Cylinder fault predictive monitoring method and device, electronic equipment and storage medium thereof

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By calculating the operating parameters of the cylinder and calculating the health value, the cylinder status is monitored in real time, and the problem of difficult to predict cylinder failures during the anti-corrosion process of the car body is solved, real-time monitoring and fault prediction of cylinder status is achieved, reducing production costs and safety risks.

CN119688276APending Publication Date: 2025-03-25FAW VOLKSWAGEN AUTOMOTIVE CO LTD

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Patent Information

Application Number: CN202411856108.0
Authority / Receiving Office: CN · China
Patent Type: Applications(China)
Current Assignee / Owner
Filing Date: 2024-12-17
Publication Date: 2025-03-25

AI Technical Summary

Technical Problem

During the anti-corrosion process of car body, the cylinders in the wax filling groove are prone to aging seals and cannot be opened or closed normally due to long-term operation in high temperature environments, resulting in wax filling failure, increasing rework costs and safety risks.

Method used

By calculating the cylinder operating parameters, including the opening and closing time during each operation, as well as fault records, the health value of the cylinder is calculated, the operating status of the cylinder is quantified in real time, and potential faults are discovered in advance and maintenance are carried out.

Benefits of technology

Real-time monitoring of the health status of the cylinder is realized, equipment hazards are discovered in advance, production failures are reduced, cylinder service life is extended, costs are reduced, and corporate efficiency is improved.

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Abstract

The invention discloses an air cylinder fault predictive monitoring method and device, electronic equipment and a storage medium thereof.The method is executed through a controller and comprises the steps that air cylinder operation parameters are received; calculating total cylinder operation parameters according to the received cylinder operation parameters; the health value H of the air cylinder is calculated according to the total operation parameters of the air cylinder, and when the total operation times N1 of the air cylinder is smaller than or equal to a first threshold value M1, the health value H of the air cylinder is equal to 1-(N1 / K1 + N2 * K2 + N3 / K3) / 100; when the total number of times N1 of cylinder operation is larger than a first threshold value M1 and the total number of times N1 of cylinder operation is a first threshold value M1, the cylinder health value is set to be h0, the total number of times of cylinder faults is set to be n2, the total number of times of cylinder operation overtime is set to be n3, and the cylinder health value H = h0-[(N1-M1) / K4 + (N2-n2) * K2 + (N3-n3) / K5] / 100. The method has the advantages that the health state of the air cylinder can be quantified and displayed in real time, maintenance personnel are guided to pay attention to the abnormal air cylinder in time, the equipment hidden danger problem of the air cylinder can be found in advance, production faults are reduced, and the use economical efficiency of the air cylinder is improved.

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Description

Technical Field

[0001] The present invention relates to the technical field of automobile body anti-corrosion, and in particular to a cylinder fault predictive monitoring method, device, electronic equipment and storage medium thereof. Background Art

[0002] In the automobile manufacturing industry, especially in the field of automobile body anti-corrosion, there are about 164 process holes that need wax injection on the bottom of a white body. All of them are achieved by the cylinder in the wax filling tank driving the wax filling nozzle to inject wax into the cavity at the bottom of the body. Ensuring that the wax film coverage in the cavity at the bottom of the body meets the quality requirements is the basis of body anti-corrosion. The application of cavity wax injection technology is relatively mature. However, problems often occur after the cylinder in the wax filling tank works for a long time in a high temperature and hot wax environment.

[0003] On the one hand, if the cylinder works in a high-temperature environment for a long time, the seal will age and the cylinder will be unable to open or close normally, resulting in the wax filling nozzle being unable to inject wax into the cavity, causing serious problems with the vehicle body quality. If it is later discovered that there is less wax in the cavity, rework will cost a huge amount of time and labor.

[0004] On the other hand, in terms of equipment maintenance, there is a lack of data support, and cylinders with abnormal data changes cannot be repaired or replaced in time under the fast-paced production of automation. When inspecting the cylinder, because the cylinder is located at the bottom of the wax filling tank, it is not easy to observe its status, and it is difficult to find hidden dangers in the equipment at the first time. When the cylinder fails during the production process, due to the high indoor environment (85℃) and the wax liquid temperature in the wax tube at 120℃, it is impossible to enter the room to deal with the failure at the first time. The temperature must be lowered to a temperature suitable for work before it can be processed. This not only affects production, but also poses a great safety risk. Summary of the invention

[0005] In order to solve at least one of the above technical problems, the present invention provides a cylinder fault predictive monitoring method, device, electronic device and storage medium thereof, which calculates the cylinder health value according to the cylinder operating parameters and quantifies the cylinder operating status in real time.

