CN103295276B

CN103295276B - Dynamic log file

Info

Publication number: CN103295276B
Application number: CN201310020709.3A
Authority: CN
Inventors: W·舒马赫-维尔格斯; M·莱姆克
Original assignee: Heidelberger Druckmaschinen AG
Current assignee: Heidelberger Druckmaschinen AG
Priority date: 2012-01-20
Filing date: 2013-01-21
Publication date: 2019-12-10
Anticipated expiration: 2033-01-21
Also published as: EP2618315A3; EP2618315A2; CN103295276A; DE102012001083A1

Abstract

the invention relates to a method for determining the need for maintenance or repair in a machine (7) having a control computer (8), wherein operating data are detected during the operation of the machine (8) and stored in a file on the control computer (8). The invention is characterized in that the rules according to which the operating data are stored in the file depend on the state of the machine (7).

Description

Dynamic log file

Technical Field

The invention relates to a method for determining the need for maintenance and repair of a machine having a control computer, wherein operating data are detected during the operation of the machine and stored in a file on the control computer.

Background

in the prior art, machines are maintained by remote maintenance systems. To enable such remote maintenance, the maintenance requirements of the machine must be communicated to a remote maintenance computer at the manufacturer. Maintenance requirements, such as wear or required consumables, are typically estimated based on operational data of the machine. Once the consumables or wear exceeds the permissible critical values, the following conclusions are drawn: the machine must be serviced and the maintenance requirements communicated by the machine's computer to a remote computer at the manufacturer. The remote maintenance computer typically then responds to the maintenance demand by dispatching a service technician to the machine operator who replaces worn parts or fills in consumable materials as necessary. Since dispatching service technicians is very expensive, attempts are made in remote maintenance systems to maximize the service interval and dispatch service technicians only in absolute emergency situations. In order to be able to estimate the service interval accurately and at the same time avoid damage to the machine, a prediction must be made that is as accurate as possible: when maintenance requirements are practically unavoidable. This synchronizes the planned actions with the maintenance cycle.

A system is proposed by patent application US 2011/0029824 a1, which predicts the failure of a machine as accurately as possible. The system is installed on the computer of the machine under observation. Service data on the machine is detected in the system and compared to failure data in a reference database. The following predictions are proposed by comparison of the service data of the machine with the error patterns in the reference database: at which point the machine being observed may fail. The time is then informed so that the corresponding maintenance procedure can be carried out in a timely manner, but not prematurely. In this way, it is ensured that the machine is serviced before it fails, but it is also not necessary that unnecessary servicing takes place early and that this would lead to corresponding costs.

A method for transmitting the data of a printing press to a remote maintenance computer is proposed by patent application EP 1207434 a 2. The evaluation of the data is performed before the operational data of the machine is transmitted to the remote maintenance computer. In this case, the operating data are compared with one or more threshold values and are automatically transmitted to the remote maintenance computer only when the one or more threshold values are exceeded, fallen below or reached. This has the following advantages: the data of the computer of the printing press are not transmitted to the remote maintenance computer continuously but only when a threshold value has been exceeded and a certain probability of failure or malfunction is expected. The method minimizes the data transmission between the remote maintenance computer and the computer of the printing press.

An operating agency supporting inexperienced operators of printing presses is proposed by patent US 7,454,263B 2. Patent US 7,860,587B 2 also supports the operation of the printing press.

disclosure of Invention

According to the invention, a method for determining a need for maintenance or repair in a machine having a control computer is proposed, wherein operating data are detected during the operation of the machine and stored in a file on the control computer, wherein the rule according to which the operating data are stored in the file depends on the state of the machine.

The object of the invention is to further improve the generation and evaluation of operating data in a remote maintenance system for machines and to enable an accurate prediction of maintenance and repair requirements.

