RU2420777C2 - Automated systems of control for repair processes with implementation of mobile repair-diagnostic complex - Google Patents

Abstract

FIELD: machine building.

SUBSTANCE: automated system of control for repair processes of complex technical systems implementing mobile repair-diagnostic complexes consists of central computer and of remote terminal connected to central computer, and also of automated work places (AWP) incorporated into this system, such as: AWP of control and diagnostic of components, AWP of control of radio-assembly works, AWP of control over elimination of damages in structures on repair object, AWP of recovery of moisture protection and of repair object marking, and AWP of control of repair operations on remote process working place. All the AWP are connected to the central computer, and each AWP structurally is connected with a corresponding process working place (PWP) of control and diagnostic, electro-radio-assembly works, works for elimination of damages of repair object structures, works for recovery of moisture protection and marking, and the remote PWP. Also, the PWP of control and diagnostic are connected to other PWP.

EFFECT: raised high speed of automated systems of control over repair process of complex technical systems.

2 cl, 1 dwg

Description

The invention relates to the field of special computing (repair tools for complex technical systems), in particular to automated information systems for managing technical repair processes using mobile repair and diagnostic systems. The invention can also be used to control the technological processes of repair of equipment and equipment in the conditions of stationary repair bodies.

Known automated information systems used to control technological processes in various subject areas. Examples are technical solutions for nuclear power plants that are given in RF patents RU No. 68723 (2007.11.27), RU No. 2156834 (2000.09.27), RU No. 2002101943 (2003.08.27). The indicated systems contain a central computer with the software installed for controlling the corresponding technological process connected to devices for measuring the parameters of the controlled technological process and to devices that control the parameters of technological plants, supply consumables to the work area and obtain output products.

The disadvantages of the known solutions are that they are designed to control continuous technological processes, and are not intended for the operational control of operator actions when performing discrete technological processes of repairing complex technical systems (in particular, weapon systems and military equipment).

Closest to the claimed technical solution is an automated process and resource management system (ACS PR) according to the patent for utility model RU 66.287 (B60P 3/14, 09.10.2007), which is taken as a prototype.

The prototype system contains a central computer with a database of reference data on serviced technical systems located in its memory, a catalog database on the components of serviced technical systems, a database of an electronic archive of maintenance and repair documentation, a database of spare property, materials and accessories (spare parts) in the composition of the repair and diagnostic complex (RDK) and in the complexes of serviced products and the remote terminal of the workstation (AWS) for monitoring and diagnostics and components of serviced technical systems, while before leaving RDK to conduct a specific type of work on a specific technical system, documents on the profile of this system are loaded into the ACS PR database, upon arrival at the place of deployment of the serviced technical system, the remote terminal is located at the place of work directly at component of the serviced technical system, and the remote terminal is equipped with measuring modules and modules for generating stimulating effects, sub yuchaemymi to corresponding points controlled components serviced by the technical system.

The advantage of the prototype system is the implementation of the control actions of the repair personnel performing technical condition monitoring and repair of components directly at their regular locations as part of the serviced technical system. The actions of the repair personnel are managed by organizing interactive access to the computer of the automated control system of the PR using a remote terminal. In this case, on the basis of the prompts in the form of fragments of repair and operational documentation issued by the ACS PR computer on the screen of the remote terminal (portable AWP), the sequence of actions of the repair personnel (operator of the remote terminal) to connect the measuring means of the remote terminal to the corresponding points, according to the assessment of the measured technical parameters the state of the controlled component of the serviced technical system, to identify the cause of the malfunction, to replace the identified malfunctioning with ennyh elements (parts of the lower level of decomposition structure technical system serviced) on known good set of single-ended ISP serviced technical system and to control the recovery efficiency of the repaired part of the technical system serviced.

A disadvantage of the known prototype system is the lack of management of technological operations for the repair of replaceable elements of a product at workplaces as part of a repair and diagnostic complex and at additionally organized remote technological workplaces assigned to RDK for the implementation of individual technological operations within the complete repair cycle of replaceable elements of a serviced technical system . The consequence of this is a decrease in the productivity and quality of repair of replaceable elements according to the profile of the RDK, as well as increased requirements for the qualifications of personnel repairing replaceable elements in the RDK.

