Method and apparatus for automatic protection of robot control system from abnormality

Abstract

The application relates to the field of robot control and discloses an abnormal automatic protection method and device of a robot control system, which comprises the following steps: collecting the running state data of the robot according to a set sampling period, wherein the running state data comprises current data, temperature data, encoder data, heartbeat data and watchdog data; calculating a transient comprehensive risk index based on the collected running state data; setting a judgment model of a hierarchical protection level and protection measures corresponding to each protection level; mapping the running state data or the transient comprehensive risk index into the corresponding protection level by using the judgment model; and executing the corresponding protection measures according to the mapped protection level. The application has the following advantages: the application can effectively avoid misjudgment or missed judgment caused by a single detection module, thereby improving the abnormal identification accuracy; and the application can flexibly execute the matching protection action according to the fault severity, thereby effectively reducing the probability of misstop.

Description

Technical Field

[0001] This invention relates to the field of robot control, and specifically to an automatic protection method and device for abnormalities in a robot control system. Background Technology

[0002] Existing robot control systems (such as patrol robots) are typically equipped with monitoring functions for current, temperature, encoders, and communication status. When a local anomaly is detected, they can trigger an alarm or stop a single module. Additionally, some systems use software watchdog timers or remote heartbeats to determine the online status of the control link. However, existing control systems have the following shortcomings in practical use:

[0003] 1. For issues such as motor overcurrent, temperature rise, and encoder step loss, different modules usually handle them separately, lacking a unified fault level judgment, which can easily lead to problems such as over-handling of minor faults or insufficient response to serious faults.

[0004] 2. Communication link detection usually relies only on remote command timeouts and does not link remote heartbeats and internal watchdogs, making it impossible to accurately distinguish between short-term packet loss and link anomalies.

[0005] 3. Some systems directly control the robot to resume movement after communication is restored, lacking mechanisms such as stopping and waiting, remote status reading, and manual confirmation. This may cause the robot to start moving again before confirming that the environment is safe. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an automatic protection method and device for robot control systems. This addresses issues such as the lack of a unified fault level assessment mechanism in control systems, leading to over-handling of minor faults or insufficient response to serious faults; the failure to link remote heartbeat and internal watchdog, making it impossible to accurately distinguish between short-term packet loss and link anomalies; and the lack of mechanisms for waiting in a stopped state, remote status reading, and manual confirmation, which could cause the robot to resume movement without confirming environmental safety.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] In a first aspect, the present invention provides an automatic protection method for anomalies in a robot control system, the method comprising:

[0009] The robot's operating status data is collected according to a set sampling period. The operating status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data.

[0010] The transient comprehensive risk index is calculated based on the collected operational status data;

[0011] Set up a judgment model for graded protection levels and the corresponding protection measures for each protection level. Use the judgment model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and execute the corresponding protection measures according to the mapped protection level.

[0012] Furthermore, the formula for calculating the transient comprehensive risk index is as follows:

[0013] ;

[0014] in, Represents the characteristic quantity of current. Weighting coefficients representing current characteristic quantities; Represents temperature characteristic quantity, Weighting coefficients representing temperature characteristic quantities; This represents the encoder's out-of-step feature. Weighting coefficients representing encoder out-of-step features; Represents the characteristic quantity of the communication link. Weighting coefficients representing characteristic quantities of the communication link; Indicates the quantity of watchdog markings. The weighting coefficients represent the watchdog flag values; each weighting coefficient satisfies the normalization constraint. .

[0015] Furthermore, the expression for the current characteristic quantity is: ,in, This represents the effective value of the three-phase current of the motor. This is the rated current of the motor;

[0016] The expression for the temperature characteristic quantity is: ,in, For real-time temperature, The baseline temperature for safe operation, The temperature threshold for shutdown; when At that time, a mandatory order ;

[0017] The expression for the encoder's out-of-step feature is: ,in, For motor command position, For encoder feedback position, This is the base value for the maximum permissible position deviation;

[0018] The expression for the communication link characteristic is: ,in, This represents the number of consecutively lost heartbeats or command responses. The threshold for determining the number of communication disconnections;

[0019] When the main task's cycle execution deviation exceeds a preset deviation threshold, the watchdog flag value... The value is 1, otherwise the watchdog flag is set. The value is 0.

[0020] Furthermore, the sampling period for the operating status data is 1 second. The value is 0.30. The value is 0.25. The value is 0.20. The value is 0.10. The value is 0.15.

[0021] Furthermore, the specific method of mapping the operating status data or transient comprehensive risk index to the corresponding protection level using the judgment model is as follows: performing a moving average process on the transient comprehensive risk index for N consecutive sampling periods to obtain the average risk value, and then using the judgment model to map the operating status data or the average risk value to the corresponding protection level.

