Equipment maintenance method based on risk priority strategy
Through a risk-first strategy-based equipment maintenance method, combined with equipment health assessment and IoT data, the equipment maintenance plan is optimized, and the problem of difficulty in troubleshooting enterprises in a timely manner under the increase in the number of equipment and cost restrictions is solved, and the risk of equipment failure is minimized Improvement and maintenance efficiency.
Patent Information
- Application Number
- CN202010537127.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2020-06-12
- Publication Date
- 2024-12-13
- Estimated Expiration
- 2040-06-12
AI Technical Summary
Under the increase in the number of equipment and cost limitations, it is difficult for enterprises to effectively and promptly eliminate faults and prevent equipment failures, resulting in equipment performance deterioration and increased economic losses.
Using a risk-first strategy-based equipment maintenance method, the failure risk value is calculated through the equipment health assessment model and importance, priority is given to high-risk equipment, and combined with IoT data and environmental parameters, maintenance plans are optimized to minimize equipment failures.
It has achieved effective reduction of equipment failure risks under limited labor costs, improved the accuracy and efficiency of equipment maintenance work, and reduced the economic losses of enterprises.
Smart Images
Figure CN111784004B_ABST
Abstract
Description
Technical Field
[0001] The invention relates to an equipment maintenance method based on a risk priority strategy. Background Art
[0002] Equipment management is a series of management behaviors implemented by the owner or user of the equipment to keep the equipment in good technical condition and ensure the safe operation of the equipment. For manufacturing enterprises, the level of equipment management affects the production efficiency, production safety, production quality and sustainable operation ability of the enterprise.
[0003] Equipment maintenance is the implementation of technical inspections and maintenance measures on equipment according to a pre-determined plan or the requirements of corresponding technical conditions to prevent equipment performance degradation and reduce the possibility of equipment failure; for failed equipment, its availability is restored through technical repair measures.
[0004] A good equipment management system can improve the digitalization and informatization level of an enterprise, and through the analysis of historical operation data and maintenance data, it can improve the accuracy of the enterprise's maintenance work and reap the benefits of cost reduction and efficiency improvement.
[0005] As the number of equipment increases, the importance of equipment health to production security increases, and enterprises invest more and more in equipment maintenance. At this time, using limited labor costs to timely eliminate faults and minimize the occurrence of equipment failures through preventive maintenance, thereby reducing the overall economic losses caused by equipment failures or equipment performance degradation, has outstanding practical application value. Summary of the invention
[0006] In order to overcome the above-mentioned defects, the purpose of the present invention is to propose an equipment maintenance method based on a risk priority strategy, which uses limited labor costs to timely eliminate faults and minimizes the occurrence of equipment failures through preventive maintenance.
[0007] The invention is an equipment maintenance method based on risk priority strategy, characterized in that the method comprises the following steps:
[0008] 1) Obtain the set of equipment to be maintained according to priority;
[0009] 2) Update the device data in the collection at the scheduled time during this maintenance period;
[0010] 3) Based on the equipment health evaluation model and updated equipment data, the evaluation value of each equipment health is obtained;
[0011] 4) Calculate the failure risk value of each device based on the health assessment value and device importance;
[0012] 5) Select the set of devices with the largest sum of risk values, and the sum of the rated maintenance durations of the devices within the set does not exceed the normal working hours of the maintenance personnel within the planned period.
[0013] Further, step 1) is specifically as follows: The devices include faulty devices, devices connected to the online Internet of Things, and preventive maintenance devices; among them, the priority of the devices is faulty devices > devices connected to the online Internet of Things > preventive maintenance devices.
[0014] Further, step 1) is specifically as follows:
[0015] 11) Obtain the devices that need to be repaired during this maintenance period from the fault handling module; among them, there are N1 devices that need to be repaired during this maintenance period, forming a set Φ1, and the sum of the rated maintenance durations is D1; the normal working hours of the maintenance personnel within the planned period is D;
[0016] If D1 ≥ D, then the devices to be maintained in this period are Φ1; if D1 < D, then execute the next step 12);
[0017] 12) The device health online diagnosis module determines whether the device needs maintenance based on the real-time data of the device operation through a pre-established diagnosis model.
