JPH07315527A - Preventive maintenance alarm system of physical distribution system - Google Patents

Abstract

PURPOSE:To shorten the down time by a failure, a repair and an inspection. CONSTITUTION:A preventive maintenance computer 10 connected to an upper class computer 1 to control a physical distribution system compares the basic data stored in a basic data storage device 11 with the operational condition data stored in an operational condition data storage device 12. For example, the basic data are the life time of the parts, the service life can be predicted irrespective of the variance of the operational load of each equipment by comparing the operation time transmitted from the upper class computer 1 with the integrated operational condition data, and outputted from a CRT 8 and a printer 9 of a work station 7.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a physical distribution system for shipping goods that meet the operation requirements, and more specifically, a preventive maintenance notification for preventing a failure or accident of each device constituting the physical distribution system. Regarding the system.

[0002]

2. Description of the Related Art A physical distribution system includes a stacker crane, an automated guided vehicle, an overhead traveling vehicle, a conveyor, and other transportation devices, and various types of devices such as various sensors, control devices, and communication devices. Since each device is organically related, a failure of one device may bring down the entire distribution system. Therefore, preventive maintenance work for preventing breakdown of each device in the physical distribution system becomes very important.

[0003]

For example, in a factory line, since the operating time and the number of operations are almost the same for each line, it is necessary to replace / inspect the same parts of the equipment constituting the line at the same timing. Is enough. However, even in the same type of crane or unmanned guided vehicle of the same type in the distribution system, the work load varies from device to device, so there is a relatively large gap between parts replacement / inspection. Will occur. Therefore, if it is regularly replaced and inspected, some parts may exceed their lifespan and malfunction, and other parts have not yet reached the end of life and need no replacement or inspection, resulting in troublesome maintenance work and new parts. Is wasted.

Therefore, an object of the present invention is to provide a preventive maintenance notification system which enables reliable and rational execution of preventive maintenance work for preventing failures of each device constituting a physical distribution system.

[0005]

In order to achieve the above object, the invention according to claim 1 provides a life time, a maintenance time, a life operation count, and a maintenance operation count for each part of each device constituting the physical distribution system. Predict and predict the replacement / inspection time for each part based on basic data consisting of any of these or a combination thereof and operating status data including the operating time and / or number of operations for each part of each device. The preventive maintenance notification system of the physical distribution system was configured to output the result.

According to a second aspect of the present invention, the operation status data is an integrated value of the operating time or the number of times of operation of each component, and each time one component is replaced or inspected, the operation state data is calculated. The preventive maintenance notification system of the physical distribution system according to claim 1 is configured such that the integrated value is reset.

The invention according to claim 3 constitutes the preventive maintenance notification system of the physical distribution system according to claim 1 so that a manual for replacement / inspection work of a component to be replaced or inspected can be output.

[0008]

Since the present invention has the above-mentioned structure, it has the following effects.

In the preventive maintenance notification system for the physical distribution system according to the first aspect of the present invention, the preventive maintenance notification is issued based on the basic data and the operation status data. The basic data includes any one of a life time, a maintenance time, a life operation count, a maintenance operation count, or a combination thereof for each part of each device constituting the physical distribution system. The operation status data includes the operation time and / or the number of operations of each part of each device.

In the preventive maintenance notification system for the physical distribution system according to the second aspect of the present invention, since the operation status data is the integrated value of the operating time or the number of operations of each part, the integrated value, the life time, and the maintenance. The time for replacement and inspection can be predicted by simply comparing the time, the number of life operations, and the number of maintenance operations. For example, it is possible to predict the time when the life time of a certain component is likely to exceed the operating time as the replacement time, output the prediction result, and perform the replacement work according to this output. Further, if the number of maintenance operations of other parts exceeds the number of maintenance operations, the result of the inspection time is output and the inspection work is performed. When a part is replaced or inspected, the integrated value for the part is reset and the integration is started again.

