JPWO2018193508A1 - Failure diagnosis device and failure diagnosis method - Google Patents

Abstract

In the master station (1) which is the failure diagnosis device, the first detection data indicating the state of the device detected when the device to which the first drive source and the second drive source are connected is operated An estimated sensor data calculating unit (30) for estimating second detection data indicating a state of the device caused by the first drive source by removing data components caused by the second drive source; and second detection data And a fault diagnosis unit (31) for diagnosing a failure of the device by comparing the threshold with the threshold.

Description

  The present invention relates to a fault diagnosis apparatus and a fault diagnosis method for diagnosing a fault in an apparatus.

  Since the device can not perform the desired operation when a failure occurs, it is desirable to properly diagnose whether the device has a failure. For this reason, conventionally, various techniques for diagnosing device failure have been proposed.

  In the abnormality detection system described in Patent Document 1, the plurality of vibration sensors measure the vibration of the motor, and the correlation of the output values obtained from the model indicating the correlation between the output values of the vibration sensors and the plurality of vibration sensors The correlation between the obtained measurement data is compared and processed. Then, the abnormality detection system detects the abnormality of the motor based on the amount of breakdown of the correlation.

JP, 2016-003875, A

  However, since the sensor data from each sensor changes when the device configuration or the device characteristics are changed, in the above-mentioned prior art Patent Document 1, a threshold for judging whether the device is abnormal or not is There is a problem that it has to be set for each device configuration or each device characteristic. For this reason, in patent document 1, when the apparatus structure or the apparatus characteristic was changed, diagnosis of the failure of an apparatus was not able to be performed easily.

  The present invention has been made in view of the above, and it is an object of the present invention to obtain a failure diagnosis device capable of easily diagnosing a failure of the device even when the device configuration or the device characteristics are changed. I assume.

  In order to solve the problems described above and to achieve the object, the present invention relates to a device that is detected when operating a device to which a first drive source and a second drive source are connected in a failure diagnosis device. Estimation data calculation unit for estimating second detection data indicating a state of the device caused by the first drive source by removing a data component caused by the second drive source from the first detection data indicating the state of Is equipped. Further, the failure diagnosis device of the present invention includes a failure diagnosis unit that diagnoses a failure of the device by comparing the second detection data with the threshold value.

  The failure diagnosis apparatus according to the present invention has an effect that diagnosis of a failure of the apparatus can be easily performed even when the apparatus configuration or the apparatus characteristic is changed.

The figure which shows the structure of the fault diagnostic system provided with the fault diagnostic apparatus concerning embodiment of this invention. A diagram showing a configuration of a mechanical device according to an embodiment Block diagram showing the configuration of the master station according to the embodiment A diagram showing an internal configuration of a first command data storage unit according to an embodiment A diagram showing an internal configuration of a sensor data storage unit according to an embodiment A diagram showing an internal configuration of a second command data storage unit according to the embodiment Flow chart showing an operation processing procedure of the failure diagnosis system according to the embodiment The figure which shows the relationship between the 1st command data and sensor data at the time of generating the fault diagnostic threshold value concerning an embodiment. The figure which shows the relationship between the 2nd command data and sensor data at the time of generating the sensor data calculation model concerning an embodiment The figure which shows the relationship between the 1st command data, the 2nd command data, and sensor data at the time of failure diagnosis concerning an embodiment is performed. The figure which shows the relationship between the 2nd command data concerning an embodiment, and presumed sensor data The figure which shows the relationship between the 1st command data concerning an embodiment, and presumed sensor data A diagram showing an example of a hardware configuration of a master station according to an embodiment

  Hereinafter, a fault diagnosis apparatus and a fault diagnosis method according to an embodiment of the present invention will be described in detail based on the drawings. The present invention is not limited by the embodiment.

Embodiment FIG. 1 is a diagram showing a configuration of a failure diagnosis system provided with a failure diagnosis apparatus according to an embodiment of the present invention. The failure diagnosis system 100 drives the master station 1 which is a failure diagnosis device, a mechanical device 2 which is an example of a device to be subjected to failure diagnosis, a first motor 4 for driving the mechanical device 2, and the mechanical device 2. One or more second motors 7 are provided. Further, the failure diagnosis system 100 includes a first slave station 3 that outputs a torque command to the first motor 4, a second slave station 6 that outputs a torque command to the second motor 7, and a mechanical device 2 disposed in the mechanical device 2. And a sensor 5 for detecting the state of the device 2.

  The master station 1 is connected to the first slave station 3, the sensor 5 and the second slave station 6 via a communication network. Also, the first slave station 3 is connected to the first motor 4, and the second slave station 6 is connected to the second motor 7. The first motor 4 and the second motor 7 are coupled to the mechanical device 2.