[0022] Furthermore, the determination model for setting graded protection levels and the protection measures corresponding to each protection level are specifically as follows:

[0023] Set a first-level soft threshold, a second-level soft threshold, and a third-level soft threshold, wherein the first-level soft threshold is lower than the second-level soft threshold, and the second-level soft threshold is lower than the third-level soft threshold;

[0024] When the average risk value is less than the first-level soft threshold and the operating status data does not meet the interruption conditions, the robot is kept in normal operating status.

[0025] When the average risk value is greater than or equal to the first-level soft threshold and less than the second-level soft threshold, or when the collected temperature data is greater than the first temperature threshold, the robot enters the first-level early warning protection. In the first-level early warning protection, an audible and visual warning signal is triggered, and the robot is controlled to continue to perform the current task according to the predetermined motion parameters.

[0026] When the average risk value is greater than or equal to the second-level soft threshold and less than the third-level soft threshold, or when the collected current data exceeds the first preset percentage value of the rated current and continues for the first preset time, the robot enters the second-level deceleration protection; in the second-level deceleration protection, the robot is controlled to perform dual limiting of rotational speed and linear speed, and the robot continues to perform the current task under the dual limiting of rotational speed and linear speed.

[0027] When the average risk value is greater than or equal to the level 3 soft threshold, or when the collected current data exceeds the second preset percentage value of the rated current, or when the collected temperature data is greater than the second temperature threshold or the temperature sensor has no effective feedback, or the encoder fails or loses synchronization, the robot enters the level 3 shutdown protection. In the level 3 shutdown protection, the robot is controlled to immediately perform mechanical braking and enter a shutdown waiting state. Among them, the second preset percentage value is greater than the first preset percentage value, and the second temperature threshold is greater than the first temperature threshold.

[0028] Furthermore, the first-level soft threshold is set to 0.35, the second-level soft threshold is set to 0.60, and the third-level soft threshold is set to 0.80; the first temperature threshold is set to 95℃, and the second temperature threshold is set to 130℃; the first preset percentage is set to 150%, the first preset time is set to 3s, and the second preset percentage is set to 200%; the dual limiting of speed and linear velocity specifically limits the motor speed to 30% of the rated speed and the linear velocity to less than or equal to 0.5m / s.

[0029] Furthermore, the method also includes:

[0030] If the robot does not receive any instructions or heartbeat data from the remote control platform within a second preset time, the robot will be triggered to execute the communication disconnection protection mechanism. In the communication disconnection protection mechanism, the robot will immediately apply mechanical braking and enter a stop waiting state.

[0031] Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements:

[0032] First layer: The robot periodically attempts to restore heartbeat communication at preset time intervals and successfully receives a response from the remote control platform;

[0033] The second layer: The robot fully reads the current status instructions and mode parameters issued by the remote control platform;

[0034] The third layer: The robot receives a manual confirmation signal from the operator or an explicit authorization instruction from a remote source.

[0035] Secondly, the present invention provides an automatic protection device for abnormalities in a robot control system, the device comprising:

[0036] The status data acquisition module is used to collect the robot's operating status data according to a set sampling period. The operating status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data.

[0037] The calculation module is used to calculate the transient comprehensive risk index based on the collected operational status data;

[0038] The level determination and protection module is used to set the determination model for the graded protection levels and the protection measures corresponding to each protection level. It uses the determination model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and executes the corresponding protection measures according to the mapped protection level.

[0039] Furthermore, the device also includes:

[0040] The communication protection module is used to trigger the robot to execute the communication disconnection protection mechanism when the robot does not receive instructions or heartbeat data from the remote control platform within a second preset time. In the communication disconnection protection mechanism, the robot is controlled to immediately perform mechanical braking and enter a stop waiting state.

[0041] Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements:

[0042] First layer: Periodically attempts to restore heartbeat communication at preset time intervals and successfully receives a response from the remote control platform;

[0043] The second layer: fully reads the current status instructions and mode parameters issued by the remote control platform;

[0044] The third layer: Obtaining explicit authorization instructions from the operator, either through manual confirmation or remote authorization.

[0045] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages:

[0046] 1. By using a continuous comprehensive risk scoring function (i.e., transient comprehensive risk index) to uniformly incorporate current, temperature, encoder, remote heartbeat signal and internal watchdog into fault judgment, it can effectively avoid misjudgment or omission caused by a single detection module, thereby improving the accuracy of anomaly identification.

[0047] 2. By performing a moving average on the transient comprehensive risk index over N consecutive sampling periods, and mapping the corresponding protection level based on the obtained average risk value, transient noise disturbances can be effectively suppressed.

[0048] 3. By setting a graded protection strategy of first-level early warning, second-level deceleration and third-level shutdown, the system can flexibly execute matching protection actions according to the severity of the fault, thereby effectively reducing the probability of false shutdown and improving safety under severe faults; at the same time, when entering the third-level shutdown protection strategy, the mechanical brake is immediately used to achieve braking, which can quickly cut off the drive output when a severe fault occurs.

