JP5583569B2 - Fillet roller defect determination device and method - Google Patents

Description

  BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fillet roller defect determination apparatus and method, and more particularly to a fillet roller defect determination apparatus and method for determining a fillet roller defect in a fillet roll processing apparatus including a fillet roller pressed against a work rotated by an electric motor. About.

Conventionally, as this kind of fillet roller loss determination device, a device for determining whether or not a fillet roller has been lost based on the amount of vibration caused by the roll application detected by a vibration sensor has been proposed (for example, Patent Document 1).
In this apparatus, when the detected vibration exceeds a predetermined reference level, it is determined that a defect has occurred in the fillet roller.
Conventionally, there has been known an apparatus for determining a tool defect based on a power value of a motor that drives a tool (see, for example, Patent Document 2).
In this equipment, the average value and standard deviation are obtained for each same sampling location from a plurality of power waveforms when a plurality of cycles are processed, and an allowable range is set based on this, and the measured power value exceeds the allowable range. It is determined that the tool is missing.

Japanese Utility Model Publication No. 1-121638 JP 2002-341909 A

However, it is difficult to detect only the amount of vibration caused by the roll application operation with the former loss determination device described above, and it cannot be determined with high accuracy. Moreover, it is very expensive because a plurality of vibration sensors are necessary. On the other hand, although it is conceivable to apply the latter defect determination device to the fillet roller, the number of data to be handled is large, a large storage capacity is required, and the control becomes complicated.
An object of the defect determination device and method for a fillet roller according to the present invention is to determine the defect of a fillet roller with high accuracy while performing simple control.

As a result of diligent research to achieve the above-mentioned main object, the present inventors calculated a value obtained by integrating the amount of power change per predetermined time of the electric motor that rotates the workpiece during fillet roll machining for one fillet roll machining. It has been found that by using it, the defect determination of the fillet roller can be enhanced, and the present invention has been completed.
That is, the defect determination device for the fillet roller of the present invention is
A fillet roller deficiency determination device for determining a deficiency of the fillet roller in a fillet roll processing apparatus including a fillet roller pressed against a work rotating by an electric motor,
Power detection means for detecting the load power of the motor every predetermined time;
A power change amount calculating means for sequentially calculating a change amount of the load power per predetermined time as a power change amount;
A power change amount integrating means for integrating the calculated power change amount as a power change amount integrated value;
Storage means for storing the power change integrated value;
An allowable range setting means for setting an integrated value allowable range as an allowable range of the power change amount integrated value based on the plurality of stored power change amount integrated values;
If the power change integrated value integrated this time is within the integrated value allowable range, it is determined that the fillet roller is not missing, and if the power change integrated value integrated this time is outside the integrated value allowable range. Defect determination means for determining that the fillet roller is defective;
It is a summary to provide.

In the fillet roller loss determination device according to the present invention, the power change amount per predetermined time is sequentially calculated, and the calculated power change amount is integrated to obtain and store the power change integrated value, and the plurality of stored power An integrated value allowable range is set based on the change amount integrated value. Then, if the power change integrated value integrated this time is within the set integrated value allowable range, it is determined that the fillet roller is not missing, and the power integrated integrated value integrated this time is outside the set integrated value allowable range. It is determined that the fillet roller is missing.
Since it is determined whether or not a defect has occurred in the fillet roller only by determining whether or not the integrated value of the power change amount is within an allowable range through one fillet roll processing, simple control is sufficient. In addition, since the power change amount integrated value is one of the indicators with high sensitivity among the indicators for the defect of the fillet roller, the defect of the fillet roller can be determined with high accuracy.

In such a fillet roller defect determination device of the present invention, the allowable range setting means calculates a moving average and a standard deviation of the latest predetermined number of the power change amount stored by the storage means, and the moving average and The integrated value allowable range may be set based on the standard deviation.
In this way, it is possible to accurately determine the power change amount integrated value. As a result, the defect determination of the fillet roller can be determined with high accuracy.

