Robot Balancer Wear Detection via Positional Sensors

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Solution Overview

Problem

Existing balancer systems in robots fail to effectively detect wear in bearings, leading to increased load on motors and potential damage to other components due to the inability to accurately monitor changes in the positional relationship between the balancer's components, especially when the gravitational load torque varies.

Innovation Solution

A balancer system with a housing, a rod, and a compression coil spring, along with a sensor to detect the positional relationship between the housing and the rod, allowing for real-time monitoring of changes in the balancer's configuration due to wear, thereby triggering notifications for maintenance before further damage occurs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bearing wear is not monitored, then the balancer system operates without additional sensors, but the motor load increases and component damage may occur

Engineering Contradiction:

Improvecomponent reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The balancer system uses its own operational parameters (current values, positional relationships) to self-diagnose bearing wear conditions. The control unit monitors existing sensor data and detects changes that indicate bearing degradation, allowing the system to monitor its own health without external monitoring equipment.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors the positional relationship between the housing and rod, and compares it against expected values. When deviations occur that suggest bearing wear, the control unit receives feedback and can trigger maintenance alerts or adjust operations to prevent further damage.

Inventive Principle:

Principle #23Feedback

2Reliability

If bearing wear is detected early, then maintenance can be performed timely, but the system requires complex monitoring mechanisms

Engineering Contradiction:

Improvesystem reliabilityVSAvoidwear detection difficulty

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The system uses its own operational parameters (current values, positional relationships) to self-diagnose bearing wear conditions. The control unit monitors existing sensor data and detects changes that indicate bearing degradation, allowing the system to monitor its own health without external monitoring equipment.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces complex mechanical wear detection mechanisms with electronic sensing and control. Instead of using mechanical indicators or complex measurement devices, the system uses sensors to detect positional relationships and a control unit to analyze current values, substituting mechanical detection with electronic measurement and processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Force

If the balancer maintains accurate positional relationships, then it effectively compensates for gravitational load, but bearing wear causes positional drift and increased motor load

Engineering Contradiction:

Improvebalancer forceVSAvoidmotor energy consumption

Core Design Contradiction:

ForceVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system detects bearing wear conditions before they cause significant positional drift or motor overload. By monitoring positional relationships and current values in advance, the system can alert operators to perform maintenance before the bearing wear progresses to a point where it significantly impacts balancer performance or energy consumption.

Inventive Principle:

Principle #10Preliminary action

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 system effectively reduces the load on motors by adjusting the auxiliary torque based on gravitational load torque changes and provides early detection of bearing wear, enabling timely maintenance and preventing adverse effects on other components.

Implementation Method 1

a force generating means (a compression coil spring) that generates a force in a direction in which the rod is drawn into the housing or in a direction in which the rod is pushed out of the housing

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

a sensor that detects at least one of a positional relationship between the first attachment axis and the housing and a positional relationship between the second attachment axis and the rod, in a direction orthogonal to the first attachment axis and the second attachment axis

Methodology Applied

Scientific EffectSensor detection:

Implementation Method 3

first bearings that support the housing so as to be rotatable about a first attachment axis parallel to the rotation axis; a second bearing that supports the rod so as to be rotatable about a second attachment axis parallel to the rotation axis

Methodology Applied

Scientific EffectBall bearing: Ball Bearing

Data Source

PatentUS12194622B2Balancer and robot system

Publication Date: 2025.01.14 FANUC LTD

AI summary

A balancer includes a housing attached to one of a first member and a second member that is rotationally driven with respect to the first member about a rotation axis in a robot including the first member and the second member. The housing is rotatable about a first attachment axis parallel to the rotation axis. A rod has one end attached to another one of the first member and the second member to be rotatable about a second attachment axis parallel to the rotation axis. A force generator generates a force in a direction in which the rod is drawn into the housing or in a direction in which the rod is pushed out of the housing. A sensor detects a positional relationship between the housing and the rod in a direction orthogonal to the first attachment axis and the second attachment axis.