JP2018078421A - Printer monitoring system and printer monitoring method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a printer monitoring system capable of achieving both reduction in a maintenance cost and operation stability of a printer, and a printer monitoring method.SOLUTION: A printer monitoring system 100 predicts a failure of a printer 21. A management server 10 includes: a determination value DB11 in which determination value information for predicting a failure of the printer 21 is registered; a sensor data reception unit 12 which receives sensor data; a failure possibility determination unit 13 which compares the received sensor data with the determination value information and determines whether the printer 21 may fail; a failure possibility notification unit 14 which notifies a user terminal 50 that the printer 21 may fail when the failure possibility determination unit 13 determines that the printer may fail; and a determination value information optimization unit 16 which optimizes the determination value information registered in the determination value DB11 on the basis of the sensor data stored in a sensor data storage unit 15 which stores received sensor data.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a printing press monitoring system and a printing press monitoring method.

  When a failure of a constituent member constituting the printing press occurs and the failure is dealt with, the period during which the printing press is stopped for repair becomes long and the productivity of printed matter is reduced. Therefore, in order to predict the failure of the printing press, for example, the following Patent Document 1 discloses a failure diagnosis system for a printing press.

  A printing press failure diagnosis system described in Patent Document 1 below first prepares a first threshold level for determining an abnormal state and a second threshold level smaller than the first threshold for determining a gray state. . Then, when the measured value of the printing press exceeds the second threshold level, a failure sign determination is performed depending on whether or not the second threshold level is continuously exceeded, or the first threshold level is exceeded. The failure sign determination is performed when the measured value is obtained.

JP 2001-326777 A

  However, in the fault diagnosis system for a printing press described in the above-mentioned Patent Document 1, the first threshold level is set to determine whether or not there is a failure, and whether or not there is a possibility that a failure will occur. Although the second threshold level is set for gray zone determination, the second threshold is not set based on the concept of failure prediction detection and is ambiguous that it is slightly lower than the first threshold. Stay in setting. Therefore, it is impossible to grasp the status of the components constituting the printing press and to make a prediction based on the failure, and to predict failures due to aging of the components and product life of the printing press. There was a problem that it was not possible.

  Therefore, it is possible to more accurately predict the components that may fail before the failure due to aging of the components of the printing press, and to fail at an appropriate time considering the product life of the printing press It has been desired to realize a printing press monitoring system and a printing press monitoring method capable of achieving both reduction in maintenance costs and operational stability of the printing press by exchanging and maintaining the structural members having the characteristics.

  Accordingly, the present invention has been made to solve the above-described problem, and provides a printing press monitoring system and a printing press monitoring method capable of achieving both reduction in maintenance cost and operation stability of a printing press. With the goal.

  The printing press monitoring system according to the present invention includes one or a plurality of printing presses, a user terminal used by a user of the printing press, a management server that communicates with the printing press and the user terminal via a communication network, The printing press includes a sensor for measuring a physical quantity generated in a component constituting the printing press, and sensor data measured by the sensor in the management server. Sensor data transmission unit for transmitting to the management server, the management server, a determination value database in which determination value information for predicting a failure of the printing press is registered, and a sensor data reception unit for receiving the sensor data The printer may fail by comparing the sensor data received by the sensor data receiver with the judgment value information. A failure possibility determination unit that determines whether or not the printer has failure, and a failure possibility that notifies the user terminal of the failure possibility when the failure possibility determination unit determines that the printing press has a possibility of failure. A determination value registered in the determination value database based on the sensor data stored in the sensor data storage unit; a sensor data storage unit that stores the sensor data received by the sensor data reception unit; And a decision value information optimizing unit for optimizing information.

  Further, in the printing press monitoring system according to the present invention, the management server includes a sensor data extraction unit that extracts the sensor data that has been measured under predetermined conditions from the sensor data stored in the sensor data storage unit, The determination value information optimization unit may optimize the determination value information based on the sensor data extracted by the sensor data extraction unit.

  Furthermore, in the printing press monitoring system according to the present invention, the sensor may include an acceleration sensor, a current sensor, a temperature sensor, a humidity sensor, or other sensors that measure physical quantities.

