A device health state evaluation method and evaluation module
By using equipment health status evaluation methods and modules, and by real-time monitoring and optimization of parts replacement, the problems of frequent equipment downtime and improper parts management in tobacco production workshops have been solved. This has enabled planned equipment health and parts replacement, thereby improving production efficiency and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHINA TOBACCO JIANGXI IND CO LTD
- Filing Date
- 2023-01-03
- Publication Date
- 2026-06-05
AI Technical Summary
The waste caused by frequent equipment downtime for maintenance and improper parts management in tobacco production workshops raises the question of how to correctly assess equipment health status to reduce downtime and optimize parts reserves.
By statistically analyzing and updating the remaining lifespan of each component within the equipment, and combining the correlation between health status f1 and hourly output, quality score, and cost consumption, the timing of downtime and the number of parts to be replaced are optimized. The equipment health status evaluation module is used for real-time monitoring and management.
Reduce equipment downtime, improve production efficiency, optimize parts procurement and storage, reduce waste, and increase equipment production capacity.
Smart Images
Figure CN115983698B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of equipment maintenance, and more particularly to the field of equipment health status assessment. Background Technology
[0002] Tobacco production workshops contain a large number of pieces of equipment, each performing the same or different functions. In order to improve production efficiency, factories hope to minimize equipment downtime for maintenance. However, in reality, equipment often needs to be shut down for maintenance due to various problems. The most common problem is the replacement of damaged parts. How to correctly evaluate the health status of equipment and thus plan to reduce downtime and improve production efficiency is an urgent problem to be solved.
[0003] Meanwhile, in order to cope with the replacement of parts, factories often store a large number of various parts. It often happens that the equipment has been scrapped, but there are still many spare parts for the equipment. This causes a lot of waste, or the equipment cannot work for a long time due to insufficient storage of individual parts, and the equipment has to wait for the purchase of parts. How to plan the storage of parts is an important issue for cost reduction and efficiency improvement.
[0004] Application content
[0005] To address the problems existing in the prior art, this application discloses a method for evaluating the health status of equipment, comprising the following steps:
[0006] The remaining lifespan of each component in the device is counted and recorded, and the remaining lifespan of each component is continuously updated over time.
[0007] Determine the time of the first shutdown for parts replacement, and the number of parts to be replaced during the first shutdown;
[0008] The number of parts replaced during the first shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z.
[0009] The equipment health status evaluation method further includes the following steps:
[0010] After the first shutdown to replace parts, the time for the second shutdown to replace parts and the number of parts to be replaced are determined based on the lifespan of each updated part.
[0011] The number of parts replaced during the second shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the hourly output X, quality score Y, and cost consumption Z of the equipment.
[0012] The method for determining the timing of the first or second downtime for parts replacement, and the number of parts to be replaced during the first or second downtime, includes the following steps:
[0013] The average time between two historical downtimes of the equipment is recorded as H0.
[0014] Among all the components, the remaining lifespan of the component with the shortest lifespan is denoted as H1;
[0015] Determine the relative sizes of H1 and H0;
[0016] When H1 is greater than HO, the downtime for replacement is 0.9H1; the replacement standard for parts is: remaining life less than kHO; where k≥1.5, f1 is positively correlated with k, the larger f1 is, the larger k is;
[0017] When H1 is less than H0, the time point for shutdown and replacement is 0.9H0; the replacement standard for parts is: the remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0018] The method for determining the timing of the first or second downtime for parts replacement, and the number of parts to be replaced during the first or second downtime, also includes the following steps:
[0019] Before recording the average time between two shutdowns of the equipment in the past as H0, determine whether there is a preset shutdown duration;
[0020] If there is no preset downtime, proceed to the step of calculating the average time between two downtimes of the equipment in history, denoted as H0.
[0021] If there is a preset shutdown market, it is recorded as h0;
[0022] Determine the relative sizes of H1 and h0;
[0023] When H1 is greater than h0, the downtime for replacement is h0; the replacement standard for parts is: remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0024] When H1 is less than h0, the time point for shutdown and replacement is 0.9H1; the replacement standard for parts is: remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0025] Parts with a remaining lifespan greater than 3H0 after replacement by equipment with a high f1 rating are converted into spare parts for equipment with a low f1 rating.
