Robot Joint Brake Performance Evaluation System
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Solution Overview
Problem
Wear or contamination of brakes in robots leads to braking failures, resulting in unsafe operation and increased downtime, as existing systems lack effective methods for evaluating and predicting the degradation of electromechanical brakes and overall braking performance.
Innovation Solution
A system comprising a processor and memory with executable instructions that measure performance data from sensors at robot joints, define performance regions based on expected values, and determine if the measured parameters exceed limits, thereby identifying when brakes need servicing or monitoring, using a combination of emergency stop and breakaway methods to assess braking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional brake monitoring methods are used, then the system is simple to operate, but the reliability of brake performance evaluation is insufficient
Solution Approach 1:
The patent replaces traditional mechanical brake monitoring methods with an electronic system that uses sensors to measure performance parameters such as stopping distance, stopping time, and deceleration. This substitution enables more reliable and precise evaluation of brake performance while allowing for automated data collection and analysis, thus improving reliability without proportionally increasing operational complexity.
Solution Approach 2:
The system implements feedback mechanisms by continuously measuring brake performance parameters during robot operation and comparing them against predetermined thresholds. When performance degradation is detected, the system provides feedback alerts to indicate when brake maintenance is required. This closed-loop feedback approach ensures reliable monitoring while maintaining system simplicity through automated decision-making algorithms.
2Loss of time
If no brake evaluation system is implemented, then the device complexity is low, but the downtime increases due to undetected brake degradation
Solution Approach 1:
The system performs preliminary evaluation of brake performance by continuously monitoring parameters during normal robot operation. By detecting degradation trends before they lead to complete brake failure, the system enables proactive maintenance scheduling. This preliminary detection capability significantly reduces unplanned downtime while keeping the added system complexity manageable through integration with existing robot control systems.
Solution Approach 2:
The brake evaluation system operates autonomously by automatically collecting performance data from sensors, analyzing the data against predefined criteria, and generating maintenance alerts without requiring constant human intervention. This self-service capability minimizes the operational burden on users while providing continuous monitoring to prevent downtime caused by undetected brake issues.
3Measurement precision
If comprehensive performance monitoring is implemented, then the measurement precision is high, but the ease of operation decreases
Solution Approach 1:
The system introduces an intermediary processing layer that automatically analyzes raw sensor data and translates it into meaningful performance evaluations and maintenance recommendations. This intermediary layer handles the complexity of data interpretation, allowing operators to interact with the system through simple alert notifications rather than complex data analysis interfaces, thus maintaining ease of operation while achieving high measurement precision.
Solution Approach 2:
The system creates simplified representations of complex brake performance data through standardized performance indicators and maintenance status indicators. Instead of requiring operators to interpret raw sensor data directly, the system generates easy-to-understand status copies that indicate brake health conditions and maintenance needs, thereby maintaining operational simplicity while leveraging precise measurements for accurate assessments.
Data Source
AI summary
A system is configured to determine the performance of a braking system for a joint of a robot. The braking system is configured to apply a brake to the joint and a servo system is configured to apply a torque to the joint. The system measures performance data at the joint, identifies a performance parameter, and defines performance regions and limits that are used to evaluate the performance parameter.