[0006] The present invention solves the technical problem by adopting the following technical solution:

[0007] A method for predictive monitoring of cylinder faults, the method being executed by a controller, comprising the following steps:

[0008] Step 1, receiving cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records;

[0009] Step 2, calculating the total cylinder operation parameters according to the received cylinder operation parameters, wherein the total cylinder operation parameters include: the total number of cylinder operations N1, the total number of cylinder failures N2, and the total number of cylinder operation timeouts N3;

[0010] Step 3: Calculate the cylinder health value H based on the total cylinder operation parameters:

[0011] When the total number of cylinder operations N1 ≤ the first threshold M1,

[0012] Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100, formula 1;

[0013] When the total number of cylinder operations N1> the first threshold M1,

[0014] When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3.

[0015] Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

[0016] Further, the first threshold M1 is set to one of 60%-70% of the rated working number of the cylinder; K1 is set to one of 15000-19000, K2 is set to one of 3-8, K3 is set to one of 8-12, K4 is set to one of 6000-8000, and K5 is set to one of 3-8; preferably, the first threshold M1 is set to 700000, K1 is set to 17500, K2 is set to 5, K3 is set to 10, K4 is set to 7500, and K5 is set to 5.

[0017] Furthermore, the method for calculating the total number of cylinder failures N2 and the total number of cylinder operation timeouts N3 includes:

[0018] When a cylinder alarm is recorded once, the total number of cylinder failures N2 increases once;

[0019] When the cylinder opening time t1> the standard opening time T1, the total number of cylinder operation timeouts N3 increases by one;

[0020] When the cylinder closing time length t2>the standard closing time length T2, the total number of cylinder operation timeouts N3 increases by one.

[0021] Furthermore, the method further comprises plotting the cylinder opening time and closing time into a trend graph.

[0022] Furthermore, the method further comprises classifying the cylinder operating status:

[0023] When the cylinder health value H ≥ 80%, the cylinder operation status is set to good;

[0024] When 60%≤cylinder health value H<80%, the cylinder operation status is set to poor;

[0025] When the cylinder health value H is less than 60%, the cylinder operation status is set to extremely poor.

[0026] Furthermore, the method also includes sending the cylinder operating parameters, the total cylinder operating parameters and the cylinder health value H to the monitoring screen.

[0027] Furthermore, the method also includes displaying the health status of the cylinder through a health bar on the monitoring screen, and the ratio of the color display length of the health bar to the total length of the health bar is consistent with the cylinder health value H. When the cylinder is in good operating condition, the health bar displays a first color, when the cylinder is in poor operating condition, the health bar displays a second color, and when the cylinder is in extremely poor operating condition, the health bar displays a third color.

[0028] Furthermore, a device for predictive monitoring of cylinder faults, applied to the above method, comprises:

[0029] A receiving module, used for receiving cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records;

[0030] A first comparison module, used for comparing the total cylinder operation times N1 with a first threshold value M1;

[0031] A calculation module, used to calculate the cylinder operation total parameters according to the received cylinder operation parameters, wherein the cylinder operation total parameters include: the total number of cylinder operations N1, the total number of cylinder failures N2 and the total number of cylinder operation timeouts N3;

[0032] And according to the total cylinder operation parameters, the cylinder health value H is calculated:

[0033] When the total number of cylinder operations N1 ≤ the first threshold M1,

[0034] Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100;

[0035] When the total number of cylinder operations N1> the first threshold M1,

[0036] When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3.

[0037] Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

[0038] Furthermore, the calculation module includes a second comparison module and a counting module, the second comparison module is used to compare the cylinder opening time t1 with the preset standard opening time T1, compare the cylinder closing time t2 with the preset standard closing time T2, and send the comparison result to the counting module; when the cylinder opening time t1>the standard opening time T1, the counting module increases the total number of cylinder operation timeouts N3 by one; when the cylinder closing time t2>the standard closing time T2, the counting module increases the total number of cylinder operation timeouts N3 by one.

