High voltage control method and system for an overloading robot

Abstract

This invention discloses a high-voltage control method and system for overloaded robots, relating to the field of robot detection technology. The method includes: extracting scene load feature vectors from the real-time task scenario of the overloaded robot; importing the robot's posture dynamics model and generating a first overload current upper limit through instantaneous joint overload analysis using a servo drive chip; performing inverse calculation on the real-time motion posture to generate multiple feasible reconfigurable postures and calculating load transfer distribution data; performing continuous joint overload analysis to generate a second overload current upper limit; and constructing a load current range and sending it to a DC-DC controller for power supply protection. This invention solves the technical problems in existing technologies where low-voltage systems cannot meet the power requirements under overload and high-impact scenarios, and high-voltage systems cannot dynamically adjust the overload current upper limit of each joint. It achieves the technical effect of improving the safety of high-voltage power supply and the overall dynamic response performance of the robot under overload scenarios.

Description

Technical Field

[0001] This invention relates to the field of robot-related technologies, specifically to a high-voltage control method and system for an overloaded robot. Background Technology

[0002] Existing low-voltage robot systems have significant drawbacks when facing overload or high-impact scenarios. First, low-voltage systems require extremely high current to output high power, resulting in significant power loss, severe heat generation, and low efficiency. Second, the low-voltage bus voltage is susceptible to fluctuations due to load variations, affecting control accuracy and system stability. Third, low-voltage solutions are insufficient in terms of size, weight, and heat dissipation to meet the demands of high-power joints operating under high-dynamic conditions for extended periods, limiting the robot's load-bearing capacity and motion performance. Some existing technologies attempt to use high-voltage power platforms to improve power transmission efficiency and reduce current loss; however, current high-voltage systems still have shortcomings in adaptive overload protection at the robot joint level. Based on fixed current limits, they cannot dynamically adjust the instantaneous or continuous overload current limits of each joint according to real-time task scenarios and dynamic posture changes of the robot, leading to false protection or untimely protection under overload impacts. Furthermore, the lack of integration between overload capacity analysis at the joint control end and dynamic voltage / current regulation at the DC-DC output makes it difficult to achieve precise high-voltage power supply protection for each joint.

[0003] Therefore, in the current related technologies, there are technical problems such as low-voltage systems being unable to meet the power requirements under overload and high-impact scenarios, and high-voltage systems being unable to dynamically adjust the overload current limit of each joint. Summary of the Invention

[0004] This application provides a high-voltage control method and system for overloaded robots, which solves the technical problems in the prior art where low-voltage systems cannot meet the power requirements under overload and high-impact scenarios, and high-voltage systems cannot dynamically adjust the overload current limit of each joint. This achieves the technical effect of improving the safety of high-voltage power supply and the overall dynamic response performance of robots under overload scenarios.

[0005] This application provides a high-voltage control method for an overloaded robot. The method includes: sending a real-time task scenario of the overloaded robot and extracting a scenario load feature vector; importing the attitude dynamics model of the overloaded robot, and using a servo drive chip to call the attitude dynamics model to perform instantaneous joint overload analysis on the scenario load feature vector, generating a first overload current upper limit for each joint; performing inverse calculation on the real-time motion posture of the overloaded robot based on the real-time task scenario to generate multiple feasible reconfigurable postures, and calculating the load transfer distribution data for each feasible reconfigurable posture; performing continuous joint overload analysis based on the load transfer distribution data, and generating a second overload current upper limit for each joint; constructing a load current range based on the first overload current upper limit and the second overload current upper limit, and the servo drive chip sending the load current range corresponding to each joint to a DC-DC controller for power supply protection.

[0006] In a possible implementation, the servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection. The method includes: the DC-DC controller includes multiple independent output channels, which are respectively connected to the power supply terminals of the servo drivers of each joint of the overloaded robot, and each independent output channel includes multiple corresponding power switches; according to the load current range corresponding to each joint, the power supply circuit connected to the input terminal of the DC-DC controller is selected, and the power switches of the corresponding independent output channels are turned on to provide power supply protection to the power supply terminals of the joint node servo drivers according to the corresponding load current range.

[0007] In a possible implementation, a multi-stage power supply circuit consisting of a high-voltage control bus, a medium-voltage control bus, and a low-voltage control bus is deployed. The DC-DC controller selects the corresponding power supply circuit to establish a power supply connection through a control bus switching module. The method includes: when the load current range is greater than a first current level threshold, the control bus switching module connects the high-voltage control bus; when the load current range is between the first current level threshold and a second current level threshold, the bus switching module connects the medium-voltage control bus; when the load current range is less than the second current level threshold, the control bus switching module connects the low-voltage control bus.

[0008] In a possible implementation, the servo drive chip calls the attitude dynamics model to perform instantaneous joint overload analysis on the scene load feature vector. The method includes: parsing the scene load feature vector through the attitude dynamics model to extract the instantaneous external force vector and instantaneous external torque vector of the end effector required for the task; mapping the instantaneous external force vector and instantaneous external torque vector to the joints of the overloaded robot using a Jacobian matrix, and calculating the instantaneous joint torque corresponding to each joint; calculating the instantaneous peak current of each joint based on the instantaneous joint torque and the motor torque constant, and generating the first overload current upper limit corresponding to each joint using the instantaneous peak current.

