CN114065958A - Preventive active maintenance processing method and system for non-standard equipment - Google Patents
Preventive active maintenance processing method and system for non-standard equipment Download PDFInfo
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Abstract
The invention discloses a preventive active maintenance processing method and system for non-standard equipment, and relates to the field of equipment preventive maintenance management. The method comprises the following steps: acquiring equipment data of non-standard equipment, and acquiring important parameters of the non-standard equipment from the equipment data; acquiring process data and equipment component states in the production process of non-standard equipment; analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening in the production process of the non-standard equipment according to the analysis result; and analyzing the problems according to the alarm information and/or the early warning information and providing matched preventive maintenance suggestions. The invention can keep the equipment in a healthy state all the time, thereby providing guarantee for high quality and high yield of products, achieving low operation cost of enterprises and improving the competitiveness of the enterprises; and the system of the invention realizes real omnibearing service for obviously improving efficiency by recording data analysis and optimizing suggestion functions.
Description
Technical Field
The invention relates to the field of preventive maintenance management of equipment, in particular to a preventive active maintenance processing method and system for non-standard equipment.
Background
The non-standard equipment is non-standard equipment, namely equipment which is not manufactured according to the unified industry standard and specification issued by the state, but is designed and manufactured according to the use requirement of the equipment; and devices that do not have an appearance or performance within the national device catalog.
At present, maintenance and repair of non-standard equipment mostly stay in a passive maintenance mode, namely, maintenance is performed only when the non-standard equipment fails, a large gap exists between the management level and the increasing operation management requirement, and the main problems exist as follows:
1. the source is not found in the fault treatment, the fault happens repeatedly, and the treatment is permanent and permanent;
2. preventive maintenance stays on the surface, tracking is not performed, and the implementation effect is not obvious;
3. the fault equipment is maintained by a manufacturer, the fault reason is unknown, and the maintenance cost is higher;
the above problems result in the reduction of the reliability and the working efficiency of the non-standard equipment, the high maintenance cost increases the operation cost of the enterprise, the negative influence is generated on the enterprise using the non-standard equipment, and the normal operation of the enterprise is influenced.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a preventive active maintenance processing method and system for non-standard equipment.
In a first aspect, an embodiment of the present invention provides a method for processing preventative active maintenance of non-standard devices, including:
step S1: acquiring equipment data of non-standard equipment, and acquiring important parameters of the non-standard equipment from the equipment data;
step S2: acquiring process data and equipment component states in the production process of non-standard equipment;
step S3: analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening in the production process of non-standard equipment according to the analysis result;
step S4: and analyzing the problems according to the alarm information and/or the early warning information and providing matched preventive maintenance suggestions.
In a second aspect, an embodiment of the present invention further provides a preventative active maintenance processing system for non-standard equipment, including:
the acquisition module is used for acquiring equipment data of the non-standard equipment and acquiring important parameters of the non-standard equipment from the equipment data;
the acquisition module is used for acquiring process data and equipment component states in the production process of the non-standard equipment;
the analysis intervention module is used for analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening the production process of the non-standard equipment according to the analysis result;
and the analysis providing module is used for analyzing the problems and providing matched preventive maintenance suggestions according to the alarm information and/or the early warning information.
In a third aspect, an embodiment of the present invention further provides a device for processing preventative active maintenance for non-standard devices, where the device includes at least one processor, a memory, and instructions stored on the memory and executable by the at least one processor, and the at least one processor executes the instructions to implement the method for processing preventative active maintenance for non-standard devices.
In a fourth aspect, an embodiment of the present invention further provides a computer-readable storage medium, which includes a computer program and when the computer program runs on a device, causes the device to execute the above method for processing active preventative maintenance for non-standard devices.
In a fifth aspect, an embodiment of the present invention further provides a chip, which is coupled to a memory and configured to execute a computer program stored in the memory to perform any one of the above methods for preventive active maintenance processing for non-standard devices.
Compared with the prior art, the invention has the following advantages:
according to the technical scheme, the quality problem which may occur when the non-standard equipment is produced and the problem which affects the production efficiency and the productivity and is caused by using the non-standard equipment can be found, tracked and determined at an early stage, the generated problem is prevented in advance, so that the quality problem does not occur, the equipment is kept in a healthy state all the time, and therefore, the high productivity is guaranteed, the non-standard equipment has stable quality, the equipment downtime is obviously reduced, the resource/material waste is reduced, the scrapping and the loss are avoided, and the low cost of enterprise operation is achieved; and the system of the invention realizes real omnibearing service for obviously improving efficiency by recording data analysis and optimizing suggestion functions.
