Industrial Robot Supervision Sensor Wiring via Power Lines
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Solution Overview
Problem
Industrial robot systems require frequent manual inspections for oil leaks, which are time-consuming and labor-intensive, and the installation of wired supervision sensors increases complexity and cost, while also potentially causing malfunctions.
Innovation Solution
Incorporating supervision sensors into industrial robot systems using a method that minimizes the need for redesigning electrical wiring, by connecting sensors to transmit data and receive power via existing motor and brake signal wires, utilizing a signal conditioning unit to encode sensor data onto these wires for communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If wired supervision sensors are installed in the manipulator for automated monitoring, then the need for manual inspection is reduced, but the complexity and cost of the electrical installation increases
Solution Approach 1:
The existing power transmission lines are made multi-functional by enabling them to carry both power and sensor data. The signal conditioning unit encodes sensor data onto the power lines, allowing these lines to serve dual purposes: supplying power to components and transmitting supervision sensor data to the controller, thereby eliminating the need for separate data wiring.
2Extent of automation
If wired supervision sensors are installed in the manipulator for automated monitoring, then the need for manual inspection is reduced, but the cost of the industrial robot system increases
Solution Approach 1:
The existing power transmission lines are made multi-functional by enabling them to carry both power and sensor data. The signal conditioning unit encodes sensor data onto the power lines, allowing these lines to serve dual purposes: supplying power to components and transmitting supervision sensor data to the controller, thereby eliminating the need for separate data wiring.
3Extent of automation
If wired supervision sensors are installed in the manipulator, then automated monitoring is enabled, but potential causes of malfunction are added through wiring
Solution Approach 1:
The existing power transmission lines are made multi-functional by enabling them to carry both power and sensor data. The signal conditioning unit encodes sensor data onto the power lines, allowing these lines to serve dual purposes: supplying power to components and transmitting supervision sensor data to the controller, thereby eliminating the need for separate data wiring.
4Reliability
If manual inspection is performed regularly to detect oil leaks, then potential problems are detected, but time and labor are consumed
Solution Approach 1:
Supervision sensors are installed in the manipulator to continuously monitor for oil leaks and other malfunctions. The sensors provide real-time feedback to the controller, enabling automated detection and alerting, which eliminates the need for periodic manual inspections and allows for immediate response to detected issues.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the need for additional wiring, simplifies the electrical installation, and enhances the reliability of the robot system by enabling automated monitoring of potential malfunctions, such as oil leaks, without increasing the risk of sensor-related malfunctions.
Implementation Method 1
the signal conditioning unit is configured to encode sensor data from the supervision sensor onto the power transmission lines for transmission to the controller, and to divert power from the power transmission lines to power the supervision sensor
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An industrial robot system comprises a manipulator with a drive chain (30) including a motor unit (31). A controller in the industrial robot system is electrically connected to the drive chain (30) by a set of power transmission lines (4a1, 4a2) and is operable to transmit electrical power on the set of power transmission lines (4a2) so as to impart a controlled movement of the manipulator. A supervision sensor (37) is arranged in the manipulator and configured to sense a property of the manipulator. The supervision sensor (37) is electrically connected to at least a subset of the power transmission lines (4a1, 4a2) for transmission of sensor data representing the property to the controller.