[0009] In a possible implementation, the real-time motion posture of the overloaded robot is inversely calculated based on the real-time task scenario to generate multiple feasible reconfigurable postures. The method includes: determining the fixed pose matrix of the overloaded robot's end effector based on the real-time task scenario; obtaining the joint constraints of the overloaded robot, including degree-of-freedom constraints, acceleration constraints, and velocity constraints; under the joint constraints, performing inverse Jacobian matrix calculation on the joints of the non-end effector based on the fixed pose matrix to obtain the initial motion vector in the joint space; and performing perturbation iterative optimization on the initial motion vector in the joint space to generate multiple feasible reconfigurable postures.

[0010] In a possible implementation, a continuous motion joint overload analysis is performed based on the load transfer distribution data to generate a second overload current limit for each joint. The method includes: obtaining the transfer external force vector and transfer external torque vector for each joint based on the load transfer distribution data corresponding to each feasible reconfigurable posture; recalculating the overload current limit for each joint under each feasible reconfigurable posture based on the transfer external force vector and transfer external torque vector; and summarizing the multiple load current limits corresponding to the multiple feasible reconfigurable postures to generate a second overload current limit for each joint.

[0011] In a possible implementation, a load current range is constructed based on the first overload current upper limit and the second overload current upper limit. The first overload current upper limit is used to characterize the peak load capacity under instantaneous joint movement conditions, and the second overload current upper limit is used to characterize the stable load capacity under continuous joint movement conditions. A basic load current range is generated based on the first overload current upper limit and the second overload current upper limit. Real-time joint status data, including joint temperature rise status, service life status, and motor magnetic saturation, are acquired to correct the basic load current range, resulting in a corrected load current range.

[0012] This application also provides a high-voltage control system for an overloaded robot. The system includes: a feature vector extraction module, used to send a real-time task scenario of the overloaded robot and extract the scenario load feature vector; a first upper limit generation module, used to import the attitude dynamics model of the overloaded robot, and use a servo drive chip to call the attitude dynamics model to perform instantaneous joint overload analysis on the scenario load feature vector to generate a first overload current upper limit corresponding to each joint; a reconstructed attitude generation module, used to perform inverse calculation on the real-time motion attitude of the overloaded robot based on the real-time task scenario to generate multiple feasible reconstructed attitudes, and calculate the load transfer distribution data for each feasible reconstructed attitude; a second upper limit generation module, used to perform continuous joint overload analysis based on the load transfer distribution data to generate a second overload current upper limit corresponding to each joint; and a load current range construction module, used to construct a load current range based on the first overload current upper limit and the second overload current upper limit, wherein the servo drive chip sends the load current range corresponding to each joint to a DC-DC controller for power supply protection.

[0013] This application proposes a high-voltage control method and system for overloaded robots. The method involves: extracting scene load feature vectors from real-time task scenarios of the overloaded robot; importing the robot's posture dynamics model and generating a first overload current limit through instantaneous joint overload analysis using a servo drive chip; performing inverse calculations on the real-time motion posture to generate multiple feasible reconfigurable postures and calculating load transfer distribution data; performing continuous joint overload analysis to generate a second overload current limit; and constructing a load current range and sending it to a DC-DC controller for power supply protection. This addresses the technical problems in existing technologies where low-voltage systems cannot meet power demands under overload and high-impact scenarios, and high-voltage systems cannot dynamically adjust the overload current limits of each joint. The method effectively improves the safety of high-voltage power supply and overall dynamic response performance in robot overload scenarios. Attached Figure Description

[0014] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments of this disclosure will be briefly described below. Flowcharts are used in this application to illustrate the operations performed by the system according to the embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed precisely in sequence. Instead, various steps can be processed in reverse order or simultaneously as needed. Furthermore, other operations can be added to these processes, or one or more steps can be removed from these processes.

[0015] Figure 1 This is a schematic flowchart of a high-pressure control method for an overloaded robot provided in an embodiment of this application.

[0016] Figure 2This is a schematic diagram of a high-pressure control system for an overloaded robot, provided as an embodiment of this application.

[0017] Figure labeling: Feature vector extraction module 10, first upper limit generation module 20, reconstructed attitude generation module 30, second upper limit generation module 40, load current range construction module 50. Detailed Implementation

[0018] To further illustrate the technical means and effects adopted by the present invention in order to achieve the intended purpose, the following detailed description is provided in conjunction with the accompanying drawings and preferred embodiments, based on the specific implementation methods, structures, features and effects of the present invention.

[0019] This application provides a high-pressure control method for an overloaded robot, such as... Figure 1 As shown, the method includes: Step S100: Issue the real-time task scenario of the overloaded robot and extract the scenario load feature vector.

[0020] Preferably, the task scheduler, path planner, or remote control system sends the description information of the specific task to be executed at the current moment to the robot's joint control unit, i.e., the real-time task scenario. This includes at least the target motion trajectory of the end effector in Cartesian space, the value of the external force that the end effector needs to withstand, the task duration and repetition frequency, environmental constraints such as the ground friction coefficient and the location of spatial obstacles, and then extracts quantitative parameters to characterize the load characteristics from the real-time task scenario through numerical calculation to determine the scenario load feature vector. This vector includes at least the instantaneous external force amplitude of the end effector in the x, y, and z directions, the instantaneous external torque amplitude of the end effector about the x, y, and z axes, the linear acceleration and angular acceleration of the end effector, and the duration, period of action, and duty cycle of the force and torque.