  The master station 1 outputs first command data 11 which is data for driving the first motor 4 to the first slave station 3 and second command data 13 which is data for driving the second motor 7. Is output to the second slave station 6.

  The first slave station 3 generates a torque command corresponding to the first command data 11 and outputs the torque command to the first motor 4. The second slave station 6 generates a torque command corresponding to the second command data 13 and outputs the torque command to the second motor 7.

  The first motor 4 that is the first drive source performs an operation corresponding to the torque command from the first slave station 3, and the second motor 7 that is the second drive source is the one from the second slave station 6. Execute the operation corresponding to the torque command. The mechanical device 2 is operated by the first motor 4 and the second motor 7.

  When the sensor 5 detects the state of the mechanical device 2, the sensor 5 outputs sensor data 12 as a detection result to the master station 1. Thereby, the master station 1 acquires the sensor data 12 output from the sensor 5.

  The master station 1 is a computer that controls the mechanical device 2. Further, based on the first command data 11, the second command data 13 and the sensor data 12, the master station 1 diagnoses whether or not the mechanical component provided in the mechanical device 2 is broken. The master station 1 according to the embodiment removes a data component caused by the second motor 7 from the sensor data 12 detected when the mechanical device 2 to which the first motor 4 and the second motor 7 are connected is operated. Thus, sensor data 12 attributable to the first motor 4 is estimated. Then, the master station 1 has a sensor data 12 attributed to the first motor 4 and a failure diagnosis threshold described later set based on the sensor data 12 detected when the first motor 4 is operated; The failure of the mechanical device 2 is diagnosed by comparing.

  FIG. 2 is a diagram showing the configuration of the mechanical device according to the embodiment. Although FIG. 2 illustrates the case where the mechanical device 2 is a Roll to Roll type device, the mechanical device 2 may be any device.

  The mechanical device 2 includes rollers 41 and 42 which are examples of mechanical parts, and processes a workpiece 40 which is an object to be processed. The first motor 4 is driven in response to the torque command output from the first slave station 3 to operate the mechanical components of the mechanical device 2. The first motor 4 here rotates the roller 41 connected to the first motor 4. Further, the second motor 7 is driven in response to the torque command output from the second slave station 6 to operate the mechanical parts of the mechanical device 2. The second motor 7 here rotates the roller 42 connected to the second motor 7.

  The first motor 4 and the second motor 7 may be any mechanical component that can drive the mechanical device 2. Examples of the first motor 4 and the second motor 7 are devices such as a rotary servomotor and an inverter. When the first motor 4 rotates the roller 41 and the second motor 7 rotates the roller 42, the work 40 placed on the rollers 41, 42 moves. The sensor 5 is attached to the outside of the mechanical device 2 and detects the state of the mechanical device 2 resulting from the operation of the first motor 4 and the second motor 7. Therefore, when the first motor 4 is driven without the second motor 7 being driven while the first motor 4 is not connected to the mechanical device 2, the sensor 5 determines the state of the mechanical device 2 caused by the first motor 4. To detect When the second motor 7 is driven without the first motor 4 being driven in a state where the second motor 7 is not connected to the mechanical device 2, the sensor 5 determines the state of the mechanical device 2 caused by the second motor 7. To detect An example of the sensor 5 is a vibration detection sensor or a temperature sensor. The state of the mechanical device 2 detected by the sensor 5 may be the state of mechanical components provided in the mechanical device 2, or the state of members connecting the mechanical device 2 and the first motor 4 or the mechanical device 2 and the first It may be in the state of a member connected to the motor 7.

  FIG. 3 is a block diagram showing a configuration of a master station according to the embodiment. The master station 1 includes a first command data generation unit 21 that generates the first command data 11 and a first command data storage unit 23 that stores the first command data 11. The master station 1 further includes a second command data generation unit 22 that generates the second command data 13 and a second command data storage unit 25 that stores the second command data 13.

  Further, the master station 1 stores a sensor data storage unit 24 that stores sensor data 12 and a threshold generation unit that generates a fault diagnosis threshold that is a threshold used as a reference when diagnosing whether the mechanical device 2 is broken. And a threshold storage unit 27 for storing a failure diagnosis threshold. The master station 1 further includes a model generation unit 28 that generates a sensor data calculation model that indicates the correspondence between the second command data 13 and the sensor data 12, and a model storage unit 29 that stores the sensor data calculation model. Have. The sensor data calculation model is a model for calculating the sensor data 12 corresponding to the second command data 13. The sensor data calculation model is represented by an equation. The master station 1 further includes an estimated sensor data calculation unit 30 that generates estimated sensor data to be described later, and a failure diagnosis unit 31 that diagnoses the presence or absence of a failure of the mechanical device 2.

