WO2021100615A1 - Dispositif d'évaluation de maintenance prédictive, procédé d'évaluation de maintenance prédictive et programme - Google Patents

Dispositif d'évaluation de maintenance prédictive, procédé d'évaluation de maintenance prédictive et programme Download PDF

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Publication number
WO2021100615A1
WO2021100615A1 PCT/JP2020/042322 JP2020042322W WO2021100615A1 WO 2021100615 A1 WO2021100615 A1 WO 2021100615A1 JP 2020042322 W JP2020042322 W JP 2020042322W WO 2021100615 A1 WO2021100615 A1 WO 2021100615A1
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Prior art keywords
value
difference value
ratio
output
predictive maintenance
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PCT/JP2020/042322
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English (en)
Japanese (ja)
Inventor
貴之 野木
雄一 竹内
隼平 中村
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芝浦機械株式会社
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Priority to DE112020005706.2T priority Critical patent/DE112020005706T5/de
Priority to KR1020217015134A priority patent/KR102574186B1/ko
Priority to CN202080008480.XA priority patent/CN113286995B/zh
Publication of WO2021100615A1 publication Critical patent/WO2021100615A1/fr

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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
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G01M13/028—Acoustic or vibration analysis
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H3/00—Measuring characteristics of vibrations by using a detector in a fluid
    • G01H3/10—Amplitude; Power
    • G01H3/14—Measuring mean amplitude; Measuring mean power; Measuring time integral of power
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00—Testing of machine parts
    • G01M13/02—Gearings; Transmission mechanisms
    • G01M13/021—Gearings
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/04—Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem"
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G06Q10/0635—Risk analysis of enterprise or organisation activities
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/20—Administration of product repair or maintenance
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/04—Manufacturing
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/10—Services

Definitions

  • the present invention relates to a predictive maintenance determination device, a predictive maintenance determination method, and a program for predicting the occurrence of an abnormality in a device.
  • the gear damage detection device described in Patent Document 1 detects the occurrence of gear damage by analyzing the output of the AE sensor and detecting the signal strength in a specific frequency region.
  • the damage detection device of Patent Document 1 has a problem that the abnormality cannot be detected unless an abnormality such as damage actually occurs in the device. Therefore, when an abnormality is detected, it is necessary to immediately stop the equipment to inspect and maintain the abnormal part, replace consumable parts (bearings, seal parts, etc.), and perform cleaning. Therefore, the equipment must be stopped at an unexpected timing, and there is a possibility that not only the equipment but also the production line must be stopped. This could have a significant impact on the production process.
  • the present invention has been made in view of the above, and is a predictive maintenance determination device, a predictive maintenance determination method, and a predictive maintenance determination device capable of notifying the occurrence of an abnormality that affects the operation of an apparatus before an abnormality actually occurs.
  • the purpose is to provide a program.
  • the predictive maintenance determination device acquires the AE sensor installed on the surface of the housing of the device and the output of the AE sensor for a predetermined time.
  • the first difference value calculation unit that calculates the first difference value between the maximum value and the minimum value of the output, the average value calculation unit that calculates the average value of the output for the predetermined time, and the predetermined time.
  • a second difference value calculation unit for calculating a second difference value between a maximum value and a minimum value of an output less than the average value among the outputs of the minute, and the first difference value with respect to the second difference value.
  • the first ratio calculation unit that calculates the ratio of the difference value and the notification unit that notifies the predictive maintenance of the device when the ratio calculated by the first ratio calculation unit is equal to or greater than the first predetermined value. It is characterized by having.
  • the predictive maintenance determination device acquires the output of the AE sensor installed on the surface of the housing of the device, and obtains the first difference value between the maximum value and the minimum value of the output for a predetermined time.
  • a third difference value calculation unit that calculates the difference value, a second ratio calculation unit that calculates the second ratio that is the ratio of the first difference value to the third difference value, and the second ratio. It is characterized by including a notification unit for notifying that an abnormality may occur in the device when the ratio of
  • the predictive maintenance determination device acquires the output of the AE sensor installed on the surface of the housing of the device, and obtains the first difference value between the maximum value and the minimum value of the output for a predetermined time.
  • the first difference value calculation unit to be calculated, the average value calculation unit to calculate the average value of the output for the predetermined time, and the third ratio which is the ratio of the first difference value to the average value are calculated. Notification that an abnormality may occur in the device based on the third ratio calculation unit and the two-dimensional map in which the first difference value and the third ratio are taken as each axis. It is characterized by having a part and.
  • the predictive maintenance determination device can notify the occurrence of an abnormality that affects the operation of the device before the abnormality actually occurs, that is, when a sign of the abnormality is detected. Therefore, it is possible to preset the timing for inspecting and maintaining the equipment, replacing consumable parts, cleaning, and the like. Therefore, the operating state of the production line can be maintained by operating another device while the device is stopped.
  • FIG. 1 is an explanatory diagram of an acoustic emission and an AE sensor.
  • FIG. 2 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the first embodiment.
  • FIG. 3 is a structural diagram of the extruder according to the first embodiment.
  • FIG. 4 is a hardware configuration diagram of the predictive maintenance determination device according to the first embodiment.
  • FIG. 5 is a functional configuration diagram of the predictive maintenance determination device according to the first embodiment.
  • FIG. 6 is an explanatory diagram of the predictive maintenance determination method according to the first embodiment.
  • FIG. 7 is a flowchart showing an example of the flow of processing performed by the predictive maintenance determination device according to the first embodiment.
  • FIG. 8 is a functional configuration diagram of the predictive maintenance determination device according to the second embodiment.
  • FIG. 1 is an explanatory diagram of an acoustic emission and an AE sensor.
  • FIG. 2 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the first embodiment.
  • FIG. 9 is an explanatory diagram of the predictive maintenance determination method in the second embodiment.
  • FIG. 10 is a flowchart showing an example of the processing flow in the second embodiment.
  • FIG. 11 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the third embodiment.
  • FIG. 12 is a functional configuration diagram of the predictive maintenance determination device according to the third embodiment.
  • FIG. 13 is a diagram showing an example of a determination criterion in the third embodiment.
  • FIG. 14 is a flowchart showing an example of the flow of processing performed by the signal analysis unit and the third determination unit in the third embodiment.
  • FIG. 15 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the fourth embodiment.
  • FIG. 16 is a functional configuration diagram of the predictive maintenance determination device according to the fourth embodiment.
  • FIG. 17 is a diagram showing an example of a determination criterion when the vibration acceleration is larger than the third predetermined value.
  • FIG. 18 is a flowchart showing an example of the flow of processing performed by the signal analysis unit and the fourth determination unit in the fourth embodiment.
  • FIG. 19 is a system block diagram showing an example of the system configuration of the predictive maintenance determination system according to the fifth embodiment.
  • AE acoustic emission
  • AE is a phenomenon in which when a solid material is deformed, the strain energy accumulated up to that point is emitted as sound waves (elastic waves, AE waves).
  • the frequency band of the AE wave is said to be about several tens of kHz to several MHz, and has a frequency band that cannot be detected by a general vibration sensor or acceleration sensor. Therefore, in order to detect the AE wave, a dedicated AE sensor is used. The AE sensor will be described in detail later.
