JPH0555916B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a maintenance guidance device that notifies the maintenance and inspection of production equipment, utility equipment, etc. in a factory.

[Conventional technology]

Conventionally, as this type of device, for example, JP-A-58-
As shown in Publication No. 211291, the number of operations and operation time are accumulated based on the operation signal indicating the ON/OFF state of the device, and when the accumulated value matches a preset setting value, Some devices are designed to make announcements or display instructions for maintenance and inspection.

[Problem to be solved by the invention]

However, in the conventional equipment described above, the set value for when maintenance and inspection should be performed is fixed, so the timing for maintenance and inspection may be inappropriate depending on the operating frequency and operation history of the equipment, and in some cases, recovery may be delayed. There was a problem that an impossible failure occurred. That is,
When production equipment, etc. is operated for a longer time or more frequently, the fatigue and wear of parts increases.As the operation time increases, the frequency of failures also increases, especially when the fatigue and wear limits are exceeded. The frequency of failure occurrence increases rapidly. Therefore, it is important for production management to perform maintenance and inspections such as lubrication before this fatigue and wear increases, and to maintain the capacity of the equipment as much as possible when it was a new product. However, in conventional equipment, the set value for when maintenance and inspection should be performed is set and fixed based on experience and theoretical values, without taking such operating history into consideration. It becomes impossible to announce the appropriate maintenance and inspection period commensurate with the current state of fatigue and wear, which may result in unrecoverable failures, or even if recovery is possible, it may prolong the repair time and increase maintenance costs. There was a problem that this resulted in a decrease in productivity.

SUMMARY OF THE INVENTION An object of the present invention is to provide a maintenance guidance device for equipment that can notify an appropriate maintenance/inspection period commensurate with the current state of fatigue of the equipment.

[Means to solve the problem]

The first aspect of the present invention is, as shown in FIG. 1 excluding the components indicated by chain lines, a maintenance guidance for equipment that monitors the operating status of equipment and provides notification that maintenance and inspection of the equipment should be carried out. The device comprises: an equipment operation detection means for detecting the operation of each equipment; an equipment discrimination means for determining the type and number of each equipment; and an operation time/number of times accumulating means for adding up the operating time or number of times each equipment is operated. , maintenance cycle storage means for storing the maintenance cycle set by the input means, cycle determination means for determining whether the integrated value of the operation time/number of times integration means has reached the maintenance cycle of the cycle storage means, and this cycle determination means. a guidance notification means for outputting a maintenance guidance notification for the equipment for which the period determination means has determined that the period has been reached; a display means for displaying this guidance notification; A clearing means for clearing the cumulative value to zero; further, a driving time/number of times accumulating means for accumulating the driving time or number of driving times accumulated by the driving time/number of times accumulating means; and a cumulative time for storing the accumulated cumulative value. / a number of times storage means; a wear time storage means for storing the predicted value of the wear time of each device inputted by the input means; An equipment wear determination means for determining whether the predicted time value has been reached, and an updated value based on the maintenance cycle value in the maintenance cycle storage means and a predetermined reduction rate for the equipment that the equipment wear determination means has determined has reached the predicted value. maintenance cycle update calculation means for calculating the maintenance cycle update calculation means, and cycle update means for replacing the maintenance cycle of the equipment that has reached the wear period in the maintenance cycle storage means with the calculated update value;
It is characterized by being composed of.

As shown in FIG. 1 as a whole including the components indicated by chain lines, the second invention of the present invention further provides equipment failure detection for detecting the presence or absence of a failure in each equipment, in addition to the first invention. means, a failure determination means for determining a failed device based on data from the equipment failure detection means and the equipment discrimination means, and an integration means for the failed device in the operation time/number of times accumulating means when the equipment failure detection means determines a failure. The present invention is characterized in that it is provided with cycle correction means for replacing the maintenance cycle for equipment of the same type as the failed equipment in the maintenance cycle storage means based on the value.

[Effect]

In the device maintenance guidance device according to the first aspect of the present invention, the maintenance cycle value, which serves as a maintenance inspection notification standard, is changed depending on the cumulative value of the operating time or number of times the device has been operated up to the present time. Furthermore, in the device maintenance guidance device according to the second aspect of the invention, when an abnormality occurs, the maintenance cycle value is further corrected to the actual value up to the occurrence of the abnormality. This is also done for devices of the same type.

To explain in more detail, in the equipment maintenance guidance device according to the first invention, the equipment operation detection means detects the operation of each equipment, and the equipment discrimination means determines the type and number of each equipment, and determines the operating time/number.
The number of times accumulating means accumulates the operating time or number of times each device is operated.