[0021] Step S200: Import the attitude dynamics model of the overloaded robot, and use the servo drive chip to call the attitude dynamics model to perform instantaneous joint overload analysis on the scene load feature vector, and generate the first overload current limit for each joint.

[0022] Step S200 further includes: analyzing the scene load feature vector through the attitude dynamics model to extract the instantaneous external force vector and instantaneous external torque vector of the end effector required for the task; mapping the instantaneous external force vector and instantaneous external torque vector to the joints of the overloaded robot using the Jacobian matrix, and calculating the instantaneous joint torque corresponding to each joint; calculating the instantaneous peak current of each joint based on the instantaneous joint torque and the motor torque constant, and generating the first overload current upper limit corresponding to each joint using the instantaneous peak current.

[0023] Preferably, the attitude dynamics model of the overloaded robot is imported. This model is a set of equations mathematically describing the mass, center of mass, moment of inertia, and joint motion constraints of each link of the robot. The scene load feature vector is analyzed using the attitude dynamics model. Specifically, through inverse dynamics calculations, the six-dimensional spatial force that the end effector must apply at the contact point to generate the motion and load required for the task under the current planned motion is deduced. The instantaneous external force vector and instantaneous external torque vector of the end effector are output, representing the instantaneous force components of the end effector in the three orthogonal directions of the Cartesian coordinate system, and the instantaneous torque components of the end effector about the three coordinate axes, respectively. The six-dimensional generalized external force vector acting on the end effector is then analytically extracted. :

[0024] Combined with the robot's joint angle vector at the current moment Construct the corresponding Jacobian matrix for the current configuration. The end-effector forces are mapped to the joint space, and the instantaneous joint torque demand vectors for each joint are calculated. :

[0025] in, For the overall machine inertia matrix, The matrix of Coriolis force and centrifugal force. This is the gravity matrix.

[0026] For any i-th joint, the torque constant of its motor is known to be... Calculate its instantaneous peak current demand. :

[0027] To ensure the hardware safety of the high-voltage power supply system, a transient limit for the battery pack discharge current is introduced. and the fuse current of the inverter power module (IGBT). As a boundary cutoff condition, the upper limit of the first overload current of each joint is ultimately generated. satisfy:

[0028] And it must meet the overall machine constraint verification: If the ratio exceeds the limit, then each joint will be contracted proportionally according to its weight.

[0029] Preferably, the Jacobian matrix is ​​a mapping matrix in robot kinematics with a dimension of 6×n (n is the number of joints). The matrix elements are functions of the angles of each joint and are used to establish a linear mapping relationship between the end effector velocity and the joint velocity. According to the principle of virtual work, there is a mapping relationship between the external force applied by the end effector and the balancing torque generated by each joint. That is, the vector formed by the instantaneous torques of each joint is equal to the product of the transpose of the Jacobian matrix and the six-dimensional spatial force / torque vector. Through this matrix multiplication operation, the six-dimensional spatial force / torque borne by the end effector is distributed to each joint of the robot, and the instantaneous joint torque value that each joint must output to balance the end effector load under the current configuration is obtained. There is a linear relationship between the electromagnetic torque and the drive current of the joint servo motor. For each joint, its instantaneous peak current is the ratio of the instantaneous joint torque to the torque constant of the joint motor. The torque constant of the joint motor is determined by the motor parameter manual. The instantaneous peak current is the peak current required by the joint under the current instantaneous impact condition. Then, the instantaneous peak current is used as the first overload current limit, which represents the maximum current that the joint can reach under instantaneous action conditions, and is used to characterize the instantaneous peak load capacity of the joint.

[0030] Preferably, the attitude dynamics model is usually constructed using the Lagrange method or the Newton-Euler method. Specifically, based on the joint distribution of the robot, an improved DH parameter method is used to fix a coordinate system to each rigid link (thigh, lower leg, etc.), define the transformation relationship between joints, import the physical properties of each joint under overload scenario, including the weight of each link, the coordinates of the link's center of gravity, and the rotational inertia matrix of the large inertia link under high pressure and heavy load. Then, the translational kinetic energy and rotational kinetic energy of each joint and the gravitational potential energy based on the gravitational field are calculated and determined. The closed dynamic equations are derived and determined by applying the Lagrange equations. The attitude dynamics model is mathematically expressed in matrix form to adapt to the real-time calculation of the servo drive chip. Its core structure includes four matrix components: inertia matrix, Coriolis force and centrifugal force matrix, gravity matrix, and end-effector contact force matrix. Among them, the inertia matrix represents the inertia of joint motion. Under overload scenarios, the value of this matrix is ​​large, reflecting the characteristic that heavy-load linkages are difficult to accelerate. The Coriolis force and centrifugal force matrix is ​​used to describe the nonlinear forces generated between joints due to velocity coupling. For example, when the hip joint rotates rapidly, the inertial force generated on the lower leg joint is a kind of inertial force. The gravity matrix is ​​the basis for extracting the instantaneous external force vector of the end effector. The end-effector contact force matrix maps the external environment (such as ground reaction force and heavy object pressure) to the equivalent torque on the joint through the transpose of the Jacobian matrix.