  The printing press monitoring method according to the present invention includes one or a plurality of printing presses, a user terminal used by a user of the printing press, and a management server that communicates with the printing press and the user terminal via a communication network. The printer includes a sensor that measures a physical quantity generated by a component that constitutes the printer, and sensor data measured by the sensor is included in the printer. Sensor data is transmitted to the management server, and the management server includes a judgment value database in which judgment value information for predicting a failure of the printing press is registered, and sensor data for receiving the sensor data The print processing by comparing the sensor data received by the reception processing and the sensor data reception processing with the determination value information A failure possibility determination process for determining whether or not the printer has a possibility of failure, and when it is determined by the failure possibility determination process that the printing press has a possibility of failure, the user terminal is given a possibility of failure. A failure possibility notification process to be notified, a sensor data storage process for storing the sensor data received by the sensor data reception process, and the sensor data stored by the sensor data storage process are registered in the determination value database. A determination value information optimization process for optimizing the determination value information.

  According to the present invention, it is possible to provide a printing press monitoring system and a printing press monitoring method capable of achieving both reduction in maintenance cost and operational stability of a printing press.

It is a block diagram which shows the structural example of the printing press monitoring system which concerns on this embodiment. It is a block diagram which shows the structural example of the management server which concerns on this embodiment. It is a block diagram which shows the structural example of the printing press and user terminal which concern on this embodiment. It is a figure which shows the example of the sensor data measured with the sensor. It is a flowchart which shows the printing press monitoring process of a printing press monitoring system. It is a figure for demonstrating an example of the judgment value information stored in judgment value DB. It is a flowchart which shows the judgment value information optimization process of a printing press monitoring system. It is a figure which shows the specific example of a form of a printing machine. It is a figure which shows the structural example of the printing press monitoring system which concerns on an Example.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments for carrying out the invention will be described with reference to the drawings. The following embodiments do not limit the invention according to each claim, and all combinations of features described in the embodiments are not necessarily essential to the solution means of the invention. .

  FIG. 1 is a block diagram illustrating a configuration example of a printing press monitoring system according to the present embodiment. FIG. 2 is a block diagram illustrating a configuration example of the management server according to the present embodiment. FIG. 3 is a block diagram illustrating a configuration example of the printing press and the user terminal according to the present embodiment. FIG. 4 is a diagram illustrating an example of sensor data measured by the sensor. Hereinafter, a configuration example of the printing press monitoring system 100 according to the present embodiment will be described.

  The printing press monitoring system 100 according to the present embodiment includes a management server 10, printing presses 21 to 2N (N is an arbitrary integer), and a user terminal 50 used by users of the printing presses 21 to 2N. The management server 10, the printers 21 to 2N, and the user terminal 50 are each connected by a communication network 60 such as the Internet.

  The management server 10 is managed by, for example, a system administrator of the printing press monitoring system 100 according to the present embodiment, and includes an information processing apparatus such as a WWW server. The management server 10 has various functions such as a function of providing information on the possibility of failure of the printing machines 21 to 2N to the user terminal 50 used by the user.

  As shown in FIG. 2, the management server 10 includes a determination value DB 11, a sensor data receiving unit 12, a failure possibility determination unit 13, a failure possibility notification unit 14, a sensor data storage unit 15, and determination value information. An optimization unit 16 and a sensor data extraction unit 17 are provided. The determination value DB 11, sensor data receiving unit 12, failure possibility determination unit 13, failure possibility notification unit 14, sensor data storage unit 15, determination value information optimization unit 16, and sensor data extraction unit 17 are stored in the management server 10. It may be provided inside or outside.

  The determination value DB 11 is a database in which determination value information for predicting a failure of the printing presses 21 to 2N is stored.

  The sensor data reception unit 12 receives sensor data transmitted from the sensor data transmission unit 32 of the printing machines 21 to 2N while being measured by the sensors 31 installed in the printing machines 21 to 2N.

  The failure possibility determination unit 13 compares the sensor data received by the sensor data reception unit 12 with the determination value information stored in the determination value DB 11, and determines whether the printing presses 21 to 2N have a possibility of failure. To do.