In the preventive maintenance notification system for the physical distribution system according to the third aspect of the present invention, a manual for the replacement / inspection work of the part to be replaced or inspected can be output, and the work can be performed with reference to the manual. It can be performed.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments shown in the drawings will be described below.

FIG. 1 is a block diagram showing the configuration of an embodiment of a preventive maintenance notification system for a physical distribution system according to the present invention.

In the figure, the physical distribution system is a host computer 1 that manages each device, and each control that receives a command from the host computer 1 to perform work and that sends and receives data to report the work record to the host computer 1. Controlled by the device. The control devices include crane control devices 2 and 3 that control cranes in automated warehouses and automated guided vehicles (AG
V) an AGV control device 4 mounted on V) for controlling an automatic guided vehicle, a trolley control device 5 for controlling a traveling dolly traveling by bringing a disk into contact with a drive shaft provided along a track, and a conveyor for controlling a conveyor There is a control device 6 and the like.

It should be noted that each of the control devices shown in FIG. 1 is only a part, and a larger number and more types of control devices than usual are connected to the host computer 1. Also, various sensors, barcode labelers, ID card readers / writers, etc. are appropriately connected. Further, as an input / output device to the host computer 1, a workstation 7 having a CRT 8 and a printer 9 attached thereto is connected.

A preventive maintenance computer 10 is connected to the host computer 1 and can receive data from the host computer 1. The preventive maintenance computer 10 stores a basic data storage device 11 that stores the life time and maintenance time of each component used in each device that constitutes the physical distribution system, and an operating status that stores the data received from the host computer 1. Data storage device 1
2 and.

The basic data is input by the workstation 7. The basic data is a value that is the basis for predicting the life of each part. For example, data of the parts manufacturer (life time, life times, maintenance time such as lubrication time, maintenance times such as lubrication times), past performance data, inspections. It consists of prediction calculation formulas. For example, in the case of a wheel of a crane, the number of rotations is the life, the number of rotations that requires lubrication, and in the case of a brake, the operation frequency is the life.

The inspection prediction calculation formula is, for example, for a crane wheel.

[Equation 1] It is expressed as. Here, h: inspection prediction index F: start point of FROM-TO T: end point of FROM-TO W: pitch of continuous automatic warehouse L: circumference of wheel H: cycle speed of inspection

For example, if the pitch W is 2 meters and the wheel perimeter L is 0.5 meters, when the crane moves from 10 stations to 3 stations, | 10-3 | × 2 ÷ 0.5
Then, the wheel has rotated 28 times. The value of the inspection prediction index h, which is obtained by summing up each time the work is performed and dividing by the inspection cycle speed H, makes it possible to know where the present condition is in the inspection cycle. If the inspection prediction index h becomes 1, it is the inspection time, so it is possible to predict the date and time at which the inspection prediction index h is likely to reach 1 from the date and time of the replacement / inspection record described later. For example, if the inspection prediction index h of a certain part has reached 0.5 in one year after replacement, it can be predicted that the inspection prediction index h will become 1 in one year.

The preventive maintenance computer 10 performs the calculation according to the inspection prediction calculation formula. In the above-described inspection prediction calculation formula, the pitch W and the perimeter L are known and can be included in the formula as predetermined values. The inspection cycle speed H is stored in the basic data storage device 11 as data of the parts manufacturer. Therefore, FROM-TO
Calculation can be performed if the starting point F and the ending point T of are known.

The host computer 1 manages the operations of the crane controllers 2 and 3. The host computer 1 gives an instruction to store and retrieve a specific item. Crane controller 2,
3 carries out the loading / unloading work according to the instruction, and moves the crane between the loading / unloading station and the shelf. When the work is completed, the crane control devices 2 and 3 transmit the work record data to the host computer 1 to report. A part of the work result data is transferred from the host computer 1 to the preventive maintenance computer 10, and the preventive maintenance computer 10 has a FROM.
Knowing the starting point F and the ending point T of -TO, the inspection prediction index h is calculated according to the inspection prediction calculation formula.

