Modular Robotic Hardware Interfaces for Predictive Maintenance
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Solution Overview
Problem
Current robotic systems lack flexibility in design, construction, and operation, making them inflexible for adapting to different tasks and prone to compatibility issues, with high maintenance costs and environmental concerns due to limited reuse and reliability.
Innovation Solution
A method for configuring a robotic system using a computer-based inventory that manages hardware modules with standardized interfaces, allowing for data collection, maintenance scheduling, and software updates, enabling modular integration of third-party components and optimizing task distribution across available devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manipulators are assigned to specific tasks with dedicated configurations, then task performance reliability is improved, but adaptability to different tasks deteriorates
Solution Approach 1:
The manipulator is divided into modular components (base unit, arm units, tool units) that can be independently selected and reconfigured. Each module has standardized interfaces allowing them to be assembled in different configurations for different tasks, maintaining reliability through proven module designs while achieving adaptability through recombination.
Solution Approach 2:
The standardized interface design enables the same base unit and arm units to work with multiple different tool units and perform various tasks. The universal interface protocol allows different manufacturer components to interoperate, making the manipulator system multi-functional across different application domains.
2Productivity
If robots are broadly used in production to maximize ROI, then productivity is improved, but maintenance costs and reliability deteriorate due to increased usage and wear
Solution Approach 1:
The system performs preliminary diagnostics and maintenance actions by monitoring module status in real-time. The base unit tracks operational data and schedules maintenance before failures occur, allowing continuous high-productivity operation while proactively managing reliability through preventive maintenance rather than reactive repairs.
3Manufacturing precision
If manipulators are designed for specific tasks with fixed configurations, then manufacturing precision is improved, but ease of manufacture and reuse deteriorate due to customization requirements
Solution Approach 1:
The manipulator is segmented into standardized modules that can be manufactured using common processes and then assembled through standardized interfaces. This allows precision-critical components to be manufactured with high precision using proven processes, while the modular assembly approach maintains manufacturing flexibility and ease of reuse across different configurations.
4Adaptability or versatility
If third-party components are integrated into robotic systems, then adaptability is improved, but compatibility and system reliability deteriorate due to interface issues
Solution Approach 1:
The standardized interface protocol acts as an intermediary layer between third-party components and the manipulator control system. This interface standardizes communication and physical connections, allowing diverse third-party tool units and sensors to integrate reliably without direct custom integration for each component, thus maintaining both adaptability and compatibility.
Data Source
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AI summary
A robotic system comprises at least two Hardware Modules (3), each comprising at least one sensor (38) for measuring an internal property, a communication unit (37), a data storage unit (36) and an embedded controller (35). The embedded controller (35) is configured to collect collected data comprising: - status data representing the current status of the Hardware Module (3); and - operating data representing usage of the Hardware Module (3). At least part of the collected data is determined from sensor data, and the embedded controller (35) is configured to store or transmit the collected data. The robotic system comprises a central computation and command unit (10) configured to receive the collected data; and to control operation of the robotic system by controlling operation of at least one actuator (39) of the at least two Hardware Modules (3).