JPH06666A - Prediction and diagnostic system of obstruction of thermal cutting machine - Google Patents

Abstract

PURPOSE:To provide an appropriate arrangement or instructions for difficult obstructions by analyzing the image information received on the support side by means of a diagnostic system to give a solution, and executing the central ized management of the data for various obstructions on the support side. CONSTITUTION:On the user side, the information including at least the image information on the obstructions is transmitted from the first control system 121 to the second control system 131 on the support side through the communication system 125. On the support side, the information is analyzed by a diagnostic device 137, and the solution is made, and an appropriate instruction is transmitted to the user side through the communication system 125. In addition, a storage device 151 to store the data, a library 153 where the program for diagnosis is stored, and a storage device 156 for keeping use to store the data and information for keeping for a long time are connected to the diagnostic device 137, the know-how of various obstructions is accumulated on the support side, reducing the load to solve the obstructions on the user side.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a diagnostic system of a thermal cutting machine for diagnosing a fault occurring during operation of the thermal cutting machine.

[0002]

2. Description of the Related Art Conventionally, when a failure occurs during the operation of a thermal cutting machine, for example, a laser processing machine, the user seeks the cause and tries to solve the problem, but when the user cannot solve the problem, the user does not solve the problem. Was informed of the current situation by telephone or fax etc. to the serviceman, and asked the serviceman's instructions regarding the corresponding measures. The service person determines the situation by telephone or FAX, and gives the countermeasure by telephone or FAX, or directly gives the countermeasure to the user.

However, a thermal cutting machine such as a laser machine has many parts to be adjusted and operated, and its operation is complicated. Further, the structure of the machine itself is complicated, and it is set for processing a work material having different cutting conditions. It is easy to cause an erroneous operation.
Therefore, in order to always operate the thermal cutting machine normally, it takes a lot of time to train the ability of the operator. In addition, when a failure occurs, it may be difficult for the user side to properly judge the status of the failure and send sufficient information to the serviceman to obtain an appropriate instruction.

[0004]

Therefore, the present invention solves the problems described above, follows the capabilities of the operator, provides the operator with appropriate measures or instructions for difficult obstacles, and processes them by analyzing the collected data. Prediction of machine failure occurrence It is to build and provide a diagnostic system for dealing with failure occurrence.

[0005]

In order to solve the above-mentioned problems, the present invention comprises a recording system for transmitting at least image information to the user side of a processing machine, and a transmitting means for transmitting this image information. A receiving unit for receiving the image information on a side supporting failure removal, and a diagnostic system for diagnosing a failure of the processing machine based on the image information, and providing a result and a countermeasure, It comprises a communication system for communicating information between the user side and the support side.

[0006]

The user side transmits the information including at least the image information regarding the failure to the support side, and the support side analyzes the information by the diagnostic system to solve the problem. Since the transmitted failure information is centrally managed by the support side, a wide variety of failure know-how is accumulated in the support side, and the burden on the user side for solving the failure is reduced. Further, since the failure can be predicted, the preparation time for solving the failure can be taken sufficiently and the downtime of the machine can be significantly reduced.

[0007]

EXAMPLES Examples in which the present invention is applied to a laser processing machine will be described below. The present invention can be applied not only to laser processing machines but also to thermal cutting machines such as plasma processing machines.

FIG. 1 shows an outline of the diagnostic system in this embodiment. In FIG. 1, a laser processing machine 11
The laser processing machine main body 13 and the laser oscillator 15 are provided to perform processing such as cutting and hole-welding a work W appropriately carried into the processing machine main body 11.

The laser processing machine 11 is generally operated by an operator on the user side. An image input device 101 for reporting the situation as an operator when a failure or the like occurs or is predicted while the processing machine is operating is installed at an appropriate location near the processing machine 11. This image input device 101 can be automatically or by an operator,
Or it operates by the command from the support side. Further, processing data for knowing various processing states of the processing machine is input to the data input device 103. These data are input to the data input device 103 via a sensor (not shown) provided at an appropriate place of the processing machine 11, and the data collection system 105 stores the data in the data storage device 107.

