Equipment management method and system

Abstract

The invention firstly provides an equipment management method which comprises the following steps: S1, collecting existing fault information, and carding and analyzing the fault information to form a standard fault library; s2, establishing an equipment fault tree by taking faults as guidance according to equipment types, and carrying out integrated management of equipment repair design and operation and maintenance data by relying on the fault tree; and S3, during maintenance, relying on the fault tree, performing repair design, operation and maintenance management and maintenance optimization work of the equipment. The invention further provides an equipment management system for executing the equipment management method. According to the equipment management method and system provided by the invention, the historical faults of the equipment are sorted, the fault causes are analyzed, and the maintenance process is reversely optimized.

Description

Technical Field

[0001] The present invention relates to the technical field of production site equipment operation and maintenance management, and in particular to an equipment management method and system. Background Art

[0002] At present, the existing equipment management model of most enterprises mainly adopts planned preventive maintenance and post-maintenance. Planned preventive maintenance is to formulate standards such as maintenance content, requirements and cycles based on maintenance experience. It does not establish a correlation with equipment failures and cannot effectively reduce the occurrence or recurrence of failures.

[0003] Therefore, in the face of the increasing contradiction between the aging of production equipment, the increasing failure rate year by year and the company's actual need to reduce maintenance costs, the existing equipment management model has been difficult to adapt to the management needs of digital transformation and cost-effective equipment operation and maintenance, and it is urgent to transform to a refined, systematic and multi-mode maintenance method. It is urgent to invent a patent for a method and system for optimizing equipment management based on fault-oriented multi-dimensional detection. Summary of the invention

[0004] The main purpose of the present invention is to solve the above problems and shortcomings, and to provide an equipment management method and system, which can optimize the maintenance process by combing through historical equipment failures, analyzing the causes of the failures, and reversely optimizing the maintenance process.

[0005] To achieve the purpose of the invention, the present invention first provides a device management method, which adopts the following technical solution:

[0006] A device management method comprises the following steps:

[0007] S1, collect existing fault information, sort out and analyze the fault information, and form a standard fault library;

[0008] S2, based on the equipment type and fault-oriented, build an equipment fault tree, and use the fault tree to carry out integrated management of equipment repair process design and operation and maintenance data;

[0009] S3, during maintenance, rely on the fault tree to carry out equipment repair process design and operation and maintenance management to optimize maintenance work.

[0010] Furthermore, the fault information such as the fault phenomenon, cause and disposal method is standardized and then input into the standard fault library.

[0011] Furthermore, in step S1, in the standard fault library, the faults are classified according to system functions and fault causes, so as to provide a basis for repair program design and operation and maintenance management.

[0012] Furthermore, step S2 also includes building a configuration tree including equipment location information, components, subcomponents, minimum units and coding information to support the full life cycle management of the equipment based on the equipment type.

[0013] Furthermore, taking the equipment configuration as the entry point and the minimum maintenance unit as the basis, an equipment fault tree oriented to the maintenance object is established.

[0014] Furthermore, step S2 also includes, based on the standard fault library in step S1, constructing a fault dictionary and fault coding, using the fault dictionary as a guide, establishing inspection and repair plans for each unit of the equipment, compiling major equipment maintenance procedures, and standardizing the repair and replacement standards for each component.

[0015] Furthermore, in step S3, the fault is handled according to the fault code with the help of the fault dictionary specification.

[0016] Furthermore, in step S3, the optimization of maintenance work includes any one or more of spot inspection optimization, scheduled minor repair optimization, lubrication optimization, and major repair work optimization.

[0017] Furthermore, the method also includes step S4, applying information management means to perform predictive maintenance.

[0018] A device management system, characterized by executing a device management method as described in any one of claims 1 to 9.

[0019] The second invention object of the present invention is to provide an equipment management system, which adopts the following technical solution:

[0020] A device management system executes a device management method as described above.

[0021] In summary, the device management method and system provided by the present invention have the following technical advantages compared with the prior art:

[0022] 1. Starting from the fault, clarify the relationship between the fault and the business, reversely optimize fault management, improve business, etc., establish new standards and specifications for equipment maintenance, and innovate equipment maintenance models;

[0023] 2. Record the entire process of equipment maintenance, organize maintenance experience, form a fault dictionary, and guide fault handling;

[0024] 3. By improving equipment maintenance work, the occurrence rate of failures is reduced, thereby reducing equipment maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 : A schematic diagram of fault classification in a device management method provided by the present invention;

[0026] Figure 2 : A schematic diagram of a fault standardization template in a device management method provided by the present invention;

[0027] Figure 3 : A schematic diagram of a work flow of equipment maintenance guided by fault category in an equipment management method provided by the present invention;

[0028] Figure 4a : A fault tree diagram in an equipment management method provided by the present invention (with the plant as the base point);

[0029] Figure 4b : A schematic diagram of a fault tree of a welding robot in an equipment management method provided by the present invention;

[0030] Figure 5 : A technical inspection document compiled based on troubleshooting in an equipment management method provided by the present invention;

[0031] Figure 6 : A technical document for scheduled maintenance and minor repairs compiled based on fault prevention and disposal in an equipment management method provided by the present invention;

[0032] Figure 7 : In an equipment management method provided by the present invention, a standardized oil product database is compiled based on fault guidance and basic parameters;

[0033] Figure 8 : A schematic diagram of a major maintenance process compiled with the equipment fault tree as a guide in an equipment management method provided by the present invention;

[0034] Fig. 9 :In an equipment management method provided by the present invention, the equipment failure is used as a guide to improve the item points and cycle logic diagram of the Haikou Municipal Party Committee;

[0035] Fig.10 : In an equipment management method provided by the present invention, a logic diagram of scheduled maintenance and minor repair items is improved based on faults;

[0036] Fig.11 : In an equipment management method provided by the present invention, a flow chart of a scheduled maintenance and minor repair cycle is improved by combining parameters such as failures and operating time;

[0037] Fig.12 : A flow chart of optimizing lubrication oil change cycle based on oil quality in an equipment management method provided by the present invention;

[0038] Fig.13 : A flowchart of major repair cycles and item points in an equipment management method based on fault frequency provided by the present invention;