The purpose of the claimed technical solution is to eliminate the disadvantages of the prototype, namely:

- providing an interactive procedure for managing technological processes to be performed at workplaces as part of RDK and at remote technological workplaces attached to RDK in accordance with the established directive technology for repairing replaceable elements of a serviced technical system according to the profile of work of the corresponding RDK;

- reducing the requirements for the level of qualification of specialists performing repair work on replaceable elements at the corresponding technological workplaces as part of the RDK and additional external workplaces attached to the RDK.

The specified technical result is achieved by the fact that in an automated control system for technological processes of repair using a mobile repair and diagnostic complex (hereinafter referred to as process control system), comprising: a central computer with reference data on serviced technical systems located in its memory, a catalog database of components serviced technical systems, a database of an electronic archive of operational and repair documentation, a database of spare property, materials, etc. accessories (spare parts) as part of the repair and diagnostic complex (RDK) and in complexes of serviced technical systems and a remote terminal of a workstation for monitoring and diagnostics of components of serviced technical systems; additional sets of equipment for automated workstations for process control containing a computer, a monitor, a barcode reader and a feedback device in the form of a manipulator installed on each technological workstation of the RDK on the technological process of repairing replaceable elements of a serviced technical system so that a repair technician, when performing operations, can compare his actions with the image on the monitor screen and confirm the actions and instructions of the central control system computer using the manipulator, while all additional workstations are combined with the central computer Automated process control systems in a local network, into which a remote terminal is also connected using the corresponding extension cable of the interface bus of the local computer network (LAN), in addition to symbolic repair documentation, a graphic instruction containing operational images of the repaired components of the serviced technical system in the sequence of their disassembly and assembly according to the repair process has been entered into the database of the control system central computer;

The device and principle of operation of the claimed system is illustrated in the drawing.

The system contains a central computer 1 and automated workstations 2 (AWS) for managing technological operations, combined with a central computer 1 using an interface line 3 into a local computer network, automated workstations 2 for managing technological operations are structurally combined with the corresponding technological repair workstations 4 (ТРМ ) The central computer 1, AWP 2, TPM 4 are placed appropriately in the technological compartment of the repair and diagnostic complex 5 (RDK). An external terminal 7 is connected to the interface bus 3 using the remote highway 6, located during work directly on the serviced technical system 8. An additional workstation 10 is connected to the interface highway 3 using the remote highway 9, which is structurally combined with an external technological workstation 11 located on time of work in temporary shelter 12.

Upon arrival at the location of the serviced technical system 8, the remote terminal 7 is transferred from the technological compartment of RDK 5 directly to the location of the equipment of the serviced technical system 8. The central computer 1, AWP 2 and TPM 4 are brought into working condition. If it is necessary to carry out work with bulky removable components of a serviced technical system 8, work with which is impossible in the technological compartment of RDK 5, external workplaces are organized. For this purpose, a temporary shelter 12 is organized near the RDK, in which external TPMs 11 are installed for the duration of the repair work, with which external additional AWPs 10 are connected, connected by a remote interface highway 9 to the LAN interface bus of system 3.

When monitoring the technical condition of the serviced technical system 8 from the central computer 1 in the sequence of the technical process of servicing and repairing the serviced technical system 8, fragments of repair documentation containing instructions to repair personnel according to the sequence of their actions are issued frame-by-frame on the remote terminal 7, images of fragments of the design of the inspected equipment are indicated connection points of measuring devices from the remote terminal 7. Measured using ter minala 7 values of the parameters of the technical condition of the controlled part of the serviced technical system 8 are compared with acceptable. The detection of a discrepancy between the measured values and the acceptable ones is a sign of the equipment approaching the limit state or a sign of failure. By successive measurements at appropriate points on the basis of the instructions of the repair documentation, faulty removable components of the lower level of disaggregation of the maintained technical system are identified (also referred to in the technical literature as replaceable structural elements). Suspected failure components are removed from the structure of the serviced technical system 8, and in their place are installed serviceable replaceable elements of the same type from the single spare parts kit included in the delivery set of the serviced technical system 8. Repeated measurements using the remote terminal 7 determine the recovery serviced technical system 8. All intermediate and final results of operations performed to control the technical condition and repair of served technical system 8 using the terminal 7 in a dialogue mode is entered into the central computer 1, including data on faulty replaceable structural elements removed from the served technical system 8 in the process of repair.

