JP5328589B2 - Work machine failure diagnosis database creation method and work machine failure diagnosis database creation system - Google Patents

Description

  The present invention relates to a method for creating a failure diagnosis database for a work machine such as a backhoe and a system for creating a failure diagnosis database for a work machine.

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

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

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

JP 2002-332664 A

  In the failure diagnosis method of Patent Document 1, many questions for diagnosing failures should be prepared by associating the answers of the question contents and the failure contents in advance at the stage of designing the work machine and associating them. Without it, the actual situation is that the correct failure content cannot be determined from the question content. Moreover, since the questions used when diagnosing a failure must be set assuming various things from the stage of designing the work machine, the amount of questions is large, and when the work machine is actually used The fact is that even questions that can hardly occur are prepared.

  In view of the above problems, the present invention provides a work machine failure diagnosis database creation method and a work machine failure diagnosis database creation system capable of easily and quickly diagnosing a failure from a question (check item) that is actually present. Is intended to provide.

The technical means of the present invention for solving this technical problem acquires the contents of repair when the work machine is repaired, and acquires the status of each part of the work machine when the repair is performed. The point is that a failure diagnosis database having check items used for failure diagnosis is created based on the repair contents and the situation of each part.
It is preferable that the status of each part at the time of repair is totaled and a part where the occurrence frequency in the same repair is a predetermined value or more is determined as a check item. In addition, it is preferable to assign a weight for fault diagnosis to at least some of the check items.

  Another technical means of the present invention includes a repair list database that stores repair contents when a work machine is repaired, and stores the status of each part of the work machine when the repair is performed, and the repair list. A diagnostic database creation means for creating a failure diagnosis database having check items for checking each part of the work machine based on the repair contents stored in the database and the situation of each part; .

The diagnostic database creation means includes a status totaling unit that counts the status of each part when repair is performed, and a check item determination unit that determines a part having an occurrence frequency equal to or higher than a predetermined value as the check item. It is preferable. Moreover, it is preferable that the diagnostic database creation means includes a weighting unit that weights at least a part of the check items for fault diagnosis.
The most preferred technical means of the present invention are as follows.
That is, the technical means of the present invention includes a repair list database for storing repair contents when a work machine is repaired, and storing the status of each part of the work machine when the repair is performed, and the repair list. Failure of a work machine provided with a diagnostic database creation means for creating a failure diagnosis database having check items for checking each part of the work machine based on the repair contents stored in the database and the situation of each part A diagnostic database creation system, wherein the diagnostic database creation means uses the repair content stored in the repair list database and the status of each part to determine the status of each part when repair is performed Recalculate the frequency of occurrence based on the number of repairs for each part's symptom for each repair content tabulated by the status tabulation unit and the status tabulation unit Lies in that the frequency of occurrence and a check item determining unit that determines as a check item site is above a predetermined value.
The status totalization unit reads the repair contents and symptoms of each part stored in the repair list database, and based on the read repair contents and each part, the total number of repairs for each repair contents and all the symptoms that occurred in each part. The check item determination unit obtains the occurrence frequency from the total number of repairs for each repair content and the total occurrence number of symptoms of each part, and when the occurrence frequency is a predetermined value or more, It is preferable to determine the site as a check item.
The diagnostic database creation means preferably includes a weighting unit that weights at least a part of the check items for fault diagnosis.

  According to the present invention, a failure can be diagnosed easily and quickly from a question (check item) that matches the actual situation.

It is a block diagram of the preparation system of the database for a failure diagnosis of the working machine in 1st Embodiment. It is a figure which shows a check sheet. The flow of summarizing the failure record shows a) the failure record stored in the failure list database, b) the failure record for each failure content, and c) the symptoms of each part for each failure content. The total is shown. It shows the relationship between check items and symptoms stored in the failure diagnosis database. It is a block diagram of a failure diagnosis support system. The screen when the failure estimation unit is activated is shown. It shows the flow from the operation information until the failure is estimated. 7 shows a list of check items in the second embodiment. It is a block diagram of the preparation system of the failure diagnosis database of the working machine in 2nd Embodiment. The screen which gives a weight to a check item by a weighting part is shown. The whole side view of a working machine is shown.

