Equipment inspection system and equipment inspection method

Abstract

An equipment inspection system and an equipment inspection method using a portable terminal that can prevent operators from missing inspections. The equipment inspection system comprises: a host computer that stores information related to the inspection of industrial machinery; at least one information medium that is installed in the industrial machinery and includes information corresponding to the inspection items of the industrial machinery; a reading device that reads the information medium; and at least one portable terminal that has a display unit for displaying inspection items corresponding to the information on the information medium read by the reading device, an input unit for operators to input inspection results of the displayed inspection items, and a communication unit that can communicate the input inspection results to the host computer.

Description

Technical Field

[0001] The present invention relates to a system and method for performing equipment inspection using a portable terminal such as a tablet device. Background Art

[0002] Generally speaking, in a machine factory where industrial machines such as industrial robots and CNC machine tools are installed, maintenance inspections of the industrial machines are performed by operators. As related prior arts, a system for assisting the inspection of equipment in a shop and a technology for downloading safety survey items of LP gas consuming equipment and supplying equipment are known (see Japanese Patent Application Publication No. 2006-048584 and Japanese Patent Application Publication No. 2014-021629).

[0003] In many cases, there are multiple industrial robots, CNC machine tools and other industrial machines in a machinery factory. For each industrial machine, operators perform regular inspections on each industrial machine. Usually, there are multiple inspection items for one industrial machine, and the inspection cycle for each inspection item is different. Therefore, it is a great burden for operators (inspectors) to confirm these inspection items without omission. Summary of the invention

[0004] One embodiment of the present disclosure is an equipment inspection system, which includes: a main computer that stores information related to the inspection of industrial machinery; at least one information medium that is installed on the industrial machinery and includes information corresponding to the inspection items of the industrial machinery; a reading device that reads the information of the information medium; and at least one portable terminal that has a display unit for displaying the inspection items corresponding to the information read by the reading device, an input unit for allowing an operator to input the inspection results of the inspection items displayed on the display unit, and a communication unit that can communicate the input inspection results to the main computer.

[0005] Another embodiment of the present invention is an equipment inspection method, which includes: accumulating information related to the inspection of industrial machinery in a main computer; installing at least one information medium including information corresponding to the inspection items of the industrial machinery on the industrial machinery; reading the information medium; displaying the inspection items corresponding to the read information medium on a portable terminal; and communicating the inspection results of the inspection items input into the portable terminal by an operator to the main computer. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The purpose, features and advantages of the present invention will become more apparent from the following description of the embodiments in conjunction with the accompanying drawings.

[0007] Figure 1 It is a diagram showing a configuration example of a device inspection system according to an embodiment.

[0008] Figure 2 This is a block diagram showing a structural example of a portable terminal.

[0009] Figure 3 Yes means Figure 1 A diagram of an example of a network configuration in a device inspection system.

[0010] Figure 4 It is a flowchart showing the process of equipment inspection.

[0011] Figure 5 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0012] Figure 6 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0013] Figure 7 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0014] Figure 8 This is a diagram showing an example in which a plurality of two-dimensional codes are provided for a machine tool.

[0015] Fig. 9 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0016] Fig.10 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0017] Fig.11 This is a diagram showing an example of a screen display of a tablet device during equipment inspection work.

[0018] Fig.12 This is a diagram showing an example of maintenance inspection items in a table format.

[0019] Fig.13 This is a diagram showing an example of storage of inspection result data in a host computer. DETAILED DESCRIPTION

[0020] Figure 1 is a diagram showing a configuration example of a device inspection system according to an embodiment of the present disclosure, Figure 21 is a functional block diagram of a portable terminal used in the equipment inspection system. The equipment inspection system 10 comprises: a host computer (server) 16 that stores information related to the inspection of at least one industrial machine 14 installed in a machine factory (schematically illustrated by a dotted line 12); at least one information medium 18 that is installed in the industrial machine 14 and includes information corresponding to the inspection items of the industrial machine 14; a reading device 20 that reads the information medium 18; and at least one portable terminal 28 that has a display unit 22 such as a liquid crystal screen for displaying the inspection items corresponding to the information on the information medium 18 read by the reading device 20, an input unit 24 such as a touch panel or a keyboard that allows an operator to input the inspection results of the inspection items displayed on the display unit 22, and a communication unit 26 that can communicate (usually wirelessly) the input inspection results to the host computer 16.

