Maintenance management system for work machine

Abstract

The present disclosure provides a work machine maintenance management system capable of predicting a replacement timing of a component of a work machine earlier. The work machine maintenance management system of the present disclosure includes a maintenance management DB server 110 that accumulates maintenance management information of a plurality of work machines, and a maintenance management control device 120 that predicts a replacement timing for a component of each work machine based on the maintenance management information. The maintenance management information contains an actual service life period of each component of each work machine from use start to replacement. The maintenance management control device 120 has a replacement cause determination section 121, a life model creation section 122, a failure model creation section 123, and a replacement timing prediction section 126. The replacement cause determination section 121 determines a replacement cause of each component as a life cause or a failure cause based on the actual service life period of each component of the plurality of work machines. The life model creation section 122 creates a life model of a component whose replacement cause is determined as the life cause by the replacement cause determination section 121. The failure model creation section 123 creates a failure model of a component whose replacement cause is determined as the failure cause by the replacement cause determination section 121. The replacement timing prediction section 126 predicts a component replacement timing of each work machine based on the life model and the failure model.

Description

Technical Field

[0001] This invention relates to a maintenance and management system for construction machinery. Background Technology

[0002] Monitoring / diagnostic systems for mechanical parts with rotating bodies are known in the past (Patent Document 1 below). The monitoring / diagnostic system for mechanical parts described in Patent Document 1 includes a sensor, a sensor information transmitting unit, a sensor information receiving unit, a diagnostic unit, a diagnostic result information transmitting unit, and a diagnostic result information receiving unit (claim 1, paragraph 0005). Figure 3 ).

[0003] The aforementioned sensors detect factors related to the lifespan of mechanical components assembled in the machinery of a customer company's sales office. The aforementioned sensor information transmitting unit transmits the information detected by the sensors, or information obtained by processing that information (i.e., sensor information), to the circuit. The aforementioned sensor information receiving unit is located in the sales office of the company that manufactures and sells the aforementioned mechanical components and receives the sensor information transmitted via the aforementioned circuit.

[0004] The diagnostic unit diagnoses the lifespan of the mechanical component based on sensor information received by the sensor information receiving unit. The diagnostic result information sending unit transmits the diagnostic result information from the diagnostic unit to the line. The diagnostic result information receiving unit is located at the customer company's branch office and receives the diagnostic result information transmitted to the line.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2001-356808 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] Compared to general-purpose machinery, large-scale construction machinery tends to have longer lead times from parts order to delivery due to its smaller production volume and larger number of parts produced to order. This tendency is particularly pronounced in very large-scale construction machinery used in operations such as mining. Therefore, even if parts replacement periods are predicted, there is a possibility that the machinery may cease operation before the replacement period can be delivered. Thus, earlier prediction of parts replacement periods for construction machinery is required.

[0010] This disclosure provides a maintenance management system for operating machinery that can predict the replacement period of operating machinery components earlier.

[0011] Methods for solving problems

[0012] One aspect of this disclosure is a maintenance management system for work machinery, comprising: a maintenance management database server storing maintenance management information for multiple work machinery; and a maintenance management control device that predicts replacement periods for each component of each work machinery based on the maintenance management information. The maintenance management system is characterized in that the maintenance management information includes the actual service life of each component of each work machinery from the start of use to replacement. The maintenance management control device includes: a replacement cause determination unit that determines the replacement cause of each component as either a lifespan-related cause or a failure cause based on the actual service life of each component of the multiple work machinery; a lifespan model creation unit that creates a lifespan model for components whose replacement cause is determined by the replacement cause determination unit to be a lifespan-related cause; a failure model creation unit that creates a failure model for components whose replacement cause is determined by the replacement cause determination unit to be a failure cause; and a replacement period prediction unit that predicts the replacement period for each component of each work machinery based on the lifespan model and the failure model.

[0013] Invention Effects

[0014] According to one of the solutions disclosed above, a maintenance management system for operating machinery can be provided that can predict the replacement period of operating machinery parts earlier. Attached Figure Description

[0015] Figure 1 This is a schematic diagram illustrating an embodiment of the maintenance management system for the operating machinery of this disclosure.

[0016] Figure 2 yes Figure 1 Functional block diagram of the maintenance management system, including the maintenance management database server and maintenance management control device.

[0017] Figure 3 It is shown Figure 2 A flowchart of the process for determining the cause of replacement of the maintenance and management control device.

[0018] Figure 4 It is shown Figure 2 The flowchart of the life model creation process for the maintenance and management control device.

[0019] Figure 5 It is shown Figure 2 A flowchart of the fault model creation process for the maintenance and management control device.

[0020] Figure 6 It is shown Figure 2 A flowchart of the operation model creation process for the maintenance and management control device.

[0021] Figure 7 It is shown Figure 2 A flowchart of the process for predicting the replacement period of the maintenance and management control device.

[0022] Figure 8 It is shown Figure 2 A flowchart of the total number of replacements for the maintenance and management control device.

[0023] Figure 9 It is shown Figure 2 A table showing an example of the total number of replacements of maintenance and management control devices.

[0024] Figure 10 It is shown Figure 2 A flowchart of the order period prediction process for the maintenance management control device.

[0025] Figure 11 This is an explanation Figure 10 The table is processed by the order period forecasting department.

[0026] Figure 12 This is an explanation Figure 2 The standardized ordering department processes tables and charts for the maintenance and management control devices. Detailed Implementation

[0027] The following describes an embodiment of the maintenance management system for the operating machinery disclosed herein, with reference to the accompanying drawings.