Further, in order to provide sufficient information to the support side, a voice input device 111 and a character input device 113 for transmitting program and graphic information are provided at appropriate places on the user side. The image input device 101, the voice input device 111, the character input device 113, the data collection system 105, and the data storage device 107 are connected to a first control system 121 provided on the user side, and via this first control system. Connected to the communication system 125. Further, a terminal device 123 with a display is connected to the first control system 121 so that it can be appropriately operated by an operator or the like.

The communication system 125 is connected to a second control system 131 provided on the support side, whereby the user side and the support side perform transmission / reception. In addition,
In this communication system, when there are a plurality of users, each user is connected to the support by a separate communication system.

The second control system 131 is connected to the terminal device 133, the monitor 135 and the diagnostic device 137. Further, the second control system is connected to an information storage means 139 for storing information of images, voices, characters and data sent from the user side.

The diagnostic device 137 includes a storage device 151 for storing data, a library 153 in which a diagnostic program is stored, and a storage device 155 for storing data and information for long-term storage. Further, it is directly connected to the information storage means 139 so that the received information such as images, voices, characters and data can be directly accessed.

Further, a voice input device 161 and a character input device 163 are connected to the second control system 131 in order to easily transmit the diagnosis result and the instruction to the user side.

The system will be described in detail below.

The image input device 101 includes, for example, a video camera, an automatic programming system, a writing system, a scan converter and the like. The video camera can input still images and moving images. The automated programming system can create still images for transmission. The writing system can send documents, catalogs, images of cut samples, and so on. The image information handled by the image input device includes, for example, a state of being machined, a shape of a product to be cut, a cutting state of the product such as gouging and a burning occurrence state, a state of a cut surface of the product such as surface roughness, etc. , Machine setting status, status of each part of machine, operation procedure and method, product input shape, data being input, etc. The information is input as a still image or a moving image as needed.

The measurement target of the data input device 103 differs depending on the diagnosis target. FIG. 2 shows an example of a measurement target when diagnosing an oscillator, when diagnosing a processing machine, when diagnosing a leak rate, and when diagnosing a laser beam.

As the character input device 113, there are a writing tablet device, a superimposing unit, etc., and a comment can be written in an image to be transmitted. FIG. 3 shows a case where a user writes a comment in a drawing using a writing tablet and the user sends it, and FIG. 4 shows an example when a support side writes a comment and sends it.
In these figures, the automatic programming system 18
A writing tablet device 185, 191 writes a message on the still image created in No. 1, 187, and images 183, 189 combined by a superimpose unit (not shown) are transmitted. FIG. 5 shows an example of the case where comments are written on various images and the user side transmits them. FIG. 6 shows an example in which the support side writes a comment in the diagnostic answer and sends it to the user side. A microphone is used as the voice input means.

The diagnostic device 137 will be described in detail below. FIG. 7 shows an example of the diagnostic processing procedure. In the figure,
In step S1, various data are loaded from the processing machine and the oscillator and stored in the storage device 151. In step S2. Graph the captured data. These graphs are output by an external display device such as a display device or a printer as needed. In step S3, diagnosis is performed. In this embodiment, the oscillator diagnosis, the laser beam diagnosis, the processing machine diagnosis, the leak rate, and the like are appropriately selected and performed. Normal, warning, and alarm are output as the diagnosis result. When outputting a warning, the alarm generation timing is predicted in step S4, and this timing is also notified. Further, when outputting a warning or an alarm, in step S5, as history data together with predetermined information, it is filed as history data in the information storage means 139. Whether the diagnostic result is sent to the second control system 131,
It is also displayed on the external display device 157 as necessary.

