Robot Cable Assembly Monitoring for Predictive Maintenance
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Solution Overview
Problem
The cable assembly in robot supply systems is frequently replaced due to various mechanical, thermal, and media-related loads, leading to high maintenance costs and reduced reliability.
Innovation Solution
Integration of sensors within the cable assembly to monitor state variables, such as bending and environmental conditions, allowing for active monitoring and prediction of remaining service life, thereby enabling replacement only when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable assembly is replaced at fixed maintenance intervals, then the reliability of the supply system is maintained, but the usage time and cost efficiency are reduced due to premature replacement
Solution Approach 1:
The patent applies preliminary action by monitoring the cable assembly's state variables (bending, temperature, media exposure) in real-time and predicting remaining service life before actual failure occurs. This allows maintenance to be scheduled based on actual condition rather than fixed intervals, extending usage time while maintaining reliability through early detection of degradation trends.
Solution Approach 2:
The patent implements feedback by continuously measuring state variables of the cable assembly and using this information to update the remaining service life prediction. The sensor data provides feedback on the actual condition of the cable, enabling dynamic adjustment of maintenance timing and optimizing the balance between reliability and usage time.
2Measurement precision
If sensors are integrated into the cable assembly for continuous monitoring, then the remaining service life can be predicted accurately, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies merging by integrating multiple sensing functions (bending sensors, temperature sensors, media exposure sensors) directly into the cable assembly structure. This combination of monitoring functions within a single integrated system reduces overall system complexity compared to using separate external sensors, while maintaining high measurement precision for predicting remaining service life.
Solution Approach 2:
The patent implements universality by designing the cable assembly to perform multiple functions simultaneously: power supply, data transmission, and condition monitoring. The integrated sensors enable the cable to monitor its own state variables (bending, temperature, media exposure), making it a multi-functional component that reduces the need for separate monitoring systems and lowers overall device complexity.
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 extends the usage time of the cable assembly, reduces maintenance intervals, and improves reliability by providing real-time data for predictive maintenance.
Implementation Method 1
The sensor is in this case especially designed as a bend sensor that in particular records the bending of the cable assembly or of the supply chain during the compensation movements.
Implementation Method 2
The response signal preferably arises due to a reflection at a 'fault point' that is caused for example by a bend. The propagation of the sensor signal within the line element and the reflection of parts of the sensor signal depends on the dielectricity of the line element, which in turn is influenced by the state variables.
Implementation Method 3
The propagation of the sensor signal within the line element and the reflection of parts of the sensor signal depends on the dielectricity of the line element
Implementation Method 4
In order to evaluate the response signals/reflected signal component, provision is made for example for a time-of-flight measurement, for example in the form of time domain reflectometry (TDR for short).
Data Source
AI summary
A method monitors a supply system of a robot having a robot arm and a robot hand movable relative thereto. The supply system has a supply chain, in particular a cable assembly, and a guide for the supply chain. The supply chain is guided along the robot arm in order to supply the robot hand. The supply system also has a number of sensors for monitoring at least one state variable of the supply system. The functional capability of the supply system is concluded, inferred or predicted from values for the state variable that are determined by the sensors.