  The failure possibility notification unit 14 notifies the user terminal 50 of a failure possibility when the failure possibility determination unit 13 determines that the printing presses 21 to 2N have a failure possibility.

  The sensor data storage unit 15 is a storage medium that stores the sensor data received by the sensor data receiving unit 12.

  The determination value information optimization unit 16 optimizes the determination value information registered in the determination value DB 11 based on the sensor data stored in the sensor data storage unit 15.

  The sensor data extraction unit 17 extracts sensor data that has been measured under predetermined conditions from the sensor data stored in the sensor data storage unit 15.

  The printing machines 21 to 2N are machines that perform printing, and have a function of transmitting and receiving information to and from the management server 10 through the communication network 60.

  As shown in FIG. 3, the printing machines 21 to 2N manage the sensor 31 that measures the physical quantities of the constituent members constituting the printing machines 21 to 2N or the entire printing machines 21 to 2N, and the sensor 31. And a sensor data transmission unit 32 for transmission to the server 10.

  The sensor 31 is for measuring the physical quantity of the constituent members constituting the printing presses 21 to 2N or the entire printing presses 21 to 2N. For example, the sensor 31 is installed on a constituent member to be monitored having a possibility of failure. As the sensor 31, for example, an acceleration sensor, a current sensor, a temperature sensor, a humidity sensor, or the like can be used. As shown in FIG. 4, the sensor data measured by the sensor 31 includes, for example, measurement time, acceleration, current, temperature, operation time, and the like.

  The sensor data transmission unit 32 is for transmitting the sensor data measured by the sensor 31 to the management server 10.

  The user terminal 50 is configured by an information processing apparatus such as a personal computer used by users of the printing machines 21 to 2N, and has a function of transmitting and receiving information to and from the management server 10 through the communication network 60.

  The user terminal 50 includes a failure possibility notification receiving unit 51 that receives a failure possibility notification from the management server 10, and a failure possibility notification display unit 52 that displays the received failure possibility notification on the screen of the user terminal 50. And comprising.

  The configuration example of the printing press monitoring system 100 according to the present embodiment has been described above. Next, an operation example of the printing press monitoring system 100 according to the present embodiment will be described. The operation of the printers 21 to 2N will be mainly described using the printer 21. Note that the printing machines 22 to 2N have the same configuration as the printing machine 21 and execute the same operation. FIG. 5 is a flowchart showing the printing press monitoring process of the printing press monitoring system. FIG. 6 is a diagram for explaining an example of determination value information stored in the determination value DB. FIG. 7 is a flowchart showing determination value information optimization processing of the printing press monitoring system.

  In the printing machine 21, the sensor 31 installed in the constituent member constituting the printing machine 21 measures the physical quantity of the constituent member or the entire printing machine 21 (step S <b> 101).

  The printing machine 21 transmits the sensor data measured by the sensor 31 to the management server 10 (step S102). As shown in FIG. 4, in this embodiment, the frequency at which the printing machine 21 transmits sensor data to the management server 10 is set to be every second, but can be changed as appropriate.

  The management server 10 receives the sensor data transmitted from the printing press 21 (step S103), and stores the received sensor data (step S104).

  The management server 10 compares the sensor data stored in the sensor data storage unit 15 with the determination value information registered in the determination value DB 11 to determine whether or not there is a possibility that the printing machine 21 may break down ( Step S105). When the management server 10 determines that there is a possibility that the printing machine 21 may break down (Y in step S105), the management server 10 notifies the user terminal 50 of the possibility of failure (step S106).

  For example, as shown in FIG. 6, in the failure possibility determination process, first, among sensor data measured in the past, the average value or the median value of the magnitude of acceleration at which the failure of the component member on which the sensor 31 is installed has occurred. Get. Then, the magnitude of the acceleration of the sensor data measured by the sensor 31 is plotted against the operating time to create an approximate curve, and curves with standard deviations 1σ and 2σ of the approximate curve are created from the sensor data measured in the past. To do.