[0018] Outside the set Φ1, all the devices determined by the device health online diagnosis module to need maintenance during this maintenance period form a set Φ2, the number of its elements is denoted as N2, and the sum of the rated maintenance durations of these N2 devices is D2;
[0019] If D1 + D2 ≥ D, then the devices to be maintained in this period are Φ1 ∪ Φ2; if D1 + D2 < D, then execute step 2.
[0020] Further, step 2) prepares a maintenance plan for the device set Φ3.
[0021] Further, the device data updated in step 2) at least includes:
[0022] (1) Cumulative working hours;
[0023] (2) The total duration since the last maintenance of the device.
[0024] Further, the device data updated in step 2) also includes any of the following data:
[0025] (3) Data reflecting the load intensity during the use of the device;
[0026] (4) The load intensity during the use of the device within the past time window;
[0027] (5) Environmental parameter values that affect equipment performance, collected or recorded during the past time window, including temperature, humidity, and / or the content of solid particulate matter in the air.
[0028] The present invention evaluates the risks caused by equipment failure and eliminates high risks first. The system is suitable for equipment owners or users to maintain and manage multiple equipment with as little manpower as possible, thereby minimizing the risk of equipment failure as a whole.
[0029] (III) Beneficial effects
[0030] The present invention proposes an equipment maintenance method based on a risk priority strategy, which has the following beneficial effects:
[0031] 1. This method takes into account the operational failure risks of different equipment during equipment maintenance. All equipment is considered as a whole, and the risk of equipment failure is prevented to the greatest extent possible when preparing the maintenance plan.
[0032] 2. This method evaluates the health of the equipment based on the historical usage data and maintenance data of the equipment, as well as the data that affects the health of the equipment during actual use. At the same time, the risk value of the equipment is calculated based on the importance of the equipment in the production process. This method has universal applicability.
[0033] 3. This method incorporates common scenarios in equipment management such as fault reporting, IoT monitoring and identification of maintenance needs, and is generally applicable.
[0034] 4. This method can be integrated with the human resources system or scheduling system to help enterprises manage maintenance personnel more accurately. BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Figure 1 This is a schematic diagram of the core functional modules of the equipment maintenance management system of the present invention.
[0036] Figure 2 This is a schematic diagram of the operation process of the equipment maintenance management method of the present invention. DETAILED DESCRIPTION
[0037] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0038] The present invention is implemented by a maintenance system composed of the following modules: the system includes core functional modules such as equipment ledger module, equipment health assessment module, equipment risk assessment module, equipment operation data acquisition module, equipment health online diagnosis module, fault handling module, preventive maintenance plan arrangement module, maintenance execution module, etc. Figure 1 shown.
[0039] The equipment ledger module is used to query and manage equipment data, which may include but is not limited to data related to production, installation and commissioning, commissioning, previous operations, and previous maintenance and repairs.
[0040] The device health assessment module is used to assess the current health status of the device.
[0041] The equipment risk assessment module is used to evaluate the risk caused by equipment failure. The higher the probability of failure, the greater the risk.
[0042] The equipment operation data acquisition module receives and stores the real-time monitoring data of equipment operation.
[0043] The equipment health online diagnosis module uses the diagnosis model to perform online analysis and judgment on the health status of the equipment.
[0044] The equipment fault handling module is used to manage equipment faults and to schedule and dispatch faults to be handled.
[0045] The preventive maintenance planning module is used to generate a list of equipment for preventive maintenance.
[0046] The maintenance execution module is used to notify equipment maintenance personnel of work tasks, track the progress of maintenance work, and provide feedback on the completion of the work.
[0047] The data stored in this system include equipment basic data, equipment operation data, and previous repair and maintenance data.
[0048] This system can be used based on PC, browser, mobile APP or WeChat.
[0049] The operation process of this system is described as follows:
[0050] The equipment fault handling module, the health online diagnosis module, and the preventive maintenance plan scheduling module can all output plans for repairing and maintaining the equipment. The difference is that the maintenance plan output by the equipment fault handling module has the highest priority, the maintenance plan output by the health online diagnosis module has the second highest priority, and the maintenance plan output by the preventive maintenance plan scheduling module has the third highest priority.
[0051] There are N devices that need to be maintained. For the convenience of description and without loss of generality, the N devices are numbered from 1 to N, and the set of N devices is denoted by Φ. The risk value and rated maintenance duration of the i-th device are ai and ti respectively, where i ∈ {1, 2, …, N}.
