Logical–Linguistic Model of Diagnostics of Electric Drives with Sensors Support
Abstract
:1. Introduction
2. The Logical–Linguistic Model of Electrical Drive Diagnostics
3. Results
3.1. The Algorithm for the Determination of the Electrical Drives’ Technical State in a Robotized Workplace
3.2. Diagnostics of Mechatronic Modules in a Robotized Workplace
3.3. Hardware for Diagnosing Robotic Mechatronic Systems
- Decomposition of mechatronic systems into modules, nodes and elements;
- Determination of diagnostic parameters in modules, nodes and elements;
- Selection of sensors to measure diagnostic parameters;
- Selection of diagnostic intervals.
3.4. Decomposition of CNC Machine into Modules, Nodes and Elements
3.5. Definition of Diagnostic Parameters in Modules, Nodes and CNC Machine Elements
3.6. Selection of Sensors to Measure Diagnostic Parameters
3.7. Selection of Diagnostic Intervals
3.8. Multicriterial Optimization of Diagnostic Systems
4. Discussion
- Intellectualization;
- Increased reliability;
- Modular design.
- The rotational frequencies of the monitored mechatronic system,
- The frequency of the noise of the balls on the outer ring,
- The noise frequency on the inner ring,
- The frequency of rotation of the bearing rolling elements.
5. Conclusions
- (1)
- A new diagnostic parameter has been used, which was calculated as the sum of the amplitude of a vibrating range from a frequency of 6.3 Hz to 1250 Hz for a one-third-octave filter;
- (2)
- Technological criteria for fuzzy logic rules were used, such as the speed of movement of the robot’s links or machine mechanisms;
- (3)
- Both new approaches have led to improved accuracy regarding the results of the diagnosis of electric drives for robots and CNC machines;
- (4)
- The continuous process of diagnosing a machine or robot was optimized on the basis of a criterion combining the responsibility of the units and the speed at which the degradation processes occur.
Author Contributions
Funding
Conflicts of Interest
References
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No Conditions | Temperature | Vibration | Current | Speed | Defect Appearance |
---|---|---|---|---|---|
1. | L | L | L | H | L |
2. | M | M | M | M | M |
3. | H | H | H | L | H |
No | Module, Node, CNC Machine Element | Diagnostical Parameters |
---|---|---|
1. | Supporting frame of tools | Temperature, motion parameters, power parameters, time intervals, spatial position accuracy |
2. | Helical gears | Temperature, motion parameters, power parameters |
3. | Gears | Vibration, dynamic parameters |
4. | Belt drives | Vibration, dynamic parameters |
5. | Spindle units | Temperature, vibration, motion parameters, spatial position accuracy |
6. | Bearings | Temperature, vibration, accuracy of spatial positions |
7. | Tool holder or tool changer | Temperature, vibration, motion parameters, spatial position accuracy |
8. | Cutting tools | Temperature, vibration, accuracy of spatial positions, power parameters |
9. | Electromotor | Current, voltage, power, temperature, vibration, movement parameters |
10. | Drive control systems | Current, voltage, power, temperature |
11. | Sensors | Motion parameters, time intervals |
12. | Poppet head | Temperature, spatial accuracy |
No | Diagnostical Parameters | Sensors |
---|---|---|
1. | Electrical current | Current sensors up to 50 A, operating frequency 0–25 kHz, Sensor range 0–50 A |
2. | Electrical voltage | Voltage sensors 10–500 V, operating frequency 0–25 kHz, Sensor range 0–500 V |
3. | Power | Power sensors 0.5–20 kW, operating frequency 0–25 kHz, Dynamic range 90 dB |
4. | Temperature | Temperature sensors 0–150 °C |
5. | Motion parameters | Accelerometers ± 2 g, encoders 10,000 pulses/rotation, Sensor range 0–10 m/s |
6. | Performance parameters | Tensile force sensors up to 10 Kn, Sensor range 0–10 Kn |
7. | Time intervals | Timers in the controller, Sensor range 0.1 ms–1 s |