[0039] Furthermore, the device also includes a monitoring screen, which is used to display the cylinder operating status, and the cylinder operating status includes cylinder operating parameters, cylinder total operating parameters and cylinder health value H.

[0040] Furthermore, an electronic device includes one or more processors and a memory, wherein the memory stores a computer program; and the processor is used to execute the computer program stored in the memory to implement the above-mentioned method.

[0041] Furthermore, a computer-readable storage medium stores a computer program, wherein the computer program is used to enable a computer to execute the above method.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] (1) By calculating the cylinder health value, the health status of the cylinder can be quantified in real time, the overall health status of the cylinder can be monitored and displayed in real time, and maintenance personnel can be guided to pay attention to abnormal cylinders in a timely manner. Equipment hidden dangers of the cylinder can be discovered in advance, and maintenance personnel can be guided to perform real-time or preventive maintenance. This can avoid vehicle body quality problems and equipment damage caused by poor equipment maintenance, reduce production failures, extend the economic use of cylinders, and improve corporate benefits in terms of quality and cost.

[0044] (2) By collecting the cylinder opening and closing operation time data in real time and plotting the collected data into a trend chart, it is possible to observe whether there are any abnormalities in the opening and closing operation time of each cylinder. The trend chart can be used to analyze the reasons for the low cylinder health value, which is helpful to guide maintenance personnel to analyze abnormal cylinders. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to better understand the above and other purposes, features, advantages and functions of the present invention, reference may be made to the embodiments shown in the accompanying drawings. The same reference numerals in the accompanying drawings refer to the same components. It should be understood by those skilled in the art that the accompanying drawings are intended to schematically illustrate the preferred embodiments of the present invention and have no limiting effect on the scope of the present invention, and the components in the drawings are not drawn to scale.

[0046] Figure 1 The figure is a flow chart of the cylinder fault predictive monitoring method of the present invention.

[0047] Figure 2 It is a schematic diagram of the monitoring screen of the present invention.

[0048] Figure 3 A schematic diagram of a cylinder status displayed on the monitoring screen of the present invention.

[0049] Figure 4 This is a trend diagram of the opening and closing operation time of a cylinder of the present invention.

[0050] Figure 5 It is a block diagram of the cylinder fault predictive monitoring device of the present invention.

[0051] In the figure: 10 - controller; 11 - receiving module; 12 - first comparison module; 13 - calculation module; 131 - second comparison module; 132 - counting module. DETAILED DESCRIPTION

[0052] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the exemplary embodiments of the present invention are described below in conjunction with the accompanying drawings, including various details of the embodiments of the present invention to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0053] In the description of the present invention, it should be noted that the term "including" and its variations represent open inclusion, that is, "including but not limited to". The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance. In addition, in the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0054] The present invention provides a method for predictive monitoring of cylinder faults, such as Figure 1 As shown, the method is executed by the controller 10 and includes the following steps:

[0055] Step 1, receiving cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records;

[0056] Step 2, calculating the total cylinder operation parameters according to the received cylinder operation parameters, wherein the total cylinder operation parameters include: the total number of cylinder operations N1, the total number of cylinder failures N2, and the total number of cylinder operation timeouts N3;

[0057] Step 3: Calculate the cylinder health value H based on the total cylinder operation parameters:

[0058] When the total number of cylinder operations N1 ≤ the first threshold M1,

[0059] Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100, formula 1;

[0060] When the total number of cylinder operations N1> the first threshold M1,

[0061] When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3.

[0062] Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

[0063] Each cylinder is electrically connected to the controller 10, and the operation data of each cylinder is sent to the controller 10. When a cylinder is opened and closed once, the total number of cylinder operations N1 increases once. By collecting data such as the total number of cylinder operations N1, the cylinder opening operation time t1, the cylinder closing operation time t2, and the number of cylinder fault alarms, the current cylinder health value H can be calculated in real time through formulas 1 and 2. The cylinder health value can directly guide maintenance personnel to inspect and replace abnormal cylinders, prevent faults in advance, reduce production faults, extend the economic efficiency of cylinder use, make full use of the cylinder life, improve cylinder utilization, and reduce costs.

