Robot Motion Axis Failure Diagnosis with Maintenance Re-Check
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Solution Overview
Problem
Existing failure diagnosis methods for robot drive systems, which rely solely on disturbance torque values, often result in erroneous determinations and decreased accuracy due to varying disturbance factors and maintenance activities, leading to frequent incorrect diagnoses.
Innovation Solution
A failure diagnosis device and method that utilize maintenance records and inspection results, such as iron powder concentration and decelerator replacement records, in addition to disturbance torque values, to re-determine the status of motion axes, thereby improving diagnosis accuracy and preventing false positives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If failure diagnosis is conducted based only on disturbance torque values, then the diagnosis process is simple and quick, but the diagnosis accuracy deteriorates due to varying disturbance factors and maintenance activities
Solution Approach 1:
The patent combines multiple data sources including disturbance torque values, maintenance records, and inspection results into a unified failure diagnosis system. This integration allows the system to cross-validate information and distinguish between torque variations caused by maintenance activities versus actual failures, thereby improving diagnosis accuracy without significantly increasing complexity
Solution Approach 2:
The patent introduces an intermediary analysis layer that processes maintenance records and inspection results before comparing them with disturbance torque values. This intermediary step acts as a filter to eliminate false positives caused by maintenance activities, allowing the system to maintain simple torque-based monitoring while improving accuracy through additional contextual information
2Measurement precision
If multiple data sources are used for failure diagnosis, then the diagnosis accuracy is improved, but the system complexity increases
Solution Approach 1:
The patent segments the failure diagnosis process into distinct modules: one for collecting disturbance torque values, another for storing maintenance records, and a third for analyzing inspection results. Each module operates independently with clearly defined interfaces, allowing the system to leverage multiple data sources while maintaining manageable complexity through modular architecture
Solution Approach 2:
The patent designs a multi-functional diagnosis system where a single integrated platform performs multiple functions: monitoring disturbance torque, managing maintenance records, storing inspection results, and synthesizing all this information for comprehensive failure diagnosis. This universal approach avoids the need for separate specialized systems for each data type, thereby controlling overall system complexity
Data Source
AI summary
A failure diagnosis device applicable to a mechanical device provided with motors independent of One another as sources to drive motion axes, respectively, and configured to acquire a moving position of each motion axis and a disturbance torque value applied to the motion axis every predetermined period, and to diagnose a failure of the mechanical device, includes a failure diagnosis unit configured to diagnose the motion axis as a failure when the disturbance torque value is larger than a predetermined failure determination threshold, and a re-determination unit configured to conduct re-determination of the failure on the motion axis, which is diagnosed as the failure by the failure diagnosis unit, based on a previous maintenance record and a previous inspection result.