Fault management method and system for door body die casting

Abstract

The invention discloses a fault management method and system for a door body die casting, and relates to the technical field of fault management, and the method comprises the steps: determining the fault level of the door body die casting according to a fault state diagram and the service life of the door body die casting; the fault management event is determined based on the fault level of the door body die casting and the form of the door body die casting, the fault management event is the maintenance conditions of different stages of the multiple fault areas, and the accuracy of the fault management event is ensured. Therefore, in the fault management event, autonomous regulation and control of the maintenance progress of the multiple fault areas are triggered based on the overall maintenance progress of the door body die casting and the preset maintenance time target; and if the multiple door body die castings are in the synchronous maintenance state, the use sequence of the multiple door body die castings is collected, the configuration of current maintenance personnel is optimized according to the use sequence of the multiple door body die castings and the overall maintenance progress of the multiple door body die castings, and the fault management accuracy of the door body die castings is guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of fault management, and in particular to a fault management method and system for door body die castings. Background Art

[0002] With the development of science and technology, door body die-castings, as one of the new energy die-castings, are configured in the door body part of new energy vehicles. Door body die-castings are made of aluminum die-casting. In the existing technology, door body die-castings have multiple fault areas as new energy vehicles are damaged. When maintaining the door body die-castings, multiple fault areas need to be maintained, and multiple fault areas need to be maintained one by one without considering the fault level of the door body die-castings and the shape of the door body die-castings, and the accuracy of the fault management events of the door body die-castings cannot be guaranteed. Summary of the Invention

[0003] The purpose of the present invention is to overcome the deficiencies of the prior art, and the present invention provides a fault management method and system for door body die castings.

[0004] An embodiment of the present invention provides a fault management method for a door body die-casting, comprising: determining a plurality of fault areas based on recognition of a current image of the door body die-casting; determining a fault status diagram of the door body die-casting based on mechanical analysis of the plurality of fault areas, and determining a fault level of the door body die-casting based on the fault status diagram and the service life of the door body die-casting; determining a fault management event based on the fault level of the door body die-casting and the morphology of the door body die-casting, the fault management event presenting maintenance conditions of the plurality of fault areas at different stages; in the fault management event, determining an overall maintenance progress of the door body die-casting based on the maintenance progress of the plurality of fault areas, triggering autonomous regulation of the maintenance progress of the plurality of fault areas based on the overall maintenance progress of the door body die-casting and a preset maintenance time target; if the plurality of door body die-castings are in a synchronous maintenance state, collecting a usage sequence of the plurality of door body die-castings, and optimizing the current configuration of maintenance personnel based on the usage sequence of the plurality of door body die-castings and the overall maintenance progress of the plurality of door body die-castings.

[0005] An embodiment of the present invention provides a fault management system for door body die castings, which is applied to the above-mentioned fault management method for door body die castings. The fault management system for door body die castings includes:

[0006] a fault area module, configured to determine a plurality of fault areas based on recognition of a current image of the door body die casting;

[0007] A fault level module is used to determine a fault state diagram of the door body die-casting based on mechanical analysis of multiple fault areas, and to determine the fault level of the door body die-casting based on the fault state diagram and the service life of the door body die-casting;

[0008] A fault management module is used to determine a fault management event based on the fault level and morphology of the door body die-casting, wherein the fault management event presents maintenance status of multiple fault areas at different stages;

[0009] The maintenance progress module is used to determine the overall maintenance progress of the door body die-casting according to the maintenance progress of multiple fault areas during fault management events, and trigger autonomous regulation of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door body die-casting and the preset maintenance time target;

[0010] The optimization module is used to collect the usage sequence of multiple door body die-castings if multiple door body die-castings are in a synchronous maintenance state, and optimize the current maintenance personnel configuration according to the usage sequence of multiple door body die-castings and the overall maintenance progress of multiple door body die-castings.

[0011] Compared with the prior art, the present invention has the following beneficial effects:

[0012] In an embodiment of the present invention, through the method in the embodiment of the present invention, multiple fault areas are determined based on the recognition of the current image of the door body die-casting; the fault status diagram of the door body die-casting is determined based on the mechanical analysis of the multiple fault areas, and the fault level of the door body die-casting is determined based on the fault status diagram and the service life of the door body die-casting; a fault management event is determined based on the fault level of the door body die-casting and the morphology of the door body die-casting, and the fault management event presents the maintenance status of multiple fault areas at different stages, is compatible with the overall consideration of the fault level of the door body die-casting and the morphology of the door body die-casting, and ensures the accuracy of the fault management event.

[0013] Therefore, in a fault management event, the overall maintenance progress of the door body die-casting is determined according to the maintenance progress of multiple fault areas, and the autonomous regulation of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door body die-casting and the preset maintenance time target; if multiple door body die-castings are in a synchronous maintenance state, the usage sequence of the multiple door body die-castings is collected, and the current maintenance personnel configuration is optimized according to the usage sequence of the multiple door body die-castings and the overall maintenance progress of the multiple door body die-castings, which is compatible with the autonomous regulation of the maintenance progress of multiple fault areas and the optimization of the current maintenance personnel configuration, thereby ensuring the accuracy of fault management of door body die-castings. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 1 is a flow chart of a fault management method for a door body die casting according to an embodiment of the present invention;

[0015] Figure 2 1 is a flow chart of step S11 in the fault management method for door body die castings in an embodiment of the present invention;

[0016] Figure 31 is a flow chart of step S12 in the fault management method for door body die castings in an embodiment of the present invention;

[0017] Figure 4 1 is a flow chart of step S13 in the fault management method for door body die castings in an embodiment of the present invention;

[0018] Figure 5 1 is a flow chart of step S14 in the fault management method for door body die castings in an embodiment of the present invention;

[0019] Figure 6 1 is a flow chart of step S15 in the fault management method for door body die castings in an embodiment of the present invention;

[0020] Figure 7 Schematic diagram of the structure of the fault management system of the door body die casting in an embodiment of the present invention. DETAILED DESCRIPTION

[0021] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0022] See also Figures 1 to 7 , a fault management method for a door body die casting, comprising:

[0023] Step S11: determining multiple fault areas based on the recognition of the current image of the door body die casting;

[0024] Step S12: determining a fault state diagram of the door body die-casting according to mechanical analysis of multiple fault areas, and determining a fault level of the door body die-casting according to the fault state diagram and the service life of the door body die-casting;

[0025] Step S13: determining a fault management event based on the fault level and the shape of the door body die-casting, wherein the fault management event represents maintenance status of multiple fault areas at different stages;

[0026] Step S14: In a fault management event, the overall maintenance progress of the door body die casting is determined based on the maintenance progress of multiple fault areas, and autonomous regulation of the maintenance progress of the multiple fault areas is triggered based on the overall maintenance progress of the door body die casting and the preset maintenance time target;

[0027] Step S15: If the multiple door body die castings are in a synchronous maintenance state, the usage order of the multiple door body die castings is collected, and the current maintenance personnel configuration is optimized according to the usage order of the multiple door body die castings and the overall maintenance progress of the multiple door body die castings;

[0028] refer to Figure 2 , in step S11, a plurality of fault areas are determined based on the recognition of the current image of the door body die casting;

[0029] In the specific implementation process of the present invention, the specific steps are:

[0030] S111: After being damaged, the door body die-casting moves to a shooting area, and circular shooting is performed on the door body die-casting to acquire a current image of the door body die-casting;

[0031] S112: determining a plurality of surface abnormal regions based on detection of the current image of the door body die-casting, and determining an overall abnormal region based on the plurality of surface abnormal regions and the surface morphology of the door body die-casting;

[0032] S113: After the door body die-casting is damaged, multiple impact positions are marked, multiple first fault positions are determined based on the multiple impact positions and the overall abnormal area, multiple second fault positions are determined based on the multiple impact positions and the surface morphology of the door body die-casting, and multiple fault areas are determined based on the mapping relationship between the multiple first fault positions, the multiple second fault positions and the area.

[0033] In an embodiment of the present application, the door body die-casting is moved to the shooting area after being damaged, and the door body die-casting is photographed in a circular manner to capture the current image of the door body die-casting, and the current image of the door body die-casting is introduced.

[0034] At this time, on the production line or in the maintenance area, manual inspection or automatic detection system is used to identify whether the door body die-casting is damaged; damage is manifested as cracks, deformation, surface scratches, dents, etc.; once damage is identified, use automated handling equipment (such as robotic arms, conveyor belts) or manual methods to move the door body die-casting from its current position to a dedicated shooting area; the shooting area should be designed with sufficient space and appropriate lighting conditions to ensure the quality of image acquisition.

