Automatic Work Line Torque Control for Fatigue-Aware Throughput
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Solution Overview
Problem
Existing automatic work line control systems fail to address the accumulation of mechanical fatigue despite maintaining processing times within takt time, leading to reduced lifespan of industrial machines.
Innovation Solution
A control device that generates a work plan based on work instruction information and adjusts the torque of mechanical operating devices to extend the life of components while maintaining work efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acceleration at the time of driving is increased to maximize efficiency of production and conveyance, then productivity is improved, but mechanical shock in a driving unit increases and the life of the industrial machine is shortened
Solution Approach 1:
The control device dynamically adjusts the acceleration profile of the industrial machine based on real-time conditions and cumulative fatigue data. Instead of using fixed acceleration values, the system continuously modifies acceleration parameters to balance productivity requirements with machine life extension, transforming the static acceleration control into a dynamic adaptive control system.
Solution Approach 2:
The control device incorporates feedback mechanisms that monitor the cumulative impact values and mechanical fatigue levels during operation. This feedback is used to adjust future acceleration commands, creating a closed-loop control system that learns from past operations and optimizes acceleration patterns to extend machine life while maintaining productivity.
2Object-affected harmful factors
If acceleration/deceleration time constant is changed to suppress impact generated in the machine, then mechanical shock is reduced, but processing time may exceed the takt time
Solution Approach 1:
The control device performs preliminary calculations of the cumulative impact values and predicts the effect of different acceleration profiles on both machine life and processing time. By pre-evaluating multiple acceleration scenarios before execution, the system identifies optimal acceleration patterns that suppress mechanical shock while ensuring processing time remains within takt time constraints.
Solution Approach 2:
The control device dynamically changes acceleration and deceleration time constants based on the current operational state and cumulative fatigue data. Instead of using fixed time constants, the system adjusts these parameters in real-time to optimize the balance between impact suppression and processing speed, allowing flexible adaptation to different operational conditions.
3Object-affected harmful factors
If maximum value of the impact generated in the machine is suppressed to be equal to or less than the predetermined threshold value, then mechanical shock is limited, but cumulative fatigue is not avoided
Solution Approach 1:
The control device implements feedback based on cumulative impact values that accumulate across multiple operations. This cumulative feedback mechanism allows the system to detect gradual fatigue accumulation even when individual impact values remain below thresholds, enabling proactive adjustments to acceleration patterns before significant fatigue damage occurs.
Solution Approach 2:
The control device introduces cumulative impact value as an intermediary parameter that bridges the gap between instantaneous impact measurements and long-term fatigue assessment. This intermediary metric allows the system to translate short-term impact data into long-term reliability predictions, enabling better decision-making for acceleration control.
Data Source
AI summary
A controller of a control device that controls an automatic work line including a plurality of mechanical operating devices generates a work plan based on work instruction information including a work amount of a work plan target time unit of the automatic work line, outputs the generated work plan, and controls torque of each of the plurality of mechanical operating devices over a target period of the work plan based on the work plan of each of the plurality of mechanical operating devices.