[0039] Fig.14 : A full-cycle maintenance diagram based on fault prediction in an equipment management method provided by the present invention;

[0040] It should be noted that these drawings and textual descriptions are not intended to limit the conceptual scope of the present invention in any way, but are intended to illustrate the concept of the present invention for those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0041] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0042] In the description of the present invention, it should be noted that the directions or positional relationships indicated by terms such as “upper”, “lower”, “front”, “back”, “left”, “right”, “vertical”, “inside” and “outside” are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0043] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0044] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0045] The present invention provides a device management method and system. The device management system includes a controller or any other storage medium capable of executing a software program (hereinafter collectively referred to as a controller). The device management method provided by the present invention is stored in the controller. Specifically, the management method includes the following steps:

[0046] S1, analyze the faults:

[0047] According to the equipment classification, collect the existing historical fault information, sort out and analyze the historical fault information, and perform standardized processing, including but not limited to:

[0048] S11, collect and organize historical fault information, use standardized and normalized methods to re-describe the fault phenomenon, fault causes and fault handling content, delete the colloquial and repetitive descriptions in the existing data, and describe the inconsistent descriptions in the same or similar fault information in a standardized and unified way to facilitate the statistical analysis of fault information and provide support for fault classification and hierarchical management.

[0049] S12, after the collected fault information is standardized and uniformly described, it is organized into a fault database. In the fault database, Figure 1 As shown, the equipment can be classified based on system functions, fault causes, handling methods, fault levels, etc. According to the classification principles, the fault information should be described in a standardized manner in the fault database.

[0050] Classify the equipment by system function, decompose the equipment by system and structure, and preferably decompose the equipment layer by layer, from components and parts to the smallest maintenance unit, and associate the maintenance unit, fault cause, maintenance data and other fault information in the database. Describe the fault information of each maintenance unit according to the standardized requirements, and in the daily equipment management process, according to the fault manifestation, directly associate it with the smallest maintenance unit in the fault database, and obtain the corresponding fault information to obtain the corresponding maintenance information.

[0051] Classify the fault causes by category, such as aging and damage, maintenance, usage and operation, software abnormality, etc., study the mechanism of the fault, analyze the fault characteristics, and provide targeted maintenance suggestions based on the fault characteristics to optimize the equipment repair process.

[0052] Classify by fault level. For example, level 1 faults can be set as faults that affect equipment production safety, level 2 faults can be set as faults that can be temporarily maintained, and level 3 faults can be set as faults that do not affect equipment use, such as appearance damage. Classify by fault level. According to the set principle, each level of fault includes multiple different types of fault names and corresponding handling procedures. The faults obtained on site can be directly searched for the corresponding classification in the database, so that risk estimation can be carried out, key points can be directly focused on, and handling procedures can be standardized.

[0053] It is also possible to classify by single device, by device name / code, conduct overall / partial evaluation of each device, create digital files, and develop targeted maintenance strategies for different devices.

[0054] It should be noted that the faults in the fault database are classified according to a predetermined classification principle, and there can be multiple predetermined classification principles, including but not limited to the above-mentioned system functions, fault cause categories, fault levels, and classification methods for single equipment. Under different principles, it is possible to conduct statistical analysis of maintenance data in a single day or cycle in multiple dimensions to optimize subsequent maintenance work. And the data in the fault database can be updated at any time according to new faults and optimization content.

[0055] S13, the fault database can export the fault data list as needed. In this embodiment, the difference between the fault data list and the list used in the existing production site is that, according to the standardized processing result of step S11 and the fault database of S12, the standardized fault code, cause category, structure (such as the smallest maintenance unit after splitting in the system function classification), level, spare parts and other related fields are added, and the following is formed: Figure 2 The standardized fault template is shown.

[0056] like Figure 2 As shown, in this embodiment, the equipment code (fixed asset number) is used as an example to classify and introduce the specific content of the fault data list. In this embodiment, for different equipment, the fault phenomena of each equipment are listed respectively, and the corresponding fault causes and solutions are obtained from the fault database; in the fault database or when used for the first time, corresponding fault codes are set for the fault phenomena and fault causes to facilitate the subsequent maintenance retrieval, statistics and other applications. According to the recorded fault phenomena, the corresponding fault codes are obtained in the database and listed in the list, and then the fault codes are obtained from the fault database. Figure 1 The corresponding fault cause category and system function are obtained in step S12, and the equipment is decomposed layer by layer according to the system function classification process in step S12 to obtain the components, parts and minimum repairable units corresponding to the fault and the model corresponding to the minimum repair unit (faulty part), and then Figure 2 Obtain the corresponding fault level from the associated spare parts library; and obtain the corresponding spare parts inventory from the associated spare parts library.

[0057] The contents corresponding to each associated field in the fault template are all standardized data. Among them, standardized fault codes are helpful for recording, counting and analyzing faults; fault cause categories can analyze fault causes and existing problems; the structure to which the fault belongs can sort out the equipment functional system, which can better locate the minimum maintenance unit from the positive direction, and determine the functional system and root structure category corresponding to the minimum maintenance unit from the reverse direction; fault level classification is based on fault level and importance, which is convenient for differentiated resource allocation; displaying spare parts information, such as spare parts code, model, inventory quantity, and fault consumption, is conducive to optimizing spare parts reserve management.

[0058] S14, performing statistical analysis on the fault data generated in S12, guiding and optimizing the equipment maintenance management work, thereby guiding the equipment maintenance work according to the fault category.

[0059] like Figure 3 As shown, the on-site fault is recorded, and the recorded content includes but is not limited to the equipment type, fault cause, fault manifestation, etc. Preferably, it can be used Figure 2 The fault template shown is used to record the fault. Figure 2In the template shown, the fault phenomenon and / or fault cause are recorded, and the corresponding fault code and other information are directly obtained from the database. Statistical analysis is performed by equipment model to obtain the fault cause category of the same type of equipment (equipment with the same model or the same function but different model), and determine whether the number of occurrences of the same fault category is greater than the predetermined number of times. If so, the corresponding item point is optimized for the specific type of fault. If not, the maintenance item for the fault point remains unchanged and it is confirmed whether other types of functional points can be optimized.