  • FIG. 1 is an explanatory diagram of an acoustic emission and an AE sensor.
  • FIG. 1A when deformation, contact, friction, or the like occurs at the AE source P inside the solid material Q, an AE wave W is generated.
  • the AE wave W spreads radially from the AE source P and propagates inside the solid material Q at a speed corresponding to the solid material Q.
  • the AE wave W propagating inside the solid material Q is detected by the AE sensor 20 installed on the surface of the solid material Q. Then, the AE sensor 20 outputs the detection signal D. Since the detection signal D is a signal representing vibration, it is an AC signal having positive and negative values. However, since it is difficult to handle the detection signal D (AE wave W) as it is when performing various calculations, it is common to treat the negative portion of the detection signal D as a rectified waveform obtained by half-wave rectification. Further, when analyzing the AE wave W, it is generally treated as a value obtained by averaging the root mean square value of the rectified waveform over a predetermined time and taking a square root, that is, an effective value (RMS (Root Mean Square) value).
  • RMS Root Mean Square
  • the propagation velocity of the AE wave W differs between the longitudinal wave and the transverse wave (the longitudinal wave is faster than the transverse wave), but the difference can be ignored in consideration of the size (propagation distance) of the solid material Q. , No distinction is made between longitudinal waves and transverse waves. That is, the AE wave W detected within a predetermined time is used as a measurement signal for analysis regardless of whether it is a longitudinal wave or a transverse wave.
  • the AE sensor 20 is included in the shield case 20a. Then, a receiving surface 20b that receives the AE wave W is formed on the bottom surface of the AE sensor 20.
  • the wavefront surface 20b is made of an insulating material.
  • a magnet 20c is installed near the bottom surface of the shield case 20a, and the AE sensor 20 is fixed to the metal housing 30a of the device 30 subject to predictive maintenance by the magnet 20c. At that time, the wave receiving surface 20b is installed in close contact with the surface of the metal housing 30a of the device 30.
  • a vapor-deposited film 20d made of copper or the like is formed on the wave receiving surface 20b.
  • a piezoelectric element 20e such as lead zirconate titanate (PZT) is installed on the upper portion of the thin-film deposition film 20d.
  • the piezoelectric element 20e receives the AE wave W via the wave receiving surface 20b and outputs an electric signal corresponding to the AE wave W.
  • the electric signal output by the piezoelectric element 20e is output as a detection signal D via the vapor deposition film 20f and the connector 20g. Since the detection signal D is weak, a preamplifier (not shown in FIG. 1B) is installed inside the AE sensor 20 in order to suppress the influence of noise mixing, and the detection signal D is set in advance. It may be output after being amplified.
  • AE is also generated by minute scratches and friction, so it is possible to detect signs of equipment abnormality at an early stage. Further, since the AE wave W spreads radially from the AE source P, if it is a metal housing, by installing the AE sensor 20, the AE wave W can be observed at any position of the housing and the detection signal D It is possible to obtain. The specific analysis method of the detection signal D will be described later. Further, since the frequency band of the signal that can be detected differs depending on the type of the AE sensor 20, it is desirable to consider the material of the device to be measured and the like when selecting the AE sensor 20 to be used.
  • the predictive maintenance determination device the predictive maintenance determination method, and the embodiment of the program according to the present disclosure will be described in detail based on the drawings.
  • the present invention is not limited to these embodiments.
  • the components in the following embodiments include those that can be easily conceived by those skilled in the art, or those that are substantially the same.
  • the first embodiment of the present disclosure is an example of the predictive maintenance determination device 12a that detects and notifies a sign that an abnormality occurs in the device.
  • FIG. 2 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the first embodiment.
  • the predictive maintenance determination system 10a applies the predictive maintenance determination device 12a of the present disclosure to the predictive maintenance determination of the gear box 30 that reduces the rotational driving force of the motor 22 to drive the extruder 40.
  • the gear box 30 is an example of the device 30.
  • the gear box 30 is configured by meshing a plurality of gears to reduce the rotational driving force of the motor 22 connected to the input side and transmit it to the output side.
  • the predictive maintenance determination system 10a detects and notifies signs of abnormality such as cracks and wear generated in the gear and wear of the shaft supporting the gear.
  • the device configuration described below is an example, and the device subject to predictive maintenance is not limited to the gear box 30. Further, the drive target of the gear box 30 is not limited to the extruder 40. The outline of the extruder 40 will be described later (see FIG. 3).
  • the predictive maintenance determination device 12a acquires the output of the AE sensor 20 installed on the surface of the metal housing 30a of the gear box 30 connected to the extruder 40. Then, the predictive maintenance determination device 12a performs predictive maintenance of the gear box 30 by analyzing the output of the AE sensor 20.
  • the AE sensor 20 a sensor having a frequency band capable of detecting the AE wave W propagating inside the metal housing 30a is used.
  • the frequency band of the AE wave W to be detected is known, it is desirable to use the AE sensor 20 having high sensitivity in the frequency band.
  • the AE sensor 20 having high sensitivity in the frequency band including 150 kHz is used.
  • the mounting position of the AE sensor 20 with respect to the metal housing 30a of the gear box 30 does not matter, but it is desirable to mount the AE sensor 20 in the vicinity of a place where an abnormality is likely to occur. For example, it is desirable to mount the AE sensor 20 in the vicinity of the output shaft of the gearbox 30.
  • the predictive maintenance determination device 12a causes an abnormality by a monitor, a speaker or the like (not shown) shown in FIG. Notify that there are signs.
  • FIG. 3 is a structural diagram of the extruder according to the first embodiment.
  • the extruder 40 rotates, for example, a resin raw material by rotating a screw 42 installed at a position where the output shaft 32 is extended as the output shaft 32 is rotationally driven in response to the output of the gear box 30. And the powdery filler are kneaded.
  • the extruder 40 shown in FIG. 3 is a twin-screw extruder having two output shafts 32 installed at an inter-shaft distance C.
  • the two output shafts 32 are arranged in parallel inside the barrel portion 44 while maintaining a constant inter-axis distance C.
  • the bases of two screws 42 that rotate in the same direction while meshing with each other are connected to each output shaft 32.
  • the output shaft 32 transmits the rotation of the motor 22 decelerated by the gear box 30 to the screw 42.
  • the screw 42 rotates at a speed of, for example, 300 revolutions per minute.
  • the insertion hole 46 is a hole provided along the longitudinal direction of the barrel portion 44, and a part of the cylinder overlaps so that two screws 42 that mesh with each other can be inserted.
  • a material supply port 47 for supplying the pellet-shaped resin raw material to be kneaded and the powder-like filler material to the insertion hole 46 is provided on one end side of the barrel portion 44 in the longitudinal direction.
  • a discharge port 48 for discharging the kneaded material while passing through the insertion hole 46 is provided on the other end side of the barrel portion 44 in the longitudinal direction.
  • a heater 49 is provided on the outer periphery of the barrel portion 44 to heat the material supplied to the insertion hole 46 by heating the barrel portion 44.
