Stepper Motor Wire Breaks Diagnose and Redundant Control System for Factory Automation

This study introduces a reliable factory automation system to reduce the downtime of factories. This system is based on the feedback voltage monitoring method to identify the fail wires of a stepper motor. This proposed system diagnoses the loose wires and malfunctioning devices in the factory automation system and continues the process with secondary networks and devices. As soon as fail devices or fail wires were recovered, this system automatically continue with the primary device. Then the secondary devices set to sleep mode. This process takes less than one second and the system helps to avoid unplanned production stoppages and breakdowns. Therefore the system reduces factory downtime. Even though there are many breakdown diagnose systems available in the market, novelty of our research is, proposing a loop feedback voltage monitoring system for the industry. Available systems use current flow sensing systems to identify breakdowns. Our proposed system is comparatively faster and lower cost than the available systems. Also, our proposed system can be inbuilt in the stepper motor driver itself.