[0028] Figure 1 This is a schematic diagram showing the overall configuration of an embodiment of the maintenance management system for construction machinery of this disclosure. The maintenance management system 100 of this embodiment is a system for performing maintenance management of construction machinery 10, such as hydraulic excavators. The construction machinery 10, which is the object of maintenance management by the maintenance management system 100, is not limited to hydraulic excavators, but may include, for example, wheel loaders, road machinery, dump trucks, boom lifts, etc.

[0029] The maintenance management system 100 mainly includes: a maintenance management database server 110 (hereinafter referred to as the maintenance management DB server 110), which stores maintenance management information for multiple operating machines 10; and a maintenance management control device 120, which predicts the replacement period for each component of each operating machine 10 based on the maintenance management information. It should be noted that... Figure 1 The diagram shows only one of the multiple operating machines 10. The maintenance management DB server 110 and maintenance management control device 120 are located, for example, in the maintenance management center 20. It should be noted that the location of the maintenance management DB server 110 and maintenance management control device 120 is not particularly limited, and can be located, for example, at the manufacturer 30, seller 40 or parts supplier 50 of the operating machine 10.

[0030] The operating machinery 10 has multiple parts that need to be replaced. Figure 1 In the example shown, the work machine 10 is a hydraulic excavator, including a multi-joint front-end machine 11, a traveling body 12 driven by a hydraulic motor, and an upper rotating body 13 that rotates above the traveling body 12. The front-end machine 11 includes: a boom 11a, which is connected to the upper rotating body 13 and driven by a boom cylinder 14; a stick 11b, which is connected to the boom 11a and driven by a stick cylinder 15; and a bucket 11c, which is connected to the stick 11b and driven by a bucket cylinder 16.

[0031] Additionally, the work machine 10 includes, for example, a controller 17 and a communication unit (not shown). The controller 17, for example, is a microcontroller comprising an input / output unit, a central processing unit (CPU), a memory, a timer, etc., which controls various parts of the work machine 10 and acquires various information related to the work machine 10. The communication unit is connected to the maintenance management DB server 110, for example, via wireless communication lines and wired communication lines. The wireless communication lines can be, for example, satellite communication lines via communication satellite 60 and ground station 70, or conventional wireless communication lines via terrestrial wireless base stations.

[0032] The controller 17 acquires operating information of the work machine 10 from sensors installed on various parts of the work machine 10, for example. Furthermore, the controller 17 transmits the operating information and attribute information of the work machine 10 to the maintenance management DB server 110 via, for example, a communication device, a wireless communication line, and a wired communication line. Here, the operating information of the work machine 10 acquired by the controller 17 includes, for example, the cumulative usage time of the work machine 10 measured by a timer. Additionally, the operating information of the work machine 10 includes, for example, at least one of the following: cumulative travel time, cumulative turning time, cumulative digging time, fuel consumption, air intake, engine oil level, coolant level, hydraulic pump discharge flow rate and discharge pressure, working oil temperature, and working oil pressure in the hydraulic cylinder. Furthermore, the attribute information of the work machine 10 includes, for example, at least one of the following: machine type, model number, identification number, user information, and location information.

[0033] The controller 17 is connected to the maintenance terminal 80, for example, via a wireless or wired communication line, and sends the operating information of the machine 10 to the maintenance terminal 80. The maintenance terminal 80, for example, includes a portable terminal such as a smartphone, tablet PC, or laptop PC, and sends the operating information obtained from the machine 10 to the maintenance management DB server 110 via a wireless or wired communication line. The maintenance terminal 80 is used, for example, by the seller 40 of the machine 10 or maintenance personnel at a service center. In cases where wireless communication between the controller 17 of the machine 10 and the maintenance management DB server 110 is difficult, the operating information of the machine 10 can be sent to the maintenance management DB server 110 via the maintenance terminal 80.

[0034] The maintenance and management DB server 110 can connect to multiple terminals 31, 41, and 51 via communication lines such as the Internet in a manner that enables information communication. These multiple terminals 31, 41, and 51 may include, for example, a terminal 31 belonging to the manufacturer 30 of the work machinery 10, a terminal 41 belonging to the seller 40 of the work machinery 10, and a terminal 51 belonging to the user or parts supplier 50 of the work machinery, and are connected to each other in a manner that enables information communication. The maintenance and management system 100 may also include, for example, a computer program mounted on the controller 17 of the work machinery 10, a maintenance terminal 80, and multiple terminals 31, 41, and 51.

[0035] Figure 2 yes Figure 1 The diagram shows a functional block diagram of the maintenance management DB server 110 and the maintenance management control device 120. The maintenance management DB server 110 and the maintenance management control device 120 are, for example, computers including input / output units, processing units such as CPUs, storage devices such as memory and hard disks, and the data and computer programs stored in those storage devices. The maintenance management DB server 110 and the maintenance management control device 120 are connected in a manner capable of mutual information communication, and are also connected to multiple terminals 31, 41, 51, and a maintenance terminal 80 via various communication lines in a manner capable of information communication.

[0036] The maintenance management database server 110 stores maintenance management information for multiple machines 10. This maintenance management information includes, for example, the actual service life of each component of each machine 10 from the start of use to replacement. Additionally, it includes, for example, the lead time from ordering to delivery for each component of the machine 10. Furthermore, it includes, for example, the inventory quantity of each component of the machine 10 and the available quantity of each component during the manufacturing period. Additionally, it includes, for example, operational information for each machine 10. Furthermore, it includes, for example, attribute information for each machine 10. Additionally, it includes market information associated with each machine 10. This maintenance management information is recorded as a database in the maintenance management database server 110.