[0052] Arrange the equipment maintenance plan in cycles. The cycle is M days, where M is any positive integer and can be set in the system.
[0053] Example 1:
[0054] The normal working hours of maintenance personnel within the current plan cycle is D. The system provides a setting function for this value, and it can also be imported from the human resources system or the scheduling system through an interface.
[0055] At the zero moment of the current plan cycle, determine the equipment to be maintained in the current period according to the following steps (as Figure 2 shown). Their numbers form the maintenance plan for this cycle:
[0056] S1. Obtain the equipment that needs to be repaired in the current maintenance cycle from the fault handling module. There are N1 such devices in total, forming a set Φ1, and the sum of their rated maintenance durations is D1.
[0057] If D1 ≥ D, then the equipment to be maintained in the current period is Φ1; if D1 < D, then execute S2.
[0058] S2. For the devices with an online Internet of Things connection established, the data during their operation is collected by the device operation data collection module. Based on the real-time data of the device operation, the device health online diagnosis module determines whether the device needs maintenance through a pre-established diagnosis model.
[0059] Outside the set Φ1, all the devices determined by the device health online diagnosis module to need maintenance in the current maintenance cycle form a set Φ2. The number of its elements is denoted as N2, and the sum of the rated maintenance durations of these N2 devices is D2.
[0060] If D1 + D2 ≥ D, then the equipment to be maintained in the current period is Φ1 ∪ Φ2; if D1 + D2 < D, then execute S3.
[0061] S3. Compile the maintenance plan for the device set
[0062] S3-1. For the devices in Φ3, update the device data at the zero moment of the current period. For each device, the updated data includes at least:
[0063] (1) Cumulative working hours. According to the actual situation, the equipment is counted in "hours", "days" or other time units (decimals can be retained);
[0064] (2) The total time since the last maintenance of the equipment;
[0065] Optionally include:
[0066] (3) Data reflecting the load intensity during the use of the equipment;
[0067] (4) Load intensity during equipment use within the past time window;
[0068] (5) Environmental parameter values that affect equipment performance, such as temperature, humidity, and the content of solid particles in the air, collected or recorded within the past time window.
[0069] S3-2. According to the equipment health evaluation model and the data of step S3-1, an evaluation value of the health of each equipment is obtained.
[0070] S3-3. According to the health assessment value and the importance of the equipment, the failure risk value of each equipment is obtained in the equipment risk assessment module.
[0071] S3-4, in the preventive maintenance plan arrangement module, the equipment to be maintained in this maintenance cycle is selected in Φ3, and the set is Θ, based on the principle of selecting the equipment set with the largest sum of risk values and the sum of the rated maintenance time of the equipment in the set not exceeding D-D1-D2. At this point, the selection of all maintenance objects in this maintenance cycle is realized.
[0072] S4. Repair or maintain the equipment in the set Φ1∪Φ2∪Θ.
[0073] S5. Write the maintenance time, effect and other data required for equipment management into the equipment record module. For equipment that is repaired due to a fault, the data is fed back to the fault handling module at the same time.
[0074] Example 2:
[0075] There are K maintenance personnel in this planning period. Through the interface of the scheduling system, their working shift durations are obtained as D(k), k∈{1,2,…,K}.
[0076] For the first maintenance personnel (k=1), facing the entire equipment set Φ, based on the shift duration D(k)|k=1, use steps S1-S3 of Example 1 to obtain the set of equipment he is responsible for maintaining this period (denoted as Ψ1).
[0077] Then, for the second maintenance personnel (k=2), facing the equipment set Φ-Ψ1, based on the shift duration D(k)|k=2, the steps S1-S3 of Example 1 are used to obtain the set Ψ2 of equipment that he is responsible for maintaining during this period.
[0078] Next, for the third maintenance personnel (k=3), facing the equipment set Φ-Ψ1-Ψ2, based on the shift duration D(k)|k=3, the S1-S3 steps of Example 1 are used to obtain the set Ψ3 of equipment that he is responsible for maintaining during this period.
[0079] And so on, until the set ΨK of equipment that the Kth maintenance personnel is responsible for maintaining in this period is obtained. K maintenance personnel repair or maintain the equipment in the equipment set Ψk that they are responsible for. The personnel who repair or maintain, the time, the effect, and other data required for equipment management are all written into the equipment ledger module. For equipment that is repaired due to a fault, data is also fed back to the fault handling module.
