Development And Research Of System Software For General-Purpose Industrial Robot Controller

With the development of production and manufacturing industry towards digitalization,networking and intellectualization,industrial robot is favored by all fields of production and manufacturing industry with its high efficiency,precision and flexibility.As the control center of industrial robot,controller directly determines the control performance of robot.Starting from the research of domestic industrial robot system especially the development of controller,the key technology and software development of the generalpurpose controller system with open structure for industrial robot based on open source RTOS real-time multi-tasking platform are systematically studied in this dissertation.The controller system software platform consists of system configuration and programming software running on Windows and controller runtime system software running on Linux+Xenomai.Functionally,the soft PLC module and robot motion control module are the core and the industrial real-time Ethernet bus serves as the servo communication bus.The system supports friendly operation and development environment,provides real-time communication interface for external sensors and general interface for typical high-speed servo bus devices.Robot applications controlling servo system and I/O devices can be developed to accomplish different tasks according to various application demands.Firstly,the research status of industrial robot controller technology at home and abroad is reviewed,and the technical characteristics and development trend of modern industrial robot controller system are described.With the analysis of functional and performance requirements of general-purpose controller,the assignment of real-time task based on function and the principle of inter task communication are given in the design of real-time multi-tasking software architecture for industrial robot.Aiming at the universality and application programming requirements,the design principle and implementing method of the robot system parameter configuration module,the PLC programming module supporting IEC61131-3 standard programming language,the configuration module for sensor real-time communication interface and the communication module with controller runtime system in the system configuration and programming software are given in detail.An improved scheme of robot motion control module is presented in the controller runtime system which aimed at the requirements of robot's intelligent control.The optimization process of robot's internal model and interpolator task is given and the design principle and implementation process of external sensor real-time communication interface task are mainly discussed.For the generality requirement of the controller's high speed servo bus interface,the technology principle of industrial real-time Ethernet for motion control is studied and the technology of EtherCAT and POWERLINK bus is analyzed concretely.On this basis,the design and implementation process of high-speed servo bus interface based on EtherCAT and POWERLINK soft master station is mainly discussed.Aiming at the requirement of system's reliability,the communication mechanism between the soft PLC module and the robot motion module,the soft PLC module and the servo interface module are optimized.Finally,the industrial computer is used as the running platform of the controller system software,and the module test is carried out for the sensor real-time communication interface and the universal high speed servo bus interface.In addition,the ER4 type 6-DOF robot is taken as the control object,and the simplified application of pegging in hole compliantly based on the system is developed.As a result,the correctness and validity of the industrial robot controller system designed in this dissertation are verified.