8. | Vibration | Accelerometers ± 2 g, operating frequency 1–25 kHz, Sensor range 0–2 g |
9. | Spatial position accuracy | Encoders 10,000 pulses/rotation, Sensor range 1–10,000 pulses/rotation |
No | Module, Node, Element | Kotv | Kdegr | Ki | Ti | k × Tmin |
---|---|---|---|---|---|---|
1. | Setting and wiring | 0.5 | 0.1 | 0.6 | 1.67 | 1.5Tmin |
2. | Ball helix | 0.4 | 0.2 | 0.6 | 1.67 | 1.5Tmin |
3. | Cog-wheel | 0.2 | 0.3 | 0.5 | 2.00 | 1.8Tmin |
4. | Belt gears | 0.2 | 0.3 | 0.5 | 2.00 | 1.8Tmin |
5. | Spindle units | 0.4 | 0.3 | 0.7 | 1.43 | 1.3Tmin |
6. | Bearing | 0.3 | 0.3 | 0.6 | 1.67 | 1.5Tmin |
7. | Tool holder or tool changer | 0.2 | 0.2 | 0.4 | 2.50 | 2.3Tmin |
8. | Cutting tool | 0.4 | 0.5 | 0.9 | 1.11 | 1.00Tmin |
9. | Electric motors | 0.2 | 0.3 | 0.5 | 2.00 | 1.8Tmin |
10 | Drive control systems | 0.2 | 0.2 | 0.4 | 2.50 | 2.3Tmin |
11 | Sensors | 0.5 | 0.3 | 0.8 | 1.25 | 1.1Tmin |
12. | Poppet head | 0.1 | 0.2 | 0.3 | 3.33 | 3.0Tmin |
No | Module, Node, Element | Failure Rate | Relative Failure Rate | Average Failure Rate |
---|---|---|---|---|
1. | Setting, slide | 13.9 | 2.0 | 2 |
2. | Ball helix | 13.9 | 2.0 | 2 |
3. | Cog-wheel | 11.6 | 1.7 | 2 |
4. | Belt gears | 11.6 | 1.7 | 2 |
5. | Spindle units | 16.1 | 2.3 | 2 |
6. | Bearing | 13.9 | 2.0 | 2 |
7. | Tool holder or tool changer | 9.1 | 1.3 | 1 |
8. | Cutting tool | 20.9 | 3.0 | 3 |
9. | Electric motors | 11.6 | 1.7 | 2 |
10. | Drive control systems | 9.1 | 1.3 | 1 |
11. | Sensors | 19.0 | 2.7 | 3 |
12. | Poppet head | 7.0 | 1.0 | 1 |
Accident Cost (Destruction) | Slow Rate of Degradation Object of Diagnosis | Average Rate of Degradation Object of Diagnosis | High Degree of Degradation or Sudden Departure of the Subject of Diagnosis |
---|---|---|---|
Significant accident costs (destruction) | Portable diagnostic devices Kotv = 0.1, Kdegr = 0.1 | Portable diagnostic devices Kotv = 0.1, Kdegr = 0.5 | Stationary diagnostic devices Kotv = 0.1, Kdegr = 0.9 |
Average cost of accident consequences (destruction) | Portable diagnostic devices Kotv = 0.5, Kdegr = 0.1 | Stationary diagnostic systems Kotv = 0.5, Kdegr = 0.5 | Continuous protection and diagnostics systems Kotv = 0.5, Kdegr = 0.9 |
High accident costs (destruction) | Stationary diagnostic systems Kotv = 0.9, Kdegr = 0.1 | Continuous protection and diagnostics systems Kotv = 0.9, Kdegr = 0.5 | Continuous protection and diagnostics systems Kotv = 0.9, Kdegr = 0.9 |
Type of Device | Possibility of using MS Diagnostic Systems | Types of MS Service | Type of Device |
---|---|---|---|
Auxiliary, duplicated, periodically used equipment | Diagnostic and periodic diagnostics are not required for portable diagnostic devices | Repairs | Auxiliary, duplicated, periodically used equipment |
Relevant main equipment | Portable diagnostic equipment, stationary diagnostic systems | Service according to the technical condition | Relevant main equipment |
One highly responsible device | System of continuous protection and diagnostics | Maintenance, continuous protection | One highly responsible device |
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Nikitin, Y.; Božek, P.; Peterka, J. Logical–Linguistic Model of Diagnostics of Electric Drives with Sensors Support. Sensors 2020, 20, 4429. https://doi.org/10.3390/s20164429
Nikitin Y, Božek P, Peterka J. Logical–Linguistic Model of Diagnostics of Electric Drives with Sensors Support. Sensors. 2020; 20(16):4429. https://doi.org/10.3390/s20164429
Chicago/Turabian StyleNikitin, Yury, Pavol Božek, and Jozef Peterka. 2020. "Logical–Linguistic Model of Diagnostics of Electric Drives with Sensors Support" Sensors 20, no. 16: 4429. https://doi.org/10.3390/s20164429
APA StyleNikitin, Y., Božek, P., & Peterka, J. (2020). Logical–Linguistic Model of Diagnostics of Electric Drives with Sensors Support. Sensors, 20(16), 4429. https://doi.org/10.3390/s20164429