[0035] In the shooting area, deploy multiple fixed-position cameras or use a rotatable camera bracket to perform 360-degree circular shooting of the door body die-casting; each camera or shooting angle should cover a part of the door body die-casting to ensure that the entire surface can be photographed; the camera should have high resolution and be able to clearly capture the details of the door body die-casting surface.

[0036] The image data captured by the camera is transmitted to the image processing system or storage device for subsequent analysis; during the image acquisition process, the consistency of the distance, angle and lighting conditions between the camera and the door body die-casting should be ensured to reduce the complexity of image processing.

[0037] Specifically, suppose that on the door body die-casting production line of a certain automobile manufacturer, a door body die-casting develops surface cracks due to mold problems during the die-casting process; the automatic inspection system on the production line identifies the damaged door body die-casting through machine vision technology; then, a robotic arm grabs the damaged door body die-casting from the production line and moves it smoothly to a dedicated shooting area; the shooting area is equipped with four high-resolution cameras, located on the four sides of the door body die-casting, forming a closed ring shooting system.

[0038] When the door body die-casting was placed in the center of the shooting area, four cameras were started simultaneously to perform a 360-degree circular shooting of the door body die-casting; each camera captured a detailed image of the door body die-casting surface, including information such as the location, shape and size of the cracks. These image data were transmitted to the image processing system in real time, providing a basis for subsequent image analysis and fault area determination.

[0039] Furthermore, multiple surface abnormality areas are determined based on the detection of the current image of the door body die-casting, and the overall abnormality area is determined according to the multiple surface abnormality areas and the surface morphology of the door body die-casting; the overall consideration of the multiple surface abnormality areas and the surface morphology of the door body die-casting is compatible to ensure the accuracy of the overall abnormality area.

[0040] At this time, the current image of the door body die-casting collected in step S111 is analyzed; edge detection, texture analysis, color contrast and other technologies are applied to identify abnormal areas in the image, which are manifested as color changes, inconsistent textures, distorted shapes or discontinuous edges; the identified abnormal areas are marked on the image, and their location, size, shape and other characteristics are recorded.

[0041] Considering the surface morphology of the door body die-casting, such as planes, curved surfaces, edges, etc., the marked abnormal areas are further screened and integrated; the correlation between the abnormal areas and the surface morphology of the door body die-casting is analyzed, such as cracks extending along the stress concentration area, scratches along the direction of the surface texture, etc.; based on these correlations, adjacent or similar abnormal areas are merged into an overall abnormal area to more accurately reflect the fault situation of the door body die-casting.

[0042] Specifically, in step S111, a 360-degree annular image of the damaged door body die-casting has been collected; next, in step S112, these images are analyzed using image processing software; the software first applies edge detection technology to identify edge changes in the image, especially those edges that contrast sharply with the surrounding areas; in this process, the software successfully identifies a long and thin crack on the surface of the door body die-casting, which starts from one edge of the door body and extends a certain length along the surface.

[0043] The software then further analyzed the crack based on the surface morphology of the door body die-casting. Since the door body die-casting is a component with a complex curved surface, the software took into account the tendency of the crack to extend along the stress concentration area. By comparing the direction of the crack and the curvature change of the door body surface, the software confirmed that the crack was indeed related to a stress concentration area of the door body. Finally, the software marked the crack as an overall abnormal area and recorded its location, length, width and other characteristics. This information provides important basis for subsequent fault analysis and treatment.

[0044] Therefore, after the door body die-casting is damaged, multiple impact positions are marked, multiple first fault positions are determined based on the multiple impact positions and the overall abnormal area, multiple second fault positions are determined based on the multiple impact positions and the surface morphology of the door body die-casting, and multiple fault areas are determined based on the mapping relationship between the multiple first fault positions and the multiple second fault positions and the area; the overall consideration of the mapping relationship between the multiple first fault positions and the multiple second fault positions and the area is compatible to ensure the accuracy of the multiple fault areas.

[0045] At this time, after the door body die-casting is damaged, the impact position is identified and recorded through manual inspection or the use of detection tools (such as knocking test, ultrasonic detection, etc.); the impact position is an obvious dent, scratch or deformation area, and is also an impact mark discovered through internal inspection; each impact position should be accurately marked on the door body die-casting or its corresponding image / model for subsequent analysis.

[0046] Determine multiple first fault locations: compare the marked impact location with the overall abnormal area determined in step S112; if a certain impact location overlaps or is adjacent to the overall abnormal area, it is regarded as a first fault location; the first fault location represents the damaged area directly caused by the impact.

[0047] Identify multiple secondary failure locations: Consider the indirect impact of the impact on the surface morphology and internal structure of the door body die-casting; analyze factors such as stress distribution and changes in material properties around the impact location to predict failure modes such as crack propagation and increased deformation; based on these predictions, identify additional secondary failure locations beyond the impact location.

[0048] Establish a three-dimensional model or image mapping relationship of the door body die-casting, and map the first fault location and the second fault location into the model; merge adjacent or similar fault locations into a fault area based on the distribution, size and shape of the fault locations; each fault area should be assigned a unique identifier for subsequent management and analysis.

[0049] Specifically, in the previous steps, the overall abnormal area and impact position on the door body die-casting have been determined; in step S113, two obvious impact positions on the door body die-casting are first marked, namely the lower left corner and the upper right corner of the door body, both of which have obvious dents and scratches; then, the two impact positions are compared with the overall abnormal area; it is found that the impact position in the lower left corner overlaps with a crack that extends from the edge of the door body, so it is regarded as a first fault position; and although the impact position in the upper right corner appears to have only slight scratches on the surface, ultrasonic testing has found that tiny cracks have already occurred inside it, so it is also regarded as a first fault position.

[0050] Then, the indirect impact of the impact on the door body die-casting was considered; by analyzing the structural design and material properties of the door body, it was predicted that the impact in the lower left corner would cause the crack to further expand along the direction of stress concentration; therefore, several additional second fault locations were identified on the potential expansion path of the crack; finally, a three-dimensional model of the door body die-casting was established, and all the determined first fault locations and second fault locations were mapped to the model; according to the distribution and morphology of these fault locations, the adjacent fault locations were merged into two fault areas: one is the crack expansion area in the lower left corner, and the other is the impact damage area in the upper right corner; through this example, we can see the specific operation process and technical implementation method of step S113 in actual application; by marking the impact location, determining the first and second fault locations, and determining the fault area based on the area mapping relationship, we can have a more comprehensive understanding of the fault situation of the door body die-casting, providing strong support for subsequent management and repair.

[0051] refer to Figure 3 In step S12, a fault state diagram of the door body die casting is determined based on the mechanical analysis of multiple fault areas, and a fault level of the door body die casting is determined based on the fault state diagram and the service life of the door body die casting;

[0052] In the specific implementation process of the present invention, the specific steps are:

[0053] S121: collecting the model of the door body die-casting, determining a three-dimensional model of the door body die-casting in a factory state based on the model of the door body die-casting and a die-casting database, and marking multiple fault areas on the three-dimensional model of the door body die-casting;

[0054] S122: Performing corresponding mechanical analysis on the locations of the multiple fault regions and outputting multiple mechanical distribution maps. At this time, based on the identification of the multiple fault regions, a fault feature is determined, and a mechanical analysis mode is determined based on the type of the fault feature and the area of the fault region.

[0055] S123: Determine a fault state diagram of the door body die-casting based on the multiple mechanical distribution diagrams and the three-dimensional model of the door body die-casting, collect the service life of the door body die-casting, and determine the fault level of the door body die-casting based on a mapping relationship among the fault state diagram, the service life of the door body die-casting, and the fault level;

[0056] In an embodiment of the present application, the model of the door body die-casting is collected, and a three-dimensional model of the door body die-casting in a factory state is determined based on the model of the door body die-casting and the die-casting database, and multiple fault areas are marked on the three-dimensional model of the door body die-casting; the overall consideration of the model of the door body die-casting and the die-casting database is compatible to ensure the accuracy of the three-dimensional model of the door body die-casting in a factory state.

[0057] At this time, the model of the door body die-casting is collected, and the three-dimensional model of the door body die-casting when it leaves the factory is obtained, including information such as geometric shape and material properties; at this time, the record matching the collected model is searched in the die-casting database; the database should contain three-dimensional model data of various models of door body die-castings.

[0058] Accurately mark the fault area determined in the previous step (such as step S113) on the three-dimensional model for subsequent analysis; at this time, use three-dimensional modeling software or special marking tools to mark the position, size and shape of the fault area on the three-dimensional model; marking is achieved through color coding, highlighting, adding annotations, etc.; ensure that the marked fault area is consistent with the actual situation to avoid omissions or mislabeling; at the same time, the marking should be clear and readable to facilitate subsequent analysis and understanding.

