Articulated Robot Joint Failure Diagnosis via Multi-Dimensional Detection
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Solution Overview
Problem
Existing articulated robot systems face challenges in accurately determining the load state of each joint, particularly when interference occurs, leading to potential damage and operational inaccuracies, as conventional methods fail to differentiate between joints based on similar electric current and encoder output variations.
Innovation Solution
A robot system controlling method that records movement and load information from detection devices, allowing for the determination of joint failures by analyzing data from before and during an abnormality, enabling precise identification of failed parts and taking necessary measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electric current and encoder output variations are used to detect joint abnormalities, then detection capability is provided, but accurate determination of load state and damage possibility is insufficient
Solution Approach 1:
The patent segments the joint detection system into multiple independent detection dimensions: electric current detection, encoder output detection, and motor rotation amount detection. By dividing the detection function across these separate components, the system captures differentiated information for each joint, enabling accurate identification of which specific joint experienced interference and its load state, thereby resolving the information loss problem.
Solution Approach 2:
The patent adds a new detection dimension by incorporating motor rotation amount detection alongside the existing electric current and encoder output detections. This dimensional expansion provides additional independent data for analyzing joint abnormalities, allowing the system to accurately determine load states and differentiate between joints even when traditional detection methods yield similar results.
2Reliability
If real-time load monitoring is implemented, then operational safety is improved, but system complexity increases
Solution Approach 1:
The patent implements multi-functionality by using the control device to perform multiple roles: it controls motor operations, detects electric current, monitors encoder outputs, and calculates motor rotation amounts. By consolidating these detection and control functions into a single control device rather than adding separate dedicated detectors for each parameter, the system achieves comprehensive real-time monitoring while minimizing the increase in device complexity.
Solution Approach 2:
The system employs self-service by utilizing the existing motor and encoder components to provide detection data. The motor's electric current consumption and the encoder's output signals, which are already present in the system for control purposes, are repurposed for abnormality detection. This eliminates the need for additional dedicated sensing hardware, maintaining system simplicity while achieving reliable operational safety monitoring.
3Measurement precision
If comprehensive joint monitoring is performed, then damage detection accuracy is improved, but response time for abnormality detection increases
Solution Approach 1:
The patent implements continuous monitoring by simultaneously and continuously detecting electric current, encoder outputs, and motor rotation amounts for all joints without interruption. This continuous data collection ensures that when interference occurs, the system immediately captures the abnormality with high precision. The real-time nature of all three detection methods working in parallel eliminates detection delays, achieving both high accuracy and rapid response.
Solution Approach 2:
The system performs preliminary action by continuously establishing baseline data for normal operation of each joint through ongoing detection of electric current, encoder outputs, and rotation amounts. When interference occurs, the system compares real-time data against these pre-established baselines, enabling immediate identification of abnormalities. This preliminary data collection and comparison capability allows the system to achieve rapid abnormality detection without sacrificing detection accuracy.
Data Source
AI summary
A method of controlling a robot system including an articulated robot and a control device is provided. The articulated robot includes links connected by joints, motors configured to drive the joints respectively, and detection devices configured to detect rotation amounts of the joints respectively. The control device controls the motors. The method includes the steps of, by the control device, recording movement information of the joints based on outputs of the detection devices; when detecting an abnormality in the operation of the articulated robot, determining presence or absence of a failure in the articulated robot based on the movement information recorded in at least a period from before detection of the abnormality until detection of the abnormality; and specifying a failure portion of the articulated robot if it is determined that there is a failure in the articulated robot in the step of determining.