[0064] Preferably, the first threshold M1 is set to one of 60%-70% of the rated working times of the cylinder; K1 is set to one of 15000-19000, K2 is set to one of 3-8, K3 is set to one of 8-12, K4 is set to one of 6000-8000, and K5 is set to one of 3-8. For example, if the rated working times of the cylinder are 1,000,000 times, the first threshold M1 can be set to one of 600,000-700,000 times, for example, the first threshold M1 can be set to 600,000 times, 650,000 times, 700,000 times, etc. K1 can be set to 15000, 15500, 16000, 16500, 17000, 17500, 18000, 18500, 19000, etc., K2 can be set to 3, 4, 5, 6, 7, 8, etc., K3 can be set to 8, 9, 10, 11, 12, etc., K4 can be set to 6000, 6500, 7000, 7500, 8000, etc., and K5 can be set to 3, 4, 5, 6, 7, 8, etc.

[0065] Preferably, the first threshold M1 is set to 700000, K1 is set to 17500, K2 is set to 5, K3 is set to 10, K4 is set to 7500, and K5 is set to 5.

[0066] At this time, when the total number of cylinder operations N1≤700000, the cylinder health value H=1-(N1 / 17500+N2*5+N3 / 10) / 100;

[0067] When the total number of cylinder operations N1>700000, the cylinder health value when the total number of cylinder operations N1 is 700000 is set to h0, the total number of cylinder failures is set to n2, the total number of cylinder operation timeouts is set to n3, and the cylinder health value H=h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100.

[0068] When the total number of cylinder operations N1 is less than or equal to 700,000 times, the cylinder health value H is calculated according to Formula 1. For example, when the total number of cylinder operations N1 is 50,000 times, the total number of cylinder failures N2 is 1 time, and the total number of cylinder operation timeouts N3 is 2 times, the cylinder health value H = 1-(N1 / 17500+N2*5+N3 / 10) / 100 = 1-(50000 / 17500+1*5+2 / 10) / 100 = 92%. When the total number of cylinder operations N1 is 175,000 times, the total number of cylinder failures N2 is 2 times, and the total number of cylinder operation timeouts N3 is 10 times, the cylinder health value H=1-(N1 / 17500+N2*5+N3 / 10) / 100=1-(175000 / 17500+2*5+10 / 10) / 100=79%.

[0069] When the total number of cylinder operations N1 is greater than 700,000 times, the total number of cylinder failures N2 at the 700,000th cylinder operation is recorded as n2, and the total number of cylinder operation timeouts N3 is recorded as n3. The health value H of the 700,000th cylinder operation is calculated according to Formula 1 and recorded as h0. Then, the health value H of the N1th cylinder operation is calculated according to Formula 2 using the health value of the 700,000th cylinder operation.

[0070] For example, when the total number of cylinder operations N1 is 700,000 times, the total number of cylinder failures N2 (n2) is 3 times, and the total number of cylinder operation timeouts N3 (n3) is 15 times, the cylinder health value h0 = 1-(N1 / 17500+N2*5+N3 / 10) / 100 = 1-(700,000 / 17500+3*5+15 / 10) / 100 = 44%; the total number of cylinder operations N1 is 7 When the total number of cylinder failures N2 is 4 times and the total number of cylinder operation timeouts N3 is 20 times, the cylinder health value H=h0-[(N1-700000) / 7500+(N2-n2)*5+(N3-n3) / 5] / 100=44%-[(720000-700000) / 7500+(4-3)*5+(20-10) / 5] / 100=34%.

[0071] The method for calculating the total number of cylinder failures N2 and the total number of cylinder operation timeouts N3 includes:

[0072] When a cylinder alarm is recorded once, the total number of cylinder failures N2 increases once;

[0073] When the cylinder opening time t1> the standard opening time T1, the total number of cylinder operation timeouts N3 increases by one;

[0074] When the cylinder closing time length t2>the standard closing time length T2, the total number of cylinder operation timeouts N3 increases by one.