Defective structural replaceable elements are transferred from the serviced technical system 8 to the technological compartment of the RDK 5 for repair. If preliminary disassembly of complex units is necessary or preparatory work is necessary (repair, drainage of dirt, etc.), then these replaceable components can be preliminarily supplied to additionally organized external technological workplaces 11.

Replaceable components of the serviced technical system that are to be repaired and received in the technological compartment of RDK 5 are transferred to technological workstations 4 and transferred from one technological place to another in the sequence of the technological repair process. The repair process control procedure using the claimed system (see drawing) can be considered by the example of repair of replaceable structural elements of electronic equipment (CEA).

Each replacement element of the CEA that has arrived for repair is preliminary subject to accounting in the central computer 1 of the system. In this case, the type of this replaceable element and its identification numbers (serial number and belonging to the design of the serviced technical system 8) are entered. The registration of the type and registration data, in case of duplication in the form of barcodes, are entered into the central computer 1 using the barcode reader included with the central computer 1.

A defective replacement element (object of repair) that has passed registration arrives (during the technical process and in accordance with the instructions of the repair documentation located in the computer database 1) at the nearest technological workstation 4-1. The number of TPM 4 and AWPs 2 structurally combined with them for managing technological operations is determined by the specialization of RDK 5 and the technological repair processes implemented as part of RDK 5. In the case of repair of replaceable elements of electronic equipment, the first TPM 4-1 is the technological workplace for monitoring and diagnosing malfunctions of replaceable elements. Structurally combined with TPM 4-1, AWP 2-1 is a corresponding automated monitoring and diagnostics system (ASKD) designed to monitor the operability and diagnosis of malfunctions of functional components of electronic equipment.

Before starting the execution of instructions for TPM 4-1, from the central computer 1 of the system, through the interface line 3 to the AWP 2-1 (ASKD), repair documentation for replaceable elements to be repaired, including diagnostic tests, as well as an indication to the ASKD operator of the sequence of actions, is transmitted during the control and diagnosis of each replaceable element. According to the instructions reproduced on the AWP 2-1 screen, the TPM 4-1 operator connects the replaceable element (repair object) to the ASKD and performs an iterative control procedure. When confirming the inoperability of the monitoring object, an indication on the iterative procedure for diagnosing malfunctions is issued on the AWP 2-1 screen. In the process of diagnosing malfunctions, on the AWP 2-1 screen, instructions are given to the operator on the locations of connecting test probes according to the diagnostic algorithm (with the display on the AWP 2-1 screen displaying the image of the construction of the controlled plug-in element and corresponding prompts on the connecting points of the probes). Based on the diagnostic results, faulty electro-radioelements (ERE) are determined as part of a controlled replaceable element (repair facility), types and reference designations of faulty ERE to be replaced. The results of the monitoring and diagnostics (with identification of the type and number of the monitoring object) are transmitted from the AWP 2-1 through the interface highway 3 to the central computer 1.

Next, the faulty replaceable element, in accordance with the sequence of the technological process reflected in the repair documentation as part of the central computer 1, is transferred from the technological place for monitoring and diagnostics TPM 4-1 to the technological workplace for electrical and radio installation work TPM 4-2. To manage the transfer procedure to AWP 2-1 and AWP 2-2, the corresponding instructions are reproduced, according to which the TPM 4-1 and TPM 4-2 operators enter the appropriate confirmations (on the transfer of the repair object and on the acceptance of the repair object).

Upon receipt of the repair object on the TPM 4-2 from the central computer 1, in accordance with the technological repair documentation contained in the databases of the computer 1 and the results of fault diagnostics received from the AWP 2-1, the following instructions are issued to the AWP 2-2 screen:

- on the preparation of a technological tool;

- about the necessary ERE and consumables;

- on the sequence of actions to remove faulty EREs and to install in their place a working ERE from the corresponding installation of repair spare parts (included in the technological equipment set of TRM 4-2).

Preparation of a technological tool (for example, a soldering unit with appropriate nozzles) and its application (for example, soldering faulty EREs and installing and soldering serviceable EREs) are carried out according to the instructions received from the central computer 1 on the AWP 2-2 screen. At the same time, to identify the repair location, the image of the necessary part of the construction of the repair object is reproduced on the AWP 2-2 screen - with the highlighting of the image of the replaced ERE (for example, by color or a blinking image fragment). The execution of each given procedure is confirmed using the manipulator included in the workstation kit.

