Industrial Robot Remote Diagnostics for Faster Return to Service
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Solution Overview
Problem
Existing methods for diagnosing and resolving issues with industrial robots are slow and require manual intervention by operators, often leading to lost productivity due to downtime, as they lack automated data capture and centralized diagnosis.
Innovation Solution
A system and method that automates the capture and upload of diagnostic files from industrial robots to a remote diagnostic system, utilizing a data collection device and a cloud-based diagnostic system to facilitate rapid diagnosis and corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual data collection methods are used, then device complexity is reduced, but loss of time increases and productivity decreases
Solution Approach 1:
The system performs preliminary actions by automatically capturing diagnostic data at the moment of failure and pre-processing it before the support team needs to analyze it. The data collection device automatically identifies relevant files, captures them, and uploads them to the cloud-based diagnostic system, eliminating the need for manual data gathering during the support process.
Solution Approach 2:
The system enables self-service by allowing the robot controller to automatically initiate data capture and upload when a failure occurs. The data collection device autonomously identifies what data needs to be captured, retrieves it from the controller, and transmits it to the remote diagnostic system without requiring operator intervention or manual file transfer.
2Loss of time
If automated data capture is implemented, then loss of time is reduced, but device complexity increases
Solution Approach 1:
The patent introduces a data collection device as an intermediary component that sits between the robot controller and the cloud-based diagnostic system. This intermediary handles the complexity of data identification, capture, and transmission, shielding the user from system complexity while enabling automated data collection. The intermediary absorbs the computational and communication overhead of automated data handling.
3Ease of operation
If manual file transfer is required, then ease of operation is improved, but loss of time increases
Solution Approach 1:
The system performs self-service by automatically capturing and transferring diagnostic data when a failure occurs. The robot controller or data collection device autonomously identifies relevant diagnostic files, retrieves them, and uploads them to the cloud-based diagnostic system without requiring operator intervention. This eliminates the need for operators to manually locate, copy, and email files while significantly reducing the time required for data transfer.
4Loss of information
If critical data is not captured immediately, then ease of operation is improved, but loss of information occurs
Solution Approach 1:
The system performs preliminary action by automatically capturing diagnostic data at the precise moment when a failure occurs. The data collection device immediately identifies and retrieves critical status information from the robot controller before any potential data loss, ensuring that all relevant diagnostic files are captured and uploaded to the cloud-based diagnostic system without delay.
Data Source
AI summary
A system and methods for automated support for industrial robots. The system includes a data collection device which communicates with all robots at a customer site, and uploads data to a remote diagnostic system. The method is activated either automatically when an alarm occurs, or by the robot operator or a remote support team. Upon activation, particular diagnostic files are captured and sent from the affected robot's controller to the data collection device and on to the remote diagnostic system. The system employs a knowledge base to diagnose the cause of the issue from the diagnostic files, and support team personnel are also involved to reach a diagnosis. Based on the diagnosis, updated software or configuration files are sent to the affected robot to correct the issue and allow the robot to return to service, instructions are provided to the robot operator, or an on-site service technician visit is scheduled.