[0059] Furthermore, corresponding mechanical analysis is performed on the locations of multiple fault areas, and multiple mechanical distribution maps are output. At this time, the fault characteristics are determined based on the identification of multiple fault areas, and the mechanical analysis mode is determined according to the type of the fault characteristics and the regional area of the fault area, thereby ensuring the accuracy of the mechanical analysis mode.

[0060] At this point, it is necessary to understand the mechanical behaviors of the fault area, such as stress and strain, under stress conditions, to provide a scientific basis for subsequent repairs or improvements. At this point, finite element analysis (FEA), computational fluid dynamics (CFD) or other mechanical simulation software is used to perform a mechanical analysis on the three-dimensional model with the fault area marked. During the analysis, the actual working conditions of the door body die-casting, such as load and boundary conditions, need to be considered.

[0061] The mechanical behavior of the fault area is intuitively displayed to facilitate analysis and understanding. At this time, based on the mechanical analysis results, mechanical distribution maps such as stress distribution map, strain distribution map, displacement distribution map, etc. are generated; these graphs display the size and distribution of mechanical parameters through color coding, contour lines, etc.; ensure that the output mechanical distribution map is clear and readable, and the colors and annotations accurately reflect the changes in mechanical parameters.

[0062] According to the shape, size, location and other information of the fault area, the main characteristics of the fault, such as crack type, depression depth, deformation degree, etc., are identified; at this time, the fault area is analyzed in detail through visual inspection, measurement tools or image processing software to extract the fault characteristics; at the same time,

[0063] According to the complexity of the fault characteristics and the size of the fault area, select an appropriate mechanical analysis mode to improve the accuracy and efficiency of the analysis; optionally, according to the fault characteristics (such as crack propagation, plastic deformation, fatigue damage, etc.) and the area of the fault area (such as small area local damage, large area overall deformation, etc.), select the corresponding mechanical analysis method and parameter settings; ensure that the selected mechanical analysis mode matches the fault characteristics and area to avoid oversimplification or complication of the analysis process.

[0064] Specifically, assume that a fault analysis is being performed on a die-cast automobile door body. Three fault areas have been identified in step S113 for this die-cast part: A (crack), B (dent), and C (deformation). Finite element analysis software is used to perform a mechanical analysis on the three-dimensional model with the fault areas marked. The loads and boundary conditions of the door body die-cast part in actual operation are taken into account, such as the impact force of opening and closing the door, the vibration of the car body, etc. Based on the mechanical analysis results, stress distribution diagrams, strain distribution diagrams, and displacement distribution diagrams are generated. In the stress distribution diagram, stress concentration is seen in the crack area A. In the strain distribution diagram, the strain in the dent area B is larger. In the displacement distribution diagram, the displacement in the deformation area C is obvious.

[0065] Through visual inspection and measurement tools, it was determined that the crack type in crack area A was a through crack with a length of approximately 5mm; the depression depth in depression area B was approximately 2mm; and the degree of deformation in deformation area C was approximately 5%; for crack area A, the fracture mechanics analysis mode was selected, focusing on analyzing the crack expansion path and speed; for depression area B, the elastic-plastic mechanics analysis mode was selected to analyze the stress concentration and plastic deformation effects of the depression on the surrounding materials; for deformation area C, the structural mechanics analysis mode was selected to evaluate the effect of deformation on the overall stiffness and strength of the door body die-casting; according to the size of the fault area, the density of the analysis grid and the calculation accuracy were adjusted to ensure the accuracy and efficiency of the analysis; through such steps, a detailed mechanical analysis of the fault area of the automobile door body die-casting was carried out, providing a scientific basis for subsequent repairs or improvements.

[0066] Therefore, the fault status diagram of the door body die-casting is determined based on multiple mechanical distribution diagrams and the three-dimensional model of the door body die-casting, the service life of the door body die-casting is collected, and the fault level of the door body die-casting is determined based on the fault status diagram, the service life of the door body die-casting and the fault level mapping relationship; the overall consideration of the fault status diagram, the service life of the door body die-casting and the fault level mapping relationship is compatible to ensure the accuracy of the fault level of the door body die-casting.

[0067] At this time, multiple mechanical analysis results are integrated to generate an intuitive fault status diagram to show the fault distribution, severity and potential impact of the door body die-casting; at this time, the mechanical distribution diagram (such as stress distribution diagram, strain distribution diagram, displacement distribution diagram, etc.) is combined with the three-dimensional model of the door body die-casting to generate a fault status diagram through superposition, fusion or color coding; the fault status diagram should clearly show the position, size, shape and changes in mechanical parameters of the fault area; ensure the accuracy and readability of the fault status diagram to avoid information omission or misleading; at the same time, consider the interaction and influence between the fault areas, as well as the impact of the fault on the overall performance of the door body die-casting.

[0068] Collect the service life of door body die-castings and understand the service history of door body die-castings to provide a basis for evaluating their remaining life and failure level; optionally, obtain their service life by reviewing the production records, usage records or maintenance records of door body die-castings; if the service life cannot be directly obtained, estimate it by asking users, on-site investigation or expert evaluation.

[0069] Based on the fault status diagram and service life, combined with the fault level mapping relationship, the fault level of the door body die-casting is quantitatively evaluated; at this time, first, according to the fault status diagram, the severity and scope of the fault area are determined; then, combined with the service life, the impact of the fault on the remaining life of the door body die-casting is evaluated; finally, according to the fault level mapping relationship (such as the fault level classification standard based on factors such as fault characteristics, severity, and service life), the fault level of the door body die-casting is determined; ensure the accuracy and applicability of the fault level mapping relationship to avoid over-simplification or complication of the evaluation process; at the same time, consider the impact of the fault level on the safety performance and reliability of the door body die-casting.

[0070] Specifically, assume that a failure level assessment is being conducted on a die-cast automobile door body. In step S122, the stress distribution map, strain distribution map, and displacement distribution map have been generated for the die-cast part, and the failure characteristics of the crack area A, the depression area B, and the deformation area C have been determined. The stress distribution map, strain distribution map, and displacement distribution map are combined with the three-dimensional model of the door body die-cast part, and a failure status map is generated by color coding. In the failure status map, the crack area A is displayed as a red highlighted area, indicating stress concentration and potential fracture risk; the depression area B is displayed as a yellow area, indicating large strain and plastic deformation; the deformation area C is displayed as a blue area, indicating large displacement and decreased overall stiffness.

[0071] By checking the production and maintenance records of the car, it was learned that the door body die-casting had been in use for 5 years; considering that the design life of the automobile door body die-casting is 10 years, the die-casting has used half of its design life; based on the fault state diagram and service life, combined with the pre-established fault level mapping relationship, an assessment was made; since the stress concentration phenomenon in the crack area A is serious and it is located at the key stress-bearing part of the door body die-casting, combined with its 5-year service life and potential fracture risk, the fault level of the die-casting was determined to be "serious"; although there are also certain degrees of faults in the depressed area B and the deformed area C, compared with the crack area A, their impact on the overall performance of the door body die-casting is smaller, and considering the service life and design life, the fault level of these two areas is determined to be "general".

[0072] In one embodiment of the present application, a fault level mapping table is collected, and the fault level mapping table is shown in Table 1:

[0073] Table 1 Fault level mapping table

[0074] Fault characteristics Severity Service life (years) Fault level crack serious <5 serious crack generally 5-10 generally crack slight >10 slight Depression serious <10 generally Depression General / mild >10 slight Deformation serious <5 serious Deformation General / mild ≥5 generally

[0075] refer to Figure 4 In step S13, a fault management event is determined based on the fault level and the shape of the door body die casting, and the fault management event presents maintenance conditions of multiple fault areas at different stages;

[0076] In the specific implementation process of the present invention, the specific steps are:

[0077] S131: collecting fault levels of the door body die-casting, and determining sub-fault levels of multiple fault areas based on the classification of the fault levels of the door body die-casting;

[0078] S132: determining first fault states of the multiple fault areas according to the sub-fault levels and corresponding area sizes of the multiple fault areas, and determining second fault states of the multiple fault areas according to the sub-fault levels and the morphology of the door body die-casting;

[0079] S133: In each fault area, the corresponding sub-fault management event is determined based on the first fault state, the second fault state and the event mapping relationship, and the fault management event is determined based on the synthesis of multiple sub-fault management events. At this time, multiple sub-fault management events are distributed in different stages of multiple fault areas, presenting corresponding maintenance conditions.