[0021] The portable terminal 28 is, for example, a tablet device or a smartphone, and has a shape and weight that can be easily held by a worker moving in the machine factory 12. The portable terminal 28 may also include a CPU or other processing unit 30 and a memory or other storage unit 32 for executing the processing described below. In addition, the reading device 20 has, for example, a camera 34 (in Figure 1 ), the camera 34 is mounted on the portable terminal 28 and is configured to be able to photograph the information medium 18, and the reading device 20 can read the information of the information medium 18 by performing image processing on the image photographed by the camera.

[0022] Here, as examples of the information medium 18, two-dimensional codes such as QR code (registered trademark), one-dimensional codes such as barcodes, and ID tags such as RFID (Radio Frequency Identification) can be cited. In addition, as a reading device for the information medium 18, a camera provided on the tablet device 28, a barcode reader, an RFID reader, etc. can be cited. In addition, if a tablet device is used as the portable terminal 28 and a camera mounted on the tablet device is used as the reading device 20, the operator does not need to hold the portable terminal and the reading device separately, which can reduce the burden on the operator.

[0023] Figure 31 is a diagram showing an example of a network structure in an equipment inspection system 10. A host computer 16, industrial machinery 14, sensors 38, PLC (Programmable Logic Controller) 40, and access points 42 are connected to a network 36 such as a factory LAN, and a portable terminal 28 such as a tablet device can communicate wirelessly with the host computer 16. In addition, data such as the operating status of the industrial machinery 14, sensors 38, and PLC 40 can be sent to the host computer 16 via the network 36. By utilizing this network structure, data related to the operating status and inspection status of all equipment in the machinery factory 12 can be viewed at a glance, and analysis / parsing of the data can also be easily performed. In addition, in the event that an inspection item is omitted, the inspection item can be easily determined, and by notifying the inspection omission to the management personnel and the like by the host computer 16, the following operations can also be performed: the management personnel can provide guidance / instructions to the responsible operator to perform the inspection.

[0024] In addition, if Figure 1 As shown, one or more client computers 44 such as personal computers may also be connected to the network 36. Figure 1 In the embodiment, the host computer 16 and the personal computer 44 are installed outside the machine factory 12 , but they may be installed inside the machine factory 12 .

[0025] like Figure 3 As shown, the industrial machine 14 includes at least one main machine 46. The "main machine" in the present disclosure refers to a machine / device in the industrial machine installed in the machine factory 12 that can perform machining, transportation and other operations independently of other machines. As a specific example, the main machine 46 can be listed. Figure 1 The machine tools 48 such as NC machine tools and the industrial robot 50 described in the specification may also include manufacturing machines, processing machines, conveyors, and cranes (not shown).

[0026] In addition, the industrial machine 14 may also include peripheral machines 52. The "peripheral machines" in the present disclosure refer to machines used in conjunction with the main machine 46, such as a supply device for supplying cooling water and lubricating oil to the main machine 46, a mist collector for collecting oil mist generated from a machine tool 48, etc., among the industrial machines installed in the machine shop 12.

[0027] Next, refer to Figure 4 Flowchart and Figure 5-Figure 13 The process of the equipment inspection in this embodiment will be described. Here, a case where a tablet device is used as the portable terminal 28 and a camera mounted on the tablet device is used as the reading device 20 will be described.

[0028] First, before the operator performs the inspection, information related to the equipment inspection (maintenance inspection) of the industrial machinery 14 in the machine factory 12 is stored / accumulated in the host computer (server) 16 (step S1). Figure 5 As shown, the operator 54 (only a finger is shown) holds the portable terminal (here, a tablet device) 28 and uses the input unit 24 such as the numeric keys displayed on the display unit (screen) 22 of the tablet device 28 to input a number for identifying the operator such as an employee number (step S2). In addition, step S2 may be omitted, or other processing such as fingerprint authentication may be used to identify the operator.

[0029] In the following step S3, Figure 6 As shown, a menu 55 for selecting equipment (or a cell including a plurality of such equipment) included in the machine factory is displayed on the display unit 22 of the tablet device 28, and then the operator selects the equipment to be inspected (here, the main equipment or the peripheral equipment) by touching the screen. In step S3, a cell (processing cell, etc.) including a plurality of equipment may be selected from the menu 55. When a cell is selected, the progress of the inspection may be displayed on the tablet device 28 for each of the equipment included in the cell.

