Locate Peak Loads Before Deciding Whether to Change the Trajectory or Replace the Motor

01

Project Background

A larger motor is not the only answer to recurring motor failures.

When a packaging-line pick-and-place robot repeatedly experiences motor problems, focusing on the motor alone is often insufficient. We analyze linkages, end-effector loads, and motion trajectories together.

Before work begins, clarify failure symptoms, the operating conditions in which they occur, and available measurements. A screen recording alone cannot establish incorrect equipment selection, and an unverified simulation cannot rule out mechanical or electrical causes.

02

Technical Approach

Parametric mechanism and joint-state analysis.

We record geometry, mass and inertia, joint constraints, end-effector loads, and motion inputs separately, checking the relationships between motion, joint states, and drive loads.

For speed and torque curves, check sampling methods, gear ratios, and units to ensure consistency between the mechanism and drive sides. Trajectory adjustments aim to reduce unfavorable peaks while maintaining cycle time.

03

Implementation Process

From one motion cycle to parameter comparisons.

First reproduce a complete work cycle, then compare trajectory smoothness, loads, and key dimensions one at a time. Check cycle time, reachability, and drive constraints together for every candidate design.

A design that reduces one peak but sacrifices production objectives will not be recommended. Results apply only to the current mechanism and operating conditions, not to arbitrary robots.

04

Deliverables and Acceptance

Deliver the parametric model, input operating conditions, joint-state curves, drive performance comparisons, and candidate parameter sets. Key charts include units, versions, and generation conditions so that recipients can regenerate results from the project.

Acceptance checks not only whether the model moves, but also whether explanations of key positions, velocities, accelerations, and loads are consistent. The party responsible for the equipment confirms drive specifications and service life using manufacturer data and tests.

05

Applicability

Suitable for equipment with reasonably well-defined mechanism parameters and describable motion tasks that requires drive or trajectory comparisons. If fundamental parameters are missing, first obtain the information or conduct identification tests before detailed optimization.

Motion simulation supports design comparison and load analysis. Service-life assessment additionally requires material properties, load spectra and test data.

06

Implementation Outcomes

Shift from motor replacement to motion strategy improvement.

We use dynamics models to break down recurring drive issues, focusing improvements on motion profiles and peak loads rather than first replacing the motor with a larger one.

On site, assess peak loads, operating temperature rise, cycle time, and failure records together, avoiding apparent reliability gains achieved solely by reducing speed.