Further, in the fillet roller loss determination device of the present invention, the apparatus includes an extraction unit that extracts a maximum power change amount from the power change amount calculated by the power change amount calculation unit,
The storage means is means for storing the power change maximum value extracted by the extraction means in addition to the power change integrated value ,
The allowable range setting means is a means for setting a maximum value allowable range as an allowable range of the maximum power change amount based on a plurality of stored maximum power change values in addition to the integrated value allowable range. Yes,
The loss determination means determines that the fillet roller is defective when the integrated value of the power change amount currently integrated is out of the integrated value allowable range and the maximum value of the power change amount extracted this time is out of the maximum allowable range. It can also be a means for determining that the user is doing.
In this way, the fillet roller is used only when the power change amount integrated value and the power change amount maximum value, which are one of the indicators with high sensitivity among the indicators for the defect of the fillet roller, are both out of the allowable range. Therefore, the defect of the fillet roller can be determined with higher accuracy.

Further, in the fillet roller defect determination device of the present invention, the allowable range setting means calculates a moving average and a standard deviation of the latest predetermined number of maximum power change values stored by the storage means, and the moving average And a means for setting the maximum allowable range based on the standard deviation.
In this way, it is possible to accurately determine the maximum power change amount. As a result, the defect determination of the fillet roller can be determined with high accuracy.

The defect determination method of the fillet roller of the present invention is:
A fillet roller defect determination method for determining a defect of the fillet roller in a fillet roll processing apparatus including a fillet roller pressed against a workpiece rotated by an electric motor,
(A) detecting the load power of the motor every predetermined time;
(B) The amount of change in the load power per predetermined time is sequentially calculated as the amount of power change,
(C) integrating the calculated power change amount as a power change amount integrated value;
(D) storing the power change amount integrated value;
(E) Based on a plurality of stored power change amount integrated values, an integrated value allowable range is set as an allowable range of the power change integrated value;
(F) If the integrated power change amount integrated this time is within the integrated value allowable range, it is determined that the fillet roller is not missing, and the integrated power change amount is not within the integrated value allowable range. Then, the gist is to determine that the fillet roller is missing.

In the fillet roller loss determination method of the present invention, the power change amount per predetermined time is sequentially calculated, and the calculated power change amount is integrated to obtain and store the power change amount integrated value. An integrated value allowable range is set based on the change amount integrated value. Then, if the power change integrated value integrated this time is within the set integrated value allowable range, it is determined that the fillet roller is not missing, and the power integrated integrated value integrated this time is outside the set integrated value allowable range. It is determined that the fillet roller is missing.
Since it is determined whether or not a defect has occurred in the fillet roller only by determining whether or not the integrated value of the power change amount is within an allowable range through one fillet roll processing, simple control is sufficient. In addition, since the power change amount integrated value is one of the indicators with high sensitivity among the indicators for the defect of the fillet roller, the defect of the fillet roller can be determined with high accuracy.

It is a block diagram which shows the outline of a structure of the fillet roll processing system 1 provided with the fillet roller defect | deletion determination apparatus 10 which is one Example of this invention. 2 is a configuration diagram showing an outline of a configuration of a fillet roll processing apparatus 30. FIG. It is an enlarged view which shows the principal part of the fillet roll processing apparatus 30 in an enlarged manner. 4 is a flowchart illustrating an example of fillet roller loss determination processing executed by the fillet roller loss determination device 10.

Next, the form for implementing this invention is demonstrated using an Example.
FIG. 1 is a configuration diagram showing an outline of a configuration of a fillet roll processing system 1 including a fillet roller defect determination device 10 according to an embodiment of the present invention.
The fillet roll processing system 1 including the fillet roller defect determination device 10 of the embodiment is similar to the base 2 and the drive head 4 that is movably disposed on the rail 2a attached to the base 2 as shown in the figure. A driven head 6 disposed opposite to the drive head 4 so as to be movable on the rail 2a, and a fillet roll processed so as to be movable on the rail 2b mounted on the base 2 so as to be substantially orthogonal to the rail 2a. An apparatus 30, a fillet roller defect determination apparatus 10 according to an embodiment that determines whether or not the fillet roller R is defective in the fillet roll processing apparatus 30, and an electronic control unit 50 that controls the entire apparatus.

  The drive head 4 includes a drive head motor M and a drive-side chuck 4 a that is connected to a rotation shaft of the drive head motor M and grips one end of a crankshaft CS as a workpiece, and is fixedly disposed on the base 2. The drive head air cylinder 14 reciprocates on the rail 2a (in the left-right direction in FIG. 1).