[0030] When the device to be inspected is selected, Figure 7 As shown, the maintenance inspection items to be inspected in the selected inspection object are displayed. In addition, it can also be set that at this time, the host computer 16 sends information such as whether each inspection item has been inspected, has not been inspected, or does not need to be inspected at the current time point to the tablet device 28, and the information is displayed in different colors so that the operator can identify it. Therefore, the operator can easily understand the accurate progress of the inspection of the equipment selected in step S2 at this time point.

[0031] like Figure 7 As shown, when the inspection target device is selected, an instruction (e.g., camera mark 58) prompting acquisition of information on an information medium such as a two-dimensional code installed on the inspection target is displayed on the display unit 22 of the tablet device 28. Then, as shown in FIG. Figure 8 As shown in the example, the operator moves to a position where the information medium (here, a two-dimensional code) 18 installed on the selected inspection target equipment (here, set as the machine tool 48) can be photographed by the camera of the tablet device 28 (step S4), and photographs the two-dimensional code 18 by the camera. As a result, the tablet device 28 can read the information of the two-dimensional code (step S5). In addition, the processing of reading information from the acquired image of the two-dimensional code can be performed by using the CPU in the tablet device 28, or the acquired image can be sent to the host computer 16, and the reading processing is performed in the host computer 16, and the reading result is sent to the tablet device 28.

[0032] Here, if the device selected in step S3 is different from the device corresponding to the photographed two-dimensional code (the two-dimensional code is installed), the information of the two-dimensional code is prioritized. In addition, if two two-dimensional codes 18 are captured in the field of view of the camera and the information of the two-dimensional code cannot be correctly read, a display (such as an "×" mark 60) for conveying this meaning to the operator can also be displayed on the display unit 22.

[0033] Here, the two-dimensional code 18 is associated with the inspection items (maintenance inspection items) of the inspection object equipment, and by reading the two-dimensional code 18, as shown in FIG. Fig. 9 As shown, the inspection items and inspection contents corresponding to the read two-dimensional code are displayed on the tablet device 28 (step S6). Here, as an example, an instruction to check whether the oil amount (spindle cooling oil amount) for cooling the spindle of the machine tool is normal is displayed as a maintenance inspection item.

[0034] Here, as a means for measuring the amount of oil, a first area 62 (see Figure 8 ) in the float type liquid level gauge 64. In this case, as a maintenance inspection, the operator uses the tablet device 28 to photograph the liquid level gauge 64 in a manner that at least the position (oil amount) of the float of the liquid level gauge 64 can be identified (step S7), and the photographing result is input / displayed on the tablet device 28 (step S8). In addition, if the oil amount is less than the specified amount, the operator also replenishes the cooling oil and inputs the replenished amount into the tablet device 28 (steps S7-S8).

[0035] At this time, if Fig. 9 As shown, the image (data) obtained by photographing the same level gauge 64 in the past (normal time) and stored in the host computer 16 can also be received from the host computer 16 and displayed on the screen. In this case, the operator can easily determine whether the current oil volume is within the normal range by comparing the past image with the image obtained this time (specifically, the position of the float of the level gauge 64). In addition, if the memory of the tablet device 28 has enough space, the past data can also be saved in the memory. In this case, it is not necessary to receive the past data from the host computer 16.

[0036] As another method of measuring the oil amount, the operator may directly read the scale (position of the float) of the liquid level gauge 64 and input the read value (numerical value) as the inspection result into the tablet device 28. In this case, if the image or input data of the past liquid level gauge is displayed on the screen, the operator can judge whether the current oil amount is within the normal range by comparing the past data (image) with the data input this time.

[0037] The maintenance inspection result (image or input value, etc.) input by the operator is sent from the communication unit 26 of the tablet device 28 to the host computer (server) 16 (step S9), and the host computer 16 accumulates the sent data as the maintenance inspection result. The accumulated data can also be browsed from other terminals 44 connected to the network 36. Therefore, the accumulated data can be obtained not only from the site but also from an office far away from the site, and analysis based on the acquired data can be performed.

[0038] The processing of steps S4 to S9 is repeated until there are no unchecked items (step S10). In this way, all the check items can be checked without omission.

[0039] Fig.13 An example of displaying the inspection history based on the inspection results is shown, specifically, the inspection results related to the liquid level meter 64 accumulated in the host computer 16 are shown. In this example, by displaying the specific inspection contents (the photographing results of the liquid level meter, the amount of oil replenishment, etc.) of each inspection item in a time series, if there is an inspection omission, the name of the inspection item, the time, etc. can be easily grasped. In this way, in the host computer 16, the inspection results can be automatically summarized and analyzed, and the results can also be browsed from other terminals 44 via the network 36.