[0075] The controller 10 does not record the number of cylinder failures. However, when a cylinder fails, the controller 10 will record the alarm information. The statistical number of cylinder alarm records can be used as the total number of cylinder failures N2. When the cylinder opening time t1> the standard opening time T1, the cylinder opening timeout, when the cylinder closing time t2> the standard closing time T2, the cylinder closing timeout. When the cylinder opening and cylinder closing, any timeout occurs, the total number of cylinder timeouts N3 increases by one.

[0076] In one embodiment, Figure 4As shown, the method further includes plotting the cylinder opening time and closing time into a trend graph. When a cylinder seal problem occurs, the cylinder opening and closing operation time will increase. By collecting the cylinder opening time and closing time data in real time and plotting the collected data into a trend graph, for example, a bar graph or a curve graph can be drawn. From the trend graph, it can be observed whether there is an abnormality in the opening and closing operation time of each cylinder each time. The operating status of the cylinder when it is opened and closed is clear at a glance, which is conducive to guiding maintenance personnel to analyze abnormal cylinders.

[0077] In one embodiment, the method further comprises classifying the cylinder operating status:

[0078] When the cylinder health value H ≥ 80%, the cylinder operation status is set to good;

[0079] When 60%≤cylinder health value H<80%, the cylinder operation status is set to poor;

[0080] When the cylinder health value H is less than 60%, the cylinder operation status is set to extremely poor.

[0081] In one embodiment, the method further includes sending the cylinder operation parameters, the cylinder operation total parameters and the cylinder health value H to the monitoring screen. The monitoring screen is electrically connected to the controller 10, and the cylinder operation parameters, the cylinder operation total parameters and the cylinder health value H involved in the operation of each cylinder can be sent to the monitoring screen through the PLC program and displayed on the front-end interface. Figure 2 and Figure 3 As shown in the figure, the monitoring screen can display the outline of the vehicle. According to the actual position of each cylinder in the vehicle, the cylinder logo is set at the corresponding position of the monitoring screen. The operating status of each cylinder can be clearly viewed from the monitoring screen. The cylinder can be selectively displayed or hidden in the monitoring screen interface when viewing. By turning on each cylinder logo, detailed cylinder status information can also be displayed, such as the equipment function group number of the current cylinder, the equipment number of the current cylinder, the total number of operations of the current cylinder, the total number of failures of the current cylinder, the open operation time, the closed operation time, the health value of the current cylinder, etc. Clicking on the operation time can also display the open and close operation trend chart of the cylinder. When the cylinder operation status is extremely poor, the cylinder logo can be displayed in red to remind the maintenance personnel in time. At present, there are 4 wax filling tanks in the wax filling area of the paint shop, with a total of 112 cylinders. Although the number is large, the monitoring screen can clearly display the status of each cylinder, so that the maintenance personnel can understand the operating status of each cylinder in time.

[0082] In one embodiment, reference Figure 3As shown, the method also includes displaying the health status of the cylinder through a health bar on the monitoring screen, the ratio of the color display length of the health bar to the total length of the health bar is consistent with the cylinder health value H, when the cylinder is in good operating condition, the health bar displays a first color, when the cylinder is in poor operating condition, the health bar displays a second color, and when the cylinder is in extremely poor operating condition, the health bar displays a third color.

[0083] The monitoring screen interface can display the health value H of each cylinder in the wax filling tank in percentage. According to the cylinder operating status, it can be displayed in three colors: the first color, the second color, and the third color. The first color can be green, the second color can be yellow, and the third color can be red. For example, when the cylinder health value H is 85%, 85% of the total length of the health bar is displayed in green, when the cylinder health value H is 70%, 70% of the total length of the health bar is displayed in yellow, and when the cylinder health value H is 58%, 58% of the total length of the health bar is displayed in red. When the health value H is ≥ 80%, it is displayed in green, indicating that the cylinder is in good operating condition; when the health value H is between 60%-80%, it is displayed in yellow, indicating that the cylinder is in poor operating condition, reminding maintenance personnel to pay attention to and check the cylinder; when the health value H is below 60%, it is displayed in red, indicating that the cylinder is in extremely poor condition, the cylinder health condition is not optimistic, and it needs to be checked and replaced in time.