  The driven head 6 is provided with a center 6a that is concentric with the drive side chuck 4a of the drive head 4 and can support the other end of the crankshaft CS. The driven head air cylinder 16 is fixedly disposed on the base 2. Is reciprocated on the rail 2a (left and right direction in FIG. 1). That is, the crankshaft CS is chucked at one end side by the drive side chuck 4a, supported at the other end side by the center 6a, and rotated around the journal portion J (not shown) of the crankshaft CS by the rotational drive of the drive head motor M. To do.

FIG. 2 is a configuration diagram showing an outline of the configuration of the fillet roll processing apparatus 30.
As shown in the figure, the fillet roll processing device 30 includes a table 32 movably arranged on the rail 2b, a support plate 34 fixedly arranged on the table 32, and a support shaft 31 parallel to the axis of the crankshaft CS. The upper arm 36 that is swingably attached to the support plate 34 by means of the above, the lower arm 38 that is also swingably attached to the support plate 34 by the support shaft 31, and the roll cassette attached to one end of the upper arm 36. 40, a workrest 42 attached to one end side of the lower arm 38 so as to face the roll cassette 40, and a pressure cylinder 44 connected to the other end side of the upper arm 36 and the lower arm 38 in a bridging manner. And the upper arm 36 and the lower arm 38 by the expansion and contraction of the rod 44a of the pressure cylinder 44. One side is opened and closed (swings around the supporting shaft 31) is configured as.
As shown in FIG. 1, the fillet roll processing apparatus 30 includes a support plate 34, an upper arm 36, a lower arm 38, a roll cassette 40, independently for each journal portion and pin portion that are processing portions of the crankshaft CS. Each has a work rest 42 and a pressure cylinder 44. Further, the fillet roll processing device 30 approaches the crankshaft CS by reciprocating the table 32 on the rail 2b (left and right direction in FIG. 2) by the operation of the table air cylinder 18 fixedly disposed on the base 2. Go away.

FIG. 3 is an enlarged view showing an essential part of the fillet roll processing apparatus 30.
As shown in the figure, the roll cassette 40 includes a fillet roller R that is rotatably held by a cassette housing (not shown) via a backup roller 40a, and the fillet part f and the pin part of the journal part J of the crankshaft CS. Pressurize the fillet part f of P. In FIG. 3, a pair of fillet rollers R and R having a substantially C-shape are shown to pressurize the fillet portions f and f at both ends of the journal portion J, but only the fillet portion f on one side is shown. Needless to say, any one of the fillet rollers R is sufficient in the case of pressure processing.

  As shown in FIG. 2, the workrest 42 includes a pair of rest rollers 42 a arranged along the circumferential direction of the crankshaft CS. The fillet roller R causes the fillet portion f of the journal portion J of the crankshaft CS to be When the fillet portion f of the pin portion P is subjected to fillet roll processing, it contacts almost the entire axial direction excluding the fillet portion f of the journal portion J of the crankshaft CS and almost the entire axial direction except the fillet portion f of the pin portion P. Thus, the lower side of the crankshaft CS is supported.

  The fillet roller loss determination device 10 includes a microprocessor centered on the CPU 72. In addition to the CPU 72, a ROM 76 that stores a processing program, a RAM 74 that temporarily stores data, an input / output port and a communication port (not shown). Prepare. The fillet roller loss determination device 10 receives a signal necessary for determining whether or not the fillet roller R is defective, such as power from a wattmeter 82 that detects power supplied to the drive head motor M. Yes. The fillet roller loss determination device 10 communicates with an electronic control unit 50 described later, and outputs data related to the power supplied to the drive head motor M to the electronic control unit 50 as necessary.

  The electronic control unit 50 is configured as a microprocessor centered on a CPU (not shown), and receives an instruction set on an operation panel (not shown) to control the operation of the fillet roll processing device 30 and the drive head motor M. The operation control of the entire apparatus is performed, such as the drive control of the switching valve 84 that switches the air supply to the drive head air cylinder 14, the driven head air cylinder 16, and the table air cylinder 18.

