WO2013077309A1 - 建設機械の稼働データ収集装置 - Google Patents
建設機械の稼働データ収集装置 Download PDFInfo
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- WO2013077309A1 WO2013077309A1 PCT/JP2012/080039 JP2012080039W WO2013077309A1 WO 2013077309 A1 WO2013077309 A1 WO 2013077309A1 JP 2012080039 W JP2012080039 W JP 2012080039W WO 2013077309 A1 WO2013077309 A1 WO 2013077309A1
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- sensor
- operation data
- construction machine
- collection device
- data collection
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M15/00—Testing of engines
- G01M15/04—Testing internal-combustion engines
- G01M15/09—Testing internal-combustion engines by monitoring pressure in fluid ducts, e.g. in lubrication or cooling parts
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/226—Safety arrangements, e.g. hydraulic driven fans, preventing cavitation, leakage, overheating
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2278—Hydraulic circuits
- E02F9/2285—Pilot-operated systems
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2278—Hydraulic circuits
- E02F9/2292—Systems with two or more pumps
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/20—Drives; Control devices
- E02F9/22—Hydraulic or pneumatic drives
- E02F9/2278—Hydraulic circuits
- E02F9/2296—Systems with a variable displacement pump
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F9/00—Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
- E02F9/26—Indicating devices
- E02F9/267—Diagnosing or detecting failure of vehicles
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- G—PHYSICS
- G07—CHECKING-DEVICES
- G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
- G07C5/00—Registering or indicating the working of vehicles
- G07C5/008—Registering or indicating the working of vehicles communicating information to a remotely located station
Definitions
- the present invention relates to a construction machine operation data collection device, and more particularly, to a construction machine operation data collection device capable of efficiently collecting operation data indicating a failure sign of a construction machine.
- ultra-large heavy machinery with a body weight of several hundred tons, represented by ultra-large hydraulic excavators, is operating around the world for debris excavation work in vast mines.
- Such ultra-large heavy machinery is required to be continuously operated in order to improve productivity by ore extraction.
- an operation data collection device is mounted on a super-large heavy machine to collect detailed operation data.
- the present invention has been made on the basis of the above-described matters, and its purpose is to reduce the amount of stored information collected and stored without degrading the quality of information that leads to maintenance, thereby showing an operation sign indicating a failure sign of a construction machine.
- An object of the present invention is to provide an operation data collection device for construction machines that can efficiently collect data.
- a first invention is provided with an operation data storage unit that receives operation data composed of measurement values of a plurality of sensors mounted on a construction machine and indicating an operation state of the construction machine.
- the normal reference value storage unit that stores the normal reference value of each sensor of the operation data
- the deviation degree calculation unit that calculates the deviation degree of each sensor relative to the normal reference value
- a storage sensor item extraction unit that extracts sensor items of operation data stored in the operation data storage unit in accordance with the magnitude of the difference of each sensor calculated by the divergence degree calculation unit.
- the memory sensor item extraction unit compares the degree of divergence with respect to a normal reference value of each sensor, and detects a sensor with a large degree of divergence.
- the items are selected in order and stored in the operation data storage unit.
- the third invention is characterized in that, in the first or second invention, the normal reference value in the normal reference value storage unit uses an average value and a variance value of the sensor acquired values.
- the divergence degree calculation unit calculates a divergence degree total value using the divergence degree of each sensor for each sensor set classified based on sensor attributes.
- the sensor item number determination threshold value information indicating the relationship between the divergence degree total value for each sensor set and the number of sensor items of the operation data selected by the sensor item extraction unit to be stored in the operation data storage unit is stored.
- a sensor item number determination threshold value storage unit, and the storage sensor item extraction unit stores the operation data storage unit based on the sensor item number determination threshold value information and the divergence degree total value for each sensor set. The number of sensor items of the operation data to be stored is determined.
- a fifth invention is the fourth invention, wherein the divergence degree calculation unit uses the sensor set as a unit for calculating the divergence degree total value as a part where the sensors are installed, or It is characterized by classifying each system system to which the sensor belongs.
- the divergence degree calculation unit classifies the sensor set, which is a unit for calculating the divergence degree total value, for each part system, It includes any one of a cooling water system, an engine intake system, an engine exhaust system, an engine oil system, and a hydraulic oil cooling system.
- the sensor set in which the part system is an engine coolant system includes an intercooler inlet temperature sensor, an intercooler inlet pressure sensor, an intercooler outlet temperature sensor, and an intercooler outlet pressure. And a sensor.
- the sensor assembly having the part system as a hydraulic oil cooling system includes an oil cooler inlet pressure sensor, an oil fan motor inlet pressure sensor, and an oil cooler fan motor drain temperature.
- a sensor, an oil cooler fan motor drain pressure sensor, a hydraulic oil temperature sensor, an oil cooler front surface temperature sensor, and an oil cooler outlet temperature sensor are provided.
- a ninth aspect of the invention is the sixth aspect of the invention, wherein the sensor set having the part system as an engine coolant system includes a radiator inlet temperature sensor, a radiator inlet pressure sensor, a radiator outlet temperature sensor, and a radiator front air.
- a temperature sensor and a fan drive motor inlet pressure sensor are provided.
- the present invention it is possible to reduce the amount of stored information to be collected and stored without degrading the quality of information that leads to maintenance, so it is possible to efficiently collect operation data indicating a sign of a failure of a construction machine. As a result, the occurrence of a failure that prevents continuous operation can be prevented with high accuracy, and the productivity of the construction machine is improved.
- BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic block diagram which shows the whole schematic structure of the hydraulic-oil cooling system of the hydraulic shovel provided with one Embodiment of the operation data collection device of the construction machine of this invention.
- FIG. 1 is a side view showing a hydraulic excavator provided with an embodiment of the construction machine operation data collection device of the present invention
- FIG. 2 is a diagram of a controller network in the embodiment of the construction machine operation data collection device of the present invention.
- FIG. 3 is a schematic configuration diagram showing a configuration
- FIG. 3 is a schematic configuration diagram showing an overall schematic configuration of a hydraulic oil cooling system of a hydraulic excavator equipped with an embodiment of an operation data collection device for construction machines of the present invention
- FIG. It is a schematic block diagram which shows the whole schematic structure of the cooling water system
- reference numeral 1 denotes a hydraulic excavator that is an ultra-large construction machine.
- 2 is a traveling body
- 3 is a revolving body provided on the traveling body 2 so as to be turnable
- 4 is a cab provided on the left side of the front of the revolving body 3
- 5 is a front provided at the front center of the revolving body 3.
- the front work machine 5 includes a boom 6 that is rotatably provided on the swing body 3, an arm 7 that is rotatably provided at the tip of the boom 6, and a bucket 8 that is attached to the tip.
- a controller network 9 is provided in the cab 4 for collecting state quantities relating to the operating state of each operating part of the excavator 1.
- the controller network 9 operates the engine control device 10, the injection amount control device 12, the engine monitor device 13, the electric lever 15 for operating the traveling body 2, and the front work machine 5.
- Electric lever 16, electric lever control device 17 that performs hydraulic control according to the amount of operation of the electric levers 15, 16, a display 18, a display control device 19, a keypad 14, and an operation data collection device 100 , Is configured.
- the engine control device 10 is a device that controls the fuel injection amount to the engine 11 (see FIGS. 3 and 4) by controlling the injection amount control device 12. Further, the engine monitor device 13 performs monitoring by acquiring state quantities relating to the operating state of the engine 11 using various sensors. Sensors for detecting the operating state of the engine 11 include, for example, a sensor group 20 for sensing the operating state of the intake / exhaust system of the engine 11 and a sensor group for sensing the operating state of the cooling water system of the engine 11. 22 is connected.
- the sensor group 20 related to the intake / exhaust system of the engine 11 is, as will be described later, an intercooler inlet temperature sensor T1 (see FIG. 4) installed at the inlet / outlet of an intercooler 67 (see FIG. 4) for cooling the air sucked into the engine 11. 4), an intercooler inlet pressure sensor P1 (see FIG. 4), an intercooler outlet temperature sensor T2 (see FIG. 4), an intercooler outlet pressure sensor P2 (see FIG. 4), and the temperature of exhaust exhausted from the engine 11.
- an exhaust temperature sensor T3 is included.
- the sensor group 22 related to the cooling water system of the engine 11 is a radiator inlet temperature sensor installed before and after a radiator 46 (see FIG. 4) for cooling the cooling water circulating in the engine.
- T4 see FIG. 4
- radiator inlet pressure sensor P4 see FIG. 4
- radiator outlet temperature sensor T5 see FIG. 4
- the engine control device 10 and the engine monitor device 13 are connected by a communication line, and the engine monitor device 12 and the operation data collection device 100 are connected via a network line.
- the engine monitor device 12 and the operation data collection device 100 are connected via a network line.
- the display 18 is provided in the cab 4 and displays various operation information and alarm information of the excavator 1 to the operator.
- the display control device 19 is connected to the display 18 and controls display.
- the keypad 14 is connected to the display control device 19 and receives various data settings, screen switching of the display 18, and the like by an operation input from the operator.
- the hydraulic pressure monitoring device 23 is a device that monitors a state quantity related to the operating state of the hydraulic system of the hydraulic excavator 1.
- Various sensors for detecting the operating state of the hydraulic system are connected to the hydraulic pressure monitoring device 23.
- a sensor group 24 for sensing the operating state of the hydraulic oil cooling system is connected.
- the sensor group 24 for sensing the operating state of the hydraulic oil cooling system includes, for example, an oil cooler inlet pressure sensor P7 installed at the inlet / outlet of the oil cooler 33 (see FIG. 3) for cooling the hydraulic oil.
- An oil cooler outlet temperature sensor T12, and a hydraulic oil temperature sensor T10 for detecting the temperature of the hydraulic oil are included.
- the oil pressure monitor device 23 and the operation data collection device 100 are connected via a network line, and the state quantity related to the operation state of the hydraulic oil cooling system detected by the oil pressure monitor device 23 is also transmitted to the operation data collection device 100. It is possible to do it.
- the operation data collection device 100 is connected to the oil pressure monitoring device 23 and the engine monitoring device 13 via the network line, and is related to the operation state of the hydraulic system, for example, the hydraulic oil cooling system from the oil pressure monitoring device 23. Sensor data and sensor data related to the operating state of the engine 11, for example, the intake and exhaust systems and the cooling water system are received. Then, the operation data collection device 100 calculates the degree of deviation from the normal reference value for each part system of the engine 11 and the hydraulic system (hydraulic oil cooling system, intake / exhaust system, cooling water system, etc.) based on the received sensor data, In particular, it operates so as to record only sensor data that is considered to contribute to the abnormality.
