JPH10118861A - Judging method for quality of electric appliance - Google Patents

Abstract

PROBLEM TO BE SOLVED: To appropriately incorporate an inspection process of electric appliances in an assembling line by judging the quality of the electric appliances by whether or not they are within the prescribed range obtained based on prescribed continuos physical values measured beforehand. SOLUTION: If an environment temperature, etc., of an inspection system are varied, a judgment reference value which is applied in judging some external machine cannot be simply applied in judging another external machine. Therefore, a sample electric current value of a target appliance to be judged is set to a judgment target value Sn, and electric sample values obtained by tracing back in the past are set to S(n-1)-S(n-9). A judgment reference value of a judgment target value Sn is calculated based on the reference data S(n-1)-S(n-9).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for judging the quality of an electric device on an inspection line provided in a series of assembly lines of the electric device.

[0002]

2. Description of the Related Art Conventionally, electric equipment such as an air conditioner is
At the time of manufacturing, after the assembly line was completed and assembled, performance inspections and the like were performed at an inspection site different from the assembly line.
This is because, for example, in the case of an air conditioner, if the state of the refrigeration cycle is not stable, the cooling capacity and the heating capacity of the air conditioner cannot be properly inspected. This is because there is not enough time for stabilization.

[0003]

As described above, conventionally,
Since it is necessary to perform a performance inspection of an electric device such as an air conditioner in a system different from the assembly line, a time delay in the inspection process is lengthened, and there is a problem that the production efficiency is not improved.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method of judging the acceptability of an electric device, which can appropriately incorporate an electric device inspection process into an assembly line.

[0005]

SUMMARY OF THE INVENTION The present invention relates to a method for judging the quality of an electric device on a test line provided in a series of assembly lines of the electric device. A configuration in which the quality of the electric device is determined from the value of the physical quantity measured later, and the determination of the quality is performed within a predetermined range obtained based on a predetermined number of consecutively measured physical quantities. It depends on whether or not. Further, the predetermined range may be set to a range of values obtained by correcting the difference between the minimum value and the maximum value with respect to an average value of the minimum value and the maximum value of a predetermined number of continuous physical quantities. Further, the predetermined range may be set to a value range obtained by adding a correction to a maximum change amount of a continuous physical quantity among a predetermined number of continuous physical quantities centered on a previously measured physical quantity. Further, the predetermined range is a range of a value obtained by correcting the difference between the minimum value and the maximum value with respect to the average value of the minimum value and the maximum value of the continuous predetermined number of physical quantities and / or It is preferable to set the value in a range obtained by adding a correction to the maximum change amount of a continuous physical quantity among a predetermined number of physical quantities continuous from the measured physical quantity.
Also, a predetermined upper limit value and a predetermined lower limit value may be set in advance in the predetermined range. Further, it is preferable that the value of the predetermined number of consecutive physical quantities measured earlier does not include the value determined to be negative. The predetermined range may be corrected using a quadratic curve when the time from the operation journal of the electric device to the measurement of the physical quantity exceeds the predetermined time.

In a method for judging the quality of an electric device in a test line provided in a series of assembly lines of the electric device having a refrigeration cycle centered on a refrigerant compressor, the refrigeration cycle of the electric device is simulated. A configuration in which the quality of the electrical device is determined from the value of the physical quantity measured after a certain period of time after the operation is performed, and the determination of the quality is the minimum value of a predetermined number of consecutive physical quantities measured earlier. Range of the value obtained by correcting the difference between the minimum value and the maximum value around the average value of the maximum and maximum values, and the maximum change of the continuous physical quantity among a predetermined number of physical quantities continuous around the physical quantity measured last time The determination is made based on whether or not the measured physical quantity is within the range of the value obtained by correcting the quantity. Further, as the physical quantity, a low-pressure side pressure in the refrigeration cycle and a current flowing through the refrigerant compressor can be used. Further, a predetermined upper limit value and a predetermined lower limit value may be set in the predetermined range in advance. Further, it is preferable that the value of the predetermined number of consecutive physical quantities measured earlier does not include the value determined to be negative. The predetermined range may be corrected using a quadratic curve function when the time from the start of the operation of the electric device to the measurement of the physical quantity exceeds a predetermined time. Further, it is preferable that the predetermined time is determined based on a moving distance and a moving speed of the electric device moving on the inspection line.

[0007]

BRIEF DESCRIPTION OF THE DRAWINGS FIG.
An embodiment of the present invention will be described in detail.

FIG. 1 shows an example of a process provided in an assembly line of an air conditioner (electric device) according to an embodiment of the present invention. The inspection system used in this step inspects an outdoor unit of a separation type air conditioner as an air conditioner. Also, in this case, a capability test can be performed on outdoor units of a plurality of models having different capabilities.

In FIG. 1, a conveyor CV sequentially transports a plurality of (in this case, 25) carts CD in a stepwise direction in the counterclockwise direction in the figure. The transport mode is, for example, 6 seconds. After moving, a stop for 12 seconds is performed.

A dummy indoor unit (to be described later) is mounted inside the conveyor CV on the lower side of the cart CD. The indoor unit is fixed to a thick pallet (not shown). The outdoor unit EX in the state is connected after being mounted on the cart CD. The outdoor unit EX mounted on this pallet is transported from a previous process of an assembly line (not shown) and
And is mounted on a cart CD at the entrance of the conveyor CV. The cart CD obtains electric power through a slider (not shown) attached to the conveyor CV, and the electric power is supplied to the indoor unit and the outdoor unit EX. Furthermore, the indoor unit and the outdoor unit EX are connected by the piping and wiring device PD.
The pipeline and the signal and power lines are connected.

FIG. 2 shows an example of the configuration of an air conditioner including an outdoor unit EX, an indoor unit, and a piping and wiring device PD.

