Welding Cable Service Life Prediction via Resistance Monitoring
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Solution Overview
Problem
Industrial robots' welding cables experience wear and disconnection due to repeated twisting and bending, making it difficult to predict when replacement is needed, as internal disconnections are hard to detect visually and conventional resistance monitoring methods are insufficient.
Innovation Solution
A prediction system that measures the electric resistance of the cable's slack portion, converts it into stress, and estimates the service life by analyzing the change in resistance values during joint movements, allowing for proactive adjustment of cable length to extend its lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous monitoring of electric resistance is implemented to predict cable breakage, then the reliability of cable failure prediction is improved, but the device complexity increases due to the need for continuous monitoring systems
Solution Approach 1:
The patent replaces complex continuous electrical monitoring systems with a simplified mechanical measurement approach. By measuring electric resistance only at the moment of cable installation and using this initial value to predict service life, the system eliminates the need for continuous monitoring equipment while maintaining reliable failure prediction capability.
Solution Approach 2:
The patent performs the electric resistance measurement action in advance during cable installation rather than continuously during operation. This preliminary measurement establishes a baseline value that is used to calculate predicted service life, eliminating the need for ongoing monitoring while preserving prediction reliability.
2Ease of operation
If internal disconnection of the cable is detected by visual observation, then the ease of operation is improved, but the measurement precision is insufficient to detect internal disconnections
Solution Approach 1:
The patent replaces visual observation with electric resistance measurement to detect internal cable disconnections. Although visual observation is simpler to perform, it cannot detect internal issues. The electric resistance measurement provides precise detection of internal disconnections by identifying changes in electrical properties that are invisible to the naked eye.
3Reliability
If the welding cable is replaced before disconnection occurs to ensure reliability, then the reliability is maintained, but the loss of time and productivity increase due to premature replacement
Solution Approach 1:
The patent performs electric resistance measurement and service life prediction at cable installation, establishing a timeline for expected failure. This allows scheduling maintenance precisely when needed rather than replacing cables prematurely, reducing maintenance downtime while ensuring reliability is maintained until the actual predicted failure point.
Solution Approach 2:
The patent uses electric resistance measurement results as feedback to calculate predicted service life and determine optimal replacement timing. This feedback mechanism enables data-driven maintenance scheduling that replaces cables based on actual degradation patterns rather than fixed schedules, minimizing unnecessary replacements and associated downtime.
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
The system effectively predicts cable disconnection before it occurs, ensuring a guaranteed service life and reducing maintenance costs by optimizing cable installation conditions, eliminating the need for operator intuition and minimizing premature wear.
Implementation Method 1
an acquisition device configured to acquire a value of electric resistance of a cable secured by fixing members to a pair of link members configured to rotate relative to each other through a joint
Data Source
AI summary
A prediction system includes an acquisition device, an execution device, and a prediction device. The acquisition device is configured to acquire a value of electric resistance of a cable secured by fixing members to a pair of link members configured to rotate relative to each other through a joint. The execution device is configured to cause the joint to execute a predetermined operation. The prediction device is configured to predict a service life of the cable based on a change in the value of electric resistance acquired by the acquisition device while the execution device is causing the joint to execute the predetermined operation.