[0080] In an embodiment of the present application, the fault level of the door body die-casting is collected, and the sub-fault levels of multiple fault areas are determined based on the division of the fault level of the door body die-casting, thereby ensuring the accuracy of the sub-fault levels of the multiple fault areas.

[0081] At this time, the fault level of the door body die-casting is collected to obtain the current overall fault level of the door body die-casting, which is the basis for the subsequent determination of the sub-fault level; optionally, through the previous evaluation steps (such as S123), the fault status diagram, service life and fault level mapping relationship of the door body die-casting have been obtained, and based on this information, the overall fault level of the door body die-casting is determined.

[0082] The overall fault level is refined into specific fault areas in order to more accurately evaluate and manage the fault conditions in each area. First, all fault areas on the door body die-casting are identified based on the fault status diagram. Then, each fault area is evaluated in detail, including the fault type, severity, and impact on overall performance. Next, a sub-fault level is assigned to each fault area based on the overall fault level and the evaluation results of each fault area. The division of sub-fault levels is determined based on factors such as the severity of the fault, the impact on overall performance, and the difficulty of repair. Finally, the sub-fault level of each fault area is recorded to form a sub-fault level list.

[0083] Specifically, assuming there is a door body die-casting, after the previous evaluation steps (such as S123), the overall fault level of the die-casting is obtained as "general"; now, it is necessary to further determine the sub-fault level of each fault area; overall fault level: general; fault area one: crack area; fault type: crack; severity: long and deep, affecting the overall strength and stability of the door body; impact on overall performance: large, resulting in the door body being unable to be used normally or posing a safety hazard; sub-fault level: serious (because the severity of the crack is high, the impact on the overall performance is also large).

[0084] Fault area 2: Deformation area; Fault type: Deformation; Severity: Minor, only affecting the appearance and local stiffness of the door body; Impact on overall performance: Minor, does not affect the normal use of the door body; Sub-fault level: General (because the severity of the deformation is low, the impact on overall performance is also small);

[0085] Fault area three: wear area; Fault type: wear; Severity: moderate, the wear area is large but the depth is shallow; Impact on overall performance: moderate, affecting the service life and appearance of the door body; Sub-fault level: slight to general (because although the wear area is large but the depth is shallow, the impact on the overall performance is between general and slight, and it is judged as slight to general as appropriate); Through such steps, a specific sub-fault level is determined for each fault area, providing a more accurate basis for subsequent management and maintenance.

[0086] Furthermore, the first fault states of multiple fault areas are determined according to the sub-fault levels of the multiple fault areas and the corresponding area areas, and the second fault states of the multiple fault areas are determined according to the sub-fault levels of the multiple fault areas and the morphology of the door body die-casting; the overall consideration of the sub-fault levels of the multiple fault areas and the morphology of the door body die-casting is compatible to ensure the accuracy of the second fault states of the multiple fault areas.

[0087] At this time, the first fault states of multiple fault areas are determined according to their sub-fault levels and corresponding area areas, and the sub-fault levels and areas of the fault areas are comprehensively considered to determine the extent of their impact on the overall performance of the door body die-casting, that is, the first fault state; optionally, for each fault area, first refer to its sub-fault level, which is the basis for evaluating the severity of the fault; then, consider the area of the fault area, the larger the area, the greater the impact of the fault on the overall performance; combine the sub-fault level and area, and formulate an evaluation standard or formula for quantifying the first fault state of each fault area; for example, set different weights for the sub-fault level and area, and then calculate the weighted sum or product; according to the evaluation results, classify the first fault state of each fault area into levels such as "high risk", "medium risk" or "low risk".

[0088] The second fault states of multiple fault areas are determined according to their sub-fault levels and the morphology of the door body die-casting. In addition to considering the sub-fault levels and areas of the fault areas, the morphology of the door body die-casting (such as shape, structure, key parts, etc.) is also combined to further evaluate the impact of the fault on the function and appearance of the door body, that is, the second fault state; optionally, for each fault area, first refer to its sub-fault level, which is a basic assessment; then, consider the morphological factors of the door body die-casting, especially whether the fault area is located in a key position (such as stress points, connections, sealing surfaces, etc.), and whether the fault affects the overall structure or appearance of the door body; combine the sub-fault levels and morphological factors to conduct a comprehensive analysis to determine the second fault state of each fault area, which requires professional knowledge and experience to judge; according to the evaluation results, the second fault state of each fault area is also classified into different levels.

[0089] Specifically, assume there is a door body die-casting. The sub-fault levels of its multiple fault areas have been determined in the previous steps. Now, the first fault state and second fault state of these fault areas need to be further determined. The first fault state is determined as follows: Fault area A: The sub-fault level is "serious" and the area is 10 square centimeters. Considering the large area and the severe sub-fault level, its first fault state is assessed as "high risk". Fault area B: The sub-fault level is "normal" and the area is 5 square centimeters. Although the area is not small, the sub-fault level is normal, so its first fault state is assessed as "medium risk". Fault area C: The sub-fault level is "minor" and the area is 2 square centimeters. Given the small area and the minor sub-fault level, its first fault state is assessed as "low risk".

[0090] Determine the second fault state: Fault area A: located at the stress point of the door body, and the sub-fault level is "serious"; since the stress point is crucial to the overall strength and stability of the door body, and the fault is serious, its second fault state is also assessed as "high risk"; Fault area B: although located in a non-critical part of the door body, the sub-fault level is "general" and the area is large, affecting the local performance of the door body; after comprehensive consideration, its second fault state is assessed as "medium risk" (or depending on the specific situation, if the morphological factor is not a decisive factor, it is also maintained as "medium risk", but emphasizes the need for attention); Fault area C: located at the edge of the door body, does not affect the overall structure and appearance, and the sub-fault level is "minor"; its second fault state is assessed as "low risk"; through such steps, the specific first fault state and second fault state are determined for each fault area, providing a more comprehensive basis for subsequent management and maintenance. These status information helps decision makers better understand the impact of the fault, thereby formulating reasonable maintenance plans and resource allocation.

[0091] Therefore, in each fault area, the corresponding sub-fault management event is determined based on the first fault state, the second fault state and the event mapping relationship, and the fault management event is determined based on the synthesis of multiple sub-fault management events. At this time, multiple sub-fault management events are distributed in different stages of multiple fault areas, presenting corresponding maintenance situations; it is compatible with the overall consideration of the first fault state, the second fault state and the event mapping relationship, ensuring the accuracy of the corresponding sub-fault management events, and at the same time, it is compatible with the overall consideration of the fault level of the door body die-casting and the shape of the door body die-casting, ensuring the accuracy of the fault management event.

[0092] At this time, the corresponding sub-fault management event is determined based on the first fault state, the second fault state and the event mapping relationship. At this time, according to the first fault state, the second fault state of each fault area, and the pre-defined event mapping relationship, the specific sub-fault management event is determined. These events are maintenance, inspection or other management measures that need to be taken for each fault area; optionally, the event mapping relationship is a predefined rule set or decision tree, which associates a specific fault state with a corresponding management event; for each fault area, find its corresponding management event in the event mapping relationship, which needs to consider the combination of the first fault state and the second fault state, as well as any relevant contextual information (such as the use environment of the door body, historical maintenance records, etc.); determine the sub-fault management events of each fault area, which are maintenance tasks, inspection plans, monitoring activities or other necessary management measures.

[0093] A fault management event is determined based on the synthesis of multiple sub-fault management events. The sub-fault management events of multiple fault areas are integrated into an overall fault management event for unified management and planning. At this time, the priority, urgency and mutual dependencies of all sub-fault management events are analyzed. Based on these analyses, a reasonable execution sequence and schedule are determined to ensure that all necessary maintenance and management activities are carried out in a timely and effective manner. An overall fault management event is synthesized, which contains detailed information of all sub-fault management events, such as task description, responsible person, execution time, required resources, etc.

[0094] In one embodiment of the present application, a sub-fault management event matching table is collected. The sub-fault management event matching table lists various fault state combinations and corresponding management events in detail. When the specific fault state of a fault area is determined, it is only necessary to search the matching table for the corresponding management event. The sub-fault management event matching table is shown in Table 2:

[0095] Table 2. Fault management event matching table

[0096]

[0097] Specifically, assume that there is a door body die-casting, and the first fault state of its fault area D is "high risk" and the second fault state is "medium risk"; according to the sub-fault management event matching table, the sub-fault management event is determined to be "prioritize a professional team to conduct a detailed inspection and formulate a maintenance plan."