- the operation data collection device 100 further includes an interface for communication with the outside.
- the operation data collection device 100 is connected to the external mobile terminal 21 via the external communication wired connector 101 or the wireless communication antenna 103 to perform communication. By doing so, the accumulated sensor data can be transmitted to the external portable terminal 21.
- reference numeral 11 denotes an engine mounted on the swing body 3 of the hydraulic excavator 1.
- a main pump 25 is driven via a pump transmission 26 by a rotational driving force of a crankshaft (not shown) of the engine 11.
- An actuator 27 (for example, a boom cylinder or an arm cylinder) is driven by hydraulic oil discharged from the main pump 25.
- a control valve 28 is connected to the discharge pipe of the main pump 25 and controls the flow rate and flow direction of hydraulic oil from the main pump 25 to the actuator 27.
- Numeral 30 is a pilot pump, which is driven via the pump transmission 26 by the rotational driving force of the crankshaft of the engine 11 in the same manner as the main pump 25, and generates a pilot original pressure for switching and driving the control valve 28.
- a pilot pressure reducing valve 31 is connected to the discharge pipe of the pilot pump 30 and reduces the pilot original pressure generated by the pilot pump 30 in accordance with a control signal from the electric lever control device 17 to generate a pilot pressure.
- 33 is an oil cooler provided between the control valve 28 and the hydraulic oil tank 34 to cool the hydraulic oil.
- 36 is an oil cooler cooling fan for generating cooling air for cooling the oil cooler 33
- 37 is an oil cooler fan drive motor for driving the oil cooler cooling fan 36
- 38 is an oil cooler fan drive pump, and a crankshaft (see FIG. It is driven via a pump transmission 26 by a rotational driving force (not shown) and supplies hydraulic oil for driving an oil cooler fan drive motor 37 via a discharge pipe.
- Reference numeral 40 denotes a drain pipe of the oil cooler fan drive motor 37.
- FIG. 3 for the sake of convenience, only one actuator and one control valve or pilot pressure reducing valve are shown correspondingly. However, in actuality, the hydraulic excavator 1 is equipped with a large number of actuators. Corresponding hydraulic devices such as control valves and pilot pressure reducing valves are provided.
- T ⁇ b> 10 is a hydraulic oil temperature sensor that detects the hydraulic oil temperature in the hydraulic oil tank 34.
- T11 is an oil cooler front surface temperature sensor that detects the air temperature in front of the oil cooler cooling fan 36 of the oil cooler 33.
- T12 is an oil cooler outlet temperature sensor, which is provided in the downstream pipe of the oil cooler 33 and detects the temperature of the hydraulic oil flowing out from the oil cooler 33.
- T9 is a fan motor drain temperature sensor, which is provided in the drain pipe 40 of the oil cooler fan drive motor 37, and detects the drain temperature of the oil cooler fan drive motor 37.
- P7 is an oil cooler inlet pressure sensor, which is provided in the upstream pipe of the oil cooler 33 and detects the pressure of the hydraulic oil flowing into the oil cooler 33.
- P8 is a fan motor inlet pressure sensor that detects the pressure of hydraulic oil flowing into the oil cooler fan drive motor 37.
- P9 is a fan motor drain pressure sensor which is provided in the drain piping 40 of the oil cooler fan drive motor 37 and detects the drain pressure of the oil cooler fan drive motor 37.
- the state quantity acquired by each sensor included in the sensor group 24 for detecting the operating state of the hydraulic oil cooling system that is, the hydraulic oil temperature detected by the hydraulic oil temperature sensor T10, the oil cooler.
- the oil cooler inlet pressure detected by the fan motor, the fan drive motor inlet pressure detected by the fan motor inlet pressure sensor P8, and the fan drive motor drain pressure detected by the fan motor drain pressure sensor P9 are input to the hydraulic pressure monitoring device 23. .
- the hydraulic pressure monitoring device 23 transmits the sensor data as sensing data related to the hydraulic oil cooling system of the hydraulic system to the operation data collecting device 100 via the network line.
- FIG. 4 the overall schematic configuration of the cooling water system and the intake / exhaust system of the engine 11, and the sensor group 20 and the sensor group 22 for sensing the operation state of the cooling water system and the intake / exhaust system are described.
- the installation position will be described.
- 45 is a cooling water pump, which is driven via the pump transmission 26 using the rotational driving force of the crankshaft of the engine 11.
- 46 is a radiator, which is discharged from the cooling water pump 45, cools the engine 11 and cools the cooling water whose temperature has risen.
- Reference numeral 47 denotes a radiator inlet pipe connected to the inlet of the radiator 46, and 48 denotes a radiator outlet pipe connected to the outlet of the radiator 46.
- a radiator cooling fan drive motor 54 is driven by pressure oil from a fan drive pump (not shown).
- a radiator cooling fan 58 is driven by a radiator cooling fan drive motor 54 and generates wind for cooling the radiator 46.
- T6 is a radiator front surface air temperature sensor, and detects the air temperature of the radiator 46 in the immediate vicinity of the radiator cooling fan drive motor 54 side.
- T4 is a radiator inlet temperature sensor, which is provided in the radiator inlet pipe 47 and detects the temperature of the cooling water flowing into the radiator 46.
- T5 is a radiator outlet temperature sensor, which is provided in the radiator outlet pipe 48 and detects the temperature of the cooling water flowing out of the radiator 46.