[0060] For example, in this embodiment, Figure 3 As shown, when the number of times a certain fault under the maintenance category occurs within a cycle is greater than the predetermined value XX, if the fault is related to the appearance and performance inspection of the equipment, the spot inspection / routine maintenance items can be optimized; if the fault is related to the deep cleaning of the equipment, the regular maintenance items can be optimized; if the fault is related to the inspection and replacement of damaged parts and precision adjustment, the minor repair items are optimized, and the optimized data is maintained in the fault database, so as to continuously optimize the maintenance operations. When the number of times a certain fault under the maintenance category occurs within a cycle is less than or equal to the predetermined value XX, the probability of occurrence of the fault is small, and it has little impact on safe production and / or product quality. Therefore, the items that affect safety and product quality corresponding to the fault remain unchanged, and no optimization and improvement are required. It can be considered whether other functional items related to the fault can be optimized.

[0061] In this embodiment, the fault records are compared with the fault database, and the types of faults obtained and the number of times the faults occur are used to optimize the operation items, operation frequency and other contents of the maintenance work such as routine inspections and scheduled maintenance and minor repairs. For aging and damage faults, guide the reasonable spare parts reserve and improve the spare parts safety inventory; for maintenance faults, guide the optimization of the repair process, optimize the scheduled maintenance items, increase the item requirements or adjust the cycle; use operation faults to guide standard operations, strengthen training, and compile highly operational operation cards; for system defect faults, system backup, improve software management, and effective backup; for maintenance quality faults, guide operation evaluation, evaluate the skills of maintenance personnel, and conduct targeted training; for spare parts quality faults, guide quality evaluation, evaluate spare parts quality, and standardize spare parts quality management; for other types of faults, continuous tracking is required, attention is paid to the frequency of occurrence, and in-depth analysis is conducted.

[0062] S2, construct the technical foundation, build the corresponding configuration tree according to the equipment type, build the equipment fault tree based on the equipment configuration tree, and rely on the fault tree to carry out integrated management of equipment repair process design and operation and maintenance data.

[0063] In step S1, when arranging the fault database, the equipment is decomposed layer by layer, from components, parts to the smallest maintenance unit. In step S2, combined with the characteristics of the equipment itself, according to the same decomposition principle, a configuration tree with hierarchical and positional relationships is built. The equipment configuration tree includes equipment location information, parts (assemblies), sub-components (parts), smallest maintenance units, and coding information, etc., to provide support for the management of the entire life cycle of the equipment.

[0064] According to the configuration tree, the functions of locating the equipment position and the components can be quickly realized. Furthermore, guided by the fault and relying on the fault database, the fault tree of the equipment is further built on the basis of the equipment configuration tree. Specifically, taking the equipment configuration tree as the starting point and the minimum maintenance unit on the configuration tree as the basis, the fault database is horizontally associated so that the minimum maintenance unit on the equipment configuration tree corresponds to and is associated with the minimum maintenance unit in the fault database, thereby integrating the configuration tree, the minimum maintenance unit, the fault category, the maintenance operation and other contents in the mode of the configuration tree, establishing an equipment fault tree for maintenance objects (equipment, components, etc.), and relying on the fault tree to realize the integrated management of equipment repair process design and operation and maintenance data.

[0065] While constructing the equipment fault tree, a fault dictionary and fault coding are constructed. In the fault dictionary, the fault phenomenon and fault cause are described in standardized language, so that accurate fault statistics can be achieved during daily maintenance. System components, fault phenomena, causes, treatment measures, levels, etc. are coded separately to standardize equipment fault management. Each fault phenomenon is matched with a standard treatment method.

[0066] The equipment fault tree can be constructed differently according to the different equipment configuration trees, such as configuration based on the plant area, configuration based on a single device, and other configuration methods. Figure 4a As shown in the figure, the factory area is used as the base point configuration. According to the regional division and equipment distribution in the factory area, the corresponding configuration tree is constructed. From the configuration tree, the corresponding workstation, spatial position, plane grid position in the factory area, factory building location and factory area of ​​the equipment can be obtained. On the basis of the configuration tree, combined with the fault database, a fault library is formed, which can analyze and count the fault data of a certain grid, factory building and equipment in the factory area. The factory area configuration tree is combined with the equipment configuration tree to further analyze and count the fault data corresponding to a certain minimum maintenance unit of a certain equipment in the factory area.

[0067] Further, a certain equipment fault tree takes the IGM welding robot fault tree as an example, such as Figure 4bAs shown, first, a device configuration tree is built. In the device configuration tree, the device components are divided and decomposed layer by layer until the device is decomposed into the smallest maintenance unit, and the equipment at each level is coded. Then, combined with the fault library, the fault object, fault cause category, fault cause, fault level and solution are obtained, and a fault dictionary is generated based on the fault library. In the fault dictionary, the fault object, fault phenomenon, fault category, fault cause, fault level and corresponding solution are explained in standardized language. Among them, the fault object corresponds to each level structure corresponding to the device configuration, especially the smallest maintenance unit, forming a complex fault tree.

[0068] Furthermore, combined with the maintenance optimization function in step S1, the repair process design, operation and maintenance data and other detection design processes are integrated into the fault tree at the same time, and the repair process design can be carried out according to the fault causes and troubleshooting methods of the fault library. The repair process design includes but is not limited to repair process establishment, preparation of work cards, construction of PHM (fault prediction and health management) model and update and maintenance of the fault library. And further carry out data maintenance of operation data, preventive maintenance data, fault correction data and operation and maintenance history management.

[0069] According to the content of the fault tree and fault library data, the inspection technical documents are compiled based on the troubleshooting of the faults. According to the six fixed benchmarks, the maintenance process content is integrated, the inspection technical standard content is optimized for the faults, the inspection and maintenance focus is highlighted, and the maintenance process benchmark table is prepared to compile the inspection technical documents based on the fault arrangement. The inspection execution form is formulated using the main framework of fixed point, fixed person, fixed method, fixed period, fixed calibration, and fixed item, and the supporting inspection work instructions include the scope of work, references, work process, inspection work route, work tools, personnel requirements, and the work content before / during / after the shift is refined according to the availability of power conditions and other instructions. In order to ensure that the inspection work is thorough, in place, and of reliable quality, the following are compiled: Figure 5 The technical documentation for inspection work based on troubleshooting is shown.