[0084] The present invention also provides a device for predictive monitoring of cylinder faults, which is applied to the above method, such as Figure 5 As shown, including:

[0085] A receiving module 11 is used to receive cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records;

[0086] A first comparison module 12, used for comparing the total cylinder operation times N1 with a first threshold value M1;

[0087] A calculation module 13, configured to calculate a total cylinder operation parameter according to the received cylinder operation parameter, wherein the total cylinder operation parameter includes: a total cylinder operation number N1, a total cylinder failure number N2, and a total cylinder operation timeout number N3;

[0088] And according to the total cylinder operation parameters, the cylinder health value H is calculated:

[0089] When the total number of cylinder operations N1 ≤ the first threshold M1,

[0090] Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100;

[0091] When the total number of cylinder operations N1> the first threshold M1,

[0092] When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3.

[0093] Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

[0094] In one embodiment, the calculation module 13 includes a second comparison module 131 and a counting module 132, the second comparison module 131 is used to compare the cylinder opening time t1 with the preset standard opening time T1, and compare the cylinder closing time t2 with the preset standard closing time T2, and send the comparison result to the counting module 132; when the cylinder opening time t1>the standard opening time T1, the counting module 132 increases the total number of cylinder operation timeouts N3 by one; when the cylinder closing time t2>the standard closing time T2, the counting module 132 increases the total number of cylinder operation timeouts N3 by one.

[0095] In one embodiment, the device further comprises a monitoring screen, wherein the monitoring screen is used to display the cylinder operating status, wherein the cylinder operating status comprises cylinder operating parameters, cylinder total operating parameters and a cylinder health value H.

[0096] The present invention also provides an electronic device, comprising one or more processors and a memory, wherein the memory stores a computer program; the processor is used to execute the computer program stored in the memory to implement the above-mentioned method.

[0097] The present invention also provides a computer-readable storage medium on which a computer program is stored. The computer program is used to enable a computer to execute the above method.

[0098] The operating data of the cylinder itself is isolated and has no value when viewed individually. However, by associating relevant data and intelligently calculating the health value in real time, the health status of the cylinder can be quantified in real time, the overall health status of the cylinder can be monitored and displayed in real time, and maintenance personnel can be guided to pay attention to abnormal cylinders in time. Hidden equipment problems of the cylinder can be discovered in advance, and maintenance personnel can be guided to perform real-time or preventive maintenance. This can avoid vehicle body quality problems and equipment damage caused by poor equipment maintenance, reduce production failures, extend the economic use of cylinders, and improve corporate benefits in terms of quality and cost.

[0099] By collecting the cylinder opening and closing operation time data in real time and plotting the collected data into a trend chart, it is possible to observe whether there are any abnormalities in the opening and closing operation time of each cylinder each time. The trend chart can be used to analyze the reasons for the low cylinder health value, which is helpful to guide maintenance personnel to analyze abnormal cylinders.

[0100] This cylinder fault predictive monitoring method is applied to the whole process of wax injection of the vehicle body. The cylinder status data information is collected, calculated and output in real time, and the cylinder status health value and cylinder operation time trend chart are displayed. The display is displayed on the front-end monitoring screen, which is convenient for human-computer interaction and the cylinder status is clear at a glance. The data is refreshed in real time to realize real-time monitoring of the cylinder status, eliminate possible equipment and quality risks, make full use of the cylinder operation life, effectively reduce production costs, and solve the problem of difficult monitoring of the wax injection cylinder status in the paint shop.

[0101] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for predictive monitoring of cylinder faults, characterized in that: The method is executed by a controller and comprises the following steps: Step 1, receiving cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records; Step 2, calculating the total cylinder operation parameters according to the received cylinder operation parameters, wherein the total cylinder operation parameters include: the total number of cylinder operations N1, the total number of cylinder failures N2, and the total number of cylinder operation timeouts N3; Step 3: Calculate the cylinder health value H based on the total cylinder operation parameters: When the total number of cylinder operations N1 ≤ the first threshold M1, Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100, formula 1; When the total number of cylinder operations N1> the first threshold M1, When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3. Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

2. The method for predictive monitoring of cylinder failure according to claim 1, characterized in that: The first threshold M1 is set to one of 60%-70% of the rated working number of the cylinder; K1 is set to one of 15000-19000, K2 is set to one of 3-8, K3 is set to one of 8-12, K4 is set to one of 6000-8000, and K5 is set to one of 3-8; preferably, the first threshold M1 is set to 700000, K1 is set to 17500, K2 is set to 5, K3 is set to 10, K4 is set to 7500, and K5 is set to 5.