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

FIG. 11 shows an example of a work machine.
As shown in FIG. 11, the work machine (backhoe) 1 includes a lower traveling device 2 and an upper swing body 3.
The traveling device 2 includes a pair of left and right traveling bodies 4 each having a rubber cover, and a crawler traveling device in which both traveling bodies 4 are driven by a traveling motor M is employed. Further, a dozer 5 is provided at the front portion of the traveling device 2.

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

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

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

  As shown in FIG. 1, in the failure diagnosis database creation system 60, first, the repair results when the work machine 1 is repaired at a repair shop or the like are rented, and the manufacturing company that manufactures the work machine 1 or the work machine 1 is rented. A failure diagnosis database is created by sending the result of the repair to a rental company or the like through a network and analyzing the result of repair by a computer 61 arranged at the manufacturing company or the rental company.

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

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

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

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

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

  Data relating the symptom of each part determined in this way and the repair contents is stored in the failure diagnosis database 64. That is, as shown in FIG. 4, the failure diagnosis database stores combinations of symptoms (check items C) and repair contents of each part obtained from past repair results. That is, in the failure diagnosis database 64, when the symptoms of 1 item, 4 items, and 11 items occur (O), the repair content “A” is performed, and the symptoms of 2 items, 4 items, 10 items, and 12 items are performed. If the error occurs, the repair content “B” is stored, and information indicating that the repair content “C” is performed when the symptoms of items 2, 3, and 5 occur is stored.

The failure diagnosis database creation system 60 of the work machine 1 will be described in detail.
As shown in FIG. 1, the failure diagnosis database creation system 60 includes a diagnosis database creation means 61 and a repair list database 63. The diagnostic database creating means 61 creates a failure diagnostic database 64 based on information stored in the repair list database 63.

  The repair list database 63 stores repair results when the work machine 1 is repaired. As shown in FIG. 3A, the repair contents when the work machine 1 is repaired are stored. In addition, the situation of each part of the work machine 1 when repair is performed is stored. In this embodiment, the repair list database 63 is provided in a computer 61 arranged at a manufacturing company or a rental company. The repair list database 63 is preferably created for each model (for each type) of the work machine 1. For example, when there are three models of the work machine 1, the repair list database 63 is created for each of the three models. Will be prepared.

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

The diagnosis database creation means 61 creates a failure diagnosis database 64 having check items for checking each part of the work machine 1 based on the repair contents and the situation (symptoms) stored in the repair list database 63. The computer 61 is arranged at a manufacturing company or a rental company.
The diagnostic database creation means (computer 61) includes a situation totaling unit 65 and a check item determining unit 66. The status totaling unit 65 and the check item determining unit 66 are configured by a program stored in the computer 61.

  The situation totaling unit 65 uses the repair results stored in the repair list database 63 to totalize the status of each part when repairs are performed for each repair content. Specifically, as shown in FIG. 3A, when the predetermined amount of repair results are accumulated in the repair list database 63 as shown in FIG. The symptom of each part is arranged, and the total number of repairs and the total number of occurrences of the symptom at each part are obtained for each repair content.

The check item determination unit 66 obtains the occurrence frequency from the total number of repairs for each repair content and the total number of occurrences of symptoms of each part, and when the value is a predetermined value or more, the corresponding part is set as the check item C. To decide. For example, the check item determination unit 66 determines, as the check item C, each part in which the total number of occurrences is half or more (50% or more) of the total number of repairs.
In this way, when the check item C for checking a predetermined part is determined by the check item determination unit 66, as shown in FIG. 4, the repair contents and the answer to the check item C (O: Yes, X: No) and Are stored in the failure diagnosis database 64. That is, the symptom of each part of the work machine 1 can be checked by the check item C, and the check item determined in this way is an item that the symptom of each part in the check sheet S.