- P4 is a radiator inlet pressure sensor, which is provided in the radiator inlet pipe 47 and detects the pressure of the cooling water flowing into the radiator 46.
- P6 is a fan drive motor inlet pressure sensor, which is provided in the inlet pipe to the radiator cooling fan drive motor 54, and detects the pressure of the pressure oil flowing into the radiator cooling fan drive motor 54.
- the fan motor inlet pressure is input to the engine monitor device 13. Then, the engine monitor device 13 transmits the sensor data as sensing data related to the engine coolant system to the operation data collection device 100 via a network line.
- 65 is an air cleaner
- 66 is a turbo
- 67 is an intercooler that cools the air pressurized by the turbo 66 and sucked into the engine 11.
- 68 is an intercooler inlet pipe connected to the inlet of the intercooler 67
- 69 is an intercooler outlet pipe connected to the outlet of the intercooler 67.
- a plurality of cylinders 70 are provided in the engine 11 and suck the air cooled by the intercooler 67 and mix it with fuel to burn it.
- 71 is an exhaust pipe for exhausting combustion gas generated in the plurality of cylinders 70
- 72 is a muffler.
- P1 is an intercooler inlet pressure sensor provided in the intercooler inlet pipe 68
- T1 is an intercooler inlet temperature sensor similarly provided in the intercooler inlet pipe 68
- P2 is an intercooler outlet pressure sensor provided in the intercooler outlet pipe 69
- T2 is an intercooler outlet temperature sensor similarly provided in the intercooler outlet pipe 69
- T3 is an exhaust temperature sensor provided in the exhaust pipe 71.
- the state quantity acquired by each sensor included in the sensor group 22 for detecting the operating state of the intake / exhaust temperature of the engine that is, the intercooler inlet temperature and the intercooler inlet pressure detected by the intercooler inlet temperature sensor T1.
- the engine cooler 13 detects the intercooler inlet pressure detected by the sensor P1, the intercooler outlet temperature detected by the intercooler outlet temperature sensor T2, the intercooler outlet pressure detected by the intercooler outlet pressure sensor P2, and the exhaust temperature detected by the exhaust temperature sensor T3. Is input.
- the engine monitor device 13 transmits the sensor data as sensing data related to the intake / exhaust system of the engine 11 to the operation data collection device 100 via the network line.
- FIG. 5 is a schematic configuration diagram showing the configuration of an embodiment of the construction machine operation data collection device of the present invention.
- the construction machine operation data collection device 100 of the present invention configures a sensor set for each part system in order to detect an abnormality for each part system such as an engine cooling water system, an engine intake system, and a hydraulic oil cooling system, and the sensor A list and normal reference values of each sensor data for each operation mode are stored. Based on the normal reference value and the sensor data, first, the degree of divergence for each part system is calculated to grasp the entire abnormal state.
- the sensor data that has a particularly large deviation from the normal reference value is stored in order from the top to the Nth place. This makes it possible to extract and store only sensor data that may contribute to the abnormality, depending on the overall abnormality occurrence status for each part system, thereby reducing the quality of information that leads to maintenance. Therefore, the amount of stored information can be reduced.
- the operating data collection device 100 includes an operating data receiving unit 102, a divergence degree calculating unit 104, an operating data storage unit 106, a parameter storage unit 108 that is a normal reference value storage unit, and a storage sensor.
- a divergence upper sensor determination extraction unit 110 which is an item extraction unit, a parameter update unit 114, and an external communication unit 116 are provided.
- the operation data receiving unit 102 receives various sensor data as state quantities for each part system from the engine monitoring device 13 (see FIG. 2) and the hydraulic pressure monitoring device 23 (see FIG. 2) connected via a communication line.
- the parameter storage unit 108 includes sensor information for detecting a state quantity for each part system such as a hydraulic oil cooling system and an engine cooling water system, information on the normal reference value of each sensor data, and deviation upper sensor determination extraction.
- the information regarding the determination threshold value for determining whether to store in the operation data storage unit 106 in the unit 110 is stored.
- the divergence degree calculation unit 104 calculates a divergence degree indicating how far the sensor data received by the operation data reception unit 102 is away from the normal reference value stored in the parameter storage unit 108 for each time interval ⁇ T. .
- the time interval ⁇ T is measured by the deviation degree calculation unit 104 from an internal clock (not shown) of the operating data collection device 100, and the time interval ⁇ T is set by a time interval setting device (not shown) that can be set from the outside.
- the divergence upper sensor determination extraction unit 110 determines the degree of divergence from the normal reference value. A process is performed in which a large sensor is identified and extracted, and the data of the extracted sensor is stored in the operation data storage unit 106.
- the external communication unit 116 performs wired and wireless communication with the external mobile terminal 21 via the external communication wired connector 101 or the wireless communication antenna 103, and stores the data in the operation data storage unit 106 for the mobile terminal 21.
- the operation data being transmitted is transmitted, and the update parameter is received from the portable terminal 21 and output to the parameter update unit 114.
- the parameter update unit 114 performs a process of rewriting the contents of the parameter storage unit 108 based on the update parameter information received from the mobile terminal 21 via the external communication unit 116.
