Teleoperation Fault Detection and Recovery Controller
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Solution Overview
Problem
Teleoperated industrial robots face challenges in fault detection and recovery, particularly when operators are physically distant from the machines, leading to potential hazards and inefficiencies due to traditional emergency stop mechanisms that hinder recovery processes.
Innovation Solution
A system with a control station and real-time communication link that includes a controller with program code for fault detection and predefined recovery rules, allowing for automated fault analysis and recovery procedures, including safe stop and contact force reduction routines, enabling the robot to recover from faults independently or with minimal operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional emergency stop mechanisms are used when faults occur, then safety is improved, but productivity deteriorates due to complete operation halt and extended recovery time requiring operator intervention
Solution Approach 1:
The system performs preliminary actions by automatically executing predefined recovery procedures immediately upon fault detection, before operator intervention is needed. The controller autonomously implements recovery actions such as resetting actuators, recalibrating sensors, or switching to backup systems, thereby maintaining operation continuity while ensuring safety through automated fault management.
Solution Approach 2:
The teleoperated machine performs self-service through automated fault detection and recovery mechanisms. The system monitors its own operational parameters, detects faults autonomously, and executes recovery procedures without requiring immediate operator intervention. This self-service capability reduces downtime and maintains productivity while ensuring safety through automated protective actions.
2Reliability
If operators are located remotely from teleoperated machines, then operator safety is improved, but fault detection and response time deteriorate
Solution Approach 1:
The system implements continuous feedback loops where sensors monitor operational parameters and transmit data to the controller in real-time. When faults are detected, the system immediately provides feedback to both the automated recovery system and the remote operator, enabling rapid response despite physical distance. The feedback mechanism ensures that fault detection and response time are not compromised by operator location.
Solution Approach 2:
The automated controller acts as an intermediary between the machine operations and the remote operator. It continuously monitors system status, detects faults autonomously, and executes recovery procedures without requiring immediate operator presence. The intermediary system bridges the gap between remote operator safety and rapid fault response by handling time-critical decisions autonomously while keeping the operator informed.
3Measurement precision
If complete operator intervention is required for fault recovery, then control precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
The system applies partial automation where the controller autonomously executes routine recovery procedures for common faults, while reserving full operator control for complex or unprecedented situations. This partial action approach maintains control precision for standard operations without requiring complete operator intervention, thereby reducing device complexity and improving productivity while preserving the ability to handle edge cases with full human oversight.
Data Source
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AI summary
A machine has at least one actuated mechanism is remotely located from a control station. A two way real-time communication link connects the machine location with the control station. A controller at the machine location has program code that is configured to determine from data from one or more sensors at the machine location if an actual fault has occurred in the machine when the machine is performing its predetermined function and to determine for an actual fault one or more types for the fault and transmit the one or more fault types to the control station for analysis. The code in the controller is configured to be a preprogrammed trap routine specific to the machine function that is automatically executed when an error in machine operation is detected at the machine location. The controller also has a default trap routine that is executed when specific routine does not exist.