In FIG. 1, an outdoor unit EX includes a compressor MP, a four-way valve MF, an outdoor heat exchanger MX, a fan MM,
Capillary tube MC, modulator / strainer M
D, manual valves MV1 and MV2, accumulator MA, and control unit MD.

The indoor unit DM includes an indoor heat exchanger MI,
It comprises a cross flow fan MK and a controller MS.

The pipe wiring apparatus PD includes a manual valve NV1 for connecting the EC side of the indoor heat exchanger MI to the manual valve MV1 of the outdoor unit EX, a large-diameter pipe PM1, and a P of the indoor heat exchanger MI. Valve NV2 and small-diameter pipe PM2 for connecting the side to the manual valve MV2 of the outdoor unit EX, the controller MD of the outdoor unit EX and the controller M of the indoor unit DM
It is composed of a signal line PL for connecting S.

In the inspection line configured as described above, when the cart CD advances by two steps from the carry-in entrance by the conveyor CV, a step of waiting for the operator OP1 is reached, and the operator OP1 uses the wiring piping apparatus P for the cart CD.
The outdoor unit EX is connected to the pipes PM1, PM2 and the wiring PL of D.
Is connected. Next, when the cart CD is transported by the conveyor CV and proceeds by one step, it reaches the step where the first inspection station ST1 is arranged. In the inspection station ST1, a dielectric strength test of the outdoor unit EX is performed. Here, the dielectric strength test is a test in which a predetermined high voltage is applied to a power terminal (not shown) of the outdoor unit EX to check the insulation resistance and the withstand voltage.

Next, when the cart CD advances by two steps by the conveyor CV, the cart CD reaches the step where the second inspection station ST2 is arranged. In the inspection station ST2, a low-voltage start test of the outdoor unit EX is performed. Here, the low-voltage start test is, for example, a test in which a voltage of about 85% of the rated voltage is applied to determine whether or not the compressor MP of the outdoor unit EX starts. At this time, the operation mode of the air conditioner is set to the heating operation.

Next, when the cart CD advances by four steps by the conveyor CV, the cart CD reaches the step where the third inspection station ST3 is arranged. In this inspection station ST3, 6 hours from the start of the heating operation of the outdoor unit EX.
Heating capacity collection after 0 seconds is performed. Here, heating capacity collection refers to measuring the current consumption of the compressor MP and the refrigerant pressure. Here, this inspection station ST
In 3, after the heating capacity is collected, the four-way valve MF is switched, and the operation mode of the outdoor unit EX is switched to the cooling operation. At this time, if the compressor MP is synchronously rotated at 50 Hz, the operation mode can be smoothly switched from the heating operation to the cooling operation without stopping the compressor MP.

Next, when the cart CD advances by five steps by the conveyor CV, the cart CD reaches the step where the fourth inspection station ST4 is arranged. In this inspection station ST4, 7 days from the start of the cooling operation of the outdoor unit EX.
After 8 seconds, the cooling capacity is collected. Here, cooling capacity collection refers to measuring the current consumption of the compressor and the refrigerant pressure.

Next, when the cart CD advances by one step by the conveyor CV, the cart CD reaches the step where the fifth inspection station ST5 is arranged. In the inspection station ST5, the refrigerant recovery 1 for recovering the refrigerant of the outdoor unit EX flowing into the dummy indoor unit MD is started. The start of the refrigerant recovery 1 is performed by a refrigerant recovery robot (not shown) closing the manual valve NV2 of the small-diameter pipe PM2 and starting pump-down for recovering the refrigerant from the outdoor heat exchanger MX.

Next, when the cart CD advances by three steps by the conveyor CV, the cart CD reaches the step where the sixth inspection station ST6 is arranged. In the inspection station ST6, the pump-down being performed, following the inspection station ST5, is ended. That is, the robot closes the large-diameter pipe PM1 to end the refrigerant recovery, and then stops the operation of the compressor MP.

Further, the number of the cart CDs is 2 by the conveyor CV.
When the step proceeds, the bogie CD reaches a step in which the operator OP2 waits, and the operator OP2 makes a comprehensive determination. Then, the truck CD by the conveyor CV
Advances by one step, the cart CD reaches the step where the operator OP3 waits, and the operator OP3
The wiring and piping device PD is removed from the outdoor unit EX.

Then, the cart CD is set to 2 by the conveyor CV.
When the step advances, the cart CD reaches the carry-out exit of the conveyor CV, the outdoor unit EX is removed from the cart CD together with the pallet, and the cart CD is led to the next step of the assembly line.

Further, the input monitoring device PC1 disposed near the operator OP1 provides the operator OP1 with a model of the outdoor unit EX mounted on the truck CD at hand, a connection mode of piping, and wiring. To display the connection mode and the like. Here, the data for this display is stored in a device information processing device described later.

The overall judgment device PC2 disposed near the operator OP2 displays the judgment result of the outdoor unit EX mounted on the truck CD in front of the operator OP2. This is for assisting the determination work of the operator OP2. Here, the data for this display is stored in the device information processing device ID.

FIG. 3 shows an example of the configuration of the cart CD.

In the figure, a pallet P is provided on a cart CD.
L, an outdoor unit EX is mounted, and an antenna AT of a wireless unit (described later) for exchanging necessary information with the wiring and piping apparatus PD, the control apparatus CC, and the inspection stations ST1 to ST6 is provided. Is provided. The pallet PL has a device information processing device ID (for example, IC) for storing various information unique to the outdoor unit EX.
Card or the like).

FIG. 4 shows an example of the configuration of the device information processing apparatus ID.