3. The method for predictive monitoring of cylinder failure according to claim 1, characterized in that: The method for calculating the total number of cylinder failures N2 and the total number of cylinder operation timeouts N3 includes: When a cylinder alarm is recorded once, the total number of cylinder failures N2 increases once; When the cylinder opening time t1> the standard opening time T1, the total number of cylinder operation timeouts N3 increases by one; When the cylinder closing time length t2>the standard closing time length T2, the total number of cylinder operation timeouts N3 increases by one.

4. The method for predictive monitoring of cylinder failure according to claim 3, characterized in that: The method also includes trending the cylinder opening time and closing time.

5. The method for predictive monitoring of cylinder failure according to claim 1, characterized in that: The method further comprises classifying the cylinder operating state: When the cylinder health value H ≥ 80%, the cylinder operation status is set to good; When 60%≤cylinder health value H<80%, the cylinder operation status is set to poor; When the cylinder health value H is less than 60%, the cylinder operation status is set to extremely poor.

6. The method for predictive monitoring of cylinder faults according to any one of claims 1 to 5, characterized in that: The method further includes sending the cylinder operating parameters, the cylinder operating total parameters and the cylinder health value H to a monitoring screen.

7. The method for predictive monitoring of cylinder failure according to claim 6, characterized in that: The method also includes displaying the health status of the cylinder through a health bar on the monitoring screen, the ratio of the color display length of the health bar to the total length of the health bar is consistent with the cylinder health value H, when the cylinder is in good operating condition, the health bar displays a first color, when the cylinder is in poor operating condition, the health bar displays a second color, and when the cylinder is in extremely poor operating condition, the health bar displays a third color.

8. A device for predictive monitoring of cylinder failures, characterized in that: The method applied to any one of claims 1 to 7, comprising: A receiving module, used for receiving cylinder operation parameters, wherein the cylinder operation parameters include: cylinder opening time t1 during each operation, cylinder closing time t2 during each operation, and cylinder alarm records; A first comparison module, used for comparing the total cylinder operation times N1 with a first threshold value M1; A calculation module, used to calculate the cylinder operation total parameters according to the received cylinder operation parameters, wherein the cylinder operation total parameters include: the total number of cylinder operations N1, the total number of cylinder failures N2 and the total number of cylinder operation timeouts N3; And according to the total cylinder operation parameters, the cylinder health value H is calculated: When the total number of cylinder operations N1 ≤ the first threshold M1, Cylinder health value H=1-(N1 / K1+N2*K2+N3 / K3) / 100; When the total number of cylinder operations N1> the first threshold M1, When the total number of cylinder operation times N1 reaches the first threshold value M1, the cylinder health value is set to h0, the total number of cylinder failures is set to n2, and the total number of cylinder operation timeouts is set to n3. Cylinder health value H = h0-[(N1-M1) / K4+(N2-n2)*K2+(N3-n3) / K5] / 100, Formula 2.

9. The device for predictive monitoring of cylinder failure according to claim 8, characterized in that: The calculation module includes a second comparison module and a counting module, the second comparison module is used to compare the cylinder opening time t1 with the preset standard opening time T1, compare the cylinder closing time t2 with the preset standard closing time T2, and send the comparison result to the counting module; when the cylinder opening time t1>the standard opening time T1, the counting module increases the total number of cylinder operation timeouts N3 by one; when the cylinder closing time t2>the standard closing time T2, the counting module increases the total number of cylinder operation timeouts N3 by one.

10. The device for predictive monitoring of cylinder failure according to claim 8, characterized in that: The device also includes a monitoring screen, which is used to display the cylinder operating status, and the cylinder operating status includes cylinder operating parameters, cylinder operating total parameters and cylinder health value H.

11. An electronic device, characterized in that: The method comprises one or more processors and a memory, wherein the memory stores a computer program; and the processor is used to execute the computer program stored in the memory to implement the method according to any one of claims 1 to 7.

12. A computer-readable storage medium having a computer program stored thereon, characterized in that: The computer program is used to make a computer execute the method according to any one of claims 1 to 7.