[0070] like Figure 5 As shown, the technical documents of the inspection operation include but are not limited to the system, inspection unit, operation content, operation standard and diagrams. Among them, the operation point is determined by ID (code), system, component and part; the operation method is determined by task category; the operation is calibrated and determined by maintenance task, and the items and standard requirements of maintenance task are determined; the regularization of inspection operation is determined by inspection routine cycle; in the technical documents of the inspection operation, the specific operation instructions of the parts corresponding to the inspection operation (which may be components or the smallest maintenance unit, without restriction) are clearly defined, the tools and quantity required for the inspection operation are also indicated with diagrams to indicate the names of the parts in the components to be operated, the inspection order of each part, the inspection mode / method and the standard requirements of the operation.

[0071] According to the content of the fault tree and fault data, the technical documents for minor maintenance repairs are compiled based on fault prevention and treatment, and fault prevention and treatment are carried out based on item optimization. When compiling the technical documents for minor maintenance repairs based on fault prevention and treatment, the six standards are combined to integrate the repair process content, optimize the repair process content according to the fault, and standardize the technical documents for minor maintenance repairs. The maintenance process form for minor maintenance repairs is compiled in combination with the six-standard framework, the item requirements of the form are improved, and the corresponding technical documents for minor maintenance repairs are compiled, such as Figure 6 The technical documents for scheduled maintenance and minor repairs compiled based on fault prevention and disposal are shown, as well as the scheduled maintenance and minor repairs operation instructions, including the scope of work, references, operation procedures, personnel requirements and division of labor, operation tools, preparations before minor repairs, minor repairs under different conditions with and without electricity, site cleaning, and other matters; the scheduled maintenance and minor repairs operation chart can highlight the operation location, operation content, quality standards that need to be achieved in a more detailed manner, and has graphical visualization.

[0072] The technical documents for scheduled maintenance and minor repairs compiled based on fault troubleshooting also use the main framework of fixed-point, fixed-person, fixed-method, fixed-period, fixed-calibration, and fixed-item repair process forms, and supporting operation instructions, which are provided to operators in a graphic and textual manner. The division of fixed-point, fixed-method, fixed-calibration, fixed-item, and fixed-period is the same as that of the technical documents for spot inspections. No further elaboration is given.

[0073] Taking the equipment running at high temperature or mechanical wear failure as an example, the preparation process of technical documents is introduced. Guided by the high temperature or mechanical wear failure of the equipment, the oil types used by various equipment in the factory are sorted out, and the equipment data and the corresponding oil types and oil sample data are collected. According to the industry standards, the key indicators of oil inspection are determined; based on the collected oil port viscosity, pH value and water content data, the quality and change trend of the oil during the operation process are analyzed to determine whether the existing oil replacement cycle is reasonable, so as to optimize the lubrication replacement cycle; the particle counting, iron spectrum analysis, spectrum analysis and other data are collected, and the mechanical wear and change trend of the equipment are analyzed according to the data changes to determine whether the mechanical wear of the equipment is within the preset range. According to the comparison results and data development trends, the hydraulic parts wear maintenance of the equipment is guided; the analysis data is confirmed and standardized to form an oil change feature library.

[0074] As mentioned above, collect the original data corresponding to the equipment and oil products and the constantly changing data during use, perform statistical analysis on the data, obtain the changing development trend of the data, so as to optimize the maintenance of equipment and oil ports, and compile the five fixed tables of lubrication based on statistical data, clearly regulate the lubrication position, lubricating grease model, lubrication cycle, lubricating oil volume and operating personnel, conduct regular oil sample testing and analysis, compile an oil change feature library, and associate the changing trend of equipment oil test data (viscosity, moisture, particle size, etc.) according to the equipment asset number, asset name, oil model, operating time and other information, compile early warning models for equipment oil quality and changing trend, mechanical wear and changing trend, so as to obtain the following: Figure 7 The oil standardization database shown is compiled based on fault guidance and basic parameters.

[0075] It should be noted that the data in the oil change feature library changes in real time, such as operating time and load rate, which are updated in real time according to the operating status of the equipment, while the professional inspection cycle and on-site inspection cycle are updated periodically according to the optimization results after data analysis. Furthermore, based on the latest data in the oil change feature library, the operating status of the equipment is reversely monitored to compare with the statistical data, determine whether there is an interval that can be optimized, and iterate and update the data, thereby continuously improving maintenance operations.

[0076] The fault tree can also be used as a guide to prepare major maintenance procedures, such as Figure 8 As shown, relying on the equipment's fault tree, combined with the equipment's characteristics and relevant information such as maintenance manuals, instruction manuals, etc., establish inspection and repair plans for each unit of the equipment. Then, combined with the company's repair technical regulations, management regulations, national standards and other information, compile equipment major repair and maintenance procedures to standardize the repair and replacement standards for each component.

[0077] Specifically, taking the preparation of the major (item) maintenance outline of the welding manipulator as an example, this paper introduces how to use the equipment fault tree to guide the preparation of the major maintenance program, such as Figure 8 As shown in the figure, the welding robot configuration tree includes the system level that decomposes the welding robot layer by layer, and finally obtains the component information of the smallest maintenance unit. Each disassembled level and component is coded separately, and the location information of each component and component is noted. Combined with the fault library data, the inspection items (items that may fail) are added to the components corresponding to each smallest maintenance unit, thereby constructing a fault tree, and according to the maintenance history and work experience, corresponding disposal measures are added for each inspection item. That is, the fault tree is generated by combining the configuration tree of the equipment with the fault library, and the corresponding disposal measures are added for each fault (inspection item).