  Then, when the magnitude of the acceleration with the standard deviation 2σ reaches the average value or the median value of the magnitude of the acceleration at which the failure has occurred, it is assumed that the constituent members of the printing machine 21 may break down. “Caution” can be notified. Moreover, when the magnitude of the acceleration with the standard deviation 1σ reaches the average value or the median value of the magnitude of the acceleration at which the failure has occurred, the failure possibility “has a possibility that the constituent members of the printing press 21 may fail. “Warning” can be notified.

  Further, from the sensor data measured in the past, the average value of the period from the time when the magnitude of the acceleration with the standard deviations 2σ and 1σ reaches the average value or the median of the magnitude of the acceleration at which the fault occurs until the fault occurs or The median can be calculated to predict the lifetime of the component related to the sensor data, and the “life prediction” can be notified together with the “caution” or “warning” of the possibility of failure. With this configuration, the user of the printing press monitoring system 100 according to the present embodiment can know that the printing press 21 has a possibility of failure before the printing press 21 breaks down. Since the lifetimes of the constituent members can be known, the maintenance of the printing press 21 can be performed at an appropriate time, and the maintenance cost of the printing press 21 can be reduced and operational stability can be obtained. Note that the standard deviation to be designated is not necessarily 1σ or 2σ. Moreover, it is not necessary to stick to the standard deviation for the indicators.

  In the failure possibility determination process, for example, a predetermined vibration frequency is registered in the determination value DB 11 by performing FFT (Fast Fourier Transform) analysis on acceleration in the sensor data measured by the sensor 31. If the condition is reached, it can be determined that there is a possibility of failure.

  Further, in the failure possibility determination process, for example, the magnitude of the acceleration with respect to the operating time when the printing press 21 is operated and the displacement of the current amount are the magnitude of the acceleration with respect to the operating time when the printing press 21 has been operated in the past. When it deviates from the tendency of the sheath to change the amount of current, it can be determined that there is a possibility of failure.

  The user terminal 50 receives the notification of the possibility of failure from the management server 10 (step S107), and displays the notification of the possibility of failure (step S108). For example, the management server 10 notifies the user terminal 50 of the possibility of failure of the printing press 21 from the management server 10 by notifying the user terminal 50 of the possibility of failure by e-mail. By receiving the e-mail and opening it, a notification of the possibility of failure can be displayed on the screen of the user terminal 50. Further, for example, the management server 10 notifies the user terminal 50 of the possibility of failure of the printing press 21, and after the user terminal 50 receives the notification of the possibility of failure, the user terminal 50 sounds a warning sound. Also good.

  On the other hand, when the management server 10 notifies the user terminal 50 of the possibility of failure (step S106), the management server 10 issues a start command for the determination value information optimization process (step S109).

  In the determination value information optimization processing shown in FIG. 7, the management server 10 determines whether or not the acquisition of sensor data is completed (step S201), and determines that the acquisition of sensor data is completed (in step S201). Y) Sensor data whose measurement is completed under a predetermined condition is extracted (step S202).

  Here, for example, whether or not the acquisition of the sensor data is completed is determined by transmitting the sensor data from the printing machine 21 for a predetermined period after the management server 10 notifies the user terminal 50 of the possibility of failure (step S106). If the management server 10 does not receive the sensor data, it can be determined that the acquisition of the sensor data is completed. In addition, when a notification that a component has been exchanged is transmitted from the printing press 21 or the user terminal 50 and the management server 10 receives the notification, it is determined that the acquisition of the sensor data is completed. Can do.

  The management server 10 extracts sensor data that has been measured under predetermined conditions (step S202), and then optimizes determination value information registered in the determination value DB 11 based on the sensor data (step S203).

  The judgment value information optimization process is extracted when the management server 10 notifies the possibility of failure of the constituent members constituting the printing press 21 and the constituent members fail before the replacement of the constituent members. Based on the sensor data of the predetermined condition, for example, the average value or the median value of the magnitude of acceleration at which the failure of the component member in which the sensor 31 measuring under the predetermined condition has occurred may be optimized. it can. In addition, for example, the determination value information optimization process may optimize the calculation standard for the standard deviations 1σ and 2σ based on the extracted sensor data of a predetermined condition. Further, for example, by obtaining the average value or median value of the period from when the magnitude of the acceleration with the standard deviation 1σ or 2σ reaches the average value or median value of the acceleration magnitude at which the failure occurred until the failure occurs, Prediction optimization can be performed.

