Diagnostic method and diagnostic system for resistance ruler

Abstract

The invention discloses a diagnosis method and a diagnosis system for a resistance ruler. The diagnosis system comprises a controller, the resistance ruler and a power mechanism. The diagnostic method for the resistance ruler includes configuring a controller to execute the following steps: generating a control command corresponding to a target operation to control a power mechanism to drive the resistance ruler, and generating a command value data set according to the control command; receiving a feedback signal generated by the resistance ruler, and processing the feedback signal to generate a feedback value data set corresponding to the command value data set; comparing the command value dataset with a corresponding feedback value dataset to generate a plurality of comparison results; and counting a plurality of comparison results obtained in a preset time period to generate a diagnosis result, and defining a degradation state and an abnormal state of the resistance ruler according to the diagnosis result. According to the diagnosis method and the diagnosis system for the resistance ruler provided by the invention, the current degradation or abnormal condition of the resistance ruler can be reflected in real time, and even whether the degradation or abnormal condition of the resistance ruler possibly occurs in the future can be predicted.

Description

Technical Field

[0001] The present application relates to a diagnostic method and a diagnostic system for a resistance ruler, and in particular to a diagnostic method and a diagnostic system for diagnosing whether a resistance ruler is degraded or abnormal. Background Art

[0002] Injection molding machine is a common plastic product manufacturing machine. In the production process of plastic products, a resistance scale is often set on the injection molding machine as a feedback signal source to indicate the position of the mold, so as to control the mold to move to different positions and adjust the moving speed of the mold accordingly.

[0003] However, after a long period of repeated operation, the resistance scale will deteriorate due to the use environment (such as temperature, humidity), operation mode (such as different speeds) and use time, resulting in the degradation of the components in the resistance scale, resulting in the decrease of the response speed of the feedback mechanism and the deterioration of stability. Since the time of the above-mentioned failure is not fixed, it is often necessary to frequently stop the production operation and maintain the resistance scale without knowing whether the injection molding machine has a failure, in order to prevent sudden failures.

[0004] Furthermore, when faced with sudden failures, it is often necessary to urgently dispatch manpower to troubleshoot the failures, which not only consumes time and manpower costs, but also delays production progress due to the occurrence of failures, thereby reducing the production capacity of the injection molding machine and reducing the profits of the producer.

[0005] On the other hand, manufacturing equipment with a position feedback mechanism using a resistor scale is often used in unmanned production lines. For example, in the product manufacturing process, the action of picking up objects is often performed by a robotic arm. Therefore, when the resistor scale installed on the product manufacturing equipment has an abnormal position feedback, the robotic arm will not be able to pick up the object normally, causing the unmanned production line to stop production. In this way, the utilization rate of the product manufacturing equipment will be reduced, and further affect its production capacity and the profit of the producer.

[0006] Therefore, how to respond to and / or predict the degradation or abnormality of the resistor scale in real time to ensure the production capacity of the equipment equipped with the resistor scale has become one of the important issues to be solved in this technical field. Summary of the invention

[0007] The technical problem to be solved by the present application is to provide a diagnostic method and a diagnostic system for a resistor scale to address the deficiencies of the prior art, so as to respond to and / or predict the degradation or abnormality of the resistor scale in real time and improve the utilization rate of manufacturing equipment.

[0008] In order to solve the above-mentioned technical problems, one of the embodiments adopted in the present application is to disclose a diagnostic method for a resistor scale, the diagnostic method is applicable to a diagnostic system including a controller, a resistor scale to be measured and a power mechanism, the resistor scale to be measured is electrically connected to the controller, the power mechanism is coupled to the resistor scale to be measured, and the diagnostic method includes configuring the controller to perform the following steps: generating a control command corresponding to a target operation to control the power mechanism to drive the resistor scale to be measured, wherein a command value data set is generated according to the control command; a feedback signal generated by the resistor scale to be measured is received and processed to generate a feedback value data set corresponding to the command value data set; the command value data set is compared with the corresponding feedback value data set to generate multiple comparison results; and multiple comparison results obtained within a predetermined time period are counted to generate a diagnostic result, wherein the degradation state and abnormal state of the resistor scale to be measured are defined according to the diagnostic result.

[0009] Optionally, the command value data set includes multiple command value data, the feedback value data set includes multiple feedback value data, and the steps of receiving the feedback signal generated by the resistor to be measured and processing it to generate the feedback value data set corresponding to the command value data set include: recording a command issuance time when the control command is generated; starting to monitor the control command corresponding to the command issuance time to obtain multiple command value data and corresponding multiple command timings, and simultaneously monitoring the resistor to be measured to obtain multiple initial feedback value data; and taking the multiple command timings after a lag time after the command issuance time as multiple sampling timings, and taking the multiple initial feedback value data corresponding to the multiple sampling timings as multiple feedback value data to obtain the feedback value data set.

[0010] Optionally, the diagnostic method for the resistance scale includes executing a lag time measurement program to obtain the lag time, and the lag time measurement program includes configuring the controller to perform the following steps: controlling the power mechanism to drive a normal resistance scale to displace; and recording a start-up time required for a displacement of the normal resistance scale to be greater than a static limit value as the lag time.

[0011] Optionally, the step of comparing the command value data set with the corresponding feedback value data set to generate a plurality of the comparison results includes: executing a data conversion program on the feedback value data set and the command value data set to compare and generate a plurality of initial comparison results under a target data type, wherein the target data type is one or more of the signal value, position calculation value, distance calculation value, speed calculation value, voltage calculation value, start-up time calculation value and slope calculation value of the resistance scale to be measured; and comparing the plurality of the initial comparison results with a standard reference value of the target data type of the resistance scale to be measured to generate a plurality of the comparison results.

[0012] Optionally, the target operation includes one or more of a plurality of actions performed by the resistance scale to be measured, wherein the plurality of actions include speed increase, speed decrease, maintaining a constant speed, and stop.

