integrates a charging judgment module (21), a joint module operation status judgment module (22), a charging module status judgment module (23), a battery status judgment module (24), and a health diagnosis information reporting module (25); The charging judgment module (21) is configured to issue a charging command only when four conditions are met simultaneously: the charging module (33) is fault-free, the joint module is in a non-high load power output state, the remaining power of the encoder battery (5) is lower than the preset power value, and the temperature of the encoder battery (5) is lower than the preset over-temperature threshold; if any one condition is not met, a stop charging command is issued immediately.

3. The intelligent charging system for joint module encoder battery of claim 2, wherein, The joint module operation status determination module (22) determines the high load power output status of the joint module by at least one of the following methods: Power-current dual threshold determination method: preset the rated power and rated current of the joint module and the corresponding threshold coefficient, monitor the output power and output current in real time, and when either the output power or the output current meets the corresponding preset threshold and continues for the corresponding set duration, it is determined to be a high load state, and configure the de-jitter delay and hysteresis interval to avoid frequent state switching. Torque-Power-Speed ​​Curve Lookup Table Evaluation Method: Pre-store three-dimensional lookup tables corresponding to the torque, speed, and power of the joint module, as well as three-dimensional lookup tables corresponding to the torque, speed, and current. Collect operating parameters in real time to obtain the limit output parameters by looking up the tables. Determine the high load state based on the ratio between the real-time output parameters and the limit output parameters. Bus current change rate rapid detection method: Real-time monitoring of bus current change rate, and determination of high load operation status based on the current rise rate within a preset short period of time and the ratio of real-time current to rated current.

4. The intelligent charging system for joint module encoder battery of claim 2, wherein, The working mode of the charging module status judgment module (23) is as follows: it pre-stores the ADC conversion data range corresponding to the overcurrent, overvoltage, open circuit, short circuit and normal working state of the charging module (33), reads the voltage and current ADC sampling data of the charging module (33) in real time, compares the preset data range to determine the working state of the charging module (33), and synchronously reports the fault signal and terminates the charging request when a fault is detected.

5. The intelligent charging system for joint module encoder battery of claim 2, wherein, The battery state judgment module (24) is configured with internal resistance estimation method and capacity decay estimation method to realize battery aging judgment; The internal resistance estimation method is as follows: the battery internal resistance is calculated by collecting the transient change data of the battery voltage and current at the moment of charging connection, and converting it into the equivalent internal resistance at the standard temperature of 20℃ by combining the preset temperature-internal resistance compensation table. When the equivalent internal resistance exceeds 1.5 times the initial internal resistance of the battery, the battery is judged to be aging. The capacity decay estimation method is as follows: the actual charging capacity is calculated by coulomb integration, and the remaining battery capacity before and after charging is obtained by interpolation of the OCV-SOC curve. The battery health status SOH is calculated. When the battery health status SOH is lower than 70%, the battery is determined to be aging and a replacement reminder is pushed. The battery health status SOH calculation formula introduces a charging efficiency compensation coefficient, and the optimized formula is: SOH = actual charging capacity × charging efficiency compensation coefficient / standard charging capacity.

6. The intelligent charging system for the joint module encoder battery according to claim 2, characterized in that, The battery status judgment module (24) uses the temperature-compensated OCV-SOC curve interpolation lookup table method and the sampling resistor combined with the coulomb integration monitoring method of the current sensing chip to realize the monitoring of the remaining battery power.

7. The intelligent charging system for joint module encoder battery of claim 1, wherein, The detection unit (4) integrates a fault detection module (41), a temperature detection module (42), a battery internal resistance detection module (43), a battery power detection module (44), a voltage detection module (45), and a current detection module (46). Each module collects corresponding operating condition data in real time and uploads it to the control unit (2) to provide data support for charging decisions, fault diagnosis, and battery health assessment.

8. The intelligent charging system for joint module encoder battery of claim 1, wherein, The system is equipped with a wired and wireless dual-mode charging mechanism; The wired charging mode is as follows: after the joint module is powered on, the voltage is stepped down by the voltage conversion module (32) to power the charging module (33) so as to realize the normal charging of the encoder battery (5); The wireless charging mode is as follows: a backup wireless charging module is configured so that when the joint module is powered off and in standby mode for a long time, the encoder battery (5) is charged through the wireless charging module.

9. A joint module encoder battery intelligent charging method, characterized in that, The method applied to the smart charging system according to any one of claims 1-8 includes the following steps: After the joint module power-on / off management module (31) detects that the joint module is powered on, it wakes up the control unit (2) and collects the working condition data of the charging module (33) and the voltage, current, temperature, internal resistance and remaining power data of the encoder battery (5) in real time through the detection unit (4); The control unit (2) detects the load status of the joint module and the aging status of the battery based on the collected data, and at the same time determines the fault of the charging module (33), the battery temperature and the power status. The control unit (2) synchronously judges whether the preset charging conditions are met. If the charging module (33) is fault-free, the joint module is in a non-high load working state, the encoder battery (5) power is lower than the preset value and the battery temperature is normal, the charging process is triggered, the voltage conversion module (32) is controlled to step down the power supply, and the charging module (33) is activated to charge the encoder battery (5). During the charging process, various operating parameters are dynamically monitored in real time. The real-time battery SOC is obtained by temperature compensation interpolation method of OCV-SOC curve. When the battery SOC reaches the preset full charge threshold and the parameters are stable, it is determined to be fully charged. The charging module (33) is immediately disconnected to terminate charging. If the joint module is powered off and in standby mode for a long time, the wireless charging mode is activated to recharge the encoder battery (5); the control unit (2) pushes the battery health data, fault information and charging status information to the display unit (1) in a synchronized manner to realize data visualization and early warning.

10. A robot, characterized in that The system includes a robot body, the robot body being equipped with a joint module, and the joint module being configured with an intelligent charging system for the joint module encoder battery as described in any one of claims 1-8.

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