[0098] refer to Figure 5 In step S14, in a fault management event, the overall maintenance progress of the door body die casting is determined according to the maintenance progress of multiple fault areas, and autonomous regulation of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door body die casting and the preset maintenance time target;

[0099] In the specific implementation process of the present invention, the specific steps are:

[0100] S141: collecting maintenance nodes of multiple fault areas, and determining maintenance progress of the multiple fault areas according to the maintenance nodes of the multiple fault areas and corresponding online maintenance images;

[0101] S142: determining an overall maintenance progress of the door body die-casting according to the maintenance progress of the multiple fault areas, the corresponding real-time images, and the real-time morphology of the door body die-casting. At this time, the overall maintenance progress of the door body die-casting presents the overall maintenance progress of the door body die-casting at the current time;

[0102] S143: Collect the preset maintenance time target, determine the remaining maintenance progress based on the tracing of the overall maintenance progress of the door body die-casting, determine the accelerated maintenance events of the multiple fault areas according to the remaining maintenance progress, the maintenance progress of the multiple fault areas and the preset maintenance time target, and trigger the autonomous regulation of the maintenance progress of the multiple fault areas according to the accelerated maintenance events of the multiple fault areas.

[0103] In an embodiment of the present application, maintenance nodes of multiple fault areas are collected, and the maintenance progress of the multiple fault areas is determined based on the maintenance nodes of the multiple fault areas and the corresponding online maintenance images; the overall consideration of the maintenance nodes of the multiple fault areas and the corresponding online maintenance images is compatible to ensure the accuracy of the maintenance progress of the multiple fault areas.

[0104] At this time, collect maintenance nodes of multiple fault areas, record and track the key time points and operation steps of each fault area during the maintenance process, so as to facilitate subsequent evaluation and determination of maintenance progress; optionally, collect key nodes such as maintenance start time, key operation completion time, and phased inspection time for each fault area through on-site records, monitoring systems, or feedback from maintenance personnel. These node information should be detailed and accurate, and be able to reflect the actual progress of the maintenance work; ensure that the collected maintenance node information is accurate to avoid progress evaluation deviations due to information errors.

[0105] Combine maintenance node information and online maintenance images to accurately assess the maintenance progress of each fault area. Use real-time or recent maintenance images obtained by the online monitoring system and compare them with maintenance node information to determine the actual completion status of the current maintenance work. Based on information such as work progress, staffing, and equipment status in the images, combined with maintenance node timestamps, comprehensively assess the maintenance progress of each fault area. Use percentages, phase divisions, or other quantitative indicators to express maintenance progress. Ensure the clarity and timeliness of online maintenance images to accurately reflect the actual status of maintenance work. Also, consider various factors that affect progress, such as weather and material availability, during the assessment process.

[0106] Specifically, suppose there is a door body die-casting maintenance project that includes three fault areas, namely fault areas A, B and C; fault area A: maintenance starts at 8 am, key operations (such as welding repairs) are completed at 10 am, and the periodic inspection time is 11 am; fault area B: maintenance starts at 9 am, and surface grinding is currently underway, and this step is expected to be completed at 1 pm; fault area C: due to material shortages, maintenance work has not yet started, but is expected to start after the materials are in place at 2 pm.

[0107] Fault area A: Through the online monitoring images, we can see that the welding repair work has been completed and the stage inspection is in progress; combined with the maintenance node information, it is judged that the maintenance progress of fault area A is about 70% (assuming that the welding repair accounts for the majority of the overall maintenance work); Fault area B: The online monitoring images show that the surface grinding work is in progress but has not yet been completed; based on the maintenance node information and the work progress in the image, it is estimated that the maintenance progress of fault area B is about 30% (assuming that the surface grinding is an important step in the overall maintenance work); Fault area C: Due to material shortages, maintenance work has not yet begun; therefore, the maintenance progress of fault area C is 0%; In summary, by collecting maintenance node information and using online maintenance images to perform progress assessment, the maintenance progress of each fault area is obtained, and subsequent work plans and resource allocation strategies are formulated accordingly.

[0108] Furthermore, the overall maintenance progress of the door body die-casting is determined based on the maintenance progress of multiple fault areas, the corresponding real-time images and the real-time shape of the door body die-casting. At this time, the overall maintenance progress of the door body die-casting presents the overall maintenance progress of the door body die-casting at the current time; it is compatible with the overall consideration of the maintenance progress of multiple fault areas, the corresponding real-time images and the real-time shape of the door body die-casting, ensuring the accuracy of the overall maintenance progress of the door body die-casting.

[0109] At this time, the maintenance progress of each fault area is summarized in order to obtain an overview of the maintenance progress of the door body die-casting as a whole; at this time, the latest maintenance progress data of each fault area is collected, and these data are expressed in the form of percentage, completion stage or completion status of specific tasks; according to the importance and scale of each fault area (such as area, impact on overall performance, etc.), it is assigned corresponding weights (if applicable); the maintenance progress of each fault area is summarized, and the weighted average or comprehensive score of the overall maintenance progress is calculated based on the weights (if assigned).

[0110] The evaluation results of the overall maintenance progress are further verified and refined through real-time images and the real-time morphology of the door body die-castings. At this time, the online monitoring system or real-time image resources such as photos and videos taken on site are used to observe the overall appearance of the door body die-castings, the connection status of each component, surface treatment and other key features. The real-time images are compared with the standard maintenance completion status or historical maintenance records to evaluate the current actual maintenance level of the door body die-castings. The morphological changes of the door body die-castings during the maintenance process (such as color, shape, size, etc.) and the impact of these changes on the overall performance and safety are considered. The overall maintenance progress is corrected and adjusted in combination with the real-time image evaluation results and the previous maintenance progress summary data.

[0111] Present the overall maintenance progress of the door body die-casting at the current time in a clear and accurate manner. At this time, based on the summary and evaluation results, determine the overall maintenance progress of the door body die-casting (expressed in percentage, stage division, color coding, etc.); prepare and publish maintenance progress reports or updates, including an overview of the overall maintenance progress, detailed progress of each fault area, existing problems and challenges, and subsequent work plans; ensure the accuracy and timeliness of reports or updates so that relevant personnel can understand the maintenance progress in a timely manner and make corresponding decisions.

[0112] Specifically, assume that there is a door body die-casting maintenance project that includes three fault areas (A, B, and C); fault area A: 70% of the maintenance work has been completed, including welding repairs and preliminary polishing; fault area B: 50% of the maintenance work has been completed, and surface treatment and anti-rust treatment are in progress; fault area C: due to material shortages, only 10% of the preparation work has been completed and actual maintenance has not yet begun; assuming that the weights of each fault area are the same (that is, each area has the same impact on the overall maintenance progress), the preliminary calculation of the overall maintenance progress is: (70%+50%+10%) / 3=43.33%.

[0113] Through the online monitoring system, it was observed that the welding repair quality of fault area A was good, but the initial grinding was slightly rough and required extra attention; the surface treatment of fault area B was in progress, but the anti-rust treatment did not seem uniform enough and needed to be strengthened; fault area C was still in the preparation stage and actual maintenance work had not yet begun, but the materials were in place and were expected to start in the afternoon; based on these observations, the overall maintenance progress was revised: taking into account that some detailed work in fault areas A and B had not yet been completed, the overall maintenance progress was adjusted to approximately 40% (slightly lower than the initial calculation of 43.33%) to reflect these potential problems.

[0114] A maintenance progress report was produced, which outlined the overall maintenance progress of the door body die-casting at 40%, and listed in detail the maintenance progress, existing problems and challenges (such as rough polishing, uneven rust prevention treatment, etc.) of each fault area; the report also included a follow-up work plan, including strengthening the detailed work of fault areas A and B, ensuring that maintenance work in fault area C started as planned, etc.; the report was sent to relevant personnel via email so that they could keep abreast of the maintenance progress and make corresponding decisions.

[0115] Therefore, the preset maintenance time target is collected, the remaining maintenance progress is determined based on the tracing of the overall maintenance progress of the door body die-casting, the accelerated maintenance events of multiple fault areas are determined according to the remaining maintenance progress, the maintenance progress of multiple fault areas and the preset maintenance time target, and the autonomous regulation of the maintenance progress of multiple fault areas is triggered according to the accelerated maintenance events of multiple fault areas; the overall consideration of the remaining maintenance progress, the maintenance progress of multiple fault areas and the preset maintenance time target is compatible to ensure the accuracy of the accelerated maintenance events of multiple fault areas.

[0116] At this time, collect the preset maintenance time target and clarify the expected completion time of the door body die-casting maintenance project, which will serve as a reference benchmark for subsequent progress control and acceleration of maintenance events; optionally, obtain the preset maintenance time target from the project plan or contract, which is expressed in the form of specific dates, time periods or working hours; ensure that the collected maintenance time target is accurate, reliable, and recognized by the project stakeholders.