[0031] Step S300: Based on the real-time task scenario, perform inverse calculation on the real-time motion posture of the overloaded robot to generate multiple feasible reconfigurable postures, and calculate the load transfer distribution data for each feasible reconfigurable posture.

[0032] Step S300 further includes: determining the fixed pose matrix of the overloaded robot end effector based on the real-time task scenario; obtaining the joint constraints of the overloaded robot, including degree-of-freedom constraints, acceleration constraints, and velocity constraints; under the joint constraints, performing Jacobian matrix inverse calculation on the joints of the non-end effector based on the fixed pose matrix to obtain the initial motion vector in the joint space; and performing perturbation iterative optimization on the initial motion vector in the joint space to generate multiple feasible reconfigurable poses.

[0033] Preferably, based on the operational requirements in the real-time task scenario, such as grasping an object at specific coordinates or applying force on a designated plane, the spatial pose that the end effector of the overloaded robot must reach is calculated. This pose remains fixed during task execution and serves as the constraint target for inverse calculation, obtaining a fixed pose matrix to describe the target position and orientation of the end effector in Cartesian space, including the orientation and position coordinates of the end effector in three-dimensional space. Next, the joint constraints of the overloaded robot are obtained, including degree-of-freedom constraints, acceleration constraints, and velocity constraints. Degree-of-freedom constraints refer to the restrictions on the motion type of each joint, such as the joint angle range for rotary joints and the joint displacement range for translational joints, as well as the number of joints and the direction of the motion axis. Acceleration constraints refer to the upper limit of the rate of change of velocity of each joint per unit time, i.e., the upper limit of joint angular acceleration, determined by motor drive capability, mechanical structure strength, and current response speed of the high-voltage servo driver. Velocity constraints refer to the maximum value of the motion velocity of each joint, i.e., the upper limit of joint angular velocity, determined by the rated speed of the motor, the allowable speed of the reducer, and safe operating limits.

[0034] Preferably, a fixed pose matrix and joint constraints are input, and the Jacobian matrix inverse solution is performed on the joints of the non-end-effector. Specifically, under the condition that the end-effector pose is a fixed pose matrix, the angle values ​​of each joint are solved by inverse kinematic equations. The angles of non-end-effector joints located upstream of the kinematic chain, such as the hip joint and thigh joint, can change while keeping the end-effector pose unchanged. Based on the fixed pose matrix, the initial motion vector of the non-end-effector joint is solved using the null space property of the Jacobian matrix, so that the end-effector pose remains unchanged, and the initial motion vector of the joint space is obtained.

[0035] Preferably, while keeping the end effector pose unchanged, a small change is applied to the angle values ​​of the non-end effect joints, and multiple joint angle combinations that satisfy all constraints are found through iterative calculation. Specifically, a perturbation is added to the initial motion vector to generate a new joint angle vector, a new end effector pose matrix is ​​calculated, and it is verified whether the deviation from the target fixed pose matrix is ​​within the allowable error range. At the same time, it is checked whether each joint angle satisfies the joint constraints. If the constraints are not satisfied, the magnitude and direction of the perturbation are adjusted, and the iteration is repeated until convergence. All multiple feasible reconfigurable poses that satisfy the joint constraints are recorded. That is, under the premise that the end effector pose remains unchanged, the overall robot configuration that satisfies all joint physical constraints and is kinematically feasible is determined by changing the angle values ​​of the non-end effect joints.

[0036] Step S400: Perform continuous motion joint overload analysis based on the load transfer distribution data to generate the second overload current limit for each joint.

[0037] Step S400 further includes: for the load transfer distribution data corresponding to each feasible reconfigurable posture, obtaining the transfer external force vector and transfer external torque vector of each joint; recalculating the overload current upper limit corresponding to each joint under each feasible reconfigurable posture based on the transfer external force vector and transfer external torque vector; summarizing the multiple load current upper limits corresponding to the multiple feasible reconfigurable postures to generate a second overload current upper limit corresponding to each joint.

[0038] Preferably, the load transfer distribution data refers to the redistribution relationship of external load among the joints due to changes in robot configuration under different reconfiguration postures. Continuous motion joint overload analysis is performed on the load transfer distribution data. Specifically, an initial motion vector is selected as the reference posture. For each feasible reconfiguration posture, the joint force / torque distribution under that posture is calculated using a posture dynamics model. Then, the difference between the force / torque distribution and the reference posture is calculated to obtain the transferred external force vector of each joint, representing the additional force component that the joint bears or releases relative to the reference posture under the reconfiguration posture, and the transferred external torque vector, representing the additional torque component that the joint bears or releases relative to the reference posture under the reconfiguration posture.

[0039] Preferably, for each feasible reconfigurable posture, the current requirement of each joint under that posture is recalculated. Specifically, the sum of the reference torque of the joint under the reference posture and the additional torque of the joint converted from the transferred external force / torque vector is calculated to determine the total torque of the joint under that posture. Then, the ratio of this torque to the motor torque constant of the joint is calculated to determine the upper limit of the overload current under that posture, thereby obtaining the upper limit of the overload current corresponding to each joint under each feasible reconfigurable posture. For each joint, the upper limits of the load current corresponding to all feasible reconfigurable postures are summarized, and the maximum value is selected as the second upper limit of the overload current corresponding to each joint, which characterizes the stable load-bearing capacity of the joint under continuous action conditions, ensuring that the power supply of the joints will not exceed the safe range under any reconfigurable posture of the robot. For each generated feasible reconfigurable posture... ( First, by reconstructing its corresponding Jacobian matrix... Recalculate the joint torque under continuous load:

[0040] This leads to the mapping and derivation of the continuous current requirement of the i-th joint in this posture: .