Next, the operation of the fillet roll processing system 1 including the fillet roller loss determination device 10 of the embodiment configured as described above, particularly, the operation when the fillet roller loss determination device 10 determines whether or not the fillet roller R is defective will be described. To do.
FIG. 4 is a flowchart showing an example of the fillet roller defect determination process executed by the fillet roller defect determination device 10, and is executed when a predetermined time Ts has elapsed since the start of the fillet roll processing. Here, the predetermined time Ts is set to a time required from the start of fillet roll processing to the end of the rise of power. In the embodiment, the predetermined time Ts is measured by a timer (not shown) after an instruction to start fillet roll processing is given.

  When the fillet roller loss determination process is executed, the CPU 72 of the fillet roller loss determination device 10 first resets a power change amount maximum value ΔPmax described later, that is, sets the value to 0 (step S100) and power. The power value P from the total 82 is input (step S102). Then, the power change amount ΔPi is calculated from the input power value P, and the calculated power change amount ΔPi is stored in a power change amount buffer set in a predetermined area of the RAM 74 (step S104). In the embodiment, the power change amount ΔPi is calculated by subtracting the power value Pn−1 read last time from the power value Pn read this time.

Next, the calculated power change amount ΔPi is compared with the power change amount maximum value ΔPmax (step S106).
When this branch is entered for the first time, since the power change maximum value ΔPmax is set to a value of 0, the calculated power change ΔPi is set as a power change maximum value ΔPmax in a predetermined area of the RAM 74. The stored power change amount maximum value is stored in the temporary storage buffer (step S108), and it is determined whether the power measurement time Tm has elapsed (step S110).
On the other hand, when this branch is entered for the second time or later, the calculated power change amount ΔPi is compared with the power change maximum value ΔPmax stored in the maximum power change amount temporary storage buffer ( Step S106) If the calculated power change amount ΔPi is larger than the power change amount maximum value ΔPmax, the power change amount ΔPi is replaced with the power change amount maximum value ΔPmax (step S108), and whether or not the power measurement time Tm has elapsed. Is determined (step S110).
Further, if the calculated power change amount ΔPi is equal to or less than the power change amount maximum value ΔPmax, it is determined whether or not the power measurement time Tm has passed without doing anything (step S110).
In the embodiment, the power measurement time Tm is set to a time slightly shorter than the time required for one fillet roll processing. Thereby, unstable electric power at the time of falling of electric power at the end of processing can be excluded from determination.

  When the power measurement time Tm has not elapsed, the processing from step S102 to step S110 is repeatedly executed until the power measurement time Tm has elapsed. When the power measurement time Tm elapses, the power change maximum value ΔPmax stored in the power change maximum value temporary storage buffer is set in a predetermined area of the RAM 74 as the power change maximum value ΔPmaxj in the current fillet roll processing. The data is stored in the power change amount maximum value buffer (step S112).

Subsequently, the power change amount integrated value ΔPj in the current fillet roll machining is calculated, and the calculated power change amount integrated value ΔPj is stored in a power change amount integrated value buffer set in a predetermined area of the RAM 74 (step S114). ).
Then, this time, the power change maximum value buffer and the power change amount including the power change maximum value ΔPmaxj and the power change integrated value ΔPj stored in the power change maximum value buffer and the power change integrated value buffer. Using the latest 20 power change maximum values ΔPmaxj−19 to ΔPmaxj and power change integrated values ΔPj−19 to ΔPj stored in the integrated value buffer, the maximum power change amount in the current fillet roll processing is calculated. The moving average value ΔPmaxjmav, the moving average value ΔPjmav of the power change amount integrated value, the standard deviation σmj of the maximum power change amount in the current fillet roll processing, and the standard deviation σsj of the power change amount integrated value are calculated (step S116). .
Here, each moving average value ΔPmaxjmav or ΔPjmav and each standard deviation σmj or σsj can be obtained by a known moving average value calculation method and standard deviation calculation method. In the embodiment, the moving average value ΔPmaxjmav is the oldest, ie, the moving average value ΔPmax (j−1) mav obtained last time, which is obtained by dividing the power variation maximum value ΔPmaxj obtained this time by the value 20, It was obtained by subtracting the value obtained by dividing the power change maximum value ΔPmax (j-20) stored in the power change maximum value buffer 21 times before by the value 20.
Further, the standard deviation σmj is the sum of the differences between each of the past 20 power change maximum values ΔPmax (j-19) to ΔPmaxj including the power change maximum value ΔPmaxj determined this time and the moving average value ΔPmaxjmav calculated this time. And the root mean square was taken.