According to the invention, the object is achieved by the above-described solution. Advantageous embodiments of the invention result from the following description and the drawings. The method according to the invention is suitable for determining the maintenance and repair requirements of machines and installations having a computer and preferably connected via the internet to a remote maintenance computer at the manufacturer or service provider. In particular, the method according to the invention can be used for maintaining complex machines, such as printing presses, whose availability must be ensured without interruption due to the high acquisition costs. In the method according to the invention, operating data of the machine are detected during operation and stored in a file on the control computer according to a defined rule. The rules determining how and when to store what operational data in the file depend on the state of the machine according to the invention. This results in: the run data need not be stored continuously in a file, but only when the rules specify. However, when the state of the machine changes (possibly by wear phenomena or by a changed machine running), the rules are matched to the changed machine state and the running data are stored according to the changed rules. It is thus ensured that not much data need be stored in the machine computer, but that operating data are stored correspondingly more when failures are expected and data are required accordingly for analysis and fault prevention, for example due to altered operation at higher machine wear.

In a first embodiment of the invention, it is provided that the operating data are stored in the file only when the operating data to be detected lie outside predefined tolerance limits stored in the control computer. In this case, the operating data are permanently compared with predefined tolerance limits stored in the control computer, but are discarded again and are not stored as long as the data lie within the predefined tolerance limits. The operating data are stored only when the predefined tolerance limits are exceeded or occur a number of times and are subsequently evaluated with respect to the probability of failure or malfunction. In this way, the amount of operating data stored in the files in the control computer can be reduced to a minimum. In particular in complex machines, such as printing presses with a plurality of drive motors and adjusting drives (all of which must be managed and have a certain susceptibility to wear), only operating data relevant to possible failure of the machine is stored and subsequently transmitted to a remote maintenance computer.

It is advantageously provided that the time or time interval at which the operating data is stored in the file depends on the machine state. This is, for example, another criterion which influences the storage process of the operating data, except that a predefined tolerance limit is exceeded. For example, a standard time interval can be predefined in such a way that the operating data are periodically monitored in a first time interval if a predefined tolerance limit is exceeded. If a further exceeding of the tolerance limit occurs within a larger, predefined second time interval, the storage of the operating data is carried out more frequently and the first time interval is correspondingly reduced, so that the operating data is stored in a short period.

It is advantageously provided that the tolerance limit is below a maximum limit at which failure of the machine is to be expected. In this way, it is ensured that, in the event of at least one time exceeding the tolerance limits and subsequent storage of operating data, a failure of the machine is not immediately anticipated, but rather at least in any case a brief continuation of operation is ensured.

It is particularly advantageously provided that the operating data comprise a current profile during operation of a drive motor in the machine. As already mentioned, the printing press has a plurality of electric drive motors. From the current profile when controlling the drive motor, it is possible to derive how the state of the drive motor or of the regulating device operated by the drive motor is. When the torque is higher due to wear at the motor or at the regulating device when controlling the drive motor, the motor current rises or shows a susceptibility to aggression, such as a steeper rise and fall. In particular, due to the higher motor current, certain tolerance limits can be exceeded, as a result of which the motor current is stored as operating data in a file and said data can be subsequently transmitted to a remote maintenance computer.

Furthermore, it is proposed that the operating data of a component in the machine be compared with the operating data of the same or similar components of the machine and that the operating data be stored in a file only in the event of a deviation. The comparison serves as a plausibility check and ensures that the lateral comparison of identical or similar components in the machine is first carried out before the operating data are stored. In this way, an anomaly of a component can be identified with respect to the same or similar components of the machine, so that only operating data of the component concerned with the anomaly have to be stored.

in a further embodiment of the invention, it is also provided that the operating data of the components of the machine are detected or stored only during the time intervals in which the components are also activated. This also serves to prevent the run data from being meaningfully recorded in the file. In this way, no identifying benefit is obtained when recording the motor current driving the motor without operating the motor at all, since the motor current is equal to zero. It is therefore only sensible to detect and store the motor current as operating data when the drive motor is also active and the control process is carried out. In particular, in printing presses with a large number of actuating drives, the amount of data recorded in the document can be reduced.