[0037] exist Figure 2 In the example shown, the maintenance and management DB server 110 includes, for example, a component database 111, a machinery database 112, an operation information database 113, and a supplementary information database 114. Additionally, the maintenance and management DB server 110 includes, for example, a user information database 115, a replacement information database 116, and a market information database 117.

[0038] The component database 111 stores, for example, the lead time, inventory quantity, and available quantity during the manufacturing period of each component of the machine tool 10, as mentioned in the aforementioned maintenance management information. Here, the lead time is, for example, the period from ordering to delivery of each component of the machine tool 10, set according to a specific region. Furthermore, the available quantity during the manufacturing period of each component indicates the supply capacity of the component supplier 50 during the manufacturing period of each component. Additionally, the component database 111 stores, for example, the calculation results of the replacement quantity totaling unit 127, the ordering period prediction unit 128, and the standardized ordering unit 129 of the maintenance management control device 120, as described later.

[0039] The machinery database 112 stores, for example, attribute information of multiple operating machines 10 mentioned in the aforementioned maintenance and management information. The attribute information of the operating machines 10 stored in the machinery database 112 includes, for example, the machine's identification number, model, type, location information, and delivery date to the user.

[0040] The operation information database 113 stores, for example, the operation information of each piece of machinery 10 mentioned in the aforementioned maintenance management information. As described above, the operation information includes, for example, the cumulative usage time, cumulative travel time, cumulative turning time, cumulative digging time, fuel consumption, air intake, engine oil level, and coolant level of each piece of machinery 10. In addition, the operation information of the machinery 10 includes, for example, the discharge flow rate and discharge pressure of the hydraulic pump, the temperature of the working oil, and the pressure of the working oil in the hydraulic cylinder.

[0041] The operating information of each machine 10, such as every hour, every half day, or every day, is periodically sent along with the attribute information of the machine 10 from the controller 17 or maintenance terminal 80 of each machine 10 to the maintenance management DB server 110. The maintenance management DB server 110 stores the received operating information of each machine 10 in the operating information database 113.

[0042] The supplementary information database 114 stores, for example, the calculation results of the operation information supplementation unit of the maintenance management control device 120, which will be described later, i.e., supplementary operation information. For example, if the operation information of a certain machine 10 is lacking due to problems such as sensor failure, the supplementary operation information is used to supplement the lack of operation information.

[0043] The user information database 115 stores, for example, the aforementioned maintenance and management information, namely the attribute information of the operating machinery 10, including the user identification information, industry, location, excavation target, and responsible sales party 40 of each operating machinery 10.

[0044] The replacement information database 116 stores, for example, the actual service life of each component of each machine 10 from the start of use to replacement, as specified in the aforementioned maintenance management information. More specifically, for example, the replacement date of each component of each machine 10 is sent from the controller 17 or maintenance terminal 80 of each machine 10 to the maintenance management DB server 110. The maintenance management DB server 110 stores the received replacement dates of each component of each machine 10 in the replacement information database 116. The replacement information database 116 calculates and maintains, for example, the period between replacement dates of each component of each machine 10, that is, the period from the previous replacement date to the next replacement date, as the actual service life of each component. Additionally, the replacement information database 116 stores, for example, the marking information of each component of each machine 10 input by maintenance personnel via the maintenance terminal 80. The marking information may be, for example, information indicating the reason for component replacement, such as lifespan replacement or fault replacement.

[0045] The market information database 117 stores, for example, market information related to each piece of operating machinery 10 from the aforementioned maintenance and management information. The market information includes, for example, at least one of the following: the price and supply and demand of the excavated materials of the operating machinery 10, such as iron ore and coal; the fuel price of the operating machinery 10; and the business climate index.

[0046] The maintenance management control device 120 includes, for example, a replacement cause determination unit 121, a lifespan model creation unit 122, a fault model creation unit 123, and a replacement period prediction unit 126. The maintenance management control device 120 may further include an operation model creation unit 124 and an operation information supplementation unit 125. The maintenance management control device 120 may further include a replacement count totaling unit 127 and an order period prediction unit 128. The maintenance management control device 120 may further include a standardized ordering unit 129. Each of the above-described units of the maintenance management control device 120 represents, for example, the function of the maintenance management control device 120 implemented by a processing unit executing a program stored in a storage device.

[0047] The following is for reference Figures 3 to 2 0. This describes the operation of the maintenance management system 100 in this embodiment. Figure 3 It means Figure 2 The flowchart illustrates the processing flow of the replacement cause determination unit 121 in the maintenance management control device 120. The replacement cause determination unit 121 determines the replacement cause of each component of the multiple machines 10 as either a lifespan-related cause or a failure cause based on the actual service life of each component. More specifically, the replacement cause determination unit 121 first executes process P101, which determines whether the replacement information database 116 contains flag information indicating the failure cause of each component of each machine 10. It should be noted that a failure cause refers to a sudden failure whose actual service life is shorter than the specified lifespan.

[0048] When the replacement cause determination unit 121 determines in process P101 that the replacement information database 116 contains flag information (yes), it executes process P102, which determines whether the fault is due to life-related replacement or fault replacement, based on the flag information, and then ends the process. Figure 3 The process is as shown. On the other hand, if the replacement cause determination unit 121 determines in process P101 that the replacement information database 116 does not store the flag information (No), it determines in process P103 whether the actual service life of the component is above the predetermined threshold Tth. It should be noted that, as mentioned above, the flag information, such as lifespan replacement or failure replacement, indicating the reason for component replacement, is stored in the replacement information database 116. However, for example, if the machine 10 has just been shipped and the component has not yet been replaced, the replacement information database 116 does not store the flag information.