[0013] Optionally, the step of counting a plurality of the comparison results obtained within the predetermined period of time to generate the diagnosis result includes:

[0014] Obtaining all the comparison results within the predetermined time period;

[0015] summing up the plurality of comparison results to generate a comparison result sum value; and

[0016] The comparison result sum is compared with a degradation evaluation standard to generate a degradation diagnosis result.

[0017] Optionally, the degradation assessment standard includes a normal range, a mild degradation range, a moderate degradation range and a severe degradation range, and the step of comparing the comparison result sum value with the degradation assessment standard to generate the degradation diagnosis result includes: judging whether the comparison result sum value is in the normal range, the mild degradation range, the moderate degradation range or the severe degradation range; in response to the comparison result sum value being in the normal range, judging that the resistance scale to be measured is normal; in response to the comparison result sum value being in the mild degradation range, judging that the resistance scale to be measured is mildly degraded; in response to the comparison result sum value being in the moderate degradation range, judging that the resistance scale to be measured is moderately degraded; and in response to the comparison result sum value being in the severe degradation range, judging that the resistance scale to be measured is severely degraded.

[0018] Optionally, the normal range is less than 1%, the mild degradation range is greater than or equal to 1% and less than 2%, the moderate degradation range is greater than or equal to 2% and less than 5%, and the severe degradation range is greater than or equal to 5% and less than 10%.

[0019] Optionally, the step of counting the multiple comparison results obtained within the predetermined time period to generate the diagnosis result also includes: obtaining all the multiple comparison results within the predetermined time period; adding up the multiple comparison results to generate a comparison result sum value; and comparing the comparison result sum value with an abnormality assessment standard to generate an abnormal diagnosis result.

[0020] Optionally, the abnormality assessment standard includes a surge range and a damage range, and the step of comparing the comparison result sum value with the abnormality assessment standard to generate the abnormality diagnosis result includes: judging whether the comparison result sum value is within the surge range or the damage range; judging that the resistor to be measured is partially damaged in response to the comparison result sum value being within the surge range; judging that the resistor to be measured is damaged in response to the comparison result sum value being within the damage range.

[0021] Optionally, the abnormal surge range is greater than or equal to 10% and less than 99%, and the damage range is equal to 100%.

[0022] Optionally, the target operation is to perform a constant speed action with the resistance scale to be tested, the target data type is the speed calculation value, and the step of comparing the sum of the comparison results with the abnormal evaluation standard to generate the abnormal diagnosis result also includes: determining whether the sum of the comparison results is within an asymmetric constant speed range; and in response to the sum of the comparison results being within the asymmetric constant speed range, determining that the resistance scale to be tested is improperly installed.

[0023] Optionally, the asymmetric constant speed range is from 0% to 100%.

[0024] Optionally, the diagnosis method for a resistance ruler includes: outputting a notification signal according to the diagnosis result to display the degradation and / or abnormal state of the resistance ruler to be tested.

[0025] In order to solve the above technical problems, another embodiment adopted by the present application is to provide a diagnostic system for a resistor scale, which is applicable to the above diagnostic method for a resistor scale, and the diagnostic system for a resistor scale includes a controller, a resistor scale to be measured and a power mechanism, the resistor scale to be measured is electrically connected to the controller, and the power mechanism is coupled to the resistor scale to be measured. The controller is configured to perform the following steps: generating a control command corresponding to a target operation to control the power mechanism to drive the resistor scale to be measured, wherein a command value data set is generated according to the control command; receiving a feedback signal generated by the resistor scale to be measured, and processing it to generate a feedback value data set corresponding to the command value data set; comparing the command value data set with the corresponding feedback value data set to generate a plurality of comparison results; and statistically analyzing a plurality of the comparison results obtained within a predetermined period of time to generate a diagnostic result, wherein the degradation state and abnormal state of the resistor scale to be measured are defined according to the diagnostic result.

[0026] To further understand the features and technical contents of the present application, please refer to the following detailed description and drawings of the present application. However, the drawings provided are only for reference and illustration and are not intended to limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a schematic diagram of a diagnostic system according to an embodiment of the present application.

[0028] Figure 2 It is a schematic diagram of a diagnostic system according to another embodiment of the present application.

[0029] Figure 3 The flowchart of the diagnosis method for the resistance ruler is shown according to the embodiment of the present application.

[0030] Figure 4 is a detailed flowchart of step S101.

[0031] Figure 5 FIG. 4 is a flow chart of a lag time measurement procedure according to an embodiment of the present application.

[0032] Figure 6 is a detailed flowchart of step S102.

[0033] Figure 7 This is a first detailed flowchart of step S103.

[0034] Figure 8 This is a second detailed flowchart of step S103. DETAILED DESCRIPTION

[0035] The following is an explanation of the implementation methods of the "diagnostic method and diagnostic system for resistance ruler" disclosed in the present application through specific embodiments. Those skilled in the art can understand the advantages and effects of the present application from the contents disclosed in this specification. The present application can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the concept of the present application. In addition, the drawings of the present application are only simple schematic illustrations and are not depicted according to actual dimensions. It is stated in advance. The following implementation methods will further explain the relevant technical content of the present application in detail, but the disclosed content is not intended to limit the scope of protection of the present application. In addition, the term "or" used in this article may include any one or more combinations of the associated listed items depending on the actual situation.

[0036] Figure 1 FIG. 1 is a schematic diagram of a diagnostic system according to an embodiment of the present application. Figure 1 As shown, the embodiment of the present application provides a diagnostic system 100 for a resistance scale, and the diagnostic system 100 includes a controller 1, a resistance scale to be measured 2, and a power mechanism 3. The resistance scale to be measured 2 is electrically connected to the controller 1, the power mechanism 3 is coupled to the resistance scale to be measured 2, and the controller 1 is electrically connected to the power mechanism 3.