It is advantageously provided that the control computer of the machine is connected to the remotely located computer via a network connection and that the control computer adapts the rules for detecting and storing the operating data in the file taking into account the data of the remotely located computer. In this case, it can be achieved that the control computer of the machine not only matches the rules for storing data on the basis of the machine state, but also takes into account the provision of a maintenance computer which is located remotely. In this way, it is possible to transmit the experience of other machines via the internet to a remotely located computer and from there to the control computer of the machine. Matching of rules on the control computer may benefit from experience with other machines. Alternatively, it is also possible for the control computer to be connected directly to a remotely located control computer of the other machine via a network connection and for the rules for detecting and storing the operating data in the file to be adapted in this way taking into account the data stored in the remotely located control computer. In such a case, a remotely located computer is not necessarily required and the control computer may benefit directly from matching of rules of other control computers at similar or same machines and take its knowledge into account in its own matching process.

drawings

The invention is described and illustrated in detail below with reference to the attached drawing figures: the figures show:

FIG. 1: a remote maintenance computer having three printers connected via the internet each having a control computer,

FIG. 2 a: according to the prior art of running data records,

FIG. 2 b: the data recording is run according to dynamic rules according to the invention.

Detailed Description

An overview of the participating components of a remote maintenance system is schematically shown in fig. 1. The management computer 2 is located at the manufacturer 1, and obtains maintenance and repair requirements and operating data from the printing press 7 to be maintained via an internet connection 9. In front of the management computer 2, a service person 4 is seated, who can display the maintenance requirements and operating data of the printing press 7 on the screen 3 by means of input via a keyboard 12 and can thus decide the corresponding on-site service intervention or other remedial measures. The printing presses 7 to be serviced each have a control computer 8, which controls the associated printing press 7. By means of the control computer 8, the printing press operator 5 can control all functions of the printing press 7. In fig. 1, the printing presses 7 each have, by way of example, a printing unit having at least one electrical actuating drive, for example a register actuating drive. The register control drives are each assigned a current sensor 11, which detects the current profile of the register drive motor and transmits it to the printing press computer 8.

According to the prior art in fig. 2a, the operating data in the machine computer 8 are stored in a specific log file according to a rule of fixed destination. Data analysis and preventive symptom identification are then carried out on the basis of the log file, the results of which can be transmitted to the manufacturer 1 via the internet connection 9 in fig. 1.

It is now proposed, according to fig. 2b, that the log file is dynamic, i.e. the rules and contents stored in the log file change and depend, inter alia, on the state of the machine. In this way, the amount and type of data can be adapted to the machine state, so that operating data are recorded correspondingly more frequently and more frequently in the more abrasive operation of the machine 7. In this way, the data quantity can be limited to a minimum and, in the case of changing operations with higher wear, it is nevertheless ensured that the service requirement is identified and reported to the manufacturer 1 in good time before the printing press 7 fails. The journal file contains a data-technical description of the printing press 7 in the form of a dynamic system. The data of the log file are automatically evaluated by the control computer 8 and analyzed with regard to the presentation of the fault symptoms. By suitable correlation of the identified fault symptoms taking into account the operational-dependent boundary conditions, a fault at the printing press 7 can be reliably identified.

An already existing remote maintenance system for remote diagnostics can also be improved by using a dynamic log file according to the invention. The printing press 7 is considered here as a dynamic system, which is subject to continuous changes, according to its technical-detailed characteristics. In this case, changes in the physical quantity are detected as dynamic changes, in particular, as soon as the observed values show a clear trend or the values change relative to the corresponding component. For this purpose, the motor current of the drive motor which executes the movement in the printing unit 10 by the spindle mechanism is detected in each of the two printing presses 10 by means of a current sensor 11. In this case, the time-current profile changes in the event of a fault, since, for example, the pitch of the spindle is contaminated in the observation time interval and a slowing down of the mechanical device therefore occursBy suitable observation of the dynamic process, an early detection of an imminent failure can thus be achieved, i.e. the motor can no longer rotate at all at a certain time due to the slowness. The observation time interval is decisive here and therefore must be adapted accordingly when detecting and storing technical data for the fault sign analysis. If the observation time interval is not suitable selectively, it cannot be determined whether there is merely a fluctuation around the median value or an upward or downward trend.