  As described above, the printing press monitoring system 100 according to the present embodiment not only simply determines whether or not a predetermined reference value is deviated, but also provides optimization based on the acquired sensor data. Determination value information can be obtained, and by using the determination value information, the life of the printing press 21 can be predicted with high accuracy.

  Based on the extracted sensor data, the management server 10 optimizes the decision value information to obtain optimum decision value information (step S203), and then updates the decision value information to the optimum decision value information (step S204). .

  In the present embodiment, since the management server 10 employs a configuration in which the determination value information optimization process is performed after the management server 10 notifies the user terminal 50 of the possibility of failure, information regarding the possibility of failure is always stored as appropriate. Since it is optimized, the decision value information is constantly optimized. Further, in the present embodiment, for example, when the constituent member of the printing press 21 having a possibility of failure is an initial defective product, the sensor data of the constituent member is excluded from the sensor data used for the determination value information optimization process. It is possible to do. Therefore, the life of the printing press 21 can be predicted with high accuracy, the maintenance of the printing press 21 can be performed at an appropriate time, and the maintenance cost and operation stability of the printing press 21 can be obtained.

  The operation example of the printing press monitoring system 100 has been described above. Next, a printing press monitoring system 110 according to an example in which the printing press monitoring system 100 according to the present embodiment is specifically applied to the printing press will be described with reference to FIGS. 8 and 9. Here, FIG. 8 is a diagram showing a specific example of the printing press. FIG. 9 is a diagram illustrating a configuration example of the printing press monitoring system according to the embodiment. In addition, about the structure same or similar to embodiment mentioned above, the same code | symbol may be attached | subjected and description may be abbreviate | omitted.

  As shown in FIG. 8, the printing machine 21 according to the present embodiment includes a paper feeding unit 33 that feeds continuous paper, a printing unit 35 that prints continuous paper, and a folding unit 39 that folds the printed continuous paper. And comprising.

  The paper feeding unit 33 is for setting paper, and it is assumed that the paper fed in the present embodiment uses continuous paper such as winding paper.

  The printing unit 35 is for continuously printing on paper that is continuously fed. The printing method executed by the printing unit 35 may be digital printing or analog printing. Further, single-sided printing or double-sided printing may be used.

  In the present embodiment, the printing unit 35 includes two cylindrical plates 36 and two printing pressure cylinders 37. The plate 36 and the printing pressure cylinder 37 are rotatably supported by a bearing (not shown).

  The folding part 39 is for folding continuous paper. In the present embodiment, the folded continuous paper is conveyed to a conveying device 41 such as a conveyor.

  In the printing press monitoring system 110 according to the present embodiment, as shown in FIG. 9, for example, a sensor 31 is installed on a component to be monitored that has a possibility of failure, such as a bearing or an electronic board (not shown).

  5 and 7 will be described in addition to the reference drawings. The sensor 31 installed in the constituent member of the printing press 21 measures the physical quantity of the constituent member or the entire printing press 21 (step S101), and the measured sensor. Data is transmitted to the management server 10 (step S102).

  In this embodiment, the sensor data measured by each sensor 31 is not particularly limited as shown in FIG. 9, but is aggregated after being aggregated by the reception module 43 that is a cache memory for transmitting and receiving sensor data. The sensor data is transmitted to the management server 10. With such a configuration, sensor data can be transferred at high speed.

  When the management server 10 receives the sensor data measured by the sensor 31 (step S103), the management server 10 stores the sensor data in the sensor data storage unit 15 (step S104). Then, the management server 10 compares the sensor data stored in the sensor data storage unit 15 with the determination value information registered in the determination value DB 11 to determine whether or not the printing press 21 has a possibility of failure. (Step S105). When the management server 10 determines that there is a possibility that the printing machine 21 may break down (Y in step S105), the management server 10 notifies the user terminal 50 of the possibility of failure (step S106).

  The user terminal 50 receives the failure possibility notification from the management server 10 (step S107), and displays the failure possibility notification on the screen of the user terminal 50 (step S108).

