Robot Joint Lost Motion Measurement via Dual Angle Sensors
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Solution Overview
Problem
Current methods for diagnosing the lifetime of robot arm transmissions, such as speed reducers, are inefficient as they often require stopping the robot arm for measurement, leading to prolonged interruptions and potential inaccuracies due to dynamic changes in mechanical conditions, especially in multi-shaft multi-joint robot arms.
Innovation Solution
A robot apparatus equipped with input-side and output-side angle sensors to measure the rotation angles of the transmission's input and output shafts, allowing for the calculation of lost motion and accurate diagnosis of the transmission's lifetime without disassembling the robot arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the robot arm is stopped to measure the wear amount of the gear from the outside, then the measurement can be performed, but the manufacture interruption period is prolonged
Solution Approach 1:
The patent replaces external mechanical measurement methods with an internal sensor-based detection system. Angle sensors mounted on the motor shaft and arm shaft electronically monitor rotation angles and calculate wear amounts through control unit computations, eliminating the need for external mechanical measurement devices and robot arm disassembly.
Solution Approach 2:
The robot arm performs self-diagnosis by using its own built-in angle sensors to continuously monitor its joint conditions. The control unit calculates wear amounts based on differences between motor shaft rotation angles and arm shaft rotation angles, enabling the system to self-assess its mechanical condition without external intervention or production stoppage.
2Measurement precision
If the robot arm is disassembled to measure the wear amount, then accurate measurement can be obtained, but more operation time becomes necessary
Solution Approach 1:
The patent replaces physical disassembly and manual measurement procedures with an electronic sensor-based system. Angle sensors and control units continuously calculate wear amounts through computational analysis of rotation angle differences, eliminating time-consuming mechanical disassembly operations while maintaining measurement accuracy.
Solution Approach 2:
The wear measurement system operates continuously during robot arm operation without interruption. Angle sensors continuously monitor rotation angles, and the control unit continuously calculates wear amounts, enabling ongoing condition assessment that does not halt production flow or require separate measurement operations.
3Adaptability or versatility
If the measuring system is applied to multi-shaft multi-joint robot arms, then comprehensive monitoring is achieved, but measurement accuracy is reduced due to dynamic mechanical condition changes
Solution Approach 1:
The patent applies angle sensors and wear calculation specifically to individual joints that require monitoring, rather than attempting to measure all joints simultaneously under dynamic conditions. The control unit calculates wear amounts for each monitored joint independently based on local rotation angle differences, allowing accurate localized measurement even when other parts of the robot arm are in motion.
Solution Approach 2:
The system dynamically adjusts its measurement approach by continuously monitoring rotation angles during operation and calculating wear amounts in real-time. The control unit processes angle sensor data dynamically, enabling accurate wear assessment that adapts to changing operational conditions rather than requiring static measurement environments.
Data Source
AI summary
The present invention enables to easily and accurately measure a joint of a robot apparatus, in particular, a lost motion of a driving system of the joint, and, to easily and accurately perform a diagnosis of a lifetime or a life expectancy of a joint mechanism of the robot apparatus based on a measured result.