Diagnosis of the oscillator is performed as follows. The oscillator diagnosis is for diagnosing whether or not the oscillator is operating normally, and an oscillator diagnosis command is started by execution. When this command is executed, library 153
Execute the oscillator diagnostic program saved in.
First, the data of the oscillator is taken in. For the data of the oscillator, the output command value provided in the laser processing machine is changed stepwise as shown in FIG. 8, and the data immediately before the next output value is instructed is measured. , Simmer voltage, simmer current, etc. are also measured. The captured data is displayed in a graph with the output command value as the horizontal axis, as shown in FIG. Based on the result of this graph, diagnosis is performed by a predetermined predetermined diagnostic formula, and a message is output as the diagnosis result. An example of the diagnostic formula is shown in FIG.
Shown in. In the above description, the graph display is used, but when the diagnosis device automatically diagnoses, a mathematical expression can be applied or a change in data can be obtained for diagnosis.

Further, the lacking data can be performed by remotely operating a measuring instrument provided in the laser processing machine by executing a measurement command on the support side.

The laser beam diagnosis will be described below. The laser beam diagnosis is for diagnosing whether or not the intensity and width of the laser beam are appropriate. When the laser beam diagnosis command is executed, the laser beam diagnosis program of the processing machine is executed and the laser beam data is acquired. To capture this data, the output command value of the laser oscillator is changed, and under each output command value, the intensity of the laser beam is measured a predetermined number of times after the trigger sensor signal is generated, as shown in FIG. These waveforms are overlaid as shown in FIG. The maximum and minimum intensities are obtained as shown in FIG. At the time of this superposition, the initial output data after the adjustment is also superposed together. Based on these graphs or data, the following three types of diagnosis are executed for each output value.

(1) Area Diagnosis The initial value of the laser beam and the measured area are compared and diagnosed. As shown in FIG. 12A, the area of the portion surrounded by the maximum value curve and the minimum value curve of the beam shape ( The area of the shaded area in the figure) A ₀ is measured, and normality, warning, and alarm are diagnosed by comparing the area A ₁ surrounded by the maximum curve and the minimum curve of the initial data. For example, the diagnosis can be performed as follows. That is, A ₁ ≦ A ₀ (1
+ Α / 100) is normal, A ₁ > A ₀ (1 + α / 10
0) gives a warning, and A ₁ > A ₀ (1 + β / 100) gives an alarm. Where α and β are positive constants and β ≧ α
Is. Also, the volume can be calculated by this method.

(2) A warning and an alarm are output when the number of data within the warning range and alarm range of the shape diagnosis initial value exceeds the numerical values set by the parameters. For the warning and alarm ranges, as shown in FIG. 12B, the maximum value curve of the data captured as the initial value and the maximum curve of the data captured as the measured value and the ratio are set in%.

(3) Shape comparison diagnosis Diagnosis is made by comparing the shapes of the laser beams that have been taken in. As shown in FIG. 12C, the diameter of the laser mode shape having the maximum mode height Pmax from the average shape of the output values. D ₀
Then, the diameter D ₁ of the laser mode shape having the measurement output mode height P ₁ = P ₀ / e ² is obtained, and normal, warning, and alarm diagnosis is performed. However, P ₀ is the mode height of the rated output value,
e is an exponential function. Each of the above diagnosis is D ₁ / D ₀ <C ₁
When Pmax / D ₁ > C _2, a warning is given and D ₁
Generates an alarm when / D ₀ <C ₃ and Pmax / D ₁ > C ₄ . C ₁ , C ₂ , C ₃ and C ₄ are parameter constants for each diagnosis.

The processing machine diagnosis will be described below. The processing machine diagnosis is to judge whether or not the processing state is normal for a predetermined item. The processing machine diagnosis is started by executing the processing machine diagnosis command, and data is first fetched. The data is taken in until the diagnostic device takes in from the information means 139 already stored by executing the data take-in command, and the predetermined diagnostic process is completed. It should be noted that, if necessary, the second control system 131 and the communication system 12 can be operated by a data capture command
5. It is also possible to directly perform telemetry and acquire data through the first control system or the like. As shown in FIG. 2, the data to be taken in is determined as necessary from each item, for example, actual output, main current, main voltage, conductivity, frequency, duty, cylinder primary pressure, assist gas pressure and the like. The captured data is plotted at each time, and diagnosis is made based on whether this value falls within the preset warning range or alarm range. This diagnosis is done simultaneously.