In the figure, a controller CCa controls the operation of the device information processing apparatus ID.
The memory MMa stores information unique to the outdoor unit EX attached to the pallet PL. Here, the unique information includes the type information of the outdoor unit EX, the model information, the body identification information, the inspection pattern referred to by each of the inspection stations ST1 to ST6, the inspection data representing the inspection result, and
It consists of a judgment value or the like representing a performance judgment result. this house,
The inspection data and the judgment value are stored in the inspection stations ST2 and ST
3, ST6, the data is written to the device information processing device ID, and the other data is stored in the memory MMa when the outdoor unit EX is mounted on the pallet.

The radio section IOa is for exchanging various data such as unique information, test data, and judgment values between the inspection stations ST1 to ST6 and the controller CCa. In addition, each of the inspection stations ST1 to ST6 performs an inspection based on this unique information, and writes the result to the device information processing apparatus ID.

FIG. 5 shows an example of the configuration of the control device CC of the cart CD.

In the figure, a controller CCb controls the operation of the control device CC, and a radio unit WRa
Is for exchanging various information with the inspection stations ST1 to ST6. Also, this radio unit WRa
Is connected to an antenna AT (see FIG. 3). Each of the inspection stations ST1 to ST6 instructs the controller CCb to perform an inspection or an operation based on the unique information, and the controller CCb performs an inspection or an operation based on the instruction, and performs an inspection result as necessary. To the inspection stations ST1 to ST6. Also,
The inspection stations ST1 to ST6 are connected to the controller CC.
The inspection result obtained from b is written in the device information processing device ID.

The sliding portion SD contacts the power line LL attached to the conveyor CV and supplies power to the outdoor unit EX. The sliding portion SD has three wires L1, L2, and L3 via a switch SWa. It is appropriately connected to one of L3. Further, the wirings L1, L2, L3 are connected to the outdoor unit EX via the piping wiring device PD. Here, the power line LL is connected to a plurality of systems of electric power (two-phase alternating current (100 (V), 200
(V)) Three-phase alternating current (100 (V), 200 (V))
, Etc.), and the controller CCb switches the switch S
With Wa, the electric power required for the outdoor unit EX is connected to the wirings L1, L2, L3 in a manner based on the unique information obtained from the inspection stations ST1 to ST6.

The outdoor unit interface circuit IFa exchanges various data with the outdoor unit EX, and is connected to the wirings L2 and L3 via the switch SWb. Therefore, the controller CCb can exchange data with the outdoor unit EX only when the switch SWb is on.

That is, the switch SWb is, for example, an inverter air conditioner having a microcomputer in the outdoor unit EX, and the controller CCb is mounted on the outdoor unit EX.
Turned on when data exchange with X is required.
On the other hand, for example, the compressor M of the outdoor unit EX is installed.
When the operation of P is controlled by supplying / cutting off the power, the switch SWb is turned off.

FIG. 6 shows an example of a processing system of the inspection system.

Referring to FIG.
ST6, the input monitoring device PC1, the comprehensive judgment device PC2, the supervising device PC3, and the operation monitoring device PC4 are connected to the bus S
B, and data is exchanged between these components via the bus SB.

The control device PC3 includes inspection stations ST1 to ST6 used in the inspection system.
The operation of the input monitoring device PC1 and the overall judgment device PC2 is generally controlled, and the inspection result history information of all the models of the outdoor unit EX inspected by the inspection system is sampled. I remember each number.

The control device PC3 includes inspection stations ST1 to ST6 connected to the bus SB, an input monitoring device PC1, a comprehensive determination device PC2, a control device PC3,
In addition, a shared memory that can be commonly accessed by all devices of the operation monitoring device PC4 is defined, and an operation mode between the devices can be set via the shared memory.

The operation monitoring device PC4 is installed, for example, in an office or the like provided for the quality control department, and is used to input various information necessary for the inspection system. When the information input by the operation monitoring device PC4 is written into the above-described shared memory, the inspection stations ST1 to ST6, the input monitoring device PC1, or the comprehensive judgment device PC2 that require the information store the necessary information. Can be obtained quickly.

FIG. 7 shows the inspection stations ST1 to ST4.
1 shows an example of the configuration.

In the figure, the controller CCc controls the operation of the inspection stations ST1 to ST4, and the limit switch LSa is set to the position of the cart CD at the inspection position.
To detect that there is a radio unit WRb
Is between the radio unit WRa of the control device CC of the cart CD,
It is for exchanging various data by wireless transmission.

The wireless section IOb exchanges various data with the wireless section IOa of the unique information processing apparatus ID by wireless transmission.

FIG. 8 shows the inspection stations ST5 and ST6.
1 shows an example of the configuration.

In the figure, a controller CCd controls the operation of the inspection stations ST5 and ST6, and a limit switch LSb is used to move the carriage CD to the inspection position.
To detect that there is a radio unit WRc
Is between the radio unit WRa of the control device CC of the cart CD,
It is for exchanging various data by wireless transmission.

The wireless unit IOc is for exchanging various data with the wireless unit IOa of the unique information processing device ID by wireless transmission. In addition, the refrigerant recovery robot unit RB includes an outdoor unit E that has flowed into the dummy indoor unit.
This is for recovering the refrigerant of X.

FIG. 8 shows the inspection station S during normal inspection.
3 shows an outline of an inspection process performed by controllers CCc and CCd of T1 to ST6.

When any of the carts CD moved by the conveyor CV is detected by the limit switches LSa and LSb, the controllers CCc and CCc (step 101)
The necessary test pattern information is read from the unique information processing device ID (process 102). Here, the inspection pattern information is
Since the value corresponding to each of the inspection stations ST1 to ST6 is stored for each of the inspection stations ST1 to ST6, the controllers CCc and CCd read the necessary inspection pattern information of the inspection stations ST1 to ST6.

