Robot Cable Damage Detection via Velocity-Varying Alarm Analysis
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Solution Overview
Problem
Conventional methods fail to detect incomplete cable breaks in robot mechanisms, as these breaks only occur when the cable is bent or twisted, making them invisible and undetectable through traditional continuity tests.
Innovation Solution
A cable damage detection apparatus and method that involves executing a robot program multiple times with varying motor velocities, generating alarms based on state quantities, and analyzing alarm occurrence frequencies to identify potential cable damage by visualizing the relationship between alarm occurrences and velocities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional continuity testing is used to detect cable breaks, then simple and quick detection is achieved, but incomplete cable breaks that occur only during specific bent or twisted states are missed
Solution Approach 1:
The system dynamically changes motor velocity during program execution to create varying cable states. By executing the same program multiple times at different velocities, the cable undergoes different bending and twisting conditions, allowing incomplete breaks that only occur at specific velocities to be detected. This dynamic approach transforms a static detection method into one that can reveal velocity-dependent cable damage.
Solution Approach 2:
The system changes the velocity parameter of motor execution to detect cable breaks. By varying velocity as a controllable parameter and observing alarm occurrences at different velocity levels, the system can identify cable breaks that manifest only under specific velocity conditions. This parameter-based approach allows systematic exploration of cable behavior under different operational states.
2Stability of the object's composition
If the robot operates at constant velocity, then stable operation is maintained, but velocity-dependent cable breaks cannot be detected
Solution Approach 1:
The system performs periodic execution of the same program at different velocities. By repeatedly executing the program multiple times with velocity variations, the system creates periodic stress conditions on the cable that can reveal velocity-dependent breaks. This periodic action pattern allows systematic detection while maintaining operational stability during each individual execution.
3Reliability
If multiple programs are executed to detect cable breaks, then detection coverage is improved, but time consumption increases
Solution Approach 1:
The system uses a single program that serves multiple functions: it both performs the robot's intended task and simultaneously tests for cable breaks at different velocities. By reusing the same program for both operational and diagnostic purposes, the system achieves comprehensive detection coverage without requiring separate dedicated test programs, thus reducing time consumption.
Data Source
AI summary
A cable damage detection assistance apparatus in a robot mechanism includes a program executor for executing a program to operate a robot, a plurality of times, while changing velocity for driving motors whenever the program is executed; a motor controller for controlling the motors; a state quantity detector for detecting a state quantity indicating an operation state of the robot during the execution of the program; an alarm generator that, when the state quantity exceeds a threshold value, generates an alarm and outputs information about a line number at that time; an alarm database for counting the number of occurrence of alarms on each line number on which the alarm has occurred, and storing the alarm occurrence number on each line number on a velocity-by-velocity basis; and an analysis display for displaying the relationship between the alarm occurrence number and the velocity on each line number.