  The first command data generation unit 21 generates the first command data 11 and outputs the first command data 11 to the first slave station 3 and the first command data storage unit 23. An example of the first command data 11 is a command for controlling the position or rotational speed of the first motor 4. The first command data storage unit 23 is a storage unit such as a memory for storing the first command data 11 generated by the first command data generation unit 21.

  The second command data generation unit 22 generates the second command data 13 and outputs the second command data 13 to the second slave station 6 and the second command data storage unit 25. An example of the second command data 13 is a command for controlling the position or rotational speed of the second motor 7. The second command data storage unit 25 is a storage unit such as a memory for storing the second command data 13 generated by the second command data generation unit 22.

  The sensor data storage unit 24 is a storage unit such as a memory for storing the sensor data 12. The example of the sensor data 12 is vibration data indicating the state of vibration or temperature data indicating the state of temperature.

  The threshold generation unit 26 reads the first command data 11 from the first command data storage unit 23, and reads the sensor data 12 from the sensor data storage unit 24. The threshold generation unit 26 generates a failure diagnosis threshold based on the first command data 11 and the sensor data 12. The failure diagnosis threshold is a threshold serving as a reference when diagnosing whether a failure has occurred. The threshold generation unit 26 sends the generated failure diagnosis threshold to the threshold storage unit 27. The threshold storage unit 27 is a storage unit such as a memory for storing the failure diagnosis threshold generated by the threshold generation unit 26.

  The model generation unit 28 reads the sensor data 12 when the second command data 13 is output from the sensor data storage unit 24, and the second command data 13 corresponding to the read sensor data 12 is stored in the second command data storage unit 25. Read from The model generation unit 28 is a sensor data indicating a correspondence between the sensor data 12 and the second command data 13 when the second command data 13 is output based on the read sensor data 12 and the second command data 13. Generate a calculated model. The model generation unit 28 sends the generated sensor data calculation model to the model storage unit 29. The model storage unit 29 is a storage unit such as a memory for storing the sensor data calculation model generated by the model generation unit 28.

  The estimated sensor data calculation unit 30, which is an estimated data calculation unit, reads out a sensor data calculation model from the model storage unit 29. Further, the estimated sensor data calculation unit 30 reads from the sensor data storage unit 24 the sensor data 12 when the first command data 11 and the second command data 13 are output, and the second command corresponding to the read sensor data 12 The data 13 is read from the second command data storage unit 25. The estimated sensor data calculation unit 30 calculates estimated sensor data based on the read sensor data calculation model, the sensor data 12 and the second command data 13. The estimated sensor data is an estimated value of the sensor data 12 output from the sensor 5 when the master station 1 outputs the first command data 11.

  The first command data generation unit 21 of the master station 1 outputs various first command data 11 to the first slave station 3 and outputs various second command data 13 to the second slave station 6. In this case, the mechanical device 2 executes an operation corresponding to the first command data 11 and the second command data 13. Then, the sensor 5 detects sensor data 12 corresponding to the operation of the mechanical device 2 and sends it to the master station 1. The estimated sensor data calculation unit 30 calculates a data component attributable to the output of the first command data 11 among the data components of the sensor data 12. The estimated sensor data calculation unit 30 sends the calculated estimated sensor data to the failure diagnosis unit 31.

  The failure diagnosis unit 31 reads the failure diagnosis threshold from the threshold storage unit 27. The failure diagnosis unit 31 diagnoses the presence or absence of a failure of the mechanical device 2 based on the estimated sensor data calculated by the estimated sensor data calculation unit 30 and the failure diagnosis threshold read out from the threshold storage unit 27.

  As described above, in the master station 1 according to the embodiment, the threshold generation unit 26 generates a failure diagnosis threshold based on the sensor data 12 detected when the first motor 4 is operated. In addition, the model generation unit 28 generates a sensor data calculation model based on the sensor data 12 detected when the second motor 7 is operated. Further, the estimated sensor data calculation unit 30 calculates sensor data 12 caused by the second motor 7 using a sensor data calculation model. The sensor data 12 corresponds to the data component caused by the second motor 7. The estimated sensor data calculation unit 30 removes the data component caused by the second motor 7 from the sensor data 12 detected when the mechanical device 2 to which the first motor 4 and the second motor 7 are connected is operated. Thus, sensor data 12 attributable to the first motor 4 is calculated. Then, the failure diagnosis unit 31 diagnoses the failure of the mechanical device 2 by comparing the sensor data 12 attributable to the first motor 4 with the failure diagnosis threshold value. The failure diagnosis threshold is a fixed value, and the failure diagnosis unit 31 diagnoses a failure when the value of the sensor data 12 exceeds the failure diagnosis threshold which is a fixed value.