Drawings
Fig. 1 is a flowchart of a preventative active maintenance processing method for non-standard equipment according to an embodiment of the present invention;
fig. 2 and fig. 3 are flowcharts of a preventive active maintenance processing method for non-standard equipment according to a second embodiment of the present invention;
fig. 4 is a block diagram of a preventative active maintenance processing system for non-standard devices according to a third embodiment of the present invention.
Detailed Description
The present application provides a method and a system for preventive active maintenance processing of non-standard devices, and the following describes in detail the embodiments of the present application with reference to the accompanying drawings. Examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the drawings are exemplary only for the purpose of explaining the present application and are not to be construed as limiting the present application.
It will be understood by those within the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention are described in further detail below with reference to the accompanying drawings.
Example one
An embodiment of the present invention provides a method for processing preventative active maintenance of non-standard devices, as shown in fig. 1, including:
step S1: acquiring equipment data of non-standard equipment, and acquiring important parameters of the non-standard equipment from the equipment data;
specifically, in this embodiment, step S1 includes: acquiring equipment data of non-standard equipment through a sensor, and acquiring standard parameters of the non-standard equipment from the equipment data;
optionally, step S1 may further include: displaying important parameters on a PC or a mobile device in a plurality of ways;
step S2: acquiring process data and equipment component states in the production process of non-standard equipment;
optionally, in this embodiment, the acquired process data includes not only real-time data but also historical data, and different process data may be acquired in different manners;
in this embodiment, in step S2, process data and device component states in the production process of the non-standard device are acquired by the sensor;
optionally, step S2 may further include: displaying process data, device component status in a variety of ways on a PC or mobile device;
optionally, in this embodiment, the sequence of step S1 and step S2 may be switched;
step S3: analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening in the production process of the non-standard equipment according to the analysis result;
specifically, the alarm information and/or the early warning information in the embodiment can remind the staff of paying attention to the problems which may occur; for example, an early warning line and a corresponding warning light are arranged, a green light indicates that the analysis result is normal, a yellow light indicates that part of the analysis result is normal and part of the analysis result is abnormal, and a red light indicates that all the analysis results are abnormal;
optionally, in this embodiment, outputting corresponding alarm information and/or early warning information according to the analysis result includes: sending corresponding alarm information and/or early warning information of different levels to personnel of different levels according to the analysis result;
in the embodiment, the process of intervening the non-standard equipment is assisted by the analysis result to improve the production capacity and reduce the production cost; for example, the progress of the whole production process is adjusted according to the output and the material quantity of non-standard equipment in the analysis result;
step S4: analyzing the problems according to the alarm information and/or the early warning information and providing matched preventive maintenance suggestions;
optionally, the matched preventive maintenance recommendation in this embodiment includes: providing the downtime, the production time, the data (such as the working time and the like) of production personnel, providing the data base for analyzing the obtained supply production output, the material consumption per month every day and week, comparing the set target consumption value and carrying out statistical analysis on the loss/rejection analysis; the method can also comprise the following steps: and providing other resource consumption data such as suggestions for saving resources when water, electricity and gas are consumed too much, and the like. Further, the method of this embodiment further includes:
establishing an expert database, namely establishing a corresponding relation according to the analysis result, the corresponding alarm information and/or early warning information and the matched preventive maintenance suggestion and storing the corresponding relation into a storage area;
optionally, the establishing of the patent database may be performed before acquiring device data of the non-standard device, and preset device features to be acquired by the non-standard device, a preset maintenance threshold corresponding to the device features, alarm information and/or early warning information, and a matched preventive maintenance suggestion; and then, acquiring equipment data of the equipment characteristics.
Optionally, the creating an expert database further includes: generating statistical conditions (such as statistics of problem types and times, statistics of misoperation times, statistics of material consumption of stock preparation, statistics of downtime and times, maintenance results and times, and the like) according to the stored data; the problems can be accurately judged according to the statistical conditions and a more optimized solution can be pushed (for example, the same part is blocked in the production process every time, a suggestion for replacing a new spare part is provided);
in this embodiment, after each automatic maintenance, the system establishes a corresponding relationship between the analysis result, the corresponding alarm information and/or the early warning information, and the matched preventive maintenance advice, and stores the corresponding relationship into the storage area, and each automatic maintenance case is stored into the expert database, so that the expert database is more and more complete and huge, the maintenance advice and the solution are further refined, and the expert database is used as a reference for a subsequent maintenance process, so that the problem which may occur when non-standard equipment is produced can be accurately solved in advance.