FIG. 5 shows an example of a failure diagnosis support system that performs failure diagnosis of the work machine 1 using the failure diagnosis database 64.
The failure diagnosis support system 50 includes a status transmission unit 51, a failure diagnosis unit 52, and a failure diagnosis database 64.
The status transmission means 51 is for transmitting the operation status of each part of the work machine 1 for fault diagnosis. The display device 25 converts the operation status of the work machine 1 into an image and displays it, and this display. And a communication device 45 that reads an image displayed on the device 25 and transmits an operation state in the image via a network.

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

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

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

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

  The failure estimation unit 56 automatically estimates a failure based on the operation status captured by the status capture unit 55 and the repair results stored in the failure diagnosis database 64. Specifically, the failure estimation unit 56 is configured by application software for estimating a failure from a situation (symptom). When the application software is started, the failure estimation database 64 is accessed and the work machine 1 By calling the check item C in the failure diagnosis database 64 corresponding to the above, a screen (check screen) having the check item C and the answer column as shown in FIG. 6 is displayed on the display unit of the computer 61. ing. That is, the failure estimation unit 56 displays a screen having a check item C corresponding to the check sheet S shown in FIG.

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

  Then, the failure estimation unit 56 collates the response of the symptom (check item C) of each part on the check screen (check sheet S) with the operation status of each part in the repair record stored in the failure diagnosis database 64. To estimate the failure. For example, as shown in FIG. 7, the failure estimation unit 56 determines that the failure is a pattern in which the first, fourth, and eleventh symptoms are “◯” and the others are “×” on the check screen. The diagnosis database 64 is searched for a pattern having the same symptom as the check screen, and the repair content “A” corresponding to this pattern is extracted. Then, the failure estimation unit 56 displays the failure content corresponding to the repair content “A”. That is, the failure estimation unit 56 determines the repair content from the symptom answer on the check screen. However, since the failure content and the repair content are front and back, if the repair content is known, the failure content is naturally found. Can do. For example, if the repair content is “controller replacement”, it goes without saying that the controller has failed. Therefore, the failure estimation unit 56 determines that the failure (estimated cause) "Failure" is determined and the details are displayed on the screen.

  In the failure diagnosis support system 50 for the work machine 1, for example, the user displays the operation information of the work machine 1 as a QR code on the display device 25, and reads the QR code displayed on the display device 25 with a camera-equipped mobile phone. The data in the read QR code is transmitted to the e-mail server 57 by e-mail, and the manufacturing company or the rental company accesses the e-mail server 57 from the company computer 52 and receives the e-mail of the operation information. By doing so, the operation information of the work machine 1 can be acquired. Then, the manufacturing company or the rental company can automatically estimate the failure from the operation information and the failure diagnosis database 64 by the failure estimation unit 56 of the computer 52, and can quickly notify the user or the like of the portion that seems to be a failure.

  FIG. 5 shows an example of a failure diagnosis support system that automatically performs failure diagnosis of the work machine 1 using the failure diagnosis database. However, failure diagnosis using the failure diagnosis database is the same as that shown in FIG. It is not limited. For example, a check sheet S in which check items are listed is created by extracting check items in the failure diagnosis database 64, and the symptoms of each part of the work machine 1 are checked at the site where the work machine 1 has failed. The failure diagnosis of the work machine 1 may be performed by filling in the sheet S and manually inputting the contents of the check sheet S into the computer 52 (failure diagnosis means).

  As described above, in the system for creating the failure diagnosis database 64 according to the first embodiment, the repair contents when the work machine 1 is repaired are stored, and the status of each part of the work machine 1 when the repair is performed is stored. A diagnostic database for creating a fault diagnosis database 64 having check items for checking each part of the work machine 1 based on the repair list database 63 to be performed and the repair contents and status stored in the repair list database 63 Means 61.

  According to this, every time the work implement 1 is repaired even if many check items C are not prepared at the stage of designing the work implement 1 (design stage) as in the prior art. It is possible to determine a new check item C that is in trouble (content of repair). Moreover, since the check items are determined based on the repair results (repair contents, symptoms of each part), it becomes a reality, and it is possible to easily and quickly diagnose failures by using this check item. Become.