[0037] In this embodiment, the controller 1 may include, for example, a storage unit and a processor unit, wherein the storage unit may be, for example, a memory, and the processor unit may be, for example, a microprocessor. In some embodiments, the controller 1 may be implemented in the form of a general-purpose computer, which includes a microprocessor, other suitable computer processors, or a central processing unit (CPU) capable of executing computer-readable instructions / software. In addition, when the controller 1 is implemented in the form of a general-purpose computer, a built-in storage unit (e.g., memory) may be used to store data, a plurality of computer-readable instructions, software, control commands, and feedback data corresponding to the control commands.

[0038] The resistance scale 2 to be measured may be, for example, a contact resistance scale or a non-contact resistance scale. The contact resistance scale may be, for example, a pull rod resistance scale. Taking the contact resistance scale as an example, the resistance scale 2 to be measured may at least include a brush, a joystick, and an online bearing.

[0039] In the diagnostic system 100, the controller 1 can issue a control command to control the power mechanism 3. For example, the controller 1 can generate a control command by executing a computer-readable executable instruction to control the power mechanism 3 to drive the resistance scale 2 to be measured to operate. When the resistance scale 2 to be measured operates, a feedback signal can be generated and transmitted back to the controller 1 for reception and storage.

[0040] In the embodiment of the present application, the diagnostic system 100 may further include a display 5 electrically connected to the controller 1, and the display 5 may be used to display the user interface 4. The display 5 may be, for example, a touch-sensitive display, and the user interface 4 may provide a plurality of options for the user to select an action item to be performed by the power mechanism 3. When the user completes the selection of the aforementioned action item, the controller 1 may generate a corresponding control command corresponding to the target operation to control the power mechanism 3 to actuate.

[0041] In a specific embodiment, the touch display can display multiple buttons, and the multiple buttons can correspond to multiple action items, such as increasing the speed, decreasing the speed, maintaining a constant speed, and stopping the resistance scale 2 to be measured. Therefore, the user can input operation information through the buttons of the touch display according to needs to complete the target operation, so that the controller 1 can receive the aforementioned target operation information to adjust the parameters used to control the power mechanism 3.

[0042] It should be noted that Figure 1 The architecture of the diagnostic system 100 is described in a simplified manner. In another embodiment, the architecture of the diagnostic system 100 of the present application can be further described as follows: Figure 2 shown. Figure 2 One specific embodiment of the power mechanism 3 is provided, and the diagnostic system 100 is applied to an injection molding machine.

[0043] The power mechanism 3 may include, for example, a motor 201, an oil tank 202, a directional valve 203, an oil cylinder 204, an oil outlet pipe 205, an oil return pipe 206, an oil outlet return pipe 207, an oil inlet pipe 208, a connecting rod 209A, and a moving mechanism 210, but the present application is not limited thereto. The moving mechanism 210 may include, for example, fixed mold plates 211A and 211B, a movable mold wall 212, a mold column 213, a slide rail 214, and a seat 215, but the present application is not limited thereto. The power mechanism 3 is coupled to the moving mechanism 210 via the connecting rod 209A, and the resistance scale 2 to be measured is coupled to the moving mechanism 210 via the connecting rod 209B. The resistance scale 2 to be measured is coupled to the power mechanism 3 via the fixed mold plate 211C.

[0044] Furthermore, the oil tank 202 is coupled to the motor 201 through the oil inlet pipe 208, the motor 201 is coupled to the directional valve 203 through the oil outlet pipe 205, the directional valve 203 is coupled to the oil tank 202 through the oil return pipe 206, and the directional valve 203 is coupled to the oil cylinder 204 through the oil return pipe 207. The oil cylinder 204 is coupled to the resistance scale 2 to be measured through the fixed template 211C, and the oil cylinder 204 and the resistance scale 2 to be measured are respectively coupled to the fixed templates 211A and 211B of the moving mechanism 210 through the connecting rods 209A and 209B, so that the power of the oil cylinder 204 can be transmitted through the moving mechanism 210, thereby driving the resistance scale 2 to be measured to move. The motor 201 is used to provide a power source, the oil tank 202 is used to store hydraulic oil, the directional valve 203 is used to change the oil outlet direction and the oil return direction, and the oil cylinder 204 is used to drive the resistance scale 2 to be measured and the moving mechanism 210.

[0045] In addition, the directional valve 203 may have two interfaces, including a first interface (not shown) connected to the oil cylinder 204 through the oil return pipe 207, and a second interface (not shown) connected to the oil tank 202 through the oil return pipe 206. The hydraulic oil can be output from the first interface to the oil cylinder 22 through the oil return pipe 207, and the hydraulic oil can flow back to the oil tank 202 from the second interface through the oil return pipe 206.

[0046] For example, when the user selects the target operation of increasing the speed of the resistance scale 2 to be measured through the user interface 4 displayed on the display 5, the controller 1 will generate a corresponding control signal corresponding to the aforementioned target operation, so that the power mechanism 3 can start after receiving the control signal of the controller 1, and can provide power to make the hydraulic oil be discharged from the oil tank 202, and then enter the motor 201 from the oil inlet pipe 208, so that the hydraulic oil can be pressurized by the motor 201 and output from the oil outlet pipe 205 to the directional valve 203.

[0047] Then, the hydraulic oil can be output from the first interface of the directional valve 203 through the return oil pipe 207 to the oil cylinder 204, thereby outputting the power provided by the motor 201 to the oil cylinder 204. The power of the oil cylinder 204 can push the movable mold wall 212A through the connecting rod 209A and the fixed template 211A, so that the movable mold wall 212A slides on the slide rail 214. The kinetic energy of the movable mold wall 212A moving on the slide rail 214 can pull the resistance scale 2 to be measured to move through the fixed template 211B and the connecting rod 209B. However, the above is an example of driving the driving power mechanism 3 to drive the resistance scale 2 to be measured to increase its speed, and the present application is not limited to this.

[0048] Based on the above architecture, you can further refer to Figure 3 , Figure 3 FIG. 1 is a flow chart of a diagnosis method for a resistance ruler according to an embodiment of the present application. The diagnosis method is applicable to the above-mentioned diagnosis system 100 , but is not limited thereto.

