Volkswagen Motor Poland - robot pneumatic attachment failure detection (case study update)

Goal

Implementation of Predictive Maintenance methodology for early detection of robot drive failures

Reduction of downtime costs and repair costs

Results

Monitoring and early detection of changes in signals indicating of pneumatic system faults

Identification of faults adversely affecting robot operating conditions and cycle delays

BENEFITS

Initially realized as designed (https://reliasol.ai/case-study-early-failure-detection-of-robot-drives/ ), the benefits included reduced repair and downtime costs in the event of drive failures. In addition, with the RSIMS application, faults in the robot's accessories can be detected and corrected earlier.

Previously, the identification of defects in pneumatic accessories due to the nature of the line occurred only when they noticeably disrupted robot operation and production. For example - leaks in the pneumatic system can increase cycle time and worsen the robot's loading conditions which ultimately translates into emergency stops of the machine. In addition - prolonged operation with such faults contributes to earlier degradation of the drives of the most heavily loaded robot axes. With RSIMS, we are able to catch and locate faults early enough to prevent failures from occurring and stopping the robot, resulting in long-term downtime.

Report: results update

This report is intended as a follow-up to the progress made in detecting faults and failures in robotic hardware using RSIMS. For details on the entire project, please see our earlier post on the site: https://reliasol.ai/case-study-early-failure-detection-of-robot-drives/ .

In the update, we focus on the progress made in identifying, monitoring and troubleshooting faults, illustrating the exact instances of detected failures, as well as the benefits RSIMS has brought in terms of reducing repair costs and minimizing downtime caused by robot drive failures. During the development of the project, a mechanism was implemented in the notification system to identify and recommend actions for typical faults and failures.

CASE 1 / Hose damage in the pneumatic system

Identified in the application were simultaneous robot overruns on axes 3, 5 and 6, which are characteristic of faults within the pneumatics system. After the overruns had been occurring for some time, the presence of water in the pneumatics system was also identified, as well as the robot gripper's closing time, which was about 3 [s] longer, resulting in longer cycle times. The localized cause was a defective pneumatics hose, which was replaced after diagnosis during scheduled maintenance work.

CASE 2 / Degradation of robot gripper valve island

Identified in the application were simultaneous parameter exceedances on axes 1, 2, 3, 4 and 5 characteristic of faults within the pneumatics system.

During inspection of the machine, air leaks and degradation of valve island components were found. The leaks were caused by the aggressive environment in which the washing process is carried out.

In the next time window allocated for repair work, the replacement of the gripper with a copy from the reserve was planned and implemented.

About company

ReliaSol is a company established in response to the growing need to increase the efficiency of machines and installations in industry.

We provide software and services that accelerate the digital transformation process. The applications we create combine real data from machines, sensors, event reports and automate drawing conclusions. The result of their work is data visualization, event prediction and monitoring of the optimal operating range of machines and entire production lines.

We will be happy to answer your questions

Reliability Solutions Sp. z o. o.
ul. Królewska 57, 30-081 Kraków, Polska