The preceding part of the above-mentioned inspection prediction calculation formula is an integrated value of the rotational speeds of the wheels. The value calculated by each operation of the crane is added to the integrated value stored in the operation status data storage device 12 and stored as a new integrated value. Most of the operating status data stored in the operating status data storage device 12 is an integrated value. For example, the number of times of operation is the brake of a crane, the travel distance (≈travel time) of a trolley, and the battery of an AGV. It is an integrated value of the operating time, the contact frequency for a relay, and the running time for a disk of a traveling vehicle.

As a result, even if two or more cranes of the same type are included in the distribution system, and even if there are variations in the work load, the lifespan and maintenance requirements can be predicted individually from the integrated values, so down due to a failure. It is possible to provide a highly reliable physical distribution system by preventing the above, shortening downtime and improving the operation rate. Further, since unnecessary inspection work is not performed, downtime associated with the inspection, labor and time for the work are saved, and new parts are not wasted.

These accumulated values are obtained from the work record data, the command data of the host computer 1, or the data transmitted from other timers, sensors, etc. as in the above example.

The operating status data storage device 12 stores various operating status data in addition to the integrated value. For example, failure / abnormal condition data. The failure / abnormality status data includes sound, vibration, temperature, output signals from the wear sensor, downtime when a failure or abnormality occurs, time of abnormality occurrence, and the like. When an abnormal sound or vibration is detected, the preventive maintenance computer 10 may output a content prompting replacement / inspection of the parts regardless of the inspection prediction index h calculated by the inspection prediction calculation formula.

Further, replacement / inspection records for each part are also stored. After the parts are replaced and inspected, the fact is input by the workstation 7 and stored in the operation status data storage device 12. As a result, the integrated value stored in the operation status data storage device 12 for the part is reset and returns to zero.

The preventive maintenance information from the preventive maintenance computer 10 is output from the CRT 8 and the printer 9. The output is done in the form of a list.The output list includes a lifespan list, a periodic inspection schedule list, a preventive maintenance inspection list, a repair history list, an operation list, a preventive maintenance parts list by machine, and an inspection work guide manual. It is also possible to output.

FIG. 2 shows a life list. The life list is
It is obtained by entering the device name in the workstation 7. Lifespan list is for equipment (here crane 3 U
It consists of the component name, model number, manufacturer, component life, usage time, estimated replacement date, next inspection, and contents that compose A). Of these, the part name, model number, manufacturer, and part life are basic data, the usage time is operating status data, and the predicted replacement date is derived from the inspection prediction index h. The next inspection is a regular inspection and is determined for each device, and the details are the inspection contents. The period and the contents of the periodic inspection are stored in the basic data storage device 11, and the time of the periodic inspection period is reset by the replacement and input of the inspection record.

By referring to the life list, the maintenance manager of the physical distribution system can know the replacement timing of each component constituting each device and the predicted maintenance timing.

FIG. 3 shows a regular inspection schedule list. The regular inspection schedule list includes an inspection time (the inspection date is used here, but it may be specified as a week, a month, or a year), a machine name, an inspection point, and a working time when the period of the regular inspection is full. This allows the maintenance manager to easily make a plan for periodic inspection.

FIG. 4 shows a preventive maintenance inspection list. A preventive maintenance inspection list is created for each device, and the inspection order, inspection points, inspection contents, normal values, and contents are the basic data storage device 1
It is stored in 1. The measured value, judgment, and time are input by the operator who inspected, and the operation status data storage device 1
Stored in 2. The operator can refer to the preventive maintenance inspection list of the equipment to be inspected to know the order, location and contents of the inspection, and the maintenance manager can manage how the preventive maintenance inspection was performed. it can.

FIG. 5 shows a repair history list. The repair history list shows the history of repairs performed in the past by repair date, machine name, failure status, cause, repair content, charge, and working time, and each data is stored in the operation status data storage device 12. Output sequentially. This content is reflected when the maintenance manager predicts the inspection date, and the inspection is postponed or the inspection is performed earlier than the expected inspection date in the life list.