To speed up the search for the necessary ERE and technological tool, the coordinates of the regular location of the appropriate installation of repair spare parts or technological equipment on the shelves as part of the TRM are used. The installation and packing identification as part of the found repair spare parts installation is carried out by reading the identification bar codes printed on the installation cases and on the ERE packages, materials and tools. Barcodes are read using the barcode readers included in the workstation 2 set. The identification of the barcode recognition results is displayed on the workstation 2 screen. All information about the replacement of ERE and other installation elements recorded during the repair of the replaceable element on the TPM 4 -2, transferred from the AWP 2-2 to the central computer 1. Based on a comparison of the work performed and the previously obtained results of fault diagnosis, the central computer 1 controls the completeness of the repair operations (replacement RE), and performs accounting ERE consumption, wear of materials and process tool (including a possible tool breakage).

The repaired replacement element according to the instructions from the central computer 1 is supplied from the TPM 4-2 to the TPM 4-1 for monitoring the restoration of performance and troubleshooting. In the event that additional unresolved malfunctions are detected, the replaceable element is returned to TPM 4-2 to eliminate the identified malfunctions. Additional work on TPM 4-2 to resolve the identified malfunctions is performed under the control of the central computer 1 of the system using AWP 2-2 similarly to the above procedure. After the complete elimination of malfunctions of the electrical circuit of the replaceable element (replacement of all faulty EREs and damaged conductors), the repair object is transferred to TPM 4-3 to eliminate the existing damage to the structural elements of the replaceable element.

Work on repairing structural damage is performed under the control of computer 1 using AWP 2-3. The interactive procedure for searching for a technological tool, parts and materials for repairing the design of a replaceable element using AWP 2-3 is carried out similarly to the previously considered procedure for replacing faulty EREs with TRM 4-2.

After eliminating structural damage, the replaceable element (repair object) with TPM 4-3 is returned to TPM 4-1 to monitor the preservation of operability, since during metalwork and mechanical operations on TRM 4-3, the integrity of electrical circuits may be violated or ERE may be damaged. In case of malfunctions, the repair object is transferred to TPM 4-2 to eliminate malfunctions. The serviceable repair object is transferred to TPM 4-4 for restoration (damaged at the previous stages of the technological process) of moisture-proof coatings and marking.

The procedure for preparing a technological tool and materials for restoring moisture-proof coatings and marking on TPM 4-4 under the control of computer 1 of the system is performed on the basis of technological repair documentation in the same way as the procedures considered on TPM 4-2 and TPM 4-3.

After restoration of moisture protection and marking, the repaired replacement element is transferred under the control of computer 1 of the system from TPM 4-4 to TPM 4-1. Here, the final performance monitoring of the repaired replacement element is performed. In the event of a malfunction of the replaceable element, fault diagnostics are performed. If faulty electrical circuits or ERE are detected, the repair object is transferred from TPM 4-1 to TPM 4-2, after which the private cycle of eliminating additionally detected faults and the subsequent restoration of the moisture-proof coating is repeated.

Upon confirmation of full serviceability on the workstation 2-1 in TPM 4-1, the repaired replacement element is taken into account in the database of computer 1 of the system as restored (completely repaired) and transmitted (with an accompanying document printed on the printer from computer kit 1) to a single spare part maintained technical system 8.

If a final defect is identified according to the results of monitoring and diagnostics (at the beginning of the repair process of the replacement element received at the RDK) of the final defect, the replaceable element that cannot be repaired is taken into account in the database of the central computer 1 of the system, placed in a separate technological container as part of the RDK and then transferred for disposal . In computer 1, initial data are generated for the subsequent replenishment of a single spare part of the item being repaired in connection with the removal of this replaceable element that cannot be repaired.