  • the screw 42 has the first screw portion 42a, the second screw portion 42b, and the like from one end side of the barrel portion 44 provided with the material supply port 47 toward the other end side of the barrel portion 44 provided with the discharge port 48. It has a third screw portion 42c. Although detailed description will be omitted, the first screw portion 42a, the second screw portion 42b, and the third screw portion 42c have different shapes in order to knead the materials uniformly.
  • the first screw portion 42a, the second screw portion 42b, and the third screw portion 42 of the screw 42 are directed from one end side where the material supply port 47 is provided to the other end side where the discharge port 48 is provided. It has a first barrel portion 44a, a second barrel portion 44b, and a third barrel portion 44c corresponding to the screw portion 42c.
  • the gap between the screw 42 and the barrel portion 44 is formed so as to gradually decrease from the gear box 30 side toward the discharge port 48 side. As a result, the material supplied from the material supply port 47 is kneaded even more uniformly.
  • the length L3 of the screw portion 42c is appropriately determined according to the material to be kneaded.
  • the molten resin is kneaded so as to be uniform. Then, the molten resin that has passed through the screw 42 is discharged from the discharge port 48 in a uniformly kneaded state.
  • FIG. 4 is a hardware configuration diagram of the predictive maintenance determination device according to the first embodiment.
  • the predictive maintenance determination device 12a includes a control unit 13, a storage unit 14, and a peripheral device controller 16.
  • the control unit 13 includes a CPU (Central Processing Unit) 13a, a ROM (Read Only Memory) 13b, and a RAM (Random Access Memory) 13c.
  • the CPU 13a connects the ROM 13b and the RAM 13c via the bus line 15.
  • the CPU 13a reads the control program P1 stored in the storage unit 14 and expands it in the RAM 13c.
  • the CPU 13a controls the operation of the control unit 13 by operating according to the control program P1 expanded in the RAM 13c. That is, the control unit 13 has a general computer configuration that operates based on the control program P1.
  • the control unit 13 further connects the storage unit 14 and the peripheral device controller 16 via the bus line 15.
  • the storage unit 14 is a non-volatile memory such as a flash memory or an HDD (Hard Disk Drive) or the like in which the stored information is retained even when the power is turned off.
  • the storage unit 14 stores the program including the control program P1 and the AE output M (t).
  • the control program P1 is a program for exerting the functions provided by the control unit 13.
  • the AE output M (t) is a signal obtained by converting the effective value of the detection signal D output by the AE sensor 20 into a digital signal by the A / D converter 17.
  • the control program P1 may be provided by being incorporated in the ROM 13b in advance.
  • the control program P1 is a file in a format that can be installed or executed in the control unit 13 and can be read by a computer such as a CD-ROM, a flexible disk (FD), a CD-R, or a DVD (Digital Versatile Disc). It may be configured to be recorded and provided on various recording media. Further, the control program P1 may be stored on a computer connected to a network such as the Internet and provided by downloading via the network. Further, the control program P1 may be configured to be provided or distributed via a network such as the Internet.
  • the peripheral device controller 16 connects to the A / D converter 17, the display device 18, and the operation device 19.
  • the peripheral device controller 16 controls the operation of various connected hardware based on a command from the control unit 13.
  • the A / D converter 17 converts the detection signal D output by the AE sensor 20 into a digital signal and outputs the AE output M (t).
  • the display device 18 is, for example, a liquid crystal display.
  • the display device 18 displays information related to the operating state of the predictive maintenance determination device 12a. Further, the display device 18 notifies when the predictive maintenance determination device 12a detects a sign of abnormality in the gear box 30 (equipment).
  • the operation device 19 is, for example, a touch panel superimposed on the display device 18.
  • the operation device 19 acquires operation information related to the setting and operation of the predictive maintenance determination device 12a.
  • FIG. 5 is a functional configuration diagram of the predictive maintenance determination device according to the first embodiment.
  • the control unit 13 of the predictive maintenance determination device 12a expands the control program P1 into the RAM 13c and operates it to notify the signal acquisition unit 51, the signal analysis unit 52a, the first determination unit 53a, and the notification unit 51 shown in FIG.
  • the unit 54 is realized as a functional unit.
  • the signal acquisition unit 51 acquires the detection signal D output by the AE sensor 20.
  • the signal acquisition unit 51 includes an amplifier to amplify the detection signal D, and also includes an A / D converter to convert the effective value of the detection signal D, which is an analog signal, into the AE output M (t), which is a digital signal. Convert.
  • the signal analysis unit 52a analyzes the AE output M (t) and calculates an evaluation value for determining whether or not a sign of abnormality is observed in the gear box 30.
  • the signal analysis unit 52a further includes a first difference value calculation unit 521, an average value calculation unit 522, a second difference value calculation unit 523, and a first ratio calculation unit 524.
  • the predetermined time may be determined to an appropriate value based on the calculation ability of the predictive maintenance determination device 12a and the like.
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time.
  • the ratio R1 (first ratio) is calculated by the signal analysis unit 52a.
  • the ratio R1 is the above-mentioned evaluation value.
  • the first determination unit 53a determines whether or not the ratio R1 calculated by the first ratio calculation unit 524 is equal to or greater than the first predetermined value ⁇ 1.
  • the notification unit 54 When the first determination unit 53a determines that the ratio R1 is equal to or greater than the first predetermined value ⁇ 1, the notification unit 54 notifies the gear box 30 (equipment) regarding predictive maintenance. Specifically, the notification unit 54 notifies the display device 18 by displaying that the gear box 30 shows signs of abnormality.
  • the notification method of the notification unit 54 is not limited to this, and notification may be performed by lighting or blinking an indicator (not shown in FIG. 4), or from a speaker or buzzer (not shown) in FIG. , Sound or voice may be output for notification.
  • the AE output M1 (t) when the gear box 30 to be evaluated has a clear abnormality (for example, the gear built in the gear box 30 is scratched).
  • the gear box 30 has a difference value between the maximum value and the minimum value of the output less than the average value Save of the AE output M1 (t) when an abnormality has occurred in the gear box 30. It was found that the ratio of the difference value between the maximum value and the minimum value of the AE output M2 (t) when is normal increases with the progress of the abnormality of the gear box 30.
  • the inventors have an AE output M (t) with respect to the difference value between the maximum value and the minimum value of the output less than the average value Save of the AE output M (t). )
  • the ratio of the difference value between the maximum value and the minimum value reaches the first predetermined value ⁇ 1 described above, it is determined that it is appropriate to determine that there is a sign of abnormality.
  • the value of the first predetermined value ⁇ 1 may be set to a value corresponding to the gear box 30 to be evaluated by conducting an evaluation experiment or the like in advance.
  • FIG. 6 is an explanatory diagram of the predictive maintenance determination method according to the first embodiment.
  • the graph 60a shown in FIG. 6 is an example of the AE output M (t) from the AE sensor 20 acquired by the signal acquisition unit 51 of the predictive maintenance determination device 12a.
  • the horizontal axis of FIG. 6 represents the time t, and the vertical axis represents the effective value (RMS value) of the AE output M (t) of the AE sensor 20.
