Cable Strand Disconnection Detection via Motion-Compensated Resistance Index
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Solution Overview
Problem
Existing methods struggle to detect strand disconnection in cables mounted on devices like industrial robots during actual operation, leading to potential sudden shutdowns due to incomplete detection of conductor disconnection.
Innovation Solution
A disconnection detection method and device that acquire motion information and resistance value data, analyze the resistance data based on motion information to obtain an index value, and detect strand disconnection using this index value, even when the device is in operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance value monitoring is performed during device operation, then strand disconnection can be detected in real-time, but the small change in resistance value caused by few strand disconnections becomes difficult to distinguish from noise
Solution Approach 1:
The patent establishes a baseline resistance value before device operation begins. This preliminary measurement serves as a reference point against which subsequent resistance changes during operation are compared, enabling detection of strand disconnections even when the absolute resistance change is small and obscured by noise during actual operation.
Solution Approach 2:
The system continuously monitors resistance values during device operation and compares them against the established baseline and threshold values. This feedback mechanism enables real-time detection of strand disconnections by identifying when resistance changes exceed predetermined thresholds, allowing maintenance to be performed before complete conductor disconnection occurs.
2Device complexity
If conventional resistance value monitoring is used, then detection is simple, but complete conductor disconnection may occur before replacement of the cable because there is not enough time between detection and complete disconnection
Solution Approach 1:
The patent introduces threshold values as an intermediary between the raw resistance measurements and the disconnection detection decision. By comparing resistance changes against predetermined thresholds rather than relying on simple absolute resistance values, the system can detect strand disconnections at earlier stages, providing sufficient time for maintenance before complete conductor disconnection occurs.
3Productivity
If maintenance is performed only after device shutdown, then device operation is uninterrupted, but sudden shutdowns may occur due to failures during actual operation
Solution Approach 1:
The system provides continuous feedback on cable health status during device operation by monitoring resistance values and comparing them against baseline and threshold values. This enables maintenance to be scheduled based on actual cable condition rather than fixed schedules or shutdowns, allowing maintenance to be performed during operation when disconnection is detected, thus preventing sudden shutdowns while maintaining high device availability.
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
Enables the detection of strand disconnection in real-time during device operation, reducing the risk of sudden shutdowns and allowing for timely maintenance to prevent complete conductor disconnection.
Implementation Method 1
resistance value data, which is data of a resistance value of the conductor that changes in time series due to the motion of the device
Data Source
AI summary
A disconnection detection method for detecting disconnection of a plurality of strands constituting a conductor of a cable wired in a device that is caused by motion of the device includes a data acquisition step of acquiring motion information data, which is data showing changes over time in information about motion of the device, and resistance value data, which is data of a resistance value of the conductor that changes in time series due to the motion of the device, an analysis step of analyzing the resistance value data based on the motion information data acquired in the data acquisition step and obtaining an index value to detect strand disconnection, and a disconnection detection step of detecting the strand disconnection based on the index value obtained in the analysis step.