[0026] The hourly output contribution rate X is the ratio of the average monthly hourly output to the average monthly orders.
[0027] The quality score contribution Y represents the yield rate;
[0028] The cost contribution Z is the raw material utilization rate.
[0029] The health status f1 and the hourly output X, quality score Y, and cost consumption Z of the equipment satisfy the following relationship: f1=jX+mY+nZ;
[0030] Wherein, j, m, and n are parameters set according to the contribution of the equipment in the factory workshop.
[0031] Aside from the first and second shutdowns, the equipment may experience multiple shutdowns.
[0032] The number of parts replaced during each shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z.
[0033] The equipment health status evaluation method further includes the following steps: when the equipment experiences unplanned shutdown, unplanned shutdown refers to shutdown that is not based on parts replacement or a preset duration, and the shutdown replacement time point is the unplanned shutdown time; the replacement standard for parts is: remaining life less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0034] A device health status evaluation module, wherein the device health status evaluation method is stored in the device health status evaluation module in software form;
[0035] The device health status evaluation module is not located in the device.
[0036] This application continuously monitors and updates the remaining lifespan of each component in the equipment, and takes into account the average downtime and unplanned downtime, thereby optimizing downtime timing and allowing multiple components to be replaced during downtime. The number of components replaced is directly proportional to the equipment health. The higher the equipment health, the stronger the equipment's production capacity and the more important it is to the factory. Therefore, more components are replaced during each downtime, thereby reducing the number of downtimes and further improving production efficiency.
[0037] At the same time, by continuously updating the remaining lifespan of each component, we can predict the replacement time of the components and replace them in a planned manner. This is beneficial for the planning of component procurement and storage, reduces unreasonable procurement and storage of components, and helps to reduce costs and increase efficiency.
[0038] At the same time, replacing some parts of the equipment with high f1 and using them as parts for equipment with low f1 will further help reduce costs. Attached image description:
[0039] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below.
[0040] Figure 1 This is a schematic diagram of the overall method for evaluating the health status of equipment in this application.
[0041] Figure 2 This is a schematic diagram of the shutdown judgment logic for this application. Detailed Implementation
[0042] The technical solutions of this application will be clearly and completely described below in conjunction with the embodiments of this application;
[0043] like Figure 1-2 As shown: To address the problems existing in the prior art, this application discloses a method for evaluating the health status of equipment, comprising the following steps:
[0044] The remaining lifespan of each component in the device is counted and recorded, and the remaining lifespan of each component is continuously updated over time.
[0045] Determine the time of the first shutdown for parts replacement, and the number of parts to be replaced during the first shutdown;
[0046] The number of parts replaced during the first shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z.
[0047] The equipment health status evaluation method further includes the following steps:
[0048] After the first shutdown to replace parts, the time for the second shutdown to replace parts and the number of parts to be replaced are determined based on the lifespan of each updated part.
[0049] The number of parts replaced during the second shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the hourly output X, quality score Y, and cost consumption Z of the equipment.
[0050] The method for determining the timing of the first or second downtime for parts replacement, and the number of parts to be replaced during the first or second downtime, includes the following steps:
[0051] The average time between two historical downtimes of the equipment is recorded as H0.
[0052] Among all the components, the remaining lifespan of the component with the shortest lifespan is denoted as H1;
[0053] Determine the relative sizes of H1 and H0;
[0054] When H1 is greater than HO, the downtime for replacement is 0.9H1; the replacement standard for parts is: remaining life less than kHO; where k≥1.5, f1 is positively correlated with k, the larger f1 is, the larger k is;
[0055] When H1 is less than H0, the time point for shutdown and replacement is 0.9H0; the replacement standard for parts is: the remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0056] The method for determining the timing of the first or second downtime for parts replacement, and the number of parts to be replaced during the first or second downtime, also includes the following steps:
[0057] Before recording the average time between two shutdowns of the equipment in the past as H0, determine whether there is a preset shutdown duration;
[0058] If there is no preset downtime, proceed to the step of calculating the average time between two downtimes of the equipment in history, denoted as H0.
