JP2023048863A - Consumption monitoring device - Google Patents

Abstract

To monitor a consumption degree of a sliding related component of a hydraulic device, and to perform inspection and replacement in accordance with a user at a suitable timing.SOLUTION: A consumption degree of a sliding related component which is a component used for a sliding portion of a hydraulic device and a consumption progression speed which is a progression speed thereof are calculated on the basis of an operation history of the hydraulic device, and an inspection and replacement recommendation timing which is a timing at which inspection and replacement of the sliding related component are recommended is calculated on the basis of the consumption degree and the consumption progression speed.SELECTED DRAWING: Figure 2

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a consumption monitoring device for monitoring consumption of parts used in a hydraulic system.

2. Description of the Related Art Conventionally, hydraulic devices such as hydraulic pumps are prevented from malfunctioning or breaking down by inspecting and replacing worn parts before their functions are impaired.

Specifically, for example, the following is performed.
(1) After the device is installed, the user or the supplier inspects and replaces the device at regular intervals.
(2) When an operation monitoring system is added to monitor the usage of parts based on the operating time, number of times of operation, frequency of operation, operating load, etc. of the device, and when the usage exceeds a predetermined threshold in the system In addition, the user is notified of inspection or replacement. An example of this is described in Patent Document 1.

However, the conventional method described above has the following problems.
For example, in the case of (1), if it is left up to the user, there may be a case where the inspection or replacement is not performed reliably because the user does not know when to perform the inspection or replacement.
Even if the supplier conducts inspections and replacements, in the case of heavy use, parts may reach the end of their service life before the next inspection or replacement period, causing the device to malfunction. too much and may incur unnecessary costs.

In the case of (2), the user who received the notification does not stop the device immediately, but continues to use it until the device can be stopped, such as when inspection/replacement arrangements are made or lot work is completed. Therefore, the notification of the actual inspection/replacement recommendations is given with a certain amount of time to spare, but as in the case of (1), in the case of heavy use, there is a risk that the parts will be damaged between the notification and the inspection/replacement. On the other hand, in the case of light use, the notification is too early, and inspection and replacement of parts may be performed much earlier than the time when they are actually needed, resulting in unnecessary costs.

Japanese Patent Application Laid-Open No. 2021-055708

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and is directed to monitoring the degree of wear of sliding-related parts of a hydraulic system, and enabling inspection and replacement at appropriate times according to the user. It is intended as much as possible.

That is, the wear monitoring device according to the present invention is based on the operation history of the hydraulic device, and it is possible to determine the degree of wear of the sliding-related parts, which are the parts used in the sliding portion of the hydraulic device, and the progress of wear, which is the rate of wear. A wear degree calculation unit that calculates the speed, and a recommended inspection/replacement timing calculation unit that calculates a recommended inspection/replacement timing, which is the time at which inspection/replacement of the sliding-related part is recommended, based on the wear degree and the wear progress speed. and

With such a system, the usage frequency and strength of use of the hydraulic device can be estimated from the rate of progress of wear, and the recommended timing for inspection and replacement of sliding-related parts can be determined based on the rate of progress of wear. Therefore, regardless of heavy use or light use, it is possible to recommend inspection and replacement at appropriate times according to the user's usage conditions. As a result, it is possible to prevent inspection and replacement from being done in time or, conversely, from being too early, so that maintenance can be performed reliably and without waste.

It is possible to perform reliable and efficient maintenance on the hydraulic system.

1 is an overall block diagram of a consumption monitoring device in one embodiment of the present invention; FIG. It is a flowchart which shows operation|movement of the consumption monitoring apparatus in the same embodiment. FIG. 4 is a data structure diagram showing a rotational speed-increased temperature table D2 in the same embodiment; FIG. 4 is a data structure diagram showing a temperature-life time table D3 in the same embodiment; It is a graph which shows the relationship between the sliding part temperature of an oil seal, and life. 4 is a graph showing the relationship between the number of revolutions of a hydraulic pump, the shaft diameter, and the temperature rise of an oil seal.