  • the AE output from the AE sensor 20 is output as a continuous waveform, and the graph 60a is a scatter diagram obtained by sampling the continuous waveform at predetermined time intervals.
  • the signal acquisition unit 51 acquires the AE output M (t) from the AE sensor 20 while the motor 22, the gear box 30, and the extruder 40 are operating together.
  • the signal analysis unit 52a performs the following signal processing on the AE output M (t).
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time (for example, 10 seconds).
  • the second difference value calculation unit 523 removes the AE output M (t) exceeding the average value Save from the output AE (t) for a predetermined time, and then the maximum of the AE output M (t) remaining after removing the AE output M (t).
  • the difference value ⁇ 2 Smax2-Smin1 (second difference value) between the value Smax2 and the minimum value Smin1 is calculated.
  • the first determination unit 53a determines whether or not the ratio R1 calculated by the first ratio calculation unit 524 is equal to or greater than the first predetermined value ⁇ 1. Then, when it is determined that the ratio R1 is equal to or greater than the first predetermined value ⁇ 1, the notification unit 54 has detected a sign of abnormality in the gear box 30 with respect to the display device 18 (see FIG. 4). Is made to perform the notification indicating.
  • the predictive maintenance determination device 12a always performs the above processing while the gearbox 30 and the extruder 40 are operating. Then, at a predetermined time, for example, every 10 seconds, the determination by the first determination unit 53a and the notification by the notification unit 54 are performed.
  • the timing of judgment and notification is not limited to this. That is, the notification may be performed at predetermined time intervals based on the determination result of the AE output M (t) over the past predetermined time. For example, notification may be performed based on the determination result of the AE output M (t) over a predetermined time (for example, 10 seconds) in the past at a timing such as once per second.
  • FIG. 7 is a flowchart showing an example of the flow of processing performed by the predictive maintenance determination device according to the first embodiment.
  • the signal acquisition unit 51 acquires the AE output M (t) for a predetermined time from the storage unit 14 (step S11).
  • the first difference value calculation unit 521 calculates the first difference value ⁇ 1 between the maximum value Smax1 of the AE output M (t) for a predetermined time and the minimum value Smin1 (step S12).
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time (step S13).
  • the second difference value calculation unit 523 has a second difference value between the maximum value Smax2 and the minimum value Smin1 of the AE output M (t) less than the average value Save from the AE output M (t) for a predetermined time. Calculate ⁇ 2 (step S14).
  • the first ratio calculation unit 524 calculates the ratio R1 (first ratio) of the first difference value ⁇ 1 to the second difference value ⁇ 2 (step S15).
  • the first determination unit 53a determines whether the first ratio R1 is equal to or greater than the first predetermined value ⁇ 1 (step S16). When it is determined that the first ratio R1 is equal to or greater than the first predetermined value ⁇ 1 (step S16: Yes), the process proceeds to step S17. On the other hand, if it is not determined that the first ratio R1 is equal to or greater than the first predetermined value ⁇ 1 (step S16: No), the process returns to step S11.
  • step S16 the notification unit 54 performs notification related to predictive maintenance of the gear box 30, that is, notification indicating that a sign of abnormality is observed. After that, the predictive maintenance determination device 12a ends the process of FIG. 7.
  • the first difference value calculation unit 521 is an AE installed on the surface of the metal housing 30a (housing) of the gear box 30 (equipment).
  • the AE output M (t) of the sensor 20 is acquired, and the difference value ⁇ 1 (first difference value) between the maximum value Smax1 and the minimum value Smin1 of the AE output M (t) for a predetermined time is calculated.
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time.
  • the second difference value calculation unit 523 has a difference value ⁇ 2 between the maximum value Smax2 and the minimum value Smin1 of the AE output M (t) less than the average value Save from the AE output M (t) for a predetermined time. (Second difference value) is calculated.
  • the first ratio calculation unit 524 calculates the ratio R1 (first ratio) of the difference value ⁇ 1 with respect to the difference value ⁇ 2. Then, when the ratio R1 is equal to or greater than the first predetermined value ⁇ 1, the notification unit 54 notifies that the gear box 30 may have an abnormality.
  • the predictive maintenance determination device 12a notifies the gearbox when it detects an AE output M (t) smaller than the AE output M (t) that occurs when a clear abnormality occurs in the gearbox 30. It is possible to notify before an abnormality that affects the operation of 30 occurs.
  • the predictive maintenance determination device 12a of the first embodiment determines the predictive maintenance of the gear box 30 (equipment) that drives the extruder 40. Therefore, since it is possible to notify before an abnormality that affects the operation of the gearbox 30 and the extruder 40 occurs, the extruder 40 is stopped for inspection and maintenance of the gearbox 30, replacement of consumable parts, cleaning, and the like.
  • the timing to perform can be planned in advance. As a result, it is possible to prevent the production line from stopping at an unexpected timing.
  • the frequency analysis generally performed when analyzing the AE wave W is not performed. Therefore, the processing load when analyzing the AE output M (t) can be reduced.
  • the second embodiment of the present disclosure is an example of the predictive maintenance determination device 12b provided in the predictive maintenance determination system 10b (not shown), which detects and notifies a sign that an abnormality occurs in the device.
  • the predictive maintenance determination device 12b includes a predictive maintenance determination method different from the predictive maintenance determination device 12a described above.
  • FIG. 8 is a functional configuration diagram of the predictive maintenance determination device according to the second embodiment.
  • the control unit 13 of the predictive maintenance determination device 12b expands the control program P2 (not shown) into the RAM 13c and operates the signal acquisition unit 51, the signal analysis unit 52b, and the second determination unit shown in FIG.
  • the 53b and the notification unit 54 are realized as functional units.
  • the functions of the signal acquisition unit 51 and the notification unit 54 are the same as those of the predictive maintenance determination device 12a described above.
  • the signal analysis unit 52b analyzes the output of the AE sensor 20 acquired by the signal acquisition unit 51 and calculates an evaluation value for determining whether or not a sign of abnormality is observed in the gear box 30.
  • the signal analysis unit 52b further includes a first difference value calculation unit 521, an abnormal value removal unit 525, a third difference value calculation unit 526, and a second ratio calculation unit 527.
  • the function of the first difference value calculation unit 521 is the same as that of the predictive maintenance determination device 12a described above.
  • the abnormal value removing unit 525 removes an output of a predetermined ratio U or more from the AE output M (t) for a predetermined time with respect to the maximum value Smax1 of the output.
  • the predetermined ratio U is determined based on a preliminary evaluation experiment or the like, and is set to, for example, 30% or the like.
  • the predetermined ratio U is set to a value corresponding to the gear box 30 to be evaluated by conducting an evaluation experiment or the like in advance. Details will be described later.
  • the ratio R2 (second ratio) is the above-mentioned evaluation value calculated by the signal analysis unit 52b.
  • the second determination unit 53b determines whether or not the ratio R2 calculated by the second ratio calculation unit 527 is equal to or greater than the second predetermined value (for example, 3).
  • FIG. 9 is an explanatory diagram of the predictive maintenance determination method in the second embodiment.
