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Models for Performing Robot Reliability and Maintenance StudiesTable of Contents:
There are many mathematical models that can be used, directly or indirectly, to conduct various types of robot reliability and maintenance studies. Three of these models are presented below. 5.6.1 Model I This model is concerned with determining the economic life of a robot. More clearly, the time limit beyond this is not economical to conduct robot repairs. Thus, the robot economic life is defined by [1619]:
where REL is the robot economic life. RIC is the robot initial cost (installed). RSV is the robot scrap value. RRC_{ai} is the robot’s annual increase in repair cost. Example 5.9 Assume that an electrical robot costs $150,000 (installed) and its estimated scrap value is $3,000. The estimated annual increase in its repair cost is $200. Estimate the time limit beyond which the robotrelated repairs will not be beneficial. By substituting the given data values into Equation (5.24), we obtain
Thus, the time limit beyond which the robotrelated repairs will not be beneficial is 38.34 years. 5.6.2 Model II This model represents a robot system that can fail either due to a human error or other failures (e.g., hardware and software) and the failed robot system is repaired to its operating state. The robot system statespace diagram is shown in Figure 5.9. FIGURE 5.9 Robot system statespace diagram. The numerals in the diagram circle and rectangles denote system states. The model is subjected to the following assumptions [9,19]:
The following symbols are associated with the diagram shown in Figure 5.9 and its associated equations: P, (r) is the probability that the robot system is in state у at time /; for / = 0 (operating normally),у = 1 (failed due to a human error), у = 2 (failed due to failures other than human errors). A is the robot system constant nonhuman error failure rate. X/, is the robot system constant human error rate. в is the robot system constant repair rate from failed state 2. вi, is the robot system constant repair rate from failed state 1. Using the Markov method presented in Chapter 4, we write down the following equations for Figure 5.9 [9,19]: At time t = 0, P_{0} (0) = ,P_{X} (0) = 0,and,P_{2} (0) = 0. Solving Equations (5.25)(5.27) using Laplace transforms, we obtain where
The robot system availability, AV_{rs} (/), is given by
As time t becomes large in Equations (5.33)—(5.35), we obtain the following steady state probability equations: where A V_{rs} is the robot system steadystate availability. P_{x} is the steadystate probability of the robot system being in state 1. P_{2} is the steadystate probability of the robot system being in state 2. For 0 =0_{h} = 0, from Equations (5.28), (5.33), and (5.34) we obtain
The robot system reliability from Equation (5.39) is where R_{rs} (/) is the robot system reliability at time t. By inserting Equation (5.42) into Equation (5.5), we obtain the following equation for MTTRF:
Using Equation (5.42) in Equation (5.10), we obtain the following equation for the robot system hazard rate:
It is to be noted that the righthand side of Equation (5.44) is independent of time t, which means the failure rate of the robot system is constant. Example 5.10 Assume that a robot system can fail either due to a human error or other failures, and its human errors and other failure rates are 0.0002 errors per hour and 0.0006 failures per hour, respectively. The robot system repair rate from both the failure modes is 0.004 repairs per hour. Calculate the robot system steadystate availability. By inserting the given data values into Equation (5.36), we get
Thus, the robot system steadystate availability is 0.8333. 5.6.3 Model III This mathematical model can be used for calculating the optimum number of inspections per robot facility per unit time [18,19]. This information is very useful to decision makers but inspections are quite often disruptive; however, such inspections generally reduce the robot downtime because they lower breakdowns. In this model, the total downtime of the robot is minimized to get the optimum number of inspections. The total downtime of the robot, TDTR, per unit time is expressed by [20] where m is the number of inspections per robot facility per unit time. c is a constant for a specific robot facility. T_{di} is the downtime per inspection for a robot facility. T_{Jh} is the downtime per breakdown for a robot facility. By differentiating Equation (5.45) with respect to m and then equating it to zero, we obtain
where m is the optimum number of inspections per robot facility per unit time. By inserting Equation (5.46) into Equation (5.45), we obtain where TDTR.’ is the minimum total downtime of the robot. Example 5.11 Assume that for a robot facility, the following data values are given:
Calculate the optimum number of robot inspections per month and the minimum total robot downtime. By inserting the above specified values into Equations (5.46) and (5.47), we obtain
and
Thus, the optimum number of robot inspections per month and the minimum total robot downtime are 3.16 and 0.12 months, respectively. Problems
Estimate the time limit beyond which the robotrelated repairs will not be beneficial.
Calculate the optimum number of robot inspections per month and the minimum total robot downtime. References

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