JP2011076313A - Automatic update system of failure diagnosis database for working machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To perform accurate failure diagnosis by updating a repair content determined from a repair record and an operating state to match an actual condition. <P>SOLUTION: The system includes: a repair list database 63 for storing a repair record when a working machine 1 is repaired; and a diagnosis database forming means 61 which forms a failure diagnosis database 64 for determining a repair content based on the repair records in the repair list database 63 and the operating state of the working machine 1. The database forming means 61 reconstructs the failure diagnosis database 64 when a repair of the working machine occurs and a repair record thereof is added to the repair list database 63. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an automatic update system for a failure diagnosis database for a work machine such as a backhoe.

Conventionally, work machines such as backhoes have been used at various construction sites and the like, and prompt response is required when they break down. Although it is possible to find and repair the cause of the failure of the work machine 1 at the construction site, it is a fact that the structure of recent work machines is complicated, and it is not easy to find the cause of the failure immediately.
In view of the above, various systems have been developed for diagnosing work machine failures (for example, Patent Document 1).

  Patent Document 1 discloses a construction machine failure diagnosis method for performing failure diagnosis by transmitting and receiving signals to and from each other by communication devices provided in a construction machine and an information management center, respectively, and a first signal relating to a failure in a construction machine. Is generated by the construction machine, and the first signal is transmitted from the construction machine to the information management center via the communication device. When the first signal is transmitted, the first signal is transmitted based on the first signal. A second step of generating a second signal for identifying a fault location in the information management center, and transmitting the second signal from the information management center to the construction machine via the communication device; And a third step of notifying the operator of failure information related to the second signal.

  In the failure diagnosis method of Patent Document 1, many questions for diagnosing a failure are displayed on a display device of a work machine, and an operator who operates the work machine answers the questions.

JP 2002-332664 A

  As in the failure diagnosis method of Patent Document 1, in reality, many questions and the like for diagnosing a failure are set assuming various things from the stage of designing the work machine. However, even if various things are assumed at the stage of designing the work machine, if the work machine is actually operated, unexpected symptoms may appear or the expected symptom and the failure content may be the same. There were inconveniences such as not doing it.

  In view of the above problems, the present invention provides an automatic update system for a failure diagnosis database for a work machine that can perform accurate failure diagnosis by updating the repair contents obtained from the repair results and the operation status so as to match the actual situation. Is intended to provide.

  The technical means of the present invention for solving this technical problem includes a repair list database in which repair results when a work machine is repaired are stored, repair results of the repair list database, and operating conditions of the work machine. A diagnostic database creation means for creating a failure diagnosis database for determining the content of repair based on the repair database. The diagnostic database creation means adds a repair record to the repair list database when the work machine is repaired. In this case, the failure diagnosis database is reconstructed.

  The repair results include actual repair contents when repairing the work machine and actual operation conditions when the work machine is repaired, and the diagnostic database creation means includes the actual repair contents and the actual operation condition of each part. It is preferable that a combination of the actual repairs and the actual operation status of each part be reconstructed when the repair results are added.

The diagnostic database creation means adds the actual repair content and actual operation status newly added at the time of repair to the actual repair content and actual operation status already stored in the repair list database, and then the predetermined repair content It is preferable to reconstruct by recalculating the actual operation status of each part when.
The repair list database is located at a company that repairs work machines, and the failure diagnosis database is located at a company that manufactures work machines. The repair results in the repair list database are diagnosed via a network. It is preferably sent to the database creation means.

  According to the present invention, it is possible to perform an accurate failure diagnosis by updating the repair contents obtained from the repair results and the operation status so as to match the actual situation.