[0078] Based on the previously constructed fault tree equipped with disposal measures, and in accordance with the company's repair technical regulations, the welding robot system's whole machine instructions, maintenance operation manuals and other relevant requirements, an outline for the major (item) overhaul of the welding robot is generated. The content includes but is not limited to the repair process code 1, structural coding, equipment structure, inspection items, and the tools and materials used in the inspection process corresponding to each inspection item, the inspection standards that the items should meet, and the handling methods when abnormalities occur. Requirements are made for the major (item) overhaul cycle, repair scope, repair method (condition repair, disassembly repair, component testing, etc.), and the repair content and standards of the maintenance parts. Specifically, Figure 8 shown.

[0079] It should be noted that various technical documents created based on faults are maintained in the fault tree and / or fault dictionary at the same time. During daily maintenance operations, the corresponding fault information can be retrieved from the fault tree and fault dictionary based on the fault code and / or fault name and / or fault phenomenon, and the corresponding operation technical documents can be obtained to guide daily maintenance operations.

[0080] S3, during maintenance, rely on the fault tree to carry out equipment repair process design and operation and maintenance management to optimize maintenance work.

[0081] According to the fault tree constructed in the previous article and various technical documents created based on the fault tree, daily maintenance work is carried out, including but not limited to repair process design, operation and maintenance management, daily maintenance work and optimization of maintenance work, especially after maintenance is carried out according to the various technical documents formulated according to the fault tree, and continuous maintenance work optimization is carried out.

[0082] Maintenance work and maintenance optimization include:

[0083] 1. Troubleshooting and optimization

[0084] Relying on the fault dictionary, standardization of abnormal reporting (faults), normalization of handling, and standardized management of process carriers are achieved. According to the abnormalities occurring on site, the corresponding standardized fault description is retrieved in the fault dictionary, and the fault name and fault code corresponding to this abnormality are determined in one or more retrieved fault descriptions, and the fault is reported.

[0085] Based on the reported fault code, the fault dictionary and / or fault tree automatically pops up similar troubleshooting processes, provides maintenance reference suggestions, and provides fault maintenance work instructions, which include pre-operation preparations such as personnel skill requirements, tool preparation, and safety protection, as well as standardized decomposition and disassembly work processes during the operation, inspection and acceptance standards for the faulty parts after the operation, cleaning and tidying up requirements, and accompanying hazard identification, etc. The operator selects the corresponding work instruction and performs standard fault handling according to the requirements of the technical documents.

[0086] After the fault handling is completed, the fault handling standardization, maintenance process and repair parts details are recorded in the standardized fault handling and process record form for maintenance operations, which is used to record fault analysis, identify typical fault characteristics, and facilitate fault dictionary maintenance; finally, there is a standardized acceptance and test result record form for maintenance operations, which standardizes the record of fault acceptance content and acceptance items to ensure maintenance quality, unify fault acceptance standards, ensure fault handling quality, and realize closed-loop management of fault handling.

[0087] Collect fault handling data within the statistical period, and analyze maintenance items such as operating procedures and inspection cycles during the same or similar fault handling processes, so as to optimize the equipment fault handling process, improve approval items, handle faults in a standardized manner with the help of a fault dictionary, and implement event classification reminders through the network system, thereby achieving maintenance optimization.

[0088] 2. Inspection optimization

[0089] Optimization of inspection items: According to the occurrence of faults, the inspection items are improved, the items where faults occur are added, and the items where no faults occur are deleted.

[0090] Optimization of inspection cycle: According to the impact and degree of harm to production after the failure of system components, the inspection items are classified and the execution cycle is optimized.

[0091] Take welding robot equipment as an example. Fig. 9 As shown, a logic diagram of perfect inspection items and cycles guided by equipment failure is shown. In this embodiment, a daily inspection table is generated based on the inspection technical document, and inspection items, inspection methods, standard requirements and inspection cycles are specified. According to the inspection table, inspections are performed one by one according to the inspection cycle. When an abnormality occurs, as described above, the abnormality is reported, and the fault is handled according to the fault tree and fault dictionary, and recorded. The recorded content includes but is not limited to the minimum maintenance unit, fault phenomenon, fault measures and the frequency of the same fault. During the recording process, the record is made according to the standardized language in the fault library and / or fault dictionary.

[0092] The fault type, fault handling method, required standard and frequency of faults at each point are counted and optimization measures are determined based on the statistical results, including:

[0093] For items that have no relevant fault records within a cycle or multiple cycles, or that can maintain operation without processing the abnormalities that occur and do not affect safe production and product quality, optimize the items to determine whether inspection is still required or change the inspection cycle;

[0094] For items that are not easy to operate and cannot effectively prevent failures, statistical analysis of failures, standard requirements, and failure handling methods is conducted to optimize and improve the inspection content of the points;

[0095] For items where failures occur less frequently and cause downtime but do not affect equipment safety production and product quality, the inspection cycle of the items can be extended;

[0096] For items that rarely fail but pose safety risks or affect product quality when abnormal, the current status of inspection can be maintained;

[0097] For items with frequent failures, add corresponding inspection items and optimize the inspection methods;

[0098] According to the above statistical analysis and optimization, the daily inspection form of the welding robot is regenerated, and the inspection method, inspection standard requirements, and cycle are optimized according to the statistical results, and the optimization results are recorded.

[0099] The inspection and optimization of each point corresponding to a single device can be performed on a cycle basis. Preferably, the optimization cycle of each point is different. Within the cycle, all points complete at least one inspection and optimization; and the optimization cycle of each point is adjusted according to the optimization results of one or more cycles.

[0100] Among them, for the analysis involving specific magnitudes such as the occurrence of fewer or more frequent faults, the comparison base can be set according to the item points for comparative judgment. The comparison base can be set by yourself and there is no requirement.

[0101] 3. Optimization of scheduled maintenance and minor repairs

[0102] Optimization of scheduled maintenance and minor repair items: Based on the analysis of the relationship between scheduled maintenance and minor repairs and faults and current problems, the content and requirements of scheduled maintenance and minor repair items are optimized with the goal of preventing faults.

