Robot Sensor Fault Detection With Two-Sensor Safeguard Operation
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Solution Overview
Problem
Current robotic detection systems activate safety settings immediately upon detecting abnormalities, leading to production inefficiencies and increased repair costs due to inability to identify failed sensors and maintain reliable monitoring.
Innovation Solution
A detection system with three sets of sensors at a robot's motor and power output terminal, using a control system to select and utilize two normal sets of sensors for safeguard operations, with backup sensors for continued operation and immediate notification of abnormal sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the safety setting is activated immediately upon detecting an abnormal system, then the robot safety is ensured, but the production efficiency is reduced due to immediate shutdown
Solution Approach 1:
The system performs preliminary identification of abnormal sensors before shutdown. The detection unit detects abnormal sensors and the control unit identifies which specific sensors have failed, allowing for targeted replacement rather than complete system shutdown. This preliminary action enables faster recovery and maintains production efficiency while ensuring safety.
Solution Approach 2:
The system provides feedback by identifying and notifying which specific sensors are abnormal. This feedback mechanism allows operators to understand the exact nature and location of the fault, enabling precise maintenance actions. The feedback loop continues after shutdown to guide the replacement process, ensuring safety while minimizing production loss.
2Object-affected harmful factors
If the robot is shut down immediately upon system abnormality, then collision and damage are prevented, but additional time is needed to identify invalid components, increasing repair costs
Solution Approach 1:
The control unit acts as an intermediary between the detection unit and the shutdown mechanism. It receives detection signals, processes them to identify specific abnormal sensors, and then triggers the shutdown. This intermediary function provides a bridge that allows for intelligent decision-making, identifying the exact faulty component before shutdown to minimize repair time and costs.
Solution Approach 2:
The system replaces manual inspection and identification of faulty sensors with an automated detection and identification system. The detection unit and control unit work together to automatically identify which sensors have failed, substituting the need for manual troubleshooting and reducing both repair time and costs while maintaining safety.
3Productivity
If three sets of sensors are used with selection of two normal sets, then continued operation is possible with abnormal sensors identified, but the device complexity increases
Solution Approach 1:
The sensor system is segmented into multiple independent sets (first, second, and third sets of sensors). Each set can be independently evaluated for normal or abnormal operation. This segmentation allows the system to continue operating with two normal sets while identifying and isolating the abnormal set, maintaining productivity while managing complexity through modular design.
Solution Approach 2:
The control unit changes the operational parameters by selecting which sensor sets are active based on their operational status. When sensors are detected as abnormal, the system changes the configuration to use only the normal sensor sets, effectively changing the system parameters to maintain optimal operation while accommodating the presence of abnormal components.
Data Source
AI summary
A detection system and detection method for the sensors of a robot. A detection system installs three sensors at the motor side and power output terminal of the robot. A detection unit detects the normal or abnormal state of three sensors to index the abnormal sensor for maintenance, and two normal sensors are selected for keeping the robot safety operation without stop.