Predicting the Next Robot Failure in Large-Scale Assembly Lines
Industrial robots on assembly lines repeat the same motions tens of thousands of times. Over time, internal components such as gearboxes gradually degrade, but their condition cannot be easily inspected from the outside, and conventional maintenance methods make it difficult to detect early signs of failure.
As a result, manufacturers often have no choice but to wait until a robot stops or its performance deteriorates, leading to unplanned downtime and emergency maintenance that directly impact production.
Seeing Inside Robots with Current Signals Alone
Data was collected using a non-intrusive approach by attaching current sensors to existing power cables. The solution can be deployed directly on-site without additional wiring or equipment modifications. Based on the collected current signals, a digital twin of each robot was created, enabling the gearbox degradation level to be quantified as a Health Index and tracked in real time, even under complex motion conditions.
When abnormal behavior is detected, it is immediately displayed on the monitoring dashboard, allowing operators to monitor the health of all robots at a glance without having to patrol the production floor.
Real-Time Monitoring and Predictive Maintenance Across the Entire Assembly Line
Installation complexity is minimized through a non-intrusive approach. Since deployment only requires attaching current sensors, there is no need to stop production or modify existing wiring. The solution can also be rapidly scaled across hundreds of robots, significantly lowering deployment barriers.
By quantifying gearbox degradation with a Health Index, operators can monitor the condition of each robot numerically and schedule maintenance before failures occur. This enables a shift from reactive maintenance following unexpected line stoppages to predictive, proactive maintenance.
A centralized dashboard provides real-time visibility into the status of every robot, eliminating the need for manual inspections across the production floor. Instant alerts enable operators to respond quickly whenever abnormal conditions are detected.
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Predicting the Next Robot Failure in Large-Scale Assembly Lines
Industrial robots on assembly lines repeat the same motions tens of thousands of times. Over time, internal components such as gearboxes gradually degrade, but their condition cannot be easily inspected from the outside, and conventional maintenance methods make it difficult to detect early signs of failure.
As a result, manufacturers often have no choice but to wait until a robot stops or its performance deteriorates, leading to unplanned downtime and emergency maintenance that directly impact production.
Seeing Inside Robots with Current Signals Alone
Data was collected using a non-intrusive approach by attaching current sensors to existing power cables. The solution can be deployed directly on-site without additional wiring or equipment modifications. Based on the collected current signals, a digital twin of each robot was created, enabling the gearbox degradation level to be quantified as a Health Index and tracked in real time, even under complex motion conditions.
When abnormal behavior is detected, it is immediately displayed on the monitoring dashboard, allowing operators to monitor the health of all robots at a glance without having to patrol the production floor.
Real-Time Monitoring and Predictive Maintenance Across the Entire Assembly Line
Installation complexity is minimized through a non-intrusive approach. Since deployment only requires attaching current sensors, there is no need to stop production or modify existing wiring. The solution can also be rapidly scaled across hundreds of robots, significantly lowering deployment barriers.
By quantifying gearbox degradation with a Health Index, operators can monitor the condition of each robot numerically and schedule maintenance before failures occur. This enables a shift from reactive maintenance following unexpected line stoppages to predictive, proactive maintenance.
A centralized dashboard provides real-time visibility into the status of every robot, eliminating the need for manual inspections across the production floor. Instant alerts enable operators to respond quickly whenever abnormal conditions are detected.