面向工业机器人关键部件的多源融合感知智能故障诊断方法研究

Multi-source fusion perception intelligent fault diagnosis methods for critical components of industrial robots

  • 摘要: 工业机器人关键部件在复杂运行工况下易发生早期性能退化,通常表现为强非稳态响应特性与多通道感知信号的显著异构性。传统诊断方法难以有效融合多源信息,鲁棒性与可解释性难以兼顾,部署适应性亦较为有限。本文聚焦工业机器人传动链路中的关键减速机构,提出一种融合物理敏感性驱动与残余感知补偿机制的双通道智能诊断方法。所选振动与扭矩信号分别表征结构响应与驱动激励,具备显著的时间尺度差异与物理信息互补特性,为多源融合建模提供了明确的物理建模依据。从物理响应机理角度构建“故障类型-动态响应特征-感知通道”的三层映射关系,量化不同信号在典型故障模式下的主导性差异;设计基于信噪比、调制指数和峰度的多尺度敏感性评估机制,引导多通道信息的自适应融合权重分配;同时引入残余感知不确定性补偿(RUC)机制,有效提升弱主导通道特征的表达能力,增强融合稳定性与诊断完整性;搭建了具备物理解释性和轻量化特征的诊断模型框架。基于公开齿轮箱数据集在多类典型故障模式下开展试验,结果表明,所提方法在多类故障识别任务中表现出更高的诊断准确性、可解释性与部署适应性,展现出面向工业机器人关键部件物理一致性融合诊断的良好理论依据与工程应用潜力。

     

    Abstract: Key components of industrial robots are prone to early-stage performance degradation under complex operating conditions, characterized by strongly non-stationary responses and significant heterogeneity across sensing channels. Traditional diagnostic methods struggle with robust and interpretable fusion of multi-source information, limiting their practical deployment. This paper proposes a dual-channel intelligent diagnostic method for robotic transmission mechanisms, integrating physics-driven sensitivity weighting and residual uncertainty compensation (RUC). Specifically, vibration and torque signals, representing structural response and driving excitation respectively, are selected due to their distinct temporal scales and complementary physical characteristics. A three-layer mapping (fault type-dynamic response characteristic-sensing channel) is constructed to quantify channel dominance for different fault modes. Then, a multi-scale sensitivity evaluation mechanism based on signal-to-noise ratio (SNR), modulation index (MI), and kurtosis guides adaptive weight allocation, while the RUC strategy enhances the expression of features from weakly dominant channels, improving fusion stability. Finally, a physically interpretable and lightweight diagnostic framework is established. Experiments conducted on a public gearbox dataset validate that the proposed method provides superior diagnostic accuracy, interpretability, and deployment potential, demonstrating significant promise for physically consistent multi-source fusion diagnosis in robotic transmission systems.

     

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