For each device, the cycle determining means determines whether the integrated value of the operation time/number of times accumulating means has reached the maintenance cycle set in the maintenance cycle storage means by the input means, and the guidance notification means determines whether the integrated value of the operation time/number of times accumulating means has reached the maintenance cycle set in the maintenance cycle storage means. The display means outputs a maintenance guidance notice for the determined equipment, the display means displays the guidance notice, and the clearing means calculates the integrated value in the operation time/number of times integration means after the guidance notice is issued for the equipment for which the period determination means has determined that the cycle has been reached. Clear to zero.

Furthermore, the driving time/number of times accumulation means is the driving time/number of times.
The operation time or number of operations accumulated by the number of times accumulation means is accumulated, the cumulative time/number of times storage means stores the cumulative value of the operation time or number of operations, and the equipment wear judgment means is inputted with the cumulative value for each piece of equipment. The maintenance cycle update calculation means updates the maintenance cycle in the maintenance cycle storage means for the equipment for which the equipment wear determination means determines that the predicted value of the wear time has been reached. An updated value is calculated based on the value and a predetermined reduction rate, and the cycle updating means replaces the maintenance cycle of the equipment that has reached the wear period in the maintenance cycle storage means with the updated value.

In the equipment maintenance guidance device according to the second invention, in addition to the operations in the first invention, the failure determination means determines a failed equipment based on data from the equipment failure detection means and the equipment discrimination means, and the period determination means When the equipment failure detection means determines that there is a failure, the maintenance cycle for the same type of equipment as the failed equipment in the maintenance cycle storage means is replaced by the integrated value of the failed equipment in the operation time/number of times integration means.

〔Example〕

FIG. 2 is a block diagram showing one embodiment of the maintenance guidance device according to the present invention. In the figure,
1-1 to 1-x are switches that are turned on when x devices (not shown) are in operation, and the operating time of each of the x devices is the sum of the on times of these switches. It is calculated by 1'-1 to 1-x' are switches that are turned on when x devices fail, and 2 is a process that inputs the output signals of switches 1-1 to 1-x and 1'-1 to 1'-x. Input device, 3 is switch 1
-1 to 1-x output signals are used to accumulate operating time for each device, and the cumulative value is compared with a set value for determining maintenance and inspection time to determine whether each device has reached its maintenance and inspection time. 4 is a display device that displays the operating hours of each device and the device number that has reached the maintenance check time, and 5 is a light. A pen, 6 a keyboard, and 7 a typewriter.

FIG. 3 is a diagram showing the relationship between the cumulative value N of operating hours of the equipment and the maintenance cycle Q. The equipment maintenance guidance device of this embodiment provides maintenance guidance for multiple types of equipment, and each type of equipment is comprised of multiple units.

For each device, the cumulative operating time N is the operating time value (actual value) up to the wear area determined for each device N ₀ a ₁ ,
During the period until N ₀ a ₂ ,...N ₀ a _x , N ₀ b _i , N ₀ c _i are reached, the maintenance cycle measurement values Qa ₁ , Qa ₂ ,...Qa _x are cleared each time maintenance and inspection work is performed. , Qb _i ,
Qc _i (indicated by a broken line in the figure) is the upper limit for each device
Each time Q ₀ a ₁ , Q ₀ a ₂ , ...Q ₀ a _x , Q ₀ b _i , Q ₀ c _i is reached, maintenance and inspection work is instructed.

Here, a, b, and c of N ₀ a ₁ , N ₀ a ₂ ,...N ₀ a _x , N ₀ b _i , N ₀ c _i represent the type of equipment, and 1 to x represent the type of a. In order to simplify the explanation, the numbers for the b and c types of devices are collectively represented by i, representing a plurality of devices. In addition, in Figure 2, a
Only types 1 to x of devices are shown, and switches for detecting the operating states of devices of types b and c are omitted.

On the other hand, in the period exceeding the wear region, the upper limit of the maintenance cycle Qa _i (i = 1 to x), Q _p b _i , Q _p c _i is the cumulative value N of the operating time up to that point and the reduction rate described later.
It is changed to become shorter depending on ka _i , kb _i , kc _i ,
By comparing the changed upper limit value with the measured value, it is notified whether or not maintenance and inspection should be performed.

In other words, if the type of equipment is only type a, under the condition of N<N ₀ a _i , maintenance and inspection can be carried out by comparing Q and Qa _i as Q = Q ₀ a _i ...(1) You will be notified whether or not to do so.