Next, inspection data such as start-up procedure information corresponding to the read inspection pattern information is stored in the supervisory device PC.
3 and notifies the control device CC of the cart CD of the read inspection data (step 103).

As a result, the control device CC operates the outdoor unit EX in accordance with the notified inspection data, so that each of the inspection stations ST1 to ST6 performs a corresponding inspection operation (step 104). Get.

Next, each of the inspection stations ST1 to ST
6 writes the inspection data obtained as a result of the inspection into the unique information processing device ID (process 105) and, if necessary, sends the inspection data together with the identification information of the outdoor unit EX to be inspected to the comprehensive judgment device PC2. Notice.

In the present embodiment, the heating capacity of the outdoor unit EX is determined based on the current consumption of the compressor MP and the refrigerant pressure obtained during the transitional period before the refrigeration cycle is stabilized from the start of the heating operation, and the cooling operation is started. The cooling capacity of the outdoor unit EX is determined based on the current consumption of the compressor and the refrigerant pressure obtained during the transient period before the refrigeration cycle is stabilized.

Next, the principle of determining the heating capacity and the cooling capacity of the outdoor unit EX will be described.

First, FIG. 10 schematically shows a refrigeration cycle during the cooling operation in a state where the outdoor unit EX is connected to the dummy indoor unit DM.

The high-pressure and high-temperature gaseous refrigerant sent from the compressor MP is sent into the outdoor heat exchanger MX via the pipe PP1, and cooled and aggregated by the fan MM (see FIG. 2) to become a liquid refrigerant. , To the pipe PP2.

The liquid refrigerant passes through the pipe PP2, passes through the capillary tube MC for pressure reduction, and flows through the pipe PP4.
To the indoor heat exchanger MI, evaporates, absorbs heat from the outside, becomes a gas refrigerant,
Returning to the compressor MP through 5 and compressed again.

FIG. 11 shows an example of a Mollier diagram in this case. In the figure, a curve SC represents a saturated liquid line.

In the same figure, in the refrigeration cycle, points A,
The state changes in the order of point B, point C, and point D. Also, point A,
The length of the side AF of the triangle (shown by oblique lines) surrounded by points B and F corresponds to the work heat equivalent of the compressor MP, and based on the magnitude of the work heat equivalent, the refrigeration cycle of the compressor MP Judgment of performance at the time (that is, judgment of cooling capacity)
Can be.

On the other hand, when the compressor MP is operated under the same conditions and an abnormality occurs in the compressor MP and the discharge pressure is low, the position of the point B is set to the absolute pressure coordinate value P1.
Falls on the line connecting the points A and B, and as a result, the side AF
Varies in length.

Similarly, when the compressor MP is operated under the same condition, the distance between the point A and the point F changes according to the current consumption of the compressor MP.
The length of F changes.

As described above, the change in the pressure on the low pressure side during the refrigeration cycle and the change in the current consumption cause the side AF to change.
Since the length of the compressor MP changes, the work heat equivalent of the compressor MP, that is, the refrigeration cycle operates normally by measuring the low pressure pressure during the refrigeration cycle, ie, the pressure at the point D, and the current consumption of the compressor MP. It is possible to make a prediction that the ability at the time can be determined. The pressure on the high pressure side during the refrigeration cycle is determined by the compressor M
Since it pulsates according to the discharge cycle of P, it is not used for performance measurement.

The present inventor has paid attention to the above points and repeated experiments, and found that the capacity of the refrigeration cycle (low pressure and current consumption) corresponds to the change at the time of abnormality. FIG. 12 shows an example of this correspondence. Here, “up” in the figure means determination based on a trend (described later).
It also includes the fact that it only changes to the extent that it is absorbed by. Therefore, "up", "down", "slightly" etc. are NG
(See below). In particular,
Regarding “1.” and “2.”, it can be said that they are symptoms that are likely to occur in reality, but if these are not measured with two physical quantities (low-pressure pressure and current consumption), one of them will fall out.

From the above, the cooling capacity of the outdoor unit EX can be determined by measuring the current consumption of the compressor MP when the outdoor unit EX performs the cooling operation and the low pressure during the refrigeration cycle. Similarly, the heating capacity of the outdoor unit EX can be determined by measuring the current consumption of the compressor MP during the heating operation and the low pressure during the refrigeration cycle.

Incidentally, the current consumption and pressure of the compressor MP obtained when the outdoor unit EX is operated are greatly affected by environmental changes such as the environmental temperature during the operation or the length of the operation time. If the environmental temperature or the like of the inspection system varies, the criterion value applied when determining one outdoor unit EX cannot be simply applied when determining another outdoor unit EX.

For example, the temperature and humidity in the room where the inspection system is installed change every moment due to changes in the weather and the temperature outside the room, and the manner of change varies every day. Therefore, the fixed judgment reference value is applied as it is. To do is hardly realistic.

Therefore, the present inventor has adopted the following determination method. Next, this will be described.

FIG. 13 shows an example of the change of a plurality of samples of the current value obtained continuously in a certain time zone. Here, the sample value of the current value of the target device to be determined is set as the determination target value Sn, and the sample values of the current values obtained in the past are sequentially determined as S (n-1) to S (n-9).
And In the method in this case, the reference data S (n-1)
ＳS (n-9) is calculated based on the determination target value Sn.

First, the reference data S (n-1) to S (n-
9) and the reference data S (n-1) to S (n).
-9) is calculated, and the minimum value Si and the maximum value S are obtained.
An intermediate value Sm of x is calculated.

Then, a value GI obtained by subtracting a value obtained by multiplying (Sx-Si) / 2 by a predetermined coefficient K1 from the intermediate value Sm is obtained.
Is set to the minimum value of the criterion, and (Sx-Si) /
A value GX obtained by adding a value obtained by multiplying 2 by a predetermined coefficient K1 to the intermediate value Sm is set to the maximum value of the determination reference.

