Robot Fault Diagnosis via Camera Image Comparison
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Solution Overview
Problem
Existing fault diagnostic methods for robot systems are inadequate in accurately detecting external damage to components such as power cables and communication lines, as they rely solely on signal feedback which can be unreliable, especially in cases of corrosion or physical contact with other devices.
Innovation Solution
A fault diagnostic device equipped with a camera attached to the robot, an arithmetic processing unit, and storage for reference images, which captures and compares images of components to judge faults based on predetermined criteria, allowing for accurate detection of external damage and operational state analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fault diagnosis is performed using signal feedback from detectors, then internal component faults can be detected, but external damage to components cannot be accurately recognized
Solution Approach 1:
The patent introduces a camera as an intermediary diagnostic tool to capture images of external components. The camera serves as a mediator between the detector system and external components, allowing visual documentation of damage to power cables, communication lines, and other external elements that signal-based detectors cannot accurately assess.
Solution Approach 2:
The patent replaces signal-based detection (electrical/mechanical feedback) with optical imaging for external component diagnosis. By substituting the mechanical/electrical detector system with an optical camera system, the invention enables accurate detection of external damage through visual capture and image processing.
2Reliability
If a camera is attached to the robot for image capture, then external damage can be detected, but the device complexity increases
Solution Approach 1:
The patent makes the robot system universal by enabling the existing camera and arithmetic processing device to perform both original functions and fault diagnosis. The camera can capture images for operational purposes while simultaneously serving diagnostic functions, and the arithmetic processing device handles both control tasks and image analysis, reducing the need for separate dedicated diagnostic hardware.
Solution Approach 2:
The robot system performs self-diagnosis by using its own camera and processing capabilities to detect faults in its components. The arithmetic processing device automatically captures images, processes them, and identifies damage without requiring external diagnostic equipment or manual inspection, enabling the system to service itself.
3Reliability
If multiple diagnosis portions are imaged and compared, then comprehensive fault coverage is achieved, but the loss of time increases
Solution Approach 1:
The patent stores reference images of diagnosis portions in advance during normal operation. These pre-captured reference images are saved in the storage device, allowing for rapid comparison with current images during fault diagnosis without requiring time-consuming re-capture of baseline images, thus reducing diagnostic time while maintaining comprehensive coverage.
Solution Approach 2:
The patent creates and stores copies of reference images during normal operation. These image copies are saved in the storage device and can be quickly retrieved and compared with current diagnostic images, enabling rapid fault detection without requiring time-consuming real-time analysis or re-capture of reference states.
Data Source
AI summary
A fault diagnostic device comprises an arithmetic processing device configured to judge a fault on the basis of an image captured by the camera. The arithmetic processing device includes an imaging command part configured to transmit a command for capturing the image of a diagnosis portion and a judgement part configured to judge whether or not the diagnosis portion has the fault. A storage part stores a reference image when the diagnosis portion is in a normal state. The imaging command part transmits an imaging command so as to capture the image of the diagnosis portion after changing a position and a posture of the robot. The judgement part compares the image of the diagnosis portion captured by the camera with the reference image and judges the fault in the diagnosis portion.