  • the graph 60b shown in FIG. 9 is an example of the AE output M (t) from the AE sensor 20 acquired by the signal acquisition unit 51 of the predictive maintenance determination device 12a.
  • the horizontal axis of FIG. 9 represents the time t, and the vertical axis represents the effective value (RMS value) of the AE output M (t) of the AE sensor 20.
  • the AE output from the AE sensor 20 is output as a continuous waveform, and the graph 60b is a scatter diagram obtained by sampling the continuous waveform at predetermined time intervals.
  • the abnormal value removing unit 525 removes an output of a predetermined ratio U or more from the AE output M (t) for a predetermined time with respect to the maximum value Smax1 of the AE output M (t).
  • the abnormal value removal unit 525 has a predetermined ratio U or more with respect to the maximum value Smax1 of the AE output M (t) from the AE output M (t) for a predetermined time.
  • the difference value ⁇ 3 Smax3-Smin1 (third difference value) between the maximum value Smax3 and the minimum value Smin1 of the output remaining after removing the output is calculated.
  • the first determination unit 53a determines whether or not the ratio R2 calculated by the second ratio calculation unit 527 is equal to or greater than the second predetermined value ⁇ 2. Then, when it is determined that the ratio R2 is equal to or greater than the second predetermined value ⁇ 2, the notification unit 54 has detected a sign of abnormality in the gear box 30 with respect to the display device 18 (see FIG. 4). Is made to perform the notification indicating.
  • the predictive maintenance determination device 12b always performs the above processing while the gearbox 30 and the extruder 40 are operating. Then, at predetermined time intervals, for example, every 10 seconds, the determination by the second determination unit 53b and the notification by the notification unit 54 are performed.
  • the timing of judgment and notification is not limited to this. That is, the notification may be performed at predetermined time intervals based on the determination result of the AE output M (t) over the past predetermined time. For example, notification may be performed based on the determination result of the AE output M (t) over a predetermined time (for example, 10 seconds) in the past at a timing such as once per second.
  • the values of the predetermined ratio U and the second predetermined value ⁇ 2 are set to the values corresponding to the gear box 30 to be evaluated by conducting an evaluation experiment or the like in advance.
  • the difference value between the maximum value and the minimum value of the AE output M2 (t) when the gear box 30 is in a normal state is when an abnormality has occurred in the gear box 30. It was found that the difference value between the maximum value and the minimum value of the output obtained by removing the data of the upper 30% of the AE output M1 (t) from the AE output M1 (t) was substantially equal.
  • the inventors obtain a difference value between the maximum value and the minimum value when the upper 30% of the data is removed from the AE output M (t).
  • the ratio of the difference value between the maximum value and the minimum value of the AE output M (t) reaches about 3 (corresponding to the second predetermined value ⁇ 2 described above), it is appropriate to determine that there is a sign of abnormality. Judged to be.
  • the AE output M (t) and the higher data from the AE output M (t) are obtained.
  • it can be regarded as an almost equivalent analysis method. Therefore, any method may be applied to make the determination, but the method described in the second embodiment, that is, the method of determining based on the data obtained by removing the data of the upper predetermined ratio of the AE output M (t). In the case of, the amount of calculation of the analysis process can be reduced because the calculation of the average value is unnecessary.
  • FIG. 10 is a flowchart showing an example of the flow of processing performed by the predictive maintenance determination device according to the second embodiment.
  • the signal acquisition unit 51 acquires the AE output M (t) for a predetermined time from the storage unit 14 (step S21).
  • the first difference value calculation unit 521 calculates the first difference value ⁇ 1 of the maximum value Smax1 and the minimum value Smin1 of the AE output M (t) for a predetermined time (step S22).
  • the abnormal value removing unit 525 removes the AE output M (t) of a predetermined ratio U or more with respect to the maximum value Smax1 of the AE output M (t) for a predetermined time (step S23).
  • the third difference value calculation unit 526 is a third of the maximum value Smax3 after the abnormal value removing unit 525 removes the predetermined AE output M (t) and the minimum value Smin1 of the AE output M (t).
  • the difference value ⁇ 3 is calculated (step S24).
  • the second ratio calculation unit 527 calculates the ratio R2 (second ratio) of the first difference value ⁇ 1 to the third difference value ⁇ 3 (step S25).
  • the second determination unit 53b determines whether the second ratio R2 is equal to or greater than the second predetermined value ⁇ 2 (step S26). When it is determined that the second ratio R2 is equal to or greater than the second predetermined value ⁇ 2 (step S26: Yes), the process proceeds to step S27. On the other hand, if it is not determined that the second ratio R2 is equal to or greater than the second predetermined value ⁇ 2 (step S26: No), the process returns to step S21.
  • step S26 the notification unit 54 performs notification related to predictive maintenance of the gear box 30, that is, notification indicating that a sign of abnormality is observed. After that, the predictive maintenance determination device 12b ends the process of FIG.
  • the first difference value calculation unit 521 is an AE installed on the surface of the metal housing 30a (housing) of the gear box 30 (equipment).
  • the AE output M (t) of the sensor 20 is acquired, and the difference value ⁇ 1 (first difference value) between the maximum value Smax1 and the minimum value Smin1 of the AE output M (t) for a predetermined time is calculated.
  • the third difference value calculation unit 526 removes the output of a predetermined ratio U or more with respect to the maximum value Smax1 among the AE output M (t) for a predetermined time, and then the maximum value of the AE output M (t) remaining.
  • the difference value ⁇ 3 (third difference value) between Smax3 and the minimum value Smin1 is calculated.
  • the second ratio calculation unit 527 calculates the ratio R2 (second ratio) of the difference value ⁇ 1 with respect to the difference value ⁇ 3.
  • the second determination unit 53b notifies that when the ratio R2 is equal to or greater than the second predetermined value ⁇ 2, the notification unit 54 notifies that the gear box 30 shows a sign of abnormality.
  • the predictive maintenance determination device 12b notifies when the AE output M (t) smaller than the AE output M (t) generated when a clear abnormality occurs in the gear box 30 is detected, so that the gear box is notified. It is possible to notify before an abnormality that affects the operation of 30 occurs.
  • the predictive maintenance determination device 12b of the second embodiment determines the predictive maintenance of the gear box 30 (equipment) that drives the extruder 40. Therefore, since it is possible to notify before an abnormality that affects the operation of the gearbox 30 and the extruder 40 occurs, the extruder 40 is stopped for inspection and maintenance of the gearbox 30, replacement of consumable parts, cleaning, and the like.
  • the timing to perform can be planned in advance. As a result, it is possible to prevent the production line from stopping at an unexpected timing.
  • FIG. 11 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the third embodiment.
  • the predictive maintenance determination system 10c detects and notifies abnormal signs such as cracks and wear generated in the gear box 30 that drives the extruder 40 by decelerating the rotational driving force of the motor 22, and wear of the shaft that supports the gears. To do.
  • the predictive maintenance determination device 12c is provided in the predictive maintenance determination system 10c to detect and notify a sign that an abnormality occurs in the device.