[0049] The following diagnostic method provided in the embodiment of the present application is applied to Figure 2 The following is an example of an embodiment shown in FIG. Figure 3 As shown, the diagnostic method may include configuring the controller 1 to perform the following steps:

[0050] Step S100: generating a control command corresponding to a target operation to control a power mechanism to drive the resistance scale to be measured.

[0051] In the above, the method of controlling the power mechanism 3 to drive the resistance scale 2 to be measured by the control command has been described, and it will not be repeated here. Figure 2 , 3 As shown, the target operation may include one or more of the actions of increasing the speed of the resistance scale 2 to be measured, decreasing the speed, maintaining a constant speed, stopping operation, etc., or any combination of the above target actions. The control command may be, for example, a drive signal transmitted to the motor 201. For example, in order to increase the speed of the resistance scale 2 to be measured, the control command may be to control the power mechanism 3 so that the speed of the motor 201 outputting the hydraulic oil is increased, thereby increasing the speed of the resistance scale 2 to be measured.

[0052] In addition, in addition to manually operating the user interface 4 to enable the controller 1 to generate a control command corresponding to the target operation, in other embodiments, the controller 1 can also automatically determine the content of the target operation. Accordingly, the controller 1 can generate a control command corresponding to the aforementioned target operation based on the user's own operation or the target operation automatically determined by the controller 1, so as to control the power mechanism 3 to drive the resistance scale 2 to be measured to operate, thereby performing subsequent diagnostic actions of the resistance scale 2 to be measured.

[0053] It should be noted that the control command corresponds to a command value data set. More precisely, the control command corresponds to a plurality of command value data contained in the command value data set. In the present embodiment, in order to adjust the moving speed of the resistor scale 2 to be measured, the command value data is a percentage value representing the speed range in which the resistor scale 2 to be measured can be executed, and the size of the aforementioned command value data is between 0% and 100%. Therefore, when the command value data is equal to 100%, it means that the moving speed of the resistor scale 2 to be measured is increased to the maximum speed. In addition, the command value data set may also include a plurality of command timings, that is, the time points corresponding to the generation of the aforementioned command value data. Therefore, the command value data set also defines the corresponding relationship between the aforementioned command value data and the aforementioned command timing.

[0054] Step S101: receiving a feedback signal generated by a resistance scale to be measured, and processing the feedback signal to generate a feedback value data set corresponding to a command value data set.

[0055] In this step, the controller 1 may, for example, receive an analog signal generated when the resistor scale 2 to be measured is displaced as a feedback signal, and record the changes in the analog signal and the corresponding timing. The resistor scale 2 to be measured may, for example, generate a feedback signal by monitoring resistance changes or voltage changes. In addition, in order to promptly reflect the operating conditions of the resistor scale 2 to be measured, the controller 1 may repeatedly monitor the operating conditions of the resistor scale 2 to be measured to generate feedback data. For example, the controller 1 may monitor the operating conditions of the resistor scale 2 to be measured once every 5 milliseconds to generate feedback data. In a preferred embodiment of the present application, the controller 1 monitors the resistor scale 2 to be measured once every 1 millisecond.

[0056] Specifically, in step S101, the controller 1 may convert the data type of the feedback data received from the resistance scale 2 to be measured. For example, when the original data type of the feedback signal generated by the resistance scale 2 to be measured is an analog value, the controller 1 may convert the received analog signal into, for example, a position calculation value, a distance calculation value, a speed calculation value, a voltage calculation value, a start-up time calculation value, and a slope calculation value.

[0057] After the controller 1 processes the feedback signal, a feedback value data set corresponding to the command value data set can be generated, wherein the feedback value data set includes a plurality of feedback value data, and each of them corresponds to the aforementioned command value data.

[0058] In this step, since the timing of the control command being issued and the timing of the resistance scale 2 to be measured actually starting to operate are different, it is impossible to directly obtain the feedback value data that truly corresponds to the control command from the feedback data, so the feedback data needs to be further processed. To be more precise, the timing of the control command being issued needs to be added with the total delay time (hereinafter referred to as the lag time) required for signal transmission and mechanical component operation, which is the timing when the resistance scale 2 to be measured actually starts to operate. Therefore, in order to obtain a feedback signal that truly corresponds to the control command, in another embodiment of the present application, the timing sampling method is further adjusted, as shown below. Figure 4 Detailed description.

[0059] Figure 4 is a detailed flow chart of step S101. Figure 4 As shown, step S101 further includes:

[0060] Step S1010: When a control command is generated, record the time when the command is issued.

[0061] In this step, when the controller 1 generates a control command, the issuing time of the control command can be simultaneously recorded as a command timing, and the command timing is stored in a storage unit.

[0062] Step S1011: starting to monitor the control command corresponding to the command issuance time to obtain a plurality of command value data and a plurality of corresponding command timings, and simultaneously monitoring the resistance scale to be measured to obtain a plurality of initial feedback value data.

[0063] In this step, the initial feedback value data may include a plurality of initial feedback values ​​and corresponding monitoring timings obtained by the controller 1 from the resistance scale 2 to be measured. For example, when the controller 1 issues a control command, the controller 1 may simultaneously record the feedback signal generated by the resistance scale 2 to be measured and the corresponding monitoring timing, for example, by repeatedly monitoring the operating conditions of the resistance scale 2 to be measured as mentioned above.

[0064] Step S1012: taking the command timings after the command issuance time and the lag time period as a plurality of sampling timings, and taking the initial feedback value data corresponding to the plurality of sampling timings as feedback value data, so as to obtain a feedback value data set.

[0065] In this step, the purpose of setting the sampling timing is to eliminate the influence of the lag time so as to obtain the initial feedback value data that truly corresponds to the command value data.

[0066] That is to say, the sampling timing is the command timing plus the lag time. After obtaining the sampling timing, this step further finds the one whose monitoring timing is equal to the sampling timing from all the initial feedback values, and the found initial feedback value data can be used as the feedback value data corresponding to the command value data. Then, after repeatedly performing this step for all the command value data, the feedback value data set can be obtained.