[0117] By comparing the current overall maintenance progress with the preset maintenance time target, the remaining maintenance workload and time to be completed are determined; at this time, the previously determined overall maintenance progress data of the door body die-casting (such as percentage, stage division, etc.) is used; according to the preset maintenance time target and the current time, the remaining available maintenance time is calculated; combined with the remaining available maintenance time and the current overall maintenance progress, the remaining maintenance workload and time distribution are evaluated.

[0118] Identify and determine which fault areas require expedited maintenance to meet preset maintenance time targets; at this point, analyze the current maintenance progress and remaining workload of each fault area; identify fault areas that are lagging behind or have potential delay risks; formulate specific measures and plans to expedite maintenance events based on the actual conditions of these areas and the preset maintenance time targets; accelerating maintenance events includes increasing manpower, deploying resources, adjusting work plans, and adopting more efficient technologies or methods.

[0119] By implementing accelerated maintenance events, the maintenance progress of each fault area is independently adjusted to ensure that the overall maintenance project can be completed on time. At this time, the specific measures and plans for accelerating maintenance events will be communicated to the relevant maintenance teams and personnel. The implementation of accelerated maintenance events will be monitored to ensure that all measures are effectively implemented. According to the actual situation and feedback during the implementation process, the strategy and plan for accelerating maintenance events will be adjusted in a timely manner. Through continuous progress monitoring and adjustment, it is ensured that the maintenance progress of each fault area gradually approaches the preset maintenance time target.

[0120] Specifically, assume that there is a door body die-casting maintenance project with three fault areas (A, B, and C), and the preset maintenance time target is to be completed within two weeks; the preset maintenance time target obtained from the project plan is two weeks (i.e., 14 days); assume that the current time is the seventh day after the start of the project; through the previous progress evaluation, it is known that the overall maintenance progress is 40% (assuming it is expressed in percentage); the remaining available maintenance time is 7 days (i.e., half of the preset time target); based on the overall maintenance progress and the remaining time, it is assessed that the remaining maintenance workload to be completed is 60% (i.e., the remaining part of the overall workload).

[0121] Analyze the current maintenance progress of each fault area: Fault area A: 50% of the maintenance work has been completed; Fault area B: 30% of the maintenance work has been completed; Fault area C: due to material shortage, only 10% of the preparation work has been completed; Identify the fault areas B and C with lagging progress; Develop specific measures and plans to speed up maintenance events: Add more manpower to fault area B and deploy more efficient grinding equipment; Give priority to solving the material shortage problem in fault area C and arrange for additional maintenance teams to provide support.

[0122] Communicate specific measures and plans for accelerating maintenance events to relevant maintenance teams and personnel; monitor the implementation of accelerated maintenance events to ensure that various measures are effectively implemented; for example, regularly check the grinding progress of fault area B and the availability of materials in fault area C; timely adjust the strategy and plan for accelerating maintenance events based on the actual situation and feedback during the implementation process; for example, if it is found that the grinding progress of fault area B is still lagging behind, consider further increasing manpower or adopting more efficient grinding methods; through continuous progress monitoring and regulation, ensure that the maintenance progress of each fault area gradually approaches the preset maintenance time target; for example, when conducting a progress assessment on a certain day within the remaining time, it is found that the overall maintenance progress has increased to 70%, and the progress of each fault area has accelerated, in line with the expected target.

[0123] In one embodiment of the present application, the preset maintenance time target is: completion within 15 days; weight distribution (based on the importance and size of the fault area): fault area A: 40%; fault area B: 30%; fault area C: 30%;

[0124] Current progress and score (Day 10): Fault area A: 70%, score = 70% * 40% = 28%; Fault area B: 40%, score = 40% * 30% = 12%; Fault area C: 60%, score = 60% * 30% = 18%; Total score: 28% + 12% + 18% = 58%; Remaining time and target score: 5 days remaining, target score = 100% - 58% = 42%.

[0125] Accelerate maintenance event determination (based on weight and residual score):

[0126] Fault Area B: High weight and low score, needs to be accelerated; measures: Same as above, increase manpower and optimize processes; Fault Area C: High weight and certain room for improvement, also needs to be accelerated; measures: Same as above, deploy tools and work overtime; Fault Area A: Although high weighted, the progress is good and the original progress can be maintained; Through the implementation of acceleration measures, the progress of fault areas B and C has been significantly improved, and the overall project was successfully completed within 15 days.

[0127] refer to Figure 6 In step S15, if multiple door body die castings are in a synchronous maintenance state, the usage order of the multiple door body die castings is collected, and the current maintenance personnel configuration is optimized according to the usage order of the multiple door body die castings and the overall maintenance progress of the multiple door body die castings;

[0128] In the specific implementation process of the present invention, the specific steps are:

[0129] S151: In the same maintenance space, collect data on multiple door body die-castings in the same maintenance space, where the multiple door body die-castings are in a synchronous maintenance state, and collect the work content of each maintenance personnel in the maintenance space;

[0130] S152: determining an incoming sequence of the plurality of door body die-castings based on the tracing of the plurality of door body die-castings, and determining a usage sequence of the plurality of door body die-castings according to the incoming sequence and corresponding models of the plurality of door body die-castings;

[0131] S153: Sort the overall maintenance progress of multiple door body die-castings in sequence according to the order of use. If the overall maintenance progress of the previous door body die-casting is lower than that of the next door body die-casting, trigger the personnel optimization of the maintenance personnel of the next door body die-casting based on the overall maintenance progress of the previous door body die-casting, the remaining maintenance tasks of the previous door body die-casting and the maintenance personnel configuration of the next door body die-casting.

[0132] In an embodiment of the present application, in the same maintenance space, multiple door body die castings in the same maintenance space are collected, the multiple door body die castings are in a synchronous maintenance state, and the work content of each maintenance personnel in the maintenance space is collected.

[0133] At this time, identify and record all door body die-castings that need maintenance in the same maintenance space to ensure that nothing is missed; at this time, use barcode or RFID technology to scan the unique identifier on each door body die-casting and record its model, serial number and other key information; or, through manual recording, have maintenance personnel check and record the information of each door body die-casting one by one; ensure that the recorded information is accurate and corresponds one-to-one to the door body die-castings in the actual maintenance space.

[0134] Ensure that all collected door body die-castings are maintained within the same time period for unified management and progress tracking; at this time, check the maintenance records or status indicators of each door body die-casting to confirm whether they are all in the maintenance process; communicate with the maintenance personnel to understand their maintenance plans and progress to ensure that the maintenance work of all door body die-castings is carried out synchronously; if a door body die-casting is found not in the maintenance status, it is necessary to promptly identify the cause and take measures to put it into the maintenance process.

[0135] Understand and record the specific work content and responsibilities of each maintenance personnel in the current maintenance space in order to conduct personnel deployment and efficiency analysis; at this time, record the door body die-castings, maintenance tasks, required tools and materials, etc. that each maintenance personnel is responsible for through work logs, task allocation tables or electronic management systems; communicate with maintenance personnel face to face to confirm their work content and progress, as well as the difficulties and needs encountered; based on the recorded information, analyze the work efficiency of maintenance personnel, identify potential bottlenecks and problems, and provide a basis for subsequent personnel optimization and resource allocation.

[0136] Specifically, assume there is a large door body die-casting maintenance workshop, which contains multiple door body die-castings of different models and degrees of damage. Now, it is necessary to collect information and confirm the status according to the steps of S151. Use an RFID scanner to scan the RFID tags on each door body die-casting one by one, and record their models (such as XYZ-1234), serial numbers (such as ABC123456) and current locations (such as maintenance area A). After the scan is completed, an electronic list containing information of all door body die-castings is obtained to ensure that no one is missed.

[0137] After checking the maintenance records of each door body die-casting, it was found that they had all started maintenance work in the past week and were expected to be completed in the next two weeks. After communicating with the maintenance personnel, it was learned that they were working according to the scheduled maintenance plan and schedule without any delays or stagnation. Therefore, it was confirmed that all door body die-castings were in a synchronized maintenance status.

[0138] By checking the work assignments of each maintenance staff member through the electronic management system, it was found that they were responsible for specific maintenance work on different models of door body die-castings, such as welding, grinding, spraying, etc.

[0139] Through face-to-face communication with maintenance personnel, we learned about their work progress, the tools and materials they needed, and the difficulties they encountered (such as the shortage of a certain model of parts). Based on this information, we analyzed the maintenance personnel's work efficiency and identified a potential bottleneck: the shortage of a certain part hindered the work progress of a maintenance personnel. We decided to contact the supplier immediately to replenish the part to ensure that the maintenance work could proceed smoothly. Through the steps of S151, we successfully collected the information and status of multiple door body die-castings in the same maintenance space, and understood the work content and progress of the maintenance personnel. This information provides an important basis for subsequent personnel deployment, resource optimization and progress tracking.