Further, the creating of the expert database according to this embodiment further includes: and generating and storing a production report according to the analysis result, wherein the production report can provide a basis for subsequent production management optimization.
The expert database in the embodiment can provide reliable and timely support for remote service.
As a further improvement of the method of the present embodiment, the method further includes:
and a feedback adjusting step, namely acquiring a preventive maintenance result and/or an alarm processing result, and adjusting important parameters of the non-standard equipment, an acquisition range of process data and/or a preset maintenance threshold and/or a preset weight of characteristic parameters and/or a suggested pushing mode according to the preventive maintenance result and/or the alarm processing result. And a feedback regulation step is added to realize closed-loop feedback regulation, so that the preventive maintenance processing method of the non-standard equipment is further perfected.
As a further improvement of the maintenance processing method, the preventative active maintenance processing method of the non-standard equipment further comprises the following steps:
and an upgrading step, namely, important parameters needing to be acquired are modified and/or a pushing mode is recommended and/or preventive maintenance suggestions and/or alarm processing suggestions are recommended to be upgraded.
The upgrading step in this embodiment may be performed remotely by a user, and the parameters to be upgraded are modified remotely.
Example two
The second embodiment of the present invention provides a preventive active maintenance processing method for non-standard equipment, which is described in detail by taking the quality, productivity and efficiency of the epoxy resin vacuum casting equipment as an example.
As shown in fig. 2, a detailed flow chart for maintaining the quality of the epoxy vacuum casting equipment;
step 201: obtaining important parameters of epoxy resin vacuum pouring equipment: stable material ratio, optimal degassing state and ideal temperature;
step 202: obtaining the conditions of the production process of epoxy resin vacuum pouring equipment: no.x O-ring failure, no.x cylinder failure, curing agent end metering pump failure, curing agent end valve failure, too much/too little curing agent, too much/too little resin, too much/too little additive;
step 203: the generated analysis results are that the mixture ratio is unqualified, the vacuum is realized, the material temperature is not proper, and logic control actions such as display, alarm and emergency stop are performed according to the analysis results;
step 204: eradicate the source of possible quality problems, and provide matched preventive maintenance recommendations as follows: systematically to analyze to determine the source that ultimately caused the problem, to find its root before the problem becomes serious, and to resolve the problem before it becomes serious and will cause damage.
FIG. 3 is a detailed flow chart for maintaining the capacity and efficiency of an epoxy vacuum casting apparatus;
step 301: obtaining important parameters of epoxy resin vacuum pouring equipment: the working state of the motor/pump group is good, the heating system is effectively controlled, the proportioning control is effective and accurate, the pouring process is smooth, the circulating valve is controlled well, and the vacuum condition of the system is excellent;
step 302: obtaining the conditions of the production process of epoxy resin vacuum pouring equipment: the method comprises the following steps of (1) gear breakage of a speed reducer, shaft breakage of the speed reducer, failure of a curing agent end speed change motor, failure of a curing agent end valve, failure of a driving system, leakage and failure of a control system;
step 303: the generated analysis result is that the production/pause cannot be realized, the waiting is realized, the equipment operation state is not good, and logic control actions such as display, alarm and emergency stop are performed according to the analysis result;
step 304: production management taboos such as low productivity, waiting or production stoppage and the like are avoided, and matched preventive maintenance suggestions are provided: systematically to analyze to determine the source that ultimately caused the problem, to find its root before the problem becomes serious, and to resolve the problem before it becomes serious and will cause damage.