The operation list is an output of information such as the operation time, the number of times of operation, and the operation rate downtime for each device, and is useful for the maintenance manager to predict the inspection date. The preventive maintenance parts list by machine is a master information output of parts and is used to grasp the stock status of the maintenance items. Contents,
Parts name, model, manufacturer, number of stocks, number of safety stocks, service life, inspection interval, unit price, lubrication date, compatible products, importance of maintenance parts, parts drawing, photograph, basic data storage device 11 and operating status data storage device Stored in 12.

The inspection work guide manual is for explaining the order and method of the inspection work interactively from the CRT 8 when performing the inspection work.
Remembered in. When the device name is entered, past repair details and part information are output on the CRT8, as well as part drawings, photographs, sequences, methods, measuring instruments, preparations, standard working time,
The operation test and the like will be described. Thus, even if a person unfamiliar with the inspection work is to perform the inspection, the inspection work can be performed relatively easily and reliably.

The embodiment of the present invention has been described above.
It is needless to say that the present invention is not limited to the above-mentioned embodiments and can be appropriately modified within the scope of the gist of the present invention.

[0036]

According to the preventive maintenance notification system of the physical distribution system according to the invention described in claim 1, the preventive maintenance notification is:
Since it is done for each part, even if there are devices of the same type in the distribution system, and even if there are variations in the workload of each, it is possible to predict the service life and maintenance requirements for each part, thus reducing downtime due to failure. It can shorten the operating rate and improve the operation rate, configure a highly reliable logistics system, reduce downtime due to unnecessary replacement and inspection work, reduce the time and effort required for unnecessary work, and waste new parts. Never.

According to the preventive maintenance notification system of the physical distribution system according to the second aspect of the present invention, the replacement / inspection timing can be easily predicted by simply comparing the integrated value with the life or maintenance request.

According to the preventive maintenance notification system of the physical distribution system according to the third aspect of the present invention, the manual for the replacement / inspection work of the parts to be replaced or inspected is output, and the work is performed with reference to the manual. Therefore, even an inexperienced person can easily and surely perform replacement / inspection work.

[Brief description of drawings]

FIG. 1 is a block diagram showing the configuration of an embodiment of a preventive maintenance notification system for a physical distribution system according to the present invention.

FIG. 2 shows a life list output in the embodiment of FIG.

FIG. 3 shows a scheduled inspection schedule list output in the embodiment of FIG.

FIG. 4 shows a preventive maintenance inspection list output in the embodiment of FIG.

FIG. 5 shows a repair history list output in the embodiment of FIG.

[Explanation of symbols]

 1 Host computer 2, 3 Crane control device 4 AGV control device 5 Cart control device 6 Conveyor control device 7 Workstation 8 CRT 9 Printer 10 Preventive maintenance computer 11 Basic data storage device 12 Operating status data storage device 13 Guide manual storage device

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yoshinori Yamada 3-18 Taiko, Nakamura-ku, Nagoya, Aichi Nagoya KS Building 3F Murata System Co., Ltd. Nagoya Office

Claims (3)

[Claims] 1. Basic data consisting of any one or a combination of life time, maintenance time, life operation count, maintenance operation count, or a combination thereof for each part of each device constituting the distribution system, and for each part of each device A preventive maintenance notification system for logistics systems that predicts the replacement / inspection time for each part based on operating status data that includes operating time and / or number of operations, and outputs the prediction results. 2. The operation status data is an integrated value of the operating time or the number of operations of each component, and the integrated value of the component is reset every time replacement or inspection is performed for one component. The preventive maintenance notification system of the physical distribution system according to claim 1. 3. The preventive maintenance notification system for a physical distribution system according to claim 1, wherein a manual for replacement / inspection work of parts to be replaced or inspected can be output.