It is a block diagram of the automatic update system of the working machine failure diagnosis database. It is a figure which shows a check sheet. The flow of summarizing the failure record shows a) the failure record stored in the failure list database, b) the failure record for each failure content, and c) the symptoms of each part for each failure content. The total is shown. It shows the relationship between check items and symptoms stored in the failure diagnosis database. The flow of summarizing the failure record when a failure record is added is shown. A) Shows the failure record already stored in the failure list database and the added failure record, b) Symptom of each part for each failure content The total is shown. It shows changes in the failure diagnosis database when failure results are added. The first modification is shown in the case where a failure record is added. A) Shows the failure record already stored in the failure list database and the added failure record, b) Symptoms of each part for each failure content The total is shown. It shows a change in the failure diagnosis database when a failure record in the first modification is added. The second modification is shown in the case where a failure record is added. A) Shows the failure record already stored in the failure list database and the added failure record, b) Symptoms of each part for each failure content The total is shown. It shows a change in the failure diagnosis database when a failure record in the second modification is added. 1 is a configuration diagram of a failure diagnosis support system. The screen when the failure estimation unit is activated is shown. It shows the flow from the operation information until the failure is estimated. The whole side view of a working machine is shown.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The work machine failure diagnosis database creation method and work machine failure diagnosis database creation system according to the present invention are used, for example, to diagnose failures in a backhoe work machine. First, a failure diagnosis database creation system will be described together with the configuration of a work machine.

FIG. 14 shows an example of a work machine.
As shown in FIG. 14, the work machine (backhoe) 1 includes a lower traveling device 2 and an upper swing body 3.
The traveling device 2 includes a pair of left and right traveling bodies 4 each having a rubber cover, and a crawler traveling device in which both traveling bodies 4 are driven by a traveling motor M is employed. Further, a dozer 5 is provided at the front portion of the traveling device 2.

  The swivel body 3 includes a swivel base 12 supported on the traveling device 2 via a swivel bearing 11 so as to be able to turn left and right around a swivel axis in the vertical direction, and a working device 13 ( Drilling device). On the swivel base 12, an engine, a radiator, a driver's seat 9, a fuel tank, a hydraulic oil tank, and the like are provided. Around the driver's seat 9, a display device 25 that displays various information related to the work machine 1 is provided. The driver's seat 9 is surrounded by a cabin 14 provided on the turntable 12.

  The working device 13 includes a swing bracket 17 supported on a support bracket 16 provided at the front portion of the swivel base 12 so as to be offset slightly to the right from the central portion in the left-right direction, and swingable to the left and right around the vertical axis. The boom 18 is pivotally attached to the swing bracket 17 so that the base side is pivotable about a horizontal axis, and is supported so as to be swingable up and down, and on the distal end side of the boom 18 around a horizontal axis. The arm 19 is pivotally mounted and supported so as to be able to swing back and forth, and a bucket 20 is provided on the distal end side of the arm 19 so as to be capable of squeezing and dumping.

  The swing bracket 17 is swung by expansion and contraction of a swing cylinder provided in the swivel base 12, and the boom 18 is swung by expansion and contraction of a boom cylinder 22 interposed between the boom 18 and the swing bracket 17. The arm 19 is swung by the expansion and contraction of the arm cylinder 23 interposed between the arm 19 and the boom 18, and the bucket 20 is a bucket cylinder 21 interposed between the bucket 20 and the arm 19. Squeezing and dumping is performed by expanding and contracting.

  As shown in FIG. 1, in the automatic update system for the work machine failure diagnosis database, the repair result when the work machine 1 is repaired at a repair shop or the like is rented, and the manufacturing company that manufactures the work machine 1 or the work machine 1 is rented. The failure diagnosis database is automatically updated by sending it to a rental company or the like via a network and analyzing the result of repair by a computer 61 arranged at the manufacturing company or rental company.

  FIG. 2 shows a check sheet. This check sheet S is for filling in the repair results. Specifically, the check sheet S is for checking the contents of repair and the situation (symptoms) of each part when the repair is performed. In this check sheet S, 19 check items C for checking the status (symptoms) of the part of the work machine 1 are prepared. This check item C is determined by collecting past repair results. It has been done.

Hereinafter, a method for determining a check item will be described.
In the repair shop, every time the work machine 1 is repaired, the repair contents and the symptoms at the time of the repair are input to the seat or the computer 62 arranged in the repair shop, and such repair results are accumulated. At the same time, the repair results are uploaded to the repair list database 63 arranged in the manufacturing company or rental company via the network. That is, first, the repair contents when the work machine 1 is repaired are acquired, and the status of each part of the work machine 1 when the repair is performed is acquired.

