Vibration response-based real-time monitoring system for RV reducer bearings

Rotary vector (RV) reducers serve as critical transmission components in industrial robotics, particularly for heavy-duty manipulators. During operation, these reducers endure combined static and dynamic loading spectra, inducing premature failures in core components such as bearings, which necessitate effective fault detection to ensure operational reliability and system functionality. While advanced monitoring theories have been proposed for modern mechanical systems, three key aspects warrant further investigation: (1) enhancing cross-platform applicability by integrating physics-based models with RV reducer-specific kinematics, (2) validating diagnostic methods using industrial operational datasets capturing natural degradation rather than artificial faults, and (3) developing dedicated monitoring protocols for bearings due to their heightened failure susceptibility under sustained high-torque conditions. This study establishes physics-driven correlations between bearing fault characteristics and vibration responses through kinematic analysis of RV reducers, improving fault identification robustness across operational conditions. A real-time monitoring system integrating vibration signal acquisition and analytical capabilities has been developed and validated via durability testing on intact reducers under operational loads. The system provides a user-friendly solution for routine operation and maintenance of industrial RV reducers, demonstrating practical engineering significance in bearing health monitoring and fault diagnosis through physics-informed methodologies.