  FIG. 4 is a diagram showing an internal configuration of a first command data storage unit according to the embodiment. The first command data storage unit 23 includes a first command data storage area 230. The first command data storage area 230 is an area for storing the first command data 11 used to generate the failure diagnosis threshold value.

  FIG. 5 is a diagram showing an internal configuration of a sensor data storage unit according to the embodiment. The sensor data storage unit 24 includes sensor data storage areas 240A, 240B, and 240C. The sensor data storage area 240A is an area for storing the sensor data 12 used to generate the failure diagnosis threshold value. The sensor data storage area 240B is an area for storing the sensor data 12 used when the sensor data calculation model is generated. The sensor data storage area 240C is an area for storing the sensor data 12 used when the estimated sensor data is generated.

  The sensor data 12 stored in the sensor data storage area 240A is detected by the sensor 5 when the second command data 13 is not output and the first command data 11 is output. The sensor data 12 stored in the sensor data storage area 240B is detected by the sensor 5 when the first command data 11 is not output and the second command data 13 is output. The sensor data 12 stored in the sensor data storage area 240C is first detection data detected by the sensor 5 when the first command data 11 and the second command data 13 are output. The sensor data storage areas 240A, 240B, and 240C do not have to be fixed areas, and may be arbitrarily changeable areas.

  FIG. 6 is a diagram showing an internal configuration of a second command data storage unit according to the embodiment. The second command data storage unit 25 includes second command data storage areas 250A and 250B. The second command data storage area 250A is an area for storing the second command data 13 used when the sensor data calculation model is generated. The second command data storage area 250 </ b> B is an area for storing the second command data 13 used when the estimated sensor data is generated. The second command data storage areas 250A and 250B do not have to be fixed areas, and may be arbitrarily changeable areas.

  FIG. 7 is a flowchart showing an operation processing procedure of the failure diagnosis system according to the embodiment. The fault diagnosis system 100 executes the device operation after performing the pre-operation preparation. The preparation before operation is processing of a preparation stage before operating the mechanical device 2, and the device operation is processing of operating the mechanical device 2. Therefore, the fault diagnosis system 100 causes the mechanical device 2 to execute the operation of the preparatory stage and collects sensor data 12 of the preparatory stage during the preparatory operation. In addition, the fault diagnosis system 100 causes the mechanical device 2 to execute an actual operation and collects actual sensor data 12 when the device is in operation. Then, the failure diagnosis system 100 diagnoses a failure of the mechanical device 2 when the device is in operation.

  When the fault diagnosis system 100 starts the preparation before operation, in step S10, the master station 1 detects sensor data 12 when the first motor 4 is driven in a state where the mechanical device 2 is not connected to the first motor 4. To collect

  Specifically, the first command data generation unit 21 of the master station 1 generates the first command data 11 similar to that when actually operating the mechanical device 2, and the first slave station 3 and the first command data Output to the storage unit 23. In this case, the second command data generation unit 22 does not output the second command data 13. Then, the first command data storage unit 23 stores the first command data 11, which is the first drive command. Further, the first slave station 3 generates a torque command corresponding to the first command data 11 and outputs the torque command to the first motor 4 to drive the first motor 4.

  Then, the sensor 5 detects the state of the mechanical device 2 when the first motor 4 is driven, and outputs sensor data 12 as a detection result to the master station 1. Thereby, the sensor data storage unit 24 stores the sensor data 12 when the first motor 4 is driven in the sensor data storage area 240A. As described above, the sensor data 12 stored in the sensor data storage area 240A by the sensor data storage unit 24 is sensor data when the master station 1 drives the first motor 4 without driving the second motor 7. It is twelve.

  Then, in step S20, the threshold generation unit 26 generates a failure diagnosis threshold. Specifically, the threshold value generation unit 26 reads the first command data 11 which is the first drive command from the first command data storage unit 23, and the third detection from the sensor data storage area 240A of the sensor data storage unit 24. The sensor data 12 which is data is read out. Then, the threshold generation unit 26 generates a failure diagnosis threshold based on the first command data 11 and the sensor data 12. The threshold generation unit 26 may generate the failure diagnosis threshold by any method. The threshold storage unit 27 stores the failure diagnosis threshold generated by the threshold generation unit 26.

  The threshold generation unit 26 may generate the failure diagnosis threshold using the sensor data 12 without using the first command data 11. In this case, the master station 1 may not have the first command data storage unit 23.