[0059] If there is a preset shutdown market, it is recorded as h0;
[0060] Determine the relative sizes of H1 and h0;
[0061] When H1 is greater than h0, the downtime for replacement is h0; the replacement standard for parts is: remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0062] When H1 is less than h0, the time point for shutdown and replacement is 0.9H1; the replacement standard for parts is: remaining life is less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0063] Parts with a remaining lifespan greater than 3H0 after replacement by equipment with a high f1 rating are converted into spare parts for equipment with a low f1 rating.
[0064] The hourly output contribution rate X is the ratio of the average monthly hourly output to the average monthly orders.
[0065] The quality score contribution Y represents the yield rate;
[0066] The cost contribution Z is the raw material utilization rate.
[0067] The health status f1 and the hourly output X, quality score Y, and cost consumption Z of the equipment satisfy the following relationship: f1=jX+mY+nZ;
[0068] Wherein, j, m, and n are parameters set according to the contribution of the equipment in the factory workshop.
[0069] Example as follows:
[0070] j, m, and n are adjusted according to the contribution rate of specific equipment in the factory. If output is the priority, j is increased. For example, for cigarette filter cutting equipment, j, m, and n are 3, 1, and 1, respectively. If quality score is the priority, Y is increased. For example, for tobacco drying equipment, k, m, and n are 1, 2, and 1, respectively. If cost is the priority, Z is increased. For example, for cigarette filter punching equipment, j, m, and n are 1, 1, and 2, respectively.
[0071] For the cigarette filter cutting equipment, k = 1.5 + 0.5f1;
[0072] Further examples of new cigarette filter cutting equipment are as follows:
[0073] Hourly Output Contribution X: The ratio of average monthly hourly output to average monthly orders is 0.8.
[0074] Quality score contribution Y: Yield rate is 0.9
[0075] Cost consumption Z: Raw material utilization rate is 0.9
[0076] Then f1 = jX + mY + nZ = 3 * 0.8 + 1 * 0.9 + 1 * 0.9 = 4.2; k = 1.5 + 0.5f1 = 3.6
[0077] An example of equipment for cutting used cigarette filters is shown below:
[0078] Hourly Output Contribution X: The ratio of average monthly hourly output to average monthly orders is 0.3.
[0079] Quality score contribution Y: Yield rate is 0.8
[0080] Cost consumption Z: Raw material utilization rate is 0.6
[0081] Then f1 = jX + mY + nZ = 3 * 0.3 + 1 * 0.8 + 1 * 0.6 = 2.3; k = 1.5 + 0.5f1 = 2.65
[0082] Aside from the first and second shutdowns, the equipment may experience multiple shutdowns.
[0083] The number of parts replaced during each shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z.
[0084] The equipment health status evaluation method further includes the following steps: when the equipment experiences unplanned shutdown, unplanned shutdown refers to shutdown that is not based on parts replacement or a preset duration, and the shutdown replacement time point is the unplanned shutdown time; the replacement standard for parts is: remaining life less than kHO; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
[0085] A device health status evaluation module, wherein the device health status evaluation method is stored in the device health status evaluation module in software form;
[0086] The device health status evaluation module is not located in the device.
[0087] This application continuously monitors and updates the remaining lifespan of each component in the equipment, and takes into account the average downtime and unplanned downtime, thereby optimizing downtime timing and allowing multiple components to be replaced during downtime. The number of components replaced is directly proportional to the equipment health. The higher the equipment health, the stronger the equipment's production capacity and the more important it is to the factory. Therefore, more components are replaced during each downtime, thereby reducing the number of downtimes and further improving production efficiency.
[0088] At the same time, by continuously updating the remaining lifespan of each component, we can predict the replacement time of the components and replace them in a planned manner. This is beneficial for the planning of component procurement and storage, reduces unreasonable procurement and storage of components, and helps to reduce costs and increase efficiency.