[0103] like Fig.10 As shown, the present invention provides a logic diagram for improving the scheduled maintenance and minor repair items guided by equipment failure. Similarly, taking the welding robot as an example, as mentioned above, the scheduled maintenance and minor repair technical documents are created based on the fault tree, including but not limited to the scheduled maintenance and minor repair maintenance manual, setting inspection standard requirements for each point, and in accordance with the maintenance manual, during the scheduled maintenance and minor repair process, the data is recorded, a fault list is generated, the fault information in the maintenance manual and the fault list is statistically analyzed, and the scheduled maintenance and minor repair is optimized according to the statistical results, specifically including:

[0104] For items that are not easy to operate and cannot effectively prevent failures, find out the defects based on the problems and operation methods that occur during the scheduled maintenance and minor repairs, so as to improve the content and requirements of the minor repair items;

[0105] For items that are repeated with the fixed maintenance items, you can consider canceling the items to reduce duplication of work;

[0106] During the minor repair process, if there is no relevant fault record for an item within a cycle or multiple cycles, the minor repair work of the item can be considered to be cancelled;

[0107] For items with frequent failures, sort out the failure phenomena, causes, and minimum maintenance units corresponding to the failures, so as to add minor repair items and avoid missing minor repair items, which may lead to hidden failure risks.

[0108] According to the above optimization process, the maintenance manual for scheduled minor repairs is regenerated, and the standard requirements and cycles of minor repairs are optimized according to the statistical results, and the optimization results and optimization instructions are recorded.

[0109] The inspection and optimization of each point corresponding to a single device can be performed on a cycle basis. Preferably, the optimization cycle of each point is different. Within the cycle, all points complete at least one inspection and optimization; and the optimization cycle of each point is adjusted according to the optimization results of one or more cycles.

[0110] Furthermore, the optimization of scheduled maintenance and minor repairs also includes the optimization of minor repair cycles. Based on a comprehensive analysis of data factors such as equipment operating time, failure downtime rate, MTBF (mean time between failures), the scheduled maintenance and minor repair cycles are optimized and adjusted.

[0111] like Fig.11 As shown, the maintenance and minor repair cycle process diagram is improved by combining parameters such as faults and operating time. The maintenance and minor repair cycle is optimized according to the equipment. The failure downtime rate of the equipment within a statistical period, such as two months, can be any abnormal state that can cause the equipment to stop, regardless of whether it will cause safety hazards or product quality problems. No restrictions are imposed. When the failure downtime rate is greater than a preset value, such as greater than 1%, and compared with the MTBF after the last minor repair, it is less than a predetermined time, such as 200h, a maintenance and minor repair plan is generated;

[0112] Or when the failure downtime rate is less than or equal to a preset value, such as less than or equal to 1%, and compared with the MTBF after the last minor repair, it is less than a preset time, such as 200h, a scheduled minor repair plan is generated;

[0113] Or when the failure downtime rate is less than or equal to the preset value, such as less than or equal to 1%, and compared with the MTBF after the last minor repair, it is greater than or equal to the predetermined time, such as 200h. If at this time, the operating time reaches the scheduled maintenance and minor repair cycle, the scheduled maintenance and minor repair plan will be appropriately extended, such as by one month or other time; otherwise, the failure downtime rate will be re-evaluated.

[0114] That is, in the process of optimizing the scheduled maintenance and minor repair cycle, the conditions of operating time ≥ standard cycle, failure downtime rate > 1% for two consecutive months (or other predetermined time), and MTBF < 200h are judged in sequence. When:

[0115] When the failure downtime rate is greater than 1% and the MTBF is less than 200h for two consecutive months (or other predetermined time), a scheduled maintenance and minor repair plan will be generated;

[0116] When the operating time meets the standard cycle, but the failure downtime rate is greater than 1% and the MTBF is less than 200h for two consecutive months (or other predetermined time), the scheduled maintenance plan will be extended for one month.

[0117] After extending the scheduled maintenance and minor repair plan, or generating it, the control system (MES system) reserves a window period, and the on-site operators confirm the minor repair plan according to the actual production situation and production plan. The MES system confirms or feedbacks the specific date on which the plan can be implemented, and finally the EAM system generates a scheduled maintenance and minor repair work order. The on-site operators implement the minor repair work on site according to the work order and accept the work results.

[0118] After extending the scheduled maintenance and minor repair plan, track and determine whether the optimized cycle operation is feasible based on the later maintenance results, and optimize the optimized cycle into the scheduled maintenance and minor repair manual.

[0119] 4. Lubrication optimization

[0120] For equipment that requires lubrication, the lubrication chart requires the hydraulic oil change cycle to be 12 months. By adding on-site oil testing and professional testing at maturity to determine the oil quality, the oil is subsequently changed / filtered based on the oil quality, thereby optimizing the oil change cycle.

[0121] like Fig.12 As shown in the flowchart of optimizing the lubrication oil change cycle based on the oil deterioration situation, 6 months after the lubricating oil is updated or the oil filtration is completed, a routine on-site test of the oil quality is carried out. If the oil quality is normal, continue to run for four months and then carry out a routine on-site test again. If the oil quality is still normal, continue to run for two months and then carry out a professional test of the oil quality. If the professional test result is still normal, the oil change cycle is optimized and the oil filtration / oil change cycle is extended by, for example, two months. After the extension of two months, a routine on-site test is carried out again. This cycle is repeated, and on-site tests are carried out every two months until the oil quality becomes abnormal and the oil change / oil filtration operation is carried out.

[0122] In actual application, oil quality inspection is carried out regularly according to the conventional inspection cycle of the oil used in the equipment, and it is not necessary to carry out according to the above settings. During the inspection process, after the interval between two adjacent inspections decreases linearly to a certain value, it should be the set oil quality change cycle, and professional inspection should be carried out. After the professional inspection, the on-site inspection cycle interval is carried out according to this fixed value until the oil quality is abnormal. If no abnormality is found in the professional inspection, the set oil filter / oil change cycle is adjusted. When any on-site inspection shows abnormal oil quality, oil filter / oil change operation is carried out.

[0123] 5. Optimization of major repair work

[0124] Improve the basis for implementing major equipment repairs based on equipment operating time, failure frequency, indicators and technical status; adjust pre-inspection execution nodes to optimize the major repair operation process in response to problems that pre-inspection cannot be implemented.