The leak rate diagnosis will be described below. The leak rate diagnosis is for diagnosing whether or not the leak amount of air (air) or the like is below an allowable value, and is performed by measuring the leak rate and leak amount of the oscillator.

The leak rate diagnosis is performed by executing the leak rate diagnosis command in the procedure shown in FIG. Note that FIG.
Explains the procedure of direct diagnosis by remote control,
Data may be collected by the preliminary data collection system 105 and stored in the information storage unit 139.

In FIG. 12, the oscillator power is turned on in step S1, and immediately after that, the data collection system 105 is turned on in step S2 to measure the oscillator gas pressure, and in step S3 the leak rate and the leak amount are measured. Diagnose. In step S4, the processing of displaying the diagnosis result and data is performed, and at the same time, in step S5, the collection system is turned off and the oscillation power supply is turned off. For the diagnosis of the leak rate, an alarm range, a warning range, and an allowable range are determined in advance, the leak rate is displayed as shown in FIG. 13, and a predetermined diagnosis is made according to the range of the value.

After the diagnosis is completed, the diagnostic device transmits oscillator diagnostic data, laser beam diagnostic data, processing machine diagnostic data, leak rate diagnostic data, history data, etc. through the first control system as required. When the warning occurs, the forecast of the alarm generation time may also be transmitted.

In the case of the present embodiment, the user side and the support side are at a remote distance, and the communication system uses digital lines, telephone lines, or the like. Further, in the above description, the case where one laser processing machine on the user side and the diagnosis system on the support side are connected has been described, but the laser processing machine on the user side is located at a plurality of remote points, and It may be supported by one diagnosis system on the support side.

FIG. 15 shows the outline of the second embodiment of the present invention. As shown in the figure, in the second embodiment,
I use the video conference system. That is, a two-way communication system is adopted in which remote locations are connected by a cable television network so that a conference can be held in the atmosphere of being in the same place. On the user side, an image communication system 201 similar to the TV conference system has two cameras 203, 203, a surface roughness measuring device 205, an A / D converter 207, an automatic programming device 209, a scan converter device 211, and lighting. The tablet device 213 and the data collection diagnosis system 215 are connected to each other, and the processing status of the processing machine photographed by the camera, the image of the automatic programming device,
An input signal or the like in the document drawing device can be transmitted. The video conference system 201 on the user side and the video conference system 231 on the support side are connected by a digital line of the advanced information system 221. Further, in the video conference system 231 on the support side, a still video device 235,
A writing device 237 and a computer 239 for measuring surface roughness
, An automatic programming device 241, a scan converter 243, a writing tablet device, and a data reproduction unit host computer 233 are connected.

The data collection / diagnosis system 215 can perform simple diagnosis in addition to data collection. Also,
This diagnosis system enables the diagnosis of the failure of the processing machine itself directly connected, and may have a learning function to facilitate the subsequent diagnosis. A complicated failure that cannot be diagnosed by the diagnosis system 215 is diagnosed by the video conference system on the support side.

In the above embodiments, the case where the user side and the support side are in remote locations has been described, but it is not necessary that they are in remote locations, and the diagnostic system may be installed on the user side of the laser processing machine. It is a thing.

[0035]

As described above, according to the present invention, even in the event of a failure, it is possible to easily and quickly know how to deal with it, so that it is not necessary to provide the operator with a high degree of training. Further, since data for various faults are centrally managed by the support side, data for faults of one thermal cutting machine can be applied to the thermal cutting machines that are arranged in other areas. In addition to the effect that the machine can be easily obtained, the failure can be predicted in advance, so that the machine can be dealt with before the machine stops.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing a configuration of a first exemplary embodiment of the present invention.

FIG. 2 is a diagram showing a relationship between a diagnosis target and a measurement element in the first embodiment.

