Lifetime Prediction of Permanent Magnet Synchronous Motor in Selective Compliance Assembly Robot Arm Considering Insulation Thermal Aging

The direct-drive selective compliance assembly robot arm (SCARA) is widely used in high-end manufacturing fields, as it omits the mechanical transmission structures and has the advantages of high positioning accuracy and fast movement speed. However, due to the intensifying dynamic coupling problem of structures in the direct-drive SCARA, the permanent magnet synchronous motors (PMSMs) located at the joints will take on nonstationary loads, which causes excessive internal temperature and reduces the lifetime of PMSMs. To address these issues, the lifetime prediction of PMSMs is studied. The kinematic and dynamic models of the SCARA are established to calculate the torque curve required by the PMSM in specific typical motion tasks. Additionally, considering thermal stress as the main factor affecting lifetime, accelerated degradation tests are conducted on insulation material. Then, the reliability function of the PMSM is formulated based on the accelerated degradation model. Based on the parameters and working conditions of the PMSM, the temperature field distribution is obtained through simulation. The maximum temperature is used as the reference temperature to conduct reliability evaluation and lifetime prediction of the PMSM. The research results show that for a typical point-to-point task, the PMSM can run for 102,623 h while achieving the reliability requirement of 0.99.