Systems and methods for analyzing brake wear of conveyor lift table motor to predict downtime events

A system for positioning a product along an assembly line, the system comprising:

• a platform configured to support the product and be raised and lowered;
• a motor including a brake and an output shaft in cooperation with the platform by way of a linkage, rotation of the output shaft in a first direction rotates the linkage to an upper position to raise the platform and rotation of the output shaft in a second direction opposite to the first direction rotates the linkage to a lower position to lower the platform, the brake is configured to stop movement of the output shaft to stop the linkage at the upper position and the lower position;
• a sensor configured to identify movement of the linkage between the lower position and the upper position;
• and
• a controller configured to receive inputs from the sensor, measure a cycle time of each one of a plurality of movement cycles of the linkage between the upper position and the upper position based on the inputs, identify a long-term average of the plurality of movement cycles and a short-term average of the plurality of movement cycles, and identify a series of recent cycle times included in the short-term average that are progressively decreasing relative to the long-term average of the plurality of movement cycles,
• wherein the controller generates a service alert for the brake of the motor in response to the identification of the series of recent cycle times that are progressively decreasing.

A method comprising:

• actuating a motor to raise and lower a platform configured to support a product being transported along an assembly line;
• identifying with a sensor movement of a linkage connecting the motor to the platform, the movement including rotation of the linkage in a first direction by the motor to an upper position to raise the platform and rotation of the linkage in a second direction by the motor to a lower position to lower the platform, a brake of the motor is configured to stop movement of the linkage at the upper position and the lower position;
• measuring with a controller in receipt of inputs from the sensor a cycle time of each one of a plurality of movement cycles of the linkage between the upper position and the lower position based on the inputs;
• identifying with the controller a series of recent cycle times that are progressively decreasing relative to previously observed cycle times;
• and
• generating with the controller a service alert for the brake of the motor in response to the identification of the series of recent cycle times that are progressively decreasing.