Transfer Robot Fault Handover Using Idle Robot Replacement
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Solution Overview
Problem
Conventional transfer robots require manual intervention and system downtime when faults occur, leading to delayed processing of tasks, especially when carrying turnover boxes, which disrupts the workflow and reduces efficiency.
Innovation Solution
A fault handling method and system that automatically dispatches an idle transfer robot to replace a faulty one, allowing it to continue executing tasks by moving the turnover box to a designated port and resuming operations without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If manual intervention is used to handle robot faults, then the robot can be moved for maintenance, but task execution is suspended and processing efficiency decreases
Solution Approach 1:
The system pre-positions idle transfer robots near the operational area and pre-programs their replacement procedures. When a fault occurs, the replacement robot is already ready to immediately take over the task, eliminating the suspension period required for manual intervention and maintenance movement.
Solution Approach 2:
The control system automatically detects robot faults, selects an idle replacement robot, and executes the task transfer without human intervention. The system self-manages the fault response process, continuously maintaining task execution while the faulty robot is later moved for maintenance.
2Reliability
If the faulty robot is moved to idle area for maintenance, then the robot can be repaired, but the turnover box task is delayed
Solution Approach 1:
An idle transfer robot acts as an intermediary that temporarily assumes the task of the faulty robot. The replacement robot carries the turnover box to the destination, ensuring task continuity. Only after the replacement is complete is the faulty robot moved for maintenance, eliminating task delays.
Solution Approach 2:
The system temporarily discards the faulty robot from active duty by replacing it with an idle robot. The task is recovered and completed by the replacement robot, while the original robot is later recovered and restored to service after maintenance, minimizing overall system downtime.
3Productivity
If automatic replacement is implemented, then task continuity is maintained, but system complexity increases
Solution Approach 1:
The control system implements a universal fault handling mechanism that works across multiple robot units. The same control logic and replacement procedure apply to any faulty robot in the fleet, and idle robots are multi-functional units capable of performing various tasks including replacement duties. This standardization manages complexity while maintaining continuity.
Data Source
AI summary
A fault handling method and system for a transfer robot, relating to the technical field of robot control. The method comprises: in response to detecting fault alarm information sent by a transfer robot and determining that a target turnover box currently carried by the transfer robot satisfies a first preset condition, outputting prompt information; dispatching a target idle transfer robot to an abnormality replacement port of a transport line device; and in response to detecting that the target idle transfer robot obtains a target turnover box at the abnormality replacement port, controlling the target idle transfer robot to continue to execute a inbound transfer task. The method effectively avoids task interruption caused by faults of transfer robots, and improves the overall task processing efficiency.