  For example, as shown in FIG. 3A, for example, in repair number 1, the repair content is “A”, and the repair at this time has symptoms of 1, 4, and 11 items (“◯”). In other words, the repair results of the repair contents and symptoms are left in the computer 61 and the repair list database 63 of the repair shop. In FIG. 3A, “-” indicates that no symptom was found or the symptom was not checked.

  Then, as shown in FIG. 3, when the number of repairs of the work machine 1 increases and the repair record is sufficiently accumulated in the repair list database 63, the computer 61 is used as shown in FIG. Summarize the symptoms of each part for each repair. That is, the repair results in the repair list database 63 are called by the computer 61, and the situation of each part when the repair is performed for each repair content is totaled.

  Next, in the same repair content, a part (item) having relatively the same symptom is picked up by the computer 61 and the item is determined as a check item C. As shown in FIG. 3C, for example, the repair with the repair content “A” is performed six times. Of these, the number of occurrences of symptoms of 1 item, 4 items, and 11 items is more than half (○ Since the number is 3 or more), 1 item, 4 items, and 11 items are determined as check items C. In addition, looking at the repair with the repair content “B”, the number of occurrences of symptoms of 2 items, 4 items, 10 items, and 12 items is more than half (the number of ○ is 3 or more). 4 items, 10 items, and 12 items are determined as check items C. Similarly, when looking at the repair with the repair content “C”, the number of occurrences of symptoms of 2 items, 3 items, and 5 items is more than half (the number of ○ is 3 or more). Items and 5 items are determined as check items C.

  Data relating the symptoms (actual operation status) and repair details (actual repair details) of each part determined in this manner are stored in the failure diagnosis database. That is, as shown in FIG. 4, the failure diagnosis database stores combinations of symptoms (check items C) and repair contents of each part obtained from past repair results. That is, in the failure diagnosis database, when the symptoms of 1 item, 4 items, and 11 items occur (O), the repair content “A” is performed, and the symptoms of 2 items, 4 items, 10 items, and 12 items are displayed. If it occurs, the repair content “B” is stored, and information indicating that the repair content “C” is performed when symptoms of items 2, 3, and 5 occur is stored.

As shown in FIG. 1, the work machine failure diagnosis database automatic update system 60 includes a diagnosis database creation means 61 and a repair list database 63. The diagnostic database creating means 61 creates a failure diagnostic database 64 based on information stored in the repair list database 63.
The repair list database 63 stores repair results when the work machine 1 is repaired. As shown in FIG. 3A, the repair contents when the work machine 1 is repaired are stored. In addition, the situation of each part of the work machine 1 when repair is performed is stored. In this embodiment, it is provided in a computer 61 arranged at a manufacturing company or a rental company. The repair list database 63 is preferably created for each model (for each type) of the work machine 1. For example, when there are three models of the work machine 1, the repair list database 63 is created for each of the three models. Will be prepared.

  The failure diagnosis database 64 is used for diagnosing a failure of the work machine 1, and as described above, the symptoms (check items C) of each part and the repair contents are stored in association with each other. . In this embodiment, similarly to the repair list database 63, it is provided in a computer 61 arranged in a manufacturing company or a rental company. The failure diagnosis database 64 is preferably created for each model (for each type) of the work machine 1. For example, when there are three models of the work machine 1, the failure diagnosis database is provided for each of the three models. 64 will be prepared.

The diagnostic database creation means 61 creates check items for checking each part of the work machine 1 based on the repair contents and the situation (symptoms) stored in the repair list database 63, and re-reads the fault diagnosis database 64. The computer 61 can be constructed and is configured by a computer 61 arranged in a manufacturing company or a rental company.
The diagnostic database creation means 61 (computer 61) includes a reconstruction calculation unit 65. These reconstruction calculation units 65 are configured by programs or the like stored in the computer 61.

The reconstruction calculation unit 65 is for reconstructing a combination of the actual repair contents and the actual operation status of each part when the actual repair is added. The reconstruction calculation unit 65 will be described in detail.
As shown in FIG. 5A, in a state where repair results (actual repair contents, actual operation status) when the work machine 1 has already been repaired are stored in the repair list database 63, the work machine 1 in a repair shop or the like. For example, it is assumed that the repair results for a plurality of repair contents D are sent to the repair list database 63 from the computer 62 of the repair shop.