  Based on the moving average values ΔPmaxjmav, ΔPjmav and standard deviations σmj, σsj obtained in this way, an allowable value range of the power variation maximum value ΔPmaxj and the power variation integrated value ΔPj is set (step S118). In the embodiment, the allowable range of the power change maximum value ΔPmaxj and the power change integrated value ΔPj is obtained by adding / subtracting each moving average value ΔPmaxjmav, ΔPjmav to each standard deviation σmj, σsj multiplied by a constant 3. It was assumed that ΔPmaxjmav ± 3σmj and ΔPjmav ± 3σsj were set, respectively.

  Then, it is determined whether or not the power change maximum value ΔPmaxj and the power change integrated value ΔPj obtained this time are within the allowable value ranges ΔPmaxjmav ± 3σmj and ΔPjmav ± 3σsj (step S120). If it is within the value range, it is determined that the fillet roll tool is normal (step S122), and if both are outside the allowable range, it is determined that an abnormality has occurred in the fillet roll tool (step S124). ), This process is terminated.

  According to the fillet roll machining system 1 provided with the fillet roller defect determination device 10 of the embodiment described above, the power change amount integrated value ΔPj in the current fillet roll machining using the sequentially calculated power change amount ΔPi per predetermined time. And the power change amount maximum value ΔPmaxj is calculated, and the power change amount integrated value buffer including the power change amount integrated value ΔPj and the power change amount maximum value ΔPmaxj and the power change amount maximum value buffer stored in the latest 20 An allowable value range ΔPjmav ± 3σsj and ΔPmaxjmav ± 3σmj are set using the power change amount integrated value ΔPj-19 to ΔPj and the power change maximum value ΔPmaxj-19 to ΔPmaxj, and the power change amount integrated value ΔPj and the power change amount maximum are set. The value ΔPmaxj is the allowable range ΔPjmav ± 3σsj and ΔPmaxjm v since the fillet roller R depending on whether it is within a range of ± 3Shigumamj to determine whether missing can be a simple control defects determination of the fillet rollers R. That is, unlike the prior art, it is not necessary to set an allowable value range every predetermined time, and whether or not the power change integrated value ΔPj and the power change maximum value ΔPmaxj are within the allowable range through one fillet roll process. It is only necessary to determine whether or not. In addition, since the power change amount integrated value ΔPj and the power change amount maximum value ΔPmaxj are one of the highly sensitive indicators for the loss of the fillet roller R, the loss of the fillet roller R can be accurately determined. .

  Further, according to the fillet roll machining system 1 including the fillet roller defect determination device 10 of the embodiment, the most recent 20 power changes including the power change integrated value ΔPj and the power change maximum value ΔPmaxj in the current fillet roll machining. Since the allowable value ranges ΔPjmav ± 3σsj and ΔPmaxjmav ± 3σmj are set using the amount integrated value ΔPj−19 to ΔPj and the maximum power change amount ΔPmaxj−19 to ΔPmaxj, the loss determination of the fillet roller R can be determined with higher accuracy. Can do.

  In the fillet roll processing system 1 including the fillet roller defect determination device 10 of the embodiment, the fillet roller defect determination device 10 is provided separately from the electronic control unit 50 that performs operation control of the entire apparatus. The apparatus 10 may not be provided and the electronic control unit 50 may determine whether the fillet roller R is missing.

  In the fillet roll machining system 1 including the fillet roller loss determination device 10 of the embodiment, the power change amount integrated value ΔPj and the power change amount maximum value ΔPmaxj are calculated, and the calculated power change amount integrated value ΔPj and the power change amount maximum value are calculated. It is determined whether or not the fillet roller R is missing depending on whether or not ΔPmaxj is within the allowable value ranges ΔPjmav ± 3σsj and ΔPmaxjmav ± 3σmj. However, only the power change amount integrated value ΔPj is calculated. The fillet roller R may be determined based on whether or not the calculated power change amount integrated value ΔPj is within the allowable value range ΔPjmav ± 3σsj.