In addition, under the condition of N≧N ₀ a _i , maintenance and inspection can be carried out by comparing Q and Qa _i as Q=Q ₀ a _i [1-(N-N ₀ a _i )ka _i ]...(2) You will be notified whether or not to do so.

FIG. 4 is a structural diagram of the management table 110 (located in the microcomputer) that stores data for such maintenance management, and shows the upper limit values of the maintenance cycle Q ₀ a _i , Q ₀ b _i , Q ₀ c _i , operating time value when reducing maintenance cycle N ₀ a _i , N ₀ b _i , N ₀
c _i , reduction rate ka _i , kb _i , kc _i are set for each device, cumulative operating time values Na _i , Nb _i , Nc _i , maintenance cycle measurement values Qa ₁ , Qb ₁ , Qc ₁ , Daily integrated values α _i , β _i , γ _i are stored.

5a and 5b are flowcharts showing the operation of the microcomputer 3 for integrating the operating time N and the maintenance cycle measurement value Q. FIG. N and Q are integrated in 1-minute units by the 1-minute process shown in figure a, and the integration results are shown in figure b.
By daily processing, it is accumulated on a daily basis. When the integration of N and Q for one day is completed, maintenance guidance processing is executed based on the integration results.

FIG. 6 is a flowchart showing the details of the maintenance guidance process. First, it is determined whether or not the upper limit value of the maintenance cycle needs to be changed, depending on whether or not there is a failure in the equipment. If there is a failure in a device, after selecting the same type of device as the failure device, it is determined whether a specific device whose upper limit value is to be excluded from being changed is specified by the keyboard 6 or the light pen 5. , change the upper limit value of devices other than the specified device to the operating time value of the failed machine (the operating time value from the time of the previous maintenance to the time of failure).
As a result, if one of the equipment groups that should undergo maintenance every 5,000 hours breaks down 4,000 hours after the previous maintenance, the maintenance cycle for the same type of equipment including the faulty machine will change. upper limit is 4000
changed in time. As a result, other devices that have the same risk as the failed device will be notified that they should undergo maintenance before a failure actually occurs.

On the other hand, if there is no malfunctioning device, the maintenance cycle Q is calculated using equations (1) and (2), and then compared with the time measurement value Qa _i from the time of the previous maintenance, whether maintenance is necessary or not. , and Q ₀ a _i <
For Qa _i equipment, its equipment number and inspection items are registered in the memory area for message output.
When the determination of whether or not maintenance is necessary for all devices is completed, the display device 4 and typewriter 7 output the device numbers requiring maintenance and inspection items registered in the message output memory area.

FIG. 7 is a flowchart showing the details of the process of changing the maintenance cycle upper limit value of the same type of equipment when a faulty machine occurs. For example, equipment a ₁ of group a in FIG.
Assuming that the failure occurs at time Na ₁ , first extract the operating time Na ₁ of failed machine a ₁ and the measured value Qa ₁ from the time of the previous maintenance, set search counter j to j = 1, and first extract j =1 first device
Compare N ₀ a _j of a ₁ and Na _j . That is, it is compared whether Na ₁ is smaller than the operating time value N ₀ a ₁ in the wear region. As a result, if Na ₁ <N ₀ a ₁ , the maintenance cycle upper limit value Q ₀ a ₁ of device a ₁ is changed to Qa ₁ .
Thereafter, set j=2, perform the same process for the second _{device a2} , and change the upper limit _{Q0a2 of} device _a2 to _Qa1 if _Na1 < _N0a2 . This process is repeated until j=x, and for equipment that has not yet reached the wear area, the maintenance upper limit value of that equipment is changed to Qa ₁ . However, for equipment that has already reached the wear region, the reduction rate ka ₁ is reduced to
Correct according to Na ₁ , and sequentially modify the maintenance cycle using this new reduction rate.

In other words, for the j-th device that has reached the wear region, it is reduced by ka _j = (Q ₀ a _j − Qa ₁ ) / Q ₀ a _j (Na ₁ − N ₀ a _j ) ...(3) Correct the rate.

As a result, even for equipment that has reached the wear range, the failure time of the failed equipment is reflected.

〔Effect of the invention〕

As explained above, according to the present invention, it is possible to notify the maintenance period commensurate with the operating performance of the equipment, thereby preventing unrecoverable failures and increases in maintenance costs caused by missed maintenance periods.
Alternatively, there is an excellent effect of being able to prevent a decrease in productivity.