[0089] At the same time, replacing some parts of the equipment with high f1 and using them as parts for equipment with low f1 will further help reduce costs.
Claims
1. A method for evaluating the health status of equipment, characterized in that, The equipment health status evaluation method includes the following steps: The remaining lifespan of each component in the equipment is counted and recorded, and the remaining lifespan of each component is continuously updated over time. Determine the time for the first shutdown to replace parts, and the number of parts to be replaced during the first shutdown; The number of parts replaced during the first shutdown is positively correlated with the equipment's health level f1; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z. The hourly output contribution rate X is the ratio of the average monthly hourly output to the average monthly orders. The quality score contribution Y represents the yield rate; The cost contribution rate Z is the raw material utilization rate. The method for determining the downtime for replacing parts and the number of parts to be replaced includes the following steps: The average time between two historical downtimes of the equipment is recorded as H0. Among all the components, the remaining lifespan of the component with the shortest lifespan is denoted as H1; Determine the relative sizes of H1 and H0; When H1 is greater than H0, the downtime for replacement is 0.9H1; the replacement standard for parts is: remaining life is less than kH0; where k≥1.5, f1 is positively correlated with k, the larger f1 is, the larger k is; When H1 is less than H0, the downtime for replacement is 0.9H0; the replacement standard for parts is: remaining lifespan less than kH0; where k ≥ 1.5, f1 is positively correlated with k, the larger f1 is, the larger k is. Parts with a remaining lifespan greater than 3H0 after replacement by equipment with a high f1 rating are converted into spare parts for equipment with a low f1 rating.
2. The equipment health status evaluation method according to claim 1, characterized in that, The equipment health status evaluation method further includes the following steps: After the first shutdown to replace parts, the time for the second shutdown to replace parts and the number of parts to be replaced are determined based on the lifespan of the updated parts. The number of parts replaced during the second shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the hourly output X, quality score Y, and cost consumption Z of the equipment.
3. The method for evaluating equipment health status according to claim 1, characterized in that, The method for determining the downtime for replacing parts and the number of parts to be replaced also includes the following steps: Before recording the average time between two shutdowns of the equipment in the past as H0, determine whether there is a preset shutdown duration; If there is no preset downtime, proceed to the step of calculating the average time between two downtimes of the equipment in history, denoted as H0.
4. The method for evaluating equipment health status according to claim 3, characterized in that, If there is a preset downtime, it is recorded as h0; Determine the relative sizes of H1 and h0; When H1 is greater than h0, the time point for shutdown and replacement is h0; the replacement standard for parts is: the remaining life is less than kH0; where k≥1.5, f1 is positively correlated with k, the larger f1 is, the larger k is; When H1 is less than h0, the time point for shutdown and replacement is 0.9H1; the replacement standard for parts is: the remaining life is less than kH0; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
5. The equipment health status evaluation method according to claim 4, characterized in that, The health status f1 and the hourly output X, quality score Y, and cost consumption Z of the equipment satisfy the following relationship: f1=jX+mY+nZ; Wherein, j, m, and n are parameters set according to the contribution of the equipment in the factory workshop.
6. The method for evaluating equipment health status according to claim 5, characterized in that, Aside from the first and second shutdowns, the equipment may experience multiple shutdowns. The number of parts replaced during each shutdown is positively correlated with the health level f1 of the equipment; the health level f1 is positively correlated with the equipment's hourly output contribution X, quality score contribution Y, and cost consumption contribution Z.
7. The method for evaluating equipment health status according to claim 6, characterized in that, The equipment health status evaluation method further includes the following steps: when the equipment experiences an unplanned shutdown, the shutdown replacement time point is the time of the unplanned shutdown; the replacement standard for parts is: the remaining lifespan is less than kH0; where k≥1.5, f1 is positively correlated with k, and the larger f1 is, the larger k is.
8. A device for evaluating the health status of equipment, characterized in that, The equipment health status evaluation method according to any one of claims 1-7 is stored in the equipment health status evaluation device in software form; The device for evaluating the health status of an equipment is not located within the equipment itself.