Adjustment and Maintenance Technology of Industrial Robots Integration and Operations Technology of Industrial Internet

1  Competition Overview

1.1  Name

【BRICS2025-ST-110】Adjustment and Maintenance Technology of Industrial Robots

【BRICS2025-ST-117】Integration and Operations Technology of Industrial Internet

1.2  Purpose

Industrial robot technology is the “core tool” of intelligent manufacturing, and its development directly reflects a country’s industrial automation level. From early “single repetitive operations” to today’s “AI-driven, human-robot integration,” industrial robots are evolving from “replacing humans” to “empowering humans,” becoming “flexible, precise, and intelligent” production partners in factories. This competition focuses on advanced technology, comprehensive capabilities, and innovative thinking, providing participants with a closed-loop growth platform integrating “learning, practice, competition, and application.”

1.3  Participants

1.3.1  Age Requirement

Participants must be over 16 years old and under 22 years old, with no gender restrictions.

1.3.2  Team Composition

Each team consists of 5 members: 2 competitors, 1 translator, 1 coach, and 1 team leader.

2  Competition Content

2.1　Competition Tasks

The competition includes 3 tasks, detailed as follows:

Task 1: Virtual Disassembly/Assembly and Fault Diagnosis of Industrial Robots (1.5 hours)
According to the disassembly/assembly process requirements and precautions specified in the task document, complete the disassembly and assembly of the robot’s axis housings and motors in the virtual disassembly/assembly assessment management system. Additionally, perform fault diagnosis and troubleshooting in the virtual scenario based on fault prompts.

Figure 1  Industrial robot virtual disassembly/assembly assessment management system

Task 2: Intelligent Operation and Maintenance of Industrial Robot Systems (1.5 hours)

Use the intelligent production line planning and digital twin simulation software (Sim-IPT) to layout the digital twin model of the industrial robot system.

Complete reachability verification and assembly process simulation debugging of the industrial robot between workstations, ensuring smooth movements, no dangerous actions, and modular programming.

Intelligent Production Line Planning and Digital Twin Simulation Software

Connect the MES software with the intelligent production line planning and digital twin simulation software, configure work order data in MES, and initiate the simulation scenario via MES work orders to enable the industrial robot in the simulation system to complete assembly tasks.

Figure 2  Intelligent production line planning and digital twin simulation software

According to the requirements of the task book, connect the MES software with the intelligent production line planning and digital twin simulation software, and configure the work order in MES. Start the simulation scenario through MES order, and let the industrial robot in the simulation scenario complete the assembly task.

Figure 3  Manufacturing Execution System (MES)

Task 3: Delivery and Verification of Intelligent Industrial Robot Solutions (15 minutes)
Verify the industrial robot system solution, monitor and record the deployment/application process, and address issues. Compile an overall technical and implementation plan for the project using a template to form a deliverable document for the industrial robot system solution.

2.2　Score Weight

The score distribution for each task is shown in Table 1:

• Score Weight Distribution of Competition Tasks

2.3　Competition Duration

The duration for each task is shown in Table 2.

• Duration of Competition Tasks

3　Evaluation Criteria

3.1　Evaluation Principles

3.1.1　Comprehensive Principle

The expert and referee teams evaluate results based on the principles of “fairness, impartiality, transparency, science, and innovation,” assessing contestants’ performance in design, equipment operation, and safe production.

3.1.2　Module Independence Principle

To ensure fair, accurate, and objective assessment, each module in the competition must be conducted and evaluated independently. The performance or results of one module must not interfere with the conditions, execution, or evaluation of subsequent modules. This principle ensures:

1. a) Independent assessment of specific skill areas;
2. b) Clear diagnosis of participants’ abilities in each module;
3. c) Fair competition regardless of early task outcomes;
4. d) Consistency in evaluation and scoring.

Thus, each module shall:

1. a) Provide a neutral and clean working environment;
2. b) Supply independent tools, materials, and data;
3. c) Include independent instructions and objectives;
4. d) Allow participants to start without relying on outputs from previous tasks.

Evaluations must assess task-specific abilities demonstrated within each module based on predefined technical standards.

3.2　Distribution of Evaluation and Measurement Scores

The distribution of subjective (evaluation) and objective (measurement) scores is shown in Table 3:

• Distribution of Evaluation and Measurement Scores

3.3　Evaluation Scores

Scoring method for evaluation scores: Four referees form a group, one of which is the rotating referee, scoring for the contestants in the same group not for their own contestants. Three referees score separately, giving a weighted score for each item of the assessment, calculating the average weighted score and the actual score. The difference in weighted scores given by the referees to each other may be less than or equal to one point. If it exceeds one point, the assessment items of the contestants need to be explained and a reasonable score is given under the deliberation and supervision of the referee president. The table of weighted scores for evaluation scores is shown in Table 4.

• Weighted Evaluation Score Criteria

3.4　Measurement Scores

Scoring Method: Scoring groups will be established by task, with each group consisting of 4 referees. All referees in a group will discuss collectively and agree on a single final score for the participant’s performance in that task. Examples of measurement scoring are shown in Table 5.

• Examples of Measurement Scoring

3.5　Evaluation Process

3.5.1　Result Scoring

Submitted works will be scored according to predefined technical standards.