[0049] In process P103, when the replacement cause determination unit 121 determines that the actual service life of each component of each machine tool 10 stored in the replacement information database 116 is above the threshold Tth of that component (yes), it executes process P104, which determines the replacement cause of the component as a lifespan-related cause, and then ends the process. Figure 3The process is shown. In process P104, the replacement cause determination unit 121 determines the replacement cause as a lifespan-related cause and records the determined replacement cause in, for example, the replacement information database 116. On the other hand, in process P103, when the replacement cause determination unit 121 determines that the actual service life of each component is lower than the threshold Tth of each component (No), it executes process P105, which determines the replacement cause of the component as a failure cause, and makes... Figure 3 The process shown is now complete. In this process P105, the replacement cause determination unit 121 determines the replacement cause as a lifespan-related issue and records the determined replacement cause in, for example, the replacement information database 116.

[0050] In this way, during process P104 or P105, the replacement reason recorded in the replacement information database 116 is changed to flag information. It should be noted that, during process P104 or P105, the flag information recorded in the replacement information database 116 can also be distinguished from the flag information input by the maintenance personnel via the maintenance terminal 80 and recorded in the replacement information database 116. In this case, during the aforementioned process P102 for determining the cause of the fault, the flag information input by the maintenance personnel can be used preferentially.

[0051] Figure 4 It is shown Figure 2 The flowchart shows the processing flow of the life model creation unit 122 of the maintenance management control device 120. The life model creation unit 122 creates a life model for each component based, for example, on the actual service life of components whose replacement cause is determined to be a lifespan cause by the replacement cause determination unit 121. More specifically, the life model creation unit 122 first performs a process P201 to determine whether there are any deficiencies in the operating information of the work machinery 10 that is the target.

[0052] In process P201, the life model creation unit 122 executes process P202, which involves creating an operation model, if it determines that the operating information of the target machine 10 is complete (or not). In process P202, the life model creation unit 122 creates a life model, for example, through multiple regression analysis, and then concludes the process. Figure 4 The processing shown in the figure uses the operating information of the machine 10 with components whose replacement cause is lifespan as the explanatory variable and the actual service life of the components whose replacement cause is lifespan as the target variable in the multiple regression analysis.

[0053] On the other hand, when the life model creation unit 122 determines in process P201 that the operating information of the target machine 10 is lacking, it executes process P203 to supplement the operating information of the machine 10. Here, Figure 2When the operating information of the operating machine 10 is lacking, the operation information supplementation unit 125 shown creates supplementary information based on the operation model of the operating machine 10 to supplement the lacking operating information. It should be noted that, similar to the fault model creation unit 123 described later, the operation information supplementation unit 125 can also create more than one group of operating machines 10 based on the attribute information of the operating machines 10, and create supplementary information based on the operation model of each group of operating machines 10 created.

[0054] In the above process P203, the lifespan model creation unit 122 supplements the missing operation information using the supplementary information created by the operation information supplementation unit 125, and then executes the lifespan model creation process P202, and ends. Figure 4 The process is shown. A lifespan model is, for example, a model that represents how a component is consumed and replaced due to the operation of the machine 10 during the actual service life of the component, with the cause of failure being its lifespan.

[0055] In the above-described process P203, the life model creation unit 122 can either store the supplemented operation information in the operation information database 113 of the maintenance management DB server 110, or store operation information different from that stored in the operation information database 113 in the supplementary information database 114. Therefore, it is possible to distinguish between the supplemented operation information stored in the supplementary information database 114 and the complete operation information stored in the operation information database 113.

[0056] It should be noted that if the amount of operating information of the machine 10 stored in the replacement information database 116 is sufficient for multiple regression analysis, the life model creation unit 122 may create a life model using only the operating information without defects, without using the operating information supplemented in processing P202. Furthermore, the life model creation unit 122 may also choose not to use the operating information of the machine 10 with a defect rate exceeding a specified value when creating the life model.

[0057] Figure 5 It is shown Figure 2 The flowchart illustrates the processing flow of the fault model creation unit 123 of the maintenance management control device 120. The fault model creation unit 123 creates fault models for each component of each machine tool 10 based on the actual service life of each component for which the replacement cause determination unit 121 determines the replacement cause as the fault. It considers the probability of faults occurring in each component of the machine tool 10, for example, depending on the purpose and operating method of the machine tool 10.

[0058] The fault model creation unit 123 creates, for example, one or more groups of working machines 10 with components whose replacement cause is the fault, based on the attribute information of the working machine 10, and creates fault models by group based on the operating information of multiple working machines 10 contained in each group.

[0059] More specifically, the fault model creation unit 123 first executes grouping processing P301. In this grouping processing P301, the fault model creation unit 123 first refers to the machine database 112, the operation information database 113, and the user information database 115. Then, the fault model creation unit 123 obtains, for example, the attribute information of the machine 10 that used a component whose failure was caused by replacement, the operation information of the machine 10 during the actual service life of the component, and the user information of the machine 10.

[0060] Furthermore, in group processing P301, the fault model creation unit 123 creates one or more groups of operating machinery 10 based on the acquired attribute information. More specifically, the fault model creation unit 123 divides the operating machinery 10 into one or more groups based on attribute information such as the model, type, location information, user identification information, industry, region, and excavated object of the operating machinery 10 whose failure is due to the replacement of a component.