EXAMPLE III
A third embodiment of the present invention provides a preventative active maintenance processing system for non-standard devices, which may be disposed on a PC or a mobile device, as shown in fig. 4, the system of this embodiment includes:
the acquisition module 401 is configured to acquire device data of non-standard devices and acquire important parameters of the non-standard devices from the device data;
specifically, in this embodiment, the acquisition module 401 is specifically configured to acquire device data of the non-standard device through a sensor, and acquire a standard parameter of the non-standard device from the device data;
optionally, the acquisition module 401 is further configured to display important parameters in multiple ways on a PC or a mobile device;
an obtaining module 402, configured to obtain process data and a device component state in a non-standard device production process;
optionally, in this embodiment, the process data includes not only real-time data but also historical data, and the obtaining module may obtain different process data in different ways;
in this embodiment, the obtaining module 402 is specifically configured to obtain process data and device component states in a non-standard device production process through a sensor;
optionally, the obtaining module is further configured to display the process data and the device component status in multiple ways on the PC or the mobile device;
the analysis intervention module 403 is configured to analyze the process data and the state of the device component with reference to the important parameter to generate an analysis result, send corresponding alarm information and/or early warning information according to the analysis result, and intervene in the production process of the non-standard device according to the analysis result;
specifically, the alarm information and/or the early warning information in the embodiment can remind the staff of paying attention to the problems which may occur; for example, the analysis intervention module sends corresponding alarm information and/or early warning information through the warning lamp, a green lamp indicates that the analysis result is normal, a yellow lamp indicates that part of the analysis result is normal and part of the analysis result is abnormal, and a red lamp indicates that all the analysis results are abnormal;
an analysis providing module 404 for analyzing the occurring problem according to the alarm information and/or the early warning information and providing a matched preventive maintenance suggestion;
further, the system of the present embodiment further includes:
establishing an expert database module for establishing a corresponding relation according to the analysis result, the corresponding alarm information and/or early warning information and the matched preventive maintenance suggestion and storing the corresponding relation into a storage area;
the expert database module is also established for generating statistical conditions (such as statistics of problem types and times, statistics of misoperation times, statistics of material consumption of stock preparation, statistics of downtime and times, maintenance results and times statistics and the like) according to the stored data; the problems can be accurately judged according to the statistical conditions and a more optimized solution can be pushed;
and the expert database module is also established and used for generating and storing a production report according to the analysis result, and the production report can provide a basis for subsequent production management optimization.
The system of this embodiment further comprises: and the feedback debugging module is used for acquiring the preventive maintenance result and/or the alarm processing result, and adjusting important parameters of the non-standard equipment, the acquisition range of the process data and/or a preset maintenance threshold and/or a preset weight of the characteristic parameters and/or a suggested pushing mode according to the preventive maintenance result and/or the alarm processing result. And a feedback regulation step is added to realize closed-loop feedback regulation, so that the preventive maintenance processing method of the non-standard equipment is further perfected.
The system of this embodiment further comprises: and the upgrading module is used for modifying important parameters to be acquired and/or recommending a pushing mode and/or a preventive maintenance recommendation and/or an alarm processing recommendation so as to upgrade.
Different users log in the system, can check the expert database for learning, experts can remotely train other users through the system, can give remote maintenance and maintenance guidance aiming at sent alarm information and/or early warning information, or experts can watch the problems of on-site non-standard equipment through video connection and VR/AR technology and give guidance suggestions, and then the scheme is stored in the expert database.
The system of the embodiment can not only display the equipment state and alarm; but also can actively analyze, diagnose and treat the problems; the system of the embodiment is suitable for the production process of the non-standard equipment, and can be used for maintaining and processing problems possibly occurring in the production process in advance, so that the production quality, the efficiency and the capacity of the non-standard equipment can be kept at certain stability; the system is provided with enough sensors and monitoring devices at important positions for acquiring data and actively finding potential risks/problems in the production process, and reminding or giving action suggestion areas to eliminate the potential risks/problems before the system lights up red; the expert database of the system is controlled by combining the PLC of the equipment, so that the remote toolkit can be greatly expanded, and the integral professional service can be provided for customers by utilizing the cloud technology, the big data calculation and the optimized analysis capability.
Optionally, an embodiment of the present application further provides an apparatus for preventative active maintenance processing of a non-standard apparatus, where the apparatus includes at least one processor, a memory, and instructions stored on the memory and executable by the at least one processor, and the at least one processor executes the instructions to implement the method for preventative active maintenance processing of a non-standard apparatus in the foregoing embodiment. When the device is a chip system, the device may be composed of a chip, and may also include a chip and other discrete devices, which is not specifically limited in this application embodiment; the chip is coupled to the memory for executing the computer program stored in the memory to perform the method for preventive active maintenance processing for non-standard devices disclosed in the above embodiments.
In the above embodiments, the implementation may be wholly or partially realized by software, hardware, firmware, or any combination thereof. When implemented using a software program, may be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer programs. The procedures or functions described in accordance with the embodiments of the present application are generated in whole or in part when the computer program is loaded and executed on a device. The computer program may be stored in a computer readable storage medium or transmitted from one computer readable storage medium to another computer readable storage medium, for example, the computer instructions may be transmitted from one base station, device, server, or data center to another base station, device, server, or data center by wire (e.g., coaxial cable, fiber optic, Digital Subscriber Line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.). The computer-readable storage medium can be any available medium that can be accessed by the device or can comprise one or more data storage devices, such as a server, a data center, etc., that can be integrated with the medium. The usable medium may be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., Solid State Disk (SSD)), among others. In an embodiment of the present application, the apparatus may include the system described above.
