Electromagnetic Brake Current Monitoring for Faster Robot Cycles
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Solution Overview
Problem
Conventional robot control systems with non-excited operation type electromagnetic brakes face challenges in shortening cycle time, accurately estimating brake life, and diagnosing abnormalities due to complex configurations and lengthy timer settings, which hinder efficient operation and production line productivity.
Innovation Solution
A robot control device that monitors and controls the current through the excitation coil to estimate the attraction and release times of the armature, detects wear on the friction plate, and performs abnormality diagnosis using simple configurations, allowing for precise control and diagnosis of the electromagnetic brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long timer time is set to ensure safety margin for brake operation, then reliability is improved, but productivity deteriorates due to longer cycle time
Solution Approach 1:
The control device monitors the actual current through the excitation coil in real-time and uses this feedback to dynamically adjust the timer time. By detecting the actual brake operation status through current monitoring, the system sets the timer time based on actual conditions rather than using a fixed conservative value, thus shortening cycle time while maintaining reliability
Solution Approach 2:
The timer time is changed dynamically based on monitored current characteristics. The control device adjusts the timer time according to the actual brake state and operational conditions, transitioning from a static conservative setting to a dynamic adaptive setting that optimizes both safety and productivity
2Reliability
If a long timer time is set to account for individual differences and material variations, then reliability is improved, but loss of time increases
Solution Approach 1:
The system monitors the actual current through the excitation coil and uses this information to adjust the timer time accordingly. This feedback mechanism allows the system to account for individual differences and material variations in real-time, setting an appropriate timer time for each specific condition rather than using a universally long conservative value
3Reliability
If discharge circuit is provided to lower counter electromotive voltage, then reliability is improved, but device complexity increases
Solution Approach 1:
The control device utilizes the existing current monitoring capability to detect brake operation status and automatically adjusts the timer time based on this information. This self-service approach allows the system to protect itself from timing errors and operational issues without requiring additional external discharge circuits or complex protective components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables shorter cycle times, accurate estimation of brake life, and efficient abnormality diagnosis, improving operational efficiency and reducing downtime in robot systems.
Implementation Method 1
when the excitation coil is energized, it releases the brake operation by attracting the armature to the exciting brake side
Implementation Method 2
when the excitation coil is de-energized, it presses the armature against the friction plate by the urging force of the spring
Implementation Method 3
presses the armature against the friction plate by the urging force of the spring, and when the excitation coil is energized, it releases the brake operation
Data Source
AI summary
A robot control device having a drive shaft driven by a servo motor including a non-excited operation type electromagnetic brake. The electromagnetic brake is configured to perform a braking operation by pressing an armature against a friction plate by an urging force of a spring when an excitation coil is not energized, and to cancel a brake operation by attracting the armature to the excitation coil side against the urging force of the spring to separate the armature from the friction plate when the excitation coil is energized. A coil current flowing through the excitation coil is obtained and the robot is controlled based on the characteristic of time change of the obtained coil current. A robot control device capable of shortening a cycle time, estimating the life of the electromagnetic brake, performing abnormality diagnosis and the like with a relatively simple configuration can be provided.