  In the fillet roll machining system 1 including the fillet roller defect determination device 10 of the embodiment, the allowable value range ΔPjmav is obtained by adding and subtracting each moving average value ΔPmaxjmav, ΔPjmav to each standard deviation σmj, σsj multiplied by a constant 3. Although ± 3σsj and ΔPmaxjmav ± 3σmj are set, the constants multiplied by the standard deviations σmj and σsj are not limited to 3, and any values such as 2 and 4 may be used. In addition, for example, the values multiplied by the standard deviations σmj and σsj may be different from each other, for example, the allowable range is ΔPjmav ± 3σsj and ΔPmaxjmav ± 4σmj.

  The best mode for carrying out the present invention has been described above with reference to the embodiments. However, the present invention is not limited to these embodiments, and various modifications can be made without departing from the gist of the present invention. Of course, it can be implemented in the form.

DESCRIPTION OF SYMBOLS 1 Fillet roll processing system 2 Base 2a, 2b Rail 4 Drive head 4a Drive side chuck 6 Drive head 6a Center 10 Fillet roller defect determination device 14 Drive head air cylinder 16 Drive head air cylinder 18 Table air cylinder 30 Fillet roll processing Device 31 Support shaft 32 Table 34 Support plate 36 Upper arm 38 Lower arm 40 Roll cassette 40a Backup roller 42 Workrest 44 Pressure cylinder 44a Rod 50 Electronic control unit 72 CPU
74 RAM
76 ROM
82 Wattmeter 84 Switching valve CS Crankshaft M Drive head motor R Fillet roller J Journal part f Fillet part P Pin part

Claims (5)

A fillet roller deficiency determination device for determining a deficiency of the fillet roller in a fillet roll processing apparatus including a fillet roller pressed against a work rotating by an electric motor,
Power detection means for detecting the load power of the motor every predetermined time;
A power change amount calculating means for sequentially calculating a change amount of the load power per predetermined time as a power change amount;
A power change amount integrating means for integrating the calculated power change amount as a power change amount integrated value;
Storage means for storing the power change integrated value;
An allowable range setting means for setting an integrated value allowable range as an allowable range of the power change amount integrated value based on the plurality of stored power change amount integrated values;
If the power change integrated value integrated this time is within the integrated value allowable range, it is determined that the fillet roller is not missing, and if the power change integrated value integrated this time is outside the integrated value allowable range. Defect determination means for determining that the fillet roller is defective;
A defect determination device for a fillet roller.   The allowable range setting means calculates a moving average and a standard deviation of the latest predetermined number of the power change integrated values stored by the storage means, and the integrated value allowable range based on the moving average and the standard deviation The defect determination device for a fillet roller according to claim 1, wherein the defect determination device is a means for setting the value. A defect determination device for a fillet roller according to claim 1 or 2,
An extraction means for extracting a power change maximum value as a maximum value from the power change calculated by the power change calculating means;
The storage means is means for storing the power change maximum value extracted by the extraction means in addition to the power change integrated value ,
The allowable range setting means is a means for setting a maximum value allowable range as an allowable range of the maximum power change amount based on a plurality of stored maximum power change values in addition to the integrated value allowable range. Yes,
The loss determination means determines that the fillet roller is defective when the integrated value of the power change amount currently integrated is out of the integrated value allowable range and the maximum value of the power change amount extracted this time is out of the maximum allowable range. A defect determination device for a fillet roller, which is means for determining whether or not it is in progress.   The allowable range setting means calculates a moving average and a standard deviation of the latest predetermined maximum amount of power change stored by the storage means, and the maximum value allowable range based on the moving average and the standard deviation The defect determination device for a fillet roller according to claim 3, wherein the defect determination device is a means for setting the value. A fillet roller defect determination method for determining a defect of the fillet roller in a fillet roll processing apparatus including a fillet roller pressed against a workpiece rotated by an electric motor,
(A) detecting the load power of the motor every predetermined time;
(B) The amount of change in the load power per predetermined time is sequentially calculated as the amount of power change,
(C) integrating the calculated power change amount as a power change amount integrated value;
(D) storing the power change amount integrated value;
(E) Based on a plurality of stored power change amount integrated values, an integrated value allowable range is set as an allowable range of the power change integrated value;
(F) If the integrated power change amount integrated this time is within the integrated value allowable range, it is determined that the fillet roller is not missing, and the integrated power change amount is not within the integrated value allowable range. If so, it is determined that the fillet roller is missing.

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