Here, a case where the threshold value generation unit 26 generates a failure diagnosis threshold value using the sensor data 12 without using the first command data 11 will be described. The threshold generation unit 26 generates a failure diagnosis threshold, for example, using the following methods (1) to (3). The method of (1) is a method of generating a fault diagnosis threshold using the sensor data 12 at the time of normal operation, and the method of (2) and (3) is that the mechanical parts of the mechanical device 2 fail at the time of normal operation. It is a method of generating a fault diagnosis threshold using the sensor data 12 up to
(1) The threshold generation unit 26 sets a value obtained by multiplying the maximum value and the minimum value of the sensor data 12 at the time of normal operation by a specific magnification as the failure diagnosis threshold value.
(2) The threshold generation unit 26 sets the value of the sensor data 12 that is earlier by a specific time from the timing at which the mechanical component breaks down as the failure diagnosis threshold.
(3) The threshold value generation unit 26 sets, as a failure diagnosis threshold value, a timing value at which the value of the sensor data 12 which has been stable in the normal operation shows a rising tendency or a falling tendency until the mechanical component breaks down.

  FIG. 8 is a diagram showing the relationship between first command data and sensor data when generating a failure diagnosis threshold according to the embodiment. FIG. 8 shows the first command data 11 and the sensor data 12 when the failure diagnosis system 100 drives the first motor 4 in step S10. The horizontal axis of the graph shown in FIG. 8 is time. The vertical axis of the graph on the upper side shown in FIG. 8 is the first command data 11, and the vertical axis of the graph on the lower side is the sensor data 12. The threshold generation unit 26 generates a failure diagnosis threshold based on the first command data 11 and the sensor data 12 as shown in FIG. 8.

  Further, in the failure diagnosis system 100, in step S30, the master station 1 collects sensor data 12 when the second motor 7 is driven in a state where the mechanical device 2 is connected to the second motor 7.

  Specifically, the second command data generation unit 22 of the master station 1 generates the second command data 13 and outputs the second command data 13 to the second slave station 6 and the second command data storage unit 25. In this case, the first command data generation unit 21 does not output the first command data 11. Then, the second command data storage unit 25 stores the second command data 13, which is the second drive command, in the second command data storage area 250A. In addition, the second slave station 6 generates a torque command corresponding to the second command data 13 and outputs the torque command to the second motor 7 to drive the second motor 7.

  Then, the sensor 5 detects the state of the mechanical device 2 when the second motor 7 is driven, and outputs sensor data 12 as a detection result to the master station 1. Thereby, the sensor data storage unit 24 stores the sensor data 12 at the time of driving the second motor 7 in the sensor data storage area 240B. The second command data 13 for driving the second motor 7 may be different from the command data at the time of actually operating the mechanical device 2. As described above, the sensor data 12 stored by the sensor data storage unit 24 in the sensor data storage area 240 B is sensor data when the master station 1 drives the second motor 7 without driving the first motor 4. It is twelve.

  In step S40, the model generation unit 28 generates a sensor data calculation model. Specifically, the model generation unit 28 reads the sensor data 12 which is the fourth detection data from the sensor data storage area 240B of the sensor data storage unit 24, and the second command data storage area of the second command data storage unit 25. The second command data 13 which is the second drive command is read out from 250A. Then, the model generation unit 28 generates a sensor data calculation model based on the sensor data 12 and the second command data 13. The model generation unit 28 may generate the sensor data calculation model by any method. The model storage unit 29 stores the sensor data calculation model generated by the model generation unit 28.

  The model generation unit 28 generates a sensor data calculation model using, for example, a system identification method. Examples of this system identification method are frequency response, transient response or least squares. When generating a sensor data calculation model using the system identification method, the model generation unit 28 generates sensor data based on the second command data 13 which is actual input data and the sensor data 12 which is actual output data. Estimate the calculated model. Specifically, when the second command data 13 is input, the model generation unit 28 estimates a sensor data calculation model in which the sensor data 12 corresponding to the second command data 13 is output. In other words, the model generation unit 28 estimates a sensor data calculation model corresponding to the processing between the input and the output based on the input second command data 13 and the output sensor data 12.

  FIG. 9 is a diagram showing a relationship between second command data and sensor data when generating a sensor data calculation model according to the embodiment. FIG. 9 shows the second command data 13 and the sensor data 12 when the failure diagnosis system 100 drives the second motor 7 in step S30. The horizontal axis of the graph shown in FIG. 9 is time. The vertical axis of the upper graph shown in FIG. 9 is the second command data 13, and the vertical axis of the lower graph is the sensor data 12. The model generation unit 28 generates a sensor data calculation model based on the sensor data 12 and the second command data 13 as shown in FIG. 9.

  The master station 1 executes the process of step S20 after the process of step S10, and executes the process of step S40 after the process of step S30. The master station 1 may execute any of the processes of steps S10 and S20 and the processes of steps S30 and S40 first. When the master station 1 executes the generation of the fault diagnosis threshold and the generation of the sensor data calculation model, the pre-operation preparation ends.