An embodiment of the present invention will be described below with reference to the drawings.

A consumption monitoring device 100 according to the present embodiment, as shown in FIG. It is calculated to notify the user of the recommended inspection/replacement timing of the oil seal 12, which is a component. The oil seal 12 here is mounted between the output shaft (hereinafter referred to as shaft 11) of the pump and the casing to prevent oil, which is the working fluid, from leaking from the casing or the like. is.

This consumption monitoring device 100 is a so-called computer comprising a CPU, a memory, an I/O port, an A/D converter, etc., and the CPU and its peripheral devices operate together according to a predetermined program stored in the memory. (1) A history recording unit 31 that stores the operation history of the oil seal 12 in the operation history storage unit D1 set in a predetermined area of the memory; (3) a recommended inspection replacement timing calculator 33 based on the wear level and the wear progress rate; and the like.

It should be noted that the computers constituting the consumption monitoring device 100 do not need to be physically integrated, and may be composed of a plurality of computers communicatively connected to each other via a LAN, WAN, or the like.

Further, as a premise, the hydraulic pump 1 includes a temperature sensor 21 for measuring the temperature of the oil (here, for example, the temperature of the oil near the discharge port) and a rotation speed sensor 22 for measuring the rotation speed of the shaft 11. is provided. Note that the temperature sensor 21 and the rotation speed sensor 22 may be pre-attached to the hydraulic pump 1 as accessories, or may be attached to the hydraulic pump 1 as accessories to the consumption monitoring device 100 afterward.
Next, the operation of the consumption monitoring device 100 will be described in detail with reference to FIG.

When a predetermined sampling time comes (step S1), the history recording unit 31 of the wear monitoring device 100 receives the oil temperature data indicating the measured value of the oil temperature from the oil temperature sensor 21, and also receives the rotation speed of the shaft 11. Rotational speed data indicating a measured value is received from the rotational speed sensor 22 (step S2).
Next, the history recording unit 31 estimates and calculates the temperature of (the sliding portion of) the oil seal 12 based on the value of the oil temperature data and the value of the rotational speed data.

Specifically, in this embodiment, as shown in FIG. 3, a rotation speed-rise temperature table D2, which is a data table showing an example of the relationship between each shaft rotation speed (rpm) and the temperature rise (° C.), is stored in the memory. is stored in a predetermined area of It should be noted that this rotational speed-increased temperature table D2 is obtained in advance through experiments, simulations, or the like.

Then, the history recording unit 31 acquires the temperature rise corresponding to the rotation speed data value (shaft rotation speed) by referring to the rotation speed-temperature rise table D2, and adds this temperature rise to the oil temperature. The obtained value is used as the temperature of the oil seal 12 (more precisely, the temperature of the lip, which is the sliding portion of the oil seal 12), and the operation history data that associates the temperature of the oil seal 12 with the sampling time is stored in the memory. is stored in the operation history storage unit D1 set in a predetermined area in association with the sampling time (step S3).

Supplementally, as shown in FIG. 6, the temperature rise is theoretically related to the sliding speed. Moreover, the temperature rise with respect to the sliding speed may vary depending on the type of oil (working fluid) and the material of the oil seal 12, as shown in FIG. Therefore, if the hydraulic pump 1 has a different diameter of the shaft 11, a different type of oil, a different material of the oil seal, etc., a different rotational speed-increased temperature table D2 corresponding to the hydraulic pump 1 is used.

Next, the consumption degree calculation unit 32 refers to the operation history storage unit D1, acquires operation history data from the start of operation to the present time, and calculates the operation time at each temperature of the oil seal 12 (step S4).

On the other hand, the operable time until the end of life at each temperature, that is, the life time, is obtained in advance by experiments, simulations, etc., and this is the temperature-life time table D3, which is a data table as shown in FIG. It is stored in a predetermined area of memory.

