德国：当工业机器人过热

R&D 德国：当工业机器人过热

07.06.2017Editor: Rosemarie Stahl

萨尔大学的一支研究小组为工业装配、搬运和包装程序开发了一套预警系统，以监督机床的整个运作状态，提出诊断分析，并提示操作员及时更换零件。

Andreas Schütze教授测试初期的检测项目，身边为研究小组成员Nikolai Helwig和 Tizian Schneider。
(Source: Oliver Dietze)

智能感应器不断从工厂内部的机器中广泛收集各类测量数据，并将获得的信号特征与正常运作条件下的特征进行对比。当系统探测到不同的特征，则表明存在潜在的故障，系统将立即通知操作员该采取的补救措施。这有助于工程师高效计划保养方案，避免突发故障和意外生产损失。

生产线上的机器人能以高精度不倦地工作，除非出现零件损坏。例如，如果使车身精准定位的线性驱动器受损，机械手臂将无法使车门放置在正常应处的位置，从而导致车门安装位置不准。再比如，由材料疲劳导致机械零件突然损坏，引起生产线全部瘫痪。由萨尔大学及机电一体化和自动化技术中心的感应系统专家Andreas Schütze带领的这支工程师队伍，与一组学术界和工业领域的合作伙伴密切合作，阻止此类情形发生。

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他们研发的系统使机床不断有效地进行自我体检。与人的体检类似，给人体安装活动追踪器，如不断运作的数字ECG和血压监测器，从而使身体状态可以随时接受分析。“我们的系统使连续监测工厂机床的当前状态成为可能，并就潜在损坏可能性发布预警。为实现这一功能，我们将感应器安装在机床内部，各感应器之间以及与当前加工程序中的感应器相互作用。这使得细微的变化都能被记录下来，” Andreas Schütze解释道。研究员们充分利用了这些现象，如技术设备开始发出奇怪的噪音，或者在发生故障前出现振动和过热的状况。其窍门是机床在正常运作下的振动和发出声音的特点，与其内部发生变化后的不同，这些细微的不同是普通感应器所检测不到的。

向智能设备转型

萨尔布吕肯机电一体化专家们开发的系统发挥作用。这些感应器能检测到这些细微的变化，并自动归结到具体的故障类型。“我们研究了在常见的损坏或故障中信号特征是怎样变化的，” Schütze教授阐释道。为了实现上述目的，研究小组对上千组测量数据呈现出的特征进行检查，鉴定这些数据与特定类型的损坏或机械磨损有关。“我们将这些信息载入感应器，把感应器改造成智能设备，从而能自动检测出信号的差异，” Schütze研究小组组员Nikolai Helwig说。这就从根本上消除了对外置分析器的需求，因为系统本身能进行自动分析。

研究小组的目标是开发一套感应器和模块，从而使企业的车间机床在运作中能具体地根据车间及设备自身的需求来进行健康检测。“这些定制化的感应器既能在机床制造时就植入进去，也能在旧机床翻新过程中植入。首先，感应器将花时间手机基线数据，也即机床在正常运作状态使的数据，” Helwig说。这一步骤结束后，接下来系统就能不断把当前运作数据，与初期设备故障或损坏而出现的典型感应器信号特征进行对比。“我们采用的方法同样也为其他工业4.0应用提供了机会。例如，该系统也适用于质量控制，可以通过分析机床在生产过程中是否运行正常来实现。”

正在开发的这套系统目前进入了测试阶段，在此阶段，感应器和测量技术方面的专家将与Bosch-Rexroth和Festo公司合作。开发的感应器将在Bosch-Rexroth公司使用，以检测机床的状况。同时，在Festo公司，感应器将用来检测上述的线性驱动器，具体包括Festo公司机床的主轴和机电汽缸。

本文首次发布于 ETMM online。

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