[0049] 4. The design includes communication disconnection detection, including commands or heartbeat data from the remote control platform. At the same time, the internal watchdog unit is designed to automatically stop feeding the watchdog and trigger a system reset when the deviation of the main task cycle execution exceeds the preset deviation threshold. The combination of the two can more accurately distinguish between short-term packet loss and link anomalies.

[0050] 5. By setting safe restart conditions for the robot after communication is lost, the robot will not move blindly as soon as communication is restored. Instead, it will read remote authorization instructions or wait for manual confirmation before resuming operation, which can improve the robot's movement safety after the communication is restored. Attached Figure Description

[0051] Figure 1 This is a flowchart illustrating the execution process of an automatic anomaly protection method for a robot control system according to the present invention.

[0052] Figure 2 This is a schematic diagram of the structure of an automatic protection device for an abnormality in a robot control system according to the present invention. Detailed Implementation

[0053] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0054] Example 1

[0055] Please refer to Figure 1 As shown, this embodiment provides an automatic protection method for abnormalities in a robot control system. This method is applied to the central control unit of the robot and includes:

[0056] The robot's operational status data is collected according to a set sampling period. This operational status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data. Current data is monitored by a motor drive monitoring unit on the robot, which monitors and calculates the effective value of the motor's three-phase current in real time. Temperature data is monitored by a temperature monitoring unit on the robot, which uses a sliding window with 60 sampling points to sample the temperature data, with a sampling period of 1 second. Encoder data is monitored by an encoder feedback monitoring unit on the robot, which compares the positional deviation between the motor drive command position and the encoder feedback position in real time. Heartbeat data is monitored by a remote communication heartbeat monitoring unit. During operation, an independent heartbeat communication task is established between the remote control platform and the robot's central control unit. The heartbeat interval is 50ms, and the remote communication heartbeat monitoring unit can monitor this heartbeat communication task in real time. Watchdog data is obtained through an internal watchdog unit set on the robot. The timeout period of the internal watchdog unit is 1s. The robot's central control unit will perform a watchdog feeding operation within the main task cycle. When the deviation of the main task cycle execution cycle exceeds a preset deviation threshold, the watchdog feeding will stop and a system reset will be triggered. It should be noted that in this invention, the watchdog is a timer that needs to be reset (fed) periodically within the main task cycle. If the timeout occurs, a system reset will be triggered. Heartbeat communication refers to sending short messages at fixed time intervals to confirm whether the communication link is normal. The encoder is a sensor that converts rotational or linear displacement into electrical signals to provide feedback on the actual position of the motor.

[0057] A transient comprehensive risk index is calculated based on the collected operational status data, and this transient comprehensive risk index is used for fault judgment. Since the transient comprehensive risk index incorporates all collected operational status data into the fault judgment, it can improve the accuracy of anomaly identification.

[0058] Set up a judgment model for graded protection levels and the corresponding protection measures for each protection level. Use the judgment model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and execute the corresponding protection measures according to the mapped protection level.

[0059] In some embodiments of the present invention, the transient comprehensive risk index R(k) is calculated using the following formula:

[0060] ;

[0061] in, Represents the characteristic quantity of current. Weighting coefficients representing current characteristic quantities; Represents temperature characteristic quantity, Weighting coefficients representing temperature characteristic quantities; This represents the encoder's out-of-step feature. Weighting coefficients representing encoder out-of-step features; Represents the characteristic quantity of the communication link. Weighting coefficients representing characteristic quantities of the communication link; Indicates the quantity of watchdog markings. The weighting coefficients represent the watchdog flag values, where k represents the discrete sampling time number (i.e., the kth sampling point); each weighting coefficient satisfies a normalization constraint: This invention utilizes a continuous comprehensive risk scoring function (i.e., transient comprehensive risk index) to uniformly incorporate current, temperature, encoder, remote heartbeat signal, and internal watchdog into fault determination, effectively avoiding misjudgments or omissions caused by a single detection module, thereby improving the accuracy of anomaly identification.

[0062] Furthermore, the expression for the current characteristic quantity is: ,in, This represents the effective value of the three-phase current of the motor. This is the rated current of the motor;

[0063] The expression for the temperature characteristic quantity is: ,in, This refers to the real-time temperature (i.e., the real-time temperature monitored by the temperature monitoring unit). The baseline temperature for safe operation, The temperature threshold for shutdown; when At that time, a mandatory order To avoid generating negative interference; as a specific embodiment of the present invention, The value is 65℃. The value is 130℃;

[0064] The expression for the encoder's out-of-step feature is: ,in, For motor command position, For encoder feedback position, This is the maximum permissible position deviation base (corresponding to 100% of the rated stroke);

[0065] The expression for the communication link characteristic is: ,in, This represents the number of consecutively lost heartbeats or command responses. The threshold for determining the number of communication disconnections is calculated based on a heartbeat interval of 50ms and a disconnection timeout of 500ms. ;

[0066] When the main task's cycle execution deviation exceeds a preset deviation threshold, the watchdog flag value... The value is 1, otherwise the watchdog flag is set. The value is 0; in specific implementation of the present invention, the preset deviation threshold can be set to 50% of the timeout period (i.e., the timeout period set by the internal watchdog unit).

