Research on sorting reliability of cable-driven gangue sorting robot system based on fault tree
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摘要: 拣矸机器人的分拣可靠性与煤的品质及分拣效率息息相关，对拣矸机器人系统分拣可靠性进行研究十分必要。现有机器人系统可靠性研究主要是针对其结构可靠性进行研究，而没有对其工作任务可靠性即分拣可靠性进行研究。针对该问题，以柔索驱动拣矸机器人系统为研究对象，采用故障树分析法对其分拣可靠性进行研究。首先，从拣矸机器人系统的结构出发，分析了拣矸机器人系统分拣故障的原因，采用演绎法构建拣矸机器人系统的分拣故障树；然后，将故障树底事件发生概率考虑为区间变量，根据区间性质、运算法则和顶事件的概率表达式得到分拣故障树顶事件概率区间参数，结合设计要求计算出反映拣矸机器人系统分拣可靠性的非概率可靠性指标；最后，基于非概率可靠性指标公式及模糊重要度定义，提出了一种区间重要度指标，对分拣故障树底事件的区间重要度进行求解并排序，结果表明分拣可靠性满足拣矸机器人可靠分拣要求，煤矸石流瞬时含矸率增大和工业相机故障是影响其分拣可靠性的重要因素。根据非概率可靠性指标计算结果和区间重要度排序找出了拣矸机器人系统的薄弱环节，并针对薄弱环节提出了3个改进措施：在分拣前对煤矸石流振荡混合；根据识别的矸石信息，智能控制带式输送机带速；在拣矸机器人系统中增加备用工业相机。Abstract: The sorting reliability of the gangue sorting robot is closely related to coal quality and sorting efficiency. It is necessary to study the sorting reliability of the sorting robot system. The existing reliability research of robot system mainly focuses on the structural reliability. There is no research on the task reliability of robot system, namely sorting reliability. In order to solve this problem, taking the cable-driven gangue sorting robot system as the research object, the sorting reliability is studied by fault tree analysis. Firstly, based on the structure of the gangue sorting robot system, the reasons for the sorting failure of the gangue sorting robot system are analyzed. The deductive method is used to construct the sorting fault tree of the gangue sorting robot system. Secondly, the occurrence probability of the bottom event of the fault tree is considered as an interval variable. The probability interval parameter of the top event of the sorting fault tree is obtained according to the interval property, the algorithm and the probability expression of the top event. According to the design requirements, the non-probabilistic reliability index which reflects the sorting reliability of the gangue sorting robot system is calculated. Finally, based on the formula of the non-probabilistic reliability index and the definition of fuzzy importance, an interval importance index is proposed. The interval importance of the events at the bottom of the sorting fault tree is solved and ranked. The results show that the sorting reliability can meet the requirements of sorting reliability of the gangue sorting robot. The increase of instantaneous gangue content in coal gangue flow and the failure of the industrial camera are important factors affecting the sorting reliability. According to the calculation result of the non-probability reliability index and the ranking of interval importance, the weak link of the gangue sorting robot system is found. Three improvement measures are proposed for the weak link. It is suggested to shake and mix the coal gangue flow before sorting. According to the identified gangue information, it is suggested to intelligently control the belt speed of the belt conveyor. It is suggested to add spare industrial camera in the gangue sorting robot system.
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图 4 拣矸机器人系统非概率可靠性指标判定
Figure 4. Evaluation of non-probabilistic reliability index of gangue sorting robot system
图 6 底事件中值重要度与离差重要度
Figure 6. Median importance degree and dispersion importance of bottom events
表 1 拣矸机器人系统分拣故障树底事件
Table 1. Bottom event of sorting fault tree of gangue sorting robot system
事件代号 事件内容 事件代号 事件内容 X1 柔索断裂 X13 继电器故障 X2 柔索变形 X14 熔断器故障 X3 索架破坏 X15 开关故障 X4 定滑轮破坏 X16 编码器通信故障 X5 卷筒破坏 X17 传感器故障 X6 末端抓斗定位不准 X18 控制卡板故障 X7 末端抓斗抓取掉落 X19 工控机故障 X8 末端抓斗空抓 X20 集成电路故障 X9 伺服电动机故障 X21 控制程序无法加载 X10 驱动器故障 X22 控制程序跑飞 X11 变压器故障 X23 瞬时含矸率增大 X12 线路故障 X24 工业相机故障 
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表 2 底事件发生概率区间变量的上界和下界
Table 2. Upper and lower bounds of the bottom event probability interval
底事件
发生概率区间变量
下界区间变量
上界底事件
发生概率区间变量
下界区间变量
上界q1 2.0×10−5 4.0×10−5 q13 5.8×10−4 7.8×10−4 q2 1.6×10−4 2.4×10−4 q14 5.8×10−4 8.2×10−4 q3 1.8×10−4 2.4×10−4 q15 3.0×10−5 5.0×10−5 q4 2.5×10−4 3.5×10−4 q16 5.4×10−4 7.8×10−4 q5 1.3×10−4 1.7×10−4 q17 2.6×10−4 3.8×10−4 q6 5.0×10−4 7.2×10−4 q18 8.0×10−5 1.6×10−4 q7 1.5×10−4 1.9×10−4 q19 3.5×10−4 5.5×10−4 q8 1.0×10−5 3.0×10−5 q20 1.2×10−3 1.6×10−3 q9 5.0×10−4 7.0×10−4 q21 6.0×10−4 1.8×10−3 q10 5.9×10−4 8.1×10−4 q22 2.5×10−4 4.5×10−4 q11 4.0×10−4 6.0×10−4 q23 1.4×10−3 2.6×10−3 q12 1.0×10−5 3.0×10−5 q24 4.2×10−3 4.8×10−3
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表 3 底事件区间重要度计算结果
Table 3. Calculation results of the interval importance degree of the bottom event
底事件 Ei Di 底事件 Ei Di X1 2.95×10−5 9.77×10−6 X13 6.70×10−4 9.70×10−5 X2 1.97×10−4 3.89×10−5 X14 6.89×10−4 1.16×10−4 X3 2.07×10−4 2.90×10−5 X15 3.94×10−5 9.75×10−6 X4 2.95×10−4 4.85×10−5 X16 6.50×10−4 1.16×10−4 X5 1.48×10−4 1.93×10−5 X17 3.15×10−4 5.83×10−5 X6 6.01×10−4 1.07×10−4 X18 1.18×10−4 3.91×10−5 X7 1.67×10−4 1.93×10−5 X19 4.43×10−4 9.75×10−5 X8 1.97×10−5 9.80×10−6 X20 1.38×10−3 1.94×10−4 X9 5.91×10−4 9.71×10−5 X21 6.90×10−4 9.70×10−5 X10 6.90×10−4 1.07×10−4 X22 3.45×10−4 9.77×10−5 X11 4.92×10−4 9.73×10−5 X23 1.97×10−3 5.88×10−4 X12 1.97×10−5 9.80×10−6 X24 4.45×10−3 2.87×10−4
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