  The failure diagnosis system 100 starts the operation of the device with the mechanical device 2 connected to the first motor 4 and the second motor 7. In step S50, the master station 1 collects sensor data 12 when the first motor 4 and the second motor 7 are driven.

  Specifically, the first command data generation unit 21 generates the first command data 11 and outputs the first command data 11 to the first slave station 3. Further, the second command data generation unit 22 generates the second command data 13 and outputs the second command data 13 to the second slave station 6 and the second command data storage unit 25.

  Thereby, the second command data storage unit 25 stores the second command data 13 which is the third drive command in the second command data storage area 250B. Also, the first slave station 3 generates a torque command corresponding to the first command data 11 and outputs it to the first motor 4, and the second slave station 6 generates a torque command corresponding to the second command data 13. Output to the second motor 7. Thereby, the first motor 4 and the second motor 7 are driven, and the mechanical device 2 is operated by the first motor 4 and the second motor 7.

  Then, the sensor 5 detects the state of the mechanical device 2 when the first motor 4 and the second motor 7 are driven, and outputs sensor data 12 as a detection result to the master station 1. Thereby, the sensor data storage unit 24 stores, in the sensor data storage area 240C, the sensor data 12, which is the first detection data when the first motor 4 and the second motor 7 are driven.

  The estimated sensor data calculation unit 30 reads the sensor data 12 from the sensor data storage area 240C of the sensor data storage unit 24 and executes the sensor data calculation model from the model storage unit 29 when executing the failure diagnosis of the mechanical device 2 The second command data 13 is read out from the second command data storage area 250 B of the second command data storage unit 25.

  FIG. 10 is a diagram showing a relationship between first command data, second command data, and sensor data when the failure diagnosis according to the embodiment is executed. FIG. 10 shows the first command data 11, the second command data 13, and the sensor data 12 when the failure diagnosis system 100 drives the first motor 4 and the second motor 7 in step S50. The horizontal axis of the graph shown in FIG. 10 is time. The vertical axis of the upper graph shown in FIG. 10 is the first command data 11, the vertical axis of the middle graph is the second command data 13, and the vertical axis of the lower graph is the sensor data 12.

  In the failure diagnosis system 100, in step S60, the estimated sensor data calculation unit 30 calculates estimated sensor data when the second motor 7 is driven. The estimated sensor data in the case of driving the second motor 7 is estimated sensor data corresponding to the second command data 13. At this time, the estimated sensor data calculation unit 30 calculates estimated sensor data corresponding to the second command data 13 in the second command data storage area 250B using the sensor data calculation model.

  The estimated sensor data corresponding to the second command data 13 is an estimated value of a data component of the sensor data 12 corresponding to the second command data 13. In the following description, estimated sensor data corresponding to the second command data 13 may be referred to as estimated sensor data X2. The estimated sensor data X2, which is the fifth detection data, is an estimated value of the data component attributable to the second motor 7 among the sensor data 12 detected when the first motor 4 and the second motor 7 are driven. is there.

  FIG. 11 is a diagram showing the relationship between second command data and estimated sensor data according to the embodiment. FIG. 11 shows the relationship between the second command data 13 collected by the master station 1 in step S50 and the estimated sensor data X2 calculated by the estimated sensor data calculation unit 30 in step S60. The horizontal axis of the graph shown in FIG. 11 is time. The vertical axis of the upper graph shown in FIG. 11 is the second command data 13, and the vertical axis of the lower graph is the estimated sensor data X2.

  After calculating the estimated sensor data X2, the estimated sensor data calculation unit 30 calculates estimated sensor data when driving the first motor 4 in step S70. The estimated sensor data in the case of driving the first motor 4 is estimated sensor data corresponding to the first command data 11. At this time, the estimated sensor data calculation unit 30 calculates estimated sensor data corresponding to the first command data 11 by subtracting the estimated sensor data X2 from the sensor data 12 read from the sensor data storage area 240C.

  The estimated sensor data corresponding to the first command data 11 is an estimated value of a data component of the sensor data 12 corresponding to the first command data 11. In the following description, estimated sensor data corresponding to the first command data 11 may be referred to as estimated sensor data X1. The estimated sensor data X1 which is the second detection data is an estimated value of a data component attributable to the first motor 4 among the sensor data 12 detected when the first motor 4 and the second motor 7 are driven. is there.

  FIG. 12 is a diagram showing the relationship between first command data and estimated sensor data according to the embodiment. FIG. 12 shows the relationship between the first command data 11 collected by the master station 1 in step S50 and the estimated sensor data X1 calculated by the estimated sensor data calculation unit 30 in step S70. The horizontal axis of the graph shown in FIG. 12 is time. The vertical axis of the upper graph shown in FIG. 12 is the first command data 11, and the vertical axis of the lower graph is the estimated sensor data X1.