As described above, first, the determination reference width for the determination target value Sn itself is calculated.

Next, the reference data S (n-
The criteria for the change from 1) were also determined.

The amount of change between each sample of the reference data S (n-1) to S (n-9) is calculated, the maximum value thereof (hereinafter referred to as the maximum change amount) is extracted, and the maximum change amount is calculated. The value multiplied by the predetermined coefficient K2 is determined as a criterion for the change between the determination target value Sn and the reference data S (n-1).

As described above, the determination criterion for the determination target value Sn itself and the determination criterion for the change from the previous value of the determination target value Sn are determined, so that the constantly changing detection value (the compressor MP It is possible to determine with certainty whether or not the current consumption and the pressure are appropriate values.

Hereinafter, a determination process performed by calculating a determination criterion based on the measurement values (reference data) obtained in the past as described above is referred to as a trend determination.

Now, the judgment processing of the outdoor unit EX is carried out by the comprehensive judgment device PC2, an example of which is shown in FIG.

First, the value of the counter C for storing the number of continuous determination operations of the same model is increased by one (step 20).
1). At this time, if the model is changed,
The value of the counter C is initialized to 0.

At that time, it is checked whether or not it is specified to shift the determination reference value according to the operation time (decision 202). When the result of the judgment 202 is YES, it is checked whether or not the heating operation time or the cooling operation time before moving to the inspection station is longer than the specified value T1 (decision 203). Here, the specified value T1 is, for example, a value twice as long as the reference time required for movement from the inspection station ST2 to the inspection station ST3.

When the result of the determination 203 is YES, a time for determining an offset value OFt for shifting a determination reference value applied in a trend determination process (described later) according to the heating operation time or the cooling operation time at that time. A length determination reference shift process (process 204) is executed to calculate an offset value OFt. When the result of the judgment 202 is NO or when the result of the judgment 203 is NO, the process 204 is not executed. In this case, the value of the offset value OFt is “0”.

Next, it is checked whether or not shifting of the judgment reference value is designated according to environmental conditions (decision 20).
5). If the result of decision 205 is YES, it is checked whether the environmental conditions have changed (decision 206). In this judgment 206, when the variation of the temperature of the compressor MP from the previous sample value exceeds a predetermined value, or when the variation of the dry bulb temperature exceeds a predetermined value, or when the humidity exceeds the predetermined value. In this case, it is determined that the environmental condition has changed. The criterion for determining that the environmental condition has changed is:
Only one of the three can be used, or any two or all three can be used.

When the result of the determination 206 is YES, an environment change determination reference shift process (process 207) for calculating coefficients Ka and Kp to be multiplied by the determination reference value applied in the trend determination process is executed. Obtain Kp. When the result of the judgment 205 is NO or when the result of the judgment 206 is NO, the process 206 is not executed. In this case, the values of the coefficients Ka and Kp are both “1”.

Next, the value of the counter C becomes a predetermined value XC (=
9) It is checked whether it is the above or not (decision 208). When the result of the determination 208 is NO at the time of switching of the inspection model or at the start of work, it is checked whether data of the same model is stored in the supervising device PC3 (determination 20).
9). If the result of the determination 209 is NO, an initial determination reference value corresponding to the inspection pattern of the outdoor unit EX to be inspected at that time is obtained from the control device PC3, and the measurement value is determined using the initial determination reference value. Initial judgment processing (processing 21
Perform 0).

When the result of the judgment 209 is YES, the previous data is obtained from the control device PC3, and a trend judgment process described later is performed using the previous data as reference data (process 211).

When the result of the judgment 208 is YES, a trend judgment process (process 212) for judging the outdoor unit EX using the reference data is executed.

The environment change determination reference shift process (process 20)
FIG. 13 shows an example of 7).

In the figure, first, the compressor temperature Yc, the dry bulb temperature Yd,
Then, the wet bulb temperature Yw is input (process 221), and the compressor temperature Yc, the dry bulb temperature Yd, and the wet bulb temperature Yw are input.
Are normalized, and the normalized compressor temperature Y
c ′, normalized dry-bulb temperature Yd ′, and normalized wet-bulb temperature Yw ′ are obtained (processing 222).

Next, the normalized compressor temperature Yc ′,
Normalized dry bulb temperature Yd 'and normalized wet bulb temperature Yw'
, The difference values dYc ′, dY from the immediately preceding sample
d ′ and dYw ′ are calculated (process 223), and a predetermined neural network operation is applied to the difference values dYc ′, dYd ′ and dYw ′ (process 224) to obtain coefficients Ka and Kp (process 225). ).

Here, the neural network calculation in this case is a calculation process for calculating a set of coefficients Ka and Kp corresponding to a set of difference values dYc ', dYd' and dYw '. For example, a number of relations between a set of difference values and a set of coefficients are obtained in advance, and the state of the neural network is converged using the relation between the set of many difference values and a set of coefficients. It is set so that a set of coefficients corresponding to the set can be specified. Thus, by providing a set of difference values to the neural network, a required set of coefficients can be obtained.

An example of the trend determination process (process 212) is shown in FIGS.

First, a predetermined value “9” is substituted for a constant Rm that determines the number of reference data (process 301), and a predetermined value “1.5” is substituted for the change amount determination data D_g (process 302).
A predetermined value “1.2” is substituted for the determination data H_g based on the maximum / minimum width of the reference data (process 303), and a flag F_f for setting to execute a predetermined filter operation is set (process 304). A predetermined value “0.5” is substituted for data H_w defining the small width (process 305), and a predetermined value “1.5” is substituted for data X_f for defining a data range to be left as reference data (process 306). .