[0067] However, the lag time varies according to the power mechanism 3, so it is necessary to test different power mechanisms 3 to obtain the lag time. Figure 5 The lag time measurement process.

[0068] Figure 5 This is a flowchart of the lag time measurement procedure of an embodiment of the present application. Please refer to Figure 5 , the measurement procedure includes the following steps:

[0069] Step S500: Control the power mechanism to drive the normal resistance scale to move.

[0070] For the sake of brevity, the manner of displacement of the normal resistor scale is not described in detail herein. The normal resistor scale may be, for example, a brand new resistor scale or a resistor scale that has been tested and determined to be not degraded.

[0071] Step S501: recording the start-up time required for the displacement of the normal resistance ruler to be greater than the static limit value as the hysteresis time.

[0072] The static limit value can be used to determine whether the normal resistance scale has actually started to operate. In detail, the normal resistance scale may generate noise such as vibration during operation due to external factors such as the power mechanism 3. In order not to mistake these noises as feedback signals of the displacement of the resistance scale, a static limit value can be set when the controller 1 receives the feedback signal of the resistance scale. The static limit value can be greater than or equal to the displacement caused by noise such as vibration, so the controller 1 can filter out noise such as vibration through the static limit value. The static limit value can have different default values ​​according to the different noise levels of the power mechanism 3 in the diagnostic system 100. For example, the static limit value in the embodiment of the present application can be 5mm.

[0073] When the value of the feedback signal is less than the static limit value, the controller 1 will determine that the aforementioned feedback signal is noise; conversely, when it is a normal resistor, the value of its feedback signal will be greater than the static limit value at this time point. At this time, the controller 1 will determine that the normal resistor starts to operate, and accordingly record the current timing as the starting time.

[0074] Therefore, in this step, when the controller 1 issues the control command, it can record the time point when the control command is issued as the starting time Ts, and when the normal resistance scale starts to operate, it can record the time point when it starts to operate as the starting time Tf, and then the two can be subtracted to obtain the lag time Tp.

[0075] Thereafter, in step S1012 , the command timings after the command issuance time and the lag time can be used as a plurality of sampling timings, and the initial feedback value data corresponding to the plurality of sampling timings can be used as feedback value data to obtain a feedback value data set.

[0076] Please refer to Figure 3 , the diagnostic method enters step S102: comparing the command value data set with the corresponding feedback value data set to generate a plurality of comparison results.

[0077] The controller 1 can read the stored command value data set and the corresponding feedback value data set and compare the two, as shown in the following formula (1):

[0078] Data=OrderValue-BackValue...Formula (1);

[0079] In formula (1), Data is the comparison result, OrderValue is the command value data, and BackValue is the corresponding feedback value data. The generated comparison result represents the difference between the actual operation of the resistance scale 2 to be measured and the ideal operation.

[0080] Considering that the data formats of command value data and feedback value data may be different, please refer to Figure 6 , which is a detailed flow chart of step S102. Figure 6 As shown, step S102 also includes the following steps:

[0081] Step S1020: Execute a data conversion procedure on the feedback value data set and the command value data set to compare them in a target data type and generate a plurality of initial comparison results.

[0082] For example, the command value data set may include multiple speed command values, and the feedback value data set may include multiple analog values. In order to compare, the controller 1 may execute a data conversion program to convert the command value data set and the feedback value data set into the same data type for comparison in the same data type. For example, the target data type may be one or more of the analog value, position calculation value, distance calculation value, speed calculation value, voltage calculation value, start-up time calculation value and slope calculation value of the resistance scale. Among them, the value of the feedback signal can be directly used as the analog value, the position calculation value and the voltage calculation value can be converted from the analog value, the slope calculation value is the ratio of time to the speed of the resistance scale 2 to be measured, and the speed calculation value can be calculated based on the position calculation value and the corresponding time difference. In addition to the above data forms, the speed calculation value can also be further used to obtain the vibration calculation value and the time difference calculation value.

[0083] For example, the user can select the target data type according to the needs. In one embodiment of the present application, the user can select the distance as the target data type and instruct the controller 1 to execute step S1020, thereby converting the data types of the command value data set and the feedback value data set into distance for comparison, and generating an initial comparison result that meets the target data type. Among them, the vibration calculation value is the change between the speed value of the control command and the speed value actually fed back by the resistance scale 2 to be measured, and the time difference calculation value is the change between the timing of the control command and the timing of the actual start of operation of the resistance scale 2 to be measured.

[0084] In other embodiments, the controller 1 may also automatically determine the target data type. For example, when the user does not select the target data type, the controller 1 may automatically determine the target data type according to the type of the control command and execute the data conversion procedure accordingly.

[0085] Therefore, the command value data and feedback value data that have been unified into the target data form can be substituted into the above formula (1), and the difference can be calculated to obtain the initial comparison result.

[0086] Step S1021: Compare the plurality of initial comparison results with a standard reference value of a target data type of the resistance tape to be tested to generate a plurality of comparison results.

[0087] In this step, the standard reference value is a reference value of a normal resistance ruler in the above-mentioned various data forms. For example, if the target data form is a position calculation value, the standard reference value may be the full length of the movable distance of the normal resistance ruler.

[0088] That is, the comparison result between the initial comparison result and the standard reference value represents the error between the actual operation of the resistance scale 2 to be tested and the ideal operation of the normal resistance scale at the corresponding sampling time. The standard reference value and the initial comparison result can be compared, for example, by obtaining a ratio between the initial comparison result and the standard reference value, and using the ratio as the comparison result of step S1021.

[0089] Please refer to Figure 3 , the diagnostic method enters step S103: multiple comparison results obtained within a predetermined period are counted to generate a diagnostic result, and the degradation state and abnormal state of the resistance scale to be tested are defined according to the diagnostic result.

[0090] In this step, the predetermined period may be the time period from the first sampling sequence to the last sampling sequence. By taking statistics of all comparison results generated within the predetermined period, a diagnosis result of the resistance scale 2 to be measured may be generated.

