Robot Operation Logging for Abnormal Cause Comparison
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Solution Overview
Problem
Current robot systems struggle to efficiently track down the cause of abnormal situations, such as system failures or human errors, due to limited chronological data and lack of detailed operational information, making it difficult to identify the specific cause and process leading to these events.
Innovation Solution
A robot device that records operation information during normal and abnormal states, allowing for comparison of data to determine the cause of an abnormal situation through a normal-state data recorder and a trigger-state data recorder, with a display for visual comparison of the recorded information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If only limited operational status data is recorded when an abnormal situation occurs, then the recording process is simple and quick, but it becomes difficult to obtain the specific cause and process leading to the abnormal situation
Solution Approach 1:
The system performs preliminary actions by continuously recording detailed operational information (including I/O states, program counters, and welding conditions) in a buffer memory before any abnormal situation occurs. This ensures that when an abnormality is detected, comprehensive data is already available for immediate analysis, eliminating the need for complex post-incident data collection while preserving complete cause analysis information.
2Loss of information
If detailed chronological operational information is recorded, then the cause of abnormal situations can be tracked down efficiently, but the data storage requirements and system complexity increase
Solution Approach 1:
The system extracts and records only the specific operational information necessary for cause analysis into a dedicated buffer memory, separate from the main control system. By focusing on extracting key parameters (I/O states, program counters, welding conditions) rather than recording all possible system data, the solution achieves complete cause analysis information while maintaining relatively simple system architecture.
Solution Approach 2:
The buffer memory is nested within the controller's memory structure, with the operation information buffer (321) organized as a structured data container that holds nested elements including I/O information, program counter data, and welding condition records. This nested organization allows comprehensive data storage while presenting a unified, manageable interface to the control system.
3Loss of information
If operational information is recorded for every cycle during normal operation, then complete process information is available for comparison, but the memory capacity is consumed quickly
Solution Approach 1:
The system applies local quality by recording detailed operational information selectively at specific locations in the data structure corresponding to abnormal events, rather than uniformly recording all cycles. The buffer memory stores complete information only for cycles containing abnormalities, while normal cycles use minimal storage, optimizing memory usage while preserving complete process information where needed.
Data Source
AI summary
Operation information on a robot is recorded in a temporary data recorder continually only for a predetermined period. The operation information for one cycle during a normal operation of the robot is retrieved from the temporary data recorder, and is recorded in a normal-state data recorder. If a storage control section determines that a predetermined trigger condition has occurred, some pieces of the operation information recorded in the temporary data recorder are recorded in the trigger-state data recorder. An operation information display displays the operation information in a normal state and the operation information in a trigger state so that these pieces of the operation information can be compared with each other.