When the initial setting is completed as described above,
The data D to be determined is input (process 307), and a difference value dD between the reference data of the immediately preceding sample and the target data D is calculated and stored (process 308).

Next, the difference values in the reference data are sequentially calculated, and the maximum value M_d of the difference values is obtained (Step 30).
9). Further, the maximum value X_a and the minimum value N_a in the reference data are calculated (process 310), and the minimum value D_min and the maximum value D_max of the determination width are calculated based on the following equation (i) (process 311).

D_min = (X_a + N_a) / 2 − ((X_a−N_a) / 2) × H_g D_max = (X_a + N_a) / 2 + ((X_a−N_a) / 2) × H_g (i)

Next, it is checked whether the flag F_f is set (decision 312), and the result of the decision 312 is YE
When S is reached, filter processing for correcting the determination width is performed based on the following equation (ii) (processing 313).

D_min = (D_min + D_min ′ × Cf) / (Cf + 1) D_max = (D_max + D_max ′ × Cf) / (Cf + 1) (ii)

Here, D_min 'represents the minimum value of the judgment width calculated at the time of the immediately preceding sample.
x ′ represents the maximum value of the judgment width calculated at the time of the immediately preceding sample. Cf is a coefficient of the filtering process. If the result of the determination 312 is NO, the processing 31
Do not execute 3.

Next, it is checked whether or not the calculated judgment width is smaller than the data M_w (decision 314). If the result of judgment 314 is YES, the calculation is performed so that the judgment width becomes a predetermined minimum value. Minimum value D_m of the determined judgment width
in and the maximum value D_max are corrected (process 31)
5). When the result of the determination 314 is NO,
The process 315 is not executed.

Next, the minimum value D_min and the maximum value D
The minimum value D_min and the maximum value D_max are corrected (step 316) so that the determination width determined by _max expands at a magnification specified by the coefficient Ka or the coefficient Kp (process 316). Further, the corrected minimum value D_min and maximum value D_max are The minimum value D_min is obtained by adding the offset value OFt.
And the maximum value D_max is corrected again (process 317),
The target data D is determined based on the following equation (iii) (process 318). When this equation is satisfied, the target data D is determined to be NG.

DD> Md × D_g and D_min> D or D_max <D (iii)

Then, it is checked whether the judgment result is "OK" (judgment 319), and the result of judgment 319 is YES
Is satisfied, it is determined that the determination result for the outdoor unit EX to be determined at that time is “OK”,
(Step 320), and when the result of the determination 319 is NO, the control unit PC3 is notified that the determination result of the outdoor unit EX to be determined at that time is "NG" (Process 321), Further, the judgment result is displayed and notified to the operator OP2 (process 322).

Next, it is determined whether or not the target data D at that time is stored as reference data (decision 32).
3). In this determination 323, if the target data D does not exceed the range of the value obtained by multiplying the difference value from the center of the determination width to the minimum value D_min and the maximum value D_max by the data X_f, it is determined that the reference data is stored. Is done. It is to be noted that whether or not the target data D is stored as reference data is determined because the original data fluctuates, and it is intended to reflect the state of the fluctuation in the reference data as much as possible. Because.

If the result of determination 323 is YES, the reference data of the model is updated (process 324), and this process ends. When the result of the determination 323 is NO, the process 324 is not executed.

The above determination process is performed on the current value and the pressure value during the heating operation and the current value and the pressure value during the cooling operation, respectively. For each measured value, the capacity of the outdoor unit EX is appropriate. It is determined based on the correspondence as shown in FIG.

In the present embodiment, whether or not the target data D is appropriate is determined in this way, so that an appropriate determination operation according to an environmental change can be performed.

When the assembly line is stopped during a lunch break or the like, this inspection line is also stopped in the same manner. FIG. 18 shows a state immediately after the stop.

In this case, the operators OP1, OP2, O
Since each of P3 enters a break, it has been moved to another place. Therefore, for the three carts CD in the transport direction of the belt conveyor CV, including the cart CD located at the entrance of the belt conveyor CV, Operator OP1
Is not connected to the outdoor unit EX.

For this reason, in the present embodiment, the following cycle stop operation is performed immediately after the line is stopped by the stop operation.

That is, the pipes not connected are returned to their original positions without any inspection. In addition, the same inspection is not performed once the inspection is performed. In addition, the comprehensive judgment is not performed at the time of the cycle, but is checked by the operator for the inspection that has been completed at the time of starting the line, and is turned to the next process.

FIG. 19 shows a processing example of the inspection station ST1 in this case.

When the cycle stop is notified from the control device CP3 (the result of the judgment 411 is YES), the value of the counter C is initialized to 1 (process 412). Next, it is checked whether or not the value of the counter C is any one of 2, 3, and 4 (decision 413). If the result of the decision 413 is NO, it is the truck CD to which the pipe wiring is connected, A predetermined dielectric strength test is performed (process 414). Also,
When the result of the determination 413 is NO, the process 414 is not executed for the cart CD at that time.

Next, the process waits until the next truck CD is detected (step 415). When the next truck CD is detected, the value of the counter C is incremented (step 416), and the value of the counter C becomes larger than 25. It is checked whether or not it has been determined (decision 417). When the result of the determination 417 is NO, the process returns to the determination 413, and the same processing is repeated.

When the result of determination 417 is YES, the operation ends.

FIG. 20 shows a processing example of the inspection station ST2 in this case.

When the cycle stop is notified from the central device CP3 (the result of the judgment 421 is YES), the value of the counter C is initialized to 1 (process 422). Next, it is checked whether or not the value of the counter C is any one of 4, 5, and 6 (decision 423). If the result of the decision 423 is NO, it is the truck CD to which the pipe wiring is connected. A predetermined low-voltage startup test is performed (process 424). When the result of the determination 423 is NO, the process 424 is not executed for the cart CD at that time.

