Robot Remaining-Life Estimation Triggered by Malfunction Signs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for estimating the remaining life of robots in industrial production lines are inaccurate in the initial stages of aging deterioration, leading to low estimation precision and the need for spare components and regular inspections to avoid production line stoppages.
Innovation Solution
A robot control apparatus with a drive control unit, detection unit, and estimation unit that detects signs of malfunction through feature amounts such as vibration, sound, or current command values, allowing for precise estimation of remaining life after a malfunction is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If remaining life estimation is performed based on current command value in the initial stage of aging deterioration, then estimation can be performed earlier, but estimation precision is low because almost no change quantitatively indicating deterioration degree appears
Solution Approach 1:
The system performs preliminary detection of signs of malfunction (such as changes in vibration, sound, or other feature amounts) before the robot actually malfunctions. By detecting these early signs and postponing the remaining life estimation until signs are present, the system prepares in advance for accurate estimation without attempting to estimate prematurely when no detectable changes exist.
Solution Approach 2:
The system dynamically adjusts the timing of remaining life estimation based on the detected state of the robot. Instead of estimating at fixed intervals or always, the system flexibly determines when to perform estimation based on whether signs of malfunction are detected, allowing the estimation process to adapt to the actual condition of the robot.
2Measurement precision
If remaining life estimation is postponed until signs of malfunction are detected, then estimation precision is improved, but maintenance response time is delayed
Solution Approach 1:
The system performs preliminary monitoring of multiple feature amounts (vibration, sound, current command values) continuously to detect signs of malfunction early. This preliminary detection phase prepares the system for accurate remaining life estimation by identifying when deterioration has progressed enough to be measurable, without delaying the actual estimation until it is too late for effective maintenance planning.
Solution Approach 2:
The system uses feedback from continuous monitoring of feature amounts to determine when signs of malfunction are detected. This feedback mechanism allows the system to automatically trigger the remaining life estimation process at the optimal moment - when sufficient deterioration signs are present for accurate estimation but before actual malfunction occurs.
3Productivity
If conventional estimation methods are used in the initial stage of aging deterioration, then continuous estimation is possible, but estimation precision is insufficient leading to need for spare components and regular inspections
Solution Approach 1:
The robot control apparatus performs self-diagnosis by detecting signs of malfunction in itself through monitoring its own feature amounts (vibration, sound, current command values). This self-service capability allows the system to autonomously determine when deterioration has reached a level where accurate remaining life estimation is possible, eliminating the need for external regular inspections while maintaining high estimation precision.
Solution Approach 2:
The system monitors changes in multiple parameters (vibration characteristics, sound levels, current command values) to detect signs of malfunction. By tracking changes in these physical parameters over time, the system can accurately determine when deterioration has progressed sufficiently for reliable remaining life estimation, replacing inaccurate conventional methods that relied on single parameters like current command value alone.
Data Source
AI summary
A remaining life of a robot body is precisely estimated. A robot control apparatus 300 includes: a drive control unit 305 that controls drive of a robot body 200; a detection unit 306 that detects a feature amount quantitatively indicating a deterioration degree of the robot body 200 that is deteriorated over time as the robot body 200 is driven; a determination unit 303 that determinates presence/absence of a sign of malfunction of the robot body 200 based on the feature amount; and an estimation unit 304 that estimates a remaining life of the robot body 200 when presence of a sign of malfunction of the robot body 200 is determined.