While the present application has been described in connection with various embodiments, other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed application, from a review of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the word "a" or "an" does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
Although the present application has been described in conjunction with specific features and embodiments thereof, it will be evident that various modifications and combinations can be made thereto without departing from the spirit and scope of the application. Accordingly, the specification and figures are merely exemplary of the present application as defined in the appended claims and are intended to cover any and all modifications, variations, combinations, or equivalents within the scope of the present application. It will be apparent to those skilled in the art that various changes and modifications may be made in the present application without departing from the spirit and scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include such modifications and variations as well.
Claims (10)
1. A preventative, active maintenance handling method for non-standard equipment, comprising:
step S1: acquiring equipment data of non-standard equipment, and acquiring important parameters of the non-standard equipment from the equipment data;
step S2: acquiring process data and equipment component states in the production process of non-standard equipment;
step S3: analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening in the production process of non-standard equipment according to the analysis result;
step S4: and analyzing the problems according to the alarm information and/or the early warning information and providing matched preventive maintenance suggestions.
2. The method of claim 1, further comprising:
establishing an expert database, which specifically comprises the following steps: and establishing a corresponding relation according to the analysis result, the corresponding alarm information and/or early warning information and the matched preventive maintenance suggestion and storing the corresponding relation into a storage area.
3. The method of claim 1, further comprising:
the upgrading step specifically comprises the following steps: and modifying the important parameters to be acquired and/or recommending pushing modes and/or preventive maintenance suggestions and/or alarm processing suggestions for upgrading.
4. The method of claim 1, further comprising:
the feedback regulation step specifically comprises the following steps: and acquiring a preventive maintenance result and/or an alarm processing result, and adjusting important parameters of the non-standard equipment, an acquisition range of process data and/or a preset maintenance threshold and/or a preset weight of characteristic parameters and/or a suggested pushing mode according to the preventive maintenance result and/or the alarm processing result.
5. A preventative, active maintenance processing system for non-standard equipment, comprising:
the acquisition module is used for acquiring equipment data of the non-standard equipment and acquiring important parameters of the non-standard equipment from the equipment data;
the acquisition module is used for acquiring process data and equipment component states in the production process of the non-standard equipment;
the analysis intervention module is used for analyzing the process data and the state of the equipment component by referring to the important parameters to generate an analysis result, sending corresponding alarm information and/or early warning information according to the analysis result, and intervening the production process of the non-standard equipment according to the analysis result;
and the analysis providing module is used for analyzing the problems and providing matched preventive maintenance suggestions according to the alarm information and/or the early warning information.
6. The system of claim 5, further comprising:
and establishing an expert database module for establishing a corresponding relation according to the analysis result, the corresponding alarm information and/or early warning information and the matched preventive maintenance suggestion and storing the corresponding relation into a storage area.
7. The system of claim 5, wherein the upgrade module is configured to modify the important parameters to be obtained and/or suggest a push and/or preventive maintenance and/or alert handling suggestion for upgrading.
8. A preventative active maintenance processing device for a non-standard device, the device comprising at least one processor, memory, and instructions stored on the memory and executable by the at least one processor, the at least one processor executing the instructions to implement the method of any one of claims 1 to 4.
9. A computer-readable storage medium, comprising a computer program which, when run on an apparatus, causes the apparatus to perform the method of any one of claims 1 to 4.
10. A chip, wherein the chip is coupled to a memory for executing a computer program stored in the memory to perform the method of any of claims 1-4.
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| CN202111198009.4A CN114065958A (en) | 2021-10-14 | 2021-10-14 | Preventive active maintenance processing method and system for non-standard equipment |
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| CN202111198009.4A CN114065958A (en) | 2021-10-14 | 2021-10-14 | Preventive active maintenance processing method and system for non-standard equipment |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115187006A (en) * | 2022-06-23 | 2022-10-14 | 深圳市卓城科技有限公司 | Intelligent fire-fighting application management system |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115187006A (en) * | 2022-06-23 | 2022-10-14 | 深圳市卓城科技有限公司 | Intelligent fire-fighting application management system |
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