Next, the process waits until the next cart CD is detected (process 425). When the next carriage CD is detected, the value of the counter C is incremented (step 426), and it is checked whether or not the value of the counter C is larger than 25 (decision 427). When the result of the determination 427 is NO, the process returns to the determination 423, and the same processing is repeated.

When the result of determination 427 is YES, the operation ends.

FIG. 21 shows a processing example of the inspection station ST3 in this case.

When the cycle stop is notified from the central device CP3 (the result of the judgment 431 is YES), the value of the counter C is initialized to 1 (process 432). Next, it is checked whether or not the value of the counter C is any one of 8, 9, and 10 (decision 433). When the result of the decision 433 is NO, it is the cart CD to which the pipe wiring is connected, A predetermined heating capacity collection process is performed (process 434). When the result of the judgment 433 is NO, the process 434 is not executed for the cart CD at that time.

Next, the process waits until the next truck CD is detected (step 435). When the next truck CD is detected, the value of the counter C is incremented (step 436), and the value of the counter C becomes larger than 25. A check is made to determine whether or not it has been performed (determination 437). When the result of the determination 437 is NO, the process returns to the determination 433, and the same processing is repeated.

When the result of determination 437 is YES, the operation ends.

FIG. 22 shows a processing example of the inspection station ST4 in this case.

When the cycle stop is notified from the central device CP3 (the result of the judgment 441 is YES), the value of the counter C is initialized to 1 (process 442). Next, it is checked whether or not the value of the counter C is any one of 13, 14, and 15 (decision 443), and the result of the decision 443 is N
When it becomes O, the truck CD to which the pipe wiring is connected
Therefore, a predetermined cooling capacity collecting process is performed (process 44).
4). When the result of the determination 443 is NO,
The process 444 is not executed for the cart CD at that time.

Next, the process waits until the next truck CD is detected (step 445). When the next truck CD is detected, the value of the counter C is incremented (step 446), and the value of the counter C becomes larger than 25. It is checked whether or not it has been determined (determination 447). When the result of the determination 447 is NO, the process returns to the determination 443, and the same processing is repeated.

When the result of decision 447 is YES, the operation ends.

FIG. 23 shows a processing example of the inspection station ST5 in this case.

When the cycle stop is notified from the central device CP3 (the result of the judgment 451 is YES), the value of the counter C is initialized to 1 (process 452). Next, it is checked whether or not the value of the counter C is any one of 14, 15, and 16 (decision 453), and the result of the decision 453 is N
When it becomes O, the truck CD to which the pipe wiring is connected
Therefore, a predetermined refrigerant recovery 1 operation is performed (Step 45).
4). When the result of the determination 453 is NO,
The process 454 is not executed for the cart CD at that time.

Next, the process waits until the next truck CD is detected (step 455). When the next truck CD is detected, the value of the counter C is incremented (step 456), and the value of the counter C becomes larger than 25. A check is made to determine whether or not it has occurred (determination 457). When the result of the determination 457 is NO, the process returns to the determination 453, and the same processing is repeated.

When the result of determination 457 is YES, the operation ends.

FIG. 24 shows a processing example of the inspection station ST6 in this case.

When the cycle stop is notified from the central device CP3 (the result of the judgment 461 is YES), the value of the counter C is initialized to 1 (process 462). Next, it is checked whether or not the value of the counter C is any one of 17, 18, and 19 (decision 463), and the result of the decision 463 is N
When it becomes O, the truck CD to which the pipe wiring is connected
Therefore, a predetermined refrigerant recovery 2 operation is performed (Step 46).
4). When the result of the determination 463 is NO,
The process 464 is not executed for the cart CD at that time.

Next, the process waits until the next truck CD is detected (step 465). When the next truck CD is detected, the value of the counter C is incremented (step 466), and the value of the counter C becomes larger than 25. It is checked whether or not it has been determined (determination 467). When the result of the determination 467 is NO, the process returns to the determination 463, and the same processing is repeated.

When the result of determination 467 is YES, the operation ends.

FIG. 25 shows a processing example of the comprehensive judgment device CP2 in this case.

When the cycle stop is notified from the control device CP3 (the result of the determination 471 is YES), the control device CP3 is notified.
Wait until the notification of the cycle stop release is sent from
2 NO loop), the determination process is not executed.

By the way, as described above, the outdoor unit E
The current consumption of the compressor in a state where the refrigeration cycle is stable after the operation of X is started, and the capacity of the outdoor unit EX is indicated by the low pressure during the refrigeration cycle. It takes about 6 minutes for cooling operation.

If the inspection process is to be performed quickly,
Since the time until the refrigeration cycle is stabilized cannot be secured, it is necessary to be able to judge the capacity of the outdoor unit EX during a transitional period until the refrigeration cycle is stabilized.

On the other hand, if an abnormality occurs in the performance of the outdoor unit EX, it is experimentally found that the current consumption of the compressor during the transitional period and the low pressure in the refrigeration cycle change in the same manner as in the stable period. Therefore, even during the transitional period, the capacity of the outdoor unit EX can be determined by measuring the current consumption and the pressure thereof.

Here, in the above-described embodiment, the current consumption and the pressure are measured 78 seconds after the cooling operation is started and 60 seconds after the heating operation is started, and the measured values are used. Although the trend determination is performed, the time until this measurement can be set as appropriate.

[0137]

As described above, according to the present invention,
Since the inspection line for electrical equipment can be incorporated into the assembly line, the time required for shipping products can be greatly reduced.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing an example of an inspection system for an air conditioner according to an embodiment of the present invention.

FIG. 2 shows an outdoor unit EX, an indoor unit, and a piping and wiring device P.
The block diagram showing the example of composition of the air-conditioning equipment consisting of D.