- FIG. 6 is a table showing a configuration example of sensor data in an embodiment of the construction machine operation data collection device of the present invention
- FIG. 7 is a divergence degree in the embodiment of the construction machine operation data collection device of the present invention
- FIG. 8 is a table showing an example of sensor information held by the parameter storage unit in the embodiment of the construction machine operation data collection device of the present invention
- FIG. 9 is a diagram showing the present invention
- FIG. 10 is a table showing an example of normal reference value information held by the parameter storage unit in one embodiment of the construction machine operation data collection device according to the present invention
- FIG. 10 is one embodiment of the construction machine operation data collection device according to the present invention.
- FIG. 11 is held by the parameter memory
- FIG. 12 is a table showing the contents of the operation data storage unit in the embodiment of the construction machine operation data acquisition device of the present invention.
- the operation data receiving unit 102 receives sensor data detected by the sensor group 20 and the sensor group 22 in the cooling water system and the intake / exhaust system of the engine 11 from the engine monitor device 13 (see FIG. 2) connected via a communication line.
- the sensor data detected by the sensor group 24 in the hydraulic oil cooling system of the hydraulic system is received from the hydraulic pressure monitoring device 23 (see FIG. 2) which is similarly connected via the communication line.
- the operation data receiving unit 102 outputs the received sensor data to the divergence degree calculating unit 104 as shown in FIG.
- FIG. 6 shows a configuration example of sensor data at each time received by the operation data receiving unit 102.
- the sensor data is composed of, for example, the reception date and time for each time and a plurality of sensor records.
- the reception date and time is measured with an internal clock (not shown) of the operation data collection device 100 described above, and indicates the date and time when a plurality of sensor records are received.
- One sensor record includes, for example, a part system ID, a sensor ID, and a sensor value.
- the part system ID is an ID that identifies an engine cooling water system, an intake system, an exhaust system, a hydraulic oil cooling system of a hydraulic system, and the like, and a sensor ID that is a sensor item is a unique ID given to each sensor. From the combination of the part system ID and the sensor ID, it can be understood from which sensor of the heavy equipment the sensor value is obtained.
- the divergence degree calculation unit 104 checks whether or not sensor data is input from the operation data reception unit 102 in step (S2000). When there is no input here, it is judged as NO and it returns to step (S2000) and waits for input. When the sensor data input is received from the operation data receiving unit 102, it is determined YES and the process proceeds to step (S2050).
- step (S2050) the divergence degree calculation unit 104 reads the sensor information stored in the parameter storage unit 108, and performs sensor data extraction processing to be handled in the subsequent processing.
- FIG. 8 shows sensor information stored in the parameter storage unit 108.
- the sensor information includes a table for interpreting the sensor data received by the operation data receiving unit 102. That is, an ID for each part system that is a target for calculating a divergence degree, a sensor ID of a sensor included therein, a unit of data acquired by the sensor, and the like are included.
- the divergence degree calculation unit 104 compares the combination of the part system ID and the sensor ID in each sensor record of the sensor data received from the operation data receiving unit 102 with the content of the sensor information, and only the sensor record with the matching ID combination To extract.
- the divergence degree calculation unit 104 reads the normal reference value information stored in the parameter storage unit 108 in step (S ⁇ b> 2100).
- FIG. 9 shows the contents of normal reference value information stored in the parameter storage unit 108.
- the normal reference value information stores normal reference values for each part system such as the engine cooling water system, the engine intake system, the engine exhaust system, and the hydraulic oil cooling system.
- a reference value a normal average value and a normal variance value of each sensor for each operation mode are stored.
- the operation mode indicates, for example, a unit classified by data according to the engine load factor and the engine speed.
- statistical classification can be performed by performing processing such as cluster analysis on sensor data obtained in the past during normal operation. For example, when a combination of data of N sensors is regarded as a vector of N elements, and each time data during normal operation acquired in the past is plotted in an N-dimensional space, the sensor data of the same operation mode is located at a substantially close position. There is a tendency to harden together. Taking advantage of this characteristic, an average value and a variance value of N pieces of sensor data are calculated and stored in advance as normal reference values with respect to a group of data that are aggregated for each operation mode.
- T1 the intercooler inlet temperature
- P1 the intercooler inlet pressure
- T2 the intercooler outlet temperature
- P2 the intercooler outlet pressure
- An average value and a variance value are calculated and stored.
- average values and variance values of the sensor data of the sensors 1 to N are calculated and stored for the operation mode 1 to the operation mode M.
- the divergence degree calculation unit 104 calculates the divergence degree for each part system and for each operation mode in step (S ⁇ b> 2200).
- the divergence degree L (e, m) of the part system e and the operation mode m is N
- the acquired values at time t of the sensors are d 1 (t), d 2 ( If t),..., d N (t)
- the calculation is performed using the following equation (1).
- ⁇ mi and ⁇ mi are the normal average value and the normal variance value of the sensor i in the operation mode m, respectively.
- the divergence degree calculation unit 104 performs the operation mode specifying process for each part system in step (S2300).
- (e) is specified as the operation mode in the target part system e. That is, the operation mode specifying process in this step corresponds to a process of calculating the distance between the sensor data and the normal reference value of each operation mode and detecting the operation mode with the minimum distance.
- the divergence degree calculation unit 104 creates divergence degree information for each part system in step (S ⁇ b> 2400) and outputs the divergence degree information to the higher divergence sensor determination unit 110.
- Sensor values d 1 (t), d 2 (t), ... d N (t) and the deviation value for each sensor value ((d i (t) - ⁇ m (e) i / ⁇ m (e ) i ) 2 (i 1,2..., N).