[0091] In detail, the so-called degraded state refers to the situation that the resistor scale has abnormal position feedback, slow response feedback and poor stability due to environmental and / or time factors such as temperature, humidity, and application conditions of different speeds. The above-mentioned degradation condition may lead to poor control effect of the controller 1, and may further interrupt the periodic command reception behavior of the resistor scale. In addition, when the position feedback is abnormal, it will not be possible to pick up the parts normally, causing the production equipment (for example, the injection molding machine mentioned above) to operate abnormally and stop production, thereby reducing production capacity. When the degraded resistor scale is used in manufacturing equipment such as an injection molding machine, the injection molded products may be due to lack of material (uneven plastic injection), saturation (excessive plastic injection) or product damage, all of which may ultimately lead to reduced machine production capacity.

[0092] On the other hand, the so-called abnormal conditions include irregular operation of the resistance scale, interruption of the periodic command receiving behavior of the resistance scale, drift of the movement of the resistance scale, etc. Similarly, when the abnormal resistance scale is used in an injection molding machine, the above abnormal conditions may cause the production process to have problems such as poor product yield and unstable product production cycle.

[0093] Therefore, in the embodiments of the present application, the generated diagnostic results are designed to be used to evaluate the above-mentioned degradation and abnormal conditions.

[0094] For degraded conditions, refer to Figure 7 , which is a first detailed flow chart of step S103. Figure 7 As shown, step S103 may further include the following steps:

[0095] Step S1030: Obtain all comparison results within a predetermined period of time.

[0096] For example, the controller 1 may periodically monitor the resistance scale 2 to obtain command value data and corresponding feedback value data within a predetermined time period set or preset by the user, and obtain a plurality of comparison results after comparison.

[0097] Step S1031: summing up the plurality of comparison results to generate a comparison result sum value.

[0098] In this step, the so-called statistical comparison results obtained within the predetermined period of time may be, for example, all the comparison results within the predetermined period of time are summed up to generate a comparison result sum value. However, the present application is not limited thereto, and other statistical methods may be used to evaluate the data characteristics presented by all the comparison results within the predetermined period of time, and the evaluation criteria may be set on the same basis to evaluate the degradation and abnormal conditions.

[0099] Step S1032: Compare the comparison result sum value with the degradation assessment standard to generate a degradation diagnosis result.

[0100] In this step, in order to obtain the degradation diagnosis result, the degradation evaluation standard may be used to determine the degradation situation corresponding to the sum of the comparison results. For example, the degradation evaluation standard may include a normal range, a mild degradation range, a moderate degradation range, and a severe degradation range.

[0101] For example, in some embodiments, the normal range can be set as the sum of the comparison results within a range greater than or equal to 0% and less than 1%, the mild degradation range can be set as the sum of the comparison results within a range greater than or equal to 1% and less than 2%, the moderate degradation range can be set as the sum of the comparison results within a range greater than or equal to 2% and less than 5%, and the severe degradation range can be set as the sum of the comparison results within a range greater than or equal to 5% and less than 10%, as shown in Table 3 below.

[0102] Table 3:

[0103] Comparison result sum value Deterioration assessment criteria Deterioration Between 0 and 1% (including 0%) Normal range No degradation Between 1% and 2% (including 1%) Mild degradation range Slightly deteriorated Between 2% and 5% (including 2%) Moderate degradation range Moderate Deterioration Between 5% and 10% (including 5%) Severe degradation range severe deterioration

[0104] That is, when the sum of the comparison results falls within the normal range, it can be determined that the resistance scale 2 to be tested has not experienced resistance scale degradation, or that the degree of degradation of the resistance scale 2 to be tested is still within the permissible range of normal operation. For example, when the sum of the comparison results is 0.2%, the controller 1 can determine that the operation of the resistance scale 2 to be tested is normal.

[0105] It should be noted that the above-mentioned degradation assessment standard can be set according to user needs. For example, when the user needs a more rigorous assessment of the degradation of the resistance scale 2 to be tested, the degradation assessment standard of the controller 1 can be adjusted. For example, the standard for mild degradation can be reduced to greater than or equal to 0.5% and less than 1%. In this way, the diagnostic system and diagnostic method provided in the embodiment of the present application can present more stringent degradation assessment results.

[0106] Therefore, it is conceivable that in step S1032, the degradation diagnosis result is based on the degradation assessment standard corresponding to the sum of the comparison results, thereby presenting the degradation situation corresponding to the resistance scale 2 to be measured. That is, when the sum of the comparison results falls within the range of mild degradation, it is judged that the resistance scale 2 to be measured has mild degradation, such as the components in the resistance scale 2 to be measured have mild degradation; when the sum of the comparison results falls within the range of moderate degradation, it is judged that the resistance scale 2 to be measured has moderate degradation, such as the components in the resistance scale 2 to be measured have moderate degradation; when the sum of the comparison results falls within the range of severe degradation, it is judged that the resistance scale 2 to be measured has severe degradation, such as the components in the resistance scale 2 to be measured have severe degradation.

[0107] For abnormal conditions, please refer to Figure 8 , which is a second detailed flow chart of step S103. Figure 8 As shown, step S103 may further include:

[0108] Step S1033: Obtain all comparison results within a predetermined period of time.

[0109] Step S1034: summing up the plurality of comparison results to generate a comparison result sum value.

[0110] Step S1035: Compare the comparison result sum value with the abnormality assessment standard to generate an abnormality diagnosis result.

[0111] Among them, steps S1033 and S1034 are the same as steps S1030 and S1031, and are not repeated here.

[0112] In step S1035, in order to obtain an abnormal diagnosis result, an abnormal evaluation standard may be used to determine the abnormal situation corresponding to the sum of the comparison results. For example, the abnormal evaluation standard may include an abnormal surge range and a damaged range.

[0113] For example, in some embodiments, the abnormal surge range can be set to a comparison result sum value within a range greater than or equal to 10% and less than 99%, and the damaged standard can be set to a comparison result sum value of 100%, as shown in Table 4 below.

