A Data-Driven Method for Predicting and Optimizing Industrial Robot Energy Consumption Under Unknown Load Conditions

The growing diversity and number of industrial robots make energy consumption prediction and optimization increasingly essential. Current data-driven approaches, particularly those based on multi-layer perception (MLP), have shown feasibility but typically overlook the variability or unknown nature of load-related parameters in real-world applications. This paper presents a KAN-LSTM model designed to accurately predict energy consumption under unknown load conditions, alongside a particle swarm optimization (PSO) algorithm for minimizing energy use. First, an industrial robot dynamics and energy consumption model is established. Then, the KAN-LSTM model is trained on datasets from the AUBO-E5 robot, with its predictions compared to alternative network models. Finally, PSO is applied to optimize energy consumption. Experimental results indicate that the KAN-LSTM model achieves high prediction accuracy (95.7–97.1%) and offers substantial energy optimization potential (53.1–64.7%). Optimized industrial robots are particularly suitable for tasks such as picking and palletizing in the courier industry, saving operational costs and increasing the sustainability of automated systems in logistics environments.