Fault data screening and failure rate prediction framework-based bathtub curve on industrial robots

Abstract

Purpose

This study aims to obtained the failure probability distributions of subsystems for industrial robot and filtrate its fault data considering the complicated influencing factors of failure rate for industrial robot and numerous epistemic uncertainties.

Design Methodology Approach

A fault data screening method and failure rate prediction framework are proposed to investigate industrial robot. First, the failure rate model of the industrial robot with different subsystems is established and then the surrogate model is used to fit bathtub curve of the original industrial robot to obtain the early fault time point. Furthermore, the distribution parameters of the original industrial robot are solved by maximum-likelihood function. Second, the influencing factors of the new industrial robot are quantified, and the epistemic uncertainties are refined using interval analytic hierarchy process method to obtain the correction coefficient of the failure rate.

Findings

The failure rate and mean time between failure (MTBF) of predicted new industrial robot are obtained, and the MTBF of predicted new industrial robot is improved compared with that of the original industrial robot.

Research Limitations Implications

Failure data of industrial robots is the basis of this prediction method, but it cannot be used for new or similar products, which is the limitation of this method. At the same time, based on the series characteristics of the industrial robot, it is not suitable for parallel or series-parallel systems.

Practical Implications

This investigation has important guiding significance to maintenance strategy and spare parts quantity of industrial robot. In addition, this study is of great help to engineers and of great significance to increase the service life and reliability of industrial robots.

Social Implications

This investigation can improve MTBF and extend the service life of industrial robots; furthermore, this method can be applied to predict other mechanical products.

Originality Value

This method can complete the process of fitting, screening and refitting the fault data of the industrial robot, which provides a theoretic basis for reliability growth of the predicted new industrial robot. This investigation has significance to maintenance strategy and spare parts quantity of the industrial robot. Moreover, this method can also be applied to the prediction of other mechanical products.

Citation

Bai, B., Li, Z., Wu, Q., Zhou, C. and Zhang, J. (2020), "Fault data screening and failure rate prediction framework-based bathtub curve on industrial robots", Industrial Robot, Vol. 47 No. 6, pp. 867-880. https://doi.org/10.1108/IR-02-2020-0031