[0125] like Fig.13As shown, based on the major (item) repair cycle and item points of fault frequency, the flow chart is improved, and the operating time, fault frequency, MTTR (mean time to repair), MTBF (mean time between failures) and other data of the equipment operation process are counted, and compared with the corresponding predetermined base, key performance and accuracy detection are carried out to detect whether the item points are abnormal and whether they can be handled through fault repair. Finally, the major repair work is determined, and the major repair work is optimized according to the situation of the major repair work.

[0126] Specifically, the judgment conditions include:

[0127] Running time>20000h (about 5 years);

[0128] The failure frequency this year is greater than 50% of the failure frequency in the previous three years;

[0129] This year's MTTR is greater than 33.3% of the MTTR of the previous three years;

[0130] This year's MTTR is greater than 50% of the MTTR of the previous three years;

[0131] The MTBF of this year is less than 50% of the MTBF of the previous three years;

[0132] This year's MTBF> historical maximum;

[0133] If the running time is not > 20000h (about 5 years), the fault repair process will be carried out;

[0134] When the running time is greater than 20,000 hours (about 5 years) and the failure frequency of this year is not greater than 50% of the failure frequency of the previous three years, the fault repair process will be carried out;

[0135] When the operating time is greater than 20,000 hours (about 5 years), the fault frequency of this year is greater than 50% of the fault frequency of the previous three years, but the MTTR of this year is not greater than 50% of the MTTR of the previous three years, the fault repair process is transferred;

[0136] When the operating time is greater than 20,000 hours (about 5 years), the fault frequency this year is greater than 50% of the fault frequency in the previous three years, but the MTTR this year is not greater than 33.3% of the MTTR in the previous three years, and the MTBF this year is greater than the historical maximum value, the fault repair process is carried out;

[0137] When the operating time is greater than 20,000 hours (about 5 years), the failure frequency this year is greater than 50% of the failure frequency in the previous three years, and the MTTR this year is greater than 33.3% of the MTTR in the previous three years, further monitoring of the equipment operating temperature and vibration data is carried out. When the actual status of the equipment such as temperature and vibration does not meet the requirements, the fault is transferred to repair;

[0138] When the conditions of operating time > 20,000 h (about 5 years), MTTR of this year > 50% of MTTR of previous three years, MTTR of this year > 50% of MTTR of previous three years are met, but the condition of failure frequency of this year > 50% of failure frequency of previous three years is not met; or the conditions of operating time > 20,000 h (about 5 years), failure frequency of this year > 50% of failure frequency of previous three years are met, but the condition of MTTR of this year > 33.3% of MTTR of previous three years and MTBF of this year > historical maximum value are not met; or when the conditions of operating time > 20,000 h (about 5 years), failure frequency of this year > 50% of failure frequency of previous three years, MTTR of this year > 33.3% of MTTR of previous three years are met, and the actual status of equipment such as temperature and vibration meets the requirements, key performance and accuracy tests are carried out. According to the test results, it is judged whether the fault repair can be passed. If so, it is transferred to fault repair disposal. If not, major repair suggestions are pushed.

[0139] Furthermore, for key performance and precision detection contents, including detection items and detection standards, detection and judgment are carried out respectively. Different equipment has different corresponding detection items and standards. Whether there are abnormalities in the detection items and the detection results are output. When it is determined to implement major repairs, the equipment is repaired according to the major technical documents compiled based on the fault tree in the previous article, and the major repair processing data is recorded. The items and cycles involved in the entire judgment process are improved and optimized, and the major repair technical documents are optimized according to the records in the optimization process of major repairs.

[0140] like Fig.13 The specific time mentioned in the flowchart shown can be adjusted according to the equipment type, production cycle, and use cycle, and cannot be set as a limitation to the present invention as mentioned above.

[0141] Furthermore, the device management method provided by the present invention further includes step S4:

[0142] S4, apply information management methods to carry out preventive maintenance.

[0143] Regarding predictive maintenance, by analyzing the collectible equipment status parameters, setting key and reasonable detection thresholds, and driving the model logic, real-time monitoring of the equipment operating status and targeted predictive maintenance can be achieved, laying the foundation for work such as optimizing equipment maintenance procedures and extending component life, thereby conducting full life cycle management of equipment based on fault prediction.

[0144] In this embodiment, a predictive maintenance method for a filter cartridge of a ventilation and dust removal device is described in detail. Fig.14The full life cycle maintenance diagram based on fault prediction shown in the figure obtains the corresponding PHM monitoring data according to the configuration tree built as described above, combines the collected product quality abnormalities with the fault tree, outputs the fault data, inputs the history into the model, and trains the model according to the preset logic of the model; inputs the real-time data into the trained model to output the abnormal components / minimum maintenance units or normal working conditions, and gives the maintenance direction according to the output results, so as to carry out preventive maintenance to avoid possible failures affecting normal production.

[0145] In the model, in the preset operation logic, by collecting the change trend of the parameters used to characterize the working status of the equipment during the operation of the equipment, and the corresponding values ​​of the accumulated days, months and years, the equipment warning and equipment failure thresholds are set, that is, the initial fault detection threshold is set, and the abnormal data related to product quality is input into the model, and compared with the initially set threshold to determine whether the equipment has a fault during operation. If so, the equipment fault is repaired, and according to the abnormal situation, it is searched in the fault dictionary to determine whether the fault occurs for the first time. If so, a fault characterization analysis is performed, the fault is classified, and a fault solution is obtained. The fault is maintained in the fault dictionary in a standardized language, and the fault dictionary is optimized and managed. If the fault does not occur for the first time, the fault is handled according to the solution provided in the fault library and / or fault dictionary, and a verification closed loop is performed. According to the verification result, the fault entry is improved, and the improved information is maintained in the fault dictionary to optimize the fault dictionary.

[0146] If it is determined that the equipment has not failed and the detection threshold is reached, the equipment operation is determined to be faulty and the equipment fault is repaired. If the detection threshold is not reached, a fault preventive maintenance warning is output and the threshold is changed according to the failure rate evolution rule.