  • the predictive maintenance determination device 12c includes a predictive maintenance determination method different from the predictive maintenance determination devices 12a and 12b described above.
  • FIG. 12 is a functional configuration diagram of the predictive maintenance determination device according to the third embodiment.
  • the control unit 13 of the predictive maintenance determination device 12c expands the control program P3 (not shown) into the RAM 13c and operates the signal acquisition unit 51, the signal analysis unit 52b, and the third determination unit shown in FIG.
  • the 53c and the notification unit 54 are realized as functional units.
  • the function of the signal acquisition unit 51 is the same as that of the predictive maintenance determination devices 12a and 12b described above.
  • the function of the notification unit 54 is as described in the first embodiment. That is, in the case of the present embodiment, the notification unit 54 performs notification according to the determination result of the third determination unit 53c.
  • the signal analysis unit 52c analyzes the AE output M (t) acquired by the signal acquisition unit 51 and calculates an evaluation value for determining whether or not a sign of abnormality is observed in the gear box 30.
  • the signal analysis unit 52c further includes a first difference value calculation unit 521, an average value calculation unit 522, and a third ratio calculation unit 528.
  • the third ratio calculation unit 528 calculates the predetermined time calculated by the first difference value calculation unit 521 with respect to the average value Save of the AE output M (t) for the predetermined time calculated by the average value calculation unit 522.
  • the third determination unit 53c of the gear box 30 is based on the difference value ⁇ 1 calculated by the first difference value calculation unit 521 of the signal analysis unit 52c and the ratio R3 calculated by the third ratio calculation unit 528. Determine the state.
  • the specific determination method will be described below.
  • FIG. 13 is a diagram showing an example of a determination criterion in the third embodiment.
  • the third determination unit 53c determines that the gear box 30 is normal. Then, at this time, the notification unit 54 does not perform any notification. At this time, the notification unit 54 may perform notification indicating that the gear box 30 is normal.
  • the difference value ⁇ 1 is smaller than the difference value first threshold value Td1
  • the third ratio R3 is equal to or higher than the ratio first threshold value Tr1 and larger than the ratio first threshold value Tr1 than the ratio second threshold value Tr2.
  • the difference value ⁇ 1 is equal to or larger than the difference value first threshold value Td1, is smaller than the difference value second threshold value Td2 larger than the difference value first threshold value Td1, and the third ratio R3 is the ratio third.
  • the difference value ⁇ 1 and the third ratio R3 are smaller than the two threshold values Tr2, that is, when the difference value ⁇ 1 and the third ratio R3 are inside the region W3 of FIG. Judged as being in a follow-up state. Then, the notification unit 54 notifies that the patient is in a follow-up required state with a medium frequency (for example, about once every 6 months).
  • the difference value ⁇ 1 is equal to or larger than the difference value second threshold value Td2, is larger than the difference value second threshold value Td2, is smaller than the difference value third threshold value Td3, and the third ratio R3 is the ratio second.
  • the threshold value Tr2 is smaller than the threshold value Tr2, that is, when the difference value ⁇ 1 and the third ratio R3 are inside the region W4 in FIG. Judge that it is in the observation state. Then, the notification unit 54 notifies that the patient is in a follow-up required state with high frequency (for example, about once every three months).
  • the third determination unit 53c determines that the gear box 30 is in a state requiring maintenance with a low degree of urgency. Then, the notification unit 54 notifies that the vehicle is in a state requiring maintenance with a low degree of urgency (for example, a state in which maintenance within 2 to 3 years is recommended).
  • the difference value ⁇ 1 is equal to or larger than the difference value second threshold value Td2, is larger than the difference value second threshold value Td2, is smaller than the difference value third threshold value Td3, and the third ratio R3 is the ratio second threshold value.
  • Tr2 or more that is, when the difference value ⁇ 1 and the third ratio R3 are inside the region W6 of FIG. 13
  • the third determination unit 53c has a gear box 30 having a medium degree of urgency. Judge that maintenance is required. Then, the notification unit 54 notifies that the urgency is in a moderate maintenance required state (for example, a state in which maintenance within 1 to 2 years is recommended).
  • the third determination unit 53c determines. It is determined that the gear box 30 is in a state requiring maintenance with a high degree of urgency. Then, the notification unit 54 notifies that the vehicle is in a state requiring maintenance with a high degree of urgency (for example, a state in which maintenance within one year is recommended).
  • a two-dimensional map 80a may be created to evaluate the state of the gearbox 30 based on the positions of the evaluation values plotted on the two-dimensional map 80a. That is, as described in the third embodiment, a plurality of threshold values are set according to the evaluation functions on the vertical axis and the horizontal axis, and the gear box 30 is based on the relationship between the measured evaluation value and the threshold value. The condition may be evaluated.
  • the number of AE sensors 20 installed in the gear box 30 is not limited to one. That is, a plurality of AE sensors 20 may be installed on the surfaces of the gearbox 30 corresponding to each axial direction, and the output of each AE sensor 20 may be evaluated by the two-dimensional map 80a shown in FIG. By simultaneously measuring the plurality of channels in this way, the state of the gear box 30 in each axial direction can be evaluated, so that the position where the abnormality of the gear box 30 has occurred can be more accurately specified.
  • the place where the AE sensor 20 is installed has variations such as the input shaft side (motor 22 side), the output shaft side (extruder 40 side), and the intermediate shaft side (center portion of the gear box 30) of the gear box 30. You may let me.
  • FIG. 14 is a flowchart illustrating an example of a processing flow performed by the signal analysis unit and the third determination unit in the third embodiment.
  • the signal acquisition unit 51 acquires the AE output M (t) for a predetermined time from the storage unit 14 (step S31).
  • the signal analysis unit 52c sorts the AE output M (t) for the predetermined time acquired in step S31 in descending order from the largest value (step S32).
  • the signal analysis unit 52c removes sudden values from the AE output M (t) sorted in descending order in step S32 (step S33). Specifically, the AE output M (t) sorted in descending order is classified in increments of 100 (0 ⁇ M (t) ⁇ 100, 101 ⁇ M (t) ⁇ 200, ...), And classified as 100. If there are only two or less data in the notch, the two or less data are removed.
  • the first difference value calculation unit 521 specifies the maximum value Smax1 and the minimum value Smin1 of the AE output M (t) (step S34).
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time (step S35).
  • the third determination unit 53c determines the state of the gear box 30 according to the reference described in FIG. 13 (step S37).
  • the first difference value calculation unit 521 is an AE installed on the surface of the metal housing 30a (housing) of the gear box 30 (equipment).
  • the AE output M (t) of the sensor 20 is acquired, and the difference value ⁇ 1 (first difference value) between the maximum value Smax1 and the minimum value Smin1 of the AE output M (t) for a predetermined time is calculated.
  • the average value calculation unit 522 calculates the average value Save of the AE output M (t) for a predetermined time.
  • the third ratio calculation unit 528 calculates the third ratio R3, which is the ratio of the difference value ⁇ 1 (first difference value) to the average value Save.
  • the notification unit 54 notifies that the gear box 30 may have an abnormality based on the difference value ⁇ 1 and the third ratio R3, that is, based on the two-dimensional map 80a.