[0114] Table 4:

[0115]

[0116]

[0117] Similarly, the above-mentioned abnormality evaluation standard can be set according to user needs. When the user needs to more rigorously evaluate the abnormal situation of the resistance scale 2 to be tested, the abnormality evaluation standard of the controller 1 can be adjusted.

[0118] In step S1035, the abnormal diagnosis result is based on the abnormal evaluation standard corresponding to the sum of the comparison results, thereby presenting the abnormal situation corresponding to the resistance scale 2 to be tested. That is, when the sum of the comparison results falls within the abnormal surge range, it is determined that the resistance scale 2 to be tested is partially damaged, such as the components in the resistance scale 2 to be tested are partially damaged; when the sum of the comparison results reaches the damaged standard, it is determined that the resistance scale 2 to be tested is damaged, such as the components in the resistance scale 2 to be tested are damaged.

[0119] In addition, the sum of the comparison results can also be used to determine whether the resistance scale 2 to be tested has an abnormal situation of improper installation. In detail, the speed calculation value can be used as the target data type. When the resistance scale 2 to be tested performs the target operation of constant speed forward and constant speed backward, the command value data and feedback value data within a predetermined period can be recorded, and the sum of the comparison results of constant speed forward and constant speed backward can be calculated respectively, thereby determining whether the constant speed forward and constant speed backward of the resistance scale 2 to be tested have an asymmetric constant speed situation. At the same speed, the sum of the comparison results of constant speed forward and constant speed backward should be the same. When there is a difference between the two, it means that an asymmetric constant speed situation has occurred, that is, the resistance scale is improperly installed. Therefore, in step S1035, the abnormal evaluation standard may include an asymmetric constant speed range, such as between 1% and 100%, and the method of comparing the sum of the comparison results with the abnormal evaluation standard is as described above, after calculating the sum of the comparison results of constant speed forward and constant speed backward respectively, the two are subtracted, thereby determining whether the subtraction result is within the asymmetric constant speed range.

[0120] It should be noted that the asymmetric constant speed may be caused by improper installation of the resistance scale, for example, the installation angle between the pull rod of the resistance scale 2 to be measured and the power mechanism 3 is inappropriate, which causes the pull rod to be skewed or deformed when the resistance scale 2 to be measured is displaced.

[0121] Furthermore, the controller 1 can also output a notification signal according to the diagnosis result. That is to say, when the controller 1 outputs the diagnosis result, it can output a corresponding notification signal to remind the user according to the degradation condition or abnormal condition corresponding to the diagnosis result. For example, when the diagnosis result shows the degradation conditions such as mild degradation, moderate degradation, severe degradation in Table 3, abnormal surge, damage and the aforementioned asymmetric constant speed in Table 4, the notification signal can be used to display push messages such as mild degradation of the resistor scale, moderate degradation of the resistor scale, severe degradation of the resistor scale, partial damage of the resistor scale, damage of the resistor scale and improper installation of the resistor scale, so as to remind the user to eliminate the problem of the resistor scale and even arrange the maintenance schedule of the resistor scale. If the diagnosis result shows that none of the above abnormal conditions or degradation conditions have occurred, the push message will show that the resistor scale 2 to be tested is in a non-abnormal state or a non-degraded state.

[0122] In addition, the notification signal can be implemented in the form of a light signal, a sound signal or an electronic signal. For example, the controller 1 can transmit the notification signal to the display 5 to display a push notification, control a warning light to flash, or emit a warning sound through a speaker.

[0123] In addition to the above push mode, the diagnostic system 100 can adopt an emergency stop mechanism during the operation of the relevant manufacturing equipment according to the diagnostic result of the resistance scale 2 to be tested. In some embodiments, the diagnostic method of the present application may include configuring the controller 1 to execute the emergency stop mechanism. The emergency stop mechanism can be designed to be executed according to the emergency stop standard.

[0124] Specifically, when the diagnosis result of the resistance scale 2 to be tested shows a degradation condition of moderate degradation (inclusive) or above and / or any abnormal condition, the controller 1 will execute an emergency shutdown mechanism to instruct the resistance scale 2 to be tested and the power mechanism 3 to stop operating.

[0125] In summary, the diagnostic method and diagnostic system for the resistor scale provided by the present application can reflect the current degradation or abnormal condition of the resistor scale in real time, and even predict whether the resistor scale may deteriorate or become abnormal in the future; in addition, through the setting of the display and the user interface, the degradation or abnormal condition of the resistor scale can be presented to the user in real time, and even a maintenance reminder message can be sent to the user, so that the user can arrange the maintenance schedule of the resistor scale in advance. Therefore, for manufacturing equipment that uses a resistor scale to execute a position feedback mechanism, sudden production stoppage can be avoided, thereby improving the output and production efficiency of the equipment equipped with the resistor scale, and saving the maintenance and labor costs required when the equipment equipped with the resistor scale suddenly stops.

[0126] The contents disclosed above are only preferred feasible embodiments of the present application, and are not intended to limit the protection scope of the claims of the present application. Therefore, all equivalent technical changes made using the contents of the present application specification and drawings are included in the protection scope of the claims of the present application.

Claims

1. A diagnostic method for a resistance ruler, characterized in that: The diagnostic method for a resistance scale includes configuring a controller to perform the following steps: Generating a control command corresponding to a target operation to control a power mechanism to drive a resistance scale to be measured, wherein a command value data set is generated according to the control command; receiving a feedback signal generated by the resistance scale to be measured, and processing the feedback signal to generate a feedback value data set corresponding to the command value data set; comparing the command value data set with the corresponding feedback value data set to generate a plurality of comparison results; and A plurality of the comparison results obtained within a predetermined period of time are counted to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance scale to be measured are defined according to the diagnosis result.