- the divergence degree calculation unit 104 returns to step (S2000) again after completing the process of step (S2400), and performs the operation data input process at time t + 1 after the time interval ⁇ T described above.
- the divergence upper sensor determination extraction unit 110 confirms whether or not the divergence degree information is input from the divergence degree calculation unit 104 in step (S4000). When there is no input here, it is judged as NO and it returns to step (S4000) and waits for input. When the input of the divergence degree information is received from the divergence degree calculation unit 104, it is determined as YES and the process proceeds to step (S4100).
- the divergence upper sensor determination extraction unit 110 reads the determination threshold information of the parameter storage unit 108 in step (S4100).
- FIG. 11 shows the contents of the determination threshold information stored in the parameter storage unit 108.
- the determination threshold information includes a table in which a range of the divergence degree L is associated with the number of divergence upper sensors to be extracted. For example, when the degree of divergence L (e, m (e)) is smaller than 1, the sensor data of the part system e is considered to be within the range of variation in normal values.
- the number of sensors to be extracted is set to increase as the deviation degree L (e, m (e)) increases.
- the determination threshold information can be changed according to an update instruction from the portable terminal 21 via the parameter update unit 114 in the configuration of the operation data collection device 100 shown in FIG. Therefore, for example, when the number of sensors is set to “ALL” for a range of divergence “L ⁇ 0”, the determination threshold information is such that all sensor data is to be extracted.
- the divergence upper sensor determination extraction unit 110 specifies the divergence upper sensor number NUM (e) for each part system e in step (S4200). That is, the divergence degree L (e, m (e)) in the part system e is determined to belong to which rank within the range of each divergence degree L of the determination threshold information, and the number NUM (e ).
- step (S4400) the divergence upper sensor determination extraction unit 110 performs output processing to the operation data storage unit 106 based on the information related to the sensor specified in step (S4300).
- FIG. 12 shows an example of the content of information stored in the operation data storage unit 106.
- the operation data storage unit 106 includes two items of management information and sensor data.
- information on the model, number, PIN (Personal Identification Number), country code, and site ID is stored as information on the heavy machine in which the operation data collection device 100 is installed.
- the model, number, and PIN are unique information for uniquely identifying the target heavy machine.
- the country code and the site ID are information for specifying the country in which the target heavy machinery is operating and the mine in which the target heavy machinery is operating.
- Information related to these codes and IDs is used for sensor data management purposes, and can be specified to identify which heavy equipment sensor data is added when sensor data is transmitted to the management system via the mobile terminal 21. Used to make
- the sensor data corresponds to information output by the divergence upper sensor determination extraction unit 110 shown in FIG. 10 in step (S4400).
- the sensor data is managed for each time, and is divided into reception date information and sensor record information for each part system.
- the sensor record information for each part system is composed of a part system ID, a divergence degree L, a divergence upper sensor number NUM, and sensor IDs and sensor values from first to NUM.
- the part system ID the same ID as the sensor information in the parameter storage unit 108 is used.
- divergence upper sensor determination extraction unit 110 returns to step (S4000) and confirms the input of divergence degree information at the next time from divergence degree calculation unit 104.
- the operation data collection device 100 extracts only data related to abnormal data indicating a failure sign from the sensor data from the heavy machinery and stores and extracts the data in the operation data storage unit 106.
- the sensor data stored in the operation data storage unit 106 is transmitted by the external communication unit 116 via the external communication wired connector 101 or the wireless communication antenna 103 in response to a request from the external portable terminal 21. To do.
- the operation data collection device 100 of the present invention comprises a sensor set for each part system in order to detect an abnormality for each part system such as an engine cooling water system, an engine intake system, and a hydraulic oil cooling system,
- the normal reference value of each sensor data for each operation mode is stored.
- the degree of divergence for each part system is calculated to grasp the entire abnormal state.
- the sensor data that has a particularly large deviation from the normal reference value is stored in order from the top to the Nth place.
- the operation data collection device 100 causes the hydraulic oil cooling in the deviation degree calculation unit 104.
- the system divergence degree information is output to the divergence upper sensor determination extraction unit 110.
- the deviation upper sensor determination extraction unit 110 reads the determination threshold information of the parameter storage unit 108, specifies the number of extraction sensors according to the deviation degree L, and specifies the number of deviation upper sensors in the hydraulic oil cooling system. For example, when the divergence degree is 1 or more and less than 2, two divergence upper sensors are specified.
- the sensor data of any one of the oil cooler front surface temperature sensor T11 and the oil cooler outlet temperature sensor T12 and having the second largest deviation from the normal reference value is stored in the operation data storage unit 106. It will be.
- the entire sensor set collected by the part system of the construction machine is monitored, and data of sensors located at a plurality of higher divergences according to the degree of divergence from the normal reference value. Therefore, when an abnormality that indicates a failure sign occurs, sensor data is always recorded in the operation data collection device 100, and as a result, a failure sign of the construction machine can be reliably performed.
- sensor data since only the data of a plurality of sensors positioned at the top of the divergence is stored according to the degree of divergence, the amount of stored information can be greatly reduced without degrading the quality of information that leads to maintenance.
- the amount of stored information collected and accumulated can be reduced without degrading the quality of information leading to maintenance. It is possible to efficiently collect operational data indicating signs. As a result, the occurrence of a failure that prevents continuous operation can be prevented with high accuracy, and the productivity of the construction machine is improved.