As shown in FIG. 5 (b), the reconstruction calculation unit 65 first recalculates the occurrence frequency for the newly added predetermined repair content D from the total number of repairs and the total number of occurrences in the symptoms of each part. However, as shown in FIG. 6, the reconstruction calculation unit 65 uses a symptom (part) as a check item for a case where the number of occurrences exceeds half (50% or more), that is, the number of occurrences is 6 or more. to add.
As shown in FIG. 5 and FIG. 6, in the case where repair results are not added with respect to the repair content D, the check items of 2 items, 3 items, and 5 items were raised to indicate symptoms (Yes, ○). However, one check item whose frequency of occurrence has exceeded 50% by the calculation of the reconstruction calculation unit 65 after the repair record is added is newly added as a symptom related to the repair content D. That is, before reconstructing the repair content D, it was determined that the repair content D is determined if the symptoms of the check items of 2, 3, 5, and 5 have occurred. If the symptoms of the check items of item 1, item 2, item 3, and item 5 have occurred, the repair content D is determined.

  As described above, the diagnostic database creation means 61 reconstructs the combination of the actual repair contents and the actual operation status of each part when the repair results are added. After adding the actual repair details and actual operation status newly added during repair to the actual repair details and actual operation status saved in The failure diagnosis database 64 is reconstructed by the reconstructing calculation unit 65 that performs the calculation.

7 and 8 show a first modified example for reconstructing the failure diagnosis database 64.
As shown in FIG. 7A, in the state where repair results when the work machine 1 has been repaired are already stored in the repair list database 63, for example, repair results for a plurality of repair contents L are stored in the repair list database 63. Is sent to.

  As shown in FIG. 7 (b), the reconstruction calculation unit 65 first calculates the occurrence frequency from the total number of repairs and the total number of occurrences in the symptoms of each part regarding the newly added predetermined repair content L. . As shown in FIG. 8, for example, when there is a symptom (item) whose occurrence frequency exceeds 50%, the reconstruction calculation unit 65 repairs 6 items, 9 items, and 13 items that are the symptom (region). It is added as a check item in L.

  As shown in FIGS. 7 and 8, when the repair record is not added, there is no item whose repair content is L and there is no check item for the repair content, but when the repair record is added, the repair content L Is newly added, and the combination of the presence or absence of each symptom corresponding to the repair content L is calculated, and the occurrence frequency exceeds 50% by the calculation of the reconstruction calculation unit 65, 6 items, 9 items, 13 items Will be newly added as a symptom of the repair content L.

9 and 10 show a second modified example in which the failure diagnosis database 64 is reconstructed.
As shown in FIG. 9A, in the state where repair results when the work machine 1 has been repaired are already stored in the repair list database 63, for example, repair results for a plurality of repair contents N are stored in the repair list database 63. Is sent to.

As shown in FIG. 9 (b), the reconstruction calculation unit 65 similarly calculates the occurrence frequency from the total number of repairs and the total number of occurrences in the symptoms of each part for the newly added predetermined repair contents N. Then, as shown in FIG. 10, 8 items, 13 items, and 20 items corresponding to a symptom having an occurrence frequency equal to or higher than a predetermined frequency are added as check items.
As shown in FIGS. 9 and 10, in the case where repair results are not added, there are no items whose repair contents are N and there are no check items for the repair contents, and there are 19 check items. ing. In the second modified example, when repair results are added, repair contents N are newly added, and new check items (20 items) are added.

FIG. 11 shows an example of a failure diagnosis support system that performs failure diagnosis of the work machine 1 using the failure diagnosis database 64.
The failure diagnosis support system 50 includes a status transmission unit 51, a failure diagnosis unit 52, and a failure diagnosis database 64.
The status transmission means 51 is for transmitting the operation status of each part of the work machine 1 for fault diagnosis. The display device 25 converts the operation status of the work machine 1 into an image and displays it, and this display. And a communication device 45 that reads an image displayed on the device 25 and transmits an operation state in the image via a network.