FIG. 3 is a diagram showing an example in which a message is inserted into a still image and transmitted / received.

FIG. 4 is a diagram showing an example in which a message is inserted into a still image and transmitted / received.

FIG. 5 is a diagram showing an example of information transmitted by a user by writing comments on various images.

FIG. 6 is a diagram showing an example in which a support side writes a comment in a diagnostic answer and transmits it to a user side.

FIG. 7 is a diagram showing a flow of a diagnosis procedure.

FIG. 8 is a diagram showing a timing of fetching output data of an oscillator.

FIG. 9 is a graph showing the output data of FIG.

FIG. 10 is a diagram showing conditions and results of a diagnostic equation of an oscillator.

FIG. 11 is a diagram showing a method of capturing laser beam data and obtaining the maximum and minimum of the data.

FIG. 12 is a diagram for explaining methods of laser beam surface area diagnosis, shape comparison diagnosis, and shape diagnosis.

FIG. 13 is a diagram showing a flow of a procedure for leak rate examination.

FIG. 14 is a diagram showing a change in leak rate according to date and time.

FIG. 15 is a schematic diagram showing the configuration of a second embodiment.

[Explanation of symbols]

 11 Laser Processing Machine 13 Laser Processing Machine Main Body 15 Laser Oscillator 101 Image Input Device 103 Data Input Device 105 Data Collection System 107 Data Storage Device 121 First Control System 125 Communication System 131 Second Control System 137 Diagnostic Device 139 Information Storage Means 151 Data Storage device 153 Library 155 Storage device for storage 201,231 Image communication system 203 Imaging camera 205 Surface roughness measuring device 209,241 Automatic programming device 213,245 Writing tablet device 215 Data collection diagnostic system 235 Still video device

Claims (6)

[Claims] 1. A system for resolving a fault of a thermal cutting machine, predicting the occurrence of a fault, preventing the fault from occurring and supporting the operation of the machine, and transmitting at least image information to a user side of the machine. A recording system and a transmission means for transmitting the image information, a receiving means for receiving the image information on the side supporting the obstacle removal, and a failure of the processing machine based on the image information. A diagnostic system for a thermal cutting machine, comprising a diagnostic system for providing the result and countermeasures, and comprising a communication system for communicating information between the user side and the support side. 2. A system for removing a failure of a thermal cutting machine, predicting the occurrence of the failure, preventing the failure, and supporting the operation of the machine, wherein the user of the machine has data on a heat source of the machine. And a data collection system for measuring and recording data relating to the processing machine and a transmission means for transmitting these data information, and a reception side for receiving the data information to a support side for supporting a failure. Diagnosing the failure of the processing machine based on the means and its data information,
A self-diagnosis system for a thermal cutting machine, comprising a diagnostic system for providing the result and a countermeasure, and comprising a communication means for communicating information between the user side and the support side. 3. A system for resolving a fault of a thermal cutting machine, predicting the occurrence of a fault, preventing the fault from occurring and supporting the operation of the machine, and transmitting image information on the machine to the user side of the machine. A recording system, a data collection system for measuring and recording data relating to the heat source of the processing machine and data relating to the processing machine main body, and a transmission means for transmitting the image information and the measurement data information. A receiving means for receiving the image information and the measurement data information on a support side that assists in troubleshooting, and a failure of the processing machine is diagnosed by using the received image and measurement data information, and a result thereof And a diagnostic system for providing countermeasures; a diagnostic system for a thermal cutting machine, characterized in that a communication system for communicating information is provided between a user side and a support side. Tem. 4. The installation place on the support side is provided in the same place as the installation place on the user side.
Alternatively, the heat processing machine diagnosis system according to the above item 3. 5. The installation site on the support side is provided at a remote location from the installation site on the user side.
Alternatively, the heat processing machine diagnosis system according to the above item 3. 6. The thermal processing machine diagnosis system according to claim 1, 2, 3, 4, or 5, wherein the thermal processing machine is a laser processing machine.