服役工况下基于电流信号的工业机器人谐波减速器故障建模

doi:10.3901/JME.2025.18.366

机械工程学报 ›› 2025, Vol. 61 ›› Issue (18): 366-377.doi: 10.3901/JME.2025.18.366

• 交叉与前沿 • 上一篇

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服役工况下基于电流信号的工业机器人谐波减速器故障建模

王嘉^1,2, 葛曼哲^1,2, 王子铭^1,2, 张露予^1,2, 王崇帅^1,2

1. 河北工业大学智能配用电装备与系统全国重点实验室天津 300401;
2. 河北工业大学电气工程学院天津 300401

收稿日期:2024-10-18 修回日期:2025-05-15 发布日期:2025-11-08
作者简介:王嘉，女，1988年出生，研究员，博士研究生导师。主要研究方向为机器人可靠性与智能化、机器人安全性检测与评估、电工装备状态监测与故障诊断。E-mail：jwangno1@163.com;张露予(通信作者)，女，1989年出生，高级试验师，硕士研究生导师。主要研究方向为工业机器人可靠性与故障诊断。E-mail：zhangluyu2011@163.com;王崇帅：男，1991年出生，讲师，硕士研究生导师。主要研究方向为减速器动力学建模与故障分析。E-mail：wangchongshuai@hebut.edu.cn
基金资助:
国家重点研发计划(2022YFB4702100)、国家自然科学基金(52405260)、京津冀基础研究合作专项(E2024202261)、河北省科技(23281805Z)和石家庄市科技(SJZZXC23008)资助项目

Modeling the Motor Current for Harmonic Reducer Faults of Industrial Robot under Service Conditions

WANG Jia^1,2, GE Manzhe^1,2, WANG Ziming^1,2, ZHANG Luyu^1,2, WANG Chongshuai^1,2

1. State Key Laboratory of Intelligent Power Distribution Equipment and System, Hebei University of Technology, Tianjin 300401;
2. School of Electrical Engineering, Hebei University of Technology, Tianjin 300401

Received:2024-10-18 Revised:2025-05-15 Published:2025-11-08

摘要/Abstract

摘要： 谐波减速器常用于工业机器人手臂、腕部等关节，通过伺服系统驱动实现动力传递。柔性薄壁轴承是谐波减速器的核心组件，在椭圆凸轮周期性挤压和交变载荷工况下易发生故障，并通过机电耦合作用使关节电机电流产生谐波。然而，机器人服役中转矩和转速随机性变化使得故障频率均存在动态非平稳特征，导致故障频率与柔性薄壁轴承形状变化(长短轴交替)产生的冲击频率相互耦合，使得故障对电流的调制效应不明晰。建立谐波减速器直连电机定子电流模型，同时考虑机器人变速变载工况、柔性轴承长短轴交替变化冲击和不同部位故障的影响，通过理论分析获得了服役工况下谐波减速器故障对直连电机电流的影响机理。分别对柔性轴承外圈、内圈故障，以及健康状态的谐波减速器开展恒速恒载、恒速变载、变速恒载和变速变载四种工况试验以及特定工况下外圈故障的仿真，结合时频域故障特征分析，验证了所建电流模型在柔性薄壁轴承不同位置故障下的适用性与准确性。

关键词: 故障建模, 电流信号, 工业机器人, 谐波减速器, 变速变载

Abstract: Harmonic drives are commonly employed in the joints of robotics, where they facilitate power transmission driven by servomotors. The flexible thin-walled bearing, an important component of harmonic drives, is susceptible to failures under the cyclic squeezing and alternative load conditions of cam, and it generates harmonics in the current of the connected motor. However, the operation conditions of robots can induce non-stationary changes in fault frequencies, coupled with the frequencies induced by the structural deformation of the flexible bearing, which makes the modulation effects of fault on current complicated. The stator current model for different faults in the flexible thin-walled bearing of harmonic drives is proposed. This model accounts for the effects of varying speed and load conditions, the frequencies due to variations of the long and short axes of the flexible thin-walled bearing, and the fault frequencies into the current model. By establishing a simulated experiment platform of harmonic drive with different faults, the tests under constant speed and load, constant speed varying load, variable speed constant load, and variable load variable speed conditions are conducted to validate the applicability and accuracy of the established current model considering fault on different part of the flexible thin walled bearing.

Key words: fault modeling, current signal, industrial robot, harmonic reducer, variable speed and load condition

中图分类号:

TG156

王嘉, 葛曼哲, 王子铭, 张露予, 王崇帅. 服役工况下基于电流信号的工业机器人谐波减速器故障建模[J]. 机械工程学报, 2025, 61(18): 366-377.

WANG Jia, GE Manzhe, WANG Ziming, ZHANG Luyu, WANG Chongshuai. Modeling the Motor Current for Harmonic Reducer Faults of Industrial Robot under Service Conditions[J]. Journal of Mechanical Engineering, 2025, 61(18): 366-377.

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服役工况下基于电流信号的工业机器人谐波减速器故障建模

Modeling the Motor Current for Harmonic Reducer Faults of Industrial Robot under Service Conditions

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