Thus, due to the introduction of additional structural elements and connections between elements in accordance with the drawing, the claimed technical effect is achieved, namely:

- an interactive procedure for managing technological operations of repairing a serviced technical system 8 is being implemented and identifying faulty replaceable components (replaceable structural elements) of a serviced technical system during repair. Repair management of the serviced technical system 8 and its interchangeable components as part of the design documentation 5 is carried out according to a single technological process based on the repair documentation downloaded to the database of the central computer 1 of the system - in full accordance with the established directive technology;

- operations of the technological process of repairing replaceable elements at technological workstations within the RDK and at additional external TRMs, organized if necessary, are controlled from the central computer 1 of the system with the organization of iterative procedures for the interaction of TPM and AWP operators structurally combined with TRM. At the same time, tips are organized in the form of images of structures of repair objects on the workstation screen and alternately highlighting fragments of the construction of the repair object to be affected by the TPM operator. Automation of iterative procedures for finding the necessary spare parts, materials and tools is provided using bar-code marking of packages (stacks) and barcode readers included in the workstation kit. This ensures a reduction in the requirements for the experience and qualifications of repair personnel;

- the organization of iterative procedures for managing technological repair operations provides a more rigorous accounting of the consumption of spare parts, materials, specialist working time, which increases the efficiency and quality of repair work, as well as the economical use of all types of resources.

The industrial feasibility of the claimed technical solution is based on the construction of the claimed system based on software and hardware known from the prior art.

Any RDK can be built on the basis of serial container bodies (for example, type KK.6.2 produced by the ShZSA plant in Shumerlya).

Technological equipment of the RDK (external technological workplaces TPM 4-N according to the profile of the work performed) can be created on the basis of decisions according to patent RU No. 66287.

The central computer 1 of the system and the AWP 2-N for controlling technological processes on the corresponding TPM (see drawing) can be configured on computers of serial means of computer technology. The system’s local network can be implemented on the basis of a standard Ethernet interface backbone using a client-server architecture: ASKD, implemented as part of AWP 2-1, can be built on the basis of a combination of a personal computer and a measurement module of a backbone-modular type (for example, according to the VXI or LXI), as well as on the basis of decisions on patent RU No. 2222865.

The portable terminal 7 can be built on the basis of a portable personal computer of the “laptop” type and a small-sized measuring subsystem of the trunk-modular type (for example, according to the VXI or LXI standard), as well as on the basis of decisions according to patent RU No. 2222865.

Repair documentation used to carry out the technological process of repairing products and their components is developed in the form of electronic interactive documents in accordance with GOST 2.602-95, GOST RVD 2.602-96 (for military equipment) and GOST 2.051-2006.

Claims (2)

1. Automated process control system (APCS) for the repair of complex technical systems (STS) using mobile repair and diagnostic systems (RDK), containing a central computer with reference information, operational, repair and other documentation on the repair of components of serviced computers located in its memory STS and a remote terminal connected to the central computer via an interface bus, located during work at the location of the serviced components of the STS, from resulting in the addition of automated workstations (AWS) specializing in automation of managing types of work as part of a closed technological cycle of repairing component parts of a product according to the profile of work assigned to the corresponding type of RDK, and including AWP for monitoring and diagnosing components parts of STS, workstation for electrical and radio installation work, workstation for repair of damaged structures of a repair object, workstation for restoration of moisture protection and marking repair, workstation for repair work management at a remote technological workplace, all workstations through an interface line are connected by direct and feedback links to the central control system computer with the formation of a local computer network, each workstation is structurally connected to the corresponding technological workstation (TRM) for monitoring and diagnostics, radio and electronic installation works, works on repair of damages to structures of repair objects, works on restoration of moisture protection and marking, remote TRM, while in accordance with and with the technological process of repair, TPM monitoring and diagnostics is functionally connected with direct and feedback connections with TPM of electric radio installation work, TPM of works on repairing structural damage to repair objects, TPM of moisture protection and marking restoration, remote TPM by means of displaying operation graphic images of repair objects on the screens of each AWP each automated workstation implements a control visual connection with the operator of the corresponding TPM, and using the manipulator included with each automated workstation, the operator of each TPM re lizuet feedback APM structurally connected with the TPM, and the composition of APM and TPM, including the number of similar jobs, determined by the composition kinds of works on the closed work cycle repair parts STS according to the type and particular specialization RDK. 2. The automated system according to claim 1, characterized in that a barcode reader is included in each workstation, identification barcodes are applied to each technological equipment, instrument and property in the RDK, by displaying the corresponding instructions on the workstation monitor control visual communication of the AWP with the TPM operator, and using the barcode reader, according to the instructions issued to the operator by means of the control visual communication of the AWP operator, an accelerated search of the property required for I am performing ongoing work on the corresponding TPM.