[0040] Figure 8 An example is shown in which a main machine such as a machine tool 48 has multiple inspection items and each inspection item corresponds to one QR code. For example, in addition to the liquid level gauge 64, the first area 62 in the machine tool 48 also has devices / measuring machines corresponding to four inspection items. Examples of inspection items include whether there is oil leakage near the first area 62, and confirmation of the value of the pressure gauge installed in the first area 62. Figure 8 In the example of , the operator must use the tablet device 28 to capture the QR code corresponding to one inspection item before performing the inspection corresponding to the inspection item. In other words, it can be set that if the operator does not obtain the information of the information medium 18 installed in the industrial machinery to be inspected, the inspection item corresponding to the information will not be displayed, and if the inspection item is not displayed, the inspection result corresponding to the inspection item cannot be input to the tablet device.

[0041] For example, Fig.10 This is an example of a display when a QR code corresponding to the oil leak is photographed. The operator visually determines whether the oil leak is normal or abnormal (suspected oil tank damage, etc.), or is not abnormal but in a state where the floor needs to be cleaned, etc., and inputs (selects) the judgment result from menu 66 as the maintenance inspection result.

[0042] in addition, Fig.11This is a display example when the two-dimensional code corresponding to the pressure gauge is photographed, and the operator reads the value of the pressure gauge and inputs the read value using the input unit 24 such as the numeric keys displayed on the screen.

[0043] As such, there are many inspection items for industrial machinery, and many of them can be measured / judged by operators on site through visual inspection. However, even for inspection items that can be automatically measured using sensors and can automatically send the measured data to a server on a regular basis (in other words, basically no operator visual inspection / confirmation is required), operators can use other measuring instruments to calibrate the sensor on site and judge whether there is a fault, so such inspection items are sometimes included. For example, the concentration of cutting oil can be monitored at all times using sensors, but operators can also go to the site to sample the cutting oil and measure the concentration using a handheld concentration meter to check whether the sensor is operating normally. In general, by regularly taking data such as the temperature of the working oil that indicates abnormalities in the equipment, appropriate measures can be taken before the equipment fails, and even if the equipment does not fail, by regularly taking data such as the cutting oil concentration that may cause poor processing, poor processing can be prevented in advance and the production efficiency of the equipment can be improved.

[0044] Fig.12 An example of inspection items for industrial machinery is shown. Usually, there are multiple inspection items for one device, and even for the same device, the inspection locations corresponding to each inspection item are different. Figure 8 As shown, when there are five inspection items that can be inspected in the first area 62 or near the first area 62, and on the other hand, there are three inspection items that can be inspected in the second area 68 or near the second area 68, it is preferred to set five QR codes 18a near the first area 62 of the machine tool 48 and three QR codes 18b near the second area 68. Fig.12 Such information (data) related to maintenance and inspection of industrial machinery is pre-stored in the host computer, and part of the information is sent to the tablet device 28 as inspection items and inspection contents (inspection operations) corresponding to the information medium, thereby enabling only the information required for inspection to be displayed in the tablet device 28.

[0045] The information medium such as the QR code attached to each device is not used to identify / determine the device itself, but is associated with the inspection items in the device and is used to display the inspection items to the operator. Therefore, it is preferred to set an information medium such as a QR code for each inspection item. In this way, the information medium must be read before each item is detected. Therefore, compared with the case where all the inspection items of the device are displayed by reading an information medium attached to a device, the operator also finds it troublesome.

[0046] However, if all inspection items in a device are listed in one process, it may lead to inspection omissions, operators mistakenly entering (inputting) inspection results, or operators slacking in moving to the specified location, just like the conventional method of recording inspection results on inspection sheets (checklists). Omissions or incorrect input of inspection items may lead to overlooking equipment abnormalities, and sometimes leaving them unattended may cause major problems such as production line stoppages, which in turn places a greater burden on operators.

[0047] Therefore, in this embodiment, the operator is required to read the information medium corresponding to each inspection item before performing the inspection operation corresponding to the inspection item, so that the operator can clearly realize the inspection operation to be performed, thereby greatly reducing the risk of inspection omission and erroneous input compared with the past. In addition, by setting the information medium near the object (liquid level gauge, pressure gauge, etc.) of the inspection item corresponding to the information medium, the operator can inspect the inspection object (inspection item) at a position almost the same as the position where the information medium is read (for example, using a tablet device to shoot a QR code), so it can also prevent the operator from inputting the inspection result even though the operator has not actually performed the inspection (imagination, etc.).