[0067] In a preferred embodiment of the present invention, the sampling period for the operating status data is 1 second. The value is 0.30. The value is 0.25. The value is 0.20. The value is 0.10. The value is 0.15. It should be noted that the specific values ​​of the above parameters are the optimal values ​​verified by actual experiments, but the present invention is not limited to these. In specific implementation, the specific values ​​can be adjusted according to actual needs.

[0068] In some embodiments of the present invention, the step of mapping the operating status data or transient comprehensive risk index to the corresponding protection level using the decision model specifically involves: performing a moving average process on the transient comprehensive risk index for N consecutive sampling periods to obtain an average risk value, and then using the decision model to map the operating status data or the average risk value to the corresponding protection level. In specific implementations of the present invention, the average risk value... The specific calculation formula is as follows:

[0069] ;

[0070] Wherein, N represents the number of consecutive sampling periods. In one specific embodiment of the present invention, the value of N is 5. Indicates the current sampling time The i-th sampling time previously.

[0071] This invention effectively suppresses transient noise disturbances by performing a moving average process on the transient comprehensive risk index over N consecutive sampling periods and mapping the corresponding protection level based on the obtained average risk value.

[0072] In some embodiments of the present invention, the determination model for setting graded protection levels and the protection measures corresponding to each protection level are specifically as follows:

[0073] Set a first-level soft threshold. Secondary soft threshold and Level 3 soft threshold Among them, the first-level soft threshold Less than the second-level soft threshold Secondary soft threshold Less than level three soft threshold Level 1 soft threshold Secondary soft threshold and Level 3 soft threshold The specific settings can be based on engineering calibration and actual tests;

[0074] When the average risk value Less than the first level soft threshold When the running status data does not meet the interruption conditions, i.e., the protection level L=0, the robot remains in normal operation, i.e., the robot's motion parameters are not interfered with.

[0075] When the average risk value Greater than or equal to Level 1 soft threshold And less than the second-level soft threshold Or when the collected temperature data is greater than the first temperature threshold When the robot enters the first-level early warning protection, i.e., protection level L=1, an audible and visual early warning signal is triggered to provide a prompt, and the robot is controlled to continue to perform the current task according to the predetermined motion parameters, i.e., the robot's motion parameters are not interfered with.

[0076] When the average risk value Greater than or equal to the second-level soft threshold And less than the level 3 soft threshold Or when the collected current data exceeds the first preset percentage value of the rated current. And continue to reach the first preset time. When this happens, the robot enters the second-level deceleration protection, i.e., protection level L=2; in the second-level deceleration protection, the robot is controlled to perform dual limiting of rotational speed and linear speed, and the robot continues to perform the current task under the dual limiting of rotational speed and linear speed;

[0077] When the average risk value Greater than or equal to Level 3 soft threshold Or when the collected current data exceeds the second preset percentage value of the rated current. Or when the collected temperature data is greater than the second temperature threshold. If the temperature sensor fails to provide effective feedback, or the encoder malfunctions or loses synchronization, the robot enters a level 3 shutdown protection state (protection level L=3). In this state, the robot immediately applies mechanical braking and enters a stop-and-wait state. In practical implementation, this invention requires equipping the robot with a mechanical brake for rapid braking. The second preset percentage value... Greater than the first preset percentage value Second temperature threshold greater than the first temperature threshold .

[0078] This invention employs a graded protection strategy consisting of a first-level warning, a second-level deceleration, and a third-level shutdown. This allows the system to flexibly execute matching protection actions based on the severity of the fault, thereby effectively reducing the probability of erroneous shutdown and improving safety under severe faults. Simultaneously, when entering the third-level shutdown protection strategy, a mechanical brake is immediately used to achieve braking, which can quickly cut off the drive output in the event of a severe fault.

[0079] As a preferred embodiment of the present invention, the first-level soft threshold The value is 0.35, which is the second-level soft threshold. The value is 0.60, a level 3 soft threshold. The value is 0.80; the first temperature threshold. The value is 95℃, the second temperature threshold. The value is 130℃; the first preset percentage value 150%, first preset time The second preset percentage value is 3 seconds. The limit is 200%; the dual limiting of speed and linear velocity specifically restricts the motor speed to 30% of the rated speed and the linear velocity to less than or equal to 0.5 m / s, i.e., the speed... , The rated speed and linear velocity of the motor. It should be noted that the specific values ​​of the above parameters are optimal values ​​determined based on engineering calibration and actual experiments. However, this invention is not limited to these values, and the specific values ​​can be adjusted according to actual needs during implementation.