[0147] The hardware architecture of the predictive maintenance platform, i.e. the model mentioned above, should be based on the network and terminals, including but not limited to the following three layers:

[0148] The bottom layer is the data collection layer, which collects the vibration, temperature, voltage, current and other related data of the equipment through various intelligent sensors, and is applied to the status detection and fault diagnosis analysis of various key equipment such as motors and bearings. Pressure difference sensors are installed on both sides of the filter cartridge of the ventilation and dust removal equipment to collect the pressure difference values ​​on both sides of the filter cartridge.

[0149] The middle layer is the data computing layer, including edge storage computing devices such as data acquisition instruments. The data acquisition instrument connects to various intelligent sensors and transmits the sensor detection data to the system platform or the local machine via Ethernet. The system platform or the local machine performs data storage and calculation. Intelligent instruments are used to calculate, store, modulate and demodulate the collected pressure difference values.

[0150] The upper layer is the data transmission layer, which uses the intelligent industrial security gateway to build a safe, reliable and trustworthy communication data security collection network to ensure the communication security of field control equipment and the company's Internet platform. Smart instruments regularly send values ​​to IOT through network cables, and finally display them on the network system platform.

[0151] In order to ensure that predictive maintenance work for other equipment can be carried out dynamically and continuously in the future, the pilot project should have an independent system platform or a system platform installed on the equipment body, and reserve network and data interfaces. In the future, it can be connected to the big data center through the company network to ensure data interoperability. At the same time, the system platform architecture should have at least four basic modules, including data acquisition module, data management module, model management module, and prediction application module, to realize the functions of data monitoring, model analysis, and predictive diagnosis.

[0152] The model logic of the filter cartridge of ventilation and dust removal equipment is as follows:

[0153]

[0154]

[0155] illustrate:

[0156] (1) Tn-1 represents the time for cleaning or replacement, and Tn represents the current real time.

[0157] (2) Pn-1 before indicates the pressure difference value before cleaning or replacement, Pn-1 after indicates the pressure difference value after cleaning or replacement, Pn indicates the real-time pressure difference value of the day, P clear indicates the pressure difference standard value after cleaning, P change indicates the pressure difference standard value after replacement, and P effective indicates the minimum threshold value for the effective pressure difference value.

[0158] (3) tn represents the time interval until the next cleaning or replacement.

[0159] (4) P represents the pressure difference value, and the average value of the valid data of the day (valid data refers to the pressure difference value > Pvalid) is taken.

[0160] (5) Prediction Logic

[0161] When Pn-1≤80%*Pclear, tn=(Pclear-Pn) / (Pn-Pn-1)*(Tn-Tn-1); Warning: It is recommended to clean the filter element after tn days.

[0162] When Pn-1>80%*P clear label, tn=(P change label-Pn) / (Pn-Pn-1)*(Tn-Tn-1); Warning: It is recommended to replace the filter element after tn days.

[0163] It should be noted that in the embodiments and protection scope provided by the present invention, from forming a standardized fault database, decomposing the equipment layer by layer into a configuration tree and a fault tree, to using the fault tree for maintenance operations and optimization of the later maintenance operations, and performing information management, in this process, the fault library can also be maintained based on the maintenance results and new faults in the production process. It is a process from nothing to something, and then from something to maintenance and update. There may be overlapping and repeated processes between the steps. In the above text, the order of steps S1 to S4 is described only for the main purpose of writing clearly, writing in sections, and being well organized. It cannot be regarded as a limitation on the process sequence of the equipment management method to be protected by this application. In actual applications, the schemes mentioned in this application can be rationally integrated according to the specific conditions of the production workshop, and the order of steps can be adjusted. The process and equipment management method for equipment management, maintenance, and information processing based on the fault library and fault tree are all within the protection scope of this application.

[0164] In summary, the device management method and system provided by the present invention have the following technical advantages compared with the prior art:

[0165] 1. Starting from the fault, clarify the relationship between the fault and the business, reversely optimize fault management, improve business, etc., establish new standards and specifications for equipment maintenance, and innovate equipment maintenance models;

[0166] 2. Record the entire process of equipment maintenance, organize maintenance experience, form a fault dictionary, and guide fault handling;

[0167] 3. By improving equipment maintenance work, the occurrence rate of failures is reduced, thereby reducing equipment maintenance costs.

[0168] As described above, similar technical solutions can be derived from the given solution content. However, any simple modification, equivalent changes and modifications made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A device management method, characterized in that: The following steps are included: S1, collect existing fault information, sort out and analyze the fault information, and form a standard fault library; S2, based on the equipment type and fault-oriented, build an equipment fault tree, and use the fault tree to carry out integrated management of equipment repair process design and operation and maintenance data; S3, during maintenance, rely on the fault tree to carry out equipment repair process design and operation and maintenance management to optimize maintenance work.

2. A device management method according to claim 1, characterized in that: In step S1, the fault information such as the fault phenomenon, cause and disposal method is standardized and then input into the standard fault library.

3. A device management method according to claim 1, characterized in that: In step S1, in the standard fault library, the faults are classified according to system functions and fault causes, providing a basis for step repair process design and operation and maintenance management.

4. A device management method according to claim 1, characterized in that: Step S2 also includes building a configuration tree including equipment location information, components, subcomponents, minimum units and coding information to support the full life cycle management of the equipment based on the equipment type.

5. A device management method according to claim 4, characterized in that: Taking equipment configuration as the starting point and the minimum maintenance unit as the basis, an equipment fault tree oriented to maintenance objects is established.

6. A device management method according to claim 1, characterized in that: Step S2 also includes, based on the standard fault library in step S1, constructing a fault dictionary and fault coding, using the fault dictionary as a guide, establishing inspection and repair plans for each unit of the equipment, compiling major equipment maintenance procedures, and standardizing the repair and replacement standards for each component.

7. A device management method according to claim 6, characterized in that: In step S3, the fault is handled according to the fault code with the help of the fault dictionary specification.

8. A device management method according to claim 1, characterized in that: In step S3, the optimization of maintenance work includes any one or more of the following: spot inspection optimization, scheduled minor repair optimization, lubrication optimization, and major repair optimization.

9. A device management method according to any one of claims 1 to 8, characterized in that: The method further includes step S4, applying information management means to perform preventive maintenance.

10. A device management system, characterized in that: Execute a device management method as described in any one of claims 1 to 9.

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