[0048] As mentioned above, in many cases, there are multiple inspection items for industrial machinery, such as Figure 8 As shown in the figure, each inspection item is carried out in a different place, and as Fig.12 As shown in FIG. 1 , the inspection cycle of each inspection item is also different, so for the main machines including at least one of the machine tools and industrial robots, it is preferred to make one information medium correspond to one inspection item. However, for the oil temperature control device and the air dryer (see Fig.12 ) and other peripheral devices, the inspection items often include multiple items that can be immediately judged by the five senses of the operator, such as abnormal sounds and the presence or absence of vibration. Even in such cases, it is sometimes inappropriate for the operator to read one information medium for one inspection item. Therefore, for peripheral devices, multiple inspection items (especially items that can be judged by the five senses) can also correspond to one information medium.

[0049] In addition, in the present disclosure, a program for causing the host computer or portable terminal to perform a process other than the process performed by the operator in the above-mentioned process can be stored in the host computer or portable terminal. For example, the program is a program for causing the portable terminal to perform the following process: causing the display unit of the portable terminal to display an inspection item corresponding to the information of the information medium read by the reading device, and if the operator inputs the inspection result corresponding to the inspection item into the input unit, the communication unit sends the inspection result to the host computer. In addition, such a program can also be provided as a computer-readable recording medium (CD-ROM, USB memory, etc.) recording the program.

[0050] According to the present disclosure, it is possible to prevent workers from missing inspection items of industrial machinery, thereby improving the reliability and operation efficiency of the industrial machinery.

Claims

1. An equipment inspection system, comprising: a host computer that stores information related to inspection of industrial machinery; at least one information medium installed in the industrial machine and including information corresponding to an inspection item of the industrial machine; a reading device for reading information from the information medium; as well as at least one portable terminal having a display unit for displaying the inspection items corresponding to the information read by the reading device, an input unit for allowing an operator to input inspection results of the inspection items displayed on the display unit, and a communication unit capable of communicating the input inspection results to the host computer, Wherein, the display unit is constituted as follows: Displays a menu for operators to select the equipment to be inspected. When the inspection object device selected by the operator from the menu is different from the device corresponding to the information read by the reading device, the inspection items of the selected inspection object device are not displayed, but the inspection items corresponding to the information read by the reading device are displayed. The display unit displays the inspection items corresponding to the information only when the information of the information medium is read by the reading device, and when the display unit does not display the inspection items, the operator cannot input the inspection results corresponding to the inspection items using the input unit. The industrial machine includes at least one main machine and a peripheral machine used in conjunction with the main machine, the main machine is equipped with a plurality of information media, the plurality of information media include information corresponding to different inspection items, each of the plurality of information media installed in the main machine includes information corresponding to one inspection item, At least one of the information media is installed in the peripheral device, and each of the information media installed in the peripheral device includes information corresponding to a plurality of inspection items.

2. The equipment inspection system according to claim 1, characterized in that: The main machine includes at least one of a machine tool and an industrial robot.

3. The equipment inspection system according to claim 1, characterized in that: The information medium is a two-dimensional code, and the reading device includes a camera provided in the portable terminal.

4. The equipment inspection system according to claim 1, characterized in that: The display unit is configured to be able to display the input inspection result and past inspection results of inspection items corresponding to the inspection result.

5. A device inspection method, comprising: storing information related to the inspection of industrial machinery in a host computer; installing at least one information medium including information corresponding to the inspection items of the industrial machine in the industrial machine; Displaying a menu for an operator to select a device to be inspected; reading the information medium; When the inspection target device selected by the operator from the menu is different from the device corresponding to the read information, the inspection items corresponding to the read information are displayed instead of the inspection items of the selected inspection target device; Displaying the inspection items corresponding to the read information medium on the portable terminal; as well as communicating the inspection result of the inspection item input into the portable terminal by the operator to the host computer, The portable terminal displays the inspection items corresponding to the information only when the information of the information medium is read, and when the portable terminal does not display the inspection items, the operator cannot input the inspection results corresponding to the inspection items using the portable terminal. The industrial machine includes at least one main machine and a peripheral machine used in conjunction with the main machine, the main machine is equipped with a plurality of information media, the plurality of information media include information corresponding to different inspection items, each of the plurality of information media installed in the main machine includes information corresponding to one inspection item, At least one of the information media is installed in the peripheral device, and each of the information media installed in the peripheral device includes information corresponding to a plurality of inspection items.

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