[0061] Next, the fault model creation unit 123 executes the fault model creation process P302. In this process P302, the fault model creation unit 123, for example, calculates the total number of parts replaced in each group where the cause of failure is the fault, to determine the total number of failures for each part, and calculates the total operating time of the machinery 10 in each group, i.e., the total operating time. Furthermore, the fault model creation unit 123 divides the total number of failures by the total operating time to calculate the number of failures per unit time for each part in each group, which is then used as the fault model, and the process ends. Figure 5 The processing is shown. It should be noted that the fault model creation unit 123 can also calculate the number of faults occurring per day for each component in each group by dividing the total number of faults by the total number of operating days of the working machinery 10 in each group, i.e., the total number of operating days, as the fault model.

[0062] Figure 6 It is shown Figure 2 The flowchart shows the processing flow of the operation model creation unit 124 of the maintenance management control device 120. The operation model creation unit 124 creates an operation model, for example, based on the operation information of each machine 10 stored in the operation information database 113 of the maintenance management DB server 110 and the market information stored in the market information database 117 of the maintenance management DB server 110.

[0063] More specifically, the operation model creation unit 124 first executes process P401, which retrieves the operation information of each machine 10 stored in the operation information database 113 of the maintenance management DB server 110. Here, the operation information includes cumulative usage time, as previously described. Next, the operation model creation unit 124 executes process P402, which retrieves market information for the period corresponding to the operation information of the machine 10 from the market information database 117. Here, as previously described, the market information includes at least one of the following: the price and supply and demand of the excavated material of the machine 10, the fuel price of the machine 10, and a business climate index.

[0064] Next, the operation model creation unit 124 performs multiple regression analysis using the accumulated usage time and market information included in the acquired operation information to create operation models for each piece of machinery 10, and then concludes the process. Figure 6 The processing is shown. It should be noted that the operation model creation unit 124 can also create operation models for each group of the working machinery 10 created by the fault model creation unit 123 through the aforementioned grouping process P301. Furthermore, the operation model creation unit 124 can also create operation models by predicting future operation times based on past operation information without using market information.

[0065] Figure 7 It is shown Figure 2 The flowchart illustrates the processing flow of the replacement period prediction unit 126 in the maintenance management control device 120. The replacement period prediction unit 126 predicts the replacement period of each component of each machine 10 based on the aforementioned lifespan model and failure model. More specifically, the replacement period prediction unit 126, for example, refers to the replacement information database 116 of the maintenance management DB server 110 and performs a process P501 to determine whether a replacement date is recorded for each component of each machine 10. In this process P501, if no replacement date is recorded (No), the replacement period prediction unit 126 refers to, for example, the machine database 112 regarding its components and performs a process P502 to set the delivery date of the machine 10 to the user as the latest replacement date.

[0066] On the other hand, in the above-described process P501, if the replacement period prediction unit 126 determines that the replacement date is recorded (yes), it further refers to the replacement information database 116 and performs a process P503 to determine whether multiple replacement dates are recorded for the components of its operating machinery 10. In this process P503, if the replacement period prediction unit 126 determines that there is only one recorded replacement date (no), it performs a process P504 to set that replacement date as the latest replacement date; if there are multiple recorded replacement dates (yes), it performs a process P505 to set the most recent replacement date as the latest replacement date.

[0067] It should be noted that the operating machinery 10 may also have multiple identical parts. In this case, multiple identical parts can be treated as a single unit. It should also be noted that even if multiple identical parts are not replaced simultaneously, they can be treated as independent units. Furthermore, each operating machinery 10 can maintain the replacement date of each part in, for example, the controller 17. The replacement period prediction unit 126 performs the process P506, which predicts the lifespan replacement date, at the end of the aforementioned processes P502, P504, or P505.

[0068] In this process P506, the replacement period prediction unit 126, for example, refers to the machine database 112 and, for each group of operating machines 10 created by the aforementioned fault model creation unit 123, refers to the operation model created by the operation model creation unit 124. Furthermore, it inputs the operating time shift based on the operation model into the lifespan model created by the lifespan model creation unit 122, and calculates the lifespan replacement date based on the latest replacement date of each component of each operating machine 10.

[0069] Here, in order to obtain the period from the latest replacement date to the current actual operating time of each component of each machine tool 10, this actual operating time can also be used as input to the lifespan model created by the lifespan model creation unit 122. In addition, the replacement period prediction unit 126 performs the above-described process P506 by using the lifespan replacement date of the currently used component as the latest replacement date, thereby being able to predict the lifespan replacement date of the new component after the currently used component is replaced, and perform longer-term component demand prediction.

[0070] Next, the replacement period prediction unit 126 performs the process P507 of predicting the replacement date of the fault. In this process P507, the replacement period prediction unit 126, for example, refers to the machine database 112 and, for each group of operating machines 10 created by the aforementioned fault model creation unit 123, refers to the operation model created by the operation model creation unit 124. Furthermore, the future operating time shift based on the operation model is input into the fault model created by the fault model creation unit 123, and the replacement date of the fault is calculated based on the latest replacement date of each component of each operating machine 10.

[0071] Here, the replacement period prediction unit 126 can, for example, input the sum of future operating times based on the operation model of each group into the fault model to calculate the fault replacement date based on the latest replacement date of each component of each machine 10. Furthermore, since the fault model is a statistically established model, the fault replacement date can also be calculated based on the application date of the fault model. Additionally, by setting the fault replacement date of the currently used component as the latest replacement date and performing the aforementioned processing P507, the replacement period prediction unit 126 can also predict the fault replacement date of the new component after replacing the currently used component, thus performing longer-term component demand prediction.