Furthermore, dynamic changes of the functional components are identified by direct comparison between the components. The detected operating data are evaluated against one another. This compares, for example, the current consumption of a drive motor in one printing unit 10 with a similar or identical drive motor in another printing unit 10. In this way, the current profiles of all comparable drive motors in the printing press 7 can be compared with one another. Additionally, a comparison with the drive motors of the other machines 7 can also be effected by providing their data via the internet connection 9. The detection of the operating data is only meaningful if the actuator is also moved. For this reason, the observation time intervals and the detection of the operating data are limited to the following time intervals: during the time interval the drive motor is active and executes the adjusting movement.

In this case, the observation time interval itself can also be used decisively for the analysis of the fault symptoms, so that, as a measure, for example, the time for the corresponding control motors in the other printing units 10 to pass through a defined path in a defined time interval is measured. The operating mode can also be used, for example, when other physical measured variables, such as voltage, current, torque, etc., are not measurable or corresponding sensor means are not present. The failure analysis is performed based on the equivalent characteristics of the drive motor. In the case of actuating drives, it is sufficient to perform a position feedback of the actuating drive, for example a zero position or a limit switch limit, only during a desired time interval. In this way, it is possible to detect the operating data only when the operating data are also meaningful, i.e. when the component concerned is actually active. The storage of data can also be increased in the case of increased loading of the machine, so that maintenance measures can be requested from the manufacturer 1 in good time before the machine fails. The dynamic log file according to the invention thus enables a flexible, reliable and data-saving operational monitoring of the machine 7 and reliably prevents failures, since maintenance requirements can be required in a timely manner.

List of reference numerals

1 manufacturer

2 management computer

3 Screen

4 service personnel

6 Printer operator

7 printing machine

8 printing machine computer

9 Internet connection

10 printing mechanism

11 Current sensor

12 keyboard

Claims

1. Method for determining a maintenance or repair requirement in a machine (7) having a control computer (8), wherein operating data are detected during operation of the machine (8) and stored in a file on the control computer (8),

It is characterized in that the preparation method is characterized in that,

The rules according to which the operating data are stored in the file depend on the state of the machine (7), wherein the rules are dynamically adapted to the changing machine state when the state of the machine changes, and the operating data are stored according to the changing rules, and the time or time interval at which the operating data are stored in the file depends on the machine state.

2. Method according to claim 1, characterized in that the operating data to be detected are stored in the file only if they lie outside predefined tolerance limits stored in the control computer (8).

3. Method according to claim 2, characterized in that the tolerance limit lies below a maximum limit at which failure of the machine (7) is expected.

4. Method according to claim 1 or 2, characterized in that the operational data comprises the course of current changes while a drive motor in the machine (7) is running.

5. Method according to claim 1 or 2, characterized in that the operating data of a component of the machine is compared with the operating data of a same or similar component of the machine (7) and the operating data is stored in the file only in the case of a deviation.

6. Method according to claim 5, characterized in that the operating data of the components of the machine (7) are detected or stored only during the time intervals in which the components are active.

7. Method according to claim 1 or 2, characterized in that a control computer (8) of the machine (7) is connected to the remotely located computer (2) via a network connection (9) and that the control computer (8) matches the rules for detecting and storing the operating data in the file taking into account the data of the remotely located computer (2).

8. Method according to claim 1 or 2, characterized in that the control computer (8) is connected via a network connection (9) to a remotely located control computer (8) of another machine (7) and the rules for detecting and storing operating data in the file are adapted taking into account the data stored in the remotely located control computer (8).

9. Method according to claim 1 or 2, characterized in that the machine (7) is a printing press.