[0080] In some embodiments of the present invention, the method further includes:

[0081] When the robot is at the second preset time If no instructions or heartbeat data are received from the remote control platform, the robot is triggered to execute a communication disconnection protection mechanism. In this mechanism, the robot immediately applies mechanical braking and enters a stop-and-wait state. In specific implementations of this invention, a second preset time... It can be set to 500ms. This invention designs communication disconnection detection, including instructions or heartbeat data from a remote control platform. At the same time, it designs an internal watchdog unit that automatically stops feeding the watchdog and triggers a system reset when the deviation of the main task's cycle execution exceeds a preset deviation threshold. The combination of these two can more accurately distinguish between short-term packet loss and link anomalies.

[0082] Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements:

[0083] First layer: The robot (specifically the robot's central control unit) periodically attempts to restore heartbeat communication at preset time intervals (e.g., 2 seconds) and successfully receives a response from the remote control platform;

[0084] The second layer: The robot (specifically the robot's central control unit) fully reads the current status instructions and mode parameters issued by the remote control platform;

[0085] The third layer: The robot (specifically, the robot's central control unit) receives a manual confirmation signal from the operator or an explicit authorization command via remote authorization. In practical implementation, the above three layers must be met simultaneously for the robot to return to normal operation.

[0086] This invention sets safe restart conditions for the robot after communication is lost, so that the robot will not move blindly as soon as communication is restored, but will resume operation after reading remote authorization instructions or waiting for manual confirmation, which can improve the robot's movement safety after recovery.

[0087] Based on the same inventive concept, this application also provides an apparatus corresponding to the method in Embodiment 1, as detailed in Embodiment 2.

[0088] Example 2

[0089] Please refer to Figure 2 As shown, this embodiment provides an automatic protection device for abnormalities in a robot control system, the device comprising:

[0090] The status data acquisition module is used to collect the robot's operating status data according to a set sampling period. This operating status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data. Current data is obtained through a motor drive monitoring unit installed on the robot. During operation, the motor drive monitoring unit monitors and calculates the effective value of the motor's three-phase current in real time. Temperature data is obtained through a temperature monitoring unit installed on the robot. During operation, the temperature monitoring unit uses a sliding window with 60 sampling points to sample the temperature data, and the sampling period is 1 second. Encoder data is obtained through an encoder feedback monitoring unit installed on the robot. During operation, the encoder feedback monitoring unit compares the positional deviation between the motor drive command position and the encoder feedback position in real time. Heartbeat data is obtained through a remote communication heartbeat monitoring unit. According to the monitoring, during operation, an independent heartbeat communication task is established between the remote control platform and the robot's central control unit. The heartbeat interval is 50ms, and the remote communication heartbeat monitoring unit can monitor this heartbeat communication task in real time. Watchdog data is obtained through an internal watchdog unit set on the robot. The timeout period of the internal watchdog unit is 1s. The robot's central control unit will complete the watchdog feeding operation within the main task cycle. When the deviation of the main task cycle execution cycle exceeds the preset deviation threshold, the watchdog feeding will stop and the system will be reset. It should be noted that in this invention, the watchdog is a timer that needs to be reset (fed) periodically in the main task cycle. If the timeout occurs, the system will be reset. Heartbeat communication refers to sending short messages at fixed time intervals to confirm whether the communication link is normal. The encoder is a sensor that converts rotational or linear displacement into electrical signals to provide feedback on the actual position of the motor.

[0091] The calculation module is used to calculate the transient comprehensive risk index based on the collected operating status data, so as to use the transient comprehensive risk index for fault judgment. Since the transient comprehensive risk index incorporates all the collected operating status data into the fault judgment, it can improve the accuracy of anomaly identification.

[0092] The level determination and protection module is used to set the determination model for the graded protection levels and the protection measures corresponding to each protection level. It uses the determination model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and executes the corresponding protection measures according to the mapped protection level.

[0093] In some embodiments of the present invention, the transient comprehensive risk index R(k) is calculated using the following formula:

[0094] ;

[0095] in, Represents the characteristic quantity of current. Weighting coefficients representing current characteristic quantities; Represents temperature characteristic quantity, Weighting coefficients representing temperature characteristic quantities; This represents the encoder's out-of-step feature. Weighting coefficients representing encoder out-of-step features; Represents the characteristic quantity of the communication link. Weighting coefficients representing characteristic quantities of the communication link; Indicates the quantity of watchdog markings. The weighting coefficients represent the watchdog flag values, where k represents the discrete sampling time number (i.e., the kth sampling point); each weighting coefficient satisfies a normalization constraint: This invention utilizes a continuous comprehensive risk scoring function (i.e., transient comprehensive risk index) to uniformly incorporate current, temperature, encoder, remote heartbeat signal, and internal watchdog into fault determination, effectively avoiding misjudgments or omissions caused by a single detection module, thereby improving the accuracy of anomaly identification.