  • the predictive maintenance determination device 12c notifies when the AE output M (t) smaller than the AE output M (t) generated when a clear abnormality occurs in the gear box 30 is detected, so that the gear box is notified. It is possible to notify before an abnormality that affects the operation of 30 occurs.
  • the determination method described in the third embodiment that is, the determination method based on the two-dimensional map 80a of FIG. 13, may be applied to the first embodiment and the second embodiment. By performing the determination based on the plurality of determination scales in this way, the state of the gear box 30 can be determined in more detail.
  • the fourth embodiment of the present disclosure is an example of the predictive maintenance determination device 12d provided in the predictive maintenance determination system 10d, which detects and notifies a sign that an abnormality occurs in the device.
  • FIG. 15 is an overall configuration diagram of a predictive maintenance determination system using the predictive maintenance determination device according to the fourth embodiment.
  • the predictive maintenance determination system 10d has a configuration in which the vibration sensor 70 is added to the configuration of the predictive maintenance determination system 2a described with reference to FIG.
  • the vibration sensor 70 is installed on the surface of the metal housing 30a of the gear box 30 and measures the magnitude of the vibration acceleration generated in the gear box 30. Specifically, the magnitude of the vibration acceleration in the range of several Hz to several tens of Hz, which is lower than the frequency range measured by the AE sensor 20, is detected.
  • the vibration sensor 70 is an example of an acceleration sensor in the present disclosure, and for example, a piezoelectric acceleration sensor or the like is used.
  • the predictive maintenance determination system 10d measures the magnitude of the vibration acceleration generated in the gear box 30 and determines the state of the gear box 30 described in the third embodiment when the vibration acceleration is larger than a predetermined acceleration. Switch the method to be performed to another judgment method. That is, in the predictive maintenance determination system 10d, when the magnitude of the vibration acceleration generated in the gear box 30 is larger than the predetermined acceleration, that is, the third predetermined value ⁇ 3, the gear box 30 is based on a determination standard different from that of FIG. Judge the state of. On the other hand, when the magnitude of the vibration acceleration generated in the gear box 30 is equal to or less than the third predetermined value ⁇ 3, the state of the gear box 30 is determined according to the determination criteria shown in FIG. According to the evaluation experiments by the inventors, the third predetermined value ⁇ 3 is preferably about 10 m / s 2.
  • FIG. 16 is a functional configuration diagram of the predictive maintenance determination device according to the fourth embodiment.
  • the control unit 13 of the predictive maintenance determination device 12d expands the control program P3 (not shown) into the RAM 13c and operates the signal acquisition unit 55, the signal analysis unit 52d, and the fourth determination unit shown in FIG.
  • the 53d and the notification unit 54 are realized as functional units.
  • the signal acquisition unit 55 acquires the AE output M (t) for a predetermined time from the storage unit 14. Further, the signal acquisition unit 55 acquires the vibration acceleration from the vibration sensor 70.
  • the signal analysis unit 52d includes a vibration acceleration determination unit 520 in addition to the functions described in the third embodiment.
  • the vibration acceleration determination unit 520 determines whether or not the vibration acceleration acquired by the vibration sensor 70 is larger than the third predetermined value ⁇ 3.
  • the function of the notification unit 54 is as described in the first embodiment. That is, in the case of the present embodiment, the notification unit 54 performs notification according to the determination result of the fourth determination unit 53d.
  • the fourth determination unit 53d determines the state of the gear box 30 by a determination method according to the magnitude of the vibration acceleration acquired by the vibration sensor 70. The specific determination method will be described later.
  • the predictive maintenance determination device 12d uses the determination criteria (two-dimensional map 80b) shown in FIG. 17, for example, to determine the gear box 30.
  • the determination criteria two-dimensional map 80b shown in FIG. 17, for example, to determine the gear box 30.
  • FIG. 17 is a diagram showing an example of a determination criterion when the vibration acceleration is larger than the third predetermined value ⁇ 3.
  • the vertical axis of FIG. 17 is the difference value ⁇ 1 (first difference value), and the horizontal axis is the minimum value Smin1 of the AE output M (t) or the average value Save of the AE output M (t). ing. Then, the fourth determination unit 53d determines whether or not an abnormality may occur in the gear box 30 based on the two-dimensional map 80b formed by the difference value ⁇ 1 and the minimum value Smin1 (or the average value Save). ..
  • the fourth determination unit 53d determines that the gear box 30 is in a state requiring follow-up observation at a low frequency (for example, about once a year). It is determined that it is in a state that requires observation). Then, the notification unit 54 notifies that the patient is in a follow-up required state with a low frequency (for example, about once a year).
  • the difference value ⁇ 1 is equal to or larger than the difference value first threshold value Td1, is larger than the difference value first threshold value Td1, is smaller than the difference value second threshold value Td2, and has a minimum value Smin1 (or average value Save).
  • the signal output threshold value Ts1 is smaller than the signal output threshold value Ts1, that is, when the difference value ⁇ 1 and the minimum value Smin1 (or the average value Save) are inside the region W12 in FIG. It is determined that the patient is in a state requiring follow-up at a medium frequency. Then, the notification unit 54 notifies that the patient is in a follow-up required state with a medium frequency (for example, about once every 6 months).
  • the fourth determination unit 53d puts the gearbox 30 in a state requiring follow-up at a high frequency. Judge that there is. Then, the notification unit 54 notifies that the patient is in a follow-up required state with high frequency (for example, about once every three months).
  • the fourth determination unit 53d determines that the gear box 30 is in a state requiring maintenance with a low degree of urgency. Then, the notification unit 54 notifies that the vehicle is in a state requiring maintenance with a low degree of urgency (for example, a state in which maintenance within 2 to 3 years is recommended).
  • the fourth determination unit 53d indicates that the gear box 30 is in a state requiring maintenance with a medium degree of urgency. Judged to be in. Then, the notification unit 54 notifies that the urgency is in a moderate maintenance required state (for example, a state in which maintenance within 1 to 2 years is recommended).
  • the fourth determination is made.
  • the unit 53d determines that the gear box 30 is in a state requiring maintenance with a high degree of urgency. Then, the notification unit 54 notifies that the vehicle is in a state requiring maintenance with a high degree of urgency (for example, a state in which maintenance within one year is recommended).
  • FIG. 18 is a flowchart illustrating an example of a processing flow performed by the signal analysis unit and the fourth determination unit in the fourth embodiment.
  • the signal acquisition unit 55 acquires the vibration acceleration from the vibration sensor 70. (Step S41).
  • the signal acquisition unit 55 acquires the AE output M (t) for a predetermined time from the storage unit 14 (step S42).
  • the vibration acceleration determination unit 520 determines whether the vibration acceleration is larger than the third predetermined value ⁇ 3 (step S43). When it is determined that the vibration acceleration is larger than the third predetermined value ⁇ 3 (step S43: Yes), the process proceeds to step S44. On the other hand, if it is not determined that the vibration acceleration is larger than the third predetermined value ⁇ 3 (step S43: No), the process proceeds to step S45.