- the operation has been described for the hydraulic oil cooling system of the construction machine.
- the cooling water system and the intake / exhaust system of the engine of the construction machine are similarly processed.
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Abstract
Description
図2に示すようにコントローラネットワーク9は、エンジン制御装置10と、噴射量制御装置12と、エンジンモニタ装置13と、走行体2を操作するための電気レバー15と、フロント作業機5を操作するための電気レバー16と、電気レバー15、16の操作量に応じて油圧制御を行う電気レバー制御装置17と、ディスプレイ18と、表示制御装置19と、キーパッド14と、稼働データ収集装置100と、により構成されている。
本発明の建設機械の稼働データ収集装置100は、エンジン冷却水系統やエンジン吸気系統、作動油冷却系統などの部位系統別の異常を検出するために、部位系統別にセンサ集合を構成し、そのセンサリストと、動作モードごとの各センサデータの正常基準値を記憶している。そして、前記正常基準値とセンサデータに基づいてまず部位系統別の乖離度を算出し、全体の異常状態を把握する。そして、部位系統別の正常からの乖離状況に応じて、特に正常基準値からの乖離が大きいセンサデータを上位から順番に第N位まで記憶するように動作する。これによって、部位系統別の全体の異常発生状況に応じて、特に異常に寄与している可能性のあるセンサデータのみを抽出して記憶することができるため、保守につながる情報の質を低下させることなく、記憶情報量を削減することが可能となる。
まず、乖離度算出部104は、ステップ(S2000)において稼働データ受信部102からセンサデータが入力されたか否かを確認する。ここで入力がない場合は、NOと判断されてステップ(S2000)に戻り入力を待つ。稼働データ受信部102からセンサデータの入力を受け付けるとYESと判断され、ステップ(S2050)に進む。
乖離度算出部104は、ステップ(S2300)において部位系統ごとに動作モード特定処理を行う。ここでは、ステップ(S2200)で計算したM個の動作モードごとの乖離度L(e,m)(m=1,2,・・・M)を比較し、乖離度が最小となるm=m(e)を、対象部位系統eにおける動作モードと特定する。すなわち、本ステップにおける動作モード特定処理とは、センサデータと各動作モードの正常基準値との距離を計算して、その距離が最小となる動作モードを検出する処理に相当する。
ここで出力する情報は、時刻tと、部位系統e (e=1,2,・・・,E)ごとの特定動作モードm(e)と、乖離度L(e,m(e))と、センサ値d1(t), d2(t),・・・dN(t)と、センサ値ごとの乖離値((di(t)-μm(e)i/σm(e)i)2 (i=1,2 ・・・,N)とを含んでいる。
まず、乖離上位センサ判定抽出部110は、ステップ(S4000)において、乖離度算出部104から乖離度情報が入力されたか否かを確認する。ここで入力がない場合は、NOと判断されてステップ(S4000)に戻り入力を待つ。乖離度算出部104から乖離度情報の入力を受け付けるとYESと判断され、ステップ(S4100)に進む。
本発明の稼働データ収集装置100は、エンジン冷却水系統やエンジン吸気系統、作動油冷却系統などの部位系統別の異常を検出するために、部位系統別にセンサ集合を構成し、そのセンサリストと、動作モードごとの各センサデータの正常基準値を記憶している。そして、前記正常基準値とセンサデータに基づいてまず部位系統別の乖離度を算出し、全体の異常状態を把握する。そして、部位系統別の正常からの乖離状況に応じて、特に正常基準値からの乖離が大きいセンサデータを上位から順番に第N位まで記憶するように動作する。
2 走行体
3 旋回体
4 運転室
5 フロント作業機
9 コントローラネットワーク
10 エンジン制御装置
11 エンジン
12 噴射量制御装置
13 エンジンモニタ装置
20 エンジン吸排気系統センサ群
21 携帯端末
22 エンジン冷却水系統センサ群
23 油圧モニタ装置
24 作動油冷却系統センサ群
25 メインポンプ
28 コントロールバルブ
30 パイロットポンプ
100 稼働データ収集装置
101 外部通信用有線コネクタ
102 稼働データ受信部
103 無線通信用アンテナ
104 乖離度算出部
106 稼働データ記憶部
108 パラメータ記憶部
110 乖離上位センサ判定抽出部
114 パラメータ更新部
116 外部通信部
T1 インタクーラ入口温度センサ
T2 インタクーラ出口温度センサ
P1 インタクーラ入口圧力センサ
P2 インタクーラ出口圧力センサ
T4 ラジエータ入口温度センサ
T5 ラジエータ出口温度センサ
T6 ラジエータ前面空気温度センサ
P4 ラジエータ入口圧力センサ
P6 ファン駆動モータ入口圧力センサ
T9 オイルクーラファンモータドレン温度センサ
T10 作動油温度センサと
T11 オイルクーラ前面温度センサ
T12 オイルクーラ出口温度センサ
P7 オイルクーラ入口圧力センサ
P8 オイルファンモータ入口圧力センサ
P9 オイルクーラファンモータドレン圧力センサ
Claims (9)
- 建設機械に搭載され、前記建設機械の動作状況を示す複数のセンサの計測値で構成される稼働データを受信して、稼働データ記憶部(106)に記憶する建設機械の稼働データ収集装置において、
前記稼働データの各センサの正常基準値を記憶する正常基準値記憶部(108)と、前記各センサの正常基準値に対する乖離度を計算する乖離度算出部(104)と、前記乖離度算出部(104)で計算した各センサの乖離度の大きさに応じて前記稼働データ記憶部(106)に記憶する稼働データのセンサ項目を抽出する記憶センサ項目抽出部(110)とを備えた
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項1に記載の建設機械の稼働データ収集装置において、
前記記憶センサ項目抽出部(110)は、前記各センサの正常基準値に対する乖離度の大きさを相互に比較して、前記乖離度の大きいセンサをセンサ項目から順番に選択して前記稼働データ記憶部(106)に記憶する
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項1又は2に記載の建設機械の稼働データ収集装置において、