[0096] Furthermore, the expression for the current characteristic quantity is: ,in, This represents the effective value of the three-phase current of the motor. This is the rated current of the motor;

[0097] The expression for the temperature characteristic quantity is: ,in, This refers to the real-time temperature (i.e., the real-time temperature monitored by the temperature monitoring unit). The baseline temperature for safe operation, The temperature threshold for shutdown; when At that time, a mandatory order To avoid generating negative interference; as a specific embodiment of the present invention, The value is 65℃. The value is 130℃;

[0098] The expression for the encoder's out-of-step feature is: ,in, For motor command position, For encoder feedback position, This is the maximum permissible position deviation base (corresponding to 100% of the rated stroke);

[0099] The expression for the communication link characteristic is: ,in, This represents the number of consecutively lost heartbeats or command responses. The threshold for determining the number of communication disconnections is calculated based on a heartbeat interval of 50ms and a disconnection timeout of 500ms. ;

[0100] When the main task's cycle execution deviation exceeds a preset deviation threshold, the watchdog flag value... The value is 1, otherwise the watchdog flag is set. The value is 0; in specific implementation of the present invention, the preset deviation threshold can be set to 50% of the timeout period (i.e., the timeout period set by the internal watchdog unit).

[0101] In a preferred embodiment of the present invention, the sampling period for the operating status data is 1 second. The value is 0.30. The value is 0.25. The value is 0.20. The value is 0.10. The value is 0.15. It should be noted that the specific values ​​of the above parameters are the optimal values ​​verified by actual experiments, but the present invention is not limited to these. In specific implementation, the specific values ​​can be adjusted according to actual needs.

[0102] In some embodiments of the present invention, the step of mapping the operating status data or transient comprehensive risk index to the corresponding protection level using the decision model specifically involves: performing a moving average process on the transient comprehensive risk index for N consecutive sampling periods to obtain an average risk value, and then using the decision model to map the operating status data or the average risk value to the corresponding protection level. In specific implementations of the present invention, the average risk value... The specific calculation formula is as follows:

[0103] ;

[0104] Wherein, N represents the number of consecutive sampling periods. In one specific embodiment of the present invention, the value of N is 5. Indicates the current sampling time The i-th sampling time previously.

[0105] This invention effectively suppresses transient noise disturbances by performing a moving average process on the transient comprehensive risk index over N consecutive sampling periods and mapping the corresponding protection level based on the obtained average risk value.

[0106] In some embodiments of the present invention, the determination model for setting graded protection levels and the protection measures corresponding to each protection level are specifically as follows:

[0107] Set a first-level soft threshold. Secondary soft threshold and Level 3 soft threshold Among them, the first-level soft threshold Less than the second-level soft threshold Secondary soft threshold Less than level three soft threshold Level 1 soft threshold Secondary soft threshold and Level 3 soft threshold The specific settings can be based on engineering calibration and actual tests;

[0108] When the average risk value Less than the first level soft threshold When the running status data does not meet the interruption conditions, i.e., the protection level L=0, the robot remains in normal operation, i.e., the robot's motion parameters are not interfered with.

[0109] When the average risk value Greater than or equal to Level 1 soft threshold And less than the second-level soft threshold Or when the collected temperature data is greater than the first temperature threshold When the robot enters the first-level early warning protection, i.e., protection level L=1, an audible and visual early warning signal is triggered to provide a prompt, and the robot is controlled to continue to perform the current task according to the predetermined motion parameters, i.e., the robot's motion parameters are not interfered with.

[0110] When the average risk value Greater than or equal to the second-level soft threshold And less than the level 3 soft threshold Or when the collected current data exceeds the first preset percentage value of the rated current. And continue to reach the first preset time. When this happens, the robot enters the second-level deceleration protection, i.e., protection level L=2; in the second-level deceleration protection, the robot is controlled to perform dual limiting of rotational speed and linear speed, and the robot continues to perform the current task under the dual limiting of rotational speed and linear speed;

[0111] When the average risk value Greater than or equal to Level 3 soft threshold Or when the collected current data exceeds the second preset percentage value of the rated current. Or when the collected temperature data is greater than the second temperature threshold. If the temperature sensor fails to provide effective feedback, or the encoder malfunctions or loses synchronization, the robot enters a level 3 shutdown protection state (protection level L=3). In this state, the robot immediately applies mechanical braking and enters a stop-and-wait state. In practical implementation, this invention requires equipping the robot with a mechanical brake for rapid braking. The second preset percentage value... Greater than the first preset percentage value Second temperature threshold greater than the first temperature threshold .