[0140] Furthermore, based on the traceability of multiple door body die-castings, the entry order of multiple door body die-castings is determined, and the usage order of multiple door body die-castings is determined according to the entry order of multiple door body die-castings and the corresponding models; it is compatible with the overall consideration of the entry order of multiple door body die-castings and the corresponding models, ensuring the accuracy of the usage order of multiple door body die-castings.

[0141] At this time, the order in which each door body die-casting enters the maintenance area is determined by tracing the entry record or related documents of each door body die-casting; at this time, the entry record sheet or electronic database of the door body die-casting is consulted to record the entry date and time of each door body die-casting; all door body die-castings are sorted according to the entry date and time to determine their entry order; if the entry record is incomplete or missing, obtain additional information by asking relevant maintenance personnel or management personnel.

[0142] Based on the arrival sequence and specific models of the door body die-castings, a usage sequence that meets maintenance needs and usage priorities is developed; at this time, factors such as the model, degree of damage, and customer emergency needs of each door body die-casting are analyzed to evaluate its maintenance priority; based on the arrival sequence and evaluation results, a preliminary usage sequence plan is developed; communicate with customers, maintenance teams, and relevant stakeholders to confirm the feasibility and satisfaction of the usage sequence plan; based on feedback, make necessary adjustments and optimizations to the usage sequence plan.

[0143] Specifically, suppose there is a maintenance workshop with multiple door body die-castings of different models placed in it. These door body die-castings have been subjected to information collection and status confirmation according to the steps of S151; now, it is necessary to determine their entry order and usage order according to the steps of S152; after consulting the entry record sheet of the door body die-castings, it is found that the earliest entry is the door body die-casting model XYZ-1234, and the entry date is the 10th of the previous month; the second is the model ABC123456, and the entry date is the 15th of the previous month; and so on, the entry dates of all door body die-castings are recorded; according to the entry date, all door body die-castings are sorted and their entry order is determined: XYZ-1234, ABC123456, ... (other models are sorted by entry date).

[0144] After analyzing the model and degree of damage of each door body die-casting, it was found that the door body die-casting model XYZ-1234 was slightly damaged and the customer had a low urgent need for it; however, the door body die-casting model ABC123456 was severely damaged and the customer urgently needed it. Based on the entry sequence and evaluation results, a preliminary usage sequence plan was formulated: first, the door body die-casting model ABC123456 was maintained because it was severely damaged and the customer urgently needed it; second, the model XYZ-1234, although less damaged, also required timely maintenance; and finally, the other door body die-casting models were maintained in the order they entered the site. Communicating with the customer and the maintenance team confirmed the feasibility and satisfaction of the usage sequence plan. The customer expressed great satisfaction with the urgent maintenance needs of the model ABC123456 and also approved the maintenance plan for the other door body die-castings. Based on the customer's feedback, the usage sequence plan was fine-tuned to ensure that each door body die-casting could be maintained before the customer's required time.

[0145] Therefore, the overall maintenance progress of multiple door body die-castings is sorted in sequence according to the order of use. If the overall maintenance progress of the previous door body die-casting is lower than that of the next door body die-casting, the personnel optimization of the maintenance personnel of the next door body die-casting is triggered according to the overall maintenance progress of the previous door body die-casting, the remaining maintenance tasks of the previous door body die-casting and the maintenance personnel configuration of the next door body die-casting, which is compatible with the autonomous regulation of the maintenance progress of multiple fault areas and the optimization of the current maintenance personnel configuration, thereby ensuring the accuracy of fault management of door body die-castings.

[0146] At this time, track and record the overall progress of each door body die-casting during the maintenance process according to the previously determined usage sequence to ensure that they are carried out in an orderly manner according to the predetermined plan; optionally, set up a progress tracking system, such as a spreadsheet or project management software, to record the current maintenance status of each door body die-casting (such as completed tasks, remaining tasks, expected completion time, etc.); regularly check (such as daily or weekly) and update the progress tracking system to ensure the accuracy and timeliness of the information; sort the door body die-castings in the progress tracking system according to the usage sequence to quickly identify which door body die-castings are lagging behind.

[0147] Identify the door body die-casting parts that are lagging behind in progress so that timely intervention measures can be taken; optionally, compare the records of adjacent door body die-casting parts in the progress tracking system, especially pay attention to their expected completion time and the proportion of completed tasks; if the expected completion time of the previous door body die-casting part is later than that of the next one, or the proportion of its completed tasks is lower than that of the next one, then the progress of the previous door body die-casting part is considered to be lagging behind.

[0148] By adjusting the maintenance personnel allocation, the maintenance process of the door body die-casting with delayed progress can be accelerated to ensure the smooth implementation of the overall maintenance plan; at this time, analyze the reasons for the delayed progress of the previous door body die-casting, such as high task complexity, insufficient skills of maintenance personnel, material shortages, etc.; evaluate whether the maintenance personnel allocation of the next door body die-casting is sufficient and whether there is room for maneuver; based on the evaluation results, formulate a personnel optimization plan, such as transferring some personnel from the maintenance team of the next door body die-casting to the maintenance work of the previous door body die-casting, or adding additional maintenance personnel to the maintenance team of the previous door body die-casting; communicate with the maintenance personnel and explain the personnel optimization plan to ensure that they understand and support the plan; implement the personnel optimization plan, and continuously track and evaluate its effectiveness.

[0149] Specifically, assume there are three door die-castings, A, B, and C, which are maintained in the order they are used. A spreadsheet is set up as a progress tracking system to record the current maintenance status of the three door die-castings A, B, and C. After a week of maintenance work, it is found that the progress of door die-casting A is lagging, and the estimated completion time is postponed from the original Tuesday to the next Thursday. However, the progress of door die-castings B and C is proceeding as planned.

[0150] By comparing the progress records of the three door body die-castings A, B, and C, it was found that the progress of door body die-casting A was indeed lower than those of B and C; by analyzing the reasons for the delayed progress of door body die-casting A, it was found that it was because a complex task took longer than expected; by evaluating the maintenance personnel configuration of door body die-castings B and C, it was found that some personnel in the maintenance team of door body die-casting B were performing relatively simple tasks, which were expected to be completed within the next few days.

[0151] Therefore, a personnel optimization plan was formulated: two experienced maintenance personnel were transferred from the maintenance team of the B door body die-casting to the maintenance work of the A door body die-casting to speed up its progress; the maintenance personnel were communicated with and the importance and urgency of the plan were explained, and they expressed their understanding and support; the personnel optimization plan was implemented, and the maintenance progress of the A door body die-casting was continuously tracked and evaluated; after the adjustment, the progress of the A door body die-casting was significantly improved, and the maintenance work was completed on time; through the steps of S153, the progress delay problem in the maintenance process of the door body die-casting was successfully identified and solved, ensuring the smooth implementation of the overall maintenance plan.

[0152] In one embodiment of the present application, it is assumed that there are three door body die castings A, B, and C, which are maintained in a predetermined order of use; a current maintenance progress matching table is established to record and compare their maintenance progress; the current maintenance progress matching table is shown in Table 3:

[0153] Table 3 Current maintenance progress matching table

[0154]

[0155] In this example, it is noted that the maintenance progress of door body die-casting A (60%) is lower than that of its subsequent door body die-casting B (80%). At the same time, considering that the complexity of the remaining tasks of A is 3 (medium) and the staffing of B is relatively sufficient (4 people), it is considered to deploy some personnel from B's maintenance team to A's maintenance work.

[0156] Personnel optimization strategy: Deploy one person from the four-person maintenance team for door body die-casting B to maintain door body die-casting A. After adjustment, one additional person joins door body die-casting A, for a total of X+1 people (X is the original number of people). The number of people working on door body die-casting B is reduced to three, but the maintenance needs of the die-casting B can still be met.