前記正常基準値記憶部(108)における前記正常基準値は前記各センサ取得値の平均値と分散値とを用いる
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項2又は3に記載の建設機械の稼働データ収集装置において、
前記乖離度算出部(104)は、センサ属性に基づいて分類されたセンサ集合ごとに各センサの乖離度を用いて乖離度集計値を計算し、前記センサ集合ごとの乖離度集計値と、前記センサ項目抽出部(110)が前記稼働データ記憶部(106)に記憶するために選択する稼働データのセンサ項目数との関係を示すセンサ項目数決定閾値情報を記憶したセンサ項目数決定閾値記憶部(108)とを有し、
前記記憶センサ項目抽出部(110)は、前記センサ項目数決定閾値情報と、前記センサ集合ごとの乖離度集計値とに基づいて、前記稼動データ記憶部(106)に記憶する前記稼動データのセンサ項目数を決定する
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項4に記載の建設機械の稼働データ収集装置において、
前記乖離度算出部(104)は、前記乖離度集計値が属する前記センサ集合を、前記各センサが設置されている部位もしくは、前記各センサが属している系統システムごとに分類する
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項5に記載の建設機械の稼働データ収集装置において、
前記乖離度算出部(104)において、前記乖離度集計値が属する前記センサ集合を、部位系統ごとに分類し、前記部位系統として、エンジン冷却水系統と、エンジン吸気系統と、エンジン排気系統と、エンジンオイル系統と、作動油冷却系統のいずれかを含む
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項6に記載の建設機械の稼働データ収集装置において、
前記部位系統をエンジン冷却水系統とする前記センサ集合は、インタクーラ入口温度センサ(T1)と、インタクーラ入口圧力センサ(P1)と、インタクーラ出口温度センサ(T2)と、インタクーラ出口圧力センサ(P2)とを備える
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項6に記載の建設機械の稼働データ収集装置において、
前記部位系統を作動油冷却系統とする前記センサ集合は、オイルクーラ入口圧力センサ(P7)と、オイルファンモータ入口圧力センサ(P8)と、オイルクーラファンモータドレン温度センサ(T9)と、オイルクーラファンモータドレン圧力センサ(P9)と、作動油温度センサ(T10)と、オイルクーラ前面温度センサ(T11)と、オイルクーラ出口温度センサ(T12)とを備える
ことを特徴とする建設機械の稼働データ収集装置。 - 請求項6に記載の建設機械の稼働データ収集装置において、
前記部位系統をエンジン冷却水系統とする前記センサ集合は、ラジエータ入口温度センサ(T4)と、ラジエータ入口圧力センサ(P4)と、ラジエータ出口温度センサ(T5)と、ラジエータ前面空気温度センサ(T6)と、ファン駆動モータ入口圧力センサ(P6)とを備える
ことを特徴とする建設機械の稼働データ収集装置。
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AU2012341569A AU2012341569B2 (en) | 2011-11-21 | 2012-11-20 | Device for collecting construction machine operation data |
DE112012004840.7T DE112012004840B4 (de) | 2011-11-21 | 2012-11-20 | Betriebsdaten-Erhebungsvorrichtung für Baumaschinen |
US14/359,307 US9291524B2 (en) | 2011-11-21 | 2012-11-20 | Operation data collection device for construction machines |
JP2013545922A JP5841612B2 (ja) | 2011-11-21 | 2012-11-20 | 建設機械の稼働データ収集装置 |
CA2856218A CA2856218C (en) | 2011-11-21 | 2012-11-20 | Operation data collection device for construction machines |
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JP2019028565A (ja) * | 2017-07-26 | 2019-02-21 | 安川情報システム株式会社 | 故障予知方法、故障予知装置および故障予知プログラム |
JP7082461B2 (ja) | 2017-07-26 | 2022-06-08 | 株式会社Ye Digital | 故障予知方法、故障予知装置および故障予知プログラム |
JP2023510494A (ja) * | 2020-01-13 | 2023-03-14 | ググシステム カンパニー リミテッド | 検測装置 |
JP7357979B2 (ja) | 2020-01-13 | 2023-10-10 | ググシステム カンパニー リミテッド | 検測装置 |
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AU2012341569B2 (en) | 2016-02-04 |
DE112012004840B4 (de) | 2022-08-04 |
CA2856218A1 (en) | 2013-05-30 |
JP5841612B2 (ja) | 2016-01-13 |
DE112012004840T5 (de) | 2014-10-02 |
CA2856218C (en) | 2018-11-06 |
US20140288768A1 (en) | 2014-09-25 |
US9291524B2 (en) | 2016-03-22 |
JPWO2013077309A1 (ja) | 2015-04-27 |
AU2012341569A1 (en) | 2014-06-12 |
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