Claims
1. Equipment maintenance method based on risk priority strategy, characterized in that: This method is implemented by a maintenance system composed of the following modules: including an equipment ledger module, an equipment health assessment module, an equipment risk evaluation module, an equipment operation data collection module, an equipment health online diagnosis module, a fault handling module, a preventive maintenance plan scheduling module, and a maintenance execution module; The equipment ledger module is used to query and manage equipment data, including data related to production, installation and commissioning, commissioning, previous operations, and previous maintenance and repairs; The equipment health assessment module is used to evaluate the current health status of the equipment; The equipment risk evaluation module is used to evaluate the magnitude of the risk caused by equipment failures; The higher the probability of a fault occurring, the greater the risk; The equipment operation data collection module receives and stores real-time monitoring data of equipment operation; The equipment health online diagnosis module analyzes and judges the health status of the equipment online through a diagnosis model; The equipment fault handling module is used to manage equipment faults, schedule and dispatch the faults to be processed; The preventive maintenance plan scheduling module is used to generate a list of equipment for preventive maintenance; The maintenance execution module is used to notify equipment maintenance personnel of work tasks, track the progress of maintenance work, and feedback the completion status of the work; Among them, The equipment fault handling module, the health online diagnosis module, and the preventive maintenance plan scheduling module can all output plans for equipment repair and maintenance; the difference is that the repair plan output by the equipment fault handling module has the highest priority, the maintenance plan output by the health online diagnosis module has the second highest priority, and the maintenance plan output by the preventive maintenance plan scheduling module has the third highest priority; There are N equipment that all need maintenance; for the convenience of description and without loss of generality, the N equipment are numbered from 1 to N, and the set of N equipment is represented by Φ; the risk value and rated maintenance duration of the i-th equipment are ai and ti respectively, i ∈ {1, 2,..., N}; The equipment maintenance plan is scheduled by cycle; the cycle is M days, and M is any positive integer that can be set in the system; The normal working hours of maintenance personnel within the planned cycle are D; At the zero moment of the planned cycle, the following steps are taken to determine the equipment to be maintained in this period, and their numbers form the maintenance plan for this cycle: S1. Obtain the equipment that needs to be repaired in this maintenance cycle from the equipment fault handling module; there are N1 such equipment, which form a set Φ1, and the sum of the rated maintenance durations is D1; If D1 ≥ D, then the equipment to be maintained in this period is Φ1; if D1 < D, then execute S2; S2. For equipment with an online Internet of Things connection established, the data during its operation is collected by the equipment operation data collection module; based on the real-time data of equipment operation, the equipment health online diagnosis module determines whether the equipment needs maintenance through a pre-established diagnosis model; Outside the set Φ1, all the equipment determined by the equipment health online diagnosis module to need maintenance in this maintenance cycle form a set Φ2, the number of its elements is denoted as N2, and the sum of the rated maintenance durations of these N2 equipment is D2; If D1 + D2 ≥ D, the equipment to be maintained this period is Φ1 ∪ Φ2; if D1 + D2 < D, then execute S3; S3-1. For the devices in Φ3, update the device data at zero o'clock in this period; for each device, the updated data includes at least: (1) Cumulative working hours; according to the actual situation, the equipment is counted in "hours", "days" or other time units; (2) The total duration since the last maintenance of the equipment; (3) Data reflecting the load intensity during the use of the equipment; (4) The load intensity during the use of the equipment within the past time window; (5) The environmental parameter values that affect the equipment performance collected or recorded within the past time window; S3-2. Obtain the evaluation value of the health of each equipment according to the equipment health evaluation model and the data in step S3-1; S3-3. Obtain the failure risk value of each equipment in the equipment risk evaluation module according to the health evaluation value and the importance of the equipment; S3-4. In the preventive maintenance plan scheduling module, select the equipment to be maintained during this maintenance period from Φ3 with the principle of selecting a set of equipment with the largest possible sum of risk values and the sum of the rated maintenance durations of the equipment in the set not exceeding D - D1 - D2, and the set is Θ; thus, the selection of all maintenance objects in this maintenance period is realized; S5. Write the time and effect of maintenance and other data required for equipment management into the equipment record module; for equipment that is being repaired due to a fault, the data is also fed back to the fault handling module.