  • the fourth determination unit 53d determines the state of the gear box 30 based on the two-dimensional map 80b (step S44). After that, the process of FIG. 18 is completed.
  • the fourth determination unit 53d determines the state of the gear box 30 based on the two-dimensional map 80a (step S45). After that, the process of FIG. 18 is completed.
  • the predictive maintenance determination device 12d of the fourth embodiment acquires the output of the vibration sensor 70 (accelerometer) installed on the surface of the gear box 30 (equipment), and outputs the vibration sensor 70.
  • the notification unit 54 causes an abnormality in the gear box 30 based on the minimum or average value of the output of the AE sensor 20 and the difference value ⁇ 1 (first difference value). Notifies that there is a risk of occurrence.
  • the output of the vibration sensor 70 is equal to or less than the third predetermined value ⁇ 3, there is a possibility that an abnormality may occur in the gear box 30 based on the difference value ⁇ 1 (first difference value) and the third ratio R3. Notify that there is.
  • the predictive maintenance determination device 12d can notify the gear box 30 before an abnormality that affects the operation of the gear box 30 occurs even when a high vibration acceleration is generated in the gear box 30.
  • a fifth embodiment of the present disclosure is an example of the predictive maintenance determination device 12e provided in the predictive maintenance determination system 10e (see FIG. 19) that detects and notifies a sign that an abnormality occurs in the device.
  • FIG. 19 is a system block diagram showing an example of the system configuration of the predictive maintenance determination system according to the fifth embodiment.
  • the predictive maintenance determination system 10e outputs the outputs (outputs amplified by the preamplifier) of the AE sensors 21a, 21b, ... Installed in the plurality of gear boxes 31a, 31b, ... It is transmitted to 12e, and the predictive maintenance determination device 12e determines the states of the gear boxes 31a, 31b, ...
  • the gear boxes 31a and 31b are rotationally driven by motors 23a, 23b, ..., To drive the extruders 41a, 41b, ..., Respectively. Further, it is assumed that the outputs of the AE sensors 21a, 21b, ... Are given identification information for identifying the gear box in which each AE sensor is installed.
  • the installation location of the predictive maintenance determination device 12e does not have to be in the vicinity of the gear boxes 31a, 31b, ... It may be located far away from the gearboxes 31a, 31b, .... Further, the gear boxes 31a, 31b, ... Connected to the predictive maintenance determination device 12e are not limited to the gear boxes installed in the same factory, and may be gear boxes installed in a plurality of factories.
  • the predictive maintenance determination device 12e has the same configuration as any of the predictive maintenance determination devices 12a to 12d described above. Then, the predictive maintenance determination device 12e outputs the outputs of the AE sensors 21a, 21b, ... To the first determination unit 53a, the second determination unit 53b, the third determination unit 53c, and the fourth determination unit 53d. The state of the gear boxes 31a, 31b, ... Is determined by the same determination method as any of the above.
  • the notification unit 54 included in the predictive maintenance determination device 12e notifies the determined content.
  • the predictive maintenance determination device 12e includes a plurality of determination logics for determining different AE output M (t) obtained from different types of gear boxes, and the predictive maintenance determination device 12e receives the AE output M (t). ), The state of the gearbox may be determined by using the determination logic corresponding to the gearbox that has detected the AE output M (t).
  • the determination result may be returned to the gear box via the Internet 100. Then, the determination result may be notified by a notification device such as an alarm (not shown in FIG. 19) installed in the gear box.
  • the predictive maintenance determination device 12e of the fifth embodiment is connected to the AE sensors 21a and 21b installed on the surfaces of one or more gear boxes 31a and 31b (equipment) via the Internet 100.
  • the outputs of the AE sensors 21a and 21b are acquired. As a result, it is possible to determine the abnormality of the gear box (equipment) at a place away from the gear box (equipment).
  • Average value calculation unit 523 ... Second difference value calculation unit, 524 ... First ratio calculation unit, 525 ... Abnormal value removal unit, 526 ... Third difference value calculation unit, 527 ... Second ratio calculation unit, Save ... Average value, Smax1, Smax2, Smax3 ... maximum value, Smin1 ... minimum value, ⁇ 1 ... difference value (first difference value), ⁇ 2 ... difference value (second difference value), ⁇ 3 ... difference value (third difference value), M (t), M1 (t), M2 (t) ... AE output, R1 ... ratio (first ratio), R2 ... ratio (second ratio), R3 ... ratio (third ratio), U ... Predetermined ratio, Td1 ... difference value first threshold, Td2 ...
  • difference value second threshold Td3 ... difference value third threshold
  • Tr1 ... ratio first threshold
  • Tr2 ... ratio second threshold
  • Ts1 signal output threshold
  • ⁇ 1 ... th 1 predetermined value ⁇ 2 ... 2nd predetermined value

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  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)
  • Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)

Abstract

Selon l'invention, une première unité de calcul de valeur différentielle (521) du dispositif d'évaluation de maintenance prédictive (12a) de l'invention acquiert des sorties AE (M(t)) d'un capteur AE (20) installé sur la surface d'un boîtier métallique (boîtier) d'une boîte à engrenages (30), et calcule une valeur différentielle (δ1) (première valeur différentielle) entre la valeur maximale (Smax1) et la valeur minimale (Smin1) de la sortie AE dans une durée temporelle prescrite. Une unité de calcul de valeur moyenne (522) calcule une valeur moyenne (Save) des sorties AE dans la durée temporelle prescrite. Une seconde unité de calcul de valeur différentielle (523) calcule une seconde valeur différentielle (δ2) (seconde valeur différentielle) entre la valeur minimale (Smin1) et une valeur maximale (Smax2) de sorties AE inférieures à la valeur moyenne (Save), parmi les sorties AE dans la durée temporelle prescrite. Une première unité de calcul de rapport (524) calcule le rapport (R1) (premier rapport) de la première valeur différentielle à la seconde valeur différentielle. Lorsque le rapport (R1) est supérieur ou égal à une première valeur prescrite (ε1), une unité de notification (54) émet une notification indiquant l'existence d'un risque d'occurrence d'une anomalie dans la boîte à engrenages (30).
PCT/JP2020/042322 2019-05-21 2020-11-12 Dispositif d'évaluation de maintenance prédictive, procédé d'évaluation de maintenance prédictive et programme WO2021100615A1 (fr)

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DE112020005706.2T DE112020005706T5 (de) 2019-05-21 2020-11-12 Vorrichtung zur bestimmung einer vorausschauenden wartung, verfahren zum bestimmen einer vorausschauenden wartung, und programm
KR1020217015134A KR102574186B1 (ko) 2019-05-21 2020-11-12 예지 보전 판정 장치, 예지 보전 판정 방법 및 기억 매체
CN202080008480.XA CN113286995B (zh) 2019-05-21 2020-11-12 预测维护判定装置、预测维护判定方法及存储介质

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TW202134622A (zh) 2021-09-16
TWI763130B (zh) 2022-05-01
KR102574186B1 (ko) 2023-09-06
JP2020193961A (ja) 2020-12-03
KR20210077740A (ko) 2021-06-25

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