[0072] Figure 8 It is shown Figure 2 The flowchart illustrates the processing flow of the replacement count totaling unit 127 of the maintenance management control device 120. The replacement count totaling unit 127 totals the replacement count of each component based on its lifespan replacement date and failure replacement date. More specifically, the replacement count totaling unit 127 performs processing P601 to obtain the lifespan replacement date of each component of each machine tool 10 calculated by the replacement period prediction unit 126, and processing P602 to obtain the failure replacement date of each component of each machine tool 10. Furthermore, the replacement count totaling unit 127, for example, refers to the user information database 115 and performs processing P603 to total the replacement count of each component for each sales party 40 responsible for each machine tool 10. The total replacement count of each component can be totaled in various units corresponding to the lifespan replacement date and failure replacement date of each component, such as daily, weekly, or monthly units.

[0073] Figure 9 This is a table showing an example of the total result of the replacement count total section 127. The replacement count total section 127 is, for example, as follows: Figure 9 The table above shows the total number of parts replaced each month, categorized by machine model 10, serial number, dealership name 40, part name, and part number. Additionally, the total replacement count is shown in section 127, for example... Figure 9 The table below shows the total number of parts replaced each month, categorized by the seller's 40 authorized dealers, part names, and part numbers.

[0074] The manufacturers 30, distributors 40, and component suppliers 50 of the operating machinery 10 are, for example, Figure 1 As shown, users can log in to the maintenance management DB server 110 or maintenance management control device 120 of the maintenance management center 20 via terminals 31, 41, and 51 and refer to... Figure 9 The table shown illustrates this. Therefore, the manufacturer 30, the seller 40, and the component supplier 50 can anticipate future component order quantities.

[0075] Figure 10 It is shown Figure 2The flowchart shows the processing flow of the ordering period prediction unit 128 of the maintenance management control device 120. The ordering period prediction unit 128 predicts the ordering period of each component based on the replacement number of each component and the preparation time of each component. The ordering period prediction unit 128 first refers to the machine database 112 and the user information database 115, and performs processing (P701) to calculate the number of components sent from the manufacturer 30 to each seller 40 based on the supply path of each component from the manufacturer 30 to each seller 40 according to the time limit.

[0076] Figure 11 This is an explanation Figure 10 The order period forecasting department 128 processes the table 701. Figure 11 The topmost item shows an example of the delivery time and quantity of parts sent from the manufacturer's (30) regional base to the seller (40). Figure 11 The second from the top indicates an example of the delivery time and quantity of parts sent from manufacturer 30 to manufacturer 30's geographical location and seller 40, respectively. Figure 11 The third from the top indicates an example of the delivery time and quantity of parts sent from manufacturer 30 to its geographical location and seller 40. Figure 11 The bottom section shows an example of the order period and quantity of components ordered by component supplier 50 from manufacturer 30.

[0077] exist Figure 11 In the example shown, component 1 is supplied from manufacturer 30 to agent a, which is a seller 40, via a regional location, and directly from manufacturer 30 to agent b, which is another seller 40, without going through a regional location. Furthermore, the lead time required for the delivery of component 1 from manufacturer 30 to the regional location is, for example, 3 months, and the lead time required for the delivery of component 1 from the regional location to agent a is, for example, 1 month. The lead time required for the delivery from manufacturer 30 to agent b is, for example, 2 months. Additionally, the lead time required for the manufacturing of component 1 by component supplier 50 and the delivery of component 1 from component supplier 50 to manufacturer 30 is, for example, 4 months.

[0078] In this situation, firstly, Figure 9 As shown in the table below, the ordering period forecasting unit 128, in the aforementioned process P701, refers to the monthly part replacement quantity for each month, calculated by the replacement quantity totaling unit 127 for the agent name, part name, and part number of each seller 40. Furthermore, the ordering period forecasting unit 128 shifts the quantity of part 1 supplied by the manufacturer 30 to agent a (seller 40) via its regional base to one month prior to the preparation time required for the delivery of part 1 from that regional base to agent a. Thus, as... Figure 11The table at the top shows the delivery time and quantity from the manufacturer's (30) regional location to the distributor (40) agent (a).

[0079] In addition, the order period forecasting department 128 will Figure 11 The table at the top shows the delivery deadline and quantity from the manufacturer's (30) regional location to the agent (40) distributor, shifting the lead time to 3 months prior to the preparation time required for the delivery of component 1 from manufacturer 30 to the regional location. Therefore, as... Figure 11 As shown in the top row of the second table from the top, calculate the sending time and sending quantity from manufacturer 30 to the regional base of manufacturer 30.

[0080] In addition, the order period forecasting department 128 will send component 1 directly from the manufacturer 30. Figure 9 The table below shows the monthly component replacement counts for distributor 40's agent b, shifted to two months prior to the preparation time required for component 1's delivery from manufacturer 30 to agent b. Therefore, as... Figure 11 As shown in the lower row of the second table from the top, the delivery period and quantity from manufacturer 30 to agent b, who is the seller 40, are calculated.

[0081] In addition, the order period forecasting department 128 totaled according to the delivery period. Figure 11 The second table from the top shows the quantities sent from manufacturer 30 to regional locations and to agent b, who is the seller 40. Thus, as... Figure 11 As shown in the third table from the top, it is possible to calculate the delivery time and total quantity from manufacturer 30 to its geographical locations and seller 40.

[0082] Next, the order period forecasting unit 128 performs process P702, which calculates the order quantity for component supplier 50 based on the deadline. The order period forecasting unit 128 will... Figure 11 The third table from the top shows the delivery time and total quantity from manufacturer 30 to regional locations and distributors 40, shifted to four months prior to the preparation time required for the manufacturing of component 1 at component supplier 50 and the delivery of component 1 from component supplier 50 to manufacturer 30. Therefore, as... Figure 11 The table at the bottom shows how to calculate the order period and quantity of component 1 from manufacturer 30 to component supplier 50. As described above, Figure 10 The processing shown has ended.