[0112] This invention employs a graded protection strategy consisting of a first-level warning, a second-level deceleration, and a third-level shutdown. This allows the system to flexibly execute matching protection actions based on the severity of the fault, thereby effectively reducing the probability of erroneous shutdown and improving safety under severe faults. Simultaneously, when entering the third-level shutdown protection strategy, a mechanical brake is immediately used to achieve braking, which can quickly cut off the drive output in the event of a severe fault.

[0113] As a preferred embodiment of the present invention, the first-level soft threshold The value is 0.35, which is the second-level soft threshold. The value is 0.60, a level 3 soft threshold. The value is 0.80; the first temperature threshold. The value is 95℃, the second temperature threshold. The value is 130℃; the first preset percentage value 150%, first preset time The second preset percentage value is 3 seconds. The limit is 200%; the dual limiting of speed and linear velocity specifically restricts the motor speed to 30% of the rated speed and the linear velocity to less than or equal to 0.5 m / s, i.e., the speed... , The rated speed and linear velocity of the motor. It should be noted that the specific values ​​of the above parameters are optimal values ​​determined based on engineering calibration and actual experiments. However, this invention is not limited to these values, and the specific values ​​can be adjusted according to actual needs during implementation.

[0114] In some embodiments of the present invention, the apparatus further includes:

[0115] The communication protection module is used to protect the robot during a second preset time. If no instructions or heartbeat data are received from the remote control platform, the robot is triggered to execute a communication disconnection protection mechanism. In this mechanism, the robot immediately applies mechanical braking and enters a stop-and-wait state. In specific implementations of this invention, a second preset time... It can be set to 500ms. This invention designs communication disconnection detection, including instructions or heartbeat data from a remote control platform. At the same time, it designs an internal watchdog unit that automatically stops feeding the watchdog and triggers a system reset when the deviation of the main task's cycle execution exceeds a preset deviation threshold. The combination of these two can more accurately distinguish between short-term packet loss and link anomalies.

[0116] Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements:

[0117] First layer: The robot (specifically the robot's central control unit) periodically attempts to restore heartbeat communication at preset time intervals (e.g., 2 seconds) and successfully receives a response from the remote control platform;

[0118] The second layer: The robot (specifically the robot's central control unit) fully reads the current status instructions and mode parameters issued by the remote control platform;

[0119] The third layer: The robot (specifically, the robot's central control unit) receives a manual confirmation signal from the operator or an explicit authorization command via remote authorization. In practical implementation, the above three layers must be met simultaneously for the robot to return to normal operation.

[0120] This invention sets safe restart conditions for the robot after communication is lost, so that the robot will not move blindly as soon as communication is restored, but will resume operation after reading remote authorization instructions or waiting for manual confirmation, which can improve the robot's movement safety after recovery.

[0121] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic protection method for abnormalities in a robot control system, characterized in that, The method includes: The robot's operating status data is collected according to a set sampling period. The operating status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data. The transient comprehensive risk index is calculated based on the collected operational status data; Set up a judgment model for graded protection levels and the corresponding protection measures for each protection level. Use the judgment model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and execute the corresponding protection measures according to the mapped protection level.

2. The automatic protection method for abnormalities in a robot control system according to claim 1, characterized in that, The formula for calculating the transient comprehensive risk index is as follows: ； in, Represents the characteristic quantity of current. Weighting coefficients representing current characteristic quantities; Represents temperature characteristic quantity, Weighting coefficients representing temperature characteristic quantities; This represents the encoder's out-of-step feature. The weighting coefficients represent the encoder's out-of-step features; Represents the characteristic quantity of the communication link. Weighting coefficients representing characteristic quantities of the communication link; Indicates the quantity of watchdog markings. The weighting coefficients represent the watchdog flag values; each weighting coefficient satisfies the normalization constraint. .

3. The automatic protection method for abnormalities in a robot control system according to claim 2, characterized in that, The expression for the current characteristic quantity is: ,in, This represents the effective value of the three-phase current of the motor. This is the rated current of the motor; The expression for the temperature characteristic quantity is: ,in, For real-time temperature, The baseline temperature for safe operation, The temperature threshold for shutdown; when At that time, a mandatory order ; The expression for the encoder's out-of-step feature is: ,in, For motor command position, For encoder feedback position, This is the base value for the maximum permissible position deviation; The expression for the communication link characteristic is: ,in, The number of consecutive lost heartbeats or command responses. The threshold for determining the number of communication disconnections; When the main task's cycle execution deviation exceeds a preset deviation threshold, the watchdog flag value... The value is 1, otherwise the watchdog flag is set. The value is 0.

4. The automatic protection method for abnormalities in a robot control system according to claim 2, characterized in that, The sampling period for the operating status data is 1 second. The value is 0.