FIG. 3 is a schematic diagram showing an example of a configuration of a cart.

FIG. 4 is a block diagram illustrating an example of a configuration of a device information processing apparatus.

FIG. 5 is a block diagram showing an example of a configuration of a cart control device.

FIG. 6 is a block diagram showing an example of a processing system of the inspection system.

FIG. 7 is a block diagram showing an example of a configuration of inspection stations ST1 to ST4.

FIG. 8 is a block diagram showing an example of a configuration of inspection stations ST5 and ST6.

FIG. 9 is a flowchart schematically illustrating an inspection process performed by a controller of an inspection station during a normal inspection.

FIG. 10 is a configuration diagram schematically showing a refrigeration cycle during cooling in a state where an outdoor unit is connected to a dummy indoor unit.

FIG. 11 is a graph showing an example of a Mollier chart during a refrigeration cycle during cooling in a state where an outdoor unit is connected to a dummy indoor unit.

FIG. 12: Refrigeration cycle capacity (low pressure and current consumption)
5 is a chart showing an example of a correspondence relationship between a change and a change at the time of abnormality.

FIG. 13 is a graph showing an example of a change in a plurality of samples of a current value continuously obtained in a certain time zone.

FIG. 14 is a flowchart illustrating an example of a determination process.

FIG. 15 is a flowchart illustrating an example of an environmental change determination reference shift process.

FIG. 16 is a flowchart illustrating a part of an example of a trend determination process.

FIG. 17 is a flowchart illustrating the remaining part of an example of the trend determination process.

FIG. 18 is a schematic diagram showing a state of an inspection line immediately after a cycle is stopped.

FIG. 19 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T1.

FIG. 20 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T2.

FIG. 21 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T3.

FIG. 22 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T4.

FIG. 23 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T5.

FIG. 24 shows an inspection station S when the cycle is stopped.
9 is a flowchart illustrating a processing example of T6.

FIG. 25 is a flowchart showing a processing example of the comprehensive judgment device when the cycle is stopped.

[Explanation of symbols]

 CV conveyor CD cart ST1 to ST6 Inspection station PC1 Input monitoring device PC2 Overall judgment device PC3 Overall device PC4 Operation monitoring device

Claims (13)

[Claims] 1. A method for judging the quality of an electric device on an inspection line provided in a series of assembly lines of the electric device, the method comprising the steps of: The electric device is configured to judge the quality of the electric device, and the judgment of the quality is performed based on whether the value is within a predetermined range obtained based on a value of a predetermined number of consecutive physical quantities measured first. Quality evaluation method for electrical equipment. 2. The predetermined range is a range of values obtained by correcting the difference between the minimum value and the maximum value, centered on the average value of the minimum value and the maximum value, of a predetermined number of continuous physical quantities. 2. The method according to claim 1, further comprising the steps of: 3. The method according to claim 2, wherein the predetermined range is a range of a value obtained by correcting a maximum change amount of a continuous physical quantity among a predetermined number of continuous physical quantities centered on a previously measured physical quantity. Item 4. The method for judging acceptability of an electric device according to Item 1. 4. The predetermined range includes a range of a value obtained by correcting a difference between the minimum value and the maximum value with respect to an average value of a minimum value and a maximum value of a predetermined number of continuous physical quantities; 2. The quality of an electric device according to claim 1, wherein the value is a value obtained by adding a correction to a maximum change amount of a continuous physical quantity among a predetermined number of continuous physical quantities around a physical quantity measured last time. Judgment method. 5. The electrical device according to claim 2, wherein a predetermined upper limit value and a predetermined lower limit value are set in advance in said predetermined range. Method. 6. The method according to claim 1, wherein the value of the predetermined predetermined number of consecutive physical quantities does not include a value determined to be negative. 6. The method according to claim 5, wherein the electric device is good or bad. 7. The method according to claim 1, wherein the predetermined range is corrected using a quadratic curve when the time from the operation journal of the electric device to the measurement of the physical quantity exceeds the predetermined time. 7. The method for judging acceptability of an electric device according to claim 2, claim 3, claim 4, claim 4, claim 5, or claim 6. 8. A method for judging the quality of an electric device in an inspection line provided in a series of assembly lines of the electric device having a refrigeration cycle centered on a refrigerant compressor, wherein the refrigeration cycle of the electric device is simulated. A configuration in which the quality of the electrical device is determined from the value of the physical quantity measured after a certain period of time after the operation is performed, and the determination of the quality is the minimum value of a predetermined number of consecutive physical quantities measured earlier. Range of the value obtained by correcting the difference between the minimum value and the maximum value around the average value of the maximum and maximum values, and the maximum change of the continuous physical quantity among a predetermined number of physical quantities continuous around the physical quantity measured last time A pass / fail judgment method for an electric device, which is performed based on whether or not the measured physical quantity is within a value range obtained by correcting the quantity. 9. The method according to claim 8, wherein the physical quantity is a pressure on a low pressure side in the refrigeration cycle and a current flowing through the refrigerant compressor. 10. The method according to claim 8, wherein a predetermined upper limit value and a predetermined lower limit value are set in the predetermined range in advance. 11. The method according to claim 10, wherein the value of the predetermined number of consecutive physical quantities measured does not include the value determined to be unacceptable. 12. The method according to claim 11, wherein the predetermined range is corrected using a quadratic curve function when the time from the start of the operation of the electric device to the measurement of the physical quantity exceeds a predetermined time. Pass / fail judgment method for electrical equipment. 13. The apparatus according to claim 1, wherein the predetermined time is determined by a moving distance and a moving speed of the electric equipment moving on the inspection line. 13. The method for judging acceptability of an electric device according to claim 5, claim 6, claim 7, claim 7, claim 8, claim 9, claim 10, claim 11, or claim 12.