[0041] At this point, the setting of the second overload current limit is not simply based on the sum of maximum values, but rather introduces an online thermal accumulation evaluation operator based on the driver junction temperature and winding temperature. Timing truncation is performed. The online heat loss integral equation for the i-th joint under continuous motion is:

[0042] in, The winding resistance varies with temperature. This refers to the real-time heat exchange power of the high-pressure liquid cooling system.

[0043] Set the evolution from the current operating condition to the maximum allowable safe junction temperature (e.g.) The allowable residual heat capacity is Set the overload continuous safe time limit as Then the time-series thermodynamic cutoff current value for:

[0044] Finally, the requirements for N sets of reconstructed attitudes are summarized and jointly converged in the time domain and thermodynamic boundary to generate the upper limit of the second overload current corresponding to the i-th joint. :

[0045] Step S500: Based on the first overload current limit and the second overload current limit, a load current range is constructed, and the servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection.

[0046] Preferably, the load current range is determined by using the first overload current upper limit as the upper limit boundary and the second overload current upper limit as the lower limit boundary. The second overload current upper limit is always less than the first overload current upper limit. If the load current is greater than the first overload current upper limit, it indicates current overload, and the DC-DC controller limits the current or cuts off the output. If the load current is less than the second overload current upper limit, it indicates insufficient power supply, and the DC-DC controller increases the output current to the second overload current upper limit.

[0047] Furthermore, step S500 also includes: constructing a load current range based on the first overload current upper limit and the second overload current upper limit, wherein the first overload current upper limit is used to characterize the peak load capacity under instantaneous joint movement conditions, and the second overload current upper limit is used to characterize the stable load capacity under continuous joint movement conditions; generating a basic load current range based on the first overload current upper limit and the second overload current upper limit; and obtaining real-time joint status data, including joint temperature rise status, service life status, and motor magnetic saturation, to correct the basic load current range and obtain a corrected load current range.

[0048] Preferably, the first overload current upper limit is the maximum peak current allowed for the joint under instantaneous action conditions, used to characterize the peak load capacity of the joint under instantaneous action conditions. This corresponds to the extremely large current that the joint motor needs to output for a short time when the robot is in a high-impact, high-dynamic action (such as rapid acceleration, collision buffering, or instantaneous grasping of heavy objects). The value is relatively large, up to 3 times the rated current, and the duration is short, such as less than 2 seconds. The second overload current upper limit is the maximum stable current required by the joint under continuous action conditions, used to characterize the stable load capacity of the joint under continuous action conditions. This corresponds to long-term continuous load conditions, such as lifting and holding, continuous driving uphill, and heavy object handling. The value is relatively small, usually within the rated current range, but the duration is long. The basic load current range is determined by using the first overload current upper limit as the upper limit boundary and the second overload current upper limit as the lower limit boundary.

[0049] Preferably, the current joint temperature is collected in real time by temperature sensors installed at key locations such as motor windings, drivers, and bearings. The temperature change rate is calculated and the historical highest temperature is statistically analyzed to obtain the joint temperature rise status. Increased temperature leads to increased winding resistance and intensified heating. Based on operation logs and historical data, or by using a lifespan counter within the servo driver to record the joint's cumulative operating time, cumulative overload counts, and cumulative total current integral, the lifespan service status is obtained. With increasing service time, motor insulation ages and bearings wear. The magnetic flux is estimated through current and voltage feedback, or the current magnetic flux, magnetic flux change rate, and saturation magnetic flux are directly measured using Hall effect sensors to obtain the motor's magnetic saturation. Increased current leads to increased magnetic flux, approaching the saturation point and entering the saturation region. The current increase no longer linearly increases torque, leading to a sharp decrease in efficiency. In the magnetic saturation state, the upper limit of the current is limited to prevent runaway. The joint temperature rise status and lifespan are then analyzed. The system generates real-time joint status data by combining service status and motor magnetic saturation, and corrects the basic load current range by multiplying the first and second overload current limits by various correction coefficients. Specifically, the temperature rise correction coefficient is ≤1, decreasing with increasing temperature (e.g., 1.0 at room temperature, 0.7 at the high temperature threshold); the lifespan correction coefficient is ≤1, decreasing with increasing lifespan loss (e.g., 1.0 for a new machine, 0.7 at the design lifespan); and the magnetic saturation correction coefficient is ≤1, decreasing as the magnetic flux approaches saturation (e.g., 1.0 for the motor in the linear region, 0.5 at the saturation point). Finally, the corrected load current range is output, thus preventing overheating damage, efficiency collapse, and runaway, ensuring the safety of the DC-DC controller's power supply protection under extreme conditions.

