Robot Manipulator Axis Fixing with Brake Fault Backup Control
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Solution Overview
Problem
Existing methods for ensuring the safety and reliability of robot manipulator axes, particularly in safety-critical situations, face challenges such as the risk of unwanted movement due to brake failures and the inefficiency of maintaining a standstill using drive torque, which leads to energy consumption and noise pollution.
Innovation Solution
A method that involves closing the brake on a robot manipulator axis, deactivating the drive actuation, and continuously monitoring the brake's function. If a fault is detected, the drive actuation is reactivated by the motion control to ensure the axis is fixed by the drive rather than the brake, reducing energy consumption and noise, and allowing for quick intervention in case of a brake failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake is closed to hold the axis motionless, then the axis is reliably fixed, but the risk of unwanted movement due to brake failure cannot be sufficiently reduced
Solution Approach 1:
The system prepares a backup holding capability through the drive actuation before brake failure occurs. The drive is kept capable of providing holding torque to compensate if the brake fails, cushioning against the harmful effect of unwanted movement.
Solution Approach 2:
The monitoring device acts as an intermediary between the brake and the control system. It detects brake function degradation and triggers the backup holding mechanism, mediating the transition from brake-only holding to combined or drive-based holding.
2Reliability
If the drive actuation is kept active to actively achieve standstill, then safety is improved, but energy consumption and noise pollution increase
Solution Approach 1:
Instead of continuous drive actuation, the system uses periodic monitoring of brake function and only activates the drive when needed (when brake fault is detected). This transforms continuous energy consumption into periodic, demand-based activation.
Solution Approach 2:
The brake monitors its own function through the monitoring device, and the system automatically transitions to drive-based holding when the brake cannot serve its function reliably, eliminating the need for continuous external energy input.
3Reliability
If the brake is not closed and standstill is achieved by drive torque, then brake failure risk is eliminated, but the manipulator remains in an active state requiring energy and producing noise
Solution Approach 1:
The system uses periodic monitoring rather than continuous drive actuation. The drive remains inactive during normal brake operation, eliminating continuous noise and energy consumption, and only activates periodically when brake faults are detected.
Solution Approach 2:
The system dynamically switches between brake-based holding (quiet, energy-efficient) and drive-based holding (noisy, energy-consuming) based on real-time brake condition, optimizing the operating state according to actual needs.
Data Source
Figure 1~2
Figure 3
AI summary
Method for fixing at least one axis of a manipulator, in particular a robot, with the steps: (S20) closing a mechanical brake of the axis; (S30) disabling actuation of a drive of an axis by motion control; (S40) monitoring the mechanical brake; (S60) Enabling actuation of the drive by motion control if a monitor detects a mechanical brake fault condition.