The wear degree calculation unit 32 acquires the life time at each temperature by referring to the temperature-life time table D3, and divides the operating time at each temperature by the life time at each temperature. By calculating the life consumption rate at each temperature and accumulating these, the current life consumption rate of the oil seal 12, that is, the consumption degree of the oil seal 12 is calculated.
An example is described below.
As a result of referring to the operation history data, the hydraulic pump 1 is
Operates for 24 hours at oil seal 12 temperature of 80°C (65°C (oil temperature) + 15°C (temperature rise due to shaft rotation))
It is assumed that the oil seal 12 temperature was 60°C (60°C (oil temperature) + 0 (temperature rise due to shaft rotation)) for 48 hours.
The degree of consumption in this case is as follows.
Consumption = (24 / 3600) + (48 / 9600) = 0.0117 = 1.17(%)

Note that the life time differs depending on the type of oil, the material of the oil seal 12, etc., so if the hydraulic pump 1 is different in oil type, oil seal material, etc., a different temperature-life time table D3 corresponding to it is used. .

The wear level calculation unit 32 further divides the wear level by the time from the start of operation to the present time to calculate an average wear progress rate (%/day) up to the present time (step S6). In the above example, since the wear rate is 1.17% in 3 days (72 hours) of operation,
Attrition progress rate (%/day) = 1.17 / 3 = 0.39.

Next, the recommended inspection/replacement timing calculation unit 33 calculates a service life timing, which is the time when the oil seal 12 reaches the end of its service life when the wear of the oil seal 12 progresses at the wear progress rate (step S7). In the above example, the rate of progress of consumption is 0.39%/day, and since it has been in operation for 3 days,
Lifetime = 100 / 0.39 - 3 = 253.41 days later.

Then, the recommended inspection/replacement time calculation unit 33 calculates the recommended inspection/replacement time for the oil seal 12 by subtracting a margin period preset by a user, a supplier, etc. The user is notified by outputting to a display or other mobile device through the line T (step S8).
Then, the process returns to step S1 again, and the above-described operation is repeated at the next sampling time.

It should be noted that the present invention is not limited to the above embodiments.
The hydraulic device may use fluid other than oil as working fluid, and is not limited to a pump, and may be a motor, cylinder, valve, or the like.
The sliding-related parts are not limited to seal members such as the oil seal 12, but may be pistons, cylinder bores, valve bodies, and the like.
An arithmetic expression may be used instead of the data table.

In the above embodiment, when calculating the temperature of the sliding portion (the lip of the oil seal 12), the oil temperature is used as a reference, and the temperature rise estimated from the sliding speed is added thereto. Ambient temperature that affects the temperature of the sliding portion, such as the internal temperature or the shaft temperature, may be used as a reference.

Also, if the temperature sensor is attached to a portion where the temperature of the sliding portion can be directly measured, the steps of measuring the sliding speed and calculating the temperature rise therefrom are unnecessary.

In the above-described embodiment, the recommended inspection replacement time is calculated by subtracting the leeway period from the service life time. In this case, the threshold is preferably varied according to the rate of progress of consumption. In other words, the threshold may be lowered when the consumption progress speed is high, and the threshold may be raised when the consumption progress speed is low. This is because the period from the inspection replacement recommended time to the life time can be made as equal as possible regardless of the rate of progress of wear.
The consumption progress speed may be the consumption progress speed in a predetermined engine, such as the most recent fixed period, instead of the average from the start of operation to the present time.

Instead of outputting the recommended inspection and replacement time to the user, there is no special notification until the recommended inspection and replacement time is reached, and immediately after the recommended inspection and replacement time is reached, the user is prompted to perform inspection and replacement, and the end of life is displayed. You may make it alert|report.
In addition, the present invention is not limited to the illustrated examples and explanations described above, and can be modified in various ways without departing from the spirit of the present invention.
The features of the wear monitoring device described above can be summarized as follows.