2. The diagnostic method for a resistance ruler according to claim 1, characterized in that: The command value data set includes a plurality of command value data, the feedback value data set includes a plurality of feedback value data, and the steps of receiving the feedback signal generated by the resistance scale to be measured and processing the feedback signal to generate the feedback value data set corresponding to the command value data set include: When the control command is generated, a command issuing time is recorded; corresponding to the command issuing time, start monitoring the control command to obtain a plurality of command value data and a corresponding plurality of command timings, and simultaneously monitor the resistance scale to be measured to obtain a plurality of initial feedback value data; and The plurality of command timings after a delay time after the command issuance time are used as a plurality of sampling timings, and the plurality of initial feedback value data corresponding to the plurality of sampling timings are used as a plurality of feedback value data to obtain the feedback value data set.

3. The diagnostic method for a resistance ruler according to claim 2, characterized in that: The diagnostic method for a resistance scale includes executing a lag time measurement procedure to obtain the lag time, and the lag time measurement procedure includes configuring the controller to execute the following steps: Controlling the power mechanism to drive a normal resistance scale to move; and The start-up time required for a displacement of the normal resistance ruler to be greater than a static limit value is recorded as the hysteresis time.

4. The diagnostic method for a resistance ruler according to claim 2, characterized in that: The step of comparing the command value data set with the corresponding feedback value data set to generate a plurality of the comparison results comprises: Executing a data conversion procedure on the feedback value data set and the command value data set to compare and generate a plurality of initial comparison results under a target data type, wherein the target data type is one or more of the signal value, position calculation value, distance calculation value, speed calculation value, voltage calculation value, start-up time calculation value and slope calculation value of the resistance scale to be measured; and The plurality of initial comparison results are compared with a standard reference value of the target data type of the resistance tape to be tested to generate a plurality of comparison results.

5. The diagnostic method for a resistance ruler according to claim 1, characterized in that: The target operation includes one or more of a plurality of actions performed by the resistance scale to be measured, wherein the plurality of actions include speed increase, speed decrease, maintaining a constant speed, and stop.

6. The diagnostic method for a resistance ruler according to claim 4, characterized in that: The step of counting the plurality of comparison results obtained within the predetermined period of time to generate the diagnosis result comprises: Obtaining all the comparison results within the predetermined time period; summing up the plurality of comparison results to generate a comparison result sum value; and The comparison result sum is compared with a degradation evaluation standard to generate a degradation diagnosis result.

7. The diagnostic method for a resistance ruler according to claim 6, characterized in that: The degradation assessment standard includes a normal range, a mild degradation range, a moderate degradation range, and a severe degradation range, and the step of comparing the comparison result sum with the degradation assessment standard to generate the degradation diagnosis result includes: determining whether the sum of the comparison results is within the normal range, the mildly degraded range, the moderately degraded range, or the severely degraded range; In response to the sum of the comparison results being within the normal range, determining that the resistance scale to be tested is normal; In response to the sum of the comparison results being within the slight degradation range, determining that the resistance scale to be measured is slightly degraded; In response to the sum of the comparison results being within the moderate degradation range, determining that the resistance scale to be tested is moderately degraded; and In response to the comparison result sum being within the severe degradation range, it is determined that the resistance scale to be measured is severely degraded.

8. The diagnostic method for a resistance ruler according to claim 7, characterized in that: The normal range is less than 1%, the mild degradation range is greater than or equal to 1% and less than 2%, the moderate degradation range is greater than or equal to 2% and less than 5%, and the severe degradation range is greater than or equal to 5% and less than 10%.

9. The diagnostic method for a resistance ruler according to claim 4, characterized in that: The step of counting the plurality of comparison results obtained within the predetermined period of time to generate the diagnosis result further includes: Obtaining all the comparison results within the predetermined time period; summing up the plurality of comparison results to generate a comparison result sum value; and The comparison result sum is compared with an abnormality assessment standard to generate an abnormality diagnosis result.

10. The diagnostic method for a resistance ruler according to claim 9, characterized in that: The abnormality evaluation standard includes a surge range and a damage range, and the step of comparing the comparison result sum with the abnormality evaluation standard to generate the abnormality diagnosis result includes: Determining that the sum of the comparison results is within the surge range or the damage range; In response to the comparison result sum being within the surge range, determining that the resistance scale to be tested is partially damaged; In response to the sum of the comparison results being within a damage range, it is determined that the resistance scale to be tested is damaged.

11. The diagnostic method for a resistance ruler according to claim 10, characterized in that: The abnormal surge range is greater than or equal to 10% and less than 99%, and the damage range is equal to 100%.

12. The diagnostic method for a resistance ruler according to claim 9, characterized in that: The target operation is to perform a constant speed action with the resistance scale to be tested, the target data type is the speed calculation value, and the step of comparing the comparison result sum with the abnormality assessment standard to generate the abnormality diagnosis result also includes: Determining whether the sum of the comparison results is within an asymmetric constant speed range; and In response to the sum of the comparison results being within the asymmetric constant speed range, it is determined that the resistance scale to be tested is improperly installed.

13. The diagnostic method for a resistance ruler according to claim 12, characterized in that: The asymmetric constant velocity range is from 0% to 100%.

14. The diagnostic method for a resistance ruler according to claim 1, characterized in that: The diagnostic method for the resistance ruler comprises: According to the diagnosis result, a notification signal is output to indicate the degradation and / or abnormal state of the resistance scale to be tested.

15. A diagnostic system for a resistance ruler, characterized in that: The diagnostic system for a resistance ruler is suitable for executing the diagnostic method for a resistance ruler according to any one of claims 1 to 14, and the diagnostic system for a resistance ruler comprises: a controller; a resistance scale to be measured, electrically connected to the controller; and A power mechanism coupled to the resistance scale to be measured; The controller is configured to perform the following steps: generating a control command corresponding to a target operation to control the power mechanism to drive the resistance scale to be measured, wherein a command value data set is generated according to the control command; receiving a feedback signal generated by the resistance scale to be measured, and processing the feedback signal to generate a feedback value data set corresponding to the command value data set; comparing the command value data set with the corresponding feedback value data set to generate a plurality of comparison results; and A plurality of the comparison results obtained within a predetermined period of time are counted to generate a diagnosis result, wherein a degradation state and an abnormal state of the resistance scale to be measured are defined according to the diagnosis result.

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