Robot Joint Actuation Lane Fault Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial robots on production lines often require costly and time-consuming maintenance due to failures, leading to unscheduled stoppages and significant losses in productivity when a robot breaks down, as repositioning and realignment can be complex and time-consuming.
Innovation Solution
A robot with a fault detection and isolation system that includes multiple actuation lanes and a control system capable of maintaining operation by isolating faulty lanes, allowing the robot to continue functioning at a reduced rate or compensating for faults, thereby minimizing downtime and enabling online repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robot is equipped with multiple actuation lanes for each joint, then the robot can continue operating at reduced capability when a fault occurs, but the device complexity increases
Solution Approach 1:
The actuation system for each joint is divided into multiple independent actuation lanes (e.g., first and second actuation lanes). Each lane can operate independently to drive the joint, allowing the system to segment the functional load and continue operation even when one lane fails.
Solution Approach 2:
The patent implements local redundancy by providing multiple actuation lanes specifically for critical joints rather than uniformly across the entire robot system. This allows the system to maintain operational capability in affected areas while avoiding unnecessary complexity in non-critical areas.
2Productivity
If the robot operates with reduced capability after fault detection, then productivity is maintained to some extent, but the manufacturing precision may be compromised
Solution Approach 1:
The control system continuously monitors the operational status of each actuation lane and provides feedback when a fault is detected. This feedback mechanism allows the system to transition smoothly from normal operation to fault-tolerant mode, maintaining productivity while managing precision through adaptive control strategies.
Solution Approach 2:
The robot's operational capability is dynamically adjusted based on the fault condition. When a fault is detected in one actuation lane, the system dynamically reconfigures to operate using the remaining healthy lanes, allowing continued production at reduced capability rather than complete shutdown.
3Manufacturing precision
If the robot is stopped for repair when a fault occurs, then manufacturing precision can be maintained, but significant time is lost due to production line stoppage
Solution Approach 1:
The multiple actuation lanes enable continuous operation of the robot even when one lane fails. The healthy lanes continue to drive the joints, maintaining production flow and eliminating the need for complete system shutdown, thereby preventing loss of time while managing precision through the remaining functional components.
4Manufacturing precision
If home positioning and realignment are performed after robot failure, then manufacturing precision is restored, but the process is lengthy and complicated
Solution Approach 1:
The system maintains positional information and operational state continuously even during fault conditions. By preserving this information in real-time, the system eliminates the need for lengthy home positioning and realignment procedures after fault recovery, as the robot can resume from its last known state rather than requiring complete repositioning.
Data Source
Figure 1
Figure 2
Figure 3A~5
AI summary
A robot (3) comprises an arm having at least one joint (31, 31 ', 31 ") comprising a joint driving means (34, 35), the joint driving means having a plurality of actuation lanes; and a fault detection and isolation (FDI) system adapted to detect a fault in any one of the actuation lanes. The fault detection and isolation system in some embodiments is operable to isolate the or each actuation lane exhibiting the fault, and/or the robot (3) is provided with a local control system connected to the fault detection and isolation system, the control system being operable to control the operation of the joint (31, 31', 31 ") and to maintain, at least partially, operation of the joint (31, 31', 31 ") when a fault is detected.