  The display device 25 includes the engine speed, battery voltage, starter ON / OFF status, water temperature sensor operating voltage, fuel sensor voltage, engine oil pressure switch voltage, accelerator sensor voltage, AI motor current, etc. The operation status of various operation units can be converted into image data (for example, QR code) and displayed. In addition, although various apparatuses etc. are mounted in the working machine 1, the apparatus which operate | moves is called an operation | movement part.

  The communication device 45 is a camera-equipped mobile phone or the like, and can read operation information in the QR code by reading the QR code displayed on the display device 25 by the camera. In addition, the communication device 45 can transmit operation information using, for example, a communication function by e-mail or the like. The electronic mail having the operation information is stored in the electronic electronic mail server 57.

  The failure diagnosing means 52 receives an operation state and diagnoses a failure of the work machine 1 based on the operation state, and is composed of a computer (personal computer). The computer 52 is arranged at a manufacturing company or a rental company. The computer 52 for diagnosing failure diagnosis may be the same computer as that used in the failure diagnosis database creation system 60.

The computer 52 (failure diagnosing means) includes a situation capturing unit 55 and a failure estimation unit 56. The status capturing unit 55 and the failure estimating unit 56 are configured by a program stored in the computer 52.
The status capturing unit 55 captures the operational status of each part of the work machine 1, and accesses the electronic electronic mail server 57 to retrieve operational information from the electronic mail server 58.

  The failure estimation unit 56 automatically estimates a failure based on the operation status captured by the status capture unit 55 and the repair results stored in the failure diagnosis database 64. Specifically, the failure estimation unit 56 is configured by application software for estimating a failure from a situation (symptom). When the application software is started, the failure diagnosis database 64 is accessed and this failure diagnosis is performed. By calling the check item C in the database 64, a screen (check screen) having the check item C and the answer column as shown in FIG. 12 is displayed on the display unit of the computer 61. That is, the failure estimation unit 56 displays a screen having a check item C and an answer column corresponding to the check sheet S shown in FIG.

  On the check screen (check sheet S), there are a plurality of items (check items C) for inputting the status (symptom) of each part, and an answer column for the symptom of each part. An answer is automatically made according to the operation situation taken into the section 55. For example, the resistance value of the boom solenoid valve is read from the sent operation status, and if the resistance value is between 6 and 15Ω, the answer is automatically “Yes”. It should be noted that replies may be made automatically for all check items C based on the operating conditions, or replies may be made automatically for some check items C.

  Then, the failure estimation unit 56 collates the response of the symptom (check item C) of each part on the check screen (check sheet S) with the operation status of each part in the repair record stored in the failure diagnosis database 64. To estimate the failure. For example, as illustrated in FIG. 13, the failure estimation unit 56 determines that the failure is a pattern in which the first, fourth, and eleventh symptoms are “◯” and the others are “×” in the check screen. The diagnosis database 64 is searched for a pattern having the same symptom as the check screen, and the repair content “A” corresponding to this pattern is extracted. Then, the failure estimation unit 56 displays the failure content corresponding to the repair content “A”. That is, the failure estimation unit 56 determines the repair content from the symptom answer on the check screen. However, since the failure content and the repair content are front and back, if the repair content is known, the failure content is naturally found. Can do. For example, if the repair content is “controller replacement”, it goes without saying that the controller has failed. Therefore, the failure estimation unit 56 determines that the failure (estimated cause) "Failure" is determined and the details are displayed on the screen.

  In the failure diagnosis support system 50 for the work machine 1, for example, the user displays the operation information of the work machine 1 as a QR code on the display device 25, and reads the QR code displayed on the display device 25 with a camera-equipped mobile phone. The data in the read QR code is transmitted to the e-mail server 58 by e-mail, and the manufacturing company or the rental company accesses the e-mail server 58 from the company computer 52 and receives the e-mail of the operation information. By doing so, the operation information of the work machine 1 can be acquired. Then, the manufacturing company or the rental company can automatically estimate the failure from the operation information and the failure diagnosis database 64 by the failure estimation unit 56 of the computer 52, and can quickly notify the user or the like of the portion that seems to be a failure.