[0050] Furthermore, step S500 also includes the following: the DC-DC controller includes multiple independent output channels, which are respectively connected to the power supply terminals of the servo drivers of each joint of the overloaded robot, and the multiple independent output channels include corresponding multiple power switches; according to the load current range corresponding to each joint, the power supply circuit connected to the input terminal of the DC-DC controller is selected, and the power switches of the corresponding independent output channels are turned on to provide power supply protection to the power supply terminals of the joint node servo drivers according to the corresponding load current range.

[0051] Preferably, the servo drive chip issues the load current interval corresponding to each joint to the DC-DC controller for power supply protection, wherein the servo drive chip is a microprocessor / digital signal processor integrated inside the robot joint servo driver or supporting the servo driver, located at the motion control layer of the robot control system, and communicatively connected with the underlying DC-DC controller through the CAN bus. The DC-DC controller is a hardware device for performing power supply protection, configured to connect the high-voltage battery pack and the power supply input terminal of each joint servo driver. The DC-DC controller integrates a plurality of output channels electrically isolated from each other, each channel can independently control its output voltage and current, the number of channels is in one-to-one correspondence with the number of joints of the overloaded robot, and the output end of each independent output channel is directly connected to the power supply input end of the servo driver of the corresponding joint through a wire harness; wherein a power switching device IGBT (Insulated Gate Bipolar Transistor) is disposed inside each independent output channel, connected in series between the bus voltage output end inside the DC-DC controller and the channel output terminal, serving as a general control valve for current output, configured to control the on-off state and the output current magnitude of the channel. The turn-on of the power switch indicates that current is allowed to flow to the joint servo driver, and the turn-off indicates that the current is cut off to realize power supply protection, and the output current value is accurately adjusted through PWM (Pulse Width Modulation) duty cycle control.

[0052] Further, step S500 further includes deploying a multi-stage power supply loop composed of a high-voltage control bus, a medium-voltage control bus and a low-voltage control bus. The DC-DC controller selects the corresponding power supply loop through the control bus switching module to establish a power supply connection, and the method includes: when the load current interval is greater than the first current level threshold, the control bus switching module turns on the high-voltage control bus; when the load current interval is between the first current level threshold and the second current level threshold, the bus switching module turns on the medium-voltage control bus; when the load current interval is less than the second current level threshold, the control bus switching module turns on the low-voltage control bus.

[0053] Preferably, the power supply circuit refers to the complete current path from the input power terminal of the DC-DC controller, through the internal power switch, to the output channel of a specific joint. A multi-stage power supply circuit is deployed, including a high-voltage control bus, a medium-voltage control bus, and a low-voltage control bus. The high-voltage control bus is directly output from the high-voltage battery pack and is suitable for high power and heavy loads. The medium-voltage control bus has its high voltage stepped down by a high-voltage DC-DC converter and is suitable for medium power and conventional loads, with a reference value of 24V. The low-voltage control bus has its medium voltage stepped down by a DC-DC module and is suitable for low power, light loads, or standby, with a reference value of 12V. The control bus switching module is a functional unit within the DC-DC controller, used to connect the input terminal of the DC-DC controller to the bus of the corresponding voltage level according to the load current range. The control bus switching module includes one high-voltage / medium-voltage / low-voltage input interface, three switching switches, and one switching logic circuit. The first current level threshold is set based on the maximum continuous output capacity of the medium-voltage bus, which is the current boundary value that distinguishes between high voltage and medium voltage; the second current level threshold is set based on the maximum continuous output capacity of the low-voltage bus, which is the current boundary value that distinguishes between medium voltage and low voltage, and the second current level threshold is less than the first current level threshold.

[0054] The DC-DC controller's internal control bus switching module connects the input terminal to the power bus of the corresponding voltage level. For example, if the load current range is less than the maximum output capacity of the low-voltage bus (meaning the entire current demand of the joint is within the output capacity range of the low-voltage bus), then the low-voltage control bus is connected. If the load current range is between the first and second current level thresholds (meaning the current demand of the joint is within the output capacity range of the medium-voltage bus but exceeds the output capacity of the low-voltage bus), then the medium-voltage control bus is connected. If the load current range is greater than the first current level threshold (meaning the minimum continuous current demand of the joint exceeds the maximum output capacity of the medium-voltage bus), then the high-voltage control bus is connected. The microcontroller or logic circuit inside the DC-DC controller generates a PWM drive signal based on the selection result, driving the gate of the power switch IGBT. The power switch switches from the off state to the on state, and current flows from the input terminal to the channel output terminal. Specifically, when the current demand equals the upper limit of the second overload current, the power switch is turned on with the maximum duty cycle (e.g., 100%), and the maximum continuous current is output; when the current demand is less than the maximum output capacity of the channel, the power switch is periodically turned on and off through PWM modulation, and the average output current is equal to the demand value.

[0055] Preferably, the input terminal of the DC-DC controller is connected to the filtered voltage bus, and the power switch performs PWM adjustment according to the upper limit value set in the load current range. The channel output terminal outputs the controlled voltage and current, which are transmitted to the power supply terminal of the joint servo driver. The DC-DC controller samples the output current in real time and compares it with the load current range. If the output current is lower than the lower limit of the load current range, the PWM duty cycle is increased and the output current is increased to ensure that the joint has enough current to complete the continuous load task. If the output current is within the range, the current PWM duty cycle is maintained. If the output current exceeds the upper limit of the load current range, the PWM duty cycle is reduced or the power switch is turned off to prevent the joint servo driver from being damaged due to overcurrent, thereby realizing the power supply protection of the joint node servo driver power supply terminal.