[0157] See also Figure 7 , Figure 7 : is a schematic diagram of the structural composition of a fault management system for a door body die casting according to an embodiment of the present invention; the fault management system for a door body die casting comprises:

[0158] A fault area module 21 is configured to determine a plurality of fault areas based on the recognition of the current image of the door body die casting;

[0159] a fault level module 22 for determining a fault state diagram of the door body die casting based on mechanical analysis of multiple fault areas, and determining a fault level of the door body die casting based on the fault state diagram and the service life of the door body die casting;

[0160] A fault management module 23 is configured to determine a fault management event based on the fault level and the morphology of the door body die-casting, wherein the fault management event represents maintenance status of multiple fault areas at different stages;

[0161] Maintenance schedule module 24, used to determine the overall maintenance schedule of the door body die casting according to the maintenance schedule of multiple fault areas in the event of fault management, and trigger autonomous regulation of the maintenance schedule of multiple fault areas based on the overall maintenance schedule of the door body die casting and the preset maintenance time target;

[0162] The optimization module 25 is used to collect the usage sequence of the multiple door body die-castings if the multiple door body die-castings are in a synchronous maintenance state, and optimize the current maintenance personnel configuration according to the usage sequence of the multiple door body die-castings and the overall maintenance progress of the multiple door body die-castings.

[0163] The technical features of the above embodiments may be combined arbitrarily. To make the description concise, not all combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

Claims

1. A fault management method for door body die castings, characterized in that: include: Determining a plurality of fault areas based on recognition of a current image of the door body die casting; Determine the fault state diagram of the door body die casting based on the mechanical analysis of multiple fault areas, and determine the fault level of the door body die casting based on the fault state diagram and the service life of the door body die casting; Determine a fault management event based on the fault level and shape of the door body die-casting, and the fault management event presents maintenance status of multiple fault areas at different stages; In a fault management event, the overall maintenance progress of the door body die-casting is determined based on the maintenance progress of multiple fault areas. Based on the overall maintenance progress of the door body die-casting and the preset maintenance time target, the maintenance progress of multiple fault areas is autonomously regulated. If multiple door body die castings are in a synchronous maintenance state, the usage order of the multiple door body die castings is collected, and the current maintenance personnel configuration is optimized according to the usage order of the multiple door body die castings and the overall maintenance progress of the multiple door body die castings.

2. The fault management method for door body die casting according to claim 1, characterized in that: The method of determining multiple fault areas based on the recognition of the current image of the door body die casting comprises: After being damaged, the door body die-casting is moved to the shooting area, and circular shooting is performed on the door body die-casting to acquire the current image of the door body die-casting; Determining a plurality of surface abnormal regions based on detection of a current image of the door body die casting, and determining an overall abnormal region based on the plurality of surface abnormal regions and the surface morphology of the door body die casting; After the door body die-casting is damaged, multiple impact positions are marked, multiple first fault positions are determined based on the multiple impact positions and the overall abnormal area, multiple second fault positions are determined based on the multiple impact positions and the surface morphology of the door body die-casting, and multiple fault areas are determined based on the mapping relationship between the multiple first fault positions, the multiple second fault positions and the area.

3. The fault management method for door body die casting according to claim 1, characterized in that: The method of determining a fault state diagram of the door body die casting according to mechanical analysis of multiple fault areas, and determining a fault level of the door body die casting according to the fault state diagram and the service life of the door body die casting, includes: Collect the model of the door body die-casting, determine the three-dimensional model of the door body die-casting in the factory state based on the model of the door body die-casting and the die-casting database, and mark multiple fault areas on the three-dimensional model of the door body die-casting; Performing corresponding mechanical analysis on the locations of multiple fault regions and outputting multiple mechanical distribution maps. In this case, the fault characteristics are determined based on the identification of the multiple fault regions, and the mechanical analysis mode is determined based on the type of the fault characteristics and the area of the fault region. The fault status diagram of the door body die-casting is determined based on multiple mechanical distribution diagrams and a three-dimensional model of the door body die-casting, the service life of the door body die-casting is collected, and the fault level of the door body die-casting is determined based on the mapping relationship among the fault status diagram, the service life of the door body die-casting and the fault level.

4. The fault management method for door body die casting according to claim 1, characterized in that: The fault management event is determined based on the fault level and the shape of the door body die-casting. The fault management event presents maintenance conditions of multiple fault areas at different stages, including: Collecting the fault level of the door body die-casting, and determining the sub-fault levels of multiple fault areas based on the classification of the fault level of the door body die-casting; The first fault states of the multiple fault areas are determined according to their sub-fault levels and corresponding area areas, and the second fault states of the multiple fault areas are determined according to their sub-fault levels and the morphology of the door body die-casting.

5. The fault management method for door body die casting according to claim 4, characterized in that: Fault management events are determined based on the fault level and shape of the door body die-casting. The fault management events present the maintenance status of multiple fault areas at different stages, and also include: In each fault area, the corresponding sub-fault management event is determined based on the first fault state, the second fault state and the event mapping relationship, and the fault management event is determined based on the synthesis of multiple sub-fault management events. At this time, multiple sub-fault management events are distributed in different stages of multiple fault areas, presenting corresponding maintenance conditions.

6. The fault management method for door body die casting according to claim 1, characterized in that: In the fault management event, the overall maintenance progress of the door body die casting is determined according to the maintenance progress of multiple fault areas, and the autonomous regulation of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door body die casting and the preset maintenance time target, including: Maintenance nodes of multiple fault areas are collected, and maintenance progress of the multiple fault areas is determined according to the maintenance nodes of the multiple fault areas and corresponding online maintenance images.

7. The fault management method for door body die casting according to claim 6, characterized in that: In the fault management event, the overall maintenance progress of the door body die casting is determined according to the maintenance progress of multiple fault areas, and autonomous regulation of the maintenance progress of multiple fault areas is triggered based on the overall maintenance progress of the door body die casting and the preset maintenance time target, further comprising: The overall maintenance progress of the door body die-casting is determined based on the maintenance progress of multiple fault areas, the corresponding real-time images, and the real-time morphology of the door body die-casting. At this time, the overall maintenance progress of the door body die-casting presents the overall maintenance progress of the door body die-casting at the current time; Collect the preset maintenance time targets, determine the remaining maintenance progress based on the tracing of the overall maintenance progress of the door body die-casting, determine accelerated maintenance events for multiple fault areas based on the remaining maintenance progress, the maintenance progress of multiple fault areas and the preset maintenance time targets, and trigger autonomous regulation of the maintenance progress of multiple fault areas based on the accelerated maintenance events of multiple fault areas.

8. The fault management method for door body die casting according to claim 1, characterized in that: If the plurality of door body die castings are in a synchronous maintenance state, the use order of the plurality of door body die castings is collected, and the configuration of the current maintenance personnel is optimized according to the use order of the plurality of door body die castings and the overall maintenance progress of the plurality of door body die castings, including: In the same maintenance space, collect data on multiple door body die-castings in the same maintenance space. Multiple door body die-castings are in a synchronous maintenance state, and collect the work content of each maintenance personnel in the maintenance space; The delivery order of the plurality of door body die-castings is determined based on the tracing of the plurality of door body die-castings, and the use order of the plurality of door body die-castings is determined according to the delivery order and corresponding models of the plurality of door body die-castings.

9. The fault management method for door body die casting according to claim 8, characterized in that: If the plurality of door body die castings are in a synchronous maintenance state, the usage order of the plurality of door body die castings is collected, and the configuration of the current maintenance personnel is optimized according to the usage order of the plurality of door body die castings and the overall maintenance progress of the plurality of door body die castings, further comprising: The overall maintenance progress of multiple door body die-castings is sorted in sequence according to the order of use. If the overall maintenance progress of the previous door body die-casting is lower than that of the next door body die-casting, the personnel optimization of the maintenance personnel of the next door body die-casting is triggered based on the overall maintenance progress of the previous door body die-casting, the remaining maintenance tasks of the previous door body die-casting and the maintenance personnel configuration of the next door body die-casting.

10. A fault management system for door body die castings, characterized in that: The door body die-casting fault management system is applied to the door body die-casting fault management method according to any one of claims 1 to 9, and the door body die-casting fault management system includes: a fault area module, configured to determine a plurality of fault areas based on recognition of a current image of the door body die casting; A fault level module is used to determine a fault state diagram of the door body die-casting based on mechanical analysis of multiple fault areas, and to determine the fault level of the door body die-casting based on the fault state diagram and the service life of the door body die-casting; A fault management module is used to determine a fault management event based on the fault level and morphology of the door body die-casting, wherein the fault management event presents maintenance status of multiple fault areas at different stages; The maintenance progress module is used to determine the overall maintenance progress of the door body die-casting according to the maintenance progress of multiple fault areas during fault management events, and trigger autonomous regulation of the maintenance progress of multiple fault areas based on the overall maintenance progress of the door body die-casting and the preset maintenance time target; The optimization module is used to collect the usage sequence of multiple door body die-castings if multiple door body die-castings are in a synchronous maintenance state, and optimize the current maintenance personnel configuration according to the usage sequence of multiple door body die-castings and the overall maintenance progress of multiple door body die-castings.

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