  Although FIG. 11 shows an example of a failure diagnosis support system that performs failure diagnosis of the work machine 1 using the failure diagnosis database, failure diagnosis using the failure diagnosis database is not limited to that of FIG. For example, a check sheet S in which check items are listed is created by extracting check items in the failure diagnosis database 64, and the check sheet S is used to check the symptoms of each part of the work machine 1 and check The failure diagnosis of the work machine 1 may be performed by inputting the result to the computer 52 (failure diagnosis means).

  As described above, the repair list database 63 in which the repair results when the work machine 1 is repaired are stored, and the failure diagnosis database 64 for determining the repair contents based on the repair results of the repair list database 63 and the operation status of the work machine. The diagnostic database creation means 61 generates a failure diagnosis database 64 when repair work is added to the repair list database 63 after the work machine 1 is repaired. Rebuilding.

According to this, every time the work machine is repaired, the failure diagnosis database 64 is updated to the one corresponding to the repair record, and as a result, the repair content required from the repair record and the operation status matches the actual situation. Therefore, failure diagnosis using the failure diagnosis database 64 can be performed more accurately.
The diagnostic database creation means 61 creates a failure diagnosis database 64 by obtaining a combination of the actual repair details and the actual operation status of each part from the repair results, and when the repair results are added, The combination with the actual operation status of each part has been reconstructed. In particular, the diagnostic database creation means 61 adds the actual repair content and actual operation status newly added at the time of repair to the actual repair content and actual operation status that have already been stored in the repair list database. It is preferable to rebuild by recalculating the actual operation status of each part when it is repair content.

The repair list database 63 is arranged in a company that repairs the work machine 1, and the failure diagnosis database 64 is arranged in a company that manufactures the work machine 1. To the diagnostic database creation means 61.
According to this, every time the work machine 1 is repaired, the repair record can be stored in the repair list database 643, and the diagnosis database creating means 61 can immediately use the stored data to diagnose the failure diagnosis database 64. Can be rebuilt. That is, the failure diagnosis database 64 is always updated to a new one, and failure diagnosis that matches the actual situation can be performed.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims. In the failure diagnosis support system 50 of the above embodiment, the operation information of the work machine 1 is transmitted using an electronic mail (electronic mail server 57), and then the operation information in the electronic mail is stored in the repair list database 63. However, the operation information of the work machine 1 may be uploaded to the repair list database 63 by the mobile phone 45 or the like without using the e-mail (e-mail server 57). The work machine 1 is not limited to a backhoe, but may be a tractor or a combine. Although the failure diagnosis database 64 is provided in the diagnosis database creation means 61 (computer), this failure diagnosis database 64 may be provided separately from the diagnosis database creation means 61.

DESCRIPTION OF SYMBOLS 1 Work machine 60 Automatic update system of failure diagnosis database 61 Diagnosis database creation means 62 Computer 63 Repair list database 64 Failure diagnosis database 65 Reconstruction calculation unit

Claims (4)

For diagnosis to create a repair list database storing repair results when repairing a work machine, and a failure diagnosis database for determining the repair contents based on the repair results of the repair list database and the operation status of the work machine A database creation means,
The diagnosis database creation means reconstructs a failure diagnosis database when repair of the work machine occurs and a repair record is added to the repair list database. Automatic update system.   The repair results include actual repair contents when repairing the work machine and actual operation conditions when the work machine is repaired, and the diagnostic database creation means includes the actual repair contents and the actual operation condition of each part. A database for failure diagnosis is obtained from the repair results, and when the repair results are added, the combination of the actual repair contents and the actual operation status of each part is reconstructed. The automatic update system for a fault diagnosis database for a work machine according to claim 1.   The diagnostic database creation means adds the actual repair content and actual operation status newly added at the time of repair to the actual repair content and actual operation status already stored in the repair list database, and then the predetermined repair content 3. The automatic update system for a fault diagnosis database for a work machine according to claim 2, wherein the system is reconstructed by recalculating the actual operation status of each part.   The repair list database is located at a company that repairs work machines, and the failure diagnosis database is located at a company that manufactures work machines. The repair results in the repair list database are diagnosed via a network. The automatic update system for a work machine failure diagnosis database according to any one of claims 1 to 3, wherein the work machine failure diagnosis database is transmitted to the work database creation means.

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