[0056] In the above text, refer to Figure 1 A high-pressure control method for an overloaded robot according to an embodiment of the present invention is described in detail. Next, reference will be made to... Figure 2 A high-pressure control system for an overloaded robot is described according to an embodiment of the present invention.

[0057] According to an embodiment of the present invention, a high-voltage control system for an overloaded robot is provided to solve the technical problems in the prior art where low-voltage systems cannot meet the power requirements under overload and high-impact scenarios, and high-voltage systems cannot dynamically adjust the overload current upper limit of each joint. This achieves the technical effect of improving the safety of high-voltage power supply and the overall dynamic response performance of the robot under overload scenarios. Figure 2 As shown, a high-voltage control system for an overloaded robot includes: a feature vector extraction module 10, a first upper limit generation module 20, a reconstructed posture generation module 30, a second upper limit generation module 40, and a load current range construction module 50.

[0058] The feature vector extraction module 10 is used to extract scene load feature vectors from the real-time task scenario of the overloaded robot; the first upper limit generation module 20 is used to import the posture dynamics model of the overloaded robot, and use the servo drive chip to call the posture dynamics model to perform instantaneous joint overload analysis on the scene load feature vectors, generating the first overload current upper limit corresponding to each joint; the reconstructed posture generation module 30 is used to perform inverse calculation on the real-time motion posture of the overloaded robot based on the real-time task scenario, generate multiple feasible reconstructed postures, and calculate the load transfer distribution data for each feasible reconstructed posture; the second upper limit generation module 40 performs continuous joint overload analysis based on the load transfer distribution data, generating the second overload current upper limit corresponding to each joint; the load current range construction module 50 is used to construct a load current range based on the first overload current upper limit and the second overload current upper limit, and the servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection.

[0059] The specific configuration of the load current range construction module 50 will be described in detail below. The load current range construction module 50 further includes: the DC-DC controller includes multiple independent output channels, each connected to the power supply terminal of the servo driver of each joint of the overloaded robot; each independent output channel includes a corresponding multiple power switches; based on the load current range corresponding to each joint, the power supply circuit connected to the input terminal of the DC-DC controller is selected, and by turning on the power switch of the corresponding independent output channel, power is supplied to the servo driver power supply terminal of the joint node according to the corresponding load current range for protection.

[0060] The specific configuration of the load current range construction module 50 will be described in detail below. The load current range construction module 50 further includes: deploying a multi-level power supply circuit consisting of a high-voltage control bus, a medium-voltage control bus, and a low-voltage control bus. The DC-DC controller selects the corresponding power supply circuit to establish a power supply connection through the control bus switching module. The method includes: when the load current range is greater than a first current level threshold, the control bus switching module connects the high-voltage control bus; when the load current range is between the first current level threshold and a second current level threshold, the bus switching module connects the medium-voltage control bus; when the load current range is less than the second current level threshold, the control bus switching module connects the low-voltage control bus.

[0061] The specific configuration of the first upper limit generation module 20 will be described in detail below. The first upper limit generation module 20 further includes: analyzing the scene load feature vector through the attitude dynamics model, extracting the instantaneous external force vector and instantaneous external torque vector of the end effector required for the task; mapping the instantaneous external force vector and instantaneous external torque vector to the joints of the overloaded robot using the Jacobian matrix, and calculating the instantaneous joint torque corresponding to each joint; calculating the instantaneous peak current of each joint based on the instantaneous joint torque and the motor torque constant, and generating the first overload current upper limit corresponding to each joint using the instantaneous peak current.

[0062] The specific configuration of the reconstructed pose generation module 30 will be described in detail below. The reconstructed pose generation module 30 further includes: determining the fixed pose matrix of the overloaded robot's end effector based on the real-time task scenario; obtaining the joint constraints of the overloaded robot, including degree-of-freedom constraints, acceleration constraints, and velocity constraints; under the joint constraints, performing inverse Jacobian matrix calculation on the joints of the non-end effector based on the fixed pose matrix to obtain the initial motion vector in the joint space; and performing perturbation iterative optimization on the initial motion vector in the joint space to generate multiple feasible reconstructed poses.

[0063] The specific configuration of the second upper limit generation module 40 will be described in detail below. The second upper limit generation module 40 further includes: obtaining the transfer external force vector and transfer external torque vector of each joint for the load transfer distribution data corresponding to each feasible reconfigurable posture; recalculating the overload current upper limit corresponding to each joint under each feasible reconfigurable posture based on the transfer external force vector and transfer external torque vector; and summarizing the multiple load current upper limits corresponding to the multiple feasible reconfigurable postures to generate the second overload current upper limit corresponding to each joint.

[0064] The specific configuration of the load current range construction module 50 will be described in detail below. The load current range construction module 50 further includes: constructing a load current range based on the first overload current upper limit and the second overload current upper limit, wherein the first overload current upper limit is used to characterize the peak load capacity under instantaneous joint movement conditions, and the second overload current upper limit is used to characterize the stable load capacity under continuous joint movement conditions; generating a basic load current range based on the first overload current upper limit and the second overload current upper limit; and obtaining real-time joint status data, including joint temperature rise status, service life status, and motor magnetic saturation, to correct the basic load current range, thereby obtaining a corrected load current range.