  The estimated sensor data calculation unit 30 outputs the calculated estimated sensor data X1 to the failure diagnosis unit 31. Then, in step S80, the failure diagnosis unit 31 executes failure diagnosis that is determination as to whether or not a failure has occurred in the mechanical device 2. The failure diagnosis unit 31 determines that a failure occurs when the estimated sensor data X1 exceeds the failure diagnosis threshold in the threshold storage unit 27.

The failure diagnosis unit 31 determines failure using, for example, the following methods (4) to (6). The methods (4) to (6) periodically check whether the estimated sensor data X1 exceeds the failure diagnosis threshold and determine the failure based on the number of times the estimated sensor data X1 exceeds the failure diagnosis threshold. It is. The failure diagnosis unit 31 can prevent an erroneous detection by using the method (5) or (6).
(4) When the estimated sensor data X1 exceeds the failure diagnosis threshold, the failure diagnosis unit 31 determines that the failure is an immediate failure. In other words, the failure diagnosis unit 31 determines that a failure occurs when the estimated sensor data X1 exceeds the failure diagnosis threshold even once.
(5) The failure diagnosis unit 31 determines that a failure occurs when the estimated sensor data X1 continuously exceeds the failure diagnosis threshold for a specific number of times. For example, when the estimated sensor data X1 exceeds the failure diagnosis threshold three consecutive times, the failure diagnosis unit 31 determines that a failure occurs.
(6) The failure diagnosis unit 31 determines that a failure occurs when the estimated sensor data X1 exceeds the failure diagnosis threshold a plurality of times of a specific number of times or a specific time. For example, if the estimated sensor data X1 exceeds the failure diagnosis threshold three times out of ten times, the failure diagnosis unit 31 determines that a failure occurs.

  The conventional failure diagnosis system creates a threshold value for determining a failure of a mechanical device using sensor data when a plurality of drive sources are operated after the device operation is started. In this case, when the plurality of drive sources are operated, data components resulting from the plurality of drive sources are superimposed on sensor data. Therefore, in the conventional failure diagnosis system, when the configuration of the mechanical device is changed, the data component of the sensor data resulting from the changed portion changes. As a result, sensor data may differ between before and after changing the configuration of the mechanical device. Therefore, since sensor data differs depending on the configuration or characteristics of the mechanical device, conventionally, it has been necessary to set a threshold for determining a failure of the mechanical device for each configuration and each characteristic of the mechanical device.

  On the other hand, even if the configuration or the characteristics of the mechanical device 2 are changed, the failure diagnosis system 100 according to the embodiment diagnoses the failure of the mechanical device 2 only by re-executing the processing of steps S30 to S70. be able to. That is, when the configuration or the characteristic of the mechanical device 2 is changed, the failure diagnosis system 100 according to the embodiment does not execute the processes of steps S10 and S20, and uses the set failure diagnostic threshold value. It is possible to diagnose the failure of

  In the embodiment, although the case where the mechanical device 2 is operated by the first motor 4 and the second motor 7 has been described, the number of drive sources for operating the mechanical device 2 may be three or more. Also in this case, the failure diagnosis system 100 can diagnose the failure of the mechanical device 2 by the same processing procedure as the above-described processing procedure.

  Here, the hardware configuration of the master station 1 will be described. FIG. 13 is a diagram illustrating an example of a hardware configuration of a master station according to the embodiment. Master station 1 can be realized by control circuit 300 shown in FIG. 13, that is, processor 301 and memory 302. An example of the processor 301 is a CPU (Central Processing Unit, central processing unit, processing unit, arithmetic unit, microprocessor, microcomputer, processor, also referred to as DSP) or a system LSI (Large Scale Integration). An example of the memory 302 is a random access memory (RAM), a read only memory (ROM), or a flash memory.

  The master station 1 is realized by the processor 301 reading out and executing a program stored in the memory 302 for executing the operation of the master station 1. Also, it can be said that this program causes a computer to execute the procedure or method of the master station 1. The memory 302 is also used as a temporary memory when the processor 301 executes various processes.

  Thus, the program executed by the processor 301 is a computer-executable computer-program product having a computer-readable non-transitory recording medium including a plurality of instructions for performing data processing. is there. The program executed by the processor 301 causes the computer to execute data processing of a plurality of instructions.

  Further, the master station 1 may be realized by dedicated hardware. Further, a part of the functions of the master station 1 may be realized by dedicated hardware and a part may be realized by software or firmware.

  As described above, in the failure diagnosis system 100, a sensor detected when the estimated sensor data calculation unit 30 of the master station 1 operates the mechanical device 2 to which the first motor 4 and the second motor 7 are connected. By removing data components originating from the second motor 7 from the data 12, sensor data 12 originating from the first motor 4 is estimated. Then, the failure diagnosis unit 31 diagnoses the failure of the mechanical device 2 by comparing the sensor data 12 caused by the first motor 4 with the failure diagnosis threshold value.

