MomentumNet-CD: Real-Time Collision Detection for Industrial Robots Based on Momentum Observer with Optimized BP Neural Network

The accurate detection and identification of collision states in industrial robot environments is a critically important and challenging task. Deep learning-based methods have been widely applied to collision detection; however, these methods primarily rely on dynamic models and dynamic threshold settings, which are subject to modeling errors and threshold adjustment latency. To address this issue, we propose MomentumNet-CD, a novel collision detection method for industrial robots that leverages backpropagation (BP) neural networks. MomentumNet-CD extracts collision state features through a momentum observer and constructs an observation model using Mahalanobis distance. These features are then processed by an optimized three-layer BP neural network for accurate collision identification. The network is trained using a modified Levenberg–Marquardt algorithm by introducing regularization terms and continuous probability outputs. Furthermore, we developed a comprehensive acquisition system based on the Q8-USB data acquisition card and the QUARC 2.7 real-time control environment. The system integrates key hardware components including a MR-J2S-70A servo driver, ATI six-dimensional force/torque (F/T) sensor, and ISO-U2-P1-F8 isolation transmitter, and the corresponding software module is developed through MATLAB/Simulink R2022b, which achieves the high-frequency real-time acquisition of critical robot joint states. The experimental results show that the MomentumNet-CD method achieves an overall accuracy of 93.65% under five different speed conditions, and the detection delay is only 12.16 ms. Compared with the existing methods, the method shows obvious advantages in terms of the accuracy and response speed of collision detection.