[0083] The manufacturers 30, distributors 40, and component suppliers 50 of the operating machinery 10 are, for example, Figure 1 The shown terminal 31, 41, and 51 can be used to log in to the maintenance management DB server 110 or maintenance management control device 120 of the maintenance management center 20, and refer to... Figure 11The table shown illustrates this. Therefore, the manufacturer 30, the seller 40, and the component supplier 50 can anticipate future component order quantities.

[0084] Finally, refer to Figure 12 illustrate Figure 2 The operation of the standardized ordering department 129 of the maintenance management control device 120. Figure 12 This is an explanation Figure 2 The standardized ordering unit 129 of the maintenance management control device 120 processes tables and charts. The standardized ordering unit 129 calculates, for example, the standardized ordering quantity and standardized ordering period for each component based on the replacement quantity and the supply quantity of each component, not exceeding the supply quantity during the manufacturing period.

[0085] The order quantity for components from component supplier 50 is standardized, for example, in a manner not exceeding the number of components available during the manufacturing period of components from component supplier 50. This requires the delivery of the required number of components from component supplier 50 to manufacturer 30, and then to seller 40, etc., within a specified timeframe. For example, the number of components 1 available from component supplier 50 during the manufacturing period is 10. In this case, for example... Figure 12 As shown in the table above, the Standardized Ordering Department 129 calculates the cumulative value of the required order quantity for each order period based on the required order quantity and order period of component 1 from manufacturer 30 to component supplier 50.

[0086] In addition, for example, Figure 12 As shown in the table above, the standardized ordering unit 129 calculates a standardized order quantity of no more than 10 units of component 1 that are available during the manufacturing period of component supplier 50. At this time, the standardized ordering unit 129 calculates the standardized order quantity, for example, by ensuring that the cumulative value of the standardized ordering unit 129 for each ordering period exceeds the cumulative value of the required order quantity. This prevents orders for component 1 from exceeding the supply capacity of component supplier 50, ensuring a stable supply of component 1. Additionally, the standardized ordering unit 129 may also consider the inventory of component 1 held by component supplier 50.

[0087] As described above, the maintenance management system 100 for operating machinery in this embodiment includes: a maintenance management database server 110, which stores maintenance management information for multiple operating machines 10; and a maintenance management control device 120, which predicts replacement periods for each component of each operating machine 10 based on the maintenance management information. The maintenance management information stored in the maintenance management database server 110 includes the actual service life of each component of each operating machine 10 from the start of use to replacement. The maintenance management control device 120 includes: a replacement cause determination unit 121, which determines the replacement cause of each component as either a lifespan-related cause or a failure cause based on the actual service life of each component of the multiple operating machines 10; a lifespan model creation unit 122, which creates a lifespan model for components whose replacement cause is determined to be a lifespan-related cause by the replacement cause determination unit 121; a failure model creation unit 123, which creates a failure model for components whose replacement cause is determined to be a failure cause by the replacement cause determination unit 121; and a replacement period prediction unit 126, which predicts the replacement period for each component of each operating machine 10 based on the lifespan model and the failure model.

[0088] Based on this configuration, the maintenance management system 100 for operating machinery in this embodiment can predict the replacement period of components of operating machinery 10 earlier. More specifically, maintenance management information containing the actual service life of each component of each operating machinery 10 is stored in the maintenance management DB server 110. Based on this actual service life, the replacement reason determination unit 121 of the maintenance management control device 120 can determine the replacement reason for each component of each operating machinery 10. Furthermore, based on the replacement reason, the maintenance management control device 120 can create a life model by component by the life model creation unit 122 and a fault model by component by the fault model creation unit 123. Moreover, based on the created life model and fault model, the maintenance management control device 120 can predict the replacement period of each component of each operating machinery 10 by the replacement period prediction unit 126, considering both lifespan and faults. Therefore, according to this embodiment, a maintenance management system 100 for operating machinery capable of predicting the replacement period of components of operating machinery 10 earlier can be provided.

[0089] Furthermore, in the maintenance management system 100 of this embodiment, the maintenance management information stored in the maintenance management DB server 110 includes, for example, the lead time from ordering to delivery for each component of each machine tool 10. Additionally, the maintenance management control device 120 includes: a replacement count totaling unit 127, which totals the replacement count of each component based on its replacement period; and an order period prediction unit 128, which predicts the order period for each component based on its replacement count and lead time. With this configuration, the maintenance management system 100 of this embodiment predicts the order period taking into account the lead time of each component, enabling earlier ordering and delivery of components. Therefore, at the site where the machine tool 10 is used, components can be delivered before replacement of the machine tool 10, minimizing downtime for the machine tool 10.

[0090] Furthermore, in the maintenance management system 100 of this embodiment, the maintenance management information stored in the maintenance management DB server 110 includes the available quantity of each component during the manufacturing period. The maintenance management control device 120 has a standardized ordering unit 129, which calculates a standardized ordering quantity and a standardized ordering period per component based on the replacement quantity and available quantity of each component, not exceeding the available quantity during the manufacturing period. With this configuration, the maintenance management system 100 of this embodiment can prevent the ordering of components that exceeds the supply capacity of the component supplier 50, and can stably supply components.

