Design and Implementation of a System for automated cable degradation detection

Abstract

This research focuses on investigating the degradation phenomena in cable-suspended robotic systems, specifically examining the impact of bending cycles, tension fluctuations, and mechanical stresses on cable lifespan. The study combines both theoretical analysis and experimental testing to explore key degradation mechanisms, including jumpy winding and radial layering, which undermine cable integrity over time. A comprehensive evaluation of existing cable-driven robotic systems, including key components like winches, pulleys, and dolly assemblies, is conducted to better understand the interplay between system design and the stress exerted on cables. In response to the need for high-fidelity testing, a novel Cable Degradation System (CDS) is developed to replicate real-world operational conditions in a controlled environment. This system enables efficient, cost-effective testing of multiple cable specimens, providing detailed insights into how cables degrade under varying loads and conditions. The system incorporates advanced calculations for drum geometry, motor torque, gear ratios, and precise sensor-based monitoring, ensuring accurate, repeatable results. By linking mechanical stress with cable degradation, the CDS provides a robust platform for predictive maintenance and design optimization, advancing the field of cable health monitoring. The research offers valuable insights into the correlation between cyclic mechanical stress and accelerated cable wear. It lays the foundation for improvements in the design and operation of cable-driven robotic systems, enhancing their safety, reliability, and performance. This work contributes to the development of predictive maintenance strategies and compact testing solutions, supporting future advancements in the field.

Date of Award	2025
Original language	English
Supervisor	Christian Zehetner (Supervisor)