  Thus, according to the embodiment, since the sensor data 12 caused by the first motor 4 is estimated, a single failure diagnosis threshold for diagnosing whether the mechanical device 2 is in failure is applied. be able to. Therefore, when the device configuration or device characteristics of the mechanical device 2 are changed, it is possible to save time and effort for generating the failure diagnosis threshold value for each of the mechanical devices 2, so that the number of preparation steps at the time of failure diagnosis is reduced. be able to. Therefore, even when the device configuration or the device characteristic of the mechanical device 2 is changed, it is possible to easily diagnose the failure of the mechanical device 2.

  The configuration shown in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and one of the configurations is possible within the scope of the present invention. Parts can be omitted or changed.

  Reference Signs List 1 master station, 2 mechanical device, 3 first slave station, 4 first motor, 5 sensor, 6 second slave station, 7 second motor, 11 first command data, 12 sensor data, 13 second command data, 21 First command data generation unit, 22 second command data generation unit, 23 first command data storage unit, 24 sensor data storage unit, 25 second command data storage unit, 26 threshold generation unit, 27 threshold storage unit, 28 model generation Part, 29 model storage part, 30 estimation sensor data calculation part, 31 fault diagnosis part, 100 fault diagnosis system.

In order to solve the problems described above and to achieve the object, the present invention relates to a device that is detected when operating a device to which a first drive source and a second drive source are connected in a failure diagnosis device. Estimation data calculation unit for estimating second detection data indicating a state of the device caused by the first drive source by removing a data component caused by the second drive source from the first detection data indicating the state of Is equipped. Further, according to the failure diagnosis device of the present invention , the first drive command for driving the first drive source output to the first drive source side in a state where the device is not connected to the first drive source And a threshold generation unit that generates a threshold based on third detection data indicating the state of the device detected when the first drive command is output , and comparing the second detection data with the threshold by, and a, and a fault diagnosis unit for diagnosing faults in equipment.

In order to solve the problems described above and to achieve the object, the present invention provides an apparatus for fault diagnosis when it is disposed between a specific member of the apparatus and a first drive source to drive the apparatus. The sensor for detecting the state, the first drive source and the specific member of the device are connected, and the second drive source and the specific member of the device are connected, and the specific member of the device is connected. When the device is operated with the first drive source and the second drive source connected , the first drive data indicating the state of the device detected by the sensor is attributed to the second drive source The estimated data calculation unit is configured to estimate second detection data indicating a state of the device caused by the first drive source by removing the data component. Further, according to the failure diagnosis device of the present invention, a first drive source for driving the first drive source that is output to the first drive source side in a state where a specific member of the device is not connected to the first drive source. A threshold generation unit that generates a threshold on the basis of a drive command for driving and a third detection data indicating a state of the device detected by the sensor when the first drive command is output; And a failure diagnosis unit that diagnoses a failure of the device by comparing the detection data with the threshold value.

Claims (4)

The data component attributed to the second drive source is derived from first detection data indicating the state of the device detected when the device to which the first drive source and the second drive source are connected is operated. An estimated data calculation unit configured to estimate second detection data indicating a state of the device caused by the first drive source by removing the data;
A failure diagnosis unit that diagnoses a failure of the device by comparing the second detection data with a threshold;
A fault diagnosis apparatus comprising: A first drive command for driving the first drive source output to the first drive source side in a state where the device is not connected to the first drive source; and the first drive And a threshold generation unit configured to generate the threshold based on third detection data indicating a state of the device detected when a command is output.
The fault diagnosis apparatus according to claim 1, A second drive command for driving the second drive source, which is output to the second drive source in a state where the device is connected to the second drive source, and the second drive The fourth detection data indicating the state of the device based on the fourth detection data indicating the state of the device detected when a command is output, the fifth detection being a data component originating in the second drive source It further comprises a model generation unit that generates a model for estimating data.
The estimated data calculation unit further includes a third drive command for driving the second drive source, which is output to the second drive source when the first detection data is detected, and the model. Estimating the fifth detection data, and estimating the second detection data by removing the fifth detection data from the first detection data;
The fault diagnostic device according to claim 1 or 2, characterized in that: Detecting the first detection data indicating the state of the device when the device to which the first drive source and the second drive source are connected is operated;
Estimating second detection data indicating a state of the device caused by the first drive source by removing a data component caused by the second drive source from the first detection data;
A fault diagnosis step of diagnosing a fault of the device by comparing the second detection data with a threshold;
Fault diagnosis method characterized in that it includes.

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