[0091] Furthermore, in the maintenance management system 100 of this embodiment, the maintenance management information stored in the maintenance management DB server 110 includes the operating information of each machine tool 10. Additionally, the lifespan model creation unit 122 creates a lifespan model using multiple regression analysis. This analysis uses the operating information of the machine tools 10 with components whose replacement cause is a lifespan factor as explanatory variables, and the actual service life of the components whose replacement cause is a lifespan factor as the target variable. Based on this configuration, the maintenance management system 100 of this embodiment can more accurately predict the lifespan of each component of each machine tool 10 based on the operating information of each machine tool 10.

[0092] Furthermore, in the maintenance management system 100 of this embodiment, the maintenance management information stored in the maintenance management DB server 110 includes attribute information and operation information of each machine tool 10. Additionally, the fault model creation unit 123 creates one or more groups of machine tools 10 with components whose replacement cause is a fault, based on the attribute information of the machine tools 10, and creates fault models for each group based on the operation information of the multiple machine tools 10 included in each group. With this configuration, for example, fault models can be created by groups of machine tools 10 with similar operation information, enabling more accurate prediction of faults in each component of each machine tool 10.

[0093] Furthermore, in the maintenance management system 100 of this embodiment, the maintenance management information stored in the maintenance management DB server 110 includes market information associated with each machine 10. Additionally, the maintenance management control device 120 includes: an operation model creation unit 124 that creates an operation model based on the operation information and market information of each machine 10; and an operation information supplementation unit 125 that creates supplementary information based on the operation model when operation information is lacking. With this configuration, the future operating time of the machine 10 based on the operation model can be input into the fault model, allowing for more accurate prediction of component failures.

[0094] Furthermore, in the maintenance management system 100 of this embodiment, the operation model creation unit 124 creates operation models in groups. Additionally, the operation information supplementation unit 125 creates supplementary information based on the operation models of each group when operation information is lacking. With this configuration, the sum of future operating times based on the operation models of each group can be input into the fault model, allowing for more accurate prediction of component failures.

[0095] The embodiments of the maintenance management system for operating machinery of this disclosure have been described in detail above with the help of the accompanying drawings. However, the specific configuration is not limited to this embodiment. Even if there are design changes or other changes that do not depart from the scope of this disclosure, these changes are also included in this disclosure.

[0096] Explanation of reference numerals in the attached figures

[0097] 1. Component, 10. Operating machinery, 100. Maintenance management system for operating machinery, 110. Maintenance management database server, 120. Maintenance management control device, 121. Replacement cause determination department, 122. Life model creation department, 123. Fault model creation department, 124. Operation model creation department, 125. Operation information supplementation department, 126. Replacement period prediction department, 127. Replacement count total department, 128. Order period prediction department, 129. Standardized ordering department.

Claims

1. A maintenance management system for operating machinery, comprising: The maintenance and management database server stores maintenance and management information for multiple operating machines; And a maintenance management control device, which predicts the replacement period for each component of each of the aforementioned operating machines based on the maintenance management information, wherein the maintenance management information is sent from multiple operating machines or maintenance terminals and includes the replacement date for each component of each operating machine. The maintenance and management system for the operating machinery is characterized by the following: The maintenance management information includes the actual durability of each component of each of the said operating machines from the start of use to the date of replacement, calculated based on the received replacement date. The maintenance management control device includes: a replacement cause determination unit, which determines the replacement cause of each component as a lifespan-related cause or a failure cause based on the actual service life of each component of the plurality of operating machines and a threshold determined for each component; a lifespan model creation unit, which creates a lifespan model for the components whose replacement cause is determined to be a lifespan-related cause by the replacement cause determination unit; a failure model creation unit, which creates a failure model for the components whose replacement cause is determined to be a failure cause by the replacement cause determination unit; and a replacement period prediction unit, which predicts the replacement period of each component of each of the operating machines based on the lifespan model and the failure model.

2. The maintenance management system for operating machinery according to claim 1, characterized in that, The maintenance management information includes the lead time for each component from order to delivery. The maintenance management control device includes: a replacement count totaling unit that totals the replacement count of each component based on the replacement period of each component; and an order period prediction unit that predicts the order period of each component based on the replacement count of each component and the stock preparation time of each component.

3. The maintenance management system for operating machinery according to claim 2, characterized in that, The maintenance management information includes the number of components available during the manufacturing period. The maintenance management control device has a standardized ordering department, which calculates a standardized ordering number and a standardized ordering period for each component based on the replacement number and the available number of each component, not exceeding the available number of the component during the manufacturing period.

4. The maintenance management system for operating machinery according to claim 1, characterized in that, The maintenance and management information includes the operating information of each of the aforementioned machines. The lifespan model creation unit creates the lifespan model through multiple regression analysis, wherein the multiple regression analysis uses the operating information of the working machinery having the component whose replacement reason is the lifespan cause as the explanatory variable, and the actual service life of the component whose replacement reason is the lifespan cause as the target variable.

5. The maintenance management system for operating machinery according to claim 1, characterized in that, The maintenance and management information includes the attribute information and operation information of each of the aforementioned machines. The fault model creation unit creates one or more groups of the operating machinery that have the component whose replacement reason is the fault cause based on the attribute information, and creates the fault model for each group based on the operation information of the multiple operating machines included in each group.

6. The maintenance management system for operating machinery according to claim 5, characterized in that, The maintenance and management information includes market information associated with each of the aforementioned operating machines. The maintenance management and control device includes: an operation model creation unit, which creates an operation model based on the operation information and market information of each of the operating machines; And an operation information supplementation unit, which creates supplementary information based on the operation model when the operation information is lacking.

7. The maintenance management system for operating machinery according to claim 6, characterized in that, The operation model creation unit creates the operation model for each of the groups. The operation information supplementation unit creates supplementary information based on the operation model of each group when the operation information is lacking.

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