(1) Based on the operating history of the hydraulic system, the wear monitoring device 100 measures the degree of wear of sliding-related parts used in the sliding parts of the hydraulic system and the rate of progress of the wear. and a recommended inspection/replacement timing calculation unit that calculates a recommended inspection/replacement timing at which inspection/replacement of the sliding-related parts is recommended, based on the degree of wear and the rate of progress of wear. , is provided.

With such a system, the usage frequency and strength of use of the hydraulic device can be estimated from the rate of progress of wear, and the recommended timing for inspection and replacement of sliding-related parts can be determined based on the rate of progress of wear. Therefore, regardless of heavy use or light use, it is possible to recommend inspection and replacement at appropriate times according to the user's usage conditions. As a result, it is possible to prevent inspection and replacement from being done in time or, conversely, from being too early, so that maintenance can be performed reliably and without waste.

(2) In order to simply and accurately obtain the degree of wear and the speed of progress of wear, the wear degree calculator calculates the degree of wear and the speed of wear progress based on the operating time for each temperature of the sliding portion. is preferred.

(3) In order to measure the temperature of the sliding portion without using a complicated structure or sensor, the wear degree calculating section calculates the temperature of the sliding portion by calculating the ambient temperature and the sliding speed of the sliding portion. It should be calculated based on

(4) An oil seal 12 can be given as a specific example of a sliding-related component for which the effects of the present invention are particularly remarkable.

(5) Based on the operating history of the hydraulic device, calculate the degree of wear of sliding-related parts that are used in the sliding portion of the hydraulic device and the rate of progress of wear, which is the rate of progress of the wear. Also included in the present invention is a consumption monitoring method characterized by calculating an inspection/replacement recommendation timing, which is a time at which inspection/replacement of the sliding-related part is recommended, based on the consumption progression speed.

(6) A consumption degree calculation unit that calculates the degree of consumption of sliding-related parts, which are parts used in sliding portions of the hydraulic device, and the speed of progress of the consumption based on the operating history of the hydraulic device. and a recommended inspection/replacement timing calculation unit that calculates a recommended inspection/replacement timing, which is the time at which inspection/replacement of the sliding-related part is recommended, based on the degree of wear and the rate of progress of wear. A consumption monitoring program characterized by causing a computer to exhibit functions as a part and a part may also be used.

100 Hydraulic device 12 Oil seal (sliding-related parts)
32 ... Consumable degree calculation unit 33 ... Inspection replacement recommended time calculation unit

Claims (6)

a consumption degree calculation unit that calculates the consumption degree and the consumption progression speed of the sliding-related parts, which are the parts used in the sliding portion of the hydraulic device, based on the operation history of the hydraulic device;
a recommended inspection/replacement timing calculation unit that calculates a recommended inspection/replacement timing, which is a recommended time for inspection/replacement of the sliding-related parts, based on the degree of wear and the rate of progress of wear. wear monitoring device. 2. The wear monitoring device according to claim 1, wherein the wear degree calculator calculates the wear degree and the wear progress speed based on the operating time for each temperature of the sliding portion. 3. The wear monitoring device according to claim 2, wherein the wear degree calculator calculates the temperature of the sliding portion based on the ambient temperature and the sliding speed of the sliding portion. 4. A wear monitoring device according to claim 1, 2 or 3, wherein said sliding-related part is an oil seal. Based on the operation history of the hydraulic device, calculating the degree of wear of sliding-related parts, which are parts used in the sliding portion of the hydraulic device, and the wear progress rate, which is the progress speed of the wear,
A wear monitoring method, comprising: calculating an inspection/replacement recommendation timing, which is a time when inspection/replacement of the sliding-related part is recommended, based on the wear degree and the wear progress rate. a consumption degree calculation unit that calculates the consumption degree and the consumption progression speed of the sliding-related parts, which are the parts used in the sliding portion of the hydraulic device, based on the operation history of the hydraulic device;
a recommended inspection/replacement timing calculation unit that calculates a recommended inspection/replacement timing at which inspection/replacement of the sliding-related part is recommended, based on the degree of wear and the rate of progress of wear; A consumption monitoring program characterized by causing a computer to exhibit the functions of .

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