Servo Mechanism Frequency Response Diagnostics Without Disassembly
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Solution Overview
Problem
Conventional methods for diagnosing defects in servo controlled mechanisms require direct physical measurement and disassembly, leading to significant downtime and costs in manufacturing due to the need for manual intervention and transportation of equipment for diagnostics.
Innovation Solution
A motion control server and method that use a processor to supply a torque command with an alternating signal wave to test the frequency response of motors and robot linkages, allowing for the generation of bode plot fingerprints for diagnostics without disassembly, enabling remote analysis of defects such as incorrect inertia and belt tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional diagnostic methods are used requiring direct physical measurement and disassembly, then measurement precision can be achieved, but device complexity and loss of time increase significantly
Solution Approach 1:
The patent replaces mechanical disassembly and physical measurement methods with electronic signal injection and computational analysis. A test signal is injected through the amplifier to the motor, and the response is analyzed to generate a Bode plot fingerprint, eliminating the need for physical disassembly while maintaining diagnostic accuracy
Solution Approach 2:
The patent introduces an amplifier as an intermediary device between the diagnostic system and the motor. The amplifier receives test signals from the motion control server, amplifies them, and delivers them to the motor, enabling non-invasive frequency response analysis without direct physical access to the motor internals
2Measurement precision
If direct physical measurement of pulley belts is performed, then measurement precision is achieved, but device complexity and ease of operation deteriorate due to disassembly requirements
Solution Approach 1:
The patent replaces mechanical belt tension measurement methods with electronic frequency response analysis. By injecting test signals and analyzing the motor's frequency response, the system can infer mechanical conditions including belt tension without physical contact or disassembly of the pulley belt system
3Measurement precision
If equipment is shipped to manufacturer for diagnostics, then measurement precision can be maintained, but loss of time and productivity decrease due to transportation and setup
Solution Approach 1:
The patent enables the diagnostic system to perform self-testing and self-diagnosis capabilities. The motion control server can autonomously generate test signals, collect responses, and generate Bode plot fingerprints without requiring external expertise or equipment removal, allowing continuous operation during diagnostics
Solution Approach 2:
The patent creates a universal diagnostic system that can test multiple motors and robot linkages through a single amplifier interface. The system can diagnose various defects including incorrect inertia, belt tension issues, and mechanical abnormalities across different components using the same electronic test methodology
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 downtime by allowing on-site diagnostics of servo controlled mechanisms, detecting defects like incorrect inertia and belt tension, and avoiding the need for equipment disassembly and transportation, thereby minimizing production disruptions and costs.
Implementation Method 1
The processor may further include, in the torque command, an alternating signal wave that is to test a frequency response of the motor and the robot linkage
Implementation Method 2
The processor may determine, for a first frequency of the alternating signal wave, a magnitude and phase shift between the aggregate of the instantaneous mechanical parameter values and the aggregate of the instantaneous torque values
Data Source
AI summary
A server includes a processor to supply a torque command to an amplifier that controls a motor that drives a linkage; include, in the torque command, an alternating signal wave that is to test a frequency response of the motor and the linkage; receive, from the amplifier, an instantaneous torque value of the motor and an instantaneous mechanical parameter value of the linkage at each time step according to a sampling rate and over a period of time; store an aggregate of both these values; determine, for a first frequency of the alternating signal wave, a magnitude and phase shift between the aggregate of the instantaneous mechanical parameter values and the aggregate of the instantaneous torque values; and generate, using an aggregate of magnitude and phase shift data for multiple frequencies of the alternating signal wave, a fingerprint to be used in performing diagnostics of motor and linkage.