  On the other hand, when the management server 10 notifies the user terminal 50 of the possibility of failure (step S106), the management server 10 issues a start command for the determination value information optimization process (step S109).

  In the determination value information optimization process, the management server 10 determines whether or not acquisition of sensor data has been completed (step S201), and if it is determined that acquisition of sensor data has been completed (Y in step S201), a predetermined condition The sensor data for which the measurement has been completed is extracted (step S202). Then, based on the extracted sensor data, the decision value information registered in the decision value DB 11 is optimized (step S203), and the decision value information registered in the decision value DB 11 is updated to the optimum decision value information (step S203). Step S204).

  As mentioned above, although preferred embodiment of this invention was described, the technical scope of this invention is not limited to the range as described in the said embodiment.

  For example, in the above-described embodiment, one user terminal 50 is installed. However, a plurality of user terminals 50 may be installed. That is, various changes or improvements can be added to the above embodiment. It is apparent from the description of the scope of claims that embodiments with such changes or improvements can be included in the technical scope of the present invention.

  100, 110 Printing machine monitoring system, 10 management server, 11 determination value DB, 12 sensor data receiving unit, 13 failure possibility determination unit, 14 failure possibility notification unit, 15 sensor data storage unit, 16 determination value information optimization unit , 17 sensor data extraction unit, 21-2N printer, 31 sensor, 32 sensor data transmission unit, 33 paper feeding unit, 35 printing unit, 36 plate, 37 printing cylinder, 39 folding unit, 41 transport device, 43 receiving module , 50 user terminal, 51 failure possibility notification receiving unit, 52 failure possibility notification display unit, 60 communication network.

Claims (4)

One or more printing presses;
A user terminal used by a user of the printing press;
A management server for communicating with the printing press and the user terminal via a communication network;
A printing press monitoring system for predicting a failure of the printing press comprising:
The printing press
A sensor for measuring a physical quantity generated in a component constituting the printing press;
A sensor data transmission unit that transmits sensor data measured by the sensor to the management server;
Including
The management server is
A judgment value database in which judgment value information for predicting a failure of the printing press is registered;
A sensor data receiving unit for receiving the sensor data;
A failure possibility determination unit that compares the sensor data received by the sensor data reception unit with the determination value information to determine whether or not the printing machine has a possibility of failure;
When the failure possibility determination unit determines that the printing machine has a possibility of failure, a failure possibility notification unit that notifies the user terminal of failure possibility;
A sensor data storage unit for storing the sensor data received by the sensor data receiving unit;
A determination value information optimization unit that optimizes the determination value information registered in the determination value database based on the sensor data stored in the sensor data storage unit;
A printing press monitoring system comprising: The printing press monitoring system according to claim 1,
The management server includes a sensor data extraction unit that extracts the sensor data that has been measured under predetermined conditions from the sensor data stored in the sensor data storage unit,
The printing press monitoring system, wherein the determination value information optimization unit optimizes the determination value information based on the sensor data extracted by the sensor data extraction unit. The printing press monitoring system according to claim 1 or 2,
The printing press monitoring system, wherein the sensor includes an acceleration sensor, a current sensor, a temperature sensor, or a humidity sensor. One or more printing presses;
A user terminal used by a user of the printing press;
A management server for communicating with the printing press and the user terminal via a communication network;
A printing press monitoring method for predicting a failure of the printing press comprising:
The printing press
Including a sensor for measuring a physical quantity generated in a component constituting the printing press,
Performing sensor data transmission processing for transmitting sensor data measured by the sensor to the management server;
The management server is
A judgment value database in which judgment value information for predicting a failure of the printing press is registered;
Sensor data reception processing for receiving the sensor data;
A failure possibility determination process for determining whether or not the printing machine has a possibility of failure by comparing the determination value information with the sensor data received by the sensor data reception process;
When it is determined by the failure possibility determination process that the printing machine has a possibility of failure, a failure possibility notification process for notifying the user terminal of a failure possibility;
A sensor data storage process for storing the sensor data received by the sensor data reception process;
Determination value information optimization processing for optimizing the determination value information registered in the determination value database based on the sensor data stored by the sensor data storage processing;
The printing press monitoring method characterized by performing this.

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