The diagnostic database creation means 61 includes a status totaling unit 65 that counts the status of each part at the time of repair, and a check item determination unit 66 that determines a part whose occurrence frequency is a predetermined value or more as a check item. ing.
According to this, a check item can be automatically and quickly created using the diagnostic database creation means 61.
[Second Embodiment]
8 to 10 show a fault diagnosis database creation method and a fault diagnosis database creation system according to the second embodiment. In the first embodiment described above, even when the check item C is determined, the importance level for determining a failure is not added to each check item itself, but in this second embodiment, the check item C The importance (weight) for determining a failure is added to.

  As shown in FIG. 8, in the method for creating the failure diagnosis database 64, for example, among the check items C from 1 item to 19 items, the check item C of 11 items to 19 items is another one item. A weight indicating that the degree of importance in determining a failure is higher than that of the check item C of -10 items. As a method of assigning a weight, for example, a check item C having a very high occurrence frequency is weighted from a list of check items C, or even if a failure occurrence frequency is low, It is preferable to give a weight to the check item C corresponding to the symptom of a part that cannot be recognized as a failure unless an internal inspection is performed. For example, check item C such as 17 items "white rust with rust on the front harness" and 18 items "black rust with green on the front harness, green rust" etc. are difficult to understand by appearance alone. Therefore, the check item C for checking the symptom of such a part should be weighted.

FIG. 9 shows a failure diagnosis database creation system in which the diagnosis database creation means 61 (computer) includes a weighting unit 69. The other parts are the same as the system for creating the failure diagnosis database 64 shown in FIG.
The weighting unit 69 assigns a weight for failure diagnosis to at least a part of the check items C in the same manner as described above. The weighting unit 69 includes a program stored in the computer 61.

  As shown in FIG. 10, when the weighting unit 69 of the computer is activated, a list of all check items C stored in the failure diagnosis database 64 is displayed on the display unit (monitor) of the computer 61. It has become. In the list of check items C, a setting unit 70 for setting whether or not each check item C is to be weighted is shown by the weighting unit 69, and is input to the setting unit 70 by an input device (keyboard, mouse) of the computer 61. A check mark “Le” can be entered. A weight is added to the check item C that is checked by the weighting unit 69.

  In this way, for example, when the symptom of each part of the work machine 1 is checked with the check sheet S having the check item C, there is a symptom in the part corresponding to the weighted check item (the answer is yes) In such a case, it is possible to quickly find a failure by checking the state of a part corresponding to the check item when repairing. In other words, weighting the check items helps to quickly find troubles that are difficult to find.

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

DESCRIPTION OF SYMBOLS 1 Working machine 61 Diagnosis database preparation means 62 Computer 63 Repair list database 64 Fault diagnosis database 65 Status totalization part 66 Check item determination part

Claims (3)

Together to save the repaired content of when the repair of the working machine, working machine and the repair list database that stores the status of each part of, each and repair what is stored in the repair list database site at the time of performing the repairs A work machine fault diagnosis database creating system comprising a diagnosis database creating means for creating a fault diagnosis database having check items for checking each part of the work machine based on the situation of
The diagnostic database creation means uses the repair content stored in the repair list database and the status of each part, and the status totaling unit that counts the status of each part when repair is performed for each repair content, A check item determining unit that recalculates the frequency of occurrence according to the number of repairs in the symptoms of each part for each repair content tabulated by the situation totaling unit, and determines a part having the occurrence frequency equal to or higher than a predetermined value as a check item A system for creating a database for fault diagnosis of a work machine. The status totalization unit reads the repair contents and symptoms of each part stored in the repair list database, and based on the read repair contents and each part, the total number of repairs for each repair contents and all the symptoms that occurred in each part. The check item determination unit obtains the occurrence frequency from the total number of repairs for each repair content and the total occurrence number of symptoms of each part, and when the occurrence frequency is a predetermined value or more, The system according to claim 1, wherein a part is determined as a check item .   The failure of the work machine according to claim 1, wherein the diagnostic database creation unit includes a weighting unit that weights at least a part of the check items for failure diagnosis. A diagnostic database creation system.

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