Abnormality Detection via Input-Output Angle Difference
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Solution Overview
Problem
Conventional methods for detecting abnormalities in power transmission mechanisms, such as speed reducers, are inadequate in predicting failures before they render machines unusable, particularly in industrial settings where downtime can significantly impact production.
Innovation Solution
An abnormality detection device that uses a combination of first and second rotational position detectors and an operation control unit to monitor the rotation angles of input and output shafts, calculating an angle difference and determining the abnormality based on variables including the reduction ratio of the power transmission mechanism, allowing for early detection of wear and potential failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensor-based detection methods are used to detect abnormalities in power transmission mechanisms, then abnormality detection capability is provided, but the detection occurs only after failure has rendered the machine unusable, causing production line disruption
Solution Approach 1:
The system performs preliminary detection of abnormalities by continuously monitoring the rotation angles of input and output shafts using rotational position detectors. By calculating the angle difference between these shafts and comparing it against predetermined thresholds, the system detects wear and potential failures before they cause complete breakdown, enabling maintenance to be performed during scheduled downtime rather than causing unplanned production interruptions
Solution Approach 2:
The system establishes a feedback loop where the operation control unit receives rotation angle data from both input and output shaft detectors, processes the angle difference through a determination unit, and generates abnormality detection results that feed back into the control system. This continuous feedback enables real-time monitoring and early warning of power transmission mechanism degradation
2Measurement precision
If rotational position detectors are attached to both input and output shafts to enable precise abnormality detection, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The rotational position detectors serve multiple functions: they provide feedback control for the operation control unit to accurately position the output shaft according to the operation program, and simultaneously enable abnormality detection by providing rotation angle data for angle difference calculation. This multi-functionality reduces the need for separate detection components while maintaining high detection accuracy
Solution Approach 2:
The operation control unit acts as an intermediary that coordinates the operation of both rotational position detectors and processes their output signals. By centralizing the processing of rotation angle data and the calculation of angle differences, the system avoids the need for separate dedicated detection hardware, thereby reducing overall device complexity while maintaining measurement precision
Data Source
AI summary
This abnormality detection device is provided with a first encoder for detecting the rotation angle of an input shaft of a decelerator, and a second encoder for detecting the rotation angle of an output shaft of the decelerator. An operation control unit controls a servo motor such that the position acquired from the output of the second encoder corresponds to a position determined by an operation program. A detection unit calculates the angle difference, which is the difference between the rotation angle acquired from output of the first encoder and the rotation angle acquired from output of the second encoder. The detection unit determines whether or not the decelerator is abnormal on the basis of the angle difference.