[0065] The high-pressure control system for an overloaded robot provided in this embodiment of the invention can execute the high-pressure control method for an overloaded robot provided in this embodiment of the invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0066] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A high-voltage control method for an overloaded robot, characterized in that, The method includes: Issue real-time task scenarios to overloaded robots and extract scenario load feature vectors; Import the attitude dynamics model of the overloaded robot, and use the servo drive chip to call the attitude dynamics model to perform instantaneous joint overload analysis on the scene load feature vector, and generate the first overload current limit for each joint. The scene load feature vector is analyzed using the attitude dynamics model to extract the instantaneous external force vector and instantaneous external torque vector of the end effector required for the task. The instantaneous external force vector and instantaneous external torque vector are mapped to the joints of the overloaded robot using the Jacobian matrix, and the instantaneous joint torque corresponding to each joint is calculated. The instantaneous peak current of each joint is calculated based on the instantaneous joint torque and the motor torque constant, and the first overload current limit corresponding to each joint is generated based on the instantaneous peak current. Based on the real-time task scenario, the real-time motion posture of the overloaded robot is inversely calculated to generate multiple feasible reconfigurable postures. The load transfer distribution data of each feasible reconfigurable posture is calculated. The load transfer distribution data refers to the redistribution relationship of the external load between the joints due to the change of robot configuration under different reconfigurable postures. Based on the load transfer distribution data, perform continuous motion joint overload analysis to generate the second overload current limit for each joint. For each feasible reconfigurable posture, the transfer force vector and transfer torque vector of each joint are obtained. Based on the transferred external force vector and the transferred external torque vector, the upper limit of the overload current corresponding to each joint under each feasible reconfigurable posture is recalculated; The upper limits of the load current corresponding to the multiple feasible reconfigurable postures are summarized to generate the second overload current upper limit for each joint. Based on the first overload current limit and the second overload current limit, a load current range is constructed, and the servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection. The system deploys a multi-stage power supply circuit consisting of a high-voltage control bus, a medium-voltage control bus, and a low-voltage control bus. The DC-DC controller selects the corresponding power supply circuit and establishes a power supply connection through a control bus switching module. The method includes: When the load current range is greater than the first current level threshold, the control bus switching module connects the high-voltage control bus. When the load current range is between the first current level threshold and the second current level threshold, the bus switching module connects the medium voltage control bus. When the load current range is less than the second current level threshold, the control bus switching module connects the low-voltage control bus.

2. The high-voltage control method for an overloaded robot as described in claim 1, characterized in that, The servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection, including the following methods: The DC-DC controller includes multiple independent output channels, which are respectively connected to the power supply terminals of the servo drivers of each joint of the overloaded robot. Each independent output channel includes multiple corresponding power switches. Based on the load current range corresponding to each joint, the power supply circuit connected to the input terminal of the DC-DC controller is selected, and the power switch of the corresponding independent output channel is turned on to provide power protection to the power supply terminal of the joint node servo driver according to the corresponding load current range.

3. The high-voltage control method for an overloaded robot as described in claim 1, characterized in that, Based on the real-time task scenario, the real-time motion posture of the overloaded robot is inversely calculated to generate multiple feasible reconstructed postures. The method includes: Determine the fixed pose matrix of the overloaded robot end effector based on the real-time task scenario; Obtain the joint constraints of the overloaded robot, including degree-of-freedom constraints, acceleration constraints, and velocity constraints; Under the joint constraints, the Jacobian matrix inverse calculation is performed on the joints of the non-end-effector based on the fixed pose matrix to obtain the initial motion vector in the joint space; The initial motion vector in the joint space is perturbed and iteratively optimized to generate multiple feasible reconfigurable poses.

4. The high-voltage control method for an overloaded robot as described in claim 1, characterized in that, The load current range is constructed based on the first overload current limit and the second overload current limit. The first overload current limit is used to characterize the peak load capacity under the instantaneous action condition of the joint, and the second overload current limit is used to characterize the stable load capacity under the continuous action condition of the joint. Based on the first overload current limit and the second overload current limit, a basic load current range is generated; The real-time status data of the joint, including joint temperature rise, service life, and motor magnetic saturation, is obtained to correct the basic load current range, resulting in the corrected load current range.

5. A high-voltage control system for an overloaded robot, characterized in that, The system is used to implement the high-pressure control method for an overloaded robot according to any one of claims 1 to 4, the system comprising: The feature vector extraction module is used to extract the scene load feature vector when a real-time task scenario is issued to the overloaded robot. The first upper limit generation module is used to import the posture dynamics model of the overloaded robot, and use the servo drive chip to call the posture dynamics model to perform instantaneous joint overload analysis on the scene load feature vector to generate the first overload current upper limit corresponding to each joint. The reconstructed posture generation module is used to perform inverse calculation of the real-time motion posture of the overloaded robot based on the real-time task scenario, generate multiple feasible reconstructed postures, and calculate the load transfer distribution data of each feasible reconstructed posture. The second upper limit generation module performs continuous motion joint overload analysis based on the load transfer distribution data and generates the second overload current upper limit for each joint. The load current range construction module is used to construct a load current range based on the first overload current limit and the second overload current limit. The servo drive chip sends the load current range corresponding to each joint to the DC-DC controller for power supply protection.

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