3.5.2　Penalty Deductions

Participants will face deductions for the following violations:

1. a) Accidents due to improper operation: 10–15 points deducted; severe cases result in disqualification;
2. b) Equipment damage or environmental pollution due to rule violations: 5–10 points deducted; severe cases result in disqualification;
3. c) Disturbing order or interfering with referees: 5–10 points deducted; severe cases result in disqualification;
4. d) Non-compliance with regulations (e.g., messy tool placement, disorganized workflow, improper attire, incomplete documentation): 5–10 points deducted based on severity.

3.5.3　Sampling Review

To ensure accuracy, the supervision team will review ≥30% of scores. Discrepancies will be reported in writing to the expert team leader, who will correct scores and confirm with a signature.

3.6　Score Tabulation

Each scoring group will evaluate their assigned modules independently, combining process scoring with post-event result scoring. Scores for work completed by participants must be finalized on the same day. USB data storage devices must not be modified after saving and must be sealed and submitted to the chief referee for safekeeping. Evaluation and measurement score sheets must be signed by all participating referees before submission to the expert team leader for safekeeping.

3.7　Ranking

Scores are summarized and ranked. If the total scores are the same, compare the scores of Task 1, and the one with the higher score ranks first. If the total scores are the same, the ranking is determined by the scores of Task 1, Task 2, and Task 3 in sequence.

3.8　Result Announcement

Results will be announced at the closing ceremony.

3.9　Awards

3.9.1　Certificates

Participating teams will receive award certificates issued by the competition organizers.

3.9.2  Gold, Silver, Bronze Medals, and Merit Awards

The competition sets gold, silver, bronze medals and merit awards. All participating teams from various countries are ranked uniformly. For the players who rank in the top 6 in each competition event, gold, silver, bronze medals and certificates will be awarded accordingly; for the players who rank outside the top 6 but in the top 9, merit award medals and certificates will be awarded.

3.9.3　Other Awards

Certificates will be issued to expert group members and referees. Organizations making outstanding contributions to the competition will receive the “Outstanding Contribution Award.” National organizing units that actively organize participation, conduct pre-competition training, and have no rule violations will receive the “Excellent Organization Award.”

4　Technical Platform

4.1  Industrial Robot Virtual Simulation System for Assembly and Maintenance

4.1.1  Platform Introduction

The industrial robot installation, commissioning and maintenance virtual simulation system is based on the training and assessment equipment for industrial robot system maintenance personnel, and the equipment is 1:1 restored. It can complete the corresponding practical training, operation training and assessment tasks. The model includes the robot body, robot controller, robot servo driver, base, operating console, etc. The robot body in the system can be disassembled and assembled, and can be disassembled to the screw level. The disassembly process accurately measure and control the clamping torque and tension.

Figure 4  Industrial robot operation and maintenance simulation software

4.1.2  Platform Functions

1. a) Industrial Robot Disassembly and Assembly Assessment Management System

The industrial robot virtual disassembly and assembly assessment management system is based on the training and assessment equipment for industrial robot system maintenance personnel, which can the corresponding practical training, operation training and assessment tasks by 1:1 restoring the equipment model. The model includes the robot body, robot controller, robot servo driver, base and operating console, etc. In the system, the robot body can be disassembled and assembled, and can be disassembled to the level of screws. The process of disassembly and assembly can be precisely measured and controlled in terms of clamping torque and tension.

Figure 5  Simulation system interface

Figure 6  Assessment interface

Figure 7  Fault diagnosis and troubleshooting

1. b) Intelligent Production Line Planning and Digital Twin Simulation Software

The intelligent production line planning and digital twin simulation software is a self-developed with independent intellectual property rights, which has been developed by Bono Robotics in collaboration with multiple scientific research institutions for 6 years. It plans and simulates robots and manufacturing processes a virtual environment, truly simulating the motion and rhythm of the production line. It realizes the analysis and planning of intelligent manufacturing production lines, and has a massive component library, production rhythm analysis statistics, CAD modeling and rapid bonding connection technology, PLC and robot controller interfaces, quick capture, machining path optimization, post-output, offline programming, virtual commission, analysis and calculation, open motion control algorithms, and digital twin functions. It is suitable for enterprise intelligent manufacturing production line planning and design, university production line learning, to reduce safety, save funds and improve efficiency.

Figure 8  Digital twin system

Figure 9  Component library

Figure 10  Instructional programming

1. c) Manufacturing Execution System (MES)

The manufacturing execution system comprehensively covers the business processes of production planning and scheduling, real-time production monitoring, management, fixture management, personnel equipment management, and warehouse management, and provides in-depth insights into the production process through the report and analysis module, improving production efficiency. It meet the teaching needs of technology such as process flow control, production plan scheduling, production data collection, data monitoring, and maintenance.

Figure 11  Organizational structure

Figure 12  System management

5　Event Safety

5.1　Safety Training

The safety officer organizes all referees, staff, and players to conduct safety training, and they can participate in the competition only after passing the training assessment.

5.2　Safety Facilities

The safety facilities requirements for the competition venue are as follows:

1. a) The venue is equipped with necessary safety isolation measures and safety passages, and complete emergency treatment facilities such as fire extinguishers. Post safety operation procedures in prominent positions and set up safety evacuation signs;
2. b) Set up security check equipment at the entrance of the venue to prohibit carrying unauthorized items into the venue.

5.3　Medical Equipment and Measures

The venue must be equipped with corresponding medical personnel and first-aid personnel, as well as corresponding first-aid facilities and plans.