30. The value is 0.

25. The value is 0.

20. The value is 0.

10. The value is 0.

15.

5. The automatic protection method for abnormalities in a robot control system according to claim 1, characterized in that, The specific steps of mapping the operating status data or transient comprehensive risk index to the corresponding protection level using the judgment model are as follows: performing a moving average process on the transient comprehensive risk index for N consecutive sampling periods to obtain the average risk value, and then using the judgment model to map the operating status data or the average risk value to the corresponding protection level.

6. The automatic protection method for abnormalities in a robot control system according to claim 5, characterized in that, The determination model for setting graded protection levels and the protection measures corresponding to each protection level are as follows: Set a first-level soft threshold, a second-level soft threshold, and a third-level soft threshold, wherein the first-level soft threshold is lower than the second-level soft threshold, and the second-level soft threshold is lower than the third-level soft threshold; When the average risk value is less than the first-level soft threshold and the operating status data does not meet the interruption conditions, the robot is kept in normal operating status. When the average risk value is greater than or equal to the first-level soft threshold and less than the second-level soft threshold, or when the collected temperature data is greater than the first temperature threshold, the robot enters the first-level early warning protection. In the first-level early warning protection, an audible and visual warning signal is triggered, and the robot is controlled to continue to perform the current task according to the predetermined motion parameters. When the average risk value is greater than or equal to the second-level soft threshold and less than the third-level soft threshold, or when the collected current data exceeds the first preset percentage value of the rated current and continues for the first preset time, the robot enters the second-level deceleration protection; in the second-level deceleration protection, the robot is controlled to perform dual limiting of rotational speed and linear speed, and the robot continues to perform the current task under the dual limiting of rotational speed and linear speed. When the average risk value is greater than or equal to the level 3 soft threshold, or when the collected current data exceeds the second preset percentage value of the rated current, or when the collected temperature data is greater than the second temperature threshold or the temperature sensor has no effective feedback, or the encoder fails or loses synchronization, the robot enters the level 3 shutdown protection. In the level 3 shutdown protection, the robot is controlled to immediately perform mechanical braking and enter a shutdown waiting state. Among them, the second preset percentage value is greater than the first preset percentage value, and the second temperature threshold is greater than the first temperature threshold.

7. The automatic protection method for abnormalities in a robot control system according to claim 6, characterized in that, The first-level soft threshold is 0.35, the second-level soft threshold is 0.60, and the third-level soft threshold is 0.80; the first temperature threshold is 95℃, and the second temperature threshold is 130℃; the first preset percentage is 150%, the first preset time is 3s, and the second preset percentage is 200%; the dual limiting of speed and linear velocity specifically limits the motor speed to 30% of the rated speed and the linear velocity to less than or equal to 0.5m / s.

8. An automatic protection method for abnormalities in a robot control system according to any one of claims 1-7, characterized in that, The method further includes: If the robot does not receive any instructions or heartbeat data from the remote control platform within a second preset time, the robot will be triggered to execute the communication disconnection protection mechanism. In the communication disconnection protection mechanism, the robot will immediately apply mechanical braking and enter a stop waiting state. Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements: First layer: The robot periodically attempts to restore heartbeat communication at preset time intervals and successfully receives a response from the remote control platform; The second layer: The robot fully reads the current status instructions and mode parameters issued by the remote control platform; The third layer: The robot receives a manual confirmation signal from the operator or an explicit authorization instruction from a remote source.

9. An automatic protection device for abnormalities in a robot control system, characterized in that, The device includes: The status data acquisition module is used to collect the robot's operating status data according to a set sampling period. The operating status data includes current data, temperature data, encoder data, heartbeat data, and watchdog data. The calculation module is used to calculate the transient comprehensive risk index based on the collected operational status data; The level determination and protection module is used to set the determination model for the graded protection levels and the protection measures corresponding to each protection level. It uses the determination model to map the operating status data or transient comprehensive risk index to the corresponding protection level, and executes the corresponding protection measures according to the mapped protection level.

10. An automatic protection device for an abnormality in a robot control system according to claim 9, characterized in that, The device further includes: The communication protection module is used to trigger the robot to execute the communication disconnection protection mechanism when the robot does not receive instructions or heartbeat data from the remote control platform within a second preset time. In the communication disconnection protection mechanism, the robot is controlled to immediately perform mechanical braking and enter a stop waiting state. Once communication is restored, determine if the robot meets the safe restart conditions. If so, control the robot to resume normal operation; otherwise, keep the robot in a stopped and waiting state. The safe restart conditions include the following three requirements: First layer: Periodically attempts to restore heartbeat communication at preset time intervals and successfully receives a response from the remote control platform; The second layer: fully reads the current status instructions and mode parameters issued by the remote control platform; The third layer: Obtaining explicit authorization instructions from the operator, either through manual confirmation or remote authorization.

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