[Brief explanation of the drawing]

Figure 1 is a block diagram showing the configuration of the present invention, Figure 2 is a block diagram showing the configuration of the present invention.
The figure is a block diagram showing an embodiment of the present invention, Figure 3 is a relationship diagram between cumulative operating time and maintenance cycles, and Figure 4 is the structure of a management table that stores data for managing maintenance cycles. Figure, 5th
The figure is a flowchart of a process for accumulating operating hours and maintenance cycles, FIG. 6 is a flowchart showing details of a maintenance guidance process, and FIG. 7 is a flowchart of a process for changing a maintenance cycle. 1-1 to 1-x, 1'-1 to 1'-x...Switch, 2...Process input device, 3...Microcomputer, 4...Display device, 6...Keyboard, 7...Typewriter .

Claims (1)

[Scope of Claims] 1. A maintenance guidance device for equipment that monitors the operating status of equipment and provides guidance for maintenance and inspection of the equipment, comprising: equipment operation detection means for detecting the operation of each equipment; and equipment operation detection means for detecting the operation of each equipment; an equipment discrimination means for determining the type and number of each equipment; an operation time/number accumulating means for accumulating the operating time or number of times of operation of each equipment; an input means for setting a maintenance cycle regarding the operating time or number of times of operation of each equipment; maintenance cycle storage means for storing the maintenance cycle set by the input means; cycle determination means for determining whether the integrated value of the operation time/number of times integration means has reached the maintenance cycle of the cycle storage means; and the cycle determination means. a guidance announcement output means for outputting a maintenance guidance announcement for the equipment that the means has determined has reached; a display means for displaying the guidance announcement output from the guidance announcement means; Clearing means for clearing the integrated value in the driving time/number of times accumulating means to zero after the guidance announcement, and further driving time/number of times accumulating means for accumulating the driving time or the number of driving times accumulated by the driving time/number of times accumulating means. a cumulative time/number storage means for storing the cumulative value accumulated by the operation time/number of times accumulation means; and a wear time storage means for storing the predicted value of the wear time of each device inputted by the input means. equipment wear determination means for determining whether the cumulative value in the cumulative time/number storage means has reached the predicted wear time value in the wear time storage means for each equipment; maintenance cycle update calculation means for calculating an update value for the equipment based on the maintenance cycle value in the maintenance cycle storage means and a predetermined reduction rate; A maintenance guidance device for equipment, comprising: cycle updating means for replacing the maintenance cycle of the equipment that has reached the wear period in the maintenance cycle storage means. 2. In an equipment maintenance guidance device that monitors the operational status of equipment and provides notification for maintenance and inspection of the equipment, equipment operation detection means detects the operation of each equipment, and determines the type and number of each equipment. an operation time/number of times accumulation means for accumulating the operation time or number of operations of each device; an input means for setting a maintenance cycle regarding the operation time or number of operations of each device; A maintenance cycle storage means for storing a maintenance cycle; an equipment failure detection means for detecting the presence or absence of a failure in each equipment; and a failure determination means for determining a failed equipment based on data from the equipment failure detection means and the equipment determination means. and a period determining means for determining whether the integrated value of the operating time/number of times accumulating means has reached the maintenance period of the period storage means for the equipment for which the equipment failure detecting means has determined that there is no failure; and the period determining means a guidance notification means for outputting a maintenance guidance notification for a device that has been determined to have reached the period; a display device that displays a guidance notification from the guidance notification device; clearing means for clearing the integrated value in the operating time/number of times accumulating means to zero, and the maintenance based on the integrated value of the faulty equipment in the operating time/number of times accumulating means when the equipment failure detection means determines that there is a failure. cycle correction means for replacing the maintenance cycle for equipment of the same type as the faulty equipment in the cycle storage means; and operation time/number accumulation means for accumulating the operation time or number of operations accumulated by the operation time/number accumulation means. a cumulative time/number storage means for storing the cumulative value accumulated by the operation time/number of times accumulation means; and a wear time storage means for storing a predicted value of the wear time of each device inputted by the input means. , equipment wear determination means for determining whether the cumulative value in the cumulative time/number storage means has reached the predicted wear time value in the wear time storage means for each equipment; maintenance cycle update calculation means for calculating an update value for the equipment based on the maintenance cycle value in the maintenance cycle storage means and a predetermined reduction rate; and the update value calculated by the maintenance cycle update calculation means. A maintenance guidance